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By T G. Vizcarra, B Wong

Optimisation projects are regularly undertaken without knowing the root cause of an issue. It is all well and good to trial a multitude of flotation reagents, change the operating characteristics of your flotation cells, or add more media into your ball mills, but time and again, root cause analysis traces issues back to the performance of hydrocyclones. In JKTech's experience, hydrocyclones are poorly operated and maintained (in both primary grinding and regrind circuits), exacerbating issues that many operations commonly experience.Recent case studies are presented where JKTech has been engaged to improve the process only to discover that the hydrocyclones were the main issue. At one operation it was found that the hydrocyclone feed density gauge was reading significantly lower to the actual density. Following re-calibration of the gauge, and with further improvement of cyclone operational and design parameters using JKSimMet, a significantly sharper efficiency curve was achieved. This resulted in improvements to downstream recoveries while alleviating pumping capacities that were previously constrained by fines and water caught up in recirculating loads.Several other case studies are presented which may seem to be relatively basic, but many basics seem to be getting lost in the day-to-day responsibilities of the modern plant metallurgist. Simple fixes to hydrocyclones can result in significant production increases, but more focus is needed in monitoring these to sustain the benefits.CITATION:Wong, B and Vizcarra, T G, 2018. What category cyclone is devastating your plant?, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 665–673 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By Eyers G. C

Long Shaft was initially developed using a rail haulage system on every working level comprising battery electric locomotives and granby trucks loaded by rail mounted rocker shovels. Production was commenced using conventional hand held cut and fill mining methods. In an effort to improve productivity and reduce operating costs a mechanised cut and fill stoping method evolved to suit the wider sections of the orebody. To further improve productivity and reduce costs the mechanised levels of the mine are progressively being redeveloped to enable the use of trackless diesel haulage equipment. An added benefit of trackless haulage equipment will be the ability to place development mullock into stopes as Fill.

Jan 1, 1988

By Webster SS

This paper uses computer modelling tech- niques to compare and contrast anomaly patterns obtained with fluxgate (vertical field) and proton precession (total field) magnetometers at typical latitudes in northern and southern Australia. The use of these modelling tech- niques is suggested as an aid to magnetic interpretation and field examples are included from Tasmania and the Northern Territory.

Jan 1, 1975

1880 - 1930 - The Golden Years of Mineral Processing Technology

Sep 13, 2010

The Cadjebut Mine is located 80 km southeast of Fitzroy Crossing. Cadjebut is owned 58 per cent by BHP Minerals and 42 per cent by Billiton Australia. Cadjebut is a 'Mississippi Valley Type' (MVT) deposit. Minerals present are sphalerite, galena and marcasite in a sedimentary host of dolomite and siltstone. The ore contains few deleterious impurities and no silver. The mill was commissioned in the first half of 1988 at a rate of 320 000 tonnes per annum. An expansion in the latter half of 1989 has since increased production to 550 000 tonnes per annum. The initial geological resource at the commencement of mining was 3.8 million tonnes at 13.5 per cent Zn and 4.4 per cent Pb. There is sufficient ore left to sustain operations to 1995 at a grade of 11.2 per cent Zn and 3.9 per cent Pb. The ore from underground is stockpiled on the surface via a drift conveyor and from the stockpile is fed into a grinding circuit consisting of a SAG and ball mill. Cyclone overflow at a Pgp of 90 pm gravitates to the flotation circuit. Lead and zinc are sequentially floated to produce an 80 per cent Pb grade at 90 per cent recovery and a 61 - 62 per cent Zn grade at 96 per cent recovery. The concentrates are thickened and filtered before being trucked to the port of Wyndham 600 km away. From Wyndham the concentrates are shipped to smelters in Asia, Europe and Australia.

Jan 1, 1992

By Taylor R. N

Flow simulations have been performed on the flash-smelting burners currently used at KNS. This paper presents studies of the heat transfer between gas and particles at the burner exit. Gas and particle temperatures, velocity and concentration profiles of the two-phase flow are calculated by the mathematical model. The predicted gas temperatures have been favourably compared against values measured by thermocouples placed near the burners in the flash furnace. The predicted particle temperatures are also reasonable when compared with the measured temperatures.

