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By B Hiebl, J Martens, L Petzold

A research team at the Iron and Steelmaking department at Primetals Technologies has established new upgrading measures for improving the efficiency of the beneficiation process in ironmaking plants, relying largely on pre-existing equipment. After the upgrade, the iron content in the final iron ore concentrate was shown to be significantly higher. Remarkably, the costs for employing the respective measures are surprisingly low.This case study is based on a Kazakh iron and steel producer, whose beneficiation process is currently generating a magnetite concentrate with a final iron content of 65.65 per cent. The study shows that the implementation of Primetals Technologies’ intelligent modification measures to the current beneficiation process, the realisation of more effective dewatering, and the utilisation of an innovative binder lead to an increased iron content in the resulting pellets, reaching a concentration of 69.17 per cent (iron ore concentrate) and 66.5 per cent (pellets).The current operation consists of three closed circuit grinding stages, four stages of low intensity magnetic separation, vacuum disc filters and straight-grate pelletising. By dividing the slurry after the second stage of grinding and the third stage of low intensity magnetic separation, it is possible to divert the more iron-rich fines before they would enter the third grinding stage and the fourth stage of magnetic separation. This then reduces the load on the existing third stage ball mill. Afterwards, the ground material is treated in an additional low intensity magnetic separator and mixed with the previously diverted fraction of the fines. An improved filtration procedure, combined with the application of a highly sophisticated binder, further reduces the amount of additives needed, so that a genuine direct reduced (DR)-grade iron concentrate is produced as a result.All laboratory, pilot and pelletising test work was executed at Primetals Technologies’ laboratories in Austria.CITATION:Martens, J, Petzold, L and Hiebl, B, 2017. Enabling iron ore concentrate for the production of direct reduced iron with pre-existing beneficiation lines, in Proceedings Iron Ore 2017, pp 227–232 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

The recommissioning of the plant at Mary Kathleen involved several distinct phases. The previous plant process was modified significantly, the plant capacity was increased by the addition of new equipment and the exist- ing equipment was in most cases overhauled. This equipment was either reused in its original duty or relocated. Maintenance requirements after the plant was cmommissioned were high because of the amount of modified equipment and also because some old items of equipment were deliberately not overhauled during recommissioning. The equipment that was overhauled has operated reliably. However some new equipment has not been as satisfactory.

Jan 1, 1978

The labour question is one that has caused mine managers much thought and anxiety and is likely to continue to do so as long as human beings exist. The difficulty is to devise some arrangement whereby the interests of miner and mine ownerare identical. Mines cannot be worked without capital, and capital is no good without labour, yet, though both have the mine in common, their interests are not exactly the same. Some men are happy so long as they can scrape through by exerting themselves as little as possible, but capitalists do not work mines for charity, they want some return for their money.Where a large number of men are employed there are bound to be examples of all sorts, good and bad, and it is because one cannot depend on all, that different methods of employment have to be adopted. Which method is selected depends to a great extent on the labour market, local conditions, nature of the ore and the way in which it occurs.A big step towards success is obtained by securing the services of good bosses, not only those who know how work should be done, but men who have a knowledge of human nature. It is a big mistake to be too lenient with a man, also to be unnecessarily harsh. A good boss will always be sought out by good men who have worked under him before, or who have heard of him from others. By a good boss we do not mean one who employs two men where one would do, or who lets the men loaf...

Jan 1, 1901

By I Sherrell, R Jain, P Jansson

With the depleting iron reserves and difficult market conditions, precision in separation efficiency is of utmost importance. Classical local control options are predominant in the industry, but their inability to adjust to resolve application problems of interest has furthered the need of developing and implementing continuous control methodologies.This paper highlights the recent development in control of Outotec SLon® vertically pulsating high gradient magnetic separator (VPHGMS) including programmable logic controllers (PLC) coupled with distributed control system (DCS), on-site human–machine interface (HMI) control panel, advanced process control, continuous online sampling using Courier® 8 and additional modernisation packages including level control and cooling monitoring. These modern control options result in improved efficiencies, promote safer operation and at the same time reduce operational manpower needs.CITATION:Jain, R, Sherrell, I and Jansson, P, 2017. Automation for efficient separation with the Outotec SLon® vertically pulsating high gradient magnetic separator, in Proceedings Iron Ore 2017, pp 211–214 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

The principal source of funding the working capital requirements of gold miners has traditionally been equity. However in the 1980s, with a substantial increase in activity in the exploration for, and the production of, gold the traditional sources of equity finance became no longer sufficient to meet demand. With the often high cost of raising equity, the need for developing alternative financing structures became critical, especially since the stockmarket crash of 1987 which at least until recently, adversely affected the amount of equity capital available for investment in mining.

