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By A Nisbett

The largest single operating loss in many hydrometallurgical plants is the poor recovery of leached product in the solids sent to tailings. Any reduction in the concentration of the valuable species in this stream will improve the project economics. Conventional design, to reduce the soluble loss, is to increase the number of wash stages or the wash/water ratio. This approach is limited in effectiveness as it can only reduce the soluble loss to that dictated by the concentration in the returning solution. For copper plants this concentration is set by the recovery in the solvent extraction (SX) plant. When using a single grade of SX feed a single grade of SX raffinate is produced generally with five to seven per cent of the copper still remaining in solution. An alternative approach has been developed by Cognis Corporation and implemented on a number of recent projects using engineering input from Miller Metallurgical Services. The SX plant feed is æsplitÆ into two different streams: a high-grade stream containing up to 75 per cent of the copper and a low-grade stream with the remaining copper. This Split-CircuitÖ concept has significant benefits in terms of both copper recovery and reduction in acid costs. The high-grade stream has the bulk of the copper removed and the raffinate sent directly back to the leach; to fully re-use the acid that has been generated during extraction in the SX process. The recycling of this higher concentrated acid stream considerably reduces the acid in the raffinate sent to washing steps. It represents a significant saving in acid consumed via the tails stream. The low-grade stream has a significantly lower SX feed grade and hence produces a lower raffinate acid and copper concentration. This lowers the economic species in the wash solution and hence reduces the soluble loss accordingly. Other operating improvements are realised with lower neutralisation costs (with the lower acid in the wash stream) and from a decreased need for in-circuit neutralisation to improve SX performance. The SX plant itself is also split into a high-grade extraction and a low-grade extraction stream to enable the low-grade raffinate to be produced. A number of circuit alternatives have been utilised that have provided a range of benefits. The circuit concept has been included into both new and existing plant operation. As a result of this experience other methods of incorporating the concept into a circuit have been developed.

Jan 1, 2005

Following the Moura No 2 Wardens Court of Inquiry and subsequent changes to the Queensland Mining Legislation there is a requirement in Queensland coal mines for: a person with the recognised competencies to be appointed at each underground coal mine to the position Ventilation Officer; and the person is directly responsible for the implementation of the mine ventilation system and for the establishment of effective standards of ventilation for the mine. The Regulations require that an underground mine must have principal hazard management plans that provide for at the least the following: emergency response, gas management, methane drainage, mine ventilation, spontaneous combustion, and strata control. Other than strata control all the plans require the ventilation officer to have roles and responsibilities to develop, control, monitor and undertake actions in relation to these plans.There are also another 34 Regulations that either directly or indirectly requires the Ventilation Officer to take actions.The purpose of this paper is to outline the information that the regulators look for in sealing plans and the actions the regulators will take if the sealing does not go to plan (TARPs being exceeded).

Jan 1, 2005

By M Tsai

Tube bundle gas monitoring systems have been used in the mining industry for over 50 years. The initial design was based on four individual gas analysers along with a series of solenoid valves, gas sample conditioning and flow control mechanisms to ensure the correct gas flow stream volume to the analyser. Simtars staff have identified flow control issues when providing operational support to coalmines on numerous occasions. The accuracy of the oxygen analysis is dependent on control of the gas flow to the analyser. Oxygen is one of the parameters used in calculating Graham’s ratio which is used for the detection of spontaneous combustion activity in coalmines. This paper will provide data which identifies the flow control issues by comparing mine site records for the two surface sample lines in the analyser room and the gas cage. Mine sites will be deidentified within the paper. The paper will discuss some of the changes that have been made in modern tube bundle systems and compare the change to the initial design specification developed by the UK National Coal Board, investigate possible operational impacts and provide a technical fix to solve the current flow issues being experienced at some mines.

