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By D Connelly

Magnetite ores can be used to produce very high-grade concentrates that are suitable feed for the direct reduction process route but the high sulfur content of some concentrates can cause substantial environmental issues. Processing of high sulfur magnetite ore is therefore increasingly problematic for the industry. Generally, the industry demands a concentrate with <0.05 per cent sulfur and <2 per cent silica. This paper reports the outcomes of a study to produce a concentrate with the requisite low sulfur content from a sulfur-rich magnetite ore. The main findings may be summarised as follows: if the sulfur is present in magnetite as nonmagnetic pyrrhotite or pyrite, it can be beneficiated using magnetic separation and hence, monoclinic pyrrhotite is magnetic and is magnetically recovered with magnetite leading to a concentrate that is too high in sulfur. X-ray diffraction and QEMSCAN analyses revealed that the magnetite concentrate was liberated at P80 30 microns and was associated with maghemite, pyrrhotite (magnetic), carbonates and hematite with very low amounts of chalcopyrite, sphalerite and arsenopyrite. Sulfur removal using flotation was the first stage of investigation and this required flash flotation in the grinding stage followed by column flotation of the initial concentrate to generate the final concentrate. At the same time, it was observed that oxidation of the pyrrhotite had a negative effect on its flotation requiring copper sulfate to activate it. Bioleaching and concentrate leaching were also considered and achieved over 90 per cent sulfur removal but were deemed unsuitable owing to the production of highly reactive wastes and high CAPEX. Reference is made to a number of operating magnetite producers and how they manage the sulfur in feed.

Sep 18, 2023

By T Weldon

In the last 15 years, it has become increasingly popular to win gold and silver from carbon strip solutions with electrolytic æsludgeÆ cells. The precious metal sludges produced in the cells are washed to the cell bottom and pumped into filters. Most new operations are specifying sludging cells, and many older operations are being retrofitted with up-to-date electrolytic sludge cells and filters. The new sludging cells are generally more energy efficient than older cells, but more importantly, the cell operations to remove product are much less labour intensive, cleaner, and the operator need not have physical contact with the electrolytically produced metal. A case study of a major North American gold producer (50 000 kg/yr) that removed old style stainless steel wool cathode cells and installed new sludging cells and sludge filters is presented. The effect of various impurities is discussed.

Jan 1, 2005

By T Goswami, G Brent

In response to concerns over greenhouse gas (GHG) emissions and an imposed cost in some jurisdictions, many mining houses have committed to reductions in their GHG emissions. However, mining faces particular challenges in this regard, notably from increasing strip ratios. Furthermore, mining activity around the globe is not expected to decrease in the foreseeable future as mineral demand is driven up by the aspirations of rapidly-developing nations. Novel approaches will thus be needed if any reductions in energy consumption and GHG emissions of mining are to be achieved.This paper presents some directions for the mining industry to pursue in reducing their GHG impact, focusing on the difference that blasting methods can make. Importantly, large productivity and revenue gains can also be realised from these methods.Key directions considered here include optimising resource recovery and quality through:reducing coal damage and loss from throw blastingrecovering thin coal seamsproducing cleaner coal with less dilution.Blast design can also significantly improve the productivity of surface mining by:improving muck pile shapingimproving mine equipment productivityimproving scheduling.We show how a particular blasting method can eliminate coal loss in overburden throw blasting and can lead to large increases in coalmine profitability. Thin seams that were previously wasted can also be recovered with this method. Furthermore, the method has been implemented to combine several separate drill and blast cycles into a single cycle, leading to productivity gains.An illustrative example is given to show how increased coal recovery can increase revenues and more than offset any potential GHG emissions liabilities. Overall mine energy and GHG emission intensities can thus be reduced.CITATION:Goswami, T and Brent, G, 2015. Blasting approaches to increase mine productivity and reduce greenhouse gas emissions in surface coal mining, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 635–644 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

