Search Documents

By A Dal-Corobbo

Traditional acid and metalliferous drainage (AMD) wastewater treatment focuses on the iron co-precipitation/adsorption process as this is a very effective method of reducing heavy metals, including copper, lead, zinc, arsenic, etc, to parts per billion (ppb) levels in AMD wastewater streams. One of the drawbacks to this method however is the large volume of sludge produced and subsequent disposal costs for the mine site concerned.A proprietary metals treatment system called high density sludge (denoted HDS) which significantly reduces the quantity of waste generated is described in this paper. This process generates a dewatered sludge that contains in the order of 50 to 55 per cent solids. This sludge is denser than conventionally dewatered sludge, which typically contains only 20 to 30 per cent solids. This advanced process has a wide range of applications and can be easily retrofitted into existing AMD treatment systems. It has been successfully installed at several mine sites to treat AMD wastewaters. This paper discusses the high density sludge process, its benefits and provides data and operating results from pilot test installations.CITATION:Dal-Corobbo, A, 2013. High-density sludge process for treating metal bearing acid and metalliferous drainage wastewaters, in Proceedings Water in Mining 2013 , pp 217-220 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By S S. Kanchibotla, I Brunton

Most blast fragmentation models assume the rock mass properties, explosive properties and blast design variables to be constants and uniformly distributed within a blast. However, in reality all these input variables vary within a blast resulting in variation in the resulting fragmentation size distribution. A stochastic modelling approach is introduced in this paper to quantify this variation. This technique takes the input variables as statistical distributions rather than constants and through several thousand iterations, generates a statistical representation of the expected fragmentation resulting from a production blast. A case study of three production blasts from a large open pit mine are presented and the modelled fragmentation æenvelopeÆ shows good agreement with the fragmentation æenvelopeÆ estimated from Split image analysis. The various blast-related parameters influence different parts of the fragmentation distribution, eg rock strength and explosive velocity of detonation have most impact on the fines. The technique is used to identify the parameters that have the greatest influence on various size fractions. Such an analysis will be useful to direct resources to efficiently minimise the variation.

Jan 1, 2001

By A D. Pradana, D R. Pradana, Y H. Putra, Z Zulhan, T Hidayat

The high temperature processing of nickel laterite ore is currently dominated by the Rotary Kiln- Electric Furnace (RKEF) technology. The ratio of SiO2/MgO (S/M) in the ore is one of the critical parameters that determines the success of the RKEF process. Incompatible S/M ratios in the ore can cause aggressive chemical interaction between the slag and MgO refractory. The slag-refractory interaction at conditions relevant to nickel laterite ore smelting was investigated in the present study. Synthetic mixtures representing the slag compositions of nickel laterite ore smelting were prepared by mixing MgO, SiO2, Al2O3, CaO, Fe2O3, and Fe and heating the mixtures in steel containers at 1300°C under an argon atmosphere for 3 hrs. Pure MgO crucible were used as containment material in the melting process of the mixtures to represent the MgO refractory. The kinetics of the slagrefractory reaction were investigated using samples with selected initial S/M ratios of 2.0 and 3.0 (wt/wt) (with constant CaO = 3 wt per cent, Al2O3 = 5 wt per cent, FeO = 10 wt per cent) by performing melting at 1500°C in MgO crucibles for 5, 30, and 120 mins under an argon atmosphere. The effect of the S/M ratio in slag on the slag-refractory interaction was also investigated by performing melting of mixtures with different initial S/M ratios of 1.75, 2.0, 2.5, and 3.0 (wt/wt) in MgO crucibles at 1500°C for 120 mins under an argon atmosphere. After the melting process, each sample was quenched in water, mounted in resin, ground, polished, and coated. The interaction between the slags and MgO refractory was then evaluated by analysing the polished samples using a scanning electron microscope equipped with an energy dispersive spectroscopy (SEM-EDS). Thermodynamic simulations using FactSage™ 8.0 thermochemical software were performed based on the experimental slag compositions, refractory, and conditions to support the evaluation process. The results show that a higher S/M ratio in slag leads to a higher tendency for the refractory component to dissolve into the slag. A higher S/M ratio in slag also leads to an increasing extent of solid-state diffusion of iron oxide into the remaining refractory grains. The dissolution of MgO into the slag is rapid; the MgO concentration in the final slag increased by 2.4 wt per cent and 5.7 wt per cent at initial S/M ratios of 2.0 and 3.0 wt/wt, respectively, within 5 and 30 mins of the melting process.

