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By Larissa Koroznikova, Steve Durkin, Patrick Bouwmeester, Michael Tuck

In currently used mining methods, blasting techniques often causes dilution of valuable ore and results in costly processing requirements. In the context of narrow vein mining of thin and highly concentrated orebodies there is a need of a mining method that can reduce dilution in order to remain economically viable. This research project explored the viability of a new mining technology, thermal fragmentation, in narrow vein mining. Thermal fragmentation technology uses a flame jet to produce extreme heat that spalls the surrounding rock to a strategically located drill hole, as an alternative to traditional blasting. This paper creates a net present value (NPV) model of a mining method using thermal fragmentation, as well as for an existing method used for narrow vein mining; comparisons and evaluations were made regarding the feasibility of the new technology. It was found that while overall costs for thermal fragmentation were relatively high, reductions in wages, haulage and processing costs, as well as increased productivity and ore recovery, meant that the new method would improve the financial performance of any operation. These results identify that there is an opportunity to introduce the thermal fragmentation technology to narrow vein mines within Australia, in order to lower costs and increase profit.

By J Hartog, V Beehan, D Beeson

Treating an ore blend from five different deposits at Newgold’s Peak Gold Mine (PGM) has always been a challenge due to the inherent variability between each of the orebodies.Operating the processing plant at PGM with a ‘normal’ level of process control and a good operations and metallurgical team has allowed the processing plant to achieve above the name plate design at 102 t/h and recoveries in the order of 92.8 per cent for gold and 88.4 per cent for copper.With a company value and culture of striving for continuous improvement, PGM implemented the Manta Cube® system, an advanced process control system, for the semi-autogenous grinding (SAG) mill, gold leach circuit and tailings thickener over a 12-month period throughout 2012 and 2013.The overall benefits of implementing the Manta Cube® system has led to an increase in mill throughput of at least two per cent, improved SAG mill liner life, a ten per cent decrease in cyanide consumption and a reduction in flocculant of at least 30 per cent with no detriment to the gold and copper recoveries.The entire project had a payback period of less than two months, and the combined benefits resulted in an overall increase in revenue of at least $5 million per annum. This is quite significant for a processing plant the size of PGM.This paper describes the methodology, overall results and economic benefit of applying the Manta Cube® system on-site at Newgold’s PGM.CITATION:Hartog, J, Beehan, V, Karageorgos, J and Beeson, D, 2014. Optimisation of the Peak Gold Mine’s processing plant through advanced process control, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 335–344 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

Taknar polymetal (Cu-Zn-Au-Ag-Pb) deposit and concentration flotation plant are located in the northeast of Iran. The flotation feed contains Chalcopyrite, sphalerite and pyrite with 4, 4 and 8 percent respectively. Cu and Zn contents are 1.26 and 3.5 present. Pyrite decreases the quality of base metal concentrates and increases the amount of sulfur compounds produced in the base metal extraction processes. Therefore, depression of pyrite is essential in the concentration of base metal sulfides by flotation. For flotation tests, 4 mixed collector systems, MIBC (20g/t), lime and tow depression systems (sodium cyanide (60g/t)-zinc sulphate and dextrin (300g/t)-zinc sulphate) were used as collector, frother, pH regulator and pyrite-sphalerite depressants in the chalcopyrite flotation stage, respectively, and SIPX, MIBC, lime and copper sulphate (as activator) were used in sphalerite flotation from first stage tailings. The results have shown that, sodium cyanide is a suitable depressant for pyrite and sphalerite in the first stage of flotation. Compared to dextrin as depressant, chalcopyrite recovery was decreased approximately 1.83%. In addition, when sodium cyanide was used as pyrite depressant, copper sulphate consumption raised approximately 90 g/t for activation of sphalerite. From Environment and HSE points of view, dextrin is natural, biodegradable, and non-toxic while cyanide is very high toxic. Keywords: sequential flotation, Cu-Zn massive sulphide, pyrite depressant, dextrin, cyanide

Sep 1, 2012

By Luben Xie, Lin Hu, Qiang Wang, Min Gan, Tao Jiang, Wenqi Li, Xiaohui Fan, Zhiyuan Yu