Jan 1, 1994

By Hellsten K, Eshuys E

The best long-term approach to exploration involves the use of extensive quality data and the integration of many different factors, methods and techniques. The successful exploration manager needs to integrate people, area selection and exploration methods, with the use of descriptive and genetic geological models. Based on a syn-metamorphic genetic model for Archaean gold, successful exploration in Western Australia requires the integration of data on anomalous gold, alteration, lithology and structure. Many other parameters such as geophysics, geochemistry and regolith studies provide additional, indirect information that needs to be integrated into the overall exploration programme. Timely access to research findings and ability to integrate these into immediate exploration has contributed considerably to the success of the gold industry in Western Australia since 1980. Extensive and deeper drilling, and the ability of computers to handle the volume of data generated have enabled effective testing of many more geological targets.

Jan 1, 1996

By B Crowdey, J Wall

The particular underground operation relating to this paper is a gold producer and has an orebody predominately consisting of rhyolite and marcasites pyrite. The ore has been identified as being reactive to nitrates.Operations currently utilise two twin boom Tamrock™ Super-Drill Jumbos for development mining. Capital (waste) headings have a nominal size of 7 m wide × 6 m high, while ore headings are designed at 5 m wide × 5 m high, with the lower reaches of the mine narrowing down to a 4.5 m × 5 m design. Production drilling is currently undertaken with an Atlas-Copco L6 Solo. Due to the reactivity of the ore, inhibited emulsion phase bulk explosives are used for all blasting activities, with electronic detonators utilised in the production sequence.Sublevel shrinkage stoping is utilised when the orebody is stronger than the host rock. After blasting the ore, and during extraction, the surrounding host rock cannot maintain integrity and it ‘collapses’ on top of the ore. Gravity forces this collapsing rock to follow the blasted ore through the drawpoints.The highest risk involved with sublevel shrinkage stoping is the necessity for charge crews to work upon ‘rills’ at the drawpoints, which are occasionally unstable, to charge the next blast ring to be fired. To overcome this issue a loading technique called ‘precharging’ is used whereby two to three rings are charged, but only the first ring is fired. This technique can minimise risks by taking the charge crew away from the rill and brow.As this mine contains hot and reactive ground, strict guidelines from the Australian Explosives Industry and Safety Group Inc (AEISG) are adhered to. These guidelines relate to the sleep time for the precharged rings.This paper describes the issues faced with precharging in hot and reactive ground, the monitoring required and the systems and procedures that were put in place to enable a successful outcome.CITATION:Crowdey, B and Wall, J, 2014. Precharging sublevel shrinkage production rings in hot and reactive ground with electronic blasting systems, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 283–288 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By J Lombardi

OZ Minerals' Prominent Hill copper-gold concentrator is located 130 kilometres south east of the town of Coober Pedy in the Gawler Craton of South Australia. The concentrator was built in 2008 and commenced commercial production in early 2009. The Prominent Hill concentrator is comprised of a conventional grinding and flotation processing plant with a 9.6Mtpa ore throughput capacity. The flotation circuit includes six rougher cells, an IsaMill for regrinding the rougher concentrate and a Jameson cell heading up the three stage conventional cell cleaner circuit. In total there are four level controllers in the rougher train and ten level controllers in the cleaning circuit for eighteen cells.Generic proportional – integral and derivative (PID) control used on the level controllers alone propagated any disturbances downstream in the circuit that were generated from the grinding circuit, hoppers, between cells and interconnected banks of cells, having a negative impact on plant performance. To better control such disturbances, FloatStar level stabiliser was selected for installation on the flotation circuit to account for the interaction between the cells. Multivariable control was also installed on the five concentrate hoppers to maintain consistent feed to the cells and to the IsaMill. An additional area identified for optimisation in the flotation circuit was the mass pull rate from the rougher cells. FloatStar flow optimiser was selected to be installed subsequent to the FloatStar level stabiliser. This allowed for a unified, consistent and optimal approach to running the rougher circuit. This paper describes the improvement in the stabilisation of the circuit achieved by the FloatStar level stabiliser by using the interaction matrix between cell level controllers and the results and benefits of implementing the FloatStar flow optimiser on the rougher train.