Aug 21, 2024

By C Tickell

Achieving occupational health and environmental noise objectives is a major consideration in the planning or operational phase of resource development and industrial projects to meet the needs of the workforce and community and comply with legislative requirements. For material handling systems, ventilation plants, mobile equipment, process plants and fixed infrastructure, noise emissions need to be considered at the design phase. The preferred approach is to provide noise emission technical specifications, but in many cases this is not stipulated. An occupational noise requirement, such as ‘not to exceed 85 dBA at 1 m’, is often provided, but this will not achieve the required occupational or environmental noise objectives and may cause overly stringent requirements when they may not be needed. It should be noted that when developing the technical specification, measuring compliance needs to be taken into account as, in some cases, measuring may be very difficult or even not possible.This paper will discuss the requirements for providing an effective noise specification that ensures the environmental and occupational noise objectives are able to be achieved and that, once installed, compliance can be measured. It discusses planning such as when to set the objective, correlating the appropriate objectives for the environmental and occupational noise requirements, allowing for measurement tolerance, providing a suitable criteria and data format for the suppliers to respond to and methodology to measure compliance. Different phases of a project require different approaches to planning for noise management and these will be discussed in the paper. Examples from 35 years of industry experience will be included.CITATION:Tickell, C, 2016. Preparing effective specifications for occupational health and environmental noise objectives in mining project design and delivery, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 781–788 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Oda Y, Hashiuchi M

In the smelting section, flexible fuels such as coal or coke are used in place of heavy fuel oil in order to utilize energy sources more efficiently. Heat recovered from the off gas of the furnace has been converted by the waste heat boiler into steam, which is used for self power generation and for heating or maintaining various temperatures. The amount of the recovered steam in the smelter is currently increasing due to maximum utilization of powdered cokes. The heat source required to maintain the temperature of the electrolyte in the tank house is electric power and steam. However until recent year this steam was provided by its own heavy oil combustion type boiler in the tank house since the amount of steam consumed in heating the electrolyte is large. Though experimental work over the last few years has shown the advantages of reducing steam in the tank house by fully covering the cell, the implementation of the full cover can lead to other operating problems. However various improvements, mainly the covering of the cell with a simple device, have led to greatly reduced steam consumption. As a result, steam for the tank house is now provided by the waste heat boiler only bringing more efficient energy usage.

Jan 1, 1987

By E Nye and T Schroeter, B Muir, M Kitson, M Gonzalez, D Mares

The single track North Strathfield Rail Underpass (NSRU) consists of a dive structure either end of a 148 m long driven tunnel skewed under three live railway tracks. The tunnel is 8 m high, 9 m wide, with a horseshoe profile, excavated by full face using a road header. Ground cover varied between 2.5 m to 3.5 m. Settlements were 5 mm to 15 mm (the latter due to a dyke). A one pass synthetic fibre reinforced shotcrete lining was installed (no lattice girders or steel sets were used). A system of automated robotic total stations was used to provide real time monitoring of the rail track and associated ground formation. No disruption to train services occurred.CITATION:Gonzalez, M, Kitson, M, Mares, D, Muir, B, Nye, E and Schroeter, T, 2014. The North Strathfield Rail Underpass – driven tunnel design and construction, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 369–374 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By R O’Sullivan, D Taylor, J G. McLellan, B Miller

