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The Auscoke project has reached-a stage where a pilot plant nominally able to produce 100 t.p.d. of coked briquettes is being brought on stream during Nov. 1971 . The targets for this stage of the project are to establish the technological and economic value of Auscoke for the iron blast furnace, and to verify the commercial feasibility of large scale plants. The project originated at the B.H.P. Central Research Laboratories (C.R.L.) and work to date has shown that using a two stage contin- uous process, strong large coke can be produced at good productivities from medium or low volatile poorly caking coals. General features of the pilot plant and processing are discussed.

Jan 1, 1972

The writer had the pleasure of several months' laboratory tests on a metallurgical process for copper ores devised by Mr. W. H. Corbould, Consulting Engineer, North Queensland. Mr. Corbould's research work in this direction commenced somesix years ago, and he eventually succeeded in obtaining a good extraction of copper and a resulting solution practically free from iron and other impurities. The commercial operation of the process was investigated and special machines with novel features were designed. OUTLINE OF THE PROCESS.The process described in detail in the following pages, required for successful application that the ores contain at least the minimum ratio of sulphur to copper, consistent with the production of sulphadising roasting conditions.

Jan 1, 1921

By D W. Wall, J P. Vagenas

Questions of sampling precision and accuracy affect every process plant in differing ways and to differing extents. To address these perceived issues, chemists, metallurgists and engineers are often asked to check their results to confirm their reliability. However, it is not possible to achieve the level of detail required to check every sample, especially if the event has already occurred. No operation has the resources to frequently sample every point in the process for the purpose of verification.One way to address this scenario is by generating a sufficiently detailed comparative data set from a dynamic mass balance simulation of the processing plant. This mass balance uses both sample and plant instrument data to model every flow, while also taking inventory changes and process chemistry into account.The mass balance data can be used to identify any bias present in plant sampling and analysis. It can also be used to verify any unexpected assay results by taking a holistic view of the process. Improving the precision and accuracy of sampling data helps support operational decision-?making and understanding. It also improves the accuracy of the dynamic mass balance used in this process, facilitating further improvements.CITATION:Vagenas, J P and Wall, D W, 2017. The benefits of automated metallurgical accounting for plant sampling, in Proceedings Eighth World Conference on Sampling and Blending , pp 203–210 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By R Jacobs

"The Jaguar project is relatively unique in that it was evaluated, financed, built and operated to completion within the last ten years, providing the opportunity to holistically review and reconcile expectations against the actual outcomes. It is a case study that allows wider conclusions to be drawn with respect to the risks and opportunities involved with project evaluation and execution.Jaguar is located in the Leonora Mining District of Western Australia and was commissioned in mid-2007 as an underground accessed, single high-grade volcanic-hosted massive sulfide (VHMS) deposit with an on-site concentrator, producing copper and zinc concentrates exported via the Port of Geraldton to South-East Asian markets.The feasibility study (FS) had several iterations (JML, 2005a); the last dated July 2005 was specifically targeted to secure project funding, and summarised the reserves-only portion of the resource and its planned exploitation. The commissioning of the mine was the transition for the owner Jabiru Metals NL from junior explorer to producer and the project was the dominant asset of the company.Jaguar operated through several significant deviations from the linear project plan set out in the FS, including the Global Financial Crisis (GFC), a corporate takeover and disruption to the mine plan from the onset of material geotechnical issues. Whilst the GFC or mining disruption were not specifically predicted in the FS or peer reviews, the generic effects of the events were assessed in the project risk assessment and they influenced subsequent management decisions. In parallel to the internal project-specific risks, the short planned life of Jaguar was a risk to the continuation of the corporate entity which was being addressed by significant investment into brownfields exploration to extend or replicate the project, and ultimately added value such that attracted a corporate takeover.Holistically, the project delivered the returns predicted in the FS, but in a much different guise than was expected. This paper will describe the reality of operations compared with the study predictions and expectations through the perspective of the project and corporate risk assessment.CITATION:Jacobs, R, 2016. Jaguar base metals project case study – has reality reflected the study?, in Proceedings Project Evaluation 2016, pp 86–97 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By N Murphy and, S Santomartino, M Cramer

