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By Frfas C, Parrilla F, Regife J. M

A project to develop the Zinclor electrowinning cell to industrial size is being conducted at Tecnicas Reunidas' Research and Development Centre with Spanish Ministry of Industry support. This project is the final development phase in zinc electrowinning from a chloride medium, the highest ZINCLOR technology development level prior to the industrial scale having already been reached. This paper covers the outcomes and conclusions corresponding to project Phases 1 and 2: Process Selection and Industrial Electrodes (1 m2) design and testing. The most important achievement reached is that there are presently available industrial cathodes and anodes for the Zinclor diaphragm cell giving an optimum response for zinc chloride electrowinning with unit power consumptions between 2.65 and 2.80 kWh/kg Zn, depending on the diaphragm type. Standard electrolysis conditions were: 65 g/L ZnC12, 3 g/L HCl, 160 g/L NaCl, 350 g/t Zn arabig gum as the addition agent, 36¦C, and 400 A/m2 current density. The selection of electrodes, diaphragms and organic additives for the industrial scale tests have been optimised. The complete electrowinning cell development, with electrodes having an active area of I m2, enables the evaluation of Zinclor Technology application for industrial processes.

Jan 1, 1993

It is indeed a privilege and honour to deliver the keynote address at this 15th APCOM symposium. APCOM has played a significant role in my own career and I am sure in the careers of many of the thousands of other participants over the years since its inception as a short course on "Computers and Computer Applications in the Mineral Industry" at the University of Arizona in 1961. The technical papers and addresses presented at the 14 past symposia provide an imposing record of sustained pro- gress and achievement in the field of computer applications. I will not attempt to analyse this technical side of APCOM but rather endeavour to provide you with a broad popular perspective of the road travelled to date and that lying ahead of us. The name of the series of symposia has changed from time to time, with titles such as Mathematical and Statistical Techniques, Mining and Exploration, and Decision Making being used at various times until in 1972 the name APCOM was coined and the present loga designed by the South African organising committee for the 10th symposium. It can conveniently be accepted as standing for:

Jan 1, 1977

PIP is regularly engaged in businesses where Greenfield Capital Projects are under- delivering on the expected business case. In most of these projects, we can identify that rigorous review has been carried out on the design and financial cost elements and substantial reporting is maintained to Boards on progress versus plan of project completion and cost. However, in all sites of this nature that we have worked at, the planning, design and execution of the operational elements or æwiringÆ of the organisation have fallen short and resulted in significant extra cost or opportunity cost (lost tonnage or quality) during start-up. When compared to the amount of planning and resources that have been poured into the capital side, the ledger on the æwiringÆ side is typically fairly sparse. This presentation outlines the importance of running a disciplined, rigorous process to prepare the human and wiring side of a start-up to ensure rapid start-ups and put the site on the pathway to high performance. It gives an outline of the rigorous process PIP has used with projects to ensure excellent start-ups.