Aug 8, 2011

By Ruston R

When coal mining first commenced in Australia, the principle objective was low cost production with development directed toward recovery of 'easy' coal. Future expans- ion of these early mines into major under- ground operations was neither envisaged nor planned. As the demand for coal grew, these mines were expanded to increase output. however, the absence of initial ventilation planning brought about ad hoc systems wh;ch required continual repair and upgrading. These systems proved satisfactory in the short term because the majority of undergrouni coal mining operations were carried out at relatively shallow depths where gas emission rates were low. By comparison, coal is now being won at depths exceeding 500 metres with a corresponding increase in gas flow from the working seams and adjacent strata. The following paper addresses, firstly, the planning and institution of a ventilation system in a mine where previous inefficiencies were many, and secondly, the value of pre- planning a mine ventilation system in the early stages of mine development, and the need to continually review and upgrade the plan to account for unforeseen ^hanges.

Jan 1, 1983

By H Benzer

Grinding clinker to finished cement consumes more energy than any other comminution process. World production of cement in 2009 was 2840 million tonnes and the energy required for comminution was 40-60 kWh/tonne depending on the clinker characteristics and the fineness of the finished cement. Machines used include single and multi compartment ball mills, HPGRs, vertical roller mills, centrifugal air separators, V separators, screens and crushers. The circuit most commonly used consists of a closed circuit HPGR followed by a single compartment ball mill and an air separator, and in operation the variables are adjusted to obtain maximum throughput with no loss of quality of the separator fines.A common objective in cement plants is to reduce energy consumption without affecting the particle size in the finished cement and simulation is used as one procedure to achieve this. Models are now available for all the machines commonly used in clinker circuits and circuit optimisation studies using simulation have been carried out in many plants leading to decrease in energy consumption per tonne of cement. In this paper the models used will be discussed briefly and several case studies will be reviewed which will highlight the effect of change in ball size in a two compartment mill, the role of the HPGR in an HPGR – ball mill – air separator circuit, and the use of a high intensity vibrating mill for producing finished cement with high additive ratio.

Aug 8, 2011

By J S-L Chan, J C. T Chu

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. In its industrial days, Hong Kong’s mining industry was thriving, benefitting from the mineral occurrences that are related to the regional Mesozoic igneous and hydrothermal activities.Hong Kong was unique in the mining sector as it was so small in landmass but with such a rich variety of commodities discovered. There are records of commercial exploitation of tungsten, iron, lead, silver, beryl, graphite, quartz, feldspar and kaolin in Hong Kong before 1981. Of these, most of them are located in the New Territories.The Lin Ma Hang lead mine was operated in the 19th century by the Portuguese and was abandoned in 1958. The Needle Hill tungsten deposit was discovered in 1935 during construction of the Jubilee Reservoir. The Ma On Shan iron mine, which operated for 70 years between 1906 and 1976, was the largest mine in the history of Hong Kong. The Mui Wo lead-silver mine on Lantau Island can be traced back to the Ming Dynasty 400 years ago. West Brother Island, which extracted graphite from 1952 to 1973, was levelled in the 1990s to make way for the development of the airport at Chek Lap Kok.Nowadays, these mines are disused and abandoned, but this extended abstract reviews the legacy of the mining industry in Hong Kong to understand the impact that it had on techniques, the economy and culture.CITATION:Chu, J C T and Chan, J S-L, 2015. The history of mining in Hong Kong , in Proceedings PACRIM 2015 Congress, pp 109–114 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By D J. Williams, M S. Zbik, A Shokouhi

