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Identifying Opportunities to Reduce the Consumption of Energy Across Mineral Processing Plants

Sep 13, 2010

New knowledge has no economic value unless it can be applied, or æcapturedÆ, as the R&D jargon has it. Australia probably spends more than $500 m per year on mineral industry R&D, distributed amongst the mining companies (IR&D Board, 1997), CSIRO, the universities and others. The investors in this research (industry, and the community via government) will expect some sort of return from their investment. The return will be poor unless the know-how developed in R&D programs can be exploited. This paper explores some of the issues involved in capturing the outcomes of mineral industry R&D in a form which can be exploited for economic benefit, and suggests ways in which it might be done better. It is based on the experience of the JKMRC in conducting applied research in mining and mineral processing and delivering it to the industry. It may seem presumptuous for a research contractor to be telling its clients how to do their job. However, the process of developing, acquiring and implementing R&D outcomes has to be a partnership between provider and receiver, in order for this process to work efficiently. This applies whether the two parties operate within a single corporation (a corporate laboratory and a business unit, for example) or are two entirely independent organisations (eg a mining company and a university). Both partners have a role to play, and the best examples of realising the benefits of R&D almost always involve the open-hearted and skilful handling of this synergy.

Jan 1, 1998

By G Harbort, K Quan

Traditional engineering practice for concentrator design uses a mixture of risk minimisation options and capital minimisation approaches. Often this is based on the preferences and experiences of the engineers involved.A geometallurgical approach involves identifying primary lithology, alteration, and mineral dispersion patterns within a deposit to allow representative samples for test programs. This provides a method to infer from laboratory test results meaningful production data for larger amounts of the ore body. Geometallurgical models can be integrated into the resource block model and subsequent mine plan and can assist in predicting when difficulties in the processing route might be expected, allow adjustment of the design to compensate for these or provide an early warning system so that production forecasts can be more adequately developed. Simulation modelling is the process of creating a computer model of a real system based on mathematical logic. In simulated time, the model explores the randomness and chronological sequencing of events observed on real systems. The objective is to mimic the real system with sufficient accuracy to make predictions of real behaviour under experimental conditions. Amec Foster Wheeler often use the ‘discrete-event’ simulation modelling technique. This method is well suited for inclusion of the statistical variation of effects in unit operation, mechanical availability, throughput and operating strategy (based on historical operating data for equipment downtime), operating schedules and equipment capacity. The net result of the simulation model is an analysis that can quantify risks in terms of system performance and capital and operating costs.CITATION:Harbort, G and Quan, K, 2017. Concentrator design – standard engineering practice versus geometallurgy and simulation, in Proceedings MetPlant 2017, pp 195–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

The Effect of Molecular Weight on the Adsorption and Efficacy of Polysaccharide Depressants

Sep 13, 2010

Jan 1, 2004

Integrated Utilisation of Desulfurisation and Skimming Slag

Sep 13, 2010

Au-Ag Recovery from Complex Ore by Flotation

Sep 13, 2010

How to Evaluate Crushed Rocks for Concrete Production

Sep 13, 2010

By Johnston RF

The motivation for, the structure of, and the overall features of a block release Graduate Diploma program designed for practising minerals engineers are outlined. It is demonstrated that because of the very specific subjects taught, the course has the potential to effect significant improvements in operating plant performance. Through lifting the skill level of the participants and therefore advancing their career prospects, the course can raise staff morale and improve plant performance and productivity in their work place.