Jan 1, 2006

By M L. Muller, A R. O’Donnell

The Mount Isa Mines (MIM) Copper Concentrator has an extensive history of reagent trials, with different reagents coming in and out of favour over the years. The research and use of carbon depressants is particularly prevalent, as carbonaceous pyrite is a major source of concentrate dilution. Years of research led to the use of naphthalene sulphonate due to its excellent carbon depression properties. However, due to rising reagent costs carbon depression ceased in the late 1990s. This led to the loss of knowledge about the use and value of naphthalene sulphonate. Cyanide is used at the Copper Concentrator for the sole purpose of pyrite depression and over the years multiple projects have been devoted to finding alternatives to it. In 2012 the neighbouring MIM Lead-Zinc Concentrator replaced cyanide with naphthalene sulphonate which resulted in cost savings and the elimination of a hazardous reagent. In 2013, plant trials were conducted at the Copper Concentrator in hopes to replicate the outcomes obtained at the Lead-Zinc Concentrator. The results of the trials conducted at the Copper Concentrator showed that naphthalene sulphonate could not replace cyanide and this work was set aside to pursue more promising projects. Further research conducted in 2014 found that mineralogy and a better understanding of the depressing mechanism of naphthalene sulphonate held the key to improved pyrite depression at the Copper Concentrator. The findings showed that Mount Isa copper ore contains two forms of pyrite; euhedral pyrite (cubic pyrite) and framboidal pyrite (carbon rimmed spheres of pyrite), both of which require different reagents to sufficiently depress them. Naphthalene sulphonate was found to be an excellent carbon depressant, suitable for depressing graphite and framboidal pyrite, whilst cyanide specifically targets euhedral pyrite.In 2015 laboratory test work was conducted to examine the use of naphthalene sulphonate in conjunction with cyanide to selectively target both forms of pyrite. This work led to a full plant trial, the results of which showed a significant increase in plant performance, with higher copper concentrate grades and recoveries being achieved. This paper aims to focus on the benefits and importance of understanding past work and linking a detailed knowledge of feed mineralogy to reagent selection for improved plant outcomes.CITATION:O’Donnell, A R and Muller, M L, 2018. Selectively targeting hydrophobic gangue minerals at the Mount Isa Mines Copper Concentrator, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 413–421 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By M Camarda, A Pirson, F Vasconcelos, J Mesquita

ArcelorMittal Prijedor is a goethitic iron ore mine located in the north-west of Bosnia and Herzegovina, which mainly supplies ArcelorMittal’s European subsidiaries. Annual production of the asset stands at the level of 1.5–2.1 million tons of iron ore product which is sent to ArcelorMittal Zenica steelmaking plant. Two types of products with approximately 50 per cent Fe are generated in Prijedor through a process composed by crushing, screening, and magnetic separation stages. Within this process one of the tailings produced is called ‘ultrafines’. The ‘ultrafines’ product corresponds to the desliming hydrocyclones overflow in Prijedor plant, which is classified in a size fraction below 25 μm and corresponds to about 5 per cent of feed. This material is richer in iron than the coarser size fractions of the ore but do not present a good performance in concentration processes. In this way, several studies have been carried out during the last years to find solutions to use the ‘ultrafines’ material without success. In this context, the possibility of dehydroxylate the goethite contained in the material transforming the mineral into hematite and thus increasing the iron grade of the final product was investigated. During the research, several dehydroxylation tests with different temperatures and time of exposure were performed. Using dihydroxylation process at temperatures higher than 800°C it was possible to produce a material with 43 per cent Fe from the original 39 per cent Fe ‘ultrafines’ sample. In addition, the dehydroxylation tests confirmed that goethite becomes completely transformed into hematite at 400°C (with an exposure time of 60 mins) and material is completely sintered at 1200°C. A simulation study based on dehydroxylation tests results showed that it would be possible to use a ‘ultrafines’ product with Fe grade higher than 45 per cent to produce a material with 50 per cent Fe through a complete dehydroxylation process.

Sep 18, 2023

By C J. Pitzer

The prevention of fatal risks is a key objective for the global resources industry, especially considering poor performance with regard to fatality rate reduction and the continued occurrence of mine disasters globally. However, the industry has a credible history, over several decades, of the development and deployment management systems to control potential Serious Injury, Fatal and Catastrophic (P-SIFC) risks. While these systems have had a significant impact on the thinking and approaches to the prevention of fatal risks, fatal accident rates have not shown the desired reduction. Recent fatal and serious injury events in Australia have led to the establishment of several enquiries to further identify improvements that could be considered. Globally, fatal accident rates remain stubbornly high or plateaued in many jurisdictions, and several catastrophic events have occurred, such as tailing dams disasters in Brazil and South Africa, and the recent coalmine disaster in Turkey. Apart from the apparent lack of progress, it is evident that the deployment of critical risk systems has introduced more bureaucracy, slower response systems and additional burdens on already overloaded middle and supervisory levels of management. Organisations are rarely able to effectively tap into the risk source of risk knowledge of the frontline worker and supervisor, for various reasons discussed in this paper. To establish a valid and valuable channel of critical risk information flow from the frontline employee, Debmarine Namibia instigated the development and deployment of a system called SafeSENTRY, where the focus is on the ‘dynamic identification of dynamic risks’. This paper outlines the system, the principles of the design, the range of risk metrics that can be derived from the observations of the frontline operators, and demonstrates how a range of posited shortcomings in critical risk management is addressed how features of the High Reliability Organization (HRO) have been developed.