A biological column leach testwork program was undertaken on a chalcocite ore. Three tests were conducted in all, using 65 in x 100 mm columns in three sections. The tests were started with varying acid strengths and inoculated with bacterial solutions from previous column testwork. The leaching of Cu was found to occur in three stages. These stages consisted of direct acid leaching, bacterial oxidation and ferric iron leaching. These leaching stages can most easily he described through the examination of not only Cu dissolution but also Fe dissolution and its subsequent oxidation and precipitation. The p11 of the system was found to he critical in establishing and maintaining the bacterial leaching system. The oxidation potential was seen to he influenced by the leaching system as the oxidation states altered. Test variables such as, 02, COz, and temperature were all found to influence the system. Final copper recoveries were in excess of 90 per cent in each column test over a leach time ranging from 211 to 328 days. Given similar leach conditions are applied, the application of this technology to site is expected to give comparable results.

Jan 1, 1994

By E A. G Marques, P M. Dight, T A. V Costa, K Mercer

Brazilian banded iron formation (BIF), known as ‘itabirite’, is the main host rock for iron ore in the Iron Quadrangle mines, Brazil. Their geneses are controversial and it is agreed that diagenetic, metamorphic and tectonic events, as well as weathering processes, were responsible for the iron concentration. In addition, it is understood that weathering processes are mainly responsible for reducing the original high intact rock strength, and for generating deep weathered profiles with low strength rocks commonly observed in Vale’s mines.A considerable amount of work has been done to correlate the macro and micro aspects of the itabirites as physical, chemical and geotechnical characteristics that directly or indirectly affect the intact rock strength; however, it is not yet clearly understood what effects the weathering processes have on the strength reduction of these rocks and its associated impact on pit slope stability. This forms a key focus of the lead author’s current research work.This paper presents a review of the geological, geotechnical and weathering characteristics of the itabirites, and early results for the evaluations of fresh itabirites from the PhD thesis research being undertaken by the authors at the Australian Centre for Geomechanics, School of Civil, Environmental and Mining Engineering, The University of Western Australia, sponsored by Vale SA.The results showed that to evaluate the density and unconfined compressive strength (UCS) correlation, not only the porosity but also the geological features should be considered, as they are responsible for data dispersion; however, the presented data suggested a trend that provides the confidence to develop advanced studies and a data population increment to establish proper correlations to support a reliable UCS method.CITATION:Costa, T A V, Dight, P M, Mercer, K and Marques, E A G, 2015. An overview of the weathering process, preliminary density and unconfined compressive strength correlations for fresh itabirites in vale mines on the western side of the Iron Quadrangle, Brazil, in Proceedings Iron Ore 2015, pp 241–254 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By X Yu, Y Shen

The iron ore products should be assessed in terms of in-furnace behaviour and overall furnace performance, their operation should also be optimised under industry-scale blast furnace (BF) conditions, in order to be sustainable and competitive, especially in the context of decarbonisation efforts in ironmaking. While lab and pilot-scale experiments can provide useful kinetics, they are expensive and risky and cannot replicate industry-scale blast furnace conditions for proper assessment and optimisation. In this paper, we review our recent progress at Shen Lab of UNSW in using state-of-the-art Computational Fluid Dynamics (CFD) models to assess iron ore products and examine the effects of their operations on BF behaviour in basic terms, including in-furnace phenomena (flow field, temperature field, species distribution fields etc) and overall BF performance (coke rate, reduction efficiency and top gas temperature etc). We have developed state-of-the-edge CFD models for different purposes, ranging from the static-state BF model featuring unique layered burden structures for offline assessment and optimisation knowledge building-up for iron ore products, to the transient-state BF model for online assessment and optimisation of iron ore productions by describing the transient behaviours of iron ore productions under industry-scale conditions. First, we have studied several iron ore products including the iron ore products used in the present BFs and emerging iron ore products like carbon composite briquette and iron-coke. Second, several iron ore operations are studied including optimisation of conventional burden operations like oxygen enrichment, batch weight tuning and new operations like coke central charging and hydrogen injection in BFs. Third, some time-sensitive operations are also investigated including the use of wet burden materials and the drop in blast temperature on BF performance. These CFD models offer cost-effective research tools for understanding the effect of iron ore products on BF performance and serve as a reliable marketing tool for existing and emerging iron ore products under a wide range of BF conditions.

