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By I Grewal, M Lundt

Dense medium separation (DMS) is one of several preconcentration methods used for early waste rejection from run-of-mine ores at relatively coarse particle sizes prior to additional milling and beneficiation. DMS has been used extensively in the coal, diamonds, mineral sands, base metals and iron ore industries to produce either a final product or as a preconcentration step. Laboratory scale and pilot test work at the Met-Solve laboratory in Canada has demonstrated successful separation and upgrading of other minerals such as lead, zinc, copper and lithium based ores using DMS.This paper reviews historical dense media systems, results from the pilot-scale multi-stage DMS Separator “Condor” system, as well as production plants and associated laboratory heavy liquid separation (HLS) test work on various minerals. The mineral systems tested included a lithium bearing ore and a fluorspar ore. Other minerals were tested but are not reported in this paper.Pilot plant test work on a fluorspar ore showed that 41.6% of the mass could be rejected to the tailings stream while 95.3% of the CaF2 was recoverable to the product stream. On a spodumene sample that was tested, it was possible to reject 55% of the mass to tailings while recovering over 90% of the lithium.In recent market conditions and with the decreasing grades in existing ores, preconcentration should be a consideration to maximise the value of certain operations.CITATION:Lundt, M and Grewal, I, 2017. Dense media separation – a valuable process for preconcentration, in Proceedings MetPlant 2017, pp 122–130 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By H Park, L Wang

Froth flotation is one of the most widely used beneficiation processes for fine and ultrafine coals and minerals. Maintaining optimal metallurgical performance in industrial flotation operation is still a challenging task owing to the lack of an effective tool to diagnose the flotation performance in realtime. For this purpose, a number of flotation performance monitoring systems with different working principles have been developed to provide instant feedback for process control and optimisation. In this paper, for the first time, five different flotation performance monitoring systems were systematically compared through an on-site trial in a coking coal flotation plant in Queensland, Australia. The monitoring systems were used to measure (i) gas holdup, (ii) overflowing froth velocity, (iii) overflowing froth height, (iv) air recovery and (v) drag force exerted by overflowing froth, in an industrial flotation column and the outputs of these systems were collected simultaneously at a wide range of operating conditions. For each monitoring system, the best regression model describing the correlation between the system output and the flotation performance was selected from various regression models (eg linear, quadratic, power-law and logarithmic) using the Akaike information criterion (AIC). A comparison of the coefficient of determination (R2 ), residual sum of squares (RSS) and measuring accuracy at 95 per cent confidence level of the best regression models of these monitoring systems suggested that the drag sensor outperformed the other systems at a wide range of flotation operating conditions. The superior performance of the drag sensor was attributed to its distinctive design that enabled intimate sensing of variation of the overflowing froth properties. Furthermore, the drag sensor had the ability to monitor feed ash content variation when the other operation variables were set almost constant.

Aug 24, 2022

By T Gready

Stawell Gold Mines operates the Magdala underground mine in western Victoria, Australia. Several orebodies are extracted by longhole open stoping at a depth of 900 m below the town of Stawell. Some stopes are backfilled with cemented slurry rock fill (CSRF) to ensure stability, increase recovery of ore reserves, minimise dilution of ore grades, and add value to the project. StawellÆs simple CSRF system is described, including the novel equipment used to minimise capital costs. Design criteria, operating procedures, monitoring systems and results are discussed in detail. Practical aspects are considered, including lessons learnt about barricades, overbreak and segregation. The economics of CSRF are discussed, including capital costs, operating costs and the total cost per ounce of gold poured. Options for mining with and without CSRF are compared in terms of return on investment and net cash flows. Examples demonstrate the method used to calculate æbreak-evenÆ stope ore grades which determine whether or not CSRF will add value in different circumstances.