The Mount Isa copper deposit is located adjacent to the city of Mount Isa, Queensland, and lies within a series of Palaeoproterozoic to Mesoproterozoic Superbasins. The deposit is hosted almost entirely within the Urquhart Shale (US), a unit of the Mount Isa Group sediments and part of the Isa Superbasin. The copper mineralisation is separated into two distinct orebodies: the X41 mine (1100 and 1900 orebodies) and the Enterprise mine (3000 and 3500 orebodies). The orebodies are situated in the hanging wall of the major controlling structures, the Paroo Fault, which has juxtaposed older basement Eastern Creek Volcanics against the younger Mount Isa Group sediments cf 1655 ± 4 Ma. Conjecture remains over the exact timing of this thrust event. However, it is clear that inflections on the Paroo Fault have a close association with the orebodies and are an important structural feature in the mineralisation of the Mount Isa copper deposit.The life-of-mine is reducing steadily and new geomechanical modelling techniques were employed to target structurally controlled mineralised zones in three dimensions. Following a structural review of the mine using underground mapping, structural data and core shed observations, a conceptual 3D mine model was constructed utilising existing data modelled in MineSight®. This conceptual model included all the main lithological units and structures. The conceptual model aimed to test the effects of deformation on the main lithological and structural components of the system and attempted to highlight areas of anomalous stress and strain that may indicate a higher likelihood of fluid focusing and mineralisation potential. This project was focused on testing the latter stages of a D3 event (NE–SW compression) and D4 event (SE–NW compression), which are considered to be responsible for the current location of the mineralisation.The fully coupled 3D finite element analysis models resulted in highlighting anomalous patterns of stress and strain and subsequent fluid flow as a result of the two deformation events. The NE–SW D3 simulation provided the best correlation with the known distribution of mineralisation. This event also indicated several areas on the Paroo Fault and within the US that have potential to host further areas of mineralisation. The SE–NW D4 simulation provided less of a correlation with known mineralised zones. However, this event may have been responsible for post mineralisation re-mobilisation of copper on a relatively small scale. Areas of maximum shear strain, shear stress, volumetric strain and fluid flow correlated well with areas of minimum principal stress and provided the best overall match with known mineralised zones. Furthermore, several additional highlighted areas provide a high potential for further discovery of copper mineralisation. Recent exploration drilling north of the Enterprise mine 3000 orebody, utilising geomechanical modelling as part of the targeting criteria, intersected copper mineralisation, providing further validation of the modelling results.CITATION:McLellan, J G, O’Sullivan, R, Miller, B and Taylor, D, 2014. Geomechanical modelling of the Mount Isa copper deposit – predicting mineralisation, in Proceedings Ninth International Mining Geology Conference 2014 , pp 197–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By H Esterhuizen

The Ernest Henry Mine (EHM) in Queensland, Australia is a Sub-level Caving operation that started production below the previously mined open pit at a depth of 535m. Current Production mining has progressed to a depth of 730m, with planned production mining to extend down to at least 1000m below surface. The inclined nature and geometry of the orebody combined with geological structures provides for challenging mining conditions. Over several years, Ernest Henry Mine has introduced measures to improve outcomes based on observations, monitoring and data analysis. As mining progresses deeper, EHM will continue to proactively take steps to ensure future outcomes are anticipated and mining can continue safely and uninterrupted. The focus of this paper is on the changes in seismic- and stress-driven behaviour of the rockmass experienced at EHM, the ground control measures implemented, and the anticipated future conditions and controls required. CITATION:Esterhuizen, H, 2018. The evolution of seismicity and ground control measures at Ernest Henry Mine, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 20–41 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By S Maryati

Surface mining activities disturb large areas, produce great sediment loads and tend to be a source of water pollution if they are not managed properly. Coal mining in Indonesia has a very high risk of soil erosion because the coal mining areas are generally located in tropical areas with a high average of rainfall (4000 - 6000 mm/year) and use surface mining methods. The main factors affecting erosion risk are climate, soil type, topography, vegetation cover and management factors. Thus, the monitoring of erosion risk in mining areas is very important due to the characteristics of coal mining in Indonesia. The objective of this research is to determine the ability of satellite images (remote sensing data) and geographic information systems (GIS) to provide an accurate and up to date spatial database for the monitoring of erosion risk in surface coal mining areas using the Universal Soil Loss Equation (USLE) method.The erosion risk analysis and spatial data processing are generated by the ArcGIS 9.3 software and need several data, namely: an erosivity map, erodibility map, a slope map, vegetation index map and land management or land cover map. The erosivity map is derived from the rainfall data, whereas the erodibility map is derived from the soil map. The slope map is derived from the SRTM-DEM (Shuttle Radar Topography Mission-Digital Elevation Model) and processed using 3D analyst tools. Furthermore, the vegetation index map and land cover map are derived from a satellite image using digital image processing techniques.This preliminary study produced results that show soil erosion monitoring, which is integrated with remote sensing and GIS technologies, has great potential for producing accurate, advance, and low cost erosion risk maps in coal mining areas. This map is very important for getting spatial distributions of the erosion and useful for developing erosion management plans.