Sep 18, 2023

By K Dagdelen

A vehicle proximity warning system is being developed using GPS and wireless local area networks to improve safety of off-highway trucks in open pit mines. After two an a half years of research, software development, and laboratory testing, field tests were carried out at operating limestone quarries and open pit mining operations to evaluate GPS accuracy and overall system effectiveness under rugged operating conditions. This article describes the progress made on this NIOSH funded project and discusses the GPS accuracy tests and overall system tests that were carried out during 2001 at the Morenci open pit copper mine in Arizona.

Jan 1, 2003

Between 1966 and 1976, Australia moved from being a non-producer to a position of meeting more than ten per cent of world nickel demand. New mine developments beginning the early-1990s have the promise of more than doubling the country&apos;s world market share - from around eight per cent to perhaps close to 20 per cent. This new surge in activity - the so-called `second nickel boom&apos; - has led to several developments which seem likely to have similar economic impacts to those of the late- 1960s and early-1970s. There are, however, some notable differences this time around. The impact of long distance commuting over the past 30 years has changed the regional development scenario. The gold industry is much stronger in Australia than it was in the late-1960s and this helps to place the importance of new nickel discoveries in a more realistic perspective. As potential players have jockeyed to complete feasibility studies and move into construction and production phases of new long-life mines, established suppliers clearly seem to be taking actions to discourage the newcomers. In what appears to be a classic oligipolistic market situation, the heightening of perceived entry barriers to the industry appears to be a particularly visible strategy undertaken. In the current scenario as well, greater vertical integration among producers appears a significant influence on market power.

Jan 1, 1996

By Johns AS

Comissioning of a new residue disposal tcluding upgraded classification for none backfill preparation, new variable speed pumps and a new residue dam took place in 1¦76. The system is described.

Jan 1, 1978

By H Jones

The paper outlines the adoption and evolution of ‘sustainable development’ as a concept in tailings management practices in the mining industry over the last 30 years. Over 500 lives have been lost in tailings facility accidents since World War 2. The paper outlines commonalities in many of these accidents, particularly the role of excess water. It considers the role effective tailings management can play in enhancing the social acceptability of mining in the future.Tailings management is a major operating cost at many mines while the cost of successfully closing tailings facilities is also very high. Current tailings management practices in the industry are outlined. The technical and engineering challenges of reducing potential risks associated with tailings by reducing water entrainment are described. The successful development of practical techniques to better manage tailings and reduce water consumption and wastage are described. For example, water removal in the alumina industry to produce a paste for dry stacking is now a reality.The future adoption of these new risk reducing techniques by the industry is discussed and the implications of the adoption or non-adoption of these techniques on the industry’s future ‘social licence’ is considered.

Nov 22, 2011

By M L, G Maddocks, A Ferrier, ers, A Forbes

Evolution’s Mount Rawdon Operation (MRO) produces gold and silver through open pit mining methods. The mining operations are scheduled to be completed in FY24 (Financial Year 2024), after which low-grade stockpiles will be processed until the end of FY27. As part of MRO’s Progressive Rehabilitation and Closure Plan (PRCP), RGS Environmental Consultants (RGS) and Deswik were engaged to develop the final landform surface and a whole of site probabilistic water balance/water quality (WB/WQ) model to evaluate the viability of several closure options with respect to water quality in the various site water storages, particularly the final void which will form a pit lake. This case study details the closure option which included (amongst other things) covering the final landforms and directing water toward or away from the final void post closure. Closure and rehabilitation for MRO had previously been planned and evaluated on a ‘domain’ basis. Furthermore, the rehabilitation plans and final water management plans for the Tailings Storage Facility (TSF), Waste Rock Storage Facility (WRSF) and other domains were not coordinated, possibly resulting in competitive rehabilitation material requirements at the commencement of closure activities. An assumption was that a legacy non-acid forming (NAF) stockpile would provide sufficient material to both supplement ex-pit material for the construction of the TSF embankment raises and to complete all closure activities, but the volumes available and the volumes required to complete the closure activities had not been quantified.