"Crystal precipitation behavior of calcium ferrite (CF) during iron ore sintering process along with the effect of cooling rate, SiO2 and Al2O3 on crystalline condensation were studied. The results show that CF, has strong ability of precipitation. The precipitation is barely affected by extenal factors. It begins to precipitate when the liquid phase cools down to about 1200oC. CF could crystallize rapidly at the cooling speed of 150 °C /min. Furthermore, decreasing of the cooling rate favors the development of crystal. Binder phase transformed from CF system to silicate system when SiO2 content was increased to 5~6%, with a constant basicity (R) 2.0. Increasing Al2O3 content could promote the precipitation of CF and the development of crystal.IntroductionCrystalline condensation is the last stage of sinter mineralization. It includes the processes that crystalline substance and amorphous substance precipitate from high temperature solution phase and the consolidation of material when melt cools down. During the crystallization process, minerals precipitate following the order from high to low melting point coupled with the decreases of free energy. Most of binder phase minerals and part of iron oxides crystallize in this process, which have an important influence on mineral composition and microstructure of sinter. They finally determine the sinter strength and metallurgical properties."

Jan 1, 2011

By A. J. Oliver, C. E. O’Neil, I. J. Itzkovitch, V. A. Ettel

A new solvent extraction process for the separation of cobalt, copper and zinc from nickel sulphate process streams has been developed. It involves selective extraction of these elements with a quaternary ammonium thiocyanate dissolved in an aromatic diluent. The chemical principles of this process have been investigated and are described, together with background physico-chemical data relating to the use of this solvent. Long-term testing in a continuous "mini-plant" circuit gave high-purity nickel and cobalt products (Ni/Co —200011 and Co/Ni ~1000/1 respectively).

Jan 1, 1976

By D. Rahal

All ores have an economic optimum particle size (Wills and Napier-Munn, 2006). This optimum value is often a compromise between the need to achieve adequate liberation for the efficient separation and recovery of valuable minerals and the energy consumed by the crushing and grinding process. It has been recognized for nearly three decades that grinding is the most expensive and least efficient stage in mineral processing (El-shall and Somasundaran, 1984). At that time it was estimated that grinding consumed between 25 and 70% of the total power required in mineral processing. This recognition drove the development of new stirred mill fine grinding technology in the 1990s (Jankovic et.al, 2003; Enderle et. al., 1997; Massey, 2008). These milling technologies have a reduced energy consumption compared to traditional fine grinding using ball mills. In the ?coarser? fine grinding applications this improvement is approximately 30%. The benefits increase to above 50% in ultrafine grinding applications (Lichter and Davey, 2006). Despite these gains, the US Department of Energy reported that an additional energy savings of up to 37% is possible in the minerals industry. They identified continuing research and development and implementing best practices in both grinding and materials handling as the primary avenues for the additional reduction (BCS, 2007).

Jan 1, 2011

By J. Laskowski, J. Lekki

"The mechanism of joint action of a frother (alpha-terpineol) and a collector (ethyl xanthate) in the flotation of chalcocite has been examined. In order to study the dynamic effects of frother and collector in bubble-particle collisions, the following aspects were investigated : determination of zeta-potential. Measurements of the thickness of fluid film on the surface of chalcocite and adsorption of xanthate, as influenced by alpha-terpineol, induction time and flotation versus concentration of alpha-terpineol and ethyl xanthate.The mechanism of the adsorption-desorption phenomenon on chalcocite with regard to non-ionic molecules, e.g. a-terpineol, has been considered, and the influence of this on the stage and thickness of the intervening wet layer between a bubble and a particle, changing the probability of collision and attachment, is suggested."

Dec 1, 1971

By S. Fuchida, Y. O. Zubair, C. Tokoro

Mining of As-bearing minerals had resulted in the release of arsenic species predominantly As(III), which is known to be more toxic, and undue exposure to it is detrimental to human organ systems. Many materials have been examined for As(III) removal, but it is still challenging to advance sustainable materials for effective removal of As(III). In this paper, a more eco-friendly and superparamagnetic Fe0-Fe3O4 composite was synthesised and evaluated for heterogeneous catalytic oxidation and removal of As(III) with peroxymonosulfate (PMS, KHSO5). The kinetic removal studies showed that removal of As(III) was probably through a chemical process and the Elovich model best represented the experimental data. The removal capacity for As(III) on Fe0-Fe3O4 with PMS (1.76 mmol/g) is superior to that without PMS (0.83 mmol/g). Combined results from XPS and ESR showed that As(III) was fully transformed to As(V) through catalytic oxidation by Fe0-Fe3O4/PMS and afterwards enhanced its removal. The removal mechanism of arsenic was ascribed to the formation of outer-sphere (electrostatic attraction) and inner-sphere complexes. The adsorbent can be separated easily from water due to its excellent magnetisation (64.5 emu/g) and also has good reusability potential as more than 85% of the initial concentration of As(III) was immobilised after five consecutive cycles. Keywords: Arsenite, Fe0-Fe3O4 composite, catalytic oxidation, removal mechanism

