Search Documents

By Jannie van Deventer

"Innovation in the minerals industry has been lagging behind comparable industries like oil and gas. An incremental innovation culture that tolerates long lead times between invention and adoption has been exacerbated by a research grant structure that inhibits radical idea generation. Entrepreneurs who can make the link between ore source, technology and finance will cause a shift in innovation culture and open up substantial opportunities in the minerals industry of the future. By extrapolating existing trends in technology within and outside mineral processing, a crystal ball vision of future innovation is shaped with the aim to lower energy and water demand, reduce CO2 emissions, decrease operating and capital costs, reduce environmental impact, and secure a social licence to operate. Advances in nanotechnology, advanced materials and biotechnology will impact mineral processing, but the initiative for technology transfer must come from mineral processors. Laminates of graphene oxide can offer efficient filtration and separation media, while microfluidic devices will be used for desalination, solvent extraction and analysis. Substantial progress is expected on benign lixiviants and separation agents, such as nanoscale supramolecular hosts that can serve as high-capacity, selective and recyclable ligands and sorbents, and solid aminobiphosphonate-based adsorbents. Radical ideas for the recovery of precious metals from non-assayable ores and the generation of energy above unity will be adopted in selected minerals projects. In-situ mining in which microbes generate lixiviants at mineral surfaces will simplify processing circuits. Specific ores will be subjected to microwave processing and electropulse liberation to enhance recovery. Ultrafine grinding using devices of low energy consumption will be done mainly dry, followed by dry separation. New flotation cells will remove efficiently either coarse particles or ultra-fine particles, with mineral surfaces being modified not just by new reagents but also by selective microbes. Innovation in mineral processing indeed has a bright future."

Jan 1, 2014

By J. Bertisen, G. Davis

Previous analyses of small samples of mining projects have found that feasibility studies tend to well under-estimate the actual capital costs of the project. Our review of 63 mining and smelting projects completed over 4 decades confirms that as-built capital costs are, on average, 25% higher than as estimated at the bankable feasibility study stage. There appears to be little attenuation over time of this bias in capital cost estimation, at first appearing to reflect an absence of learning on the part of the consulting engineer. We instead argue that this persistence of bias is intentional, driven by a scarcity of project financing and the need to inflate the project economics in a bid to secure financing. Around this intentional bias is a considerable amount of scatter. Roughly half of all projects’ as-built capita costs fall outside of the expected ±15% of the feasibility study capital cost estimate, even after allowing for intentional estimation bias. Cost overruns of 100% or more happen in roughly 1 out of 13 projects. The data reveal that a shifted lognormal probability distribution should be used when modeling mining project capital costs in a Monte Carlo analysis.

Jan 1, 2007

By C. Kennedy, S. Jensen

Traditionally, mineral processing plants are designed to achieve the highest recovery of valuable material with limited regard for the cost of managing waste products-both solid and water components. As an industry, we are confronting ever more stringent environmental standards and lower grade deposits requiring more intensive processing. The most profitable processing route can, in fact, lead to costly issues downstream. Issues or risks associated with waste management include water treatment and handling and storage of potentially acid generating material. The capital and operating costs of dealing with these issues are significant and should be considered as a consequence of plant design and optimisation. The authors of this paper are involved with a number of projects where process operation changes offer opportunities to mitigate risks associated with water and waste management. Examples of these changes will be discussed along with the estimated benefits to the value of the project and reduction of long-term environmental risks. Process changes include 1) the application of in-plant water treatment as opposed to dealing with the entire tailings management facility and 2) the potential to reduce metal leaching and acid rock drainage through the preferential liberation of carbonate minerals in the grinding process.