Acid rock drainage (ARD) can have detrimental effects on mining infrastructure, water reuse options and environmental discharge. As a result, some form of short- or long-term treatment is required at many mine sites. Successful treatment depends on a number of factors including the selection of an appropriate treatment technology and its correct implementation. A variety of passive and active technologies are available for dealing with ARD. Passive treatment solutions do not require continuous chemical inputs but take advantage of naturally occurring chemical and biological processes. They are often low cost, site specific approaches and are predominantly used in post-closure situations. Passive systems are well suited to drainage with low acid loads and low soluble aluminium concentrations, and are more effective with highly reduced (ie low oxygen) water. While they are often regarded as permanent fixes, most require some form of ongoing maintenance and all have an engineered life expectancy (ie finite carbonate and organic matter budgets). Passive treatments include, oxic limestone drains, anoxic limestone drains, limestone diversion wells, various reducing and alkalinity producing systems, pyrolusite limestone beds, aerobic and anaerobic wetlands, permeable reactive barriers (organic ¦ carbonate and zero valent iron), slag leach beds, and gas redox and displacement systems (GaRDS). Active treatment solutions require a continuous or semi-continuous activity (eg reagent dosing) to correct water quality issues. They can be engineered to treat virtually any type of drainage or site specific ARD issue, and have no set acid load or redox limitations. Tasks handled by active treatment systems are almost invariably larger and more costly than for passive systems. Active treatment approaches include; pH control, adsorption/absorption, ion-exchange, electrochemical concentration, biological mediation/redox control, flocculation/filtration and crystallisation. A range of generally available and proprietary technologies has been developed around these approaches. Active treatment involving pH correction with alkaline amendments is the most common and cost-effective form of ARD treatment. A variety of fixed plant and portable treatment systems are available. Calcium-based reagents, including quicklime (CaO), hydrated lime (Ca(OH)2) and limestone (CaCO3) remain the reagents of choice for the majority of active ARD treatment worldwide. This is principally due to their widespread availability, non-proprietary nature, and variety of proven dispensing technologies and cost-effectiveness. Limestone, in particular, is a very low cost reagent. However, due to æefficiency of useÆ problems with limestone in passive treatment systems, combined with its very low cost, there has been a recent emphasis on developing active treatment systems that use limestone efficiently. As the requirement for treatment increases, there is a growing emphasis on treatment sludge management and sludge stability. The final choice of a suitable treatment technology is dependent upon water chemistry (eg pH, type of metal contamination, acidity), flow rates, acid load, local natural resources (neutralising materials, topography), climate, site logistics, environmental risk and economics. The benefits and limitations of both passive and active treatment technologies are summarised.

Jan 1, 2003

By D Connelly

The initial results for the cyanide leach gold recoveries were very poor on a high-grade primary sulphide ore of 6.2 g/t Au with no silver. Subsequent mineralogy showed the ore to be a characteristic pyrite, carbonaceous refractory gold ore (double refractory). This was a very disappointing finding. A small scale gravity and flotation test programme was developed to produce a concentrate with the majority of the gold. This also failed with most of the gold remaining in the tailings. An ICP scan also showed variable levels of antimony. A Desktop Study was undertaken with minimal laboratory test work looking at Pressure Oxidation (POX), roasting, ultra-fine grinding, graphite passivation and consideration of any new technologies that might be applicable to this type of ore. The subsequent Study highlighted how difficult these double refractory gold ores are to process and highlighted some recent technology developments may be applicable. CITATION: Connelly, D, 2018. Technology options for processing complex and double refractory gold ore, in Proceedings Complex Orebodies Conference 2018, p 94 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