Oct 12, 2022

The unique characteristics of the Target orebody and modernistic approach to mining present significant challenges and a concomitant high potential for new opportunities. The break-away from the traditional labour intensive mining methods improves both safety and productivity significantly. The intention of the paper is to illustrate the application of well known mining methods to the particular requirements of a complex orebody at depth. The evolutionary process followed to establish the final mining method design provides insight behind the finished product, and the modern approach to the planning and service principles equips the reader with a suite of mining engineering ideas.

Jan 1, 2000

By R Stefansen

Stockyard operations are governed by the interaction between the different disciplines required to successfully schedule and control the supply chain of raw material through the stockyard in combination with the effectivity of the operation of the stockyard equipment. The system demonstrates a proven technology for implementing a centralised operation of full unmanned stockyard equipment, using a high precision absolute positioning system based on a Real-Time Kinematic (RTK) Global Navigation Satellite System (GNSS) receivers in combination with 3D rangefinders. The system implementation maps the surface profile of the stockyard inventory and allows in combination with proprietary algorithms for full operation of the stockyard machines without on-board operators. The operational impact of delayering the process by moving to a centralised operation is examined, together with the combined effect on the overall safety in the stockyard as a result of a change in reliance on operator skill dependencies. Average performance gains range from 10–20 per cent. The performance of the automation system is related to a consistency and reliability of uniform operation, which has an impact on the life expectancy and the effectiveness of the equipment. The effects of having instantaneous and correct information about the stockyard inventory volume measurement are investigated in relation towards spot price trading in current fast reacting markets.CITATION:Stefansen, R, 2017. Advanced automation for centralised stockyard operations, in Proceedings Iron Ore 2017, pp 105–110 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

The T33-34 blast, the first major blast at Mount Isa Mines, broke 1,360,000 tonnes of copper ore using 349 tonnes of explosives. The original concept of firing T33, T34, T35 and U37 separately was changed during the life of the project due to adverse ground conditions. These conditions also caused the stoping method to be modified after the firing of the stopes had started. To stabilise the two stopes T33 and T34 where large fall off was occurring, rib pillars were left in the original slot. This caused the blast design to be more complex as these rib pillars had to "lead" the blast. The implication of such a large blast on the underground and surface environment was thoroughly investigated and precautions taken. The charging time of the blast was six weeks. Hook-up was started four days before the blast and continued until two hours prior to the blast. Detailed scheduling was carried out of other work that had to be done in the 24 hours before the blast to ensure that there were no delays in the firing.

Jan 1, 1977

Natural gas was introduced to the Melbourne reticulation system in April 1969 and since that date sales to industrial consumers in the Gas & Fuel Corporation of Victoria area of supply, have increased by over 50% This increase has occurred despite the fact that the areas in which the new fuel is available have been dependent on the progress of the conversion operation from manufactured gas. The half way mark for conversion was reached in May 1970. The reason for the adoption of natural gas by industrial users is usually the result of objective financial analysis leading to the conclusion that the new fuel will give the lowest overall production cost. Many factors are involved in such an analysis of which the price of the fuel is only one. Amongst other important elements in the cost calculation are:- -ò òò -(1) The effect of fuel on product quality (2) Maintenance and handling costs for alternative fuel. In addition to economic gains for the individual user, the use of natural gas should benefit the whole community through its effect on such things as, air pollution and overseas balance of payments.

Jan 1, 1970

By Gutsche O, Kapur PC

Experimental data on the production of fines as a function of specific grinding energy consumption show that in general the energy utilisation in a choke fed high-pressure roll mill is higher than in a ball mill, but lower than in the single-particle mode of comminution under slow compressive loading. There is some evidence to suggest that the presence of water in feeds improves the energy efficiency of pressurised roll milling somewhat. Within a wide range of energy input, the size distributions of the ground product are self-similar, the logarithmic median size decreases linearly with the amount of fines produced and the inverse of the median size increases linearly with the energy spent. The production of fines as a function of energy expended follows essentially the same pattern as the one frequently encountered in media mills. The kinetics of grinding in the high-pressure roll mill can be simulated satisfactorily by modifying the standard particle population balance equation in order to account for energy dissipation in the tightly compressed bed. Common characteristics and important differences in grinding by the media mill and the high-pressure roll mill are highlighted.

