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By M P. Schwarz

This paper describes modelling studies of the flotation cells used by BHP Billiton Nickel West Ltd in the slimes circuit at Mt Keith. The aim is to achieve a better understanding of the hydrodynamic limitations in the existing cells to improve nickel recovery. Computational fluid dynamics (CFD) simulations have been performed on the 100 m3 mechanically-stirred cells. The data produced by the simulations include velocity vectors, gas holdup distribution, solids distribution, bubble size, superficial gas velocity and turbulent parameters. These results have been checked and found to match hydrodynamic measurements at the plant. An analysis of the data found that one of the limitations in fine particle recovery was related to the air bubbles discharged with the tailing. The air in the discharge was caused by the high viscosity of the pulp. In the presence of fine particles, the pulp exhibits high viscosity with a yield stress. The increased drag due to high viscosity caused the bubbles to rise more slowly up the cell. This results in a significant hold-up of bubbles, some of which report to the tailing with associated loss of valuable minerals. A parametric CFD study of the operating variables shows that less air would be discharged in the tailing by decreasing the following: air flow rate,pulp density,stirring speed, andfrother addition. Simulation results indicate that these changes would cause a lowering of the air hold up in the cell especially near the discharge area. Predictions of the bubble-particle attachment rates under various operating conditions have also been calculated. Although it is possible to increase attachment rates by increasing stirring speed or by increasing pulp density, the amount of air discharged and the amount of nickel loss through the tailing will also increase. The project showed that CFD modelling is a powerful tool for studying hydrodynamic effects of bubble-particle interactions in flotation cells.

Jan 1, 2008

By C R. Sundberg

Despite nearly a half-century of continuous production, the low-grade iron ore (taconite) deposits of North America remain economically competitive sources of raw materials for the domestic steel industry. The continued viability of these mature integrated mining-concentrationagglomeration complexes requires highly efficient utilisation of assets, especially the mineral resource. At Cleveland-CliffsÆ five North American managed operations, enhanced ore characterisation techniques are playing a critical role in their continued success. Due to the low-grade nature and complex mineralogical composition of these deposits, ore characterisation cannot solely rely on assay grades. Historically, taconite ore characterisation has augmented assay grades with bench-scale concentration tests to quantify recoverable mineral. The economic necessity for improvements in mill efficiencies and final product quality has mandated significantly greater knowledge of ore-related impacts. Cliffs Technology Center has met this challenge by developing a variety of novel iron ore characterisation techniques. The applications developed include both in situ and laboratory procedures, plus unconventional data integration methods uniquely suited for these deposits. This paper details the evolution of these novel ore characterisation techniques and their application to each phase of the operation: mining-concentrating-and pelletising. The improved ore characterisation techniques have contributed to successes at individual Cleveland-Cliffs managed operations including mineral recoveries exceeding 95 per cent and productivity increases exceeding ten per cent while consistently achieving customer product quality objectives.

Jan 1, 2002

Felspar occurs in association with quartz in the Broken Hill lode pegmatites and is brilliant green, greenish white, and white in colour. The pegmatites occur mainly in the walls in sporadic patches, parallel to the general dip of the ore deposit. The occurrences are of no economic value.Deposits of marketable felspar occur in pegmatite in a number of localities around Broken Hill, New South Wales.The majority of these are in the form of an irregular outcrop, usually of tapering length and depth. The maximum depth of any deposit yet worked in the district is about 40 ft. The felspar is occasionally contaminated by "blows" of quartz, mica and beryl, but the two latter are profitably marketable when separated.Felspars vary in colour from pink, through grey to snow white, and the colour is not indicative of the mineral content. The largest deposit at present being worked is the Egebeck quarry, about 14 miles south of Cockburn. It is a prominent outcrop, roughly circular and about 150 ft. in diameter, covered by one to three feet of overburden.The felspar is mainly massive, but contains some cleavage planes at approximately 90°. Intrusions of quartz and mica occur in patches, but the deposit appears likely to improve in size, regularity and quality below the present working floor.COMMERCIAL USES.Commercial felspars are mainly used in the ceramic industry, for which a high-grade potash felspar is required.The dental industry requires limited amounts of soda felspar with a very low Fe20s content. The poorer grades...