Jan 1, 2002

By F Radke, P A. Tilyard

Determination of the mineralogical location (deportment) of minor and trace elements (including credit and penalty elements) in base metal concentrates can indicate whether further processing is likely to (a) reduce the levels of the penalty elements, and/or (b) direct selected elements into other plant products, thereby increasing current concentrate grade or increasing payment for credit elements. To determine the deportment of elements requires knowledge of the proportions of the minerals present and their individual element contents. In addition, knowledge of the liberation and locking is important, as this can affect any possible further processing. Mineral proportions can be determined by a variety of methods including chemical analysis, point-counting, area-counting, QEM*SEM, image analysis and mineral separation. In the case of a Broken Hill zinc concentrate, several of these methods were used and gave consistent results.

Jan 1, 1998

Vertical flow systems (SAPS, vertical flow wetlands) are increasingly used for passive treatment of mine drainage that is net acid. Data on 30 systems in eastern US show that well designed systems typically add about 40 g/d/m2 of alkalinity to influent net acid water. If they are designed with a conservative loading rate of 25 g/d/m2 and carefully constructed, they produce net alkaline water. Alkalinity added depends on influent acidity, Fe, pH, and retention time, and ranges widely, from 7 to 484 mg/L, so this is not a useful design criterion. Some waters may benefit from retention times longer than the conventional 12 - 16 hours, but the design must be partly based on cost-benefit considerations. Systems with fine limestone added to the compost layer perform better than average, perhaps to an alkalinity generation rate of 80 g/m2/d. A variety of problems are noted in the 30 systems and others reported in the literature. Systems with high influent Fe (> ~75 mg/L, varying with pH) tend to gradually decrease in flow rate because of precipitation and settling of Fe hydroxides on top of the compost layer. Some high-Fe systems precipitate Fe in the limestone layer, suggesting inadequate compost thickness, or short-circuiting through thin spots. Systems with Al exceeding about 10 mg/L tend to plug because of Al hydroxide precipitation in the limestone layer. Flushing only removes a small part of this precipitate, but can extend life. Some systems are ineffective because of failure of the inflow system. Some systems are uneconomic because they are oversized. A continuing program of inspection and maintenance is necessary for long-term performance.

Jan 1, 2003

By G Baird, M Seto

A low-cost methodology that allows the determination of in situ stresses using oriented core specimens has been investigated. The technique can be used to determine the stresses during the early stages of a project, even in undeveloped areas of a mine. The research aim was to compare the experimental results estimated by the Acoustic Emission and Deformation Rate Analysis methods with those estimated by conventional Hollow Inclusion cell measurements. The studies have been focused on full stress tensor determination from a single oriented rock core. In all cases the rock core specimens recollected the in situ stresses reasonably well compared with the standard overcoring method.

Jan 1, 2000

By Smith N. S, Rholl S. A, Otterness R. E

The Bureau of Mines is conducting research to develop blast designs for the control of fragmentation and rock displacement and the reduction of overall mining costs. This Bureau experiment, a program of 25 reduced-scale blasts conducted at the University of Missouri-Rolla's experimental quarry, determined the effects on fragmentation of changes in burden, spacing, explosive diameter, and stemming-explosive length. Combined with previous work at this experimental quarry examining air gap, delay, and decoupling effects, this experiment provided a data base of over 50 shots. The fragmented rock, 1000 to 3000 kg from each 3- to 4-hole blast in the 1 m bench of massive dolomite, was completely screened to assess fragmentation. The explosive used for all the tests was extra dynamite initiated by seismic caps fired from a sequential blasting machine with delays of 5.2- to 13-ms/m of burden. Empirical equations were developed which predicted the effect of shot design parameters on the fragmentation. These formulas predicted the average fragment size of each of the 25-shots to within 13 percent. For spacing to burden ratios of 1, 1.4 and 2, there were optimum burden to explosive diameter ratios (B/de) of 30, 26 and 20, respectively. Decreasing the B/d. ratio beyond these levels resulted in little or no reduction in the average size. For B/de ratios above these levels the average size increased but, at least a 15 percent reduction in the average size results when the shot design parameters are optimized.