Production sharing and cost apportionment in joint ventures is commonplace in Australasia today and elsewhere. It is a recognised convention that, with the exception of a free carry situation, joint venture participants usually share the proceeds of the joint venture in direct proportion to their respective participating interest, after having first paid its respective cash calls, in advance, to cover the projectÆs ongoing operating and capital cost requirements.In surface mines, the parties simply pay their way and take their proceeds in this manner. In underground mines, the situation is no different, though treatment of capital, depreciation and tax may differ between the parties. A common feature in many cases is the creation of a joint venture entity to conduct the business. This entity then collects cash from the parties, banks it, employs the staff, runs the operation, provides reports and pays out the proceeds. This convention appears to be relatively simple in application. In practice, it has been known to be complicated in the situation where the participants take their product at the mine gate and undertake their own marketing and selling arrangements. A more complex situation presents itself where the joint venture tenement boundary with an unrelated third party straddles an economic deposit. In this scenario, both the joint venture parties and the third party may wish to mine the deposit, sharing some infrastructure and costs, yet taking their own product as it is produced. A case study outlining such a situation is presented in the paper, outlining firstly how the major cost categories were identified and treated for cost apportionment purposes. Secondly, a mechanism for the equitable apportionment of product is suggested. Finally, issues such as timing and cost reporting are dealt with, together with a checklist of points which should be considered when a similar situation might arise in the future.

Jan 1, 2002

By R Hargreaves, C Morley

The authors often see problems on mine sites that are due to insufficient feedback between technical discipline silos as the realities on the ground fail to inform the models and plans used to drive resource exploitation. Resource modelling, reserve definition, life-of-mine planning, short-term mine planning and scheduling, mine operations and beneficiation operations are all processes that inform each other, but in many instances feedback between these processes occurs in an ad hoc way and only after problems have come to light.Universal reconciliation uses a multidisciplinary approach across the entire mining value chain to identify both opportunity and loss of value and to maximise operational performance. This paper will look at the operational effectiveness of universal reconciliation and will outline the important elements that make it successful, including how to map out the detail underpinning modelling, planning and execution processes. We do this by documenting the physical processes, logical work practices, organisational roles and responsibilities, data origin and quality, working assumptions and information management practices at an operation. The results quickly show how misinformation and assumption causes suboptimal decisions to be taken, where inefficiencies exist and what the opportunity is to remedy these issues.A universal reconciliation study opens up an opportunity for stakeholders to reassess how the operation should be run and how operational effectiveness should be measured. Clear envelopes for reconciliation become obvious and questions about the practicality and data quality can be addressed.A reconciliation code of practice is a key element of a successful universal reconciliation project and the authors outline the important aspects that will provide an operating model, showing the effectiveness of the resource and reserve modelling, the practicality of the mine planning and scheduling practices, how well the mine operations team are executing these schedules and how effective the processing area is given what it is fed. Most importantly, a system that allows operations time to react before the losses become systemic and that is based on identifying early warnings from hard data when these processes start to wobble is outlined. Finally as a case study, the revenue and cost benefits resulting from universal reconciliation diagnostic projects for nine mine sites is documented.CITATION:Hargreaves, R and Morley, C, 2014. Universal reconciliation – a multidisciplinary approach across the entire mining value chain to identify loss of value and maximise operational performance, in Proceedings Ninth International Mining Geology Conference 2014 , pp 411–420 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By D Baas, Y Atasoy

With increased pressure for companies to cut costs during design of new mineral processing plants, overall plant design has changed over the last decade with less design for feed blending and less installed surge capacity. This has changed the operability of new mineral processing plants, where disturbances due to variable ore types have resulted in the evolution of new control techniques. These techniques are necessary to maintain stability and optimise the performance of these new plants. This paper describes the benefit of applying these new control techniques in a new mineral processing plant in Australia utilising RockwellÆs ControlLogix system architecture.