There is a considerable difference in the particle size distribution (PSD) of clay mineral-rich coarse coal reject with variations in the test moisture state and the chemistry of the water used for testing. The coarse coal reject tested were collected from Jeebropilly Mine, located in the Ipswich Coalfields of south-eastern Queensland. Differences between the results of dry and wet sieving analysis indicate a significant breakdown of the clay mineral-rich coarse coal reject on wetting-up. Wet sieving caused a breakdown of the gravel-sized fraction to silt and clay size without significant breakdown to sand size. There is also a considerable variation in the results of hydrometer analyses of the clay mineral-rich coarse coal reject with variations in the chemistry of the water used, particularly at the fine end of the particle size range. The waters used included tap water, coal processing water and deionised water. In addition, the method of dispersion applied prior to hydrometer analysis can have a significant effect on the PSD of clay mineral-rich coarse coal reject, with boiling and sonic vibration causing the most breakdown of the clay particles. This paper describes the testing methodology used and the test results obtained, and attempts to explain the results in terms of clay mineralogy and water chemistry.CITATION:Shokouhi, A, Williams, D J and Zbik, M S, 2015. Influence of water on particle size distribution of clay mineral-rich coarse coal reject, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 239–246 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By A V. Ozsever

The selectivity in flotation columns involving the separation of particles of varying degrees of floatability is based on differential flotation rates in the collection zone, reflux action between the froth and collection zones, and differential detachment rates in the froth zone. Using well known theoretical models describing the separation process and experimental data, froth zone and overall flotation recovery values were quantified for particles in an anthracite coal that have a wide range of floatability potential. For highly floatable particles, froth recovery had a very minimal impact on overall recovery while the recovery of weakly floatable material was decreased substantially by reductions in froth recovery values. In addition, under carrying-capacity limiting conditions, selectivity was enhanced by the preferential detachment of the weakly floatable material. Based on this concept, highly floatable material was added directly into the froth zone when treating the anthracite coal. The enriched froth phase reduced the product ash content of the anthracite product by five absolute percentage points while maintaining a constant recovery value.

Jan 1, 2005

By Liu Wenyong, Huang Yucheng, Yang Ba

High-water rapid-solidifying material, called æhigh-water materialÆ, is a new material developed by the authors over many years. The material can solidify nine times its volume of water into solid. The material is a fine kind of binder with special properties. The solidifying body of high-water material with water has quite a high early strength. The compressive strength of the material within three days can reach the same strength as conventional Portland in 28 days. One ton of the material can replace three tons of conventional Portland cement as binder. Some important achievements have been made in application of high-water material. In metal mines, based on the material, a new full-tailing cemented backfill technology has been developed. The characteristic of the new technology is that high-water material is used as binder and full tailing or alluvial sand is used as backfill aggregate. Because of the application of the new technology, major technical problems in backfill technology such as classifying of tailing, dewatering, transportation of pulp, low strength of backfill body, environmental contamination and so on, have been solved.

Jan 1, 1998

By G King, Q Shu, W Cao, F Gyakwaa, H Singh, S Wang, M Huttula, T Fabritius

Metallurgical slag, such as refining slag, is essential to enhance or promote steel cleanliness. The CaO–MgO–Al2O3–SiO2 system is the primary source of oxides-based inclusions. It plays a vital role in applications in various pyrometallurgical processes. Numerous thermodynamic databases and physicochemical properties of slag studies mainly focus on quenched samples and measurements at room temperature. Consequently, the present study explored the physicochemical, structural properties and crystallisation evolution for CaO–MgO–Al2O3–SiO2 glassy slags via in situ hightemperature Raman spectroscopy and synchrotron X-ray diffraction. The study was carried out by synthesising CaO–MgO–Al2O3–SiO2 slag with varying Al2O3/SiO2 ratios. The results from the in situ high-temperature measurement demonstrated a pattern showing a transformation of a broad peak from the glassy matrix to crystalline peaks. The study showed crystallisation of dominant phases such as Ca2SiO4, Ca2Al2SiO7 and CaAl2O4 that correspond and are attributable to changes of structural units during in situ high-temperature measurements. The results further showed a correlation between an increase and transformation in crystalline phases observed from the spectra obtained from non-isothermal heating of the samples.