Jan 1, 1993

By Robins R. G

The dissolution of metallic copper powder in aqueous solutions of cupric sulphate under the influence of ethylene gas was investigated. The dissolution reaction stoichiometry obtained was: Cue+(aq) + Cu(s) + 2C2H4(g) = 2(CuC2H4)+(aq) The rate of formation of the copper (I)-ethylene complex in the above reaction was studied in a laboratory autoclave and the effect pH, temperature, ethylene partial pressure and initial concentration on the dissolution rate was measured experimentally and expressed theoretically in terms of several simple conceptual kinetic models. The results led to the selection of optimum conditions for the reaction and the suggestion of an "ion-molecule reaction" mechanism to explain the very low activation energies for the reaction system. The area of application of this reaction lies in the direction of refining impure copper such as cement copper. Several experiments were performed in which an acidified solution of cupric sulphate under ethylene pressure was used to dissolve copper from the cement copper powder in the form of the copper (I)-ethylene complex, followed by the release of gas pressure to disproportionate the complex and precipitate a purer metallic copper.

Jan 1, 1987

By Daxian Z, Youdi Z, Shucai Y

The Huolinhe surface mine is a very large-scale surface coal mine, located in the north-east area of China with a production rate of 1.2 Mtpa. Its coal haulage system has a large capacity, long transportation line and high degree of automation. The system comprises two crushing plants, many belt conveyors, four surge bunkers, one loading bunker, one coal storage and five end product bunkers. In this paper, the network patterns of semi-continuous systems in surface mines are studied, the reliability calculation methods and a simulation model are established and the software for computing the reliability of a semi-continuous system is worked out. By considering the whole coal haulage system in the Huolinhe surface mine, the authors developed the system reliability-numerical simulation method. The steps and the computing results of this method are described in detail. Through the calculation, we can master the present situation of system reliability and the main factors impairing system reliability, expose the system weak links, put forward the ways of enhancing system reliability and furnish the basis for improving the system and equipment. The way of increasing capacity and methods of enhancing system reliability are further raised.

Jan 1, 1995

By Susanto A

As part of the current NERDDC funded project studying Dragline/Hopper/ Crusher/Conveyor systems for overburden removal, an investigation was carried out to assess the feasibility of automating the swing-to-dump phase of the dragline digging cycle in order to main- tain consistent performance of spotting the bucket above the hopper prior to dumping. The study involved design of automatic position controls for the hoist, drag and swing drives and simulation of detailed mathe- matical models of the three electromechanical systems and their associated electrical control schemes. The design of the hoist and drag systems to position the bucket in the boom plane is relatively straightforward. Simulation results show fast and accurate performance, with no evidence of interaction between the two drive systems through the ropes. The design of the swing position control system involves special strate- gies to cater for variable inertia and to damp the pendulum oscillations of the bucket. The use of a bucket pendulum model and variable dynamic compensation embedded within the feedback control loop, along with optimal speed/angle slowdown trajectories, has yielded fast and damped positioning responses under simulation.

Jan 1, 1989

By Q Wang

Net present value (NPV) has been the main criterion in mining project evaluation and production plan optimisation. It is a common practice in NPV calculations to take into account only the tangible cost items in the corporate accounting system. The costs incurred due to damage to the local ecosystem and environment are left out and treated as externalities. Such practice on the one hand underestimates the total cost of a mining operation and, on the other hand, ignores the difference in ecological/environmental impacts between different mine plan alternatives. This paper attempts to measure the ecological costs of mining and to incorporate such costs into the evaluation scheme in mining project evaluation and mine planning. The ecological costs of mining are estimated based on the areas and types of land (eg forest land, grazing land, crop land) damaged by mining activities and the carbon emission from fossil fuel consumption. For the land areas (and their associated ecosystems) directly damaged by mining activities, the ecological costs are measured by the prevention and restoration costs, the lost values of eco-services of the damaged land, including bio-product production, soil erosion control, water run-off control, oxygen release, air pollutant absorption and formation of soil nutrients. The ecological cost of carbon emission from the energy consumption of a mining operation is measured by the cost of cultivating the equivalent forest land required to uptake the emitted carbon. A case study on a large-scale open pit mining project is presented to demonstrate the influence of ecological costs on the mine planning outcome.