Jan 1, 2008

By A Scott, I Onederra

Most iron ores occur in mine benches as complex mixtures of lithologies and ore types. This significantly complicates their characterisation for both blast design and fragmentation modelling. A great deal of technical and research effort has been applied to the development of models to predict fragmentation from rock blasting. A number of quite useful engineering models are currently available to blasting engineers and consultants, and more sophisticated approaches using mechanistic descriptions of rock breakage continue to be developed and applied by researchers and explosives companies.The engineering or empirical models that are in more general use within the industry, such as the Kuz-Ram model, require appropriate data if they are to generate useful fragmentation predictions. Some of these models have reached significant sophistication and have made very useful contributions to both routine blasting operations and the exploration of new blasting paradigms. However, these models struggle to adequately deal with rock that is as complex as iron ore. This paper reviews the characteristics of the most successful blast fragmentation models available to the industry and discusses approaches to the derivation of suitable rock mass properties to adequately describe blast fragmentation in a range of iron ores.CITATION:Scott, A and Onederra, I, 2015. Characterising the blasting properties of iron ore, in Proceedings Iron Ore 2015, pp 481–490 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By H Holmstr÷m, A Widerlund, M Lindvall

At the Kristineberg mine in northern Sweden sulfide-rich, poorly buffered tailings have been deposited in five impoundments located along a valley. The tailings area has been remediated by applying a combination of till cover and flooding. A new method that has been applied to parts of the tailings area is to raise the groundwater table to saturate the tailings. By increasing pH by liming, thereby reducing metal mobility, a water-covered downstream impoundment is functioning as a trap for metals released from the till-covered impoundments upstream. In this paper the efficiency of the system approach used at Kristineberg is evaluated. Progressive changes of water quality from groundwater in the upstream till-covered impoundments via surface streams within the pond system to the water in the flooded downstream pond and its outlet are described. The results show that the system approach used in the design of the remediation programme of the tailings works as planned. The sulfide oxidation rate has decreased in the till-covered impoundments, and, as predicted, there is an out-flush of old weathering products which will continue for at least five years before equilibrium is reached. The groundwater in the till-covered impoundments has high concentrations of Fe, S, Mg and Zn, but the concentrations of metals such as Cu, Cd and Pb are much lower than before the till cover was applied. The limed pond is an efficient metal trap, with concentrations as high as 2.76 per cent Zn and 0.28 per cent Cu in the calcite-gypsum sludge developed on the tailings. The outlet from the flooded pond, and thus from the whole mining area, releases small amounts of metals to the recipient in comparison to the amounts that are in movement within the mining area. During the period May to November, 13 kg dissolved Zn and 111 kg particulate Zn was released to the recipient, whereas a total of 27 000 kg was transported by surface water within the impoundment system during the same period. The results from Kristineberg show that when planning remediation of complex mining areas, it is useful to adopt a system approach in which different methods are used on different parts of the area along the flow path of the drainage water, whereas flooding of the downstream pond is the key to the performance of the entire system.

Jan 1, 2003

By N J. Goodman

The HIsmelt technology was developed and proven in Western Australia (WA) after more than 30 years and several billion dollars of research and development. The HIsmelt technology was transferred to China and is now successfully operating at the Molong plant in Shandong Province, China using WA iron ore fines as the major feedstock. Several more plants are under construction in China, and the technology has been approved by the Chinese Government as an environmentally acceptable alternative to the blast furnace. The unique flexibility of the HIsmelt process offers multiple pathways to decarbonise the production of steel in the near future. These pathways include:  Use of sustainably grown biomass converted to Biochar to replace coal as the reductant.  Pre-reduction of iron ore fines using hydrogen or biomass to direct reduced iron (DRI) powder.  Capture of carbon dioxide from the HIsmelt off gas and geo-sequestration underground. These pathways are highly suitable for the Australian iron ore industry as they utilise:  The large areas of land and long growing season available in Australia for the production of large tonnages of sustainably grown biomass.  Coarse iron ore fines directly without the need for fine grinding and pelletising.  Existing oil, gas and other underground gas reservoirs to store carbon dioxide. The HIsmelt technology will allow Australia to transition from ‘Asia’s quarry’ to Asia’s supplier of low cost, low carbon and high quality metallics that are required to produce ‘green’ steel with net zero carbon dioxide emissions. In addition, HIsmelt pig iron can be converted locally into steel via electricarc or basic-oxygen steelmaking furnaces to supply all of Australia’s demand for green steel.

