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By S Freij, P W, R Gunawan, D Zhang, B Feng

The Mt Whaleback iron ore mine is located adjacent to Newman, approximately 1200 km north of Perth, in the Pilbara District of Western Australia. Approximately 15 per cent of the waste materials are in the zones with high concentrations of sulfide and carbonaceous minerals and are referred to as æreactive shaleÆ. The reactive shale has the potential to undergo self-heating and can react with the ammonium nitrate (AN) based explosives used in mining operations, resulting in spontaneous combustion and spontaneous explosion. The sulfide-rich shales also have the potential to produce acid rock drainage (ARD). In the present study, over 200 shale samples have been collected from different locations in the Mt Whaleback iron ore mine, including blasthole drill cuttings, fresh mine faces and waste dumps. These samples have been systematically characterised for their geochemical properties. Based on the characterisation results, a pH test was developed as a cost-effective, fast and efficient tool for the assessment of reactive ground in the mining industry. This paper summarises the results of the sample characterisations and discusses the key findings arising from the interpretation of results. These results have significant implications in the safe storage of the reactive shales and the prevention of spontaneous explosion, spontaneous combustion and ARD.

Jan 1, 2005

By Allen RL, Clifford BA, Wright JV, Bull S

The Bunga Beds of the Late Devonian - Boyd Volcanic' Complex is a well exposed succession of rhyolite, sedimentary rocks and minor basalt outcropping along the south coast of New South Wales. The sedimentary rocks vary from shallow water basin margin facies, to deep-water basin centre facies, and the majority of .the volcanics are associated with the deep water facies association. The volcanics are dominated by rhyolite domes, lavas and cryptodomes, whose margins are extensively autobrecciated and quench fragmented. In situ pyroclastics represent a very minor volcanic component and are restricted to the remnants of two small doors- top tuff cone successions. Pyroclastic debris is common in the sedimentary succession enclosing the volcanics and was clearly derived from shallow to emergent basin margin areas through mass-flow redeposition. The succession has bearing on the origin of the fragmental component of, the volcanics that host Kuroko- type massive sulphide deposits. The characteristics of these fragmental volcanics are not well documented. We suggest that based on the Bunga Beds,'Kuroko-type volcanic successions are dominated by coherent rhyolite/ felsic lavas and intrusive domes, autobreccias and hyaloclastites, that in situ pyroclastics are rare or lacking, and that redeposited volcanic debris is abundant. Pyroclastic debris is most likely to have been derived from shallow areas marginal to the deep-water volcanic centre that produce the Kuroko-type volcanics and sulphides.

Jan 1, 1987

By Armstrong M

Two methods of Monte-Carlo simulations, one suggested by Matheron (1972) and the other by Rudenno (1983), have been tested for simulating coal deposits. To do this 2160 values of ash percentages were simulated using 60 known data points in a two dimensional grid, 20 m x 40 m. 1L is found that while both methods conserve the mean of the known distribution in the results of the simulations, only the first method reproduces the spatial covariance (i.e. the variogram), of the experimental data. The results show that for simulation of regionalized variables only the first method tested yields the desired results.

Jan 1, 1985

New knowledge has no economic value unless it can be applied, or æcapturedÆ, as the R&D jargon has it. Australia probably spends more than $500 m per year on mineral industry R&D, distributed amongst the mining companies (IR&D Board, 1997), CSIRO, the universities and others. The investors in this research (industry, and the community via government) will expect some sort of return from their investment. The return will be poor unless the know-how developed in R&D programs can be exploited. This paper explores some of the issues involved in capturing the outcomes of mineral industry R&D in a form which can be exploited for economic benefit, and suggests ways in which it might be done better. It is based on the experience of the JKMRC in conducting applied research in mining and mineral processing and delivering it to the industry. It may seem presumptuous for a research contractor to be telling its clients how to do their job. However, the process of developing, acquiring and implementing R&D outcomes has to be a partnership between provider and receiver, in order for this process to work efficiently. This applies whether the two parties operate within a single corporation (a corporate laboratory and a business unit, for example) or are two entirely independent organisations (eg a mining company and a university). Both partners have a role to play, and the best examples of realising the benefits of R&D almost always involve the open-hearted and skilful handling of this synergy.