Jan 1, 2014

By P. den Hoed, R. I. Rambiyana

"Four sulphide minerals - pyrite (FeS2), pyrrhotite (Fe1-xS), pentlandite ([Ni,Fe]9S8), and chalcopyrite (CuFeS2) - contain the base metals and most of the iron in concentrates of platinum group metals (PGMs). In the pyrometallurgical processing of PGM concentrates these sulphides form a matte during smelting, and iron and sulphur are removed from the matte during the converting process. This paper discusses the roasting of Merensky concentrate in air before smelting, with the purpose of reducing the matte load to the converter.Roasting tests were conducted in a bench-scale rotary kiln at temperatures from 350°C to 700°C. The concentrate tested contained 17.4% sulphur and consisted of 23% pyrrhotite, 16% pentlandite, 11% chalcopyrite, and 2% pyrite. The particles were fine (d50 = 22 µm), and all the sulphide particles were liberated. Roasting in air at 550°C and 650°C for 20 minutes removed respectively 60% and 70% of the sulphur. The iron in the sulphides was oxidized to Fe3O4 (magnetite) at temperatures below 500°C and to Fe2O3 (haematite) at temperatures above 550°C. At 700°C the bed sintered and copper oxides formed. At temperatures below 450°C oxidation was incomplete: pyrrhotite remained and only 30% of the sulphur was removed. Smelting tests were conducted to assess matte fall and the deportment of copper and nickel to matte. It was evident that roasting resulted in lower matte falls (a drop of approximately 60%) compared with matte falls from unroasted concentrate. The iron and sulphur levels in the matte were reduced to below 3.5% and 22% respectively.This paper also briefly describes the mechanisms by which pyrrhotite, chalcopyrite, and pentlandite are oxidized during roasting. For chalcopyrite, the mechanism proceeds through an intermediate solid solution phase, which extends from Cu1.02Fe1.04S2 to Cu2.04Fe0.72S2 to a copper-rich solid solution of bornite (Cu4Fe1.4S4-Cu2S). The oxidation of pentlandite proceeds through a monosulphide solid solution (Ni0.39Fe0.53S-Ni0.74Fe0.15S) to a solid solution of heazlewoodite ([Ni,Fe]3}xS2). These mechanisms are explored in relation to chemical thermodynamics and microstructures."

Jan 1, 2015

By Monika Patrycja Polak - Micewicz

This paper presents an approach for estimating the fatigue life for the base of powered roof supports (shield) manufactured by the FAZOS roof support company. FAZOS?s powered roof supports are designed to operate on an inclined coal seam in full caving with a medium, strong roof strength. This shield support is utilized in conjunction with a shearer and face conveyor for a complete longwall mining system. To design shield support, it is essential for contractor to know the physical (hardness, toughness, etc.) and mechanical properties of material (tensile strength, Young?s modulus, etc.) used for the shield support as well as the geotechnical properties of the mine site. The fatigue strength of the shield support material depends on the mean stress, alternating stress, cycle frequency, transport dimensions, mine environment and other factors. In order to estimate the fatigue life for a powered roof support system, it is assumed in this paper that the support must keep the roof stable in the mine under variable load cycles. The approach selected in this study contains Goodman?s model (Goodman, 1899) for all blocks in the design housing which is subjected to sinusoidal load. On this basis, the degree of fatigue damage was calculated and compared to the results of experimental tests. It will be shown that there is a significant detrimental effect on the fatigue life of the base of the powered roof supports due to geometrical notches. The Ramberg-Osgood model and damage accumulation rule (Palmgren-Miner) (Miner M., 1945) were used and numerical analyses were conducted, utilizing ANSYS finite element software. These analyses play a very important role in longwall casing design. The proposed method allows assessment of the yield state and forecast of the structure cracking, taking plastic strains occurrence into account. The presented method is universal and can be applied for fatigue life estimation of other subassemblies of powered roof supports. The final portion of the paper presents results of variable amplitude loading simulations on the S355N and S690Q steel used to make powered roof supports. The results of the physical tests were compared with the results from finite element methods. The proposed approach to calculate fatigue life gives the best correlation between the experimental results and calculated values of fatigue life for the powered roof support base. Finally, the design process uses a simple approach to predict fatigue life in a short time, reducing design costs and providing longer service life for roof supports.

