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An airlift pump is fitted to the screw conveyor of a decanter type centrifuge in order to pump out soft cakes which are difficult to discharge from a standard decanter. The new patented2 design improves separation performance and allows more stable operation, particularly when operating the decanter as a thickener.

Jan 1, 1989

By J Player, P Evans, G Sweby

Achieving quick underground access after the completion of an open pit mine can be critical to maintaining project value and ensuring regular ore feed to the mill. This paper outlines the design and construction for two portals in an active open pit to commence underground development quickly whilst installing appropriate ground control to maintain long term access in an uncertain setting. Implementation of the portal designs was complicated by the change in underground design from hangingwall access to footwall access late in the life of the open pit due to preferable ground conditions. The portal locations did not have easy access for ground support installation integrated into the pit design due to the timing of the underground design changes. Practical implementation of the ground support systems subsequently became a key part of the project. Intact rock strength, rock mass characteristics, gradational weathering / alteration profile and structural information were modelled against pit displacement monitoring as the basis from which the portals were located and ground support schemes designed. Conditions around one of the portals necessitated numerical modelling to estimate the appropriate level of ground control for long term stability. The design was completed whilst the open pit was actively on-going and the portal areas not entirely exposed. The rock mass assessment and analysis for the two portals indicated different ground support scheme capacities would be required. The expected level of control for one of the portals also necessitated the use of monitoring with extensometers and load cells to ensure the rock mass response and ground support scheme performed as planned. Construction of the portals demonstrates the benefit of a considered design process, a plan which allows practical installation of ground support schemes where access is limited, the benefit of ongoing monitoring to ensure performance remains within design limits and the challenges involved working within an active pit with limited floor space.

Mar 15, 2021

The production of copper by the Outokumpu direct blister process commenced in July 1988. The problems and incidents encountered in commissioning the main smelter equipment are outlined. Early difficulties were encountered in process control, hot metal handling, dust buildup in the off gas handling equipment, waste heat boiler tube failures, foam over of hot metal into the waste heat boiler and failure of ancilliary equipment.

Jan 1, 1989

By D K, S Freij, A Rossiter, X Han, B Feng

In mining operations, the removal of overburden to expose the ores is achieved by rock blasting using ammonium nitrate based explosives, eg ammonium nitrate-fuel oil mixtures, commonly known as ANFO. However, ammonium nitrate can react with pyritic shales that are often found in many mines, leading to premature detonation or spontaneous explosion. In order to minimise the occurrence of spontaneous explosion, the reactivity of the shale in a mine must be assessed. This will provide a better understanding of blasting risks and thus will improve the safety and the cost efficiency of blasting through the selection of appropriate explosives. In this study, shale samples were collected from different locations in Western AustraliaÆs Mt Whaleback iron ore mine and geochemically characterised. The reactivity of the shale samples towards ammonium nitrate and ANFO was investigated using a combination of large-scale firing range tests and laboratory isothermal reactor tests. Results of the firing range tests show that the reactive ingredients of the shale are the limiting factor for the reactions between shale and ANFO. Based on the firing range test results, further isothermal reactor tests were conducted to investigate the reactivity of shale samples towards ammonium nitrate under controlled conditions. Analysis of the results from the firing range tests and the isothermal reactor tests shows that there are correlations between the reactivity of shale samples and several geochemical characteristics such as sulfate, sulfur, ferrous and zinc content.

Jan 1, 2005

Polish coal mines are well equipped with methane monitoring systems,nevertheless the worsening conditions force a continuous impro- vement in the field of environmental monitoring. Application of modern electronic components make it possible to design the new modular telemonitoring system incorporating the best features of the older systems,widely employed in Polish collieries, eliminating their weak points. Several new sensors and portable instru- ments for methane monitoring and early fire detection have been developed and tested in mining conditions.