Jan 1, 1998

By D R. Lueking

A technology involving separate unit processes for the generation and use of ferric ions for the oxidation of sulphidic minerals has been developed. The technology utilises a stand-alone automated bioreactor for ferric-ion generation (termed SAAB-FIG) and produces a low pH, ferric ion-rich leach liquor with a high oxidation potential. This leach liquor is then employed, in a separate unit process, to oxidise sulphidic minerals and regenerate ferrous iron that may subsequently be recycled to the bioreactor for the continual generation of ferric ions. The technique was successfully applied for the recovery of copper from chalcocite (Cu2S) and chalcopyrite (CuFeS2), as well as other ores and concentrates containing copper sulphide minerals. Coarse ore, ground ore and concentrates were treated with acidic solutions containing 8 to 12 (g/L) Fe(III) ions at a variety of temperatures. This process yielded over 50 per cent of the contained copper from both chalcopyrite and chalcocite samples. Maximum reaction rates and copper recoveries were found to be highly dependent upon temperature and pH and leach liquors containing bacterial cells displayed little difference in their leaching efficiency when compared to cell-free leach liquors.

Jan 1, 2000

The efficient development and exploitation of an orebody relies on an understanding of the mineral characteristics of the deposit. This information is valuable throughout the mining cycle - during exploration, assessment, testing, design, operation and rehabilitation. Problems can arise at each stage if there is an inadequate appreciation of the mineralogy involved and its effects on the treatment process. Modern image analysis systems now permit a more quantitative understanding of the mineralogy of an ore to be gathered. Where previously the metallurgist had to rely on qualitative information to guide technical decisions, it is now possible to give numerical estimates to the compositional and textural properties which govern the mineral concentration processes. Ore samples can be characterised according to modal abundances, mineral grain size parameters and mineral associations, all of which affect the liberation and concentration of the values. The paper will discuss the application of quantitative process mineralogy by considering a number of case studies. These include: ore characterisation to assist in exploration, assessment and mine planning; modal analysis of complex mineral suites to assist in the evaluation of ores, the deportment of values between products and the recovery or loss of these values; liberation analysis for ore testing, plant optimisation and performance monitoring; and characterisation of tailing to guide estimates of leachability, stability and rehabilitation options.

Jan 1, 1998

Traditional methods for monitoring, and hence controlling, pyrometallurgical processes rely heavily upon the skill and experience of operators. A skilled operator will usually achieve consistent, though often conservative, results, whilst an un-skilled operator will require considerable time and training to achieve the same results. Semtech Metallurgy AB have demonstrated that continuous and precise control of pyrometallurgical processes can be achieved through on-line analysis of pyrometallurgical flame off-gas using optical spectroscopy. The feasibility of the technology has been demonstrated on a large number of full-scale tests at production plants and by several commercial installations. Evidence suggests that installation of this technology, called Semtech Optical Production Control (OPC), has resulted in considerable economic benefits to the plant efficiency and asset life. These economic benefits are believed to be a direct result of improved objective on-line control. Technically the following benefits have been demonstrated: improved metal grade control, reduced metal losses, reduced processing time, and improved personnel safety. SemtechÆs OPC is a non-intrusive technology which relies on the fact that the composition of the vapour phase above a high temperature melt is closely related to the instantaneous status of the melt. This enables on-line real-time analysis of the furnace melt to accurately determine melt status and in particular reaction endpoints. Originally developed for on-line monitoring of copper converting in a Pierce-Smith vessel the field of applications for the technology is steadily growing. This paper introduces the Semtech OPC technology; discusses various applications and outlines the demonstrated benefits.

Jan 1, 2002

By M Magee, D Way

The Mount Isa Copper Concentrator was commissioned in 1973. In 1991, two autogenous grinding mills were installed replacing two stages of crushing, one stage of rod milling and one stage of primary ball milling. The cyclone overflow P80 of the secondary ball milling circuit was reduced to 120 microns due to the increased operating power in the AG/SAG mill circuits. A study of the mineralogy of the milled products and the plant flotation recovery indicated that the installed secondary grinding energy was more than what was required for adequate liberation of the chalcopyrite and half of it had potential for more effective use elsewhere. Halving the secondary grinding energy meant only one of the two secondary ball mills would be needed. The predicted saving in operating cost of one less ball mill was more than two million dollars per annum. This paper summarises various plant trials that were conducted in the Copper Concentrator to decommission one of the two secondary ball mills.