Jan 1, 1992

By Lovitt M

Ora Banda Gold Mine is located in the Eastern Goldfields of Western Australia. Mining is carried out underground by sublevel open sloping resulting in large open stopes. A Mass Blast of approximately 250 000 tonnes was carried out in July 1994 to recover a rib pillar between two stopes, and the crown pillar between the underground mine and the abandoned open pit above. Strategic development within 50 m of the blast consisted of two ventilation shafts and the main decline. This development required careful design and prediction of the blast results. This paper describes the design of the blast, the prediction of the likely effects, the measures taken to reduce the risk to important development, and the results of the blast.

Jan 1, 1995

By Otuonye F

An outburst is the spontaneous ejection of pulverized coal and gas from the working face in an underground mine. It is caused by overstressing the rock, due predominantly to the influence of geological structures on in situ stresses, stress concentration from the excavation and overburden load on mine openings, and large volumes of gas sorbed in the rock. The spontaneous release of high pressure gas creates intense shock waves which may cause damage to the mine ven- tilation system and the pulverized rock/coal ejected may cause injury or death to miners. The gases emitted pollute the mine air and may also result in death to miners.

Jan 1, 1988

By Stewart A. M, Price D

This paper presents recent findings concerning longwall caving mechanisms relating to Australian mining conditions and their effect upon longwall support requirements and behaviour. The findings are based on a program of intensive hydraulic support monitoring in a variety of Australian mining conditions coupled with geotechnical observations.

Jan 1, 1992

By Pradhan GK

Blasting is one of the most important operations involved in surface coal mining. The removal of over-burden waste in surface coal mines of India had experienced many improvements in terms of blasting, explosives selection, blast design, equipment selection, deployment. etc. Two case studies of very large surface coal mines have particular importance in their blasting operations. Both these units have been equipped with large capacity excavating machines, hauling units and also have some difficult mining situations. Blasting is done in benches in close proximity to human dwellings and over coal seams developed by underground methods with problems of high wall stability etc, as well. The various steps taken to improve the blasting operations ensure smooth operation of the equipment to meet the targetted coal production.

Jan 1, 1991

The process of evaluating orebodies at the feasibility study stage is extremely important. In recent times many groups have indicated that they would like ore reserve estimation to be numeric and objective. Whilst sampling, geological, mining and mathematical principles may be used to analyse the data, all ore reserve methods require the use of experience factors and as such are value j ddgment statements.

Jan 1, 1990

This paper reviews the issues of mining machinery automation with special emphasis on underground applications. Automation is desirable because it offers the following advantages: ò increased safety by reducing human exposure to hazards of underground mining; ò higher productivity; and ò reduced wear of equipment. In spite of these advantages and in spite of numerous attempts over the past several decades, mining automation has been a difficult proposition, partly because no two mining operations are exactly alike and these operations are carried out in an unpredictable environment. This is the main difference between automation in factories and in mines and that is why mining automation has been lagging so far behind factory automation. Automation is possible only when the machine 'knows' its workspace. In a factory, this workspace can be 'described' to the machine because it is sufficiently controlled. In a mine, the environment undergoes continuous change and the only way the machine can 'know' its workspace is through real-time sensing.

Jan 1, 1995

The Manto Verde copper mine (Atacama Region, Chile) is due to go into production in 1996. It will produce 40 000 tonne/year of copper cathode by heap leaching/SX-EW. Mineralogical studies were undertaken in conjunction with the metallurgical testwork program to characterise the ore and its response to leaching by dilute sulphuric acid. The leachable copper mineralogy is dominated by the oxide copper minerals: brochantite and malachite with minor chrysocolla and atacamite. The gangue minerals include abundant orthoclase, specularite, quartz and chlorite with minor muscovite and trace smectite clay, calcite and limonite. The study showed that complete or partial decomposition of calcite, chlorite, smectite and wad consumed acid and generated solution impurities (Ca2+, Fe2+, Mg2+, A13+, K+, Si4+ and Mn4+2+ ). Although these were manageable at Manto Verde, their uncontrolled build-up could have affected the operation in several ways: the degradation of heap penneability and fonnation of crud in the SX plant from the precipitation of gypsum, goethite, colloidal silica and jarosite; and the entrainment of contaminated pregnant leach solution in the SX organic resulting in the transfer of impurities to the electrolyte and subsequent effects on cathode quality and electrowinning efficiency. In conclusion, process mineralogy played an important role in understanding and managing potential mineral-related problems in the heap leaching and SX-EW recovery of Manto Verde ore.

