Search Documents

By J Wu

Swirl Flow Technology (SFT), a novel approach for agitation in large industrial slurry tanks, was jointly developed and patented by CSIRO and Queensland Alumina Ltd (QAL). Currently, SFT is used in 16 alumina precipitation tanks at QAL, with the first installation in January 1997. This paper provides insight to the underlying fluid dynamics, which were investigated through pilot-scale experiments. A key finding was that SFT produces tank wall velocities approximately four times that of conventional draft tube agitator systems for the same power input, whilst for solids suspension, much less power is needed. SFT is energy efficient and practical in scaling suppression as demonstrated by the full-scale experience at QAL.

Aug 8, 2011

Opening AddressThank you for inviting me here today to open what promises to be a significant conference on the technological aspects of extractive metallurgy. I would especially like. to welcome delegates who have travelled great distances in order to contribute to, and be participants in, this examination of the technical innovations which have always been a crucial part of our industry.

Jan 1, 1992

Computer software has been developed to link real-time information generated by underground mine ventilation airflow monitoring sensors into a network simulation program to undertake network simulations and allow interpretation of key system data and operational changes. Results were used in the development of a computerised monitoring and simulation system to provide immediate or real-time data on air behaviour within each branch of an underground mine ventilation network through linking of sensors to the ventilation network simulation software. The outcome of the project is an online system that can report changes in the mine ventilation system, allow causes of changes to be isolated and rectified, improve balancing of available air throughout the mine, allow improved approaches to regulator setting and dispense with much of the labour used for underground ventilation measurement. The work activities in both coal and metalliferous Australian mines have involved examination and modelling of regulators, software modification and considerable mine site testing and optimising activities. There is some discussion on approaches to control of flow through ventilation systems with increased information. New systems will be part of a total mine information management system. They will have to be cost effective and justified by gains in productivity. New systems will need to provide simulation of contaminant production such as diesels, vehicle heat, strata heat, radiation, blast fumes and other gases. More robust real-time ventilation simulation systems will be required. Personnel and vehicle identification and production tracking will be collected to provide integrated ventilation system monitoring and control. This paper examines a study to gain greater understanding of computerised real-time airflow monitoring and control within the mine production system to provide immediate simulated information in each branch of an underground ventilation network and to allow interpretation of key system data and operational changes. A case study implementing a real-time airflow monitoring and control is discussed. Approaches to control of flow through ventilation systems with increased information are discussed. The concept of a system that can be linked to or be part of a total mine information management system is developed. Such a system can form the base for mine automation that allows mines to incrementally and cost effectively implement monitoring and control to further seek gains in productivity.

Jan 1, 2005

South Crofty's ventilation network is large and complex. Of the total exhaust air quantity 40% enters the mine by leakage routes through old workings, this air carries high concentrations of radon gas and results in the mine becoming a classified work place under the Ionising Radiation Regulations 1985. Improvements in the control of the ventilating air and dilution by increased air quantity have reduced the average contamination to aelow-0.2 WL. The major part of the radon originates from ground water inflows and from concentrations of radium within the mine with direct emanation from rock surfaces being negligible. Of 600 kBgs-1 total radon leaving the mine 93% cannot be accounted for from known and accessible sources.

Jan 1, 1988

By Zharinov SE

Geonechanical modelling of island arc sys- tems and their analogs is investigated. Slow seismotectonic movements along the inclined deep fault zone under the compressive horizontal stress conditions are proposed to be the princi- pal mechanism controlling the structures and processes in the active continental margins. A model of shearing surface crack in an elastic half-plane is used for simulation. The main ele- ment of the model is viscous interaction bet- ween the crack sides, the viscosity varying with depth. To describe the stress-strain state of the medium an integro-differential singular equation is derived and solved numerically. The results of simulation are in good agreement with geological and geophysical data on the ac- tive continental margins.