Mar 29, 2023

By D R. Anstey

The growing demand for iron ore from Western Australia has led to an increased focus on the development of magnetite and lower grade iron ore deposits. The need to process and beneficiate the ore from these projects can result in the generation of significant quantities of iron ore tailings over the life of a project. Over the coming decades, the management of iron ore tailings will become a significant aspect of the mining landscape in Western Australia.The tailings generated from iron ore projects differ signifi cantly from other mineral tailings currently produced in Western Australia. Iron ore tailings are generated on a scale not matched by any other mineral process and can often contain asbestiform or potentially acid forming components. New iron ore projects are coming under increased environmental scrutiny because of their large scale operations and the sensitive environments in which they occur. This combination of factors creates some unique challenges for the management of tailings generated by iron ore mining in Western Australia.This paper presents the fi ndings of two studies conducted in recent years to overcome the challenges posed by iron ore tailings. The paper discusses the role of laboratory testing in the development of management strategies for asbestiform minerals in tailings. It also presents a numerical modelling approach for evaluating the rates of rise in the storage of magnetite tailings. The paper concludes by outlining how the findings of these studies can be applied to reduce tailings management costs, lower risks and improve environmental outcomes for the management of tailings from iron ore mining.

Jul 11, 2011

By J P. Sykes, A Trench

"World-class mine projects are increasingly failing to become world-class mines. Non-technical, socio-political and environmental problems seem, in part, to be the cause. However, the intangible and qualitative nature of these problems means overcoming them will require a greater systemic understanding of how the various technical and non-technical factors interact. This is particularly important as the concept of sustainable development has changed the industry paradigm sufficiently that it is no longer clear what world-class means. Finally, this better systemic understanding of mine projects needs communicating back to the exploration sector to improve exploration targeting.However, a disconnect between the exploration and mining sectors and between geologists and mining’s other professional disciplines means this is currently not possible. The use of economic evaluation techniques to assess the risk and value presented by the various technical and non-technical factors can assist with this by giving the varied professions a common language and including inputs from all disciplines. This paper therefore suggests a theoretical framework for analysing the various technical and non-technical factors, particularly the most challenging intangible and qualitative ones, and incorporating them into the typical economic evaluation techniques used in the mining industry.Understanding the risk and value relating to both technical and non-technical risks, however, places a greater emphasis on mining geologists to be conversant with a wide range of disciplines. Mining geologists will have to develop three types of knowledge:focusedinter-disciplinarybroad. In addition, they will have to become systemic thinkers to connect these types of knowledge. This multidisciplinary approach will require the use of fundamental critical thinking skills, common sense, intuition, experience and quantitative modelling techniques, dependent on the situation. As a result, both companies and professional societies, such as the Australasian Institute of Mining and Metallurgy, will have to develop ways of improving mining geologists’ inter-disciplinary and broad knowledge.CITATION:Sykes, J P and Trench, A, 2014. Resources versus reserves – towards a systems-based understanding of exploration and mine project development and the role of the mining geologist, in Proceedings Ninth International Mining Geology Conference 2014 , pp 243–270 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 18, 2014

The history of the discovery and development of the Kambalda nickel orebody. is reviewed and the decision to process the Kambalda concentrates by the Sherritt-Gordon process at Kwinana is discussed. The Kwinana Nickel Refinery is described and the problems encountered in the first year of operation are Outlined.

