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By R Zhou, B J. Monaghan, S J Chew, R J. Longbottom, D J. Pinson, H Li, P Zulli, G Zhang, L Lu

Steelmakers are increasingly motivated to use iron ore resources with a wider range of grades and mineral types that were previously considered unsuitable or uneconomical for sintering. In this respect, specific issues, which now require further investigation and understanding, include the sintering of ore types with:- overall higher gangue content- elements that cause problems in the steel manufacturing operations- distinctive sintering performance compared with traditional hematite-rich iron ores. Laboratory-based investigations of the sintering performance and the behaviour of gangue impurities during sintering is an important step towards the successful utilisation of these resources in steelmaking.In terms of laboratory-based sintering investigations, there are two generally accepted experimental scales utilised prior to undertaking industrial-scale trials, which include: bench-scale tablet (compact) testing and pilot-scale pot testing. The former has the advantages of flexibility and more precise control of sintering conditions; but it is difficult to simulate the heterogeneity of a sinter bed. The latter, which is carried out in pots with diameters between 150–500 mm, simulate the commercial sintering process and conditions quite well, but is time-consuming and labour-intensive due to operational complexity. It is therefore desirable to establish a smaller scale pot testing facility that avoids the disadvantages of the normal sintering pot but can provide comparable information.To explore the feasibility of small-scale pot testing, a ‘millipot’ facility was established to examine the sintering performance of iron ores and other non-traditional ferrous materials. The millipot has a diameter of 53 mm and height of 400 mm. The facility has the capability to monitor the sintering temperature at a number of locations (axial, radial) within the sinter bed and to adjust the suction (‘windbox’) pressure. This paper describes the development of the millipot facility and operational procedures, together with initial tests undertaken in order to match its performance with industrial sintering performance.CITATION:Li, H, Zhou, R, Pinson, D J, Zulli, P, Lu, L, Longbottom, R J, Chew, S J, Monaghan, B J and Zhang, G, 2017. A millipot set-up for sintering investigation of iron ores, in Proceedings Iron Ore 2017, pp 85–90 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Steve Kral

Mining is a risky business. The cost of exploring for new mineral deposits is high and the success rate of finding one worthy of development is relatively low. And once a deposit is identified, there is no guarantee that it will become a mine. Mining companies have to spend a lot of time and money on due diligence, prefeasibility and feasibility studies, and sustainable development and environmental issues before deciding whether the deposit will become a profitable mine. And then there are the millions of dollars spent in developing the deposit and building a mine. No wonder the mining industry has trouble attracting investment capital. Companies take a large risk in developing reserves and investors take a similar risk in investing in them. So mining companies must be as accurate as possible in determining mineralization that makes it to reserve status. After all, reserves are a company’s most important asset and one of the critical factors analysts and funding sources look at when determining if a mine or mining company is worth the risk.

Jan 1, 2003

Advances in Optical Image Analysis and Textural Classification of Iron Ore Fines

Sep 13, 2010

By L. B. Slichter

Prospecting is certainly the world's biggest and best gambling business. It is a game where the chips cost many thousands and where many millions, even billions, can be won. An attractive feature of this gamble is the fact that the players are free to rig the odds as favorably as possible. Only the limited bounty of nature, the restrictions of the laws of the land, the competition from other players, the limited sagacity of the player himself— only these, and other factors, restrict the possibilities for large winnings. Today probably about half the land surface of the earth remains to be searched for signs of ore visible at the surface. It is fortunate that so much land still remains for exploration by relatively economical methods. Looking to the future, it is a good guess that the costs of finding ore will increase in response to increasing technical difficulties. To continue to achieve profits from prospecting, it will become necessary to analyze the business more skillfully, in a more and more sophisticated manner. Whenever feasible, qualitative concepts must be replaced by their quantitative equivalents, improvements, and extensions. THE GAMBLE The fact that prospecting is a gambling business reminds us at once of the elementary rule known as the law of gambler's ruin. I hesitate to mention so simple a rule in this company of experts. This rule expresses the rather serious chance of going broke when the odds for success are small, merely by a normal run of bad luck regardless of the long-run expectations of gain. The only sure way of avoiding this special risk of gambler's ruin is to have enough capital, and the will, to continue the play many times and thus ride out the inevitable runs of bad luck. For example, if the probability of success is one in ten for each venture, there is a 35 pct chance that ten successive ventures will fail in a row. But if one has the capital to continue the play through a run of 100 failures, then the chance of gambler's ruin is only 5 in 100,000. Almost any management, I suppose, would be under terrific pressure to cease the play during a long run of bad luck. To continue to prospect under such circumstances requires great confidence in the premises, and a firm conviction in the long-term expectation of profit. There is evidence which I shall mention that in the future even the strongest companies may not have the necessary capital to prospect on the ideal scale. Joint ventures will be very desirable as a means for extending the available venture