Jan 1, 2012

By D. C. Panigrahi

Extensive field studies have been carried out to investigate the pillar fire problems in one coal mine in India. A Thermal IR gun and a Thermovision camera have been employed for thermal scanning to assess the state of heating in selected pillars. Special sampling set-ups have been designed to collect gas samples from the holes drilled into the selected pillars and the multigas detector is used to analyse the composition of samples in situ. In order to predict the spontaneous heating in coal pillars, different gas ratios have been calculated and it has been observed that some of the established gas ratios, viz. Graham?s ratio, Young?s ratio etc. have resulted in negative values in samples containing high amounts of methane. The modified gas ratios have been proposed which will be useful for predicting the pillar fires. These ratios may also be used for assessing the condition of fires in sealed-off areas.

Jan 1, 2004

By Thomas Leonard Watson

Jan 1, 1906

By G. A. Grandy, P. F. Thomas, C. D. Danecki

When considering the mill drive system for a grinding application, a large number of questions must be answered. Depending on the mill size and type, the mill can be driven by several configurations of drive systems: a single low-speed motor connected to a pinion driving a ring gear, two low-speed motors connected to two pinions and driving a ring gear, or a gearless motor mounted directly. In addition, a gear drive system can have a reducer placed between a high-speed motor(s) and pinion(s) or a power path splitting pinion stand. In some designs the reducer is integral with the pinion stand driven by a high-speed motor. The technical and commercial implications of several mill drive options are presented. Initial cost, cost of installation, cost of commissioning, and cost of operation and maintenance are presented for each drive option considered. The impact of each drive system on the design, cost and operation of the overall plant electrical system is discussed. Also, consideration is given to mill drive availability, and the potential cost resulting from delays in plant production.

Jan 1, 2001

By P. Roy

Smelting or converting of sulphide concentrates and mattes in a batch operation presents a challenge when directing the off- gas to a conventional acid plant. The Hindustan Zinc Ltd. (a division of the Vedanta Group of companies) Chanderia Lead Zinc smelter was presented with such a challenge that was met with the adoption of the Cansolv® SO2 Scrubbing System. The Ausmelt top submerged lance technology used at Hindustan Zinc generates a furnace gas stream that containsbetween 0.1 vol% and 12 vol% SO2 during the three stages of batch smelting. Cansolv® SO2 Scrubbing Technology captures the SO2 to ensure that treated flue gas exits the facility at a concentration below 100 ppmv SO2 and it releases SO2 in a controlled fashion, to more closely match the needs of the existing acid plant. The application of a regenerable scrubbing system to capture SO2 from a batch-operated furnace and convert it to acid in a conventional acid plant was a first of its kind in the world. This paper provides an update on the design and operation of the Hindustan Zinc SO2 recovery system and suggests two improvements to the basic flow sheet that optimize the cost of SO2 scrubbing further.

Jan 1, 2007

By L Matthews, D O’Dea, P C Hayes, J Manuel, B Monaghan, T Honeyands, D Pinson, J Leedham

Many different approaches have been used in the past to characterise iron ore sinter mineralogy to predict sinter quality and elucidate the impacts of iron ore characteristics and process variables on the mechanisms of sintering. Characterisation techniques include optical image analysis and point counting, X-ray diffraction and scanning electron microscopy. Each technique has its advantages and disadvantages depending on the objectives of the measurement. It is generally acknowledged that silicoferrite of calcium and aluminium (SFCA) is very important to the quality of the sinter produced; however, strict definitions of the phases and textures of SFCA are not generally agreed. This paper summarises the state-of-the-art in sinter characterisation applied in Australia by both academics and industrial researchers. The results from various techniques are compared and the relationships between the measurement results are discussed.CITATION:Honeyands, T, Manuel, J, Matthews, L, O’Dea, D, Pinson, D, Leedham, J, Monaghan, B, Li, H, Chen, J, Hayes, P C, Donskoi, E and Pownceby, M I, 2017. Characterising the mineralogy of iron ore sinters – state-of-the-art in Australia, in Proceedings Iron Ore 2017, pp 49–60 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Joan Weinberg

