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Lean Iron Ore Beneficiation in India

Sep 13, 2010

By J R. Goff, R Carver, D S. Sheppard

The REGCHEM (Regional Exploration Geochemistry) stream sediment geochemistry database of open file mining company data, managed by GNS Science, was recently made accessible via the internet (http://maps.gns.cri.nz/website/minmap/). REGCHEM provides coverage of selected elements in mineral rich areas of New Zealand. Analysis of REGCHEM data highlights problems with inconsistencies between different surveys in terms of sampling methods, number and types of elements analysed, analytical techniques and detection limits. New, consistent multi-element geochemical surveys with national coverage are required. To test sampling, analytical and data treatment techniques for the new surveys, a pilot stream sediment geochemical survey was carried out in the Thames area, Hauraki Goldfield. Seventy samples were collected in an area of 220 km2 representing about one sample every 3 km2. The samples were analysed for 50 elements, mostly by XRF.   Regional patterns are apparent in the concentrations of some elements. Several elements, such as As, Cd, Cu, K, Pb, Sb, Se, and Zn exhibit anomalous concentrations mainly in the western part of the study area, related to Au-Ag-Zn-Pb-Cu epithermal quartz veins and porphyry Cu occurrences in hydrothermally altered andesitic terrane.   Mercury is anomalous in southern samples, reflecting cinnabar occurrences in the Kauaeranga valley (eg Mangakirikiri), and the occurrence of cinnabar as a late stage mineral in some of the Thames epithermal veins. Ba and U are anomalous in the eastern samples, and these anomalies are probably related to the presence of rhyolitic rocks in the eastern part of the project area.

Jan 1, 2006

By D Duan

In this study, aimed at two kinds of ore (lump ore and iron ore fines) and four types of Australian iron ore resources (haematite iron ore, Mara Mamba iron ore, limonite iron ore, and mixed iron ore, such as Newman, MAC, Yandi and Pilbara iron ore), the physical and chemical properties and high-temperature properties were investigated in detail, to master their behaviour and effects in sintering, blast furnace, and non-blast furnace processes. Then, according to the individual properties of Australian iron ores, Chinese domestic iron ores and Brazilian iron ores, etc, the optimisation of ore-proportioning for sintering, blast furnace, and non-blast furnace processes was studied based on the interaction of the individual iron ores and their complementary properties, and the corresponding tests were carried out. The test work results indicated that this method not only improved the technical and economic indexes of sintering, blast furnace, and non-blast furnace processes, but also increased the addition of Australian iron ore. All of these provide the theoretical basis and technical support for highly effective use of Australian iron ore resources in iron and steel enterprises in China.

Jul 11, 2011

By Williams M

Sheet flotation is a new two dimensional column flotation cell that produces continuous spectrum of products. Analogous to a shaking table in its performance and analysis, sheet flotation is a sheet of bubbles rising through packing contained between two walls. Feed enters the sheet at the lower left and the product exit along the top and right edges. Iligh grade materials exit at the top left, middlings exit at the top right comer and low grade waste materials exit at the bottom right. As in the case of a shaking table, two motions are required: up and right. Bubbles furnish the upwards movement for hydrophobic particles, slanted packing the rightward movement for hydrophilic particles. The sheet flotation cells is analysed as a 40 x 40 array of simple cells. In practice, 1000 x 1000 arrays of simple cells may be expected. With larger arrays, excellent separations may be expected. Because there is no recycle, there is no build-up of middlings in

Jan 1, 1993

By Barber C, Buselli G

Detailed monitoring of point sources of groundwater pollution is expensive due to the high cost of drilling monitoring boreholes. Whether groundwater pollution is due to mining, industrial or domestic waste disposal, a universal difficulty when monitoring groundwater contamination is the placement of boreholes to adequately define the extent of the pollution plume. This paper reports groundwater 'resistivity variations determined from transient electromagnetic soundings at a domestic waste disposal site north of Perth in Western Australia. Together with available hydrogeological and water quality data, the geophysics provides a broad "plume scale" picture of groundwater contamination. A simple three dimensional model of plume development, which takes account of the dimensions of the wastes, has also been developed and shows good agreement with the spread of contamination indicated by the geophysics for relatively small values of the dispersivities. Better estimates of these parameters are still required. The work indicates that a combination of geophysics and modelling with ground-truth data from groundwater quality monitoring of boreholes is required to avoid difficulties in interpretation of data and to better define the extent and migration of pollution in Groundwater.