Jan 1, 1988

The Wild Dog gold-silver-copper deposit represents a new ore-deposit type in Papua New Guinea. The telluride vein mineralisation is associated with a Tertiary caldera and has similarities with that from the Baguio district, Philippines, Vatakoula, Fiji, and the San Juan Mountains, southwestern Colorado. The deposit, discovered in July 1983, has negligible stream silt and concentrate anomaly, and a float-train limited to within 300m of the prospect. The comparatively recent exposure of the vein system may explain the limited stream expression of the deposit. At least three major veins occur in the deposit; the vein system strikes north- northeasterly, dips 78¦W, and has a maximum strike length of 1350m. Veins are enveloped by a wallrock dominated by an assemblage of quartz-illite-pyrite. Four types of silicification related to multiple vein filling events have been defined on the basis of field relationships, drill-core intersections, petrology and fluid inclusion study. To December 1986 a total of 22 diamond drill holes (2304m) and 40 reverse circulation drill holes (1833m) have been completed on the deposit, defining a 750m zone of interest. The upper 30m of the deposit is oxidised. Much of the high-grade mineralisation in both the sulphide and oxide portions of the deposit is restricted to ore- shoots which strike parallel to the overall vein structure and are vertical to steeply westward dipping. They are defined geochemically by the lg/t Au cutoff and geologically by the relative increase in the vein density of auriferous grey-black sulphidic silica, the final vein filling event. Metallurgical studies and the results of close-spaced drilling have demonstrated the very good repeatibility on duplicate assays, and the extremes of grade variability of mineralisation over very short distances. The good assay agreement on duplicate samples .s indicative of fine, dispersed gold.

Jan 1, 1987

How many of you have felt tired and light-headed after standing or working in the sun or by the oppressive, hot, muggy conditions of an Australian summer? For those of you who have, you've experienced the minor effects of heat stress. Heat

Jan 1, 1994

Subsidence prediction methods can be divided into two basic types: empirical and analytical. Empirical methods are based largely on a combination of experience, intuition and observations from a large number of observed subsidence data. They are simple in their application, but they are not based on any principle of mechanics. Analytical methods are based on equivalent material modelling principles, where the ground surrounding the extraction is mathematically represented by idealised materials that deform according to the principles of continuum mechanics. Wide applicability and improved understanding are the principal advantages claimed for this approach. In NSW, significant progress has been achieved in the area of subsidence prediction during the last ten years. Empirical prediction curves are available in NSW for predicting the ground movement in the Southern and Newcastle Coalfields. A' comparison of subsidence values predicted from these curves with the actual monitored values indicates that the curves are adequate for use in conjunction with the existing damage assessment methods. Future research for improving the existing empirical prediction curves can only be justified if it is cost effective. There are several numerical models currently in use in NSW for predicting subsidence. The models do not appear to be superior in their ability to predict subsidence when compared with the empirical curves. the performance of these models will no doubt improve along with advances in defining strata properties and failure mechanisms.

Jan 1, 1991

The mmmg of alluvial gold involves many deposits of theMesozoic, Tertiary, and Quaternary Ages in processing. Majorfeatures of the composition of such alluvial deposits are the lowcontent of gold and the small size of the gold particles. Atpresent, the gold-miners treat alluvial deposits in which a portionof fme gold (0.25 mm) exceeds 45 per cent. It is expected that by2000 these resources will be the main deposits mined (Zamyatinet aI, 1991).Under real industrial conditions the losses of minus 0.25 mmmetal are 50 per cent and more. The low level of recovery of finegold is observed not only at concentrators equipped with sluices,but also at concentrators equipped with modern diaphragm andpistonless jigs (Table 1).

Jan 1, 1993

Low tonnage quartz vein-hosted stibnite lodes are widely distributed in rocks of the Tasman Fold Belt System in eastern Queensland, with particular concentrations in the Hodgkinson - Broken River Fold Belt and to a lesser extent in the Gympie Province of the New England Fold Belt: Higher grade deposits have been worked intermittently on a small scale since 1873, resulting in the production of about 5500 tonnes of antimony ore/concentrate with an estimated grade of about 55% Sb. Future production of antimony may be as a by-product from deposits, currently being explored/mined for gold in the Hodgkinson/Mitchell River area and the Amanda Bel goldfield. Establishment of an antimony processing plant in Queensland using the Quelar Process would provide a more reliable market for small producers and could stimulate future exploration and production.