Jan 1, 1993

By C Hawtin, B Miller, D Ashton

Ernest Henry mine (EHM) is an Iron oxide copper-gold sublevel cave mine located 30 minutes north of Cloncurry in North-West Queensland. The underground mine lies beneath open pit excavations, which were in operation from 1999 to 2011. Fault structures carry large quantities of water from the cover sequence aquifer into the underground mine area. The open cut excavations exacerbates vulnerability of the underground mine to the high intensity wet season storms of northern Queensland. These factors combine to make hydrogeological issues high priority for mine operation. Water-related risks include the cost of removing water from the mine, flooding risk and mud rush potential.Turnover of key technical staff in late 2015 at EHM resulted in the mine being left in an untenable position of losing the primary source of technical knowledge. Due to encouragement of cross-disciplinary activity coupled with workload and resource sharing, the management team were confident in utilising on-site personnel to offset loss of experienced personnel.Remaining geology personnel took additional responsibility for hydrogeological monitoring equipment and planning of upcoming work. Consultant input was limited to review only and an emphasis was placed on knowledge transfer to the geology team. Using this strategy, a 13 hole dewatering program was successfully implemented, achieving a significant water level drop in areas of elevated hydrological risk, whilst also upgrading the hydrological monitoring sensor array.Through a development program centred on cross-disciplinary exposure, the technical team was able to retain key technical knowledge despite staff turnover and produce strong results outside traditional training and roles. This paper serves as a case study on the methods, strengths and drawbacks of putting a focus on cross-disciplinary exposure as a method to combat staff turnover.CITATION:Ashton, D, Miller, B and Hawtin, C, 2017. Go with the flow – managing hydrogeological staff turnover at Ernest Henry mine, in Proceedings Tenth International Mining Geology Conference 2017, pp 129–136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By P Trotta

The majority of water to the Olympic Dam mine and the nearby townships of Roxby Downs and Andamooka is supplied from the Great Artesian Basin (GAB). There are no permanent local water sources available to Olympic Dam. The use of water from the Great Artesian Basin by Olympic Dam receives considerable attention by BHP Billiton and is extensively regulated by the Government of South Australia. Olympic Dam has robust business management systems in place to ensure the sustainable use of water from the GAB including ISO9001 and ISO14001 systems to deliver the targeted outcomes and obligations of the Olympic Dam Environmental Management and Monitoring Program. The management systems ensure that Olympic Dam retains accountability for its water demand from the GAB over the life of the mine. This accountability has delivered continuous improvement in water use efficiency driven by operating discipline, implementation of water saving projects, using water on a fit for purpose basis including substitution from non-GAB sources, and risk management to prevent and mitigate water supply disruptions to Olympic Dam and Roxby Downs. Since the establishment of Olympic Dam, BHP Billiton has funded a reduction in GAB water flow from bores, previously going to waste, that is greater than the annual average flow used by Olympic Dam.

Jan 1, 2009

Pilot-Scale Study of Deep Cone Thickener for Phosphatic Clay Dewatering

Sep 13, 2010

The Liddell longwall equipment consists of 118 four leg supports, a shearer and armoured face conveyor of 170mm length. The equipment was supplied to Coal & Allied Operations Pty Limited (Coal and Allied) by Westfalia Australia Pty Limited (Westfalia). The project commenced as a feasibility study in 1983, a proposal was put to the board of directors in March 1984 and a specification distributed. Nine companies tendered for the supply of a longwall face and the supplier was selected from a short list of four companies. At the same time Coal & Allied examined the facilities at Liddell Colliery and decided to upgrade the conveyor belt system to cater for the high production from a longwall face. The surface facilities, transport system, water and electrical supplies to the colliery were also to be upgraded. During the twelve months to December 1985, the colliery was upgraded while the longwall equipment was being manufactured. The manufacturing process involved roof support testing, compatibility testing and finally a build up of 40m of longwall face

Jan 1, 1986

The main aim of the conference is to work towards improved useage of steelplant slags which have largely been considered waste mater- ials, This paper summarised investigations carried out on the suitability of air cooled blast furnace slag, blast furnace granulated slag and basic oxygen steelmaking slag as road base materials. All slag samples were obtained from the PortòKembla Works of Australian-Iron and Steel Pty Ltd. Since road making materials are increas- ingly being characterised by use of resilient moduli, the compressive strengths and resilient moduli were determined for road base of the following slags. 1 Air cooled crushed blast furnace slag 2 mixes of air cooled blast furnace slag, granulated slag, and lime 3 mixes of air cooled blast furnace slag,-granulated slag and basic oxygen steelmaking slag. Evaluation of a local dacite (dense medium grained igneous rock, classification rhyolite), generally considered an excellent road base course material, was carried out for use as a reference material.