Jan 1, 1946

By P Mason, J F. Huntington, K M. Scott

Short-wave infrared (SWIR) spectral reflectance of the hydrothermally altered volcanic rocks in the footwall of the Hellyer Zn-Pb massive sulfide deposit was measured with a portable PIMATM infrared spectrometer. The Al-OH absorption band was used to derive information on the cation composition of white mica. The wavelength range of the Al-OH band from 2194 nm to 2222 nm reflects variation in the number of octahedral Al (Alvi) in white mica from 3.9 to 3.2 (based on four octahedral cations per formula). This Alvi range indicates a substantial compositional variation, covering most of the compositional region between muscovite (Alvi = 4.0) and phengite (Alvi = 3.0). Moreover, the spectral reflectance data show that the compositional variations of white mica are spatially related to the hydrothermal alteration zoning, such that the white mica of more phengitic composition tends to form in the main upflow fluid channels in the centre of the footwall alteration system. The results suggest that the octahedral Al content of white mica, which is spectrally definable by the wavelength of the Al-OH band using a field instrument such as the PIMATM, can be used to map fossil hydrothermal systems and potentially as vectors to mineralisation.

Jan 1, 2004

We can look at the water treatment and management strategies at some recently commissioned mines and minerals processing sites to see the likely future of water in mining. The future of water in mining will be based on a holistic approach to understanding the site water balance, appropriate treatment, reuse where possible, and environmentally managed discharge where required. This paper describes advanced and innovative water treatment and reuse processes as used by mines and mineral processing operations from around the world. Underground mining can often require dewatering to prevent groundwater seeping into and flooding the mine workings. Mining and processing often accumulates wastewaters in a tailings dam. The mine water can contain contaminants such as dissolved salts, iron, arsenic, manganese, heavy metals and acidic and odorous sulfates. On-site reuse, environmental discharge requirements, as well as community needs for water, drive mine operators to consider the most appropriate water treatment process. Mining water treatment for the future is described using case studies of innovative processes. The case studies include treatment of mine dewatering water for beneficial application from Australian mines, Ballarat Goldfields and Bendigo mining, treatment of produced water from oil and gas projects, and treatment for arsenic removal of tailings water from mining and processing at Goldcorp mines in Canada. Advanced and innovative processes including membrane filtration, reverse osmosis at extreme conditions, advanced biological treatment and water management are all part of these case studies. This paper uses real case studies of advanced and innovative mine water treatment processes to explain and examine the technology and the reasons for designing specific processes. The focus is on innovative processes that may be more widely used in future mining û where the water is used for sustainable environmental discharge or treatment to a quality that can be beneficially used by the mine or the local community.

Jan 1, 2008

With the advent of the resources boom in the late-1960s most of the larger scale resources projects in Australasia were commissioned on an æowner miningÆ basis, where the mine owners owned and operated the primary mining equipment. Then, in the 1980s with the arrival of the gold mining boom in Western Australia and elsewhere, a change occurred û most of the mining activities were carried out on a contract mining basis. Over recent years, however, there has been a marked trend amongst larger Australasian open pit mining operations back towards owner-controlled and operated mining operations. The reasons for this are many and are addressed in the paper, but centre on the concept of the owner being prepared to assume more of the mining risk in exchange for the advantage of not having to pay a contractorÆs profit margin. Where mining contracts are entered into, the older æschedule of ratesÆ format is being replaced with less adversarial and more entrepreneurial contract alternatives involving operating cost and risk sharing in a spirit of æfair dealingÆ. Leasing and maintenance issues have also been influenced in recent years by the advent of more flexible contract arrangements with equipment suppliers. Group purchasing has also had some influence for project operators. For many mine owners, the optimal risk management profile involves a practical offsetting of the assumption of mining risk on the one hand, against the removal of litigation risk and potentially reduced operating costs on the other. Potential pitfalls may arise where equipment size and type requirements vary with time or where manpower management, mining flexibility, job skills or safety exposure factors are relevant. These issues are commented on in the context of some well known examples, and an update is provided on contract mining versus owner operation in large-scale Australasian open pit mining generally.