Jan 1, 1961

By E. J. Roberts

Hydrometallurgical operations and many processes in the chemical industry require the separation of dissolved material from solids. One of the decisions which has to be made in designing a plant for such an operation is how this separation shall be accomplished. It is the purpose of this paper to set forth the general principles involved in such separations in order that the optimum flowsheet and equipment may be selected. Countercurrent Decantation with thickeners, or C.C.D. as it is generally known, is, of course, only one way of separating dissolved material from undis-solved. Other unit operations such as Countercurrent Filtration (C.C.F.) and Countercurrent Classification (C.C.C.) are widely used. The same principles may also be applied to centrifugally assisted decantation, as with nozzle or solid bowl type centrifugals, and to separations using screens, either gravity or centrifugal type. Another form of countercurrent washing applicable to granular materials is practiced in continuous ion exchange operations. All of these operations depend on two basic principles, or combinations of these principles. In C.C.D. type operations the solids are concentrated into the smallest possible volume of liquor in each step and the resulting pulp then mixed with a more dilute liquor and recon cen trated, the liquors separated from the more dilute stages being advanced to dilute the more concentrated liquor in a previous solids concentrate, as is shown in Fig. I. This will be termed the solids concentration-solution dilution principle, or, for short, solution dilution. countercurrent decantation- type circuits. The second principle used in washing solubles from solids is that of solids concentration-solution displacement. Here the solids are restrained from movement while wash solution is forced through the interstices in a counter-current fashion, as in Fig. 2. In the simplest application of this principle, once the "cake" has been formed, it is not disturbed until the operation is completed. In continuous filters, the cake is merely moved under the successive washes and the displaced filtrates removed as in Fig. 4. Often, however, after one or two displacement washes, a repulping step is introduced, the cake reformed and washed again. This procedure brings the solution dilution principle into play as well as the solution displacement principle. Merely thickening ahead of filtration, which is often operationally advantageous, does not hybridize he circuit. It still can be a pure solution displacement operation from the washing

Jan 1, 1961

By T Higuchi, L Lu

The quality of iron ore fines have been deteriorating, which has affected sinter quality and productivity adversely. New pretreatment and sintering technologies are therefore required to tackle the gradual change in the quality of iron ore fines. In the sintering process, iron ore fines are first granulated with fluxes such as limestone and coke breeze, and are then loaded and fired in a sinter machine. Sinter productivity and quality are heavily influenced by the reactions occurring in the sintering bed. Hence fundamental understanding of these high temperature properties of ores is urgently needed.Formation of initial sinter melt, penetration and assimilation of nucleus particles by the initial melt, and consolidation and final solidification of final sinter melt are believed to be the key sintering reactions. The assimilation and penetration phenomena have been studied separately in the literature with model particles and diffusion couples and are therefore difficult to relate to sinter quality. In addition, the effect of ore mineralogy has not been studied in detail.In this study, tablets consisting of coarse particles from various iron ore fines as nucleus particles and chemical reagents as adhering fines were made and fired under various sintering conditions to investigate the penetration and assimilation behaviour simultaneously. The degree of assimilation, pore structure, compressive strength of the resultant analogue sinters were evaluated and the relationship between sinter strength and ore characteristics was further discussed. The nucleus particles from Ores A and B were found to be more porous and assimilated more readily with sinter melt, resulting in a viscous melt and a macro-porous sinter structure. The nucleus particles from Ores C and D on the other hand, assimilated less readily with sinter melt, resulting in a fluid melt and a denser sinter structure. This is consistent with the results reported in the literature, suggesting that the present evaluation method can be utilised for studying sintering reactions and predicting sinter quality.CITATION:Higuchi, T and Lu, L, 2017. Evaluation of sintering behaviour based on ore characteristics, in Proceedings Iron Ore 2017, pp 303–308 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Robert W. Metcalf