Aug 2, 2023

In todayÆs evolving and globalised world, mining companies are being pressured to move beyond compliance towards long-term sustainability and sustainable development. Companies are expected to æengageÆ communities and measure the success of these engagements without a clear understanding of æhowÆ to do this. This move, away from compliance, develops more of a focus on sustainability and æcommunityÆ social responsibility rather than corporate social responsibility. This shift leads to the development of world-class projects that provide sustainable development for people, reduce the incidence of costly delays, and promote good global citizenship for companies. The process of æengagingÆ communities in mining project design and development leads to sustainable development, a stronger license to operate, and a reduction in social and political risk. To create this mutually beneficial relationship between communities and companies, communities must be æengagedÆ in the project development and risk assessment processes as early as possible, preferably during the exploration or the concept phases. How to create this æengagementÆ and manage this risk will be discussed.

Jan 1, 2007

By A Tolley

Bauxite residue or ‘red mud’ is a by-product of the Bayer Process, the primary process of alumina refining. Due to its high alkalinity and variable composition, its storage and disposal poses high environmental risks to water sources, surrounding ecosystems and human health. The high alkalinity (pH 12–13) is a significant factor in its classification as hazardous waste; to mitigate this, Australian refineries have integrated neutralisation processes into bauxite refining. Both sea water and carbon dioxide neutralisation processes are applicable. Multiple studies have demonstrated pH reduction from 12–13 to 7–10, depending on the method. The key advantages of CO2 neutralisation are that it allows for carbon sequestration and is more effective when utilised as a pre-treatment for recovery of metals, while sea water neutralisation is more established and has been integrated into two Australian refineries. This paper proposes the application of the bacteria Exiguobacterium oxidotolerans for bioleaching of iron from hematite in bauxite residue. The genus Exiguobacterium is characterised by its high levels of adaptability, halotolerance and alkaliphilic nature. E. oxidotolerans is successful at eluting Fe2+ from hematite via reductive dissolution, which complexes with oxalic acid produced during metabolism. This aquatic bacterium presents a novel process pathway for iron elution due to direct interaction of E. oxidotolerans with hematite via the cell membrane and operates within the pH range of neutralised red mud. The proposed mechanism is extracellular electron transfer, a microbial metabolic process where electron transfer is facilitated between bacterial cells and extracellular material. Currently this is being investigated for promotion of seaweed growth in coastal environments as soluble iron aids and fortifies colonies. This has potential downstream applications for cleaner iron and steel production. While theoretical, this paper explores the neutralisation, bioleaching and application of the Fe(II)- and Fe(III)-oxalate complexes formed.

Sep 18, 2023

By J Zhou, D M. Hunter, S M. Iveson, K P. Galvin

The recovery and concentration of ultra-fine iron ore can provide significant economic benefits. Presently, there are limited options available given the low settling rates achieved by conventional gravity separation and the relatively poor performance of reverse flotation. The Reflux Classifier is a new water-based gravity separation technology that consists of a set of parallel inclined channels positioned above a vertical fluidised section. This arrangement promotes a powerful throughput advantage compared to conventional fluidisation and a highly selective hydrodynamic basis for achieving sharp separations. A high shear rate develops within the inclined channels, which generates sufficient hydrodynamic lift to convey the lower-density particles (even if they are relatively coarse) to overflow while retaining the high-density particles (even those that are ultra-fine) for discharge to the underflow. The technology has previously been used around the world on particle sizes in excess of 0.1 mm. The present work, however, is concerned with density-based separations down to much finer particle sizes approaching 0.01 mm.A major advantage of the Reflux Classifier technology is the achievement of simultaneous gravity separation and desliming via a single-stage separation. A series of continuous experiments was conducted using an iron ore feed with head grade of 35 wt per cent FeT and nominal top size of 0.106 mm, with 59 wt per cent being below 0.038 mm in size. At a low throughput of 1.5 t/(m2 h), the Reflux Classifier produced high-grade products at a high recovery. For the entire feed, grades of 66.1 wt per cent FeT with Fe recoveries of 80 per cent were achieved in a single-stage separation. Within the 0.020–0.038 mm size fraction, grades of 68.8 per cent were achieved with iron recoveries of 94.7 per cent. Excellent recoveries of up to 57.0 per cent were achieved for the -0.020 mm size fraction. The ability of the inclined channels to retain the fine dense material further enhances the effectiveness of the Reflux Classifier by creating an autogenous dense medium effect within the vertical section. This helps to elevate large gangue particles up into the overflow.CITATION:Hunter, D M, Zhou, J, Iveson, S M and Galvin, K P, 2015. Gravity separation of ultra-fine iron ore in the reflux classifier, in Proceedings Iron Ore 2015, pp 143–148 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By G Forbes, D J. Bradshaw, G S. Heinrich, D