Nov 22, 2011

By P J. Cullen, B P. Banerjee, S Raval

Continuous monitoring of mining impacts on the surrounding environment is a necessary sustainability criterion. Traditional monitoring approaches such as in situ sampling and airborne and satellite-based remote sensing have several limitations. Over the past few decades, unmanned aerial vehicles (UAVs) have evolved into popular platforms for remote sensing. UAV-based remote sensing has been successfully applied in different sectors, including agriculture, forestry, urban environments and disaster management. However, the potential of UAVs for mine environmental monitoring has not yet been fully established. This paper envisages the use of UAVs and sensor systems to monitor the environment of future mines.CITATION:Banerjee, B P, Raval, S and Cullen, P J, 2015. Unmanned aerial vehicles for mine environment monitoring, in Proceedings Third International Future Mining Conference, pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By A Rantala, J Timperi and J Kaartinen, T Maksimainen, O Haavisto

"X-ray fluorescence (XRF) is the most common technique used for online slurry assaying in base metal flotation applications. Typically, assays from feed, concentrate and tailings slurries are used to monitor and control the flotation circuit, with possible additional sampling locations in other main slurry flows inside the circuit. The elemental content detection from the XRF spectrum is relatively straightforward as the spectrum contains element-specific peaks whose height corresponds to the element concentration in the sample. However, centralised XRF analysers measure the elemental concentrations line-by-line, which may increase the sampling interval for an individual line and cause unnecessary response delays, especially in large flotation plants. Reflectance spectroscopy is an emerging technique that can be used to obtain more frequent measurements from slurries. The measurement is based on the mineral-specific absorbance of light in the visible and near-infrared (VNIR) wavelength range. Due to this relatively inexpensive and simple measurement system, it is possible to conduct the measurement simultaneously in several slurry lines. However, the information contained in the VNIR spectra is more difficult to interpret as concentrations of all the minerals in the sample contribute to the measured spectrum and changes in solids content, particle size and mineralogy disturb the elemental content estimation. Therefore, frequent calibration of the measurement is required. This study presents the application of combined reflectance spectrum and XRF measurements for rapid online slurry assaying in a copper-nickel flotation plant. The XRF assays are utilised as calibration samples for the reflectance spectrum measurement, keeping the calibration model up-to-date. The rapid reflectance spectrum analysis is then used to provide an almost continuous estimate of the slurry contents, enabling further improved process monitoring and control.Citation:Haavisto, O, Maksimainen, T, Rantala, A, Timperi, J and Kaartinen, J, 2016. Reflectance Spectroscopy with X-ray Fluorescence for Rapid Online Assaying in a Copper-nickel Flotation Plant, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 85–92 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By A Parry, C Fitzmaurice

After conducting laboratory ore sorting testwork on samples of a low grade nickel ore stockpile at Western Areas’ Flying Fox nickel mine, a mobile crushing, screening and ore sorting plant was located adjacent to the stockpile. An initial two month trial of the ore sorter program proved successful and was extended to process the entire Flying Fox low grade stockpile in a further four month campaign. A total of 167 660 t of low grade ore was processed, providing highly upgraded feed trucked 26 km to the Cosmic Boy concentrator. A more than three-fold grade increase was achieved on ore sorter accepts. The moderately upgraded fines that by-passed the mobile ore sorter were also subsequently blended into plant feed. This paper describes the mineralogy of the Flying Fox low grade ore, the mobile ore sorting campaign and provides some commentary on the economic and environmental benefits achieved in the ore sorting campaign. The ore sorting campaign demonstrated the benefits of being able to utilise mobile ore sorting equipment temporarily located adjacent to sub-economic low grade stockpiles in order to effectively treat these stockpiles and produce viable plant feed.CITATION:Parry, A and Fitzmaurice, C, 2018. The upgrading of low-grade nickel ore stockpiles at Western Areas Ltd Forrestania operations, using a mobile ore sorting plant, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 541–550 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By C J. Moran