Real output expanded at a 3.0% rate worldwide in 1987, a slightly lower pace than the 3.2% rate in 1986. The decline was accounted for largely by slower growth in the U.S.S.R. and the East European countries, as well as in the developing countries (table 1). According to the International Monetary Fund, output of industrial countries output grew 3.1% and rose most strongly in Japan, the United Kingdom, and Canada (table 2). U.S. economic growth remained at 2.9%, the same as in 1986. Consumer and government spending declined in industrial countries, while gross fixed investment: rent increased. This increase in fixed investment expenditures could be attributed partly to lagged results of some 1986 developments: the fall in oil prices, declining interest rates, and exchange rate changes. The U.S. budget deficit, as well as the large external deficits and surpluses among major industrial countries, hindered further growth .2 A report from the Organization for Economic Cooperation and Development (OECD) indicates that the impact of the October stock market crash was short-lived because it hit economies that were growing strongly, anyway.3 The growth of output in the developing countries slowed in 1987; however, output declined in the fuel-exporting developing countries. These countries have been adversely affected by weakness in oil prices and the depreciation of the U.S. dollar. The weighted average of inflation rates in industrial countries--as measured by the [ ] GNP deflator, was 2.9% in 1987, down from 3.4% in 1986. Prices rose 3.0% in the United States, up from 2.6% the previous year. Inflation for 1988 is expected to remain slightly higher in the United States than in Japan and the Federal Republic of Germany because of recent exchange rates changes and the elimination of slack productive capacity and labor in the U.S. economy. Prices in developing countries as a whole rose more than 10 percentage points in 1987. Higher import prices, caused by

Jan 1, 1988

By Robinson KJ

Education in Australia now has to respond to a very wide political and policy agenda. The political emphasis is upon increasing participation and retention rates with a view to greater graduation rates in `high-tech' disciplines. There is an implied linkage between `education' and `economic well-being'. Our argument is that equalitarianism in education tends towards mediocrity. In this context many Geoscience educators view the future with pessimism. The argument is that science has been `sold short' and needs revitalising. We contend that Geoscience coursework should be a feature of both secondary and tertiary education in Australia. To this end we propose six policy initiatives to increase the content of Geoscience in education programmes.

Jan 1, 1989

By D. C. Oldroyd

Western Coalfield?s Tandsi Mine, has difficult support conditions and a history of roof falls, resulting in mining roadway widths and depths being restricted for safety reasons. Rock Mechanics Technology Ltd was contracted to improve the support system to allow the introduction of mechanised room and pillar mining. The introduction of a ?world best practice? bolting system resulted in major improvement in roof stability, allowing mining restrictions to be lifted and Tandsi to become one of the first two Indian mines to introduce a mechanised continuous miner system. The first year?s production was some six times previous levels. Because of the improvement in the support system, RMT was also able to design a partial de-pillaring system suitable for the Tandsi continuous miner districts together with the introduction of monitoring procedures and guidelines to maintain safe roof support conditions. In situ monitoring of pillar and roof behaviour was undertaken as the first pillars were extracted to confirm the design. De-pillaring operations have also proved highly productive, and to date there has been no associated support related major injury or dangerous occurrence. The success of this project demonstrates the potential for mechanised room and pillar mining in India.

Jan 1, 2006

By C. Scheffer

This paper describes a model that can simulate the behaviour of a pneumatic intensifier that is generally referred to as an ?air pump? (AP). The AP is used in many South African underground mines, and utilizes compressed air with pressures between 0.3?0.6 MPa to pump water up to pressures of 12?18 MPa. The high pressure water is used in numerous underground mines to pressurize props and roof bolts that act as safety and roof support devices. The simulation model reproduces the intensifier's operation under various conditions and therefore can be used to investigate the AP's sensitivity towards environmental conditions, design parameters (such as spring stiffness, plunger diameter, nozzle diameter etc.) and operating conditions. Model validation by comparison with laboratory experiments showed good correlation. The model can subsequently be used to investigate design changes aimed at improving the AP's performance and reliability over a wider range of operating conditions.