Jan 1, 1990

By D Bruggemann, F Sereshki

There has been an ongoing research on coal and gas outburst for the past two decades at the School of Civil, Mining and Environmental Engineering, University of Wollongong. Research study began with a humble beginning, initially conducting basic laboratory studies on the coal and gas properties, progressing into the determination of gas content of coal by sorption technique and the effect of gas pressures on coal strength. The present laboratory facilities and research interests are extended to include the study of coal permeability and shrinkage properties and their effect of gas drainage characteristics with respect to gas type, and pressures. All the changes are examined with respect to changing in-site geological conditions of the coal deposit investigated. The aim is to provide a long-term support to industry in establishing a data bank for Australian coal deposit characteristics and properties.

Jan 1, 2005

This paper discusses the implementation and potential limitations of the method for estimating sampling and analytical errors of multiple source mine output blended into a shipping product, described by Everett and Ziegelaar (2010). The practice of quality measurement varies between iron ore miners. The common objective is to monitor effective resource utilisation and control of product quality to customers. A flow diagram is given presenting the various options used by iron ore mine operators and the merits of the different options are discussed.

Mar 1, 2010

By Alichurch P. D

Perseverance nickel deposit is located at latitude 27¦ 491S, longitude 1200 42'E, 330 km north of Kalgoorlie, Western Australia. Gossanous outcrops were discovered in April, 1971, and after further detailed surface investigations, percussion drilling led to diamond drilling by June, 1971. Up to December, 1972, 127 diamond holes totalling 45,590 m were drilled to indicate 33 million tonnes averaging 2.2% Ni using a 1% cut-off grade. The deposit occurs in a lenticular ultra- mafic unit emplaced in metasediments locally forming the eastern flank of the Archaean green- stone belt trending NNW from Leonora to Wiluna. To the east a major strike fault separates the metasediments from gneiss; westwards there is a sequence of metavolcanics with further ultra- mafic units. Length of the lens is 3500 m and it attains a maximum width of 800 In. The eastern contact is moderately regular, but the western contact is prominently embayed. Local strikes are NNW, and dips are steeply W. A set of strike faults cuts the ultramafics and enveloping quartzites. These are normal faults, parallel to the major eastern fault, dipping 65-70¦W. They impart a serrated pat- tern to the sub-outcrop of the western contact. Massive serpentinite is the dominant rock in

Jan 1, 1973

This paper discusses some topical issues on the mining administration and legislation fields including:  1. Licensing û Administration and associated specialist functions including:Processing and volumes of mining privilege applicationsFuture organisation and possible decentralisationSpecialist staffFacilitiesGuide to the Mining Act 1971 2. Mining Amendment Act 1981 Transitional procedures 3. Planning Tribunal First hearing of objectionsPoints of principle resulted there from 4. Quarries and Tunnels Bill Currently before Parliament û implications for metallurgical mining

Jan 1, 1982

By R Coleman

The flotation mechanism plays a key role in the flotation process. It is used to provide the contact between solid particles and bubbles and also the energy for these particles and bubbles to attach. The mechanism must therefore provide sufficient mixing to keep the solids in suspension so that they can be transported into the froth and recovered to the concentrate. The design of the mechanism is critical and over the past decade Outotec has developed and optimised a new mechanism design to improve metallurgical and energy performance. The FloatForce® mechanism consists of a rotor and stator arrangement and has been specifically designed to provide sustained mixing at higher air flows and lower power inputs.Over 500 FloatForce® mechanisms have been installed in existing and new operations. This paper outlines the technological aspects of the FloatForce® mechanism and provides metallurgical, operational and energy performance results from a number of flotation circuits in which these have been installed.