Given that the mining industry is committed to sustainable development principles and that Australia is experiencing changes to the regulatory environment that aim to modernise the water sector and encourage adoption of consistent approaches, there is a well defined need for the Australian minerals industry to develop a water accounting framework. This requires: key terms and definitions for water metrics for use in the Australian minerals industry that is consistent with the wider water sector, a suite of metrics representing key components of an operationÆs water balance, a calculation method for some of the metrics, and a reporting protocol. This paper presents the methodology that was used to derive these four components. Existing accounting frameworks were reviewed and key terms and definitions that were consistent with current requirements were proposed. A calculation methodology was developed to obtain some of the key indicators and variables that cannot be easily measured directly (water loss through evaporation is an example). The adopted terms and definitions dictated model development, with the conclusion that a systems approach was the most effective calculation process. To test the proposed definitions and calculation methodology, values for water metrics were derived for eight sites. The proposed framework and definitions could deal with the specific situations selected as case studies. The associated calculation methodology produced complete accounts at various levels. Some elements of the accounts could be directly checked against available data and simulations. The framework captured well variations in the reuse efficiencies; reuse efficiency could even vary for similar processes. It is concluded that this preliminary accounting framework provides a consistent language and metrics for quantifying and communicating water management, both at the intersection of the site with the surrounding landscape (through detailed reporting of site inputs and outputs) and within operational activities. Using this consistent framework for quantifying and documenting water use within an operation will provide a platform for compiling and comparing minerals industry water use with other sectors. This may support benchmarking activities within regions or companies and help demonstrate leadership amongst water users in water resource stewardship. The approach presented here is applicable to a wide variety of mining and processing activities, and biophysical environments, and can be adopted as the first step towards developing national water accounts for the Australian Minerals Industry.

Jan 1, 2009

By S Shafiee, N Abbate

The evaluation of mining projects requires a methodology that will give flexibility and manage the existing uncertainty within the projects. The discount cash flow (DCF) and other traditional evaluation approaches, which are widely used in evaluating a significant number of mining projects, have simply assumed that the main variables remain constant in their evaluation; elements such as discounted rate, mine life, operating cost and production rate. The DCF ignores managementÆs flexibility to adapt and reforecast and revise decisions. Real options valuation (ROV) is one of the modern evaluation methodologies that provide a tool to adapt and revise mining projects under uncertainty and future variables movements. ROV brings more variables into the evaluation model compared to DCF and assumes them as uncertain and dependent. Finally, ROV provides a range of solutions that can assist in managing this flexibility.This paper endeavours to compare ROV and DCF for mining projects comprehensively and applies these two techniques in the model. The paper shows that ROV will be inclusive of extra value in mining projects due to variables not allowed for, or even ignored, when the DCF model alone is used. One of the significant advantages of the ROV method is being able to evaluate mining projects under different scenarios from the inception of the projects. Furthermore, ROV gives the ability to evaluate the mining project while allowing for abandonment, temporary suspension, or expanding the mining project. In other words, the ROV evaluation process creates an analytical environment, which allows for optimisation of the mining plan within the mining project, as well as the ability to change the capital structure dependant on existing circumstances over the life of the project. The ROV is a new evaluation method that can add value in mining project analysis and offers opportunities to amplify gains, or to mitigate losses. This paper also discusses some of the reluctance to use ROV instead of DCF in current project evaluation.CITATION:Shafiee, S and Abbate, N, 2012. Now, this is the time for mining companies to choose - Real option valuation or discount cash flow, in Proceedings Project Evaluation 2012 , pp 225-234 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By R Battison, R Duggan, S Esen, K Henley, P Dare-Bryan