Corundum, natural alumina, or aluminum oxide (A1203) is the hardest mineral known except diamond. Theoretical composition is Al 52.9 percent and 0 17.1 percent, but it always contains small quantities of impurities, chiefly silica, iron, and lime. The melting point of corundum is above 1950° C., and it is insoluble in the strongest acids. Its hardness (9 on the Mohs scale) varies slightly according to purity, and its specific Gravity ranges from 3.95 to 4.10, 4 being a fair average. The index of refraction is 1.760 to 1.768 and its streak is white. Luster is adamantine to Vitreous, come specimens pearly, and color varies widely from white, gray, pink, and blue to black, brown, or bronze. Gem varieties are transparent or translucent, and of more brilliant coloring - red, blue, yellow, purple, or green. Corundum occurs in opaque massive or block structure with parting planes little developed or only roughly delineated and in granular form as minute crystals or small, irregular grains interspersed throughout the contact zones of schists and gneisses.

Jan 1, 1944

By L. Andrews

Mineralogy, traditionally associated with concentrator studies, is being increasingly applied to problems in pyrometallurgy. Such investigations commonly make use of a number of techniques, and the results are combined for a meaningful interpretation, which can lead to a successful solution for the problem. Mineralogical techniques are described for various pyrometallurgical operations. Examples are given of studies and investigations involving mineralogy in chemical-looping combustion, feed monitoring to platinum-smelting furnaces, and losses to slag in base metal and platinum smelting.

Jan 1, 2011

"For effective steel refining in the ladle (secondary steelmaking) the amount of steelmaking slag that is transferred from primary steelmaking must be limited, because the steelmaking slag contains iron oxide, manganese oxide, and phosphorus oxide. Adverse effects of slag carry-over include increased consumption of deoxidizers, phosphorus pick-up by the steel, and increased ladle refractory wear. Infrared imaging at longer wavelengths is an effective non-contact method to detect slag in the tapping stream. Various devices are used to shut off the tapping stream rapidly. These include slag darts, pneumatic slag stoppers, and slide gates for steelmaking converters, and eccentric bottom tapping for electric arc furnaces. IntroductionOxygen converters and electric arc furnaces are used for primary steelmaking. For both process types, the product (liquid crude steel) has a similar composition: largely liquid iron, with around 800–1000 parts per million (ppm, by mass) dissolved oxygen and low but significant concentrations of carbon, nitrogen, and phosphorus. The steel is tapped into a ladle, which serves as the refining vessel to adjust the final steel composition and temperature before casting.Some steelmaking slag is inevitably tapped with the liquid steel. The mass of steelmaking slag tapped with the steel is termed ‘slag carry-over’. Controlling and limiting slag carry-over from steelmaking is a primary requirement for clean steel production (Fandrich, Lüngen, and Wuppermann, 2008). Steel cleanliness refers to limiting the concentrations of dissolved impurities (such as nitrogen, oxygen, phosphorus, and sulphur) and of nonmetallic inclusions (oxides, sulphides, and nitrides) in liquid steel and in the final solid steel product. Of these, the strongest effect of slag carry-over is on the content of dissolved phosphorus in the liquid steel"

Jun 1, 2019

By Daniel Hauer

Blocking. (5) The “blocking” of boulders is a much cheaper way of breaking them up than “mud capping.” It should always be used in preference to that method except when too much time will be consumed by a crew of men waiting for the drilling to be done, as shown in example of cost No. 1, as given under “mud capping.” Under such circumstances the time consumed would be a greater cost to the contractor than the extra amount of dynamite. Then, too, on large thin boulders to drill one hole would result only in breaking the stone into such pieces as would again have to be broken; and the many holes might equal the cost of extra dynamite. Under such circumstances if method (6) cannot be used, “mud capping” will have to be resorted to, to do the work economically.