Jan 1, 1987

By P Waters, S Miller

BHPBilliton operates the Mt Whaleback Mine located in the semi-arid Pilbara Region of Western Australia. Approximately 200 Mt of net acid generating (NAG) material still remains to be mined. Acid Rock Drainage (ARD) was first identified at the site in 1995 following cyclonic storms. This resulted in the development of strategies that have allowed the mine to successfully manage ARD whilst continuing to operate. BHPBilliton Iron Ore is working toward prevention of ARD in its operations, however, historical practices have left residual areas that must be considered. Three significant sources of ARD have been identified that must be managed: stormwater run-off from exposed pyritic shales in pit surfaces; basal flows beneath overburden storage areas following rainfall events; and contaminated water from pit dewatering. The mine contains all ARD water onsite. This is achieved by: storage of all affected water in the ARD dam; evaporation of affected water from the ARD dam and the adjacent evaporation ponds; pumping from upstream dams to prevent stormwater from being affected; and emergency storage and treatment in-pit as a contingency. The site ARD management strategy is approved by senior management and endorsed by State Government regulatory authorities and relevant external stakeholders. Additional strategies are also under evaluation to effect long-term closure of the operation. Record rainfalls from 1998 - 2001 have tested the capabilities of the ARD strategy and management plan. Learnings from these events, coupled with recommendations from an extensive technical audit in 2000, have been incorporated into the strategy for ARD management. This paper presents the strategy and an overview of the ARD management plan that can be considered and applied by other affected sites in the management of ARD.

Jan 1, 2003

By J Lea, D C. Kettlewell

The Carina iron ore deposit lies 105 km northeast of Southern Cross, WA. The area designated the Yilgarn Iron Ore Project (YIOP) is comprised of five prospects along an east-southeast trending greenstone belt that extends from the Helena-Aurora Ranges in the northwest to the Yendilberrin Hills in the southeast, over a strike length of approximately 40 km. The YIOP project encompasses the previously identified iron deposits of Bungalbin, Bungalbin East and Mt Walton. The Carina deposit was discovered by Polaris Metals NL in May 2007. The Carina deposit is located within and parallel to the structurally complex northwest trending Mount Dimer shear zone. The volcanosedimentary Archaean-aged greenstone sequence consists of ultramafic and mafic lavas and flows with interbedded sediments dominated by chert and banded iron formation (BIF). Supergene enrichment processes formed a goethite orebody replacement of BIF sequences within a doubly plunging synclinal fold structure. Mineralised outcrops dominated by goethite form a low ridge 1500 m long, up to 90 m wide and drilled to over 200 m in depth. In the vicinity of the Carina deposit, iron occurrences have been identified over at least a 12 km strike length and the exploration potential of the area is identified as 30 - 40 Mt. Polaris Metals began exploration in the area in 2006. Target generation in the area used existing state geological survey maps and regional magnetic survey data to focus on BIF occurrences associated with major structures. Early field investigations resulted in the identification of a large outcrop of predominantly goethite mineralisation at Carina. Detailed geological and structural mapping was completed, followed by close-spaced reverse circulation and diamond drilling. The mineralisation is predominantly goethite with specular and coarse platy haematite localised along structures that cut the goethite mineralisation. Mineralised zones are moderately vuggy and larger cavities occur in proximity to fault zones that transect the orebody. A capping by a thin veneer up to 9 m thick of canga or ferricrete occurs in places. By December 2008, 178 reverse circulation and 11 diamond drill holes (seven surface holes, four tails) were completed. The current JORC-compliant resource estimate is based on assays from 72 RC drill holes and using a 55 per cent Fe cut-off stands as an Inferred Resource of 27.9 Mt at 58.6 per cent Fe, 1.3 per cent Al2O3, 3.7 per cent SiO2, 0.09 per cent P, and 10.1 per cent LOI. Assaying has recently been completed and will be incorporated into a new updated resource later in 2009.

Jan 1, 2009

By C Rule

In 2003, Anglo Platinum, in a joint development with Xstrata Technology, installed the world’s first 10 000 litre IsaMillTM in a concentrate regrind duty at the Western Limb Tailings Re-treatment Plant. The success of that installation was the enabling event for Anglo Platinum to proceed with a substantial investment in horizontal stirred milling technology. Since 2006 an additional three IsaMillsTM in concentrate regrind duties and a further 18 IsaMillsTM in the more technically challenging coarse grinding mainstream applications, have been commissioned in group Concentrator operations - bringing the total number of IsaMillsTM installed in Anglo Platinum plants to 22.A collaborative approach between Anglo Platinum and Xstrata Technology towards improving milling efficiency and reducing operating costs, through internal mill component wear optimization and operating recipe development, has resulted in further improvements in the overall success of IsaMillsTM in the flow sheets of many Anglo Platinum operations. The addition of IsaMillsTM in the Anglo Platinum flow sheets has improved plant PGM recoveries by as much as 5%.This paper explores the improvements made to the IsaMillsTM flow sheet and mill internal design and shares some of the operating experience with IsaMillsTM technology in Anglo Platinum