Jan 1, 1988

By J Guo, K Williams, J Y. Guo, A W. Roberts, M Jones, B Chen

Numerical simulations using the discrete element method (DEM) were carried out to investigate the flow patterns and stress field redistribution at the hopper and feeder interface. The influences of different filling heights, belt speeds and clearances between the hopper bottom and feeder surface on feeder loads were studied. Meanwhile, experiments were conducted by utilising wedged plane-flow hoppers with different configurations and horizontal feeders with various clearances. The simulation results were compared with theoretical values and experimental measurements. In terms of the cases presented in this study, simulation results reveal good agreements with experimental observations regarding the flow pattern. Being similar to the theoretical values, the simulations provide close predictions on vertical feeder loads for steady flow states, but they may show significant overestimations for initial states. Additionally, suggestions are given for relevant simulation parameters based on the comparisons shown in this investigation.CITATION:Guo, J, Roberts, A W, Williams, K, Jones, M, Chen, B and Guo, Y J, 2017. Simulation investigation of flow patterns and feeder loads at hopper/feeder interface, in Proceedings Iron Ore 2017, pp 173–182 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By H W. Wu, D Humphreys

The structure of a comprehensive research project into mine fires study applying the Ventgraph mine fire simulation software, preplanning of escape scenarios and general interaction with rescue responses is outlined. The project has Australian Coal Association Research Program (ACARP) funding and also relies on substantial mining company site support. This practical input from mine operators is essential and allows the approach to be introduced in the most creditable way. The effort is built around the introduction of fire simulation computer software to the Australian mining industry and the consequent modelling of fire scenarios in selected different mine layouts. Application of the simulation software package to the changing mine layouts requires experience to achieve realistic outcomes. Most Australian mines of size currently use a ventilation network simulation program. Under the project a small subroutine has been written to transfer the input data from the existing mine ventilation network simulation program to æVentgraphÆ. This has been tested successfully. To understand fire simulation behaviour on the mine ventilation system, it is necessary to understood the possible effects of mine fires on various mine ventilation systems correctly first. Case studies demonstrating the possible effects of fires on some typical Australian coal mine ventilation circuits have been examined. The situation in which there is some gas make at the face and effects with fire have also been developed to emphasise how unstable and dangerous situations may arise. The primary objective of the part of the study described in this paper is to use mine fire simulation software to gain better understanding of how spontaneous combustion initiated fires can interact with the complex ventilation behaviour underground during a substantial fire. It focuses on the simulation of spontaneous combustion sourced heatings that develop into open fires. Further, it examines ventilation behaviour effects of spontaneous combustion initiated pillar fires and examines the difficulties these can be present if a ventilation reversal occurs. It also briefly examines simulation of use of the inertisation to assist in mine recovery. Mine fires are recognised across the world as a major hazard issue. New approaches allowing improvement in understanding their consequences have been developed as an aid in handling this complex area.

Jan 1, 2005

An integrated palynological and sedimentological investigation of four wells from the eastern margin of the Gippsland Basin has resulted in a scheme for classification of palynofacies in this area. Thirteen different palynofacies assemblages are recognised and assigned to particular environments based on the enclosing sediments, which range from alluvial, through coastal barrier to continental shelf environments. Close correlation is observed between the interpreted energy regime of the palynofacies assemblage, and that of the enclosing sediments. Assemblages characterised as reworking surfaces can be correlated with unconformity producing events (ie tectonic activity associated with the opening of the Tasman Sea), and some of the minor eustatic sea level Changes.

Jan 1, 1992

By Z Tong, M Gao, X Wang

In response to the need for improved magnetic separators for beneficiation of fine grained iron ores that have been finely ground to liberate the iron minerals from the gangue, a series of high efficiency wet drum permanent magnetic separators (T-GCT) has been developed by Maanshan Tiangong Technology Co Ltd. These magnetic separators have high efficiency for separating superfine strongly magnetic minerals and the ability to produce high-grade concentrates with high recovery. They are ideal replacements for conventional drum magnetic separators, especially for treating superfine particles.

Jan 1, 2009

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 Wilson A. F

The use of stable isotopic measurements as a technique for elucidating the origin and history of the water in hydrothermal fluids is relatively new. Recept studies have emphasized the importance of meteoric water in the formation of many hydrothermal ore deposits including many epithermal gold-base metal deposits which occur in faulted volcanic terrane. Other vein-type gold ores are believed to have formed from fluids of magmatic or metamorphic origin and exhibit characteristic d18O values. Preliminary oxygen and carbon isotopic data for some important gold deposits of eastern Australia have emphasized the diverse origins of their ore fluids.The Mount Morgan gold-copper orebody is shown to be of the volcanogenic massive sulphide type with ore fluids predominantly of sea water origin. The Charters Towers fissure veins formed during hydrothermal activity associated with intrusion of Lolworth Igneous Complex equivalents. Oxygen isotopic studies of the quartz reefs at Stawell and Gympie have been inconclusive. The ore fluids have a d18O value of about 7 per mil and may be of magmatic or metamorphic derivation.