Jan 1, 2006

The latest outcome of science is that aII bodies are composed of vibrating atoms or molecules. In almost all mineral bodies when changing from the gaseous or liquid condition to the solid, if the vibrating molecules are allowed free play, they arrange themselves in a symmetrical manner, and at a definite angle to each other: This angle varies with each system of crystallization. In a great many bodies this process may be brought about artificially, and the growth of the crystal watched. The most common method is to dissolve some substance in water or some other liquid, on slowly evaporating the liquid, the substance dissolved will solidify and the molecules will arrange themselves in their particular crystalline form.The element carbon crystallizes in two forms; as graphite in the form of a short six-sided prism', and in the diamond generally as the octohedron in the cubical system of crystallization. Orystalline bodies, as a rule, have plain faces but what is remarkable in the diamond is that in a great many cases the faces are rounded. Its great beauty as a gem when cut, and the high artificial value placed upon it by fashion, as well as its value as a cutting and boring instrument-it being the hardest body in nature-has caused many attempts to be made to form it artificially. These attempts have met with fair success as a scientific experiment, but as a commercial speculation they have been a complete failure. The most noted of these experIments was carried out by Mr. Hannay, of Glasgow.Paraffin spirit with lithium was submitted td prolonged heating in strong wrought-iron tubes securely welded. In most of the experiments the tubes exploded; but in a few cases the experiments were successful, and on cutting open the tubes small crystals of diamonds were found embedded in a black mass.Despretz produced minute diamonds under the influence of a powerful electric current from coal.

The stability of paste fill bulkheads forms an integral part of a successful paste fill system. Bulkheads are constructed at the draw points of open stopes to contain paste fill while the initial pour cures and forms a consolidated plug. Mobilization of uncured paste fill as a result of a bulkhead failure can lead to significant consequences, including endangering the safety of personnel, property damage and production losses and delays. The loading conditions in the paste fill and the resultant lateral loads on the bulkheads are complex and are dependent on many factors. This paper presents a case study of several paste fill bulkhead failures; the results of an in-situ pressure monitoring program to ascertain the pressure loads, and the subsequent paste fill bulkhead evaluation.

May 1, 2007

By Pavel Vasak

The Laurentian University Virtual Reality Laboratory (VRL) has provided a unique platform for the development and testing of novel seismic and microseismic data processing and visualization technology. In collaboration with Vale?s Creighton Mine, the technology was implemented at the mine site and consists of a VRL system and site calibrated Seismic Excavation Hazard Map (SEHM) software. The SEHM was developed as a practical solution for the mine operator to identify areas of elevated, active rock mass damage processes caused by recent mining activity. This paper is a pictorial representation of the 3D stereoscopic demonstration of the Creighton Mine seismic data distribution and interpreted SEHM for the first quarter of 2009. A live demonstration is scheduled at the Laurentian University VRL as one of the conference field trips. The demonstration highlights the technology transfer of research concepts into a near-real-time excavation hazard system that utilizes the key aspects of virtual reality technology; the ability to integrate large datasets (geology, mine excavation, (seismic) monitoring data, production scheduling, stress model, etc.); the ability to manipulate and visualize large datasets in both space and in time (mining sequence); and the ability to review the datasets by a group of experts in an immersive (3D stereoscopic), collaborative environment to better understand the processes and context of the mining-induced seismicity and evaluate potential risks to the mining operation.