Increased catch bench crest loss has been observed in recent years at Barrick’s Cowal Gold Mine situated in central New South Wales, Australia. A project was initiated to diagnose the cause of the crest loss, and evaluate ways to limit its effect on final walls.A range of different blast measurement techniques were utilised to evaluate the progressive damage caused to catch berms by presplit, production and trim blasts. Techniques employed included; single point vibration measurement, cross-hole seismic analysis, precision berm surveys, horizontal p-wave velocity measurements, crest loss volume calculation and water level changes between blasts.Blast measurements showed that the majority of damage to the catch berm was caused by the presplit blasts, which registered vibrations greater than 700 mm/s at 5 m behind the presplit line. As a result, considerable changes were made to the blast designs after a series of computer simulations via mechanistic blast modelling (MBM). The uncharged presplit collar was increased from 2 m to 4 m, and every second hole was left uncharged. Vibration modelling using a multiple seed wave (MSW) model was used to optimise trim blast delay timing. Burden relief was changed from 16 ms/m to 27 ms/m using one hole firing per 4 ms time window, and the initiation angle was changed from shallow to steep. These changes in the presplit loading and trim timing helped reduce catch bench crest loss by 1–2 m.Trim shots using a high strength bulk emulsion explosive were also identified as contributors to berm damage after analysis of blast monitoring and MBM modelling. The modelling study resulted in the generation of alternative blast designs to minimise the crest loss, including the use of low-density/low-velocity of detonation (VOD) bulk explosive product (Flexigel™ Advantage) in trim pattern designs. This was trialled on the Northern and Eastern pit walls to evaluate the damage to catch berms on final walls. The trials demonstrated that berm vibration was reduced significantly; fragmentation was similar (or slightly blockier) compared to the fragmentation using the old blast designs; displacement of the berm was reduced, so increased catch bench widths were attained. This paper summarises the trials, and presents a summary of the crest loss to date.CITATION:Battison, R, Esen, S, Duggan, R, Henley, K and Dare-Bryan, P, 2015. Reducing crest loss at Barrick Cowal Gold Mine, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 189–202 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By C Bellia, A Maldonado, S Strong, H Baxter

This paper discusses the technical and cost benefits of alternative data collection techniques used to collect lithological information, obtain laboratory testing samples and perform in situ testing. A comparison between diamond coring and sonic coring techniques is made using data from a recent geotechnical investigation for a final pit slope cut-back. The impacts of the coring method on laboratory strength testing results, material character testing and, ultimately, the mass strength parameters and subsequent slope design adopted are compared. The sonic coring method was chosen out of necessity and enabled the collection of tube samples of a clay unit of interest as well as bulk samples for material character and geochemical testing. The sonic coring generated unexpected degradation of clastic units, while cohesive clay-dominated units were recovered well. The likelihood that disturbance due to the coring method would result in lower than expected triaxial strength results was recognised ahead of time, with surplus samples collected and single-stage triaxial strength testing undertaken. This testing compared favourably with historic three-stage testing, where sample degradation occurred during the later stages. Material character testing of fine-grained, clay-dominated units was comparable with historic diamond core testing, while grain size estimates for more clastic units tended to be finer than previous results. The use of sonic coring over non-cored methods enabled the collection of material texture data, geotechnical properties and a full suite of geochemical analyses. This provided a comprehensive understanding of the lithological and geotechnical character of the rock and soil mass. A high-confidence geotechnical model was developed. The end result was the development of a slope design that was more aggressive than was previously designed (5° steeper inter-ramp angle), which has proven to be appropriate to the conditions following excavation. Overall, sonic coring was a cost-effective means of obtaining additional geotechnical data for the site.CITATION:Baxter, H, Bellia, C, Maldonado, A and Strong, S, 2015. Case study assessing alternative data collection techniques and analysis methods to assist with geotechnical slope design, in Proceedings Iron Ore 2015, pp 419–428 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

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

MIM Holdings Limited (MIM) committed to a long-term future in copper in the Carpentaria Mineral Province in 1996 with the development of the Enterprise and Ernest Henry mines, and an upgrade of MIMsÆ copper smelter in Mount Isa, and copper refinery in Townsville. The upgrade of the copper smelter will enable the smelter to produce 250 000 tpa of copper with a single primary smelting unit, the copper Isasmelt furnace installed in 1992. The copper Isasmelt furnace currently smelts concentrate containing 145 000 tpa copper. To reduce the risk associated with the copper smelter upgrade, and shorten the ramp up time of the upgraded smelter, two high-rate trials were undertaken in 1997 to demonstrate that the copper Isasmelt furnace could, with an additional 525 tpd of tonnage oxygen, treat concentrates containing 250 000 tpa copper. During the trials the concentrate feed rate to the Isasmelt furnace was increased from its average rate of 100 tph of concentrate to 150 tph of concentrate. The increase in the capacity of the furnace was achieved by: supplementing the installed tonnage oxygen capacity of 595 tpd with an additional 300 tpd supply; reducing variability in the furnace feed rate from ¦25 per cent to less than ¦5 per cent; and reducing tramp air. The Isasmelt furnace smelted concentrate at a rate of 140 to 150 tph for four hours 25 minutes during Trial 1, and at a rate of 150 tph of concentrate for five hours and 30 minutes during Trial 2. The oxygen utilisation was 100 per cent during the trials with the process remaining under control. As a result of the development work for the trials the average treatment rate of the furnace under normal conditions increased by ten per cent.