Jan 1, 1971

By D Semini, B Newcombe

Base-metal sulfide refractory gold ores often contain a portion of ‘free’ gold that is amenable to recovery using gravity concentration methods, whilst the refractory portion of the gold is better recovered using flotation. The decision as to whether a plant treating a refractory gold ore should utilise gravity concentration or a flash flotation circuit (or a combination of both) within the grinding circuit is usually made at the design stage of flow sheet development. Very limited data is available in the published literature which provides an industrial scale comparison on which to base such a decision and conventional laboratory testing methods are often the only way of obtaining such data. The optimum processing route will also be mineralogy dependent.This paper presents the findings of operating a refractory gold plant with either flash flotation (normal operation) or a combination of flash and gravity recovery methods treating the cyclone underflow stream and will demonstrate the regions of the recovery profile that each contributes to. Size-by-assay analysis has been performed on a number of streams around the operating plant to gain an insight into the changes that occur when the gravity circuit is in operation in addition to the flash flotation circuit. A discussion around the implications to overall plant operation in combining the use of a batch process (gravity concentration) with a continuous process (flotation) is presented.CITATION:Newcombe, B and Semini, D, 2014. Interactions between flash flotation and gravity concentration – an industrial case study of a refractory gold concentrator, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 427–436 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By B Poborowski, A Chen

"For some time, the Australian and Chinese underground coal mining industries have evolvedindependently with minimal infl uence on each other. Despite the fact that in recent years severaltechnologies and solutions have become common to both industries, this trend has seeminglycontinued to the point that there are still many important diff erences in legislation and hazardmanagement systems in both countries. Austar Coal Mine as an Australian based and Chineseowned enterprise has a unique opportunity to benefi t from the technology and knowledge ofboth nations. This paper compares the Australian and Chinese approach towards spontaneouscombustion hazard management in order to exchange experience, identify possible improvements and learn from each other."

Jun 1, 2012

By D J. Bradshaw, E M. Wightman, B Newcombe

Flash flotation plays an integral role in many of the gold and sulfide mineral concentrators around the world, and yet despite this widespread use, very little information on this unit process is available in the published literature. For operations to maximise the performance of their flash flotation circuits, understanding how these cells operate, the nature of the particles they target and how to predict whether a flash flotation cell should be used on a specific ore type is of vital importance. This paper provides a summary of the key findings of a large flash flotation research project based in the operating environment of a refractory gold concentrator. The influence of key flotation performance criteria including gas dispersion, residence time and particle segregation within the cell will be discussed and recommendations for process improvements will be made throughout. The nature of the particles within the flash cell will be examined, as will the impact on the type of particles that are passed to downstream processes when the flash flotation cell is taken off-line. The development of a laboratory method to determine whether an ore is suitable to undergo the flash flotation process is also presented for its potential to aid in flow sheet development and optimisation for new ores.CITATION:Newcombe, B, Bradshaw, D J and Wightman, E M, 2012. Into the belly of the flash à Insights into the mechanisms at work within a flash flotation cell, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 163-170 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By F Diaz, G Hovestadt, B Friedrich, D Latacz, M Sommerfeld

The metallurgical sector significantly contributes to the global carbon footprint and encounters the challenge of developing more sustainable production methods. This study introduces novel approaches aimed at reducing CO2 emissions within the industrial sector, some of which have been developed up to the demonstration scale. In two case studies, urban waste from the agricultural sector (corn, olives, coconut etc) and waste electrical or electronic equipment (WEEE) recycling residues (shredder light fractions (SLF)) were subjected to thermal treatment. The resulting materials were then used as substitutes for conventional fossil-based reducing agents in both the copper and ferroalloy industries. Furthermore, hydrogen was employed at different scales to assess its efficacy as a reducing agent for recovering metal oxides from fayalitic copper slags. Our findings reveal promising prospects and defined specific challenges for the integration of these alternative reducing agents in the industry. The synergistic use of pyrolysed SLF, bio-coke, and hydrogen presents a viable pathway to significantly diminish CO2 emissions while simultaneously improving the sustainability of the metallurgical sector.