Jan 1, 1979

The Argyle AK1 Pit has been operating and producing over 25 per cent of the worldÆs diamonds by volume for over 20 years. The mining boom in Western Australia is creating upward cost pressures to ArgyleÆs mining operation while the price received for its product remains flat in comparison to many other Western Australian commodities. This incongruity, which when combined with other circumstances such as the pit being close to the end of its mine life, a decline in head grades and a tightening in operational constraints caused by the pitÆs maturity, is causing the leadership team at the mine to utilise innovative strategies in order to ensure that the open pit continues to perform economically until its final closure in late 2010. The strategies that will be discussed in this paper are step change business improvement methods, localisation of the workforce, employment of Aboriginal people and the use of a clear and concise consultation process in order to provide certainty to a workforce working in a pit during boom times where pit closure is imminent.

Jan 1, 2007

Additional Attractive Force Between Alumina Particles Due to Low Solubility of Dicarboxylic Acids

Sep 13, 2010

By M Suzuki

Although several models for the surface tension of molten oxide slag have been proposed, suitably accurate predictions of this property are not yet possible. The surface tension, or surface excess free energy, of molten oxides is largely determined by the ionic coordination induced by surface relaxation. However, the associated mechanism of surface structural relaxation for molten oxide mixtures such as slag is complex and not yet fully understood. To allow a better evaluation of surface relaxation characteristics, the present work analysed the ionic coordination associated with the surface-relaxed states of several oxide mixtures. This work especially focused on calcium aluminate slags because these materials exhibit complex relationships between composition and surface tension. The effects of incorporating low concentrations of SiO2 as a surface active component on the surface ionic coordination were also examined. X-ray absorption techniques were used to assess oxygen and cationic elements in glassy samples after surface relaxation treatments, and molecular dynamics simulations based on a polarisable ion model of molten slag with vacuum/melt interfaces were also performed. The X-ray absorption techniques provided data related to electron yields (which are primarily associated with surface features) and fluorescence yields (which evaluate the bulk material). Thus, the ionic coordination characteristics of both regions were investigated. The results of molecular dynamics calculations allowed statistical analysis of the distributions of Al- or Sicentred polymorphs as well as the bond angles between cations and oxygen anions in the vacuumexposed and bulk regions in the equilibrated melt. The results indicated that bridging oxygen ions were preferentially distributed in the relaxed surface region rather than non-bridging oxygens. These bridging oxygen ions represented vertex connections between AlO4 or SiO4 tetrahedra. In the case of the calcium aluminate slags, the addition of one Ca2+ ion as charge compensation for two Al3+ ions was found to be necessary to form two AlO4 tetrahedra. This specific feature of surface ionic coordination could be responsible for the complex trends observed in surface tension data. The incorporation of low concentrations of SiO2 reduced the proportion of tetrahedrally-coordinated Al ions such that higher coordination states become dominant in the bulk of the material, whereas AlO4 tetrahedra were preferentially distributed in the surface region. SiO4 tetrahedra were the preferred Si-centred polymorph and were likely connected to one another to form bridging oxygen ions at the surface. On the basis of these results, a model to predict slag surface tension was proposed, and the energy of the formation of the ionic clusters resulting from surface relaxation was taken into account.

Aug 21, 2024

By White L. R, Boger D. V

The paper describes the surface chemistry and particle physics that control the fundamental flow properties (Theology) of mineral particle slurries. We further address, through a series of case studies, the design data that emerges from experimental studies of the flow properties of complex, high volume fraction mineral slurries. The case studies are drawn from mineral oxide concentrate processes, tailings dewatering operations and from filter cake production and management. The paper emphasises the essential links between design of process slurry handling systems and the control of the flow of such slurries by control of the pulp chemistry.

Jan 1, 1992

The Application of Roasting Pretreatment for Antimonial Refractory Gold and Silver Ores

Sep 13, 2010

The Mineralogy and Reactivity of Pyrrhotite from Selected Nickel Ore Deposits and its Effect on Flotation Performance

Sep 13, 2010