Jun 19, 2024

By D Tucker, K Harney

Hatch forecasts that an increasing share of seaborne traded iron ore will be ultrafine, being either concentrate or pellet feed. This provides several challenges for the iron and steel industries, but the principal concern is: how much ultrafine iron ore can be consumed on sinter strands and with a minimal effect on productivity?This paper will identify new supply by project through 2020. Demand will be estimated for sinter production and practical steps will be identified to increase ultrafine consumption in sinter strands. The long-term iron ore price will be forecast to balance supply and demand. The paper will conclude by assessing how the pricing of ultrafine ore will develop relative to the Chinese iron ore indices.CITATION:Tucker, D and Harney, K, 2015. Iron ore ultrafines challenges and opportunities, in Proceedings Iron Ore 2015, pp 501–504 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

In setting out to describe the methods and machinery employed at Iron Knob the writer does not attempt to give any information as to the situation, topography or geological features of the locality. This, together with estimates of the quantities of ore still available, has been carried out in a most thorough manner by R. L. Jackr and F. R. Hockey. This essay is intended to deal with working methods as they exist to-day, beginning with drilling, blasting, quarry traction, etc., and touching on such details as the supplyof electricity, water and compressed air.At the present time almost the entire output of ore is won from the hill known as Iron Monarch. The form of the hill, a smooth, rounded dome, rising some 640 ft. above the plain and having a base diameter of n miles, lends itself ideally to the "bench" system of open-cut quarrying.Fig. 1 shows the relationship of the benches "A," "B" and "E" in their order of development. Bench "E" is at present the principal working, but, as the greater part of the ore above this level has now been removed, bench "A," some...

Jan 1, 1936

Chalcopyrite concentrate was combusted in oxygen-nitrogen atmospheres, the composition of which ranged from 1-100 per cent oxygen. Factors studied included particle size, experimental temperature and oxygen concentration. The study was assisted by chemical and X-ray diffraction (XRD) analysis and temperature measurements of single particles. Size reduction occurring after melting was found to have a major effect on the overall reaction time. Thus time to attain ignition was largely determined by the original particle size, whereas combustion time was independent of this factor. For particles larger than 40 I'm in air the time to attain ignition predominated. The maximum temperatures measured for single particles were the result of pyrite present in the concentrate. Chalcopyrite did not attain thesame temperatures. Vaporization, either as CU(g) or CuO(g) lImited the temperature. Maximum temperatures measured for single particles of pyrite ranged from 1610°C in 14 per cent oxygen to 2360°C in 100 per cent oxygen (both at 700°C). Measured temperatures were compared with those calculated from a diffusion-based model.

Jan 1, 1983

Differences in the assay results of replicate samples engender doubts on the reliability of ore sampling and of assaying procedures. An analysis of variance is a technique to estimate the variability at each level of the procedures. In an example, the variability of one-metre core samples was far greater than that of the assaying technique.

Jan 1, 1976

The extent to which man's activities are influencing the earth's climate is subject to considerable debate. Internationally however, this debate has been put aside somewhat by the Kyoto Protocol. This international agreement is the political response to the threat of Global warming, predicated on the precautionary principle.NZ is seeking to be a leader in the Kyoto Protocol. Given our unique GHG emission profile and the structure of our economy, and the major uncertainties in both the science of climate change and the Kyoto Protocol itself, this desire to lead is absolutely inappropriate in this instance. We face a different, and often more severe, set of challenges in an economy that prices C emissions than virtually all of our trading partners. Unfortunately, these differences have not been reflected in climate change policy development to date. This represents a major threat to New Zealand's economy, wealth and jobs, particularly in the sectors that have been the core drivers of our economy over the last 20 years or so - agriculture, energy, primary processing. We do not, and should not, seek to avoid the issue but we must protect our economy and move with or follow our trading partners and competitors, not lead them.

Jan 1, 2002