Oct 1, 2010

By T. R. Curr, R. T. Jones

Keywords: Pyrometallurgy, Mintek, DC arc furnace, plasma, smelting, chromite, ilmenite, cobalt, slag, zinc fuming, dust, magnesium, laterite, ferronickel, arc modelling, Pyrosim, thermodynamics The Pyrometallurgy discipline at Mintek was initiated in the early 1970s, to support a growing ferroalloy industry in South Africa. In addition to a range of pyrometallurgical options, Mintek specialises in DC arc furnace technology and has pilot plant facilities up to 5.6 MVA, as well as a strong base in process and arc modelling. Industrial processes have been developed for ferrochromium production, ilmenite smelting, and cobalt recovery from slag. Recent work has been done on such processes as the production of ferronickel from laterite ores, the fuming and condensation of magnesium, and the recovery of platinum group metals from 'difficult' feedstocks.

Jan 1, 2006

By A. J. MOORE

When the writer first saw the square-set timbering, he was at once impressed with the fact that the frames made by the sets, along the lode and across it, were composed of panels with rectangular openings, and it was puzzling to understand howsuch a collapsible construction could resist pressure that came unevenly on it. Later he learnt that the sets did not satisfactorily resist such pressure, but mullock filling had, to a great extent, to undertake this duty for them. So it appeared that the setswere practically an expensive scaffolding, enabling the miners to work in the face and carry the stope forward, till the filling was put in behind them to take the pressure of the roof and sides of the excavation. Of course some of the pressure is takenby the sets, but this is because "the set timbers prevent the filling being done perfectly; if it were practicable to remove the sets before filling, the filling by itself would more effectively support the back and wall, than do the combined sets andmullock. On the whole, therefore, the sets can hardly be said to be of much benefit where pressure has to be resisted. Despite this, the system has been of immense service in mining wide lodes, but for all that, it can only be pronounced a makeshift.This is no reflection on Deidesheimer, the famous originator of the square set, for, as will be shown later on, this way of...

Jan 1, 1912

By Willemijn Husslage

Tata Steel Group At a glance ? Part of the Tata Group ?Tata Steel Group: ?Fortune 500 company ?Top 10 global steel producer ?Annual crude steel capacity of 28 million tonnes ?More than 80,000 employees ?Manufacturing operations in 26 countries across 5 continents ?Serving customers all across the globe ?Turnover 2009-10: $22.8 billion

May 1, 2011

By Martin Nevens

"In 1998, the Iron Ore Company of Canada initiated an aggressive program to improve the performance of its Carol Lake Concentrator located in Labrador City, Newfoundland. This program was termed the Concentrator Upgrade Program. The Concentrator Upgrade Program was a group of initiatives developed with the common goal of improving the overall process and operations of the IOCC Carol Lake Concentrator. The main goal of the program was to increase the annual production capacity of the concentrator from 18.0 million tomes to 21.6 million tomes. This gain in capacity was to be done mainly through improvements in process iron recovery. The target iron recovery value was 80+% versus a historical value of 70%. This improvement in iron recovery would translate to a natural weight recovery improvement from 44% to 50%.The Concentrator Upgrade Program provided the first opportunity in 30 years to make fimdamental changes to the concentrator flowsheet. To accomplish this, several pilot plants were built to evaluate new circuits. AAer 2 years, a new flowsheet was selected for the primary gravity separation circuit and the magnetite circuit. The centrepiece of the new flowsheet was the introduction of Hindered Settling Separators to the metallurgical process.The Concentrator Upgrade Program has since proceeded into detailed engineering and, as of February 2001, construction. The first one of IOCC’s 3 primary AG Mills (Mill 11) has been converted to the new flowsheet at the time of writing and is in the throes of commissioning. This paper will review the flowsheet development program in the pilot plant for the gravity separation circuit and examine the overall benefits to the operation of the IOCC Carol Lake Concentrator."