Jan 1, 1990

By McConachy G. W, Wright J. V

During the 110 years since the discovery of the Broken Hill PbZnAg deposit six major mining companies have mined the ore body and explored the ore environment. Despite this activity, no new orebodies have been found at Broken Hill. The failure to discover large new resources cannot be attributed to a lack of activity because major companies have maintained substantial exploration commitments over many decades. This suggests that not only was a unique coincidence of conditions required to form the deposit but also that full recognition and definition of the critical parameters may not yet have been recognised. In an attempt to illuminate some of the more unusual and poorly studied characteristics of the ore environment some new areas of investigation are presented here which may contribute to understanding the ore deposit setting and focus exploration towards different and perhaps more productive targets. Sedimentological characteristics of the host succession of the Broken Hill deposit are apparently unique along the line of lode. An upward-coarsening megasequence reflected in the development of clastic psammites stratigraphically below the ore deposit is one important ingredient which has received little exploration focus. These psammites also host mineralisation and form part of a spectrum of quart-zrich rocks collectively referred to as gametiferous psammites, garnet quartzites and blue quartz lodes. Sedimentological data interpreted from outcrop, drill core and downhole geophysical well logs support a elastic origin for some of these rocks; an interpretation which is at variance with traditional interpretations favouring an exhalative origin. A clastic origin for many of the footwall psammites, and their close spatial association with the orebodies suggests their role in ore formation was important. It is interpreted as a critical part of the fluid flow architecture within the sedimentary basin, which focussed ore forming fluids into an unique environment favourable for trapping mineralisation. Detailed stratigraphic correlation near the deposit has also highlighted that quartzofeldspathic rocks (Potosi gneisses and lode pegmatites) have complex relationships with ore. Suites of stratabound quartzofeldspathic pegmatites have received limited study, but their distribution and voluminous development suggests they may be as important to ore formation as the psammitic lode rocks which host the orebodies. These associations are not in conflict with some recent ore forming models invoking deposition in a shallow water environments of deposition. The geochemistry of parts of the host sequence has been studied extensively in the past but this has not been merged with current stratigraphic subdivisions. A large drillhole data base now permits the geochemistry to be related to the sedimentary succession and reveals that a signature involving stratigraphic vectors best illustrated by changes in MnO, Na2O, Pb and Zn can be detected. This is interpreted to reflect sedimentary basin processes as opposed to a classical volcanic hydrothermal alteration pipe associated with seafloor venting. The stratigraphic setting together with characteristics of some of these poorly understood areas is discussed to emphasise that construction of sound models for exploration requires the total ore environment to be studied with attention directed to the geometry and setting of the full range of host rocks. Control of the greater portion of the line of lode by a single company, Pasminco Australia Limited, now permits disparate datasets and observations to be merged and presents new opportunities and encouragement for model refinement and exploration success.

Jan 1, 1993

BHP is the world's largest copper concentrate producer with production from mines at Escondida (Chile), Ok Tedi (Papua New Guinea), and Island Copper (Canada). The entire concentrate production is further processed into refined copper by third-party smelters around the world. In anticipation of an expansion in the global copper concentrate production capacity and a corresponding increase in treatment and refining charges by copper smelters, BHP has continuously evaluated various opportunities for downstream copper processing. An expansion in the Escondida mine production, combined with BHP's interest in processing some of its concentrate production on-shore in Chile, ultimately resulted in the development of the Escondida Leach Process. This process was specifically developed for higher grade concentrates, such as from Escondida. An ammoniacal lixiviant and air are used under ambient conditions to leach less than one-half of the contained copper values. After solid-liquid separation, the solution is subjected to solvent extraction regenerating the ammoniacal lixiviant and the copper loaded organic phase is stripped in spent electrolyte returned from the electrowinning plant where ultra-high quality SX-EW copper is produced. The solid leach residue can, if required, be upgraded by flotation to produce a high-grade copper concentrate with improved fuel values and a pyrite tail for disposal. After an 18-month bench and pilot plant scale program and an engineering feasibility study, Minera Escondida Limitada decided to build an 80 000 tonnes of copper per year facility near Antofagasta, Chile. The installed investment cost amounted to around $160 million. The plant went into commercial production in November 1994 and better than 99.9995 per cent Cu cathodes were produced right from the start. BHP believes that the process and the commercial plant are an excellent example of a novel approach advancing the science of copper metallurgy in harmony with present demands for environmentally sound processes and high quality products.

Jan 1, 1995

By H Kim, M J. Sun

In order to reduce carbon emissions from the steelmaking process and achieve carbon neutrality, global steel companies are establishing their own medium to long-term strategies and implementation plans using competitive technological advantages held by each steel company. At this point, Hyundai Steel has formulated a product-oriented carbon-neutral strategy based on innovative processing that makes use of Hyundai Steel’s own strength. Based on our experience in electric arc furnace product manufacturing and blast furnace operation in an integrated steel mill, Hyundai Steel is driving the Hy3 (Hy-cube) project, which involves a unique hybrid production system utilising hydrogen and hydrogen-based renewable energy sources. This initiative aims to achieve carbon-neutral production and eventually specialise in producing premium carbon-neutral automotive parts. The project has originality in that it involves not only designing processes using electric furnaces to produce premium steel products such as car body panels and electrical steel sheets, but also aims to reduce carbon emissions from the process, developing carbon-neutral products based on market demand. To assess the feasibility of the Hy3 project, Hyundai Steel conducted two pilot productions. The first pilot was producing a prototype of lower-arm part using electric arc furnace with three different kinds of raw materials: molten iron, HBI (hot briquetted iron), and scrap. Successful performance evaluation of auto parts with 1 GPa strength was achieved. The second pilot has been focused on tire cord steel, with the first-phase tests yielding a 33 per cent reduction in carbon footprint (CFP). Using the advantages of operating experience in electric arc furnace, Hyundai Steel is preparing for test operations producing various automotive parts using an electric arc furnace (EAF) to advance the Hy3 concept. From a medium to long-term technological development perspective, Hyundai Steel’s blueprint includes producing high-end carbon-neutral steel products using hydrogen-reduced iron as raw material.