Jan 1, 2020

By Grant Davis

An International Symposium on the Ecology and Revegetation of Drastically Disturbed Areas was held at the Pennsylvania State University in August 1969. Scientists from 13 foreign countries and 18 states in the United States attended this meeting, which focused on those areas disturbed by mining. The symposium enabled scientists from all over the world to get together for two weeks and discuss informally some of the knotty problems of reclaiming these disturbed areas. Trying to present the results of each of the 64 papers delivered at the symposium might be difficult. So, I will try to bring you up to date on the general status of research on the reclamation of surface-mined areas, particularly in revegetation and hydrology. I will also mention some research that is under way but was not presented at the symposium.

Jan 1, 1970

By Muhammad Tawalbeh

The calculated temperature history of a single particle of MgCl2 hydrates when it came in contact with fused salt electrolyte at 650 °C was determined using the measured heat transfer coefficient for the molten salt bath at 650 °C. The calculations revealed that the entire interior of the particle reached the temperature required for the formation of MgOHCI from hydrated MgCl2 in less than 2 seconds. This was much less than the time required for dissolution of the prills as observed in experiments. It is very likely that the formation of MgOHCI during prill dehydration and dissolution is a result of hydrolysis in the interior of the prills.

Jan 1, 2004

By S. Chander

The mechanism of oxidation of sulfur in pyrite is a function of the rate and driving force for oxidation. New evidence is presented in this article to show that at moderate potentials, a sulfur-rich hydrophobic layer is formed. Under ordinary conditions, the sulfur layer is covered with a layer of iron oxides, hydroxides, sulfate or oxy-sulfide ions. Under these conditions, pyrite is hydrophilic. In the presence of iron-chelating agents or iron sequestering ions, iron layer might not form. Under these conditions, sulfur-layer is exposed and pyritic might become hydrophobic. Stronger oxidizing conditions decompose the sulfur-layer, thereby making the surface hydrophilic.

Jan 1, 1992

By Howard P. Hamlin, John W. Sweeney

Shales , clays , and loess in Iowa were tested and evaluated to determine feasibility of producing lightweight aggregate by commercial rotary - kiln or sintering methods . Preliminary testing was conducted in a muffle furnace . Rotary - kiln tests were conducted in a 16 - inch by 14 - foot rotary kiln . Concrete cylinders and cubes were tested to determine qualities of the aggregate . Three samples made suitable lightweight aggregate by rotary - kiln methods and two by sintering .

Jan 1, 1964

"Outotec’s TankCell® e500 flotation cell was commissioned during 2014 at the Kevitsa Mine in northern Finland. The TankCell® e500 is the first cell in this size class (500m3) to be run in an operational duty and it has been working as the first rougher in the copper flotation circuit. Treating around 850tph with an average grade of 0.3% Cu the TankCell® e500 has run with an average copper recovery of 71% and an average enrichment ratio of 50. In addition the cell has proved to be very energy efficient, operating with a specific energy of around 0.4kW/m3 under production conditions. This presentation will provide a review of the installation and operation of the TankCell® e500 at Kevitsa and will summarize the results found in the published literature from the various testing campaigns conducted around the cell. INTRODUCTION The TankCell e500 was installed and commissioned at the Kevitsa mine in northern Finland in 2014. Post startup the cell was initially run for testing and optimization with various test campaigns undertaken. but was subsequently taken into a production duty (Mattson et al., 2015a). At Kevitsa the cell is run as the first copper rougher replacing the previous two copper roughers (both 160m3) in this duty. The unit is running at between 38-40% solids at a feed rate of approximately 850tph. Since operational the average copper recovery from this single cell has been around 71% copper. This is typically with an enrichment ratio of around 50 being fed with an average head grade of 0.3% copper. More details on the circuit configuration and production performance of the e500 at Kevitsa can be found in Mattson et al., (2015a) and Murphy et al., (2016). In addition through the optimization program with the use of a variable speed drive controlling rotor speed it was found the the e500 was very energy efficient under production conditions. During this work the cell was found to run at a specific energy of around 0.4kW/m3 which exceeded design expectations (Xia et al., 2015)."