Nov 8, 2021

By M Pyle, T Vizcarra, G Ballantyne, B Foggiatto

Bulk Ore Sorting (BOS) has the potential to add significant value to mining operations by manipulating the feed grade and throughput to the processing plant. However, assessing the performance of BOS is complex, as it is influenced by geology, equipment, spatial and time domains. This increases the risk (real and perceived) of the technology. To manage risk, brownfield operations have the option to: (a) first test the variability in feed grade using a detector on the feed conveyor and subsequently construct the diverter and associated materials handling equipment when the value is established; or (b) conduct site trials with standalone sorting plants. The approaches described for brownfield projects are not available for greenfield projects where the in-situ heterogeneity needs to be quantified and translated into an economic evaluation to test the viability of BOS. Ausenco has developed a methodology that allows assessing the in-situ ore heterogeneity and uses an in-house technoeconomic model to determine the value of BOS for greenfield projects and assess the effects of sorting performance on project economics. The in-situ grade heterogeneity can be measured on a length of drill core and fitted to a mathematical model to assign a heterogeneity index. Given the spatial location, this heterogeneity index can be mapped across a deposit in combination with the average grade. Linking this information with relevant mixing models can determine the likely technical performance of BOS at an operation. However, the real value is only realised when this technical understanding is linked with an economic model and used to optimise the mine plan. Three case studies will be presented that show how Ausenco applies this methodology to assess the value of bulk ore sorting for greenfield studies.

Nov 10, 2020

By S Dunham

For decades we’ve been focusing on reconciliation as a tool to validate mineral resource estimates. And for decades we’ve been misleading ourselves. The concept of reconciliation is simple. Predict, measure, compare and assess the quality of the prediction. This four-step process reflects the ideas of statistical process control and the plan-do-check-act cycle of Shewhart and Deming fame and our intuitive understanding of using system feedback to improve performance. In an ideal world where data is robust and dense this type of feedback loop can be useful. In the mining industry however, there are some fundamental flaws with the conceptual framework. At almost every stage of the process from pre-estimation through to final production the mining system is plagued by material challenges with data and measurement quality and quantity, system delays, and losses from a supposedly closed system. These issues can and do impact on the benefits sought from reconciliation. Instead of providing feedback leading to improved estimation, reconciliation can result in poor decisions, distracting investigations, and exacerbate the noise in an already noisy system. Before we can rely on reconciliation as a management tool, we need to address the multiple challenges present in our everyday practices. Some of the most critical issues are addressed in this paper.

May 24, 2023

By T Leach, I Pringle

The Bowdens Silver Deposit is a low sulfidation epithermal silver-base metal deposit that has formed on the northern margin of a hydrothermal system within air-fall breccias, ignimbrites and crystal tuffs of rhyolitic composition. The deposit lies near the north-eastern margin of the Lachlan Fold Belt and the rhyolitic host rocks are of Early Permian age. The silver mineralisation occurs as flat-lying zones of disseminations and silicic fracture-filling within the Rylstone Volcanics and is closely associated with sulfides of iron, arsenic, lead and zinc. High-grade silver mineralisation is also found in steeply-dipping fracture zones which host banded sulfide veins. Studies of the alteration products indicate that high temperature fluids, flowing from south of the current project area, resulted in quartz (¦adularia) û illite/sericite alteration. Cool, low pH steam-heated waters on the northern and eastern margins of the prospect area resulted in siderite û smectite-illite clay û Fe-carbonate û marcasite û kaolinite alteration. Mixing of the two fluid types resulted in the deposition of iron and base metal sulfides, a decrease in both sulfur activity and pH of the mineralising fluid, and subsequent silver mineralisation.