Jun 19, 2024

By J A. Braithwaite

Social licence to operate is not a new concept for the mining industry, referring to stakeholder approval or acceptance for the activities and impacts of a project, company or industry. It is intangible, dynamic and non-permanent, hence it needs to be earned and then maintained (Thomson and Boutilier, 2014). It has also been argued that social licence extends beyond building approval or acceptance, into engagement for long-term development (Owen and Kemp, 2012).There are many examples where stakeholder opposition – or withdrawal of social licence – have increased capital and operating costs, extended schedules and impacted reputation. At its extreme, the withdrawal of social licence to operate can also contribute to or be the catalyst for mine closure.The key benefit of obtaining a social licence is a reduction of risk. Stakeholder support and advocacy, as well as the implementation of social performance programs that contribute to social licence, can be beneficial in terms of schedule, costs and other benefits.While decisions to close a mine are generally driven by resource availability or economic conditions, the social, economic and environmental legacy remaining post-closure is of importance to many stakeholders. With a number of significant mines now approaching closure within Australia, we are seeing heightened community concern about the economic and social impact of mine closure and the success of land rehabilitation. So how does the concept of social licence to operate extend into the closure phase of the mining life cycle?CITATION:Braithwaite, J A, 2016. Social licence to close?, in Proceedings Life-of-Mine 2016 Conference, pp 176–179 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By C Reed

Titaniferous magnetite deposits are a significant source of vanadium for use in high strength steel alloying and other chemical applications. The mineralogy of the deposits varies markedly and the ore characteristics strongly influence the process route selected and the metallurgical outcomes. Characterisation of the ores reveals the presence of magnetite, ilmenite and other minerals such as spinel hematite and goethite with variable degrees of weathering along with weathered products of host rock. The standard processing route is to crush, grind and magnetically recover a concentrate for salt roasting to produce a soluble vanadate. Ore beneficiation is practised to generate an iron based mineral concentrate containing much of the vanadium with low silica levels of two per cent. Typical processing problems encountered are fine liberation size, over grinding of the magnetite and variable response to magnetic separation resulting from the weathering profile. Beneficiation options are restricted, and generally focused on producing a combined iron and titanium rich concentrate containing vanadium due to the fact that ilmenite and magnetite and their products of weathering are magnetic and have similar specific gravities making their separation difficult. The ilmenite usually contains low levels of vanadium making its separation highly desirable from the iron mineralisation containing higher levels of vanadium. Salt roasting of vanadium ores followed by water leaching has been the standard processing route for many years. The cost of suitable sodium salts, availability of capital and increasing energy costs and energy availability are critical factors in determining the viability of aspiring vanadium producers. To date, only Windimurra has acquired full capital funding, secured energy and sodium salt supplies at suitable cost that enable the construction of the project. Low overall recoveries of vanadium to concentrate roasting at up to 1200¦C are critical cost issues. In this paper, factors influencing the recovery of vanadium are reviewed and emerging processing trends explored. The important features of the processing of titaniferous magnetites have been condensed from the literature, published works, company websites, our own work and personal communication.