Jan 1, 1994

By Yamada K, Abe H

Magnetic scanning type mass spectrometers have been given improved sensitivity with a large dynamic range and considerable resolution by the addition of a computer-controlled electric equipment. A mass spectrometer equipped with this newly developed electric system was applied to studies of the activities of liquid iron-silicon alloys and of liquid iron-phosphorus alloys at 1600¦C. The range of silicon concentration was 5.8at%-51.1 Si= at%, and values of ySi -3.1+0.15 and es 11.5 +1.5 were obtained. The concentration range of phosphorus was 1.3at%-5.7at% and a value of eP=7.3+0.1 was obtained.

Jan 1, 1980

By Beck RW, Booth GW

Differences in the gold contents of sub-sample duplicates, derived from a single bulk sample are a function of analytical and random error, inhomogeneity within the bulk and natural variations in the distribution of particluate gold. By minimising bulk sample inhomogeneity and determining analytical precision, the residual natural variation may be modelled statistically to give an estimate of Bold particle sizes.

Jan 1, 1989

By Robinson B, Ham B

Outbursts have occurred irregularly in the Collinsville Coal field since 1954 when an incident claimed seven lives. Further significant outbursts occurred in 1960, 1961, 1972 and more recently in the No. 2 mine in 1978. From the information collected over 25 years a comprehensive program to minimize the hazard of outbursts has evolved. Further developments of techniques to combat outbursts are being developed.

Jan 1, 1980

By Witkowski A

I have the pleasure to present 6 excellent papers in this section all of major relevance to the mining environment of today where competing social, legal and monetary interests and their often complex interaction require serious consideration. This is particularly true today where huge fluctuations in commodity prices makes mining a perilous undertaking while the world increasingly are becoming aware of the serious threat that mans activities has on his environment. The 6 papers deal with such complex issues as safety in an underground environment; How to protect sensitive wetlands well into the next century; The enormeous waterproblems in China and conflicting dewatering/water supply needs; Disposal of contaminated water in sensitive areas and the dynamic interaction between mining companies and legislation.

Jan 1, 1988

By Gooday PE, Brech GE

Ore reserve categories used by Pancontinental Mining fall into one of three fundamental groupings: Geological In Situ Reserves Mining Reserves Production Estimates The first of these describes the total reserve within stated parameters without implication as to its mineability. The second is that part of the Geological In Situ Reserve which is considered mineable under a specific mining plan. The third is the Mining Reserve adjusted with appropriate dilution and recovery factors and thus represents the best estimate of the tonnage and grade of production. This practical three category system mirrors the standard steps traditionally taken in ore reserve estimation and readily conveys the basis of the estimates. An important, but secondary classification can be added to qualify the level of confidence in these estimates using the terms: Proved (or Measured) Probable (or Indicated) Possible (or Inferred) These terms can be applied to any of the fundamental groupings, but it is generally implicit that the level of detail required to produce meaningful Mining Reserves or Production Estimates would require the basic Geological Reserve to be at a Proved or at least Probable level of confidence. The application of these classification systems by Pancontinental is illustrated by reference to the Paddington Gold Project. The methods of calculation are described including the use of geostatistics. Reconciliations of actual production with predictions from reserves are carried out monthly and annually. To date there has been an excellent correlation with Production Estimates, based on both manual and geostatistical calculations.

Jan 1, 1987

Changes in mining technology have led to an increase in the number of underground sulfide dust explosions reported in Australian and overseas mines. Samples collected at the Elura mine consisting primarily of pyrite, pyrrhotite, arsenopyrite, sphalerite and galena, were tested in 8 litre explosion chamber. The dusts were found to be capable of producing dangerous dust explosions with maximum explosion pressures of 440 kPa and rates of pressure rise of 5200 kPa/s. The hazards of a sulfide dust explosion are associated with the pressure wave and flame front of the explosion and the toxic gases remaining after the explosion.

Jan 1, 1984

The orebodies at Kambalda are complexly faulted, folded and intruded. It is realized that the ore reserve calculations will be wrong and steps are taken to minimise the errors. The calculations are a combination of computer data handling and manual input. Initially Geological Ore Reserves are calculated and then production data and experience are used to produce a Planned Mining Reserve. At all stages maximum professional judgement is incorporated. The basis of the calculation is the polygonal method of area estimation, and production reconciliations together with the style of data available indicate that it is a most suitable technique. It is also a tech- nique that is easily communicated to all levels from operators to management.

Jan 1, 1979