Jan 1, 2005

By R. V. Higgins, G. B. Shea

"FOREWORDIn the second year of World War II, the petroleum industry in California was taxed to near capacity to satisfy the expanded war demand for petroleum products, particularly fuel oil. With discoveries of crude oil in California declining and known reserves being depleted rapidly, conditions appeared to warrant study of the possibilities of utilizing the outcropping bituminous sandstone deposits in California for obtaining new sources of oil if the war should he prolonged. At conferences in Washington, D. C., with members of the Petroleum Administration for War and the Geological Survey, Bureau of Mines engineers emphasized the importance of determining the extent of those outcropping deposits of oil-impregnated rocks and of developing a practical process for commercial recovery of the contained bitumen to assure, if necessary, a supplementary supply of fuels. The desirability of such a study was recognized, and in July 1943 the Petroleum Field Office of the Bureau of Mines at San Francisco, Calif., in cooperation with the Geological Survey and the Petroleum Administration for War, initiated a study of the bituminouss sandstone problem. It was agreed that all mapping and geological work in connection with the study would be done by the Geological Survey, all engineering studies in developing a process for extracting the oil would be carried out, by the Bureau of Mines, and that the Petroleum Administration for War would aid in final adoption of the results in the field if circumstances warranted such action.Deposits of bituminous sandstones in California occur principally in the immediate region of the Coast Range mountains, notably at Pt. Arena, in Mendocino County, about 110 miles north of San Francisco; near Santa Cruz, in Santa Cruz County; in the Edna area in San Luis Obispo County; in the Sisquoc area in Santa Barbara County; and in the Ojai and Santa Clara Valleys in Ventura County. 4/ In addition oil-bearing sands outcrop near McKittrick and Maricopa, in western Kern County, and along the east edge of the Kern River oil field. Among the several prominent deposits of these source materials, those occurring near the cities of Santa Cruz and San Luis Obispo, and the town of Sisquoc are the largess."

Oct 1, 1948

By D. Wolfe, K. Reid, T. Nunn

"The Aurora North mine has been operating for more than ten years, and is the source of over half of Syncrude’s bitumen production. In order to minimize front-end rejects, and to allow for high throughput, the ore top size at Aurora has been set at a nominal 125 mm. These relatively large lumps have a significant effect on both pump performance and pipeline pressure gradient. Current design methods underestimate the solids de-rating effect of lumpy slurries in pumps, and do not accurately describe the distribution or magnitude of the lump effect on pipeline pressure gradient. Data from the Aurora hydrotransport systems has been compiled, to quantify the effect of lumps on the pump head ratio and pipeline pressure gradient, and how this effect changes as lump ablation occurs along the length of the pipeline. A model has been built, using a logarithmic curve, which predicts the effect of 125 mm lumps on pipeline pressure gradient as a function of velocity and the distance from the start of a hydrotransport pipeline. This model is applicable only to Aurora hydrotransport operation, but similar models could be developed for other operations using the same methods. Using accurate pipeline pressure gradients and pump head ratios when designing future hydrotransport pipeline systems will help improve their reliability and operability."

Jan 1, 2014

By S. K. V. Avasarala

This paper presents a case history of design, prediction, probe and production pile driving monitoring, loading tests and installation of over 3,300 prestressed concrete piles for a building complex consisting of 12, 5- and 6-story over parking buildings. The project was recently completed in three-phases over a span of 4 years. The subsoil conditions were explored by performing 25, Standard Penetration Test (SPT) borings throughout the site. Various types of driven pile foundations were considered and following an evaluation of high structural loads and site-specific constraints such as variable depth of bearing layer of Florida limestone and quality of clay and limestone layers, a prestressed concrete pile support system was selected as the most economical and effective foundation approach. The building foundations were designed for a pile capacity of 353 kN (40 tons) in compression, 45 kN (5 tons) in lateral capacity for a deflection of 0.64 cm (0.25 in.), and 133 kN (15 tons) in uplift capacity. The axial and lateral allowable pile capacity and lengths were predicted using SPT91 and LPILE computer programs, which are generally used in Florida. The validation of these capacities was derived from 144 probe piles and performance of 12 pile loading tests on selected probe piles. Prior to installation of probe or production piles, a termination criterion was established using 1-dimensional wave equation analyses in addition to the design pile embedment requirement. The predicted pile capacities compared very well with the capacities from the loading tests on probe piles. This information was effectively utilized as part of the overall quality control program to install a total of 4,186 prestressed concrete piles (including 144 probe piles) in different building areas across the project site to depths ranging from 8 to 21 m (25 to 90 ft) below existing ground elevation as part of foundation support system. This engineered, monitored, and tested foundation solution provided an effective and satisfactory basis for completion and approval of the foundation work for this 12, 5- and 6-story over parking building complex. A recent reconnaissance has indicated that all the building foundations are performing satisfactorily.