Aug 8, 2011

By M Carr, C Wheeler, M Lurie, B Chen

The demand for steel products in modern society is prompting the iron ore industry to optimise their operations to ensure sustainability of fines and lump products. One of the key components in the iron ore transportation chain are belt conveyors. The energy consumption of modern belt conveyor systems has reduced considerably over the past few decades, however, there is still significant scope for further reductions, especially when heavily loaded long overland belt conveyors are considered. A new rail based continuous bulk material transportation system has been developed by researchers at the University of Newcastle to reduce the energy consumption of heavily loaded and long overland conveyors. The Rail-Running Belt Conveyor technology is a state-of-the-art continuous belt conveying technology which provides an innovative and novel departure from conventional continuous bulk material transportation systems with significant energy and economic benefits. This paper presents an overview of a Rail-Running Belt Conveyor variant which considers an enclosed belt. Enclosed belt conveying has the benefits of encapsulating the bulk material, and thereby reducing dust emissions and moisture ingress, in addition to being able to negotiate smaller radius horizontal and vertical curves leading to greater flexibility. To quantify the primary differences between conventional conveying technologies, the Denver office of thyssenkrupp Industrial Solutions (USA) developed a case study for an 11 km long conveyor. The conveyor design throughput was 2750 t/h and included a small net elevation loss of 10 m. When considering CAPEX the Rail-Running Pipe Conveyor equipment supply cost is approximately 45 per cent of the cost of a conventional pipe conveyor, while savings upwards of US$50M emerge for CAPEX combined with five years of OPEX. The savings vary with the topography and density of the bulk commodity, with iron ore generally showing increased savings because the high bulk density increases rubber losses in conventional conveyors.

Nov 8, 2021

The New Broken Hill Consolidated Airshaft is the first major undertaking in the development of New Broken Hill Consolidated Ltd's. property, which adjoins that of The Zinc Corporation Ltd. on the latter's southern boundary.The Zinc Corporation ore-body has a southerly pitch. The Zinc Corporation's New Main Shaft is 1000 ft. north of the common boundary, and the general plan of development of the New Broken Hill Consolidated property is by driving south from this shaft on the lower levels. No downcast airway from the surface was available south of the Zinc Corporation's New Main Shaft; this shaft acts as the main downcast to the bottom of the Zinc Corporation mine, the general air flow then being northward and upward to the upcast shaft at the extreme north end of the Zinc Corporation property.Rock temperature is 920 F. at 2000 ft., increasing by 10 Fahr. each 72 ft., the rock temperature at 3000 ft. being estimated at 1060 Fahr. With the general air flow northward from the Zinc Corporation's New Main Shaft, adequate ventilation under these temperature conditions would not be practicable for any great distance south of this shaft without another main airway from the surface. Accordingly the New Broken Hill Consolidated Airshaft is being sunk at a point 1000 ft. south of the common boundary, i.e., 2000 ft. south of the Zinc Corporation's New Main Shaft, to ventilate future New Broken Hill Consolidated workings and that part of the Zinc Corporation mine between the boundary and the New Main Shaft.

Jan 1, 1940

By E C. Holloway

"The financial valuation of mining assets has a number of fundamental differences to the valuation of many other asset groupings. One such difference is that typically, the greater proportion of both the cost and revenue sides of the cash flow are inherently governed by systemic market forces.As a result, the range of outcomes for the valuation of each mining asset is more unpredictable, with higher levels of risk and uncertainty. In contrast, the management function of many other non-mining businesses or industry groups can control at least a portion of the cash flow by maintaining the margin or controlling the sales price. The management teams of mining businesses and operations typically have limited options, and are thus price-takers for both costs and revenues. As mining is an inherently cyclical industry, large, long-life operations can exist through several price cycles, making valuation both subjective and challenging.The outcomes of both static- and stochastic-based valuations, as well as the internal probabilities of the associated cash flow statements, are significantly impacted when the correlations between the appropriate parameters are quantified, modelled and incorporated into the valuation framework. The appropriate parameters for correlation modelling primarily include those that are governed by systemic market forces. Applying this process results in a different risk profile for the asset by allowing the risks resulting from systemic market movements to be more accurately quantified and then objectively minimised. This process also reduces the level of residual uncertainty in the valuation outcome.This paper presents a valuation methodology to pragmatically incorporate this level of valuation sophistication and statistically quantify the associated increase in the level of confidence of the valuation outcomes reported.CITATION:Holloway, E C, 2016. Correlated valuation methodology, in Proceedings Project Evaluation 2016, pp 181–200 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By J M. F Clout

