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Advances in Optical Image Analysis and Textural Classification of Iron Ore Fines

Sep 13, 2010

By P Taskinen, D Lindberg

The increase in metals demand in the electrifying globe means significant growth in the smelting of copper, nickel, zinc, and lead, produced from primary sulfide sources or using sulfide mattes as the intermediates of the process chains. This means that leaner and complex mineral deposits will be evaluated as ores and are in the future traded in the commodity market for smelting and refining to pure metals. An important issue in the trend is the technology metals, like antimony, tellurium, and gallium, which exist as trace elements in sulfide ores and form no ores of their own. Their recovery becomes important in the coming decades as will be the case with growing slag amounts without use in other industries. The key is to produce environmentally acceptable slags in the smelting operations. It sets new boundary conditions to the treatment of flue dusts. This means that all material streams of smelting and refining must be re-evaluated for the deportments of the main and minority metals. In copper smelting, the recoveries of precious metals are today important for the feasibility of the custom smelters but due to low prices of many minority metals they are discarded in slag landfills. It is one of the emerging issues also in the secondary copper smelting today and once the demand grows, the same question will be faced also in the mining-beneficiation-smelting-refining chain of the primary production of nickel, zinc, and lead. The distributions of many technology metals in the copper and nickel smelting have been recently studied using methods where the chemically bound trace elements in the slag and its phases at the smelting conditions have been studied. Thus, the key data about options for process modifications and additional processing steps are piling up. Short processing routes in the metals smelting and refining are attractive due to their simplicity. At the same time, complexity of many raw materials challenges the fluxing at high oxygen partial pressures in low silica slags with high metal concentrations. The compromise between high primary recovery and safe operation is a demanding task in conditions where slag foaming outside the processing window is evident. The increase in the demand of pure nickel is challenging the raw material basis where low-grade sulfide ores are soon smelted along with nickel laterites to matte. It is a demanding task at high MgO concentrations. The low solubility of MgO in iron silicate slags requires new fluxing strategies and new smelting end points for the operation at reasonable temperatures; the direct nickel matte smelting in one-matte mode may be an option.

Aug 21, 2024

SOME notes on the works of the Electrolytic Refining and Smelting Company of Australia will no doubt be of interest to members of the Institute, more especially as much of the work is new to Australasia. As many of the members who may read this paper have not been in a position to visit works of this kind, and are consequently not thoroughly acquainted with all the operations carried on, the author has taken the liberty, in some cases, to enter into explanation which would otherwise be unnecessary. The works are situated at Port Kembla (New South Wales), about fifty miles south of Sydney, and are approachable both by rail and water. The Government has recently built a low-level jetty upwards of five hundred feet long, and intends installing at an early date an electrically operated portable crane to facilitate the handling of material to and from the boats. This will mean: a considerable reduction in the length of time that boats are laid up at the jetty. There are also under construction two breakwaters, which, when complete, will materially assist shipping operation...

Jan 1, 1910

By Crook KAW

New sedimentological and biostratigraphic data indicate that the Leron Formation in the Markham Suture Zone, Papua New Guinea (PNG) represented Pleist- ocene alluvial fan-delta deposition in shallow marine to lacustrine environments. The distribution of sedimentary regimes in the Leron Formation indicates that during collision zone evolution, various tectono-sedimentary regimes do not always track the movement of the triple-junction systematically as idealized by Crook's (1989a) model. The migration of various tectono-sedimentary regimes are also controlled and influenced by the effects of second-order geometric features of the convergent margins. Leron Formation in the Markham Valley represents late to post-collisional marine to fluvial molasse. Foraminifera indicate that the collision and concomitant suturing of the Markham valley occurred after 1.32Ma.

Jan 1, 1991

By D François-Bongarçon

The theory of sampling (TOS), and therefore representative sampling, is based on three fundamental principles: sample correctness, which handles the search for non-bias; segregation, the effects of which must be eliminated or minimised; and variance control to help achieve the desired reproducibility. After briefly reviewing these very few, albeit essential first principles of Gy’s TOS, the state-of-the-art in TOS is examined through the prism of these principles and the prospects for the future are explored, with suggestions for further research where relevant. Regarding segregation, which is currently the focus of much research, new orientations are proposed. For correctness, which takes on a major importance when it comes to sampling devices, some new, important principles that have been put forth by recent research, are described in details.CITATION:François-Bongarçon, D, 2014. State of affairs and current research trends in theory of sampling fundamentals, including segregation and correctness, in Proceedings Sampling 2014 , pp 11–16 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 29, 2014