Jan 1, 2002

By Richmond GD

The Hellyer concentrator of Aberfoyle Limited commenced production in 1989 processing a fine grained, massive sulphide ore containing Zn, Pb, Ag, Cu and Au as values. Four concentrates are produced - copper/silver, lead, zinc and bulk (Pb/Zn) - with overall payable recoveries (1991) of 80 per cent Zn, 55 per cent Pb, 50 per cent Ag, 30 per cent Cu and ten per cent Au. Metallurgical development work commenced immediately after plant commissioning, and continues. The flotation response and liberation analysis on a size basis highlighted reagent balance problems associated with tower mill regrinding of sphalerite, poor conditioning of flotation pulps, poor selectivity for fine galena, and insufficient liberation. These were the main causes of values lost to tailings, values reporting to the 'wrong' concentrates and of impurities in the concentrates. Modifications to tower mill regrind circuit operation, and the use of improved conditioning techniques have greatly improved concentrator performance, particularly in the finer (-5 micron) size fractions. Studies of concentrator and laboratory flotation by size and liberation analysis are the basis of diagnostic metallurgy. The techniques used to evaluate the improved concentrator performance are discussed.

Jan 1, 1993

Results are presented of the investigation of gas dynamics of the blast furnace process obtained on laboratory models and operating furnaces. Gas residence times were measured using a helium tracer technique developed for the purpose. Residence times were determined in furnaces of 1007 m3 and 1719 m3 and results used in the calculation of the burden parameters and to estimate the distribution of the gas flow along the furnace radius. The effect of tuyere injection of coal dust on gas distribution was also investigated and the advantage of continuous injection compared with intermittent injection is noted. The unevenness of gas distribution across the furnace area is found to correlate well with differences in the size analysis of the iron-bearing component of the burden. The mixing of the gas streams between the neighbouring raceways was studied. It is shown that in the central region of the furnace gases from every tuyere are mixed together, whilst in the peripheral regions mixing is more localised and includes only the sections consisting of five adjacent tuyeres. A solution is proposed to the problem of a theoretical evaluation of the critical gas velocity. A simple relationship between the Reynolds and the Archimedes numbers was obtained from which, after substitution of the burden size data and the gas parameters, it is -possible to evaluate the critical gas velocity. Conclusions include information relating to the optimisation of the gas distribution and views on reducing gas injection at elevated furnace levels.

Jan 1, 1975

By Nightingale RJ

A column (50 cm 4) provided with a bell charging mechanism and a rectangular perspex insert was used to investigate the inter-relationship between charging pattern, size analysis and velocity profile for a number of charging methods. It is shown that a strong correspondence exists between size distribution and velocity profile for bell charged ore and coke and that decreased coke volumes cause higher pressure drops and increased central flow in beds with "V" shaped layers. It is also shown that a bell charged mixed burden exhibits greater segregation than when it is bell charged as layers and that when uniformly charged the mixed burden shows least segregation and a virtually flat velocity profile. A relationship is derived for "V" profile charges showing the extent of central segregation with furnace size.

Jan 1, 1975

By R van Berkel

Regional synergies concern the capture, recovery and reuse of by-products, water and energy between industrial operations in close proximity. The Centre for Sustainable Resource Processing (CSRP) undertakes applied research to further advance regional synergies in the Kwinana Industrial Area in Western Australia in order to achieve greater efficiencies in water, energy and materials consumption and reduction in waste and emission generation. The Kwinana Industries Council (KIC) and its member organisations recognise water consumption and disposal as key environmental issues. Some 30 companies in Kwinana consume a total of more than 35 000 ML/yr of fresh water. Over the past years significant progress has been made towards the reduction of water consumption and improvements in effluent disposal. As part of the CSRP Kwinana Synergies Project, water balances for the ten major water consuming companies have been completed, including workshop sessions with company staff on water synergy opportunities. This work resulted in a set of synergy opportunities which are currently being pursued. In parallel to the Kwinana project, the CSRP has commissioned a supporting project that delivers a toolkit to guide a more targeted and less resource intensive way to identify feasible water synergy opportunities. One of these tools focuses specifically on water, and takes count of input and output water flows within a given industrial area to deliver listings of prioritised water synergy opportunities. This paper discusses the water mapping and workshop approach taken in Kwinana and its outcomes, which are to identify and evaluate water synergy opportunities. The results from the trial application of the developed Regional Eco-Efficiency Opportunity Assessment Toolkit are also presented.