Jan 1, 1995

Gold rooms represent a high security area and preventing theft is a challenging task. Where gravity concentrates or high value unit intermediate products are present, particular and specific security procedures must be put in place. This paper describes the development and implementation which reflects best practice in gold room security. Procedures involving key holder systems, key locks, swipe cards and double locks preventing any one person having access to the gold room, including specific procedures for gravity gold concentrators, will be addressed. The use of monitoring and how to deal with alarms and potential hold ups will be reviewed. The use of cameras and archival DVD recorders is common in gold rooms. The use of electronic surveillance, movement detectors, seismic monitors and the two person policy and gold room entry procedures are described, including how to deal with visitors. The importance of confidentiality regarding smelting and gold pick-up days, plus strategies employed to minimise storing large quantities of gold on site will be presented. The role of metallurgical accounting in providing quality auditable information and the minimum standards of record keeping required is discussed. The role of the Gold Squad will be outlined. Regular auditing and risk analysis and several case studies are cited where security was deficient or improved.

Aug 1, 2010

By J. Hu, F. Lin, R. Chen, F Peng, S. Yang, W. Yu

"Microseismic monitoring technology has become one of the most effective method of mine ground pressure monitoring after decades of development. But safety assessment of mine ground pressure by using microseismic monitoring is still in the development stage, it needs to be perfected continuously in practice, and choose the optimal assessment indexes and methods. The definitions and physical meanings of wave velocity, b value, and EI-VA value are introduced in this paper. Statistical calculation of the microseismic events in Luomu Mine is finished by using these indexes, then the functions and calculation results of V, b value, and EI-VA value with the variable of time are also given in the paper. The preliminary safety assessment method is established in Luomu Mine, and it has achieved good results in practical application.1.1 Engineering background The Luomu Mine is a super large molybdenum and tungsten production base in China, ore reserves is up to 2 billion tons, first in Asia and third in the world. It begins mining since the 1960. and bases on underground mining until 2002. In order to recover resources more effectively, it began to use opencast mining method and formed a production of 30000t/d in the early 1990. After about 30 years of underground mining, a large mined out spaces was formed under open pit mine, up to area of 1.2 million m2 and volume of 18 million m3, as shown in figure 1. The large number of mined out spaces seriously affects the normal production, mining and handling of mined out spaces are in the high risk. In the past years, several rock mass collapsions happened, and it caused a serious security threat to persons and equipments. According to the distribution characteristics of mined out spaces, Luomu Mine is divided into A, B, C, D and E mining area. The stability of D mining area is studied in this article. D mining area mainly includes 1376,1350,1340,1317 mined out spaces and 1280 deep large mined out area, as shown in figure 2. The mined out spaces of D mining area is extremely complex and high-risk. Therefore, a microseismic monitoring system was built to monitor the stability of D mining area, a large number of valuable datum has been obtained, and it has a striking effect (Cheng & Peng, 2013; Peng et al., 2013)."

Jan 1, 2015

By M L. van Kampen

The Resource Management Act 1991 provides for activities to be classified as permitted, controlled, restricted discretionary, discretionary, non-complying or prohibited in district and regional plans. This paper looks at the use of the prohibited activity status to restrict, in particular, mining. Often the use of prohibited activity status for mining appears to have no basis other than the negative perceptions that the local community and/or the planner drafting the plan has toward mining and quarrying.   The paper will address the current appeal regarding the use of prohibited activity status now before the Court of Appeal, and the history to the litigation. The relevance of the outcome of the appeal to the minerals sector will also be explained.

Jan 1, 2007