Geological, textural and mineralogical classification of iron ores is routinely conducted by mine and exploration geologists on reverse circulation percussion, blasthole cone and bulk samples for grade control, defining ore and waste, determining lump:fines ratio and predicting downstream processing characteristics. Classification is based on physical hardness, colour, streak and other visual characteristics. However, logging is generally restricted to the five to 20 per cent of chips above about 2 mm. This means that most of the sample is too fine to be reliably logged for anything but colour or streak and the textural types must be inferred from other information. A recently developed software package called æRecognitionÆ allows automated identification and classification of iron ore textural types and gangue on a particle basis in polished section down to 0.01 mm using processed digital images. It is not designed to be used as a routine logging tool, but is applicable where higher definition is required at the resource evaluation stage on selected percussion, drill core or bulk samples. æRecognitionÆ processes data obtained after optical image analysis of fine iron ore samples. It contains several parts, like æRecognitionÆ, æCompositionÆ, æLiberation by Total IronÆ, æLiberation by PhasesÆ and æStatisticsÆ, which allow vast and diverse information to be obtained about the iron ore samples being studied. Identification and classification of the textural type of each particle is performed according to the CSIRO-Hamersley Iron Ore Group Classification Scheme. The recognition procedure encompasses a good knowledge of different ore types and a logical knowledge tree, managing fuzzy boundary problems and the potential for a few different ore types in the same particle to be considered. This new technology introduces strict criteria to make the process of identifying particles more objective. Automated recognition standardises the identification procedure and significantly saves time. It enables users without a strong background in mineralogy to perform accurate texture identification. The æRecognitionÆ package has a modern user-friendly interface and Word compatible output. The combination of all the features mentioned makes the package a convenient tool for detailed studies of fine iron ores.

Jan 1, 2005

By C Augustin, M Hahn, K Nienhaus

Operators of mining machinery like haul trucks or excavators have very limited information about the exact distance to other equipment as well as to the natural boundaries like berms, walls and structures such as crushers. The industry is seeking solutions to provide safety and positioning. The authors have developed a solution approach which is being used in several installations. This solution consists of three parts: first robust and compact two-dimensional (2D) radar scanners that provide range and angular information of the environment especially under difficult conditions like dust, rain, snow and fog; second an intelligent data processing framework flexible enough to adopt to different machines and operation modes like speed, inclination, visibility, tire friction, GPS position, orientation and acceleration; and third a high quality and easy to use interface giving highly condensed data to the operator, not blinding the operator at night and being sunlight readable. The truth of present proximity detection sensors is that they not only have a high false alarm rate but furthermore cover only a fraction of the possible scenarios. This makes them unsuitable for stand-alone collision avoidance systems. On the other side, mine dispatch systems only deliver database and GPS information, but no information regarding the real environment. The indurad company and its Australian partner CTS (http://www.cts.com.au) addressed these aspects by developing smart productivity enhancement driver assistance tools like lane and crusher dumping assistance.An innovative driver assistance tool developed in cooperation with the coal shearer manufacturer Eickhoff and the RWTH Aachen University has been awarded with the annual research award of its customer RAG, being the largest German hard coal producer, as well as with the bauma Innovation Award in 2010.

Sep 26, 2011

The profitability of individual ore blocks can be classed as clearly profitable, clearly not profitable, and those in between which are by nature quite sensitive to their major cost and revenue drivers. It is often the case that the most effort goes into the least profitable ore blocks to ensure that these will in fact not generate a loss. In these cases a cut-off grade policy is often not sufficiently live to separate individual sources given the volatility of financial markets and individual circumstances of some sources particularly in remnant operations such as Mount Isa MinesÆ Lead Mine. Standard sensitivity analysis can determine which factors stope profitability is most sensitive to. However, this does not usually indicate the likelihood of any input change, nor the combined effect of multiple inputs changing. The author attempted to modify the Lead Stream financial model that determines cash margin by inserting probability distribution functions and then using Monte Carlo simulations to determine the probability of any particular ore block making a profit. This effectively demonstrates the combined effect of varying a number of inputs simultaneously to provide a probability of making a profit. The limitations of this analysis lie in the accuracy that individual probability distributions can be specified. Attempts to generate valid functions from first principles have proved difficult for a number of reasons and these are discussed along with some practical alternatives.