Jan 1, 2006

Blasting is known to be both an important and an easily quantified cost factor in rock breaking operations. However, the indirect costs and benefits of the blasting operation are not easily determined due to the irreversibility of the mechanisms involved and the multiplicity of influencing factors. A general conceptual model showing the relationship between blasting and mining costs is well known, but serious attempts to address the critical real relationships have all floundered on the fact that not enough is yet known about either detonation physics or blasting effects. This can only be remedied to the extent that blasting instrumentation enables researchers to pin down not only the relationship between the detonation process and its impact on a particular environment, but also the downhill costs of handling the rock, repairing any damage and building in "Safety Factors" to provide for imponderables. It is vital to standaraize on specifications for instrumentation and measurement techniques and there is a need to review what has been achieved in blasting expertise so as to focus on the most fruitful paths for future work.

Jan 1, 1990

Until recently, nickel laterite projects have been largely ignored, due to their supposedly higher treatment costs compared with sulphides, and to their perceived processing difficulties. A number of laterite projects in the 1970s were abandoned because of high capital and operating costs, while others experienced severe technical difficulties. Conventional wisdom had it that laterites would not be exploited until most of the sulphide orebodies had been depleted. Why then, have Australian mining and exploration companies started a resurgence of interest in the treatment of nickel laterites? It all began with the Bulong project, which has been under study since 1987, while more recently two further projects, Murrin Murrin and Cawse, have been initiated and are being fast-tracked to take advantage of the current high nickel and cobalt prices. A further project in NSW, Syerston, has also been investigated at bench-scale, but no further development has yet been announced. All these projects have the following advantages: 1. Good location near a major mining centre and,reasonably close to power, water, roads, accommodation and a developed service industry. 2. Straightforward, low cost mining. 3. Low cost of acid or sulphur. 4. Good to very good cobalt credits. In addition, there have been significant technological developments in the design and operation of high pressure autoclaves and high rate thickeners, as well as solvent extraction and electrowinning technology. This has helped to decrease capital costs and technical risks, and has allowed the development of alternative flowsheets to the existing laterite operations (Taylor, 1996).

Jan 1, 1996

By I D. Hair

A numerical groundwater model was used to predict the nature of interactions between heavy mineral sands mining operations and the groundwater regime at North Stradbroke Island, Southeast Queensland. North Stradbroke Island is formed mainly of massive vegetated Cainozoic aged dune sands. Since the 1950s, a number of operations have mined rutile, zircon and ilmenite on North Stradbroke Island. In such mining operations, a dredge and an associated processing plant are floated in a pond either above or below the prime groundwater table The numerical model was based on the North Stradbroke Island Groundwater Management Model, developed in 2001 by the Department of Natural Resources and Mines (NR&M). This model was constructed using the modular, cell-centred, finite-difference groundwater flow model, MODFLOW, developed by the United States Geological Survey (USGS). The NR&M model was refined to improve model resolution and detail for simulating dredge mine paths. Of particular interest were: water table fluctuations induced by mining for the identification of slope stability risk; the optimisation of sand spear arrays supplying mine make-up water requirements; inflow and outflow rates to the dredge pond for overall mine water balance; and interactions with Eighteen Mile Swamp and water supply bores controlled by the Redland Shire Council (RSC). Depending on the water level in the dredge pond compared with the surrounding groundwater table, water either flows out of the dredge pond into the groundwater regime or from the groundwater system into the dredge pond. The MODFLOW river package (RIV) was utilised for the modelling study. Dredge pond movement was simulated using specialised software developed by Watermark Numerical Computing (WNC) to interpolate pond positions and map the dredge path to the model grid both spatially and temporally. As tailings placement affects the groundwater system through increased recharge, the MODFLOW recharge package (RCH) was utilised to simulate different recharge efficiencies. Long-term model predictions were made for the period from July 2002 to May 2021. Results of the modelling showed that exchanges of flow between mining operations and the groundwater regime could be effectively managed. The study provided valuable information which was used to develop an appropriate mine water management plan.