Jun 19, 2024

The tangible effects of leakage are presented graphically, and a technique for quantifying the leakage characteristics of a ventilation column using the æSolveÆ capabilities of a common spreadsheet is demonstrated. A case study of a working decline in Western Australia is used to demonstrate the potential for more realistic design of development ventilating systems, and for more cost effective management of the condition of the duct.

Jan 1, 2002

By D R. Andrew, K T. Morrison, J F. Tiedgen

Waste blasting in iron ore operations can pose a number of technical challenges, including blasting through variable geology and blasting soft ground in wet conditions. Blast patterns are designed to be loaded with a specific range of explosives with unique characteristics and properties. Each explosive product will produce an optimal blast outcome for a given set of blast parameters and ground conditions. Sites characterised by softer rock typically require low-density, low-energy explosives. Historically, these products have contained a high ratio of porous ammonium nitrate prill and are only suitable for dry blastholes. When blastholes within a pattern are found to be unsuitable for such explosives due to wet, damp or muddy blasthole conditions, a new product is selected. While it is easy to switch products to match blasthole conditions, the different properties of the new non-ideal product can impact blast performance and increase loading times and costs.Flexigel™ is a solids-sensitised emulsion blend suitable for loading at variable densities and energies in dry, damp, muddy or wet blastholes. It is a universal product that can be loaded to match ground and blasthole conditions or complement other explosive products.At Fortescue Metals Group’s Cloudbreak site, Flexigel™ was trialled through a series of matched pair blasts in order to optimise blast outcomes in conditions that were non-ideal for existing explosive products and to reduce the overall cost of drill and blast operations. Flexigel™ yielded improved instantaneous dig rates and improved loading efficiency when compared to a traditional emulsion blend. The results also indicated that variable-density and variable-energy products afford greater flexibility for optimising blast outcomes across all ground and blasthole conditions trialled.Trials of Flexigel™ at Cloudbreak have shown that a variable-density solution is available for conditions where traditional explosive products are non-ideal. As such, Flexigel™ is able to fill a major void at any operation where the desired low-density, low-energy explosive product must be substituted for a more expensive traditional emulsion blend or heavy ammonium nitrate/fuel oil.CITATION:Andrew, D R, Morrison, K T and Tiedgen, J F, 2015. Flexigel™ – a variable-density solution, in Proceedings Iron Ore 2015, pp 413–418 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

The Operation of the LAROX PF-50 Pressure Filter at 'Ellatzite-Med' Flotation Plant, Bulgaria The implementation of Larox pressure belt filter, type Larox PF-50 provided within 6˜8% moisture content of the produced copper concentrate, which allowed good market realisation. The start-up of the pressure filter in 2009 reduced the electricity costs several times and had a positive impact on the technological regime of flotation. This article reveals the investigation results from the operation of the pressure filter according to different situations (density of the pulp, time for filtration, pressure of the material, pressure of the drying air, time for drying with air and other factors). The investment made in the pressure filter application is a guarantee for the successful operation of 'Ellatzite' flotation plant, Bulgaria in the coming years.

Sep 13, 2010

Successful evaluation and exploitation of resources and reserves relies on the collection of high quality sample data. The quality of the sample data must be maintained through the application of a robust quality assurance and quality control (QAQC) program, including documentation of sampling procedures, training of sampling personnel and the regular monitoring of control samples. However, the application of QAQC programs in the minerals industry is often poor and the purpose misunderstood. It is all too common to have good quality control data collected, but no analysis work carried out until after drilling is completed. In a lengthy drill program, this can lead to problems not being discovered and corrected as they happen. Moreover, rectifying problems afterwards will be costly in terms of time and money, if not impossible. The consequences of poor quality sample data are many and include such effects as over- or underestimation of block grades, misclassification of ore and waste, and lower confidence in the resource/reserve models. The purpose of this paper is to highlight, using case studies, the importance of good QAQC practices to monitor the quality of sampling and laboratory sample preparation and analysis.