Sep 26, 2011

The issue of retrenchment is a topic of considerable relevance for the Papua New Guinea (PNG) mining, petroleum and gas industries. The unique environments in which Porgera Joint Venture (PJV) and other similar operations operate are likely to confront these industries with particular dilemmas that will require a range of investments to mitigate the problems associated with retrenchment and employment. This paper discusses retrenchment and employment in the PNG mining industry using the specific case study of PJV. The paper deals with the issue of employment and retrenchment of local workforces in the PNG context, which presents a serious challenge for the resources industry and the achievement of sustainable development objectives. The issue of future retrenchment of the workforce as a result of mine closure is an obvious challenge for both PJV and the Porgeran community at large, who have now come to rely upon both the employment opportunities presented through the mining. This paper examines these challenges and in doing so highlights some progress made by PJV. The paper also discusses downsizing, strategic practices and holistic approaches of retrenchment and employment. In doing so the paper highlights issues that have been overlooked in both academic and applied studies from global and local perspectives in the PNG mining sector. The latter sections articulate the relevance of the information provided by the case study in the wider context of retrenchment. The conclusion promotes a perspective that a great deal more investment will be required by all stakeholders to respond to the challenges of managing retrenchments and mine closure.

Jan 1, 2009

By Y-B Kang, W-Y Cha, Y-M Cho

Molten slag used in the secondary refining process (RH process) for the production of Ultra-Low C (ULC) steel is typically composed of CaO-Al2O3-MgOsat.-FetO with minor constituents. FetO in the RH slag is the main source of reoxidation of the molten ULC steel in the ladle by 2Al + 3(FetO) = (Al2O3) + 3Fe, thereby serving as the source of the alumina inclusions. On the other hand, FetO also enhances the fluidity of the slag, thereby increasing inclusion absorption capacity. Optimum slag chemistry design is therefore required to produce clear ULC steel. The reoxidation kinetics was investigated in the present study by employing high-temperature experiments and developing the reaction rate model. Initial compositions of slag ((% CaO)0/(% Al2O3)0 and (% FetO)0)) and reaction temperature were varied and change of [% Al] in the molten steel was measured. The rate-controlling step was analysed. It was found that the rate-controlling step in some cases changed during the reoxidation: from a mass transport of Al in the molten steel to a mixed transport including Al2O3 in the molten slag. The experimental data validated the reaction rate model based on the elucidated reaction mechanism and FactSage thermodynamic database. The model suggested that high (% CaO)0/(% Al2O3)0 suppresses the reoxidation only when (% FetO)0 is low (5 or lower in the present study).

Jun 19, 2024

By P Kumar, J Safarian

Understanding how ore interacts with flux particles at elevated temperatures to create molten slag is crucial since it governs the dynamics of a chemical reaction. This study explores the smelting behaviour of pre-reduced Nchwaning manganese ore when combined with lime, with the objective of examining the evolving interaction between pre-reduced ore particles and lime over time. The research sheds light on the interaction between solid and liquid and the phases that emerge during this process. To achieve this, a sessile drop furnace was employed to rapidly heat the materials positioned adjacent to each other on an alumina substrate and to observe the smelting process as it unfolded over time. This method allowed for the direct observation of the melting temperatures and the flux-ore reaction progression rate, and the potential disruptive events that might occur. By comparing the molten interfaces of the fluxed materials at various time intervals, this study provides insights into the relative rate of slag formation from the two materials. The results indicate that the main slag formation initiated at approximately 1400°C and continued to advance with time, with complete mixing occurring around 1500°C. The possible phases formed were identified using Scanning Electron Microscopy and modelled using Fact Sage thermodynamic software. In addition, the iron particles in the pre-reduced Mn ore were separated and settled from a rich MnO-containing slag. It was found that the separation of molten iron droplets from the slag depends on the rate of solid MnO particles dissolution into the adjacent slag phase.