Traditionally, operators on mineral flotation plants have relied on visual inspection of the froth surface when making adjustments to process set-points. Machine vision systems are being developed to relate froth surface descriptors, which can be consistently measured in real time, to flotation performance. By investigating the impact of various selected operating variables on both froth surface characteristics and metallurgical performance it is possible to develop a management strategy for the control and optimisation of the process. This paper presents the results of testwork conducted at Kennecott copper mine which investigates the relationship between the froth colour and the concentrate grade and discusses the factors which affect the froth colour. This work shows that the main factors that influence the froth colour in this system are molybdenum, copper and iron concentrate grade, pulp and concentrate per cent solids and pulp iron grade.It goes on to develop models to predict the concentrate grade based on colour information and velocity and stability information. It also shows that the most accurate prediction is made with combined colour and stability information.

Jan 1, 2005

Structural assemblages of veins, shear zones, and wallrock alteration zones arising from fault-valve action on steep reverse fault systems are reviewed using observations from mesothermal gold-quartz lodes in the Archean Yellowknife, Abitibi, and Yilgarn greenstone belts of Canada and Western Australia, the Cretaceous Mother Lode system in the Foothills Metamorphic Belt of the western Sierra Nevada, California and the Victorian goldfield hosted in a folded quartz-turbidite succession of Paleozoic age in Australia. Despite differences in the host rock assemblages, the deposits have many structural characteristics in common. These form a useful exploration guide when re-evaluating comparable, but poorly described gold-quartz vein systems such as those in the Reefton area of New Zealand.

Jan 1, 1992

By T Vizcarra, G Sandoval, C L. Evans

One of the challenges in the development of mineral processing simulators is modelling the liberation characteristics of particles produced by comminution circuits. Understanding the mineral characteristics of these particles is one of the keys to predicting their behaviour in separation circuits. While more fundamental research seeks to model the non-random breakage of ores this work examines whether we can move forward now by using observed characteristics of ores to model the composition of particles generated in comminution processes. Several researchers have noted the similarity of the liberation characteristics for a selected size fraction of particulate material, whether the fraction comes from a coarse material, such as the product from a jaw crusher, or a more finely ground material, such as the product from a ball mill. In most cases these observations were reported as an aside and were not the main focus of the published work. This observed behaviour has the potential to be a useful tool for modelling the particle characteristics in mineral comminution and separation circuits, particularly as we move towards the development of multi-component models. However, before the behaviour can be used widely we need to understand which ore types follow the observed pattern and which do not. The current work examines a range of ores and identifies which exhibit the pattern of similarity of composition for particles in a given size class that has been produced as the result of a variety of breakage conditions. The impact of mineralogy and texture on the evolution of liberation characteristics for both valuable and gangue minerals is discussed.

Jan 1, 2008

By Kuganathan V

The processing of black coal in Australia segregates waste in the form of coarse reject and fine tailings. The coarse reject is relatively easy to handle, while the tailings can be problematic. Conventionally, the two waste materials are disposed of separately, the coarse reject in dumps, and the tailings in man-made containments. Aqueous tailings slurry is pumped to a &apos;wet&apos; tailings storage, where the fine particle size of the tailings limits dewatering. Their low bearing capacity and high compressibility result in tailings deposits being difficult to rehabilitate. Disposing of the waste streams separately moves away from the heterogeneous mixture in the undisturbed ground, and concentrates potential problems with each waste stream. The feasibility and desirability of the co-disposal of tailings and coarse reject by combined pumping is demonstrated. This technique is in operation at Jeebropilly Mine and is proposed for a number of other coal mines.