Jan 1, 2004

By R Shaw

There are many small to medium carbonate hosted complex zinc containing deposits where the zinc is not economically recoverable either as concentrate or metal. High grade (>20% Zn) run of mine ore can be processed but even this material gives relatively poor returns. Considerable effort has gone into developing new technology for either upgrading the ore and/or recovering zinc metal hydrometallurgically but there has been limited success. Minetometal has developed a process capable of economically treating these deposits to give marketable lead and zinc products. This paper reviews alternative processes for these ores and gives a detailed description of the Minetometal Process. CITATION: Shaw, R, 2018. Processing carbonate hosted zinc-lead ores, in Proceedings Complex Orebodies Conference 2018, pp 130–131 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By G R. Hancock, J F. Martín Duque

Post-mining landscapes are required to geomorphologically and ecologically integrate with their surrounds (Martín Duque et al., 2015). Designing and constructing an erosionally stable landform is the first and arguably most important part of the rehabilitation process. Without an erosionally stable landform topsoil and nutrients are lost, shallow groundwater is depleted as well as when excessive erosion occurs, expose suboptimal materials. Here we examine the ideas of geomorphic design and rehabilitation and how the landform can be tested and enhanced using computer based design and landscape evolution models. Specifically we evaluate the complementary capabilities of landscape modelling (SIBERIA) (Hancock and Willgoose, 2017) and geomorphic design software (Natural Regrade with GeoFluv) (Bugosh et al., 2016), in order to maximise erosional stability on post-mining landscapes (Zapico et al., 2018). CITATION:Hancock, G R and Martín Duque, J F, 2018. Geomorphic design and landscape evolution modelling for best practice mine rehabilitation, in Proceedings Life-of-Mine 2018, pp 119–121 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By O Dominguez

Significant value can be added to ore supplied from the mine to the mill by measuring its quality in real time and performing grade control additional to that within the mine. Responsibility for ore quality between the mine and mill stockpiles is not always clear due to operational siloes so geologists and mining engineers need to be involved collaboratively with metallurgists to optimise ore value prior to processing. Sensors, such as the GEOSCAN-M which utilises high specification Prompt Gamma Neutron Activation Analysis (PGNAA), that measure conveyed ore flow representatively (continuous and fully penetrative) and in real time have been used in the minerals sector since 2003 and have been successfully applied in multiple commodities. Quality can be measured within the mine where material is conveyed underground or in-pit. Bulk ore sorting is used to divert increments of waste from the ore stream to upgrade material sent to the crushed ore stockpile (COS) as well as to create run-of-mine (ROM) stockpiles of different qualities to maximise blending opportunities and accommodate processing priorities, eg blending out deleterious content. The real time composition measurement can be combined with moisture and fragmentation analysis data for improved ore type characterisation, to control ore blending, for feedback to the mining schedule and block model reconciliation, and feed forward control for grinding and processing operations. The paper discusses various parameters measured and derived in existing operations that are used to maximise coarse waste rejection and metal recovery, optimise plant feed quality consistency, and reduce consumables; power, grinding media, water, reagents, and minimise fine tailings generation. Innovative geometallurgy applications are also discussed.

Mar 22, 2022

By Bhattacharyya A. K

In this paper, the current methods for predicting surface subsidence due to underground coal mining are evaluated first. A single index, called a strata parameter (P), is then proposed to describe the overall character of the undermined strata in the context of surface subsidence. Based on the strata parameter, a method for predicting the maximum surface subsidence for various panel width (w)/depth (h) ratios is presented, which has been tested against specific empirical curves or data from several coalfields in different countries. From the data relating to several coalfields, a linear relationship between the reported average angle of draw and the strata parameter has been established. It has also been found that the strata parameter can be used for studying the locations of the inflection points and the shapes of transverse subsidence profiles.

Jan 1, 1995

By Rowe P, Rogers D, Warren M

Pressure cyanidation of the minus 10 micron slimes fraction of the Fimiston flotation concentrates for the recovery of gold values has been evaluated as an alternative processing route to the roasting and atmospheric cyanide leaching of the calcine. Laboratory and pilot trials have demonstrated that gold extractions of greater than 94 per cent can be achieved at cyanide consumptions of 12-24 kg/t and oxygen consumptions of 0.1-0.3 Nm3/t with total pressures of 1000-2000 kPa. Economic and operational assessment of several reactor configurations suggests autoclaves may be preferred over pipe reactors at treatment rates of 10 t concentrate/h.

Jan 1, 1996