Jan 1, 2002

Knowledge of the hydrogeological setting of a mine forms an integral part of a mining operation. Groundwater impacts, initially, on mine feasibility. Then, on commencement of mining, it interacts on the operational components of dewatering, water supply, tailings leachates, mine wall stability, stormwater run-off, water disposal, impact on regional environment and mine closure planning. The recording of hydrogeological information is frequently overlooked during resource and reserve definition as well as during the course of mining when prime opportunity exists for the collection and collation of this data. In recent times, the exclusion of hydrogeological data has been exacerbated by use of high air pressure drill rigs that exclude water inflow. The recording of water data has been further inhibited by the use of computer coded drill logs that do not include the site geologistÆs or drillerÆs comments on drilling problems and observations associated with groundwater intersections. Geologists now infrequently directly supervise drill rigs, but visit the rig only intermittently to evaluate drilling progress. They do not see first hand drill performance characteristics at water make zones. Drill cuttings, as drill chips and cores, are now mostly logged away from the drill site so that wet sample locations, visual water flow evidence and verbal comments from the driller are not recorded. As a result, mine geologists now do not direct adequate attention to the delineation of lithologies and structures that store and transmit water. This paper provides examples of water sighting and recording techniques applicable to a mining operation. Examples are also provided where hydrogeological conditions have been disregarded with serious impact on the progress of mining. The recording of hydrogeological data should be maintained and formatted by the site geologists into a useful database for review as and when required by specialists in hydrogeology, geotechnical and mining engineering and the environment. The information can be coded by the site geologist for inclusion into the mine database. A groundwater dataset, compiled during the progress of field investigations, will save the considerable cost of re-drilling and hole re-entry testing which would otherwise be required to provide base level hydrogeological information required for progress of mining. Apart from working mine use, a hydrogeological dataset is a necessary component for planning mining closure and mine legacy conditions.

Jan 1, 2003

By E K. Chiw, S-M Jung, S M. Masuka, ika

The world reserves of high-grade iron ore have depleted necessitating the need to utilise any existing natural iron ore deposits to meet the demands of the world’s expanding economy using hydrogen in the reduction process to curb CO2 emission. These low-grade ores include iron ores with high phosphorus content. The thermodynamic conditions in the blast furnace allow for the reduction of phosphorus that readily dissolves into the molten iron. Phosphorus in the gaseous state readily dissolves into the molten iron and therefore must be removed due to its negative influence on the mechanical properties of steel. The removal of phosphorus from molten iron is difficult causing the phosphorus to concentrate in metallic iron. The aim of this study is to provide basic knowledge on the phosphorus distribution after reduction using the CO-H2 and possibly provide the optimum conditions for phosphorus partitioning into slag, increasing the probability of its removal by magnetic separation. Total porosity, pore size distribution and surface area of the pellets used were measured using a mercury pressure porosimeter. The reduction was carried out using thermogravimetric analyses (TGA). The reduction rate increased with increasing H2 and was highest when 100 per cent H2 was used. Metal elements distribution in the reduced pellet was clarified using electron probe microanalysis (EPMA) and showed that phosphorus was distributed in the same areas as Ca. More phosphorus was concentrated in slag when 50 per cent CO–50 per cent H2 was used, increasing the probability of dephosphorization using magnetic separation. The concentration of phosphorus into slag was related to the rate of reduction. Further investigations into the reduction kinetics of this ore by CO-H2 is suggested to validate these findings. Nevertheless, a comprehensive thermodynamic analysis of the reduction of phosphorus containing phases found in iron ore with carbon, CO and H2 was provided to assist in selecting the optimal reduction experimental conditions.

Sep 18, 2023