Aug 8, 2011

A number of terrane reconstructions conflict with global plate histories or with data from adjacent regional studies. Paleogeographic maps have ignored terranes thus are over-simplified. This paper represents an attempt to "marry" Mesozoic global plate reconstructions and terrane analysis to produce examples of a "third generation" of global plate tectonic maps. The best approach to global terrane analysis involves intercomparison of all regional data and the evolving global model. Data conflicts within and between terranes and regions must be resolved by a system of relative data reliability "weighting." The most reliable and useful data are those which constrain "departure" (rift) and "arrival" (collision) times. Certain ad hoc decisions aid in the analysis (e.g. only one net vector allowed per plate). The maps that follow summarize Early Mesozoic global tectonic history at three critical junctures: 240 MA (Triassic); 180 MA (Jurassic); and 120 MA (Cretaceous). Due to space limitations, maps drawn at 20 m.y. intervals appear elsewhere. A preliminary Middle Triassic reconstruction is presented in Figure 1. Major plates and continental blocks are labeled; smaller blocks are marked with abbreviations. Examination of Figure 1 indicates the necessity of modeling Triassic tectonics with at least 68 blocks. Spalling- off of microcontinental slivers from Gondwanaland is active some 70 m.y. before the actual breakup of the supercontinent. In the SW sector of the Pacific, the Australian margins were embroidered with several terranes (e.g. Sumba) which eventually rifted away and crossed Tethys. The NW sector at this time included 10 microcontinental chips forming a huge archipelago along the Asian margin. All blocks inboard of Indochina collided by latest Triassic. Terranes of the NE sector include several (e.g. Arctic Alaska) along the North American margin, and at least six large blocks (e.g. Stikinia) drifting SE with the Farallon Plate. The SE sector

Jan 1, 1987

By L Mariano

Three selected iron ore samples from the major bedded and channel iron deposits of Western Australia were analysed using a scratch test commonly used in the oil and gas industry. The portable commercial equipment dubbed Wombat cuts a groove on the surface of the sample with a cutter under imposed depth of cut and cutting velocity. The normal and tangential components of the force acting on the cutter are recorded with a high degree of precision (about 1N) at fine spatial resolution of about 20 measurements per millimeter.The intrinsic specific energy inferred from the scratch test measurements is found very well correlated with a classical measure of strength such as the uniaxial compressive strength, for over 300 sedimentary rock samples.The results obtained on the iron ore samples are comparable to those obtained on oil and gas sedimentary rocks. This method could provide an objective and semi-automated measurement of material strength and brittleness in iron ores that can possibly be correlated to the lump to fines ratio.

Jul 11, 2011

By Grano S. R, Ralston J

It is the perennial problem most metallurgists face when examining data collected from laboratory float tests and plant surveys - there are more numbers than we know what to do with! The objective of this paper is to analyse and interpret a set

Jan 1, 1994

The Takasima Coal Mines comprise four islands near the entrance to Nagasaki Harbour, and are owned and worked by the Mitsu Bishi Company.There are several unusual features in the occurrence and working of these coal seams, the steep angle of "dip," the numerous seams of good coal separated by hundreds of feet of sedimentary rocks, the extensive faulting of the strata, and the way in which the coal is won, when so little surface is available for works, and where there is the ever present danger of subsidence of the roof and consequent flooding of the workings by the ocean. The author trusts that short notes on these few points will be of interest to members.The Islands are named respectively Hasima (Extreme Island), Nakanosima (Middle Island), Takasima (High Island), and Yokosima, and are situated about one mile from the main land.

Jan 1, 1901

By N Takamatsu

The environments surrounding the iron and steel industry have changed greatly in recent years. Reported in this paper are the technologies adopted by the Japanese iron and steel industry to fititself to change in global steel demands, degradation of iron ore and coal, prolonging service life of the facilities and requirements of energy saving. In addition, innovative technologies for CO2 emission control in iron making processes are also discussed.