Jan 1, 2003

By P Andrieux

By 1996 ground control-related problems at Brunswick Mine had raised serious concerns regarding the safe and economical extraction of large portions of the reserves. These difficulties were mainly caused by high stress levels in pillars, instabilities resulting from wide spans supported by ageing support elements, and chronic difficulties supplying rock fill from the surface quarry to the underground workings, which resulted in many large voids remaining open for long periods of time. Significant changes have been implemented at the site since 1996, amongst which were a change of mining method, the introduction of paste backfill, the establishment of stress management measures, and the introduction of shotcrete on a large-scale. This paper focuses on the regional ground conditions associated with both the previously used primary-secondary mining method and the newly implemented pyramidal pillarless technique, as well as on some of the stress management measures implemented at the mine.

Jan 1, 2000

DuPont is a chemical and energy multi-national of approximately 90,000 employees. Often regarded as the world leader in injury reduction and process safety management, DuPont operate 140 manufacturing sites around the globe. Conoco is a wholly owed subsidiary of DuPont which is involved in oil, gas and coal exploration.   Throughout this paper I will discuss DuPont statistics, developing a safety culture and training process as well as discussing possible short comings in the New Zealand safety focus. I will conclude with my recommended improvements and issues for New Zealand companies to focus on.   It is very difficult to compare DuPont and New Zealand statistics through lack of compatibility in recording methods and my ability to interpret ACC's Injury Statistics. However through considering DuPont's statistics, and comparing them to your own companies or departments, you will agree they are indeed impressive. I hope that by discussing DuPont's safety philosophy, and possible shortfalls within New Zealand Legislation many of you will find ideas and inspiration which will help you to further reduce your own injury rates.

Jan 1, 1997

By Yeliseyev AK, Shestakov AM

Comminution is the most power-intensive process in the technology for ferrous quartzite concentration. That is why improving comminution efficiency leads to the most appreciable economic effect on the concentration process. The trend towards reducing the lump size of crushed ore before charging the mill is considered to be of major importance in improving comminution efficiency. A considerable number of investigations have been performed in this direction. At the same time, a strong interest is also maintained in the increase of comminution efficiency due to optimisation of process taking place in the mill. Recently, investigations of the power intensity of the breaking process inside the mill have been carried out at the Krivoy Rog Mining Institute. It was ascertained that the routine conditions of comminution at a low mill ball charge ratio resulted in an unnecessarily high power consumption due to the force of impact of falling and milling bodies far exceeding the power required for comminution. For example, the power value for falling balls of 60 - 125 mm in diameter reaches 0.3 kNm, and the force and stress due to ball contact with the lining reaches 60 kN and 250 MPa respectively. These values exceed the force required for comminution by a factor of ten. Analysis of the mechanism of ore particle size reduction during comminution in the ball mill indicates that the size reduction is due to impact load, attrition load, and static load. The efficiency of size reduction is very low. During comminution in the ball mill, impact loads prevail and amount to 85 - 90 per cent of the total load. In this situation, not more than 10 - 15 per cent of destruction is due to attrition.

Jan 1, 1993

Although this is a symposium on "The Occurrence, Preparation and Use of Australian Black Coal", I do not think that, in these days, any of the main energy resources can be considered only in terms of country of origin or only by itself in isolation from other energy resources. Accordingly, I propose to comment on solid fuels generally in the world energy scene, and make some brief references to Australian solid fuels, and to some other matters in the latter part of this paper. In this address I am drawing heavily on the 1974 survey of energy resources published just recently by the World Energy Conference. I do this for a number of reasons. Firstly, the survey is the latest and most comprehensive publication of its kind; secondly, it is the result of several years' work by a panel of eminent people, from all the energy industries and from some 16 widely spread countries; thirdly, substantial assistance was given by the U.S. Atomic Energy Commission in its compilation; and, finally, to let all know of the existence of the book, as I believe it to be a source document for all those interested in world energy resources. The United Nations "J" series of statistical papers provide important information on the annual production and consumption of and trade in the various forms of energy. In their respective areas, these two publications are primary information sources. Our present sources of energy throughout the world are fossil fuel deposits (coal, oil, gas), nuclear materials, water, geothermal, solar and tidal - but we are at present heavily dependent upon the natural stores of non-renewable fossil energy resources. Fig. 1 shows the changing use of energy resources in the present century. A comparison between 1900 and 1973 shows clearly the shift which has taken place.