Jan 1, 2016

By Q. Shi, Q. Feng

"The influence mechanism of chlorite on the flotation of pyrrhotite was investigated through flotation tests, Zeta potential measurements, optical microscope photos, solution ion measurements and absorption measurements. It is observed that, the addition of chlorite influences the flotation of pyrrhotite seriously. The IEP (isoelectric point) of pyrrhotite and chlorite is 7.6 and 4.3 respectively, in the condition of slight alkalinity, both pyrrhotite and chlorite are negatively charged, and the hetero-aggregation will not occur. With the existence of oxygen in solution, the iron ions are dissolved from pyrrhotite surface because of the oxidation of pyrrhotite during pulp conditioning. The dissolved iron ions adsorb onto the surface of chlorite in the forms of iron hydroxyl and iron hydroxide, and the adsorption results in the opposite charge of chlorite surface. As a result, the hetero-aggregation between pyrrhotite and chlorite occurs. The adsorption of chlorite changes the surface property of pyrrhotite and restricts the adsorption of amyl xanthate onto pyrrhotite surface, and then decreases the flotability of pyrrhotite.INTRODUCTIONIn sulfide ores processing, magnesium silicate bearing gangue minerals often report to the concentrate causing downstream processing problems as well as increased smelting costs. Talc,chlorite and serpentine are gangue minerals commonly encountered in complex sulfide ores (Engel, Middlebrook, & Jameson, 1997; Pietrobon et al., 1997; Witney & Yan, 1997; Chen, Grano, Sobieraj, & Ralston, 1999a, 1999b; Bremmell, Fornasiero & Ralston, 2005; Senior & Thomas, 2005; Wang, Somasundaran, & Nagaraj, 2005; WieseHarris & Bradshaw, 2007). All of them are characterized with uniform crystal structures consisting of silicon-oxygen tetrahedron and magnesium-oxygen octahedron. The magnesium-oxygen octahedron layers are broken during the liberation of serpentine to expose the magnesium-oxygen bonds with strong ionicity and hydration, which results in natural hydrophilicity of serpentine. In water, the hydroxyl on serpentine surface ruptures and dissolves into the aqueous phase while the Mg2+ remains, resulting in surface positive charge (Tao, 2012). As serpentine has a positive potential at alkaline condition, it is therefore likely that it will attach through electrostatic attraction to the negatively charged mineral surface and reduce both the flotation rate and recovery of target minerals (Lu et al., 2011). For talc, characterized as good natural hydrophobicity, the liberation comes from the interlaminar fracture to remain molecular bonds on surface with weak hydration. Being naturally hydrophobic, talc easily reports to flotation concentrates, thus reducing concentrate grade (Shortridge, Harris, Bradshaw, & Koopal, 2000; Beattie, Huynh, Kaggwa, & Ralston, 2006). Meanwhile, both molecular bonds and magnesium-oxygen bonds are exposed on chlorite surface when liberation occurs, resulting in moderate natural hydrophobicity between serpentine and talc (Tao, 2012). And thus the mechanisms of influence of chlorite on sulfide ores are more difficult to study."

Jan 1, 2016

By Peter N. Blakey

The Kidd Creek orebody is a massive, base metal deposit with widths up to 600 feet and a strike length of 2,200 feet. The orebody dips eastwards at 70° to 80° and is amenable to sub-level open stoping. Five distinct zones (Fig.1) based on structural wall rocks and ore type parameters occur within the orebody. These zones are: Zone 1 - Mainly copper stringer ore Zone 2 - Massive pyrite ore Zone 3 - Massive sphalerite and chalcopyrite Zones 4 and 5 - Are banded and variable in nature Compressive strengths vary from zone to zone with an average of 22,000 p.s.i. and highs of 40,000 p.s.i. The mine is developed from a ramp extending from surface to the 1600 foot level and a 24 foot diameter, 3050 foot vertical shaft with main levels at 400 foot intervals. Sub-levels at 100 foot vertical intervals are driven from the ramp. transverse and longitudinal pillars to support the crown pillar left under the open pit. The layout allows an opportunity to enlarge or reduce pillar sizes and also to introduce fill on any horizon should conditions warrant. It also offers a large number of operating stopes spread through the various ore zones giving good ore blending characteristics. All ore from the stopes is handled through drawpoints using Wagner ST8 scooptrams with an average one way haul length of 650 feet.