Jan 1, 2002

By J L. Mauk

The Gladstone Hill area hosts epithermal veins similar to those at Martha Hill, which is less than one kilometre away. There are several vein types in the Gladstone Hill area including (1) pyrite-marcasite, (2) quartz, (3) base metal sulfide, and (4) calcite. Pyrite veinlets formed first, whereas the quartz and carbonate veins formed later. The base metal sulfide vein occurs at depth and is predominantly comprised of quartz and chlorite intimately intergrown with pyrite, sphalerite, galena, and rare chalcopyrite. Platy calcite and massive calcite veinlets were the last vein types to form. Several vein textures occur in the Gladstone Hill area, including colloform and crustiform banding, lattice-bladed, zonal, comb, massive and feathery textures. Crustiform banded veins are the dominant texture and contain variable gold-silver grades. Colloform banded veins consist of ubiquitous quartz and minor chalcedony with gold grades as high as 60 g/t. The lattice-bladed texture forms from the deposition of calcite, which has been replaced in many samples by quartz, indicating that boiling and later cooling has taken place. Unreplaced platy calcite only occurs at deeper levels (>300 m). Zonal and comb textures are preserved in quartz and late-stage amethyst veins. Feathery textures within quartz are commonly associated with breccias and some colloform banding, and with significant Au-Ag grades.   The homogenisation temperatures (Th) of primary and secondary inclusions in quartz, amethyst and platy calcite range from 166 to 274¦C, with salinities <1.3 wt% NaCI equiv. The presence of vapor-dominated inclusions and primary fluid inclusions in platy calcite suggests that boiling occurred intermittently throughout deposition. The veins formed under a relatively flat lying paleowater table that occurred 280 - 300 m above sea level. The fluids involved in vein formation were alkali chloride in composition and low in CO2.

Jan 1, 2001

By N. D. L. Burger

A low noise blast hole drilling system was developed to limit the risk of noise-induced hearing impairment in mining operations. Noise- induced hearing loss has been identified as a major occupational health risk in SA mines. The noise generated by pneumatic percussion drills is a major contributor to such noise-induced hearing loss. This motivated the South African Safety in Mines Research Advisory Committee (SIMRAC) to commission the development of a low noise rock drill system. The system had to be designed, manufactured, tested and demonstrated in a simulated underground mining environment. The specification required noise levels below 90 dBA. Other important design considerations were ease of manual transport, setting up and operation. The primary design concept was to encapsulate a standard SecoS215 pneumatic rock drill in a composite material tube. The tube is pushed onto the rock face by a pneumatic cylinder and is sealed at the rock face by an elastic seal. The drill is pulled towards the rock face by a rope and pulley mechanism fitted inside the tube. This mechanism is powered by a second pneumatic cylinder. The actions of moving and setting the drill require two persons. However, the team can carry out the drilling function itself on several drills simultaneously because of the self-thrusting design. The drill is supported by two camlocks. The exhaust (air containing dust, water, rock debris, oil and grease) is removed from the encapsulating tubes via an exhaust tube to the end of the stope. In this way exhaust noise and air pollutants are disposed of away from personnel. Tests were conducted in a test stope. Noise levels of under 90 dBA were achieved, thereby attaining the primary design specification. This was achieved without materially compromising ease of handling. Penetration rate was somewhat improved compared to that of the standard drill, so that productivity could be maintained. Keywords: Drill, rock drill, quiet, noise, mine, underground.

Jan 1, 2004

By Cocquio D. S, Bauchau C

In the course of an integrated airborne survey in 1975, a uranium-molybdenum deposit was discovered by Minatome Australia Pty Limited in North Queensland, Australia, approximately 70 km by road west of Townsville.The mineralization occurs in a welded tuff unit within the Carboniferous St James Vokanics. It is structurally controlled by a complex of subvertical east-west fractures and is exposed over a strike length of 350 m. Drilling has traced a further 150 m extension underneath a barren capping consisting of a thick pile of vokano-sediments. The maximum width of the orebody is 150 m, and its vertical thickness is approximately 100 m.The primary ore minerals are coffinite, pitchblende and molybdenite, accompanied by various alteration products (particularly uranium molybdates).The vein-type mineralization is considered epigenetic.A comprehensive program of surface drilling and underground exploration is in progress to establish the uranium and molybdenum reserves.

Jan 1, 1980