Jan 1, 2004

Some attempt to minimise the importance of the greenhouse phenomenon. They do so by observing that global temperatures are still within the range of recent variations and that it is still not possible to predict with any certainty what the precise consequences of greenhouse will be. Both observations are true though the conclusion is dangerous. Ice core samples from the Antarctic and Greenland have established the composition of the atmosphere and global temperature over almost the last 200,000 years. The profile of these twin variables shows that they have moved together; when the concentration of CO2 has been up, the temperature has been up and when the former has been down the temperature has also been down. Over almost 200,000 years the CO2 content has ranged between lows of 190 ppm and highs of 270ppm. In just 200 years of industrialisation the CO2 content of the atmosphere has increased to 350 ppm, 50% higher that the mean of the last 200,000 years and 30% higher than at the start of the industrial age. Carbon dioxide is now increasing at 0.5% p.a. Methane, about twenty times more effective than CO2 as a greenhouse gas has doubled in concentration in the last two centuries and is now increasing at about 1.1% p.a. Methane, nitrous oxide, chlorofluorocarbons together with a number of lesser gases will double the greenhouse effect due to in creased CO2 over the next 40-50 years.

Jan 1, 1989

By G A. Davis, D G. Laughton

The great variability of mineral and energy prices has motivated some governments to incorporate a windfall profits tax into their mineral taxation regimes. Windfall profits taxes are a means for governments to capture additional mineral revenue when mineral prices are considered higher than some historic level. Governments need to be aware of the effects of such contingent taxes on the exploration, development and operating decisions of mining companies. Mining companies need to be able to calculate the full impact of windfall profits taxes on the economics of their projects. This paper examines the valuation of a multi-phase copper-gold project in the presence of a windfall profits tax. Real options Monte Carlo simulation is used to characterise the different exposures of the mine owner and of the government to the risky cash flow streams that they receive from the project. The results highlight that Monte Carlo simulation paired with the real option valuation method is able to account appropriately for the differing risk exposures, while the traditional discounted cash flow valuation model is not. Our key conclusion for governments and mining companies is that the impact of contingent tax and royalty terms can and should be assessed using advanced valuation techniques, and the results used to improve contract designs under the constraint of actual and perceived fiscal system stability.

Jan 1, 2007

By J Herbertson

æZero waste steel making productionÆ has already been the subject of several studies and also the successful result of some companies. Regarding waste and by-products, slags are the largest in terms of weight, although among the least hazardous. All steelmakers around the world are presently looking into profitable solutions, according to their local conditions: environment constraints, available markets, and mode of operation. Today the major technical methods of slag value capture include different levels of magnetic separation and screening to remove entrained steel, for production of aggregate in civil works. A survey of different retrieval processes shows that pyrometallurgical processing of steelmaking slags will increase the recovery ratio of iron and other metals. In the process, the remaining part of the material, a mixture of metallic oxides, can be easily transformed into hydraulic binder such as cement. Can steelmakers consider the slag as a co-product, and not only a waste or by-product? The ability of pyrometallurgical processes to treat other wastes and by-products generated in the steelplant is an opportunity for the steelmakers to reach the æzero waste productionÆ status. A technical survey of the experiences and possible solutions of pyrometallurgical processing is presented as well as technical descriptions of technological, economical and profitability analysis in relation with foreseeable markets.

Jan 1, 2002

By O Ostrovski

Iron ore reduction and iron cementation by CH4-H2-Ar gas was investigated in a laboratory isothermal fixed bed reactor. Iron ore was first reduced to metallic iron by hydrogen, then carburised to cementite by methane. Increasing temperature and hydrogen content accelerated the reduction process. Methane had almost no effect on the reduction process. Meanwhile, higher temperatures increased the rate of cementation and also the rate of free carbon deposition. The optimal temperature for cementite formation was found to be 750¦C. At this temperature, reduction of iron ore to cementite by gas containing 55 vol per cent hydrogen, 35 vol per cent methane and 10 vol per cent argon was completed in about 15 minutes. Addition of sulphur into the reducing/carburising gas strongly retarded the process of cementite formation and free carbon deposition. Cementite is an unstable phase which decomposes to iron and carbon. The rate of cementite decomposition increased with temperature up to 600¦C and above 750¦C . In the temperature range from 600¦C to 750¦C the rate of cementite decomposition decreased with temperature. Cementite was the most stable at 750¦C and least stable at 600¦C. The two-interface grain model was used to describe the process of iron ore reduction and the volume reaction model was employed to model the iron cementation process. The simulated results for both reduction and cementation are consistent with the experimental data.