Jan 1, 2008

By S N. Nyoni, K C. Corin, C T. O’Connor

Considering future water scenarios, as influenced by the increasing scarcity of water and the move towards sustainable process engineering etc, the closed water circuit becomes an important point of study in metallurgical operations, such as in milling and flotation. However, a deterrent in the use of recycled process water is often a lack of understanding of the effects of the accumulation of dissolved ions and other process chemicals. Recovery of the valuable minerals may be impacted by the concomitant complex mineral-pulp chemistry interactions. Literature indicates that these interactions are not necessarily antagonistic to process outcomes. Wet milling using steel media results in the dissolution of Fe from the media, the rate of which is dependent, inter alia, on the type of media and the chemical conditions of the aqueous environment in the mill. The pulp-phase interactions of dissolved ions with sulfide minerals may result in significant changes to the chemical conditions in the mill, which may subsequently impact negatively on the flotation recoveries. To understand the effect of these interactions in the context of the processing of sulfide minerals, this study seeks to consider the effect of three factors, viz mineral type – pyrite (Py) and galena (Gn) -, milling media of different compositions – forged steel (FS), 21 per cent high chrome and ceramic media -, and water chemistry, viz, deionised water (DI) and synthetic plant water (SPW). Ceramic media and galena are used for the respective control cases where the milling media and sulfide mineral contribute no Fe species. Using DI as a control case, a high ionic strength case is used to mimic the changes in water chemistry for a closed water circuit. Batch flotation tests are used as a diagnostic tool to determine the effects of these media-water-mineral interactions to investigate correlations between the chemical reactions occurring and chemical species present during the milling process and the ultimate flotation performance.

Aug 24, 2022

What is the real value of your data?Given that the cost of collecting and analysing an individual sample is always rising, it is important to understand the true value of a sample and that you are confident that you receive good value for your exploration dollar. Unfortunately too many samples are still collected today that will end up as worthless data; a liability to those who own it and a hindrance to finding that ore body.

Jan 1, 1986

By H Jha, M C. Thomas, P Gupta, S K. Sit

The modern jig with a state-of-the-art control system is much more effective than its older version. This improved control system is used to modulate the amplitude and the frequency of the jig cycle. These two prime parameters are optimised with respect to feed characteristics for best jigging performance. Based on this understanding any jigging plant can be optimised. In addition to these established facts present study shows process efficiency improves further through optimisation of the feed quality.

Jan 1, 2007

This paper describes the application of the Total Productive Management (TPM) technique as a performance improvement initiative for a coal mining operation. It discusses the objectives of TPM, with the driver for improved production performance being the Overall Equipment Effectiveness (OEE) of the equipment or process, and with the development of "ownership" as the behavioral approach to equipment management and continuous improvement through cross-functional and area-based teams. It illustrates the concept of equipment management as defects management.The scope for application of TPM to the coal mining industry is immense. The harshness of the operating environment can be a major generator of equipment defects, and a current paradigm in the industry accepts these defects as an unavoidable outcome defining maintenance costs in this environment. However recent benchmarking studies have highlighted that maintenance costs per operating hour in some mining operations are more than double the vendor's estimate of "best practice". The paper refers to these studies which also compare maintenance costs of fixed and mobile plant and equipment to "best practice" outcomes in comparable process industries.

Jan 1, 1998

By L Hussey

Mt Keith concentrator treats low grade disseminated nickel sulfide ore supplied from the adjoining open pit mine. It is a traditional crushing, two-staged closed circuit grinding circuit (SAG & Ball Mills), followed by a complex split-size rougher, scavenger and cleaner flotation circuit. In 2016, 10.5 Mt was milled, at an average head grade of 0.54% Ni, yielding 35 000 nickel metal tonnes in concentrate.Historical analysis of the plant data indicated that of all the nickel lost in the fines rougher circuit tails stream, 25.6% was recoverable in an eight minute laboratory scale flotation test. These results implied that this fine nickel was readily available for recovery in the plant, either through operational improvements or additional flotation capacity. With operation optimisation ongoing, and capital within the business focused elsewhere, plant personnel were challenged to think differently about improving recovery.In 2012, a separate project to improve plant recovery when treating high talc ore was completed. Amongst other vessels, this project saw the installation of two 150 m3 Outotec Cells to the scavenger section of the fines rougher, middlings and scavengers (RMS 1) circuit. Since installation, the operation of these cells resulted in difficulties immediately upstream with instability in the scavenger cells. It was therefore decided that these cells would be better suited to treating the fines rougher circuit tails.The alterations required to divert these flows were minimal, with the capital project totalling $220 000.In the two years since installation, the fines rougher tailings nickel grade has dropped by 9.9%. The scavenger circuit has also seen a 2.8% reduction in tailings nickel grade, and instability issues were immediately resolved. This project serves as a lesson in how existing plant infrastructure may be better utilised to maximise recovery. Although this is especially applicable when capital constrained, such re-appropriation can be considered at any point to maximise return on existing assets. CITATION:Hussey, L, 2017. Repurposing flotation capacity at Mt Keith nickel concentrator, in Proceedings MetPlant 2017, pp 254–258 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017