Jan 1, 1976

By A M. Ebbels, D Pratt

The current commodities super-cycle has seen an explosion in the number of mining projects demanding human resources throughout the world. The demand for key personnel currently far outweighs the international talent pool and will take several years to subside. A highly effective project team can be the difference between a successful project and a bad public relations exercise. Building an effective team and retaining the team members has become one of the major influencing factors for successful project development in the mining industry in the last decade.Increasingly, international teams are being established combining skill sets, subject matter experts, unique previous experiences and diverse cultures to deliver mining projects all around the world.This paper explores the characteristics of a highly effective team, the communication and geographic challenges and some potential pitfalls which influence the ability to form effective teams within the mining industry.CITATION:Ebbels, A M and Pratt, D, 2012. A great project team - Bringing together location and culture, in Proceedings Project Evaluation 2012 , pp 197-202 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By R. Shimpo

Equilibrium calculations by a computer may sometimes fail in giving solutions when the system includes a large number of components and more than three phases, and especially when no definite information about stable phases is given. An improved method of calculation is presented in which the number of phases need not to be initially fixed, phases can appear or disappear in the course of' calculation and a new method is combined with the Newton-Raphson method to obtain solutions easily. The improved method is applied to the copper smelting operation and all the successive stages of the operation are successfully simulated.

Jan 1, 1983

By Bearman R. A, Parkin R. M

In the comminution industry cone crushers are widely used for secondary and subsequent stages of size reduction. Traditionally cone crushers have been operated and monitored manually. Alteration of discharge setting is now commonly achieved via hydraulic means, however, compensation of liner wear can still involve plant shutdown and loss of production. Drift in discharge setting due to liner wear is still a major problem that must be addressed to improve product quality, consistency and reduce recirculating load. The continuous demand for better quality products and the high cost of reprocessing or discarding unsaleable material, highlights the need for re-examination of the technology associated with the crushers to ensure optimum control and system efficiency. A collaborative project between Pegson Ltd, one of the leading UK manufacturers of jaw and cone crushers, De Montfort University Leicester, and Transfer Technology plc was established to address the technological requirement for automation of the control of cone crushers. The machine chosen for the study is a 900 Autocone cone crusher manufactured by Pegson Ltd. The design philosophy is based on a mechatronic approach providing a complete solution through a distributed network of intelligent sensors, artificial intelligence technology and adaptive control. The modular design of the system ensures a progressive sophistication in technology that allows the automation to be phased in as required. This will ensure maximum benefits to all sectors of the aggregate industry. It is estimated that the automation will result in savings of around ten per cent. The savings will result from minimising the production of unsaleable products by reliable condition monitoring and automation of the control and maintenance of system parameters to optimise system efficiency. Extension of the methods and principles into the mining sector is anticipated. The control over the size of crusher product will offer great benefits to the mining industry with significant implications for subsequent milling and beneficiation processes.

Jan 1, 1995

By E. J. (Kirk) Conway

Thirty-five years ago underground coal mining equipment consisted of simple but rugged machines powered by electric motors and hydraulics. The machines were maintained by maintenance personnel armed with a basic knowledge of hydraulics, electricity, and mechanical design. Over the years the the machine has been transformed into powerful complex mining systems. The maintenance burden has also increased. During this period significant advances have been made in maintainability engineering and system design techniques. Many of these innovations and techniques are applicable to the design of underground mining equipment. The objectives of this project were to; (1) determine the extent to which maintainability design concepts and principles have been applied to the design of underground coal mining equipment, (2) try to assess the impact of equipment design for maintenance on productivity and safety, and (3) develop a maintainability design guideline to enhance the design of new or rebuilt equipment. An equipment design review was completed at ten operational coal mines. Interviews were also conducted with mine management, safety, and maintenance personnel to identify machine specific design advantages and problems. Visits were also made to six original equipment manufacturers to discuss the design of their equipment for maintenance. Volume I presents an overview of the protocol used and a summary of the findings. Volume II includes the maintainability design guide for underground mobile mining equipment.

Jan 1, 1989

By Van H. Manning

The term war minerals has been applied t.o those ores and minerals that were largely imported. before the war. Among the mon important of these are manganese, essential for making high-grade steel for munitions and industrial use; graphite, for u,.akin1 crucibles; tin, for plating utAmsils and for bearing-met.al; mereury, used as fulminate t.o explode shells; pot.uh, for making fertilizer and explosives; tungsten and molybdenum, for high-speed t.ool steel; antimony, for hardening bul!et lead; chromite, for tool steel, for tan- , ning leather, and as a refractory lining in furnaces; magnesite, for :refract:A>ry linings; mica, as insulating material; platinum, for the manufacture of sulphuric acid and for electrical apparatus. When the United States entered the war it was clear that every ship would be needed and that the number available for importing minerals would be small. Hence a quick and thorough survey of domestic resources was necessary. . Throughout the war the scope and volume of the war-minerals work increased until it covered practically every mineral that was known t.o be or was liable to be in short supply.

Jan 1, 1919