Mar 1, 2010

By I Treloar, T Elenbaas, E Isaaks

Critical reviews of grade control generally focus on blasthole sampling and the estimation of ore control block model (OCM) grades, with little or no attention given to dig-line design. For example, the estimation of block grades is deemed important as estimation errors lead to the misclassification of ore types and subsequent dollar loss. Recognition of the problem that the underestimation of block grades may be more or less costly than overestimation led to the application of loss functions to the classification of individual OCM blocks by ore type. The method is known as maximum profit selection (MPS). However, each OCM block may be misclassified a second time by dig-line design. Although each block may initially be assigned an optimum ore type by MPS, OCM blocks are seldom individually mineable by ore type. As a result, a common solution to this problem is the design of mineable polygons or dig lines loosely constrained by a minimum mining width. All material within a properly designed dig-line polygon can be mined and sent to a single destination such as the mill, stockpile or waste dump. These dig lines are often designed manually or by simple variations of computer-generated contour lines. They are generally suboptimal and result in additional misclassifications of ore types. This paper provides an algorithm for constrained optimum dig-line design where dig-line misclassifications are also evaluated through loss functions or MPS. Constrained optimum dig-line designs minimise the dollars lost by dig line misclassifications for a given minimum mining width constraint. A case study is provided illustrating constrained optimum dig-line design and subsequent benefits.CITATION:Isaaks, E, Treloar, I and Elenbaas, T, 2014. Optimum dig lines for open pit grade control, in Proceedings Ninth International Mining Geology Conference 2014 , pp 425–432 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By J Carter, B J. Armstrong

Best practice for the submission of samples to an internal or commercial laboratory requires quality control materials to be included for the purpose of independently and comprehensively assessing laboratory performance. These quality controls include the use of certified reference materials (CRMs) and may be blind to the laboratory. Iron ore companies purchase these materials from reputable manufacturers from stock of run-of-mine materials at the appropriate grades. The international standard, ISO 17034 (ISO, 2016), specifies the competency requirements for organisations manufacturing reference materials, and includes rigorous requirements for the assessment of homogeneity, stability and establishment of property values and their uncertainties. Homogeneity is one of the most important measures of suitability for all certified reference materials and refers to the degree to which the composition and properties of a sample are uniform throughout the batch, relative to the analytical precision of the method. More specifically, homogeneity studies of candidate reference materials should be assessed for both within sample variance and between sample variance with appropriate statistical controls. The design and application of homogeneity studies are discussed as they apply to both crushed and pulverised reference materials. Crushed certified reference materials have been utilised by the iron ore industry for a number of years and provide the user with a critical assessment of variances in sample preparation in addition to analysis. Crushed reference materials are similar in presentation to an RC sample and are generally used as discrete parcels of material submitted to the laboratory from the field. Pulverise certified reference materials miss the sample preparation step and are subsampled from th delivered sachet at the point of analysis. This paper compares the relative homogeneity performance of crushed and pulverised certified reference materials by grade across key iron ore chemical constituents. Outcomes are benchmarked to the international standard ISO 9516 (ISO, 2003) for the determination of various elements in iron ores by lithium borate fusion and X-ray fluorescence. Practical implications are discussed with reference to a case study from an iron ore laboratory in the Pilbara.

Sep 18, 2023

Mine site rehabilitation is the repair of the disturbance caused by mining on the immediate mining area and also on the surrounding environment. The long-term objectives of rehabilitation can vary from simply returning an area to a safe and stable condition, to restoring the mined land to a state as close as possible to its pre-mining condition, capable of being self-supporting and having a beneficial final land use. This paper investigates the importance and benefits of environmental planning, in particular for rehabilitation, and how input into daily operations can allow mining to progress with limited impact on the surrounding environment. It will also identify some of the key mistakes currently made during mining which could be averted by implementing prior planning and incorporating environmental consideration into daily operations. A number of rehabilitation opportunities will also be detailed for the different stages of the life cycle of a coal mine.

Jan 1, 2007