Jan 1, 1998

By A Giyose, V Malysiak, K Davey

Batch flotation tests were conducted on a haematite-bearing Sishen iron ore slimes sample from South Africa using reverse cationic flotation. The effect of grinding on flotation performance, the flotation response of various key impurities in the sample, and the feasibility of increasing metal recovery by refloating tailings in a scavenger flotation step were investigated. The test results indicate that reverse cationic flotation is effective in rejecting impurities from the iron ore sample tested. From a head grade assaying 6.4 per cent SiO2, 2.14 per cent Al2O3, 0.402 per cent K2O, 0.082 per cent P and 0.194 per cent TiO2, the levels of impurities were reduced to 1.83 per cent SiO2, 0.88 per cent Al2O3, 0.095 per cent K2O, 0.066 per cent P and 0.174 per cent TiO2 in the final concentrate at a Fe recovery of 74 per cent. The flotation response of SiO2, Al2O3 and K2O were found to be better than that of P and TiO2. The testwork demonstrated that grinding to 80 per cent passing about 49 microns is essential for upgrading the Sishen iron ore to produce >67 per cent Fe concentrate grade. This grind size corresponds to about 80 per cent liberation of haematite from the gangue minerals. Fe recoveries up to 76 per cent were obtained by refloating the rougher tailings in a scavenger stage, with little effect on the final concentrate grade. Size-by-size Fe recovery data obtained indicated that particles below ten microns were mostly lost in the desliming stage conducted prior to flotation whilst some reported to the froth by entrainment. Some of the coarser haematite-gangue composite particles reported to the froth product by genuine flotation.

Jan 1, 2009

By G Stovpchenko, G Jianjun, L Medovar

Electroslag remelting (ESR) today and into the future, will still be the main process for producing high-quality ingots by suppressing segregation, not just refining chemical composition from impurities. This paper analyses state-of-the-art electroslag refining with a focus on ESR with consumable electrodes, and recent technology with liquid metal supply (ESR LM) in view of their refining abilities and development trends, taking into consideration that the size of the ingots required by industry continues to grow, and the composition of new materials sophisticates to withstand increasingly higher mechanical and temperature loads . The yield of suitable metal in large ingots produced by conventional casting is low due to problems of element segregation by height and crosssection. For example, conventional ingots for nuclear powerplant rotors today reach nearly 700 t in weight. Attempts to directly replace such giant ingots with big-diameter ESR ingots weighing approximately 400 t were also unsuccessful because of growing segregation. Modern ESR equipment and technologies produce 200–250 t of ingots of satisfactory quality, reaching 2.5 m in diameter, implementing the change of consumable electrodes during remelting to increase ingot length. Another way to mitigate segregation is to enlarge the smaller diameter ESR ingot by a 500– 800 mm coaxial layer to the desirable diameter by ESR in the current-supplying mould (CSM). Modelling and experiments prove that refining from impurities and non-metallic inclusions at ESR most effectively occurs at the slag bath and liquid metal pool interface because the ESR LM has provided the same desulfurisation. ESR’s special refining capabilities in CSM come from the much longer time of LM residence shown at titanium purification from hard-melting nitride inclusions that are unremovable in vacuum arc remelting (VAR) and electron beam melting (EBM). Implementation of ESR technologies in CSM, especially with LM supply, is prospective to produce heavy enlarged and hollow forging ingots with prevented development of segregation due to dividing cross-section and reducing overheat of solidifying metal.

Jun 19, 2024