Jul 11, 2011

By A Vickerfält, J Huss, J Martinsson

The European Union has listed vanadium (V) as one of the critical raw materials for the transition to a future green society, as stated in the Critical Raw Material Act, written by Grohol and Veeh (2023). In the steelmaking industry based on V-containing iron ore, V is a possible by-product from the slag. A requirement for slags to be suitable for V extraction is a V content preferably above 8 wt per cent as V2O3 and a phosphorus (P) content below 0.1 wt per cent as P2O5. Hence, it is important to keep V in the slag phase while the P is moved to the metal phase during the steelmaking process.

Aug 21, 2024

By S K. Michelic, M Schickbichler, A Kharicha, E Karimi-Sibaki

The requirements for the controllability of metallurgical processes are increasingly becoming the focus of both industry and research. Advances in this field of research not only impact the stability of processes but often also influence the quality of the final product. One important way to examine processes in-depth, and thus show potential for improvement, is to describe them using physicsdriven models. In metallurgy, thermodynamic and kinetic descriptions of interactions between individual components of a system are often used to describe and analyse important metallurgical phenomena across the entire process. However, for the creation of physics-based models, boundary conditions and process variables must be implemented to enable a description that is as realistic as possible. The collection and generalisation of boundary conditions and process variables is, therefore, an important step towards functional models. The focus of this study is the determination of mass transfer coefficients between all components in a steel/slag/refractory system. For this purpose, experimental and theoretical methods are applied. Laboratory scale experiments are carried out in an induction furnace, and the mass transfer coefficients of the defined steel/slag/refractory system are calculated from changes in the chemical composition of the various components. Additionally, a calculation of the mass transfer coefficients based on dimensionless quantities is carried out. By comparing the values of the mass transfer coefficients determined theoretically and those determined experimentally in the trials, the suitability of the calculation is examined. The collection of mass transfer coefficients provides essential findings for future kinetic descriptions of inclusion modification based on the effective equilibrium reaction zone (EERZ) approach.

Aug 21, 2024

The large rotary blast hole drills for hole sizes of 250 to 375 mm in diameter have been utilized by large open pit metal and coal mines for production drilling all over the world. The design of such rotary drills is in most cases about two decades old and it has not been done much in order to apply a modern technology on rotary drilling. The most modern large rotary drill, Tamrock RI 10, consists of an advantageous rotary head with a squirrel cage AC motor controlled by a frequency converter, a beneficial mast structure with a possibility for inclined drilling, hydraulic driven, independent crawlers, and a modern ergonomic cabin to provide a comfortable working condition for the oper- ator. Several automatic features are available as options. The rig has been designed to be operated by one man only. With this modern rig the produc- tion rate can be increased and production cost kept on a low level.

Jan 1, 1989

By S Adamson

Morphological analysis of alluvial gold recovered from the same segment of a placer by four common commercial methods indicates that gold shape and the presence of quartz intergrowths or sulphide overgrowths substantially influence the recovery efficiency of each method. The amount and types of gold saved by each method varies according to the different hydrodynamic conditions under which each of the methods operates. Reverse circulation drilling has the lowest efficiency and preferentially loses moderate-high flatness gold and intergrown or overgrown gold particles with relatively low density. Gravity riffle, hydraulic riffle, and jigcentrifugal concentrator systems respectively save progressively more of these problematic gold morphotypes, but still lose significant and sometimes substantial amounts (of profit) to the tailings. Because of the differences in recovery efficiency, reverse circulation drilling probably underestimates the grade of most placers and may have resulted in bypassing several economic deposits. Losses to tailings by commercial recovery plants arise from inadequacies in fundamental plant design features. These inadequacies compromise plant efficiency by limiting the ability of plants to simulate the wide range of hydrodynamic conditions necessary to operate effectively throughout placer systems. Incorporation of sand pumps and multiple recovery methods into the more sophisticated plants only partly overcomes these inadequacies. At best, efficiency will be maximised in a few segments of the placer determined by individual plant design, and will decrease progressively upstream and downstream of those segments. Without prior knowledge of the morphological characteristics of the gold to be mined, it is difficult to choose the most appropriate plant design, or to estimate what proportion of the gold will be recoverable by any given plant. If the relevant relationships are not considered beforehand, the recovery plant is likely to lose a significant proportion of the gold, and sacrifice maximum profit.