Jan 1, 2000

In the future, Illawarra Coal, the primary metallurgical coal producer in the southern coal fields of New South Wales, will face many unique challenges not found in other coal or minerals production areas. To manage these challenges and determine the best strategy for the business, Illawarra Coal has adopted a systematic strategic planning process, which starts from the broadest possible options analysis and culminates in a ægo-forwardÆ operating case that individual mine sites use as the basis for short-term planning. This paper will discuss two major topics. Firstly an overview of the Illawarra Coal and BHP Billiton strategic planning processes. This will demonstrate the range of variables and inputs that are required for the planning process, and the system which is followed to evaluate different alternatives for the extraction of the resource. Secondly, having discussed the primary external and internal factors that must be accounted for in the planning process, and the main issues affecting the viability and likelihood of each alternative, the paper will discuss the particular challenges that Illawarra Coal will face in the coming decades. These challenges include: market and price uncertainty; managing impact on surface features, infrastructure and environment; community interaction; transport and logistics constraints; unknown mining environments; lack of geological knowledge; limited surface access for new mining domains; changing attitudes to longwall mining in the Illawarra; ageing workforce; and cost and overhead management. The paper intends to discuss how these issues impact the business currently and how they are incorporated into Life of Asset plans and overall corporate strategy for Illawarra Coal.

Jan 1, 2007

By Haartti J

Generally when equipment is chosen for solving a dewatering problem, the equipment is based on one of following physical methods: gravity (sedimentation, screens), vacuum (vacuum drum and disc filters, belt filters), pressure (filter presses, hyperbaric filters) and centrifugal forces (centrifuges). The choice of method and type of equipment depends, among other things, on the requirements on the maximum water content allowed in the filter cake and on the particle size distribution and the concentration of solids in the material to be dewatered. All the above-mentioned equipment has its benefits and drawbacks. The conventional vacuum filters of drum or disc type are of a simple construction with few parts to be replaced, but these filters produce a filter cake with a fairly high moisture content, and a dryer is required for additional drying. In most cases the use of pressure makes it possible to produce filter cakes with the desired moisture content but the equipment is of complicated construction, leading to high maintenance costs . In addition to this the consumption of compressed air is high. The capillary filtration to be described in this article is a dewatering method which combines the benefits of both the conventional vacuum disc filter and the filter press. The capillary filter produces low cake moistures with a machine of very simple construction similar to that of the vacuum disc filter.

Jan 1, 1993

By E Wan, K Stokes

Since 1978, the nickel concentrator at Leinster has been subject to continuous change. In 1971 a significant nickel sulphide deposit was discovered on Leinster Downs Station, within three years the extent of the deposit was determined. In 1978 the Agnew Mining Company began production of nickel concentrate from the Perseverance Mine and continued to do so until production ceased in 1986. In 1988 WMC purchased the mothballed project and began the first phase of many expansion initiatives. Milestones in the life of Leinster have included:open cut mining of the Perseverance orebody and the discovery of the RockyÆs Reward orebody, as well as the metallurgical challenges in treating each of these; underground mining at both Perseverance and RockyÆs Reward; construction and commissioning of the WMC grinding and flotation circuits; variations in the reagent schemes, including the introduction of æliquidÆ reagents; development of mill linings to reduce maintenance; circuit re-configuration and simplification; development of Harmony open cut; strategies for increasing throughput at the drier; and changes to tailings facilities to cope with increased throughput. This paper outlines the steps which have been required to expand the Leinster Nickel Concentrator from 650 000 tpa to 2.5 Mtpa and those steps which will be required in the future.

Jan 1, 2000

By J Walasiak

In the climate planning of mines and tunnelling with anticipated poor climatic conditions, and especially in case of longer working shifts, the main question is whether it can be reliably prevented that certain climatic limits laid down be exceeded. Working at high temperature and/or humidity can lead to reduced human working energy û a very important economic aspect û and to a risky lack of concentration on the part of the miners or to heat collapse and extremely dangerous heat stroke. With the Deutsche Montan Technologie GmbH (DMT) climate prediction programs, both the dry and the extremely significant humid heat transfer can be calculated. This is due to the high planning reliability involved. With the help of these climate prediction programs it is already possible to determine the anticipated climatic values for the operation phase as early as the planning stage of new ore or coal fields or of tunnel construction projects and to design the optimum air cooling system for every underground project with due regard to technical and economic aspects.