Jan 1, 1981

Between February and August of 1986, Dr Alfred Petrick visited New Zealand sponsored under a Fulbright grant administered by the New Zealand-United States Educational Foundation. The grant supported a research project completed by Dr Petrick having as an objective, the preparation of a preliminary economic evaluation of the mining of six Otago lignite deposits as a source of energy for steam power generation or in liquid fuels. The research is limited to consideration of preliminary geological and engineering data on the six deposits and to the time constraints of the Fulbright visit. This paper is a summary of the final Fulbright report. The complete report including the listings of the computer programs is available from the Otago School of Mines.

Jan 1, 1986

By Probert D. H, Wright E. A, Taylor B. L

A general description of the geology of the Southern Coalfield is given. The relationship between the Illawarra Coal Measures, the overlying Triassic and the underlying Upper Marine Series, of Permian age as are the Coal Measures, is briefly explained and thestratigraphy of each is described. The eight coal seams are then treated in slightly more detail as to their thickness, quality, areas of distribution and best occurrences.In the last few years each of the authors has been concerned with one phase or other of the stTucture of the field in detail or in mining operations with the result that it is now possible to name a number of monoclines, anticlines, domes and synclines defined in detail. A minor quantitative study has been made of faults and dykes with regard to form, direction intensity and inter-relationship. It seems probable that with the further collection of data a more detailed study in these matters will be of considerable value to the economy of mining in the Southern Coalfield.

Jan 1, 1958

By M P. Schwarz

In recent years, computational fluid dynamic (CFD) modelling of mechanically stirred flotation cells has been used to study the complexity of the flow within the cells. In CFD modelling, the flotation cell is discretised into individual finite volumes where local values of flow properties are calculated. The flotation effect is studied as three subprocesses including collision, attachment and detachment. In the present work, these subprocesses are modelled in a laboratory flotation cell. The flotation kinetics involving a population balance for particles in a semi-batch process has been developed. From turbulent collision models, the local rates of bubble-particle encounters have been estimated from the local turbulent velocities. The probabilities of collision, adhesion and stabilisation have been calculated at each location in the flotation cell. The net rate of attachment, after accounting for detachments, has been used in the kinetic model involving transient CFD simulations with removal of bubble-particle aggregates to the froth layer. Comparison of the predicted fraction of particles remaining in the cell and the fraction of free particles to the total number of particles remaining in the cell indicates that the particle recovery rate to the pulp-froth interface is much slower than the net attachment rates. For the case studied, the results indicate that the bubbles are loaded with particles quite quickly, and that the bubble surface area flux is the limiting factor in the recovery rate at the froth interface. This explains why the relationship between flotation rate and bubble surface area flux is generally used as a criterion for designing flotation cells. The predicted flotation rate constants also indicate that fine and large particles do not float as well as intermediate sized particles of 120 - 240 ¦m range. This is consistent with the flotation recovery generally observed in flotation practice. The magnitude of the flotation rate constants obtained by CFD modelling indicates that transport rates of the bubble-particle aggregates to the froth layer contribute quite significantly to the overall flotation rate and this is likely to be the case especially in plant-scale equipment.

Jan 1, 2005

By G Gibson, B Bessen

In coal preparation, large dense medium cyclones (DMC) at low pressure heads (typically 9D where D = cyclone diameter) are the norm. This contrasts with high density mineral applications where, largely for historical reasons, smaller cyclones at high heads are the standard. There are advantages in preferring large diameter cyclones at low heads, assuming that metallurgical performance does not suffer significantly. These include simpler plant layouts, easier maintenance, smaller spares inventories, reduced wear, reduced medium pumping demands, smaller buildings and overall lower capital and operating costs. In 2008, therefore, Xstrata Zinc decided to trial a single DSM-design 800 mm cyclone in one of its four DMC lines at Mt Isa, replacing the four 400 mm cyclones previously installed. Circumstances allowed a low head of 9.5 D to be trialled, compared with the existing 400 mm head of 21.5 D. This paper describes the trial, including tests using painted ore particles as tracers, estimates of yield and metal recovery, and wear monitoring. The larger unit performed well. There was no evidence that metallurgical performance in terms of metal recovery and waste reject rate suffered, and there was some evidence that it may have improved. Cyclone life increased, and preliminary data suggest that the replacement cost of the 800 mm cyclones is less than half that of the 400 mm units, and this is expected to improve. The plant layout and operability have also improved significantly. Xstrata has therefore decided to convert the whole plant to four low head 800 mm units, replacing the original 16 high head 400 mm units. The paper includes an explanation of the effect of static head on DMC separating force. It also reviews earlier research on diamond applications, and applies a general DMC process model to the Xstrata case, both of which confirm that large, low head cyclones are appropriate in mineral applications, contrary to conventional practice. Such units could significantly reduce both the capital and operating costs of DMC plants in mineral applications.