Jan 1, 2001

Scale build-up in titanium palladium alloy spent electrolyte heat exchangers in the residue treatment plant commissioned at Risdon, Tasmania in 1971 was shown to be a mixture of manganese dioxide and anhydrite (CaSO4). The manganese dioxide was deposited as a result of thermal decomposition of permanganate ions present in the spent electrolyte. It was shown that deposition of manganese dioxide and associated anhydrite scale could be prevented by prior reduction of permanganate ions to the manganous (Mn++) state by the addition of ferrous ions. In the plant this was conveniently accomplished by injecting into the inlet line to the heat exchangers sufficient zinc plant solution containing ferrous sulfate to decolourise the spent electrolyte. This action prevented deposition of such scale for another 21 years, until the heaters were finally decommissioned in March 1992. Measurements indicated that addition of the reducing solution lowered the anodic potential of the titanium alloy by 200 - 300 mV (depending on the solution resistance), but that it was still +300 to 400 mV with respect to a standard calomel electrode. It was shown that, if necessary, a small impressed current could be applied to provide anodic protection. Before scale deposition was overcome by the addition of ferrous sulfate solution, badly scaled heat exchangers were cleaned by recirculating a solution of hydrogen peroxide in spent electrolyte or dilute aqueous sulfuric acid, after laboratory testing of a variety of possible solvents for the scale. Corrosion tests indicated that attack on the titanium alloy by the acidic peroxide cleaning solution was insignificant.

Jan 1, 2005

By N Currey, G W. Wilson, P Ritchie

Kidston Gold Mine in Queensland, Australia has a 310 ha tailings impoundment that has undergone final closure rehabilitation. Kidston Gold Mine evaluated their closure options for this low acid generating tailings impoundment, and due to a lack of cover soils and the cost of importing material, the mine decided to investigate the possibility of direct vegetation onto the tailings impoundment surface. The mine subsequently embarked upon a well planned and detailed research program to determine the feasibility and sustainability of this closure option. The research program included vegetation trials, toxicology studies for metal uptake by vegetation, as well as a comprehensive closure water balance model for the tailings impoundment complex. This paper describes the results of the long-term closure water balance for the tailings impoundment complex for the pre-closure state of the impoundment, as well as predictions towards the impoundment performance once final rehabilitation of the tailings impoundment complex has been achieved. The water balance presented is unique in that it is founded on unsaturated flow principles and accounts in full the impacts of the surface flux boundary conditions. This novel approach enables the prediction of actual infiltration rates into the tailings impoundment surface, which in turn allows for the calculation of how much seepage will exit from the tailings dam toe drains.

Jan 1, 2003

By S-C Shim, H-R Lee, Y Kang, H Shin

Since iron oxide and silicon oxide are major gangue components in various types of ore, FeO-SiO2 base slag, ie fayalite slag, has been often encountered in pyrometallurgical processes of non-ferrous metals. During most matte production processes such as the smelting of Cu, Pb, and Ni, the FeOSiO2 based slag is inevitably formed and plays an important role in refining crude metal as well as engineering aspects. Recently, similar pyrometallurgical approaches have been attempted in the recovery of valuable metals (Ni, Co, Cr) from wasted secondary batteries. Thus, the viscosity of the FeO-SiO2 based slag has great significance in properly controlling smelting processes. However, when molten metal or matte does not coexist with the slag during the measurement, there has been a serious difficulty in maintaining Fe valance and consequently, the slag composition. In the present research, the viscosity of molten FeO-SiO2 slag was measured in 1573~1673 K using a rotational viscometer. In order to keep the state of iron oxides, the oxygen partial pressure was controlled using CO/CO2 gas mixture. The optimised ratio of CO/CO2 could be calculated using Fe/Fe2+ and Fe2+/Fe3+ equilibria at each temperature. The composition of the slag, particularly Fe valance, after the measurement was analysed with the aid of an inductively coupled plasma – optical emission spectroscopy (ICP-OES) and an automatic potentiometric titrator. The measurement showed that the FeO-SiO2 slag has considerably low viscosity values in the molten state, and it sharply increases as the temperature decreases. In spite of the careful oxygen partial pressure control, a part of Fe2+ was found to be oxidised to Fe3+, with a maximal case reaching about 20 per cent. The increase in viscosity of FeO-SiO2 at low temperatures can be attributed to the composition change due to an unavoidable Fe2+ oxidation. In addition, the relationship between the change in the viscosity and the liquidus temperature of FeO-SiO2 based slag was discussed to understand the composition dependence of viscosity.

Jun 19, 2024