Jun 19, 2024

By S Dirdjosuwondo, R Plaisance, L Thoma

PT Freeport Indonesia, a subsidiary of New Orleans-based Freeport McMoran Copper and Gold of New Orleans, operates a large mining complex on the Western half of the Island of New Guinea in Tembagapura, Irian Jaya, Indonesia. The IOZ (Intermediate Ore Zone) mine, one of the underground orebodies, is mined by block caving. The area affected by the cave collects a large quantity of rain and ground waters mixing with fine rock particles. The mixture, commonly called æwet muckÆ, sometimes spills into drawpoints and makes the working environment hazardous to the loader operators. Wet muck is observed in an increasing number of drawpoints in the IOZ mine and remote LHD (Load-Haul-Dump) technology has been implemented to handle the ore. The driving force for this automation project has been the safety of the loader operators. The system has been developed mainly in-house and incorporates state-of-the-art features. Up to eight remote loaders and nine rock breakers are controlled from an underground control room located approximately 400 metres from the active extraction panels. The two underground crushers and nine conveyor feeders are also operated remotely from an adjacent control room. The development of FreeportÆs remote system has taken time and considerable effort. Not only the success of the IOZ mine was at stake but also the fulfillment of environmental commitments pertaining to the mill tailings. Approximately eight per cent of the mill feed must come from underground skarn deposits to neutralise the acid-generating tailings generated by the huge Grasberg open pit ores.

Jan 1, 2000

By A. W. CAMERON

Over a 4 hr period of steady plant operation samples were taken at regular intervals from points within the grinding and flotation circuits. Size fractions of each composite sample were analysed for lead and zinc values and a comparison made of the behaviour of the lead, zinc, and gangue minerals, size by size throughout the whole circuit.Analysis of the breakage behaviour using dynamic mathematical models gave the rates of breakage of each size fraction of each main component. Simulated grinding experiments showed that the main grinding circuit had some reserve capacity.In the lead flotation circuit all lead values between 150 mesh (Tyler) and 5 microns had excellent flotation characteristics, and a major proportion had a high rate of flotation which was practically the same for all sizes. Increase in overall lead recovery would require improvement of the flotation behaviour of ultra-fine lead minerals. These were slow floating and were responsible for approximately half the lead losses in the final zinc concentrate and one-third of the lead losses in the final tails.All sizes of zinc values between 100 mesh and 7 microns floated well and the performance of the zinc flotation circuit was mainly limited by the relatively poor flotation of the very fine zinc values. Approximately 60 per cent of the zinc lost to the final tails lay within the minus 7 micron fraction.The overall flotation conditions were conducive to very good selective flotation of the major proportion of the values and limitations in metallurgical performance were mainly due to the properties of the ultra-fines.

Jan 1, 1971

By Davey FJ

The Hikurangi Margin of eastern North Island New Zealand represents the feather edge of the over-riding Indo-Australian Plate at its convergent boundary with the subducting Pacific Plate. Towards the south, convergence becomes slower and increasingly oblique, and sediment supply from the Southern Alps becomes increasingly rapid. In this environment a 150 km wide, imbricate thrust, accretionary prism has grown since the Miocene, uplifting slope ridges and basins and a range of coastal hills. Offscraping of thick, axially transported, trench-fill turbidites begins in a zone of proto- thrusts, which extends up to 25 km beyond the principle, slope-toe, deformation front. On the slope, landward tilted, trench-slope basins are separated by ridges. The ridges ride up on thrusts that sole out at a major decollement. The decollement dips landwards at 3 degrees to a depth of 14 km at the coast, where it coincides with an onshore zone of high seismicity. Beneath the decollement, about 1 km of consolidated, oceanic sediment is going under the margin with the underlying oceanic basement. Some of these sediments may underplate the frontal ranges to the west and geochemical evidence of subducted sediment is found in the volcanic zone beyond. A rapid decrease in the width of the accretionary prism to the north is associated with a decrease in sediment supply and perhaps with a dislocation in the downgoing plate. To the south, the accretionary prism narrows, swings westward, and merges into the zone of very oblique collision that marks the transform between mirror image subduction to north and south of New Zealand.