Jan 1, 2005

THE writer of this paper well realizes that the majority of engineering and metallurgieal works have from time to time evolved mechanical devices which are of great value as regards application in an operating plant.Many of these deviees would not be apparent to an individual making a brief inspection of works such as these, and it is for this reason that the writer proposes to outline a few of the devices which have been evolved by the engineering department of the Broken Hill Associated Smelters Pty. Ltd.NOVEL METHOD OF MACHINING A SPHERICAL JOINTFig. 1 represents one half of a casing for a ball-joint coupling. In the ordinary methods of boring an external spherical casing, that is with a radius bar attached to the tool rest of a lathe, there is always an error in the bore. It has two flat sides, and this error is inherent in the ordinary orthodox method and cannot be corrected. The engineers of the Broken Hill Associated Smelters Pty. Ltd. undertook a job that had to be extremely accurate, and the tool shown in Fig. 2 was evolved. The tool is not exactly fool proof, but in the hands of an average mechanic an absolutely perfect FIG. 1. sphere can be bored. The casing has to be held in the lathe in such a manner that one half can be removed without affecting the setting of the work. The business end of the tool is then placed inside the...

Jan 1, 1922

By Worner H. K

The paper briefly summarises the work of the Titanium Research Section in the Metallurgy Department of the University of Melbourne and mentions the development of a new electrolytic process for titanium production. This process utilises the "hot-spot" cathode technique and titanium carbide anodes. An introduction is given to three further papers on titanium metallurgy to be presented to the Institute.INTRODUCTIONThe unique combination of strength, lightness and corrosion resistance possessed :by titanium and its, alloy has made them of great interest to engineers. However, high cost, difficulties of production and limited knowledge of techniques of application restrict their usage at present almost exclusively to high priority armaments.The cost of the metal is divided between extraction and processing and much research has been carried out to devise new and cheaper methods for winning the metal from its ores. Processing costs will be reduced when production volume increases.Extraction research is proceeding rapidly overseas and Kellogg (1955, p. 72) reports that 'at least seventeen companies in the U.S.A. are interested in titanium production. Of these, two are producing the metal by a modified Kroll process, three are building Kroll plants and the remainder are in various stages of research activity. The Horizons Corporation alone is contemplating electrolytic extraction and is building a pilot plant. Steinberg et aI. (1955, p. 252, p. 332) have reported the early work done by the HorizonsCorporation on electrolysis of potassium fluotitanate and titanium monoxide in fused salt electrolytes. Of these two, the former appears to be the more attractive process.

Jan 1, 1956

By A D. Bugarski, B R. Conard, G H. Sc

The objective, of the Diesel Emissions Evaluation Program (DEEP)-sponsored project at IncoÆs Stobie mine, was to conduct a long-term field evaluation of selected diesel particulate filter (DPF) systems, available to the underground mining industry. Nine state-of-the-art DPF systems were retrofitted to heavy-duty and light-duty vehicles and were subjected to extensive long-term in-mine evaluation. Periodic efficiency tests were conducted at various stages of the study (in 2001, 2002 and 2004) to establish in-use efficiencies and durabilities of the tested DPF systems. During efficiency tests, the vehicles/engines were operated over several steady-state operating conditions. Various instruments were used to measure particulate and gaseous emissions upstream and downstream of the filter systems. The results were used to assess the effects of the filter systems on the concentrations of diesel particulate matter (DPM), nitric oxide, nitrogen dioxide and carbon monoxide in the vehicle exhaust. Experience with the operational issues related to deployment of the filter systems on underground mining vehicles, coupled with the assessment of the filtration efficiencies, were the primary objectives of the study. The variety of filtration systems and regeneration concepts used in this study offered the opportunity to investigate the advantages and disadvantages of the various types. Some of the major issues studied were criteria for selecting the filter media, means of regeneration, the long-term operational reliability, and the occurrence of unwanted secondary emissions.

Jan 1, 2005

Water is a key resource input to copper heap leach operations in both quality and quantity. A number of recent developments in analysis of the technology have shown that water consumption can be optimised. The leach consumption has been generally considered in terms of minimisation of the evaporative loss by changing the application method (drippers or wobblers). Modelling of the irrigation effects on leach rate has shown that the poorer surface coverage from drippers has an adverse effect on the leach extraction rate. This is particularly evident in the early part of the leach. The use of different irrigation systems during alternate parts of the leach cycle can have benefits in minimising the water consumption without an unacceptable outcome from extended extraction times. By combining the leach rate effect with the evaporative loss estimates, an economic decision matrix can be generated to allow the operator to select an appropriate leach irrigation strategy, combining both irrigation delivery and irrigation rate. In the SX-EW plant, the total quantity of EW bleed and SX scrub stage bleed (both for iron control) can be reduced to an absolute minimum. The economic minimum may be different depending on the cost of producing the high-quality water used to replace the bleed streams. Adjustment of the SX process, in particular use of multiple entrainment control steps, can provide significant reductions in the total bleed and make up requirements.

Jan 1, 2003