Jan 1, 1975

Nickel laterite approximately 40% of the remainder caning deposits. ores are the source of the world's nickel with from sulphide ore Although laterite ores are near the surface and cheap to mine they require significantly more energy to treat than sulphide ores. The escalation of oil prices comiencing in 1973 meant that nickel laterite refineries using oil as an energy source were placed at distinct disadvantage relative to sulphide refineries or those with coal derived energy. The Queensland Nickel refinery commenced a construction programme; in 1980 to allow ore drying and power generation to be converted from oil to coal. Since late 1981 ore drying has been undertaken using heated air from two moving grate spreader grate stokers. The changeover from oil to coal drying proceeded without process disruptions. This paper discusses the plant changes required to allow the receipt of coal and the operating performance obtained from the coal fired air heaters.

Jan 1, 1987

During the 20th century, the iron ore mining industries of Canada and the United States passed through several periods of transformation. The beginning of the 21st century has seen yet another period of transformation, with the economic failure of a number of steel companies, the acquisition of their facilities by more viable steelmakers, and the consolidation of control within the North American iron ore industry. Changes in Canadian and United States iron ore production and the market control structure involved are analysed. The consolidation of ownership, formation of foreign joint ventures within North America, planned divestitures of upstream activities by steelmakers, and industry changes made to ensure availability of feedstocks will be reviewed. The traditional isolation of the Canadian and United States iron ore operations and their strong linkage to downstream steel production will be discussed in the context of a changing global economy. Management-labour conflicts that have taken place and agreements made during 2000 through 2004 will be discussed in the context of the economic environment leading up to these agreements. Cooperative agreements between competing Canadian and United States companies to resolve client needs in processing and blending will be examined. A joint industry-government project designed to use new technology to produce direct reduced iron nuggets of 96 - 98 per cent iron content using non-coking coals will also be assessed. Changes in iron ore transportation methods, ownership and infrastructure will be reviewed for both rail and inland waterway transport between Canadian and United States companies. A brief analysis of social and environmental issues relating to sustainable development of the Canadian-United States iron ore industry will be included.

Jan 1, 2005

The society in which we live is one of change, and we professionals are part of that society. The importance of this simple and obvious statement is often overlooked. My Presidential Address examines the question: can professionalism survive in our changing society?There is ample evidence to show that our society is changing, and that the rate of change is exponential. This rapid and accelerating rate of change is what Alvin Tomer refers to as "future shock". Rapid change means that we do not have time to become accustomed to what is happening around us and to feel comfortable with it; the greater the rate of change the greater the discomfort. The effect that this has on people is varied; the change may be either expected or totally unexpected.The rate and extent of change in society is not the same for all countries nor for all industries or occupations. Change is more rapid in Japan, Korea or Taiwan, than in Australia. It is more rapid in our cities than in the bush, more rapid for professional businessmen than for farmers. In our minerals and petroleum industries, we are still adjusting to the great changes that have taken place over the last fifteen years. In the past, products from our industries were sold on a free and open market. Today, mineral development and production in most undeveloped countries and some developed countries is manipulated for political, social and economic reasons. Changes of this nature have had a devastating effect on the operations of established mineral producers in the democracies.Because of the accelerating nature of change, we must recognise that the past is not a reliable guide to the future.Although extrapolation of the past into the future is a basic ingredient of commercial survival, extrapolation is less and less reliable.I borrow from others in quoting the Irish proverb: "The future is not what it was".The future is where our business lies and most of us at this Conference must endeavour to understand it and adjust to it. I believe in the old adage that:You can't know where you're going if you don't know where you've been and where you are at.There are a number of major factors which have created change within our social, economic, and industrial environment in recent years.

Jan 1, 1985