Jan 1, 1987

An account of milling "methods and costs at Mount Isa Mines Limited up to the year 1938 has been published. The present paper outlines the methods since adopted in the milling of lead-zinc ores and presents a description of the equipment now being provided for the milling of copper ore.The programme approved for the mining, milling and smelting of both lead-zinc and copper ores involves the milling 9f 50,000 tons of lead-:-zinc ore and 35,000 tons of copper ore per month.The crushed ores will be delivered to the surface from alternate levels through No. 2 Ore shaft and conveyed to their respective crude ore bins at the crushing plant. The ores will be crushed and milled in separate circuits in common buildings and the tailings will be stored on a common tailings dump. The water services to the two circuits will be separate.LEAD ZINC PLANTCrushing PlantThe crushing plant described in the previous paper was located adjacent to the Urquhart shaft. The crushing plant had grown considerably over the years by the addition of a 4ft. BY-mons shorthead crusher and a set of Traylor 72 in. x 20 in. crushing rolls and, whilst operating satisfactorily, was difficult to maintain and cramped in many places. As a satisfactory layout for the new copper crushing plant could not be made in the vicinity of the, existing plant, it was decided to construct a new plant on the western side of theconcentrator building and provide identical equipment in...

Jan 1, 1953

The Phoenix mine on the Mararoa Reef at Norseman, Western Australia, provides an outstanding: AUstralian instance of the recurrence of payable ore beneath the bottom of an abandoned mine, and an interesting and instructive example of the development ofideas with regard to ore recurrence in a particular district. The Mararoa Reef is the most productive of several hypothermal goldquartz vains in pre-Cambrian basic volc81olics which strike northsouth and dip on the average, 45 degrees east. The Phoenix minewas abandoned at 500 ft. vertical depth after producing 342,000 tons of 9.9 dwt. recovery grade (equivalent to nearly half of the total production of the Norseman field) from a 2,500 ft.. long, horizontally disposed oreshoot, which is reported to have had an ore outcrop only 30 ft. in length.Interest in the field was revived in 1933, and by 1941 new ore mined and developed on the Mararoa Reef by Central Norseman Gold Corporation N.L. amounted to approximately 700,000 tons of 6.7 dwt. recovery grade. In the same period another oreshoot of similar size and grade was developed by Norseman Gold Mines N.L., south of the old Mararoa company's site. As shown by the plans, the ore occurs in discontinuous shoots. The intervening area of shear is poor in quartz as well as in gold. Geological work on behalf of Western Mining Corporation Ltd., and Central Norseman Gold Corporation N.L. has been in progress in the mine and in the field more or less continuously from 1913 to 1941 and again since 1946. This paper describes the successive advances in the understanding of the exploratory problem up to late 1941, to which several investigators have contributed. It is published by permission of the Board of Directors of Central Norseman Gold Corporation N.L., owners and operators of the Phoenix and other mines.Development of the Prospect.In 1933 Western Mining Corporation acquired an option over the Phoenix property and adjacent leases. H. E. McKinstryl visited the mine and recognised that the ore occurred primarily on the flatly dipping sections of the vein, as distinct from the steeply dippingsections, in a wide shear zone with reverse movement. Many of the flatly dipping fractures were seen to exhibit tension phenomena and to link one shear plane to the next below on the footwall side. The flat links carried much more quartz than the steeper shears.Later, H. J. C. Conolly, assisted by J. D. Campbell, examined the prospect and by contouring the vein with reference to an inclined...

Jan 1, 1950