Jan 1, 1992

By R L. Brathwaite

The rocks of New Zealand can be grouped into three main elements: the Early to Mid Paleozoic Western Province, Late Paleozoic to Early Cretaceous Eastern Province, and several overlying Late Cretaceous to Cenozoic sedimentary basins. The Western and Eastern provinces were formed on or near the margin of Gondwanaland, whereas the Late Cretaceous to Cenozoic sedimentary basins developed after the separation of New Zealand from Gondwanaland in the Late Cretaceous. &nbsp; The Early to Mid Paleozoic Western Province rocks are exposed in Nelson, Westland and Fiordland and include metamorphosed sandstone, mudstone, limestone, and volcanic rocks, intruded by granite batholiths and maficultramafic igneous complexes. The main associated mineral deposits are gold-quartz lodes hosted by Paleozoic greywacke and argillite. Other type of deposits present include: volcanogenic massive sulphide lead-zinc; vein and greisen tungsten and tin; and magmatic nickel-copper sulphide, platinum group element, and magnetiteilmenite deposits. Granite stocks and batholiths, intruded during the Cretaceous, have associated porphyry molybdenum deposits. &nbsp; The Late Paleozoic to Early Cretaceous Eastern Province includes the greywacke rocks forming the axial ranges of the North and South islands, and a belt of schists in Marlborough, the Southern Alps and Otago. The schists host many shear-zone related, gold-quartz lodes and, in the Southern Alps, lenses of serpentinite with talcmagnesite and nephrite jade. Volcanogenic massive sulphide copper deposits and volcanogenic manganesechert deposits, occur in both the schist and greywacke, and a belt of Permian age ultramafic rocks (Dun Mountain Ophiolite) has associated copper, chromite and chrysotile asbestos deposits. &nbsp; The Late Cretaceous to Cenozoic rocks are found in a number of sedimentary basins onshore and offshore of the North and South Islands. Many of these basins developed during the rifting of New Zealand from Gondwanaland in the Late Cretaceous. They contain New Zealand&apos;s economic petroleum, coal and limestone deposits. Uplift and erosion of the mountain ranges shed gold into rich placer deposits in the South Island. &nbsp; From the Miocene, volcanic rocks feature prominently on the eastern South Island (e.g. Banks Peninsula southeast of Christchurch and the Otago Peninsula northeast of Dunedin) and northern North Island (Northland and Hauraki), and volcanism continues today in the Taupo Volcanic Zone. The North Island volcanic rocks have associated epithermal mineralisation, mainly gold and silver, but also copper, lead, zinc, mercury, and antimony, as well as deposits of sulphur, perlite, pumice and zeolite. Porphyry copper style mineralisation is associated with subvolcanic intrusive rocks. Erosion of the volcanic rocks has shed titanomagnetite onto the west coast of the North Island forming significant coastal placer deposits. Similarly, erosion of the Alpine schists in the South Island has resulted in placer ilmenite deposits on the coast of Westland.

Jan 1, 1997

By S Brunt

A new elution process has been developed for the recovery of gold thiosulfate from ion exchange resins. This is a synergistic system which utilises a base eluent, such as nitrate or trithionate, along with an additive that improves the elution of gold. The use of the additive enables lower eluent concentrations to be adopted, as well as weaker eluents such as chloride. With the chloride + additive system, complete gold elution can be achieved within 12 BV when utilising an eluent flow of 5 BV/h. When the eluent flow is reduced to 2 BV/h, complete elution is achieved within 8 BV. Similar results are obtained when using nitrate or trithionate as the base eluent. A copper pre-elution process has also been developed, whereby the majority of copper can be stripped within 5 BV prior to gold elution. This method is a significant improvement on the ammonia + oxygen pre-elution previously suggested. The development of a new analytical procedure based on ion chromatography with UV detection is also described for the quantification of polythionates in leach solutions and loaded on resins. This enables analysis to be carried out for resin-in- leach type processes where the polythionates are being formed in solution and simultaneously adsorbed onto the resin.

Jan 1, 2007