Jan 1, 2009

This paper discusses the history and development of the system and the benefits that are being gained for Yabulu from Solar Drying. Following the end of mining of the local Greenvale and Brolga nickel deposits, QNI Yabulu Refinery is dependent upon imported ore from over 15 different mines in New Caledonia, Indonesia and the Philippines.

Jan 1, 2003

By Guarascio M, Massacci P

In process simulation, more reliable prediction of industrial results and evaluation of data for design purposes and process optimisation may be attained by the combined use of: the modelling and simulation of ore characteristics, and 2. the modelling and simulation of the process. It is well known that geostatistical methods allow the defining of models of orebodies in which the variables considered are the grades of the valuable components. These models are proper for reserve estimation, geostatistical contouring, design and simulation of the exploitation method, and, in addition, for evaluating the variability of the ROM which is expected to be fed to the processing plant. However, no data are normally incorporated in the orebody model in order to evaluate the ore characteristics relevant for a reliable process simulation. The procedure for process simulation aimed at predicting plant results normally used so far consists in collecting samples from different orebody sites and building up a so-called 'representative sample'. On this sample, the ore characteristics (eg liberation, washability, grindability, etc) and the processing tests are referred to as the 'average behaviour in the orebody', assumed constant. A more reliable methodology consists in collecting samples from different orebody sites, in performing tests to characterise the samples from the point of view of the process (ore patterns), and in using synthetic parameters (process features). The values of the parameters are processed using geostatistical methods in order to develop a model for simulating the feed to the process. The estimation may thus be referred to the amount of recoverable minerals instead of to the existing minerals. Furthermore, the selection of the processes, the sizing of equipment and the design of control devices, as well as the prediction of results, become more accurate and reliable.

Jan 1, 1993

By C Skublak

The Government of Canada recently passed a new regulation to control the liquid discharges from metal mines in Canada. The Metal Mining Effluent Regulation of the Federal Fisheries Act will come into force within the next six months. As a result the Ontario Regional Office of Environment Canada has developed a compliance promotion program to accompany the new regulation. How the mines implement the regulation will be key to its success. This paper will briefly outline the components of this regulation, including the reporting structure, the discharge parameters and limits, as well as the requirement for the mines to conduct long-term environmental effects monitoring on their effluent discharge. The presentation will give a brief account of the compliance promotion program, and then focus on the spill trends from Ontario mining operations. The province of Ontario has the largest concentration of metal mining operations in the country with approximately 40 active mines.

Jan 1, 2002

By F K. Altuntov

The study presented in this paper is based on the Kiirunavaara underground mine located in the northern part of Sweden. The deposit is mined using the sublevel caving (SLC) mining method. This paper briefly reviews the alternative SLC layouts, as well as presents challenges for the application. In Kiirunavaara currently, the traditional SLC design is employed, however, continuous improvement of material transportation systems used in mines generates a need for investigation of the current and future production area layouts in sublevel caving mines. When identifying the potential benefits of the alternative production area layouts, the production targets and effects must be further investigated to understand the benefits and potential effects. In this study, several different layouts have been investigated and evaluated. The designs include different development configurations and orepass infrastructure moved further away from the orebody and still require further investigation.

Mar 29, 2023

By G Anderson, V Lawson, P Voigt

Glencore operates zinc concentrators at both Mount Isa and McArthur River. Both orebodies have a history of complexity and required the development of new technologies to maximise the value from these long-life assets. The Mount Isa orebodies were plagued since operations started in 1931 with complex mineral textures making separation challenging and many areas uneconomic. Examples are given in Figure 1 with different grain sizes from the same orebody in different areas. The McArthur River deposit, located in the Northern Territory, was discovered by Mount Isa Mines geologists in 1955 (Logan, Murray and Williams 1990). The extremely fine-grained nature of the ore was quickly recognised and the difficult separation of the minerals was soon obvious. The geographical, metallurgical and economic factors resulted in the orebody not being developed until the technologies for the mineral separation had been developed. The development of the IsaMill allowed for an economic mineral separation flowsheet to be developed and ore treatment commenced in May 1995 (Nihill, Stewart and Bowen 1998). CITATION: Lawson, V, Anderson, G and Voigt, P, 2018. Developing technologies for a complex orebody, in Proceedings Complex Orebodies Conference 2018, pp 116–118 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018