The Autogenous Fine Grinding Kelsey Axial Displacement (KAD) Mill The marginal improvements which continue to be made to fine grinding practices have exposed the limits of conventional technologies and highlighted the need for a radically new approach. The patented autogenous Kelsey Axial Displacement (KAD) Mill design consists of a rotating spherical grinding chamber, which shares the same spherical centre as the shaft-mounted counter-rotating disc assembly. The axis of the disc assembly can be inclined to the axis of the spherical grinding chamber by pivoting the disc shaft about the common spherical centre. The inter-particle energy transfer required for breakage results from particle velocity differentials created by the discs intercepting the rotating mass. Particle size reduction is concentrated in high shear zones, which envelop the outer surface and periphery of the discs. This paper traces the development of the KAD Mill from pilot to commercial scale. Pilot work covers a range of minerals including magnetite, calcite, dolomite, barite, limestone and talc. Test results include open and closed circuit operation in wet and dry modes. Conventional milling constraints and energy consumption issues are addressed while new dimensions are added to the feed size range acceptable for wet and dry grinding to fine and ultra-fine sizes.

Sep 13, 2010

By Eggleton R. A

X-ray diffraction techniques are commonly used in the identification and quantification of fine-grained materials. A relationship exists between the size of crystals in a sample and the degree to which they diffract X-rays. The Scherrer equation relates the broadness of diffraction peaks to the size of crystals responsible for diffraction (Klug and Alexander, 1974). Relatively large crystals of the order of I - 10 ¦m strongly diffract X-rays; the diffractogram of such crystals exhibit narrow intense peaks. As the size of the crystals in a sample is reduced, diffraction peaks become broader and less intense. Crystals less than 10 nm generally exhibit broad, diffuse and low intensity peaks. Some material is so fine-grained and poorly-diffracting that X-ray patterns show very little information in a normal one-hour scan thereby necessitating very long acquisition times of up to 12 hours. The term poorly-diffracting material (PDM) was coined for such material found within the bauxite deposit of Weipa, northern Queensland (Tilley and Eggleton, 1994; 1996). Common regolith minerals such as hematite, goethite and layer silicate clays are quite commonly fine enough to possess a poorly-diffracting character. Noncrystalline and poorly crystalline Fe-Si-Al-oxyhydroxides such as allophane, opal, ferrihydrite and hisingerite, have either a nondiffracting (amorphous) or poorly-diffracting nature (Eggleton, 1987).

Jan 1, 1997

After a five year period representing the strongest resource and commodity rally ever experienced, we are now faced with a subdued recovery following the global financial crisis. This renewed economic growth will be steady but eventually attain levels that reignite export demand out of China and other emerging nations, which are now reliant on increasing domestic demand to support their economies. This backdrop of weaker share prices and less available investment capital creates a greater imperative for company management to ensure that its share price is fully valued. The mining geologist plays an important role in achieving this outcome through direct estimation of asset value (resources) but also in strongly communicating the æupsideÆ value opportunity in both mine site and adjacent brownfields exploration and an efficient and technically sound mining operation. The contribution of mining geologists to assist in conducting analyst site visits should not be underestimated, particularly with reduced analyst coverage of the resources sector and some simplification in company analysis through ranking companies on Reserve and Resource positions.

Jan 1, 2009

By F M. Weir, M Fowler

A discrete fracture network (DFN) approach involves numerical modelling that explicitly represents how defects may be spatially distributed through a rock mass. A DFN is a 3D realisation of the ‘smaller scale’, non-deterministic defects; it is not an attempt to model larger, deterministic structures that should be identified as part of an engineering geology model. The approach utilises structural data in stochastic analyses to give a range of possible models that provides a tool for visualisation and analysis of a rock mass and indicates the potential large-scale slope or tunnel performance and stability.Stochastic fracture modelling for rock mass characterisation has significantly advanced over the past 25 years. With recent improvements to field data collection and computational power, it has become recognised internationally as a valuable tool for modelling some geomechanical problems encountered when designing excavations in fractured rock masses.This paper provides an introduction to the DFN approach, particularly the necessary input parameters and derivation of these from typical structural data sources, such as boreholes or scan line mapping. Of particular importance for engineering applications is validation of the simulated fracture network and techniques for doing so are discussed here.CITATION:Weir, F M and Fowler, M, 2014. An introduction to discrete fracture network modelling and its geotechnical applications, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 435–444 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By M Korte, J McMaster, C Brent

The Barrick Osborne concentrator has gone through a number of upgrades since commissioning and has increased production from the original 119 t/h design capacity to a milling throughput of 265 t/h in 2008. This was achieved incrementally over several years, by maximising operating efficiencies, in order to minimise capital expenditure, and take advantages of economies of scale; but more importantly it was reached with no measurable loss of recovery. Osborne currently processes a blend of underground and open pit material from the nearby Trekelano deposit. Following primary/secondary crushing, the material is processed through a rod/ball mill grinding circuit ahead of rougher/scavenger flotation that produces a copper concentrate. Osborne was seeking a further increase in plant throughput of the order of 15 per cent, but at more sustainable levels of secondary crusher plant utilisation. In early 2008, Osborne contracted Metso Process Technology and Innovation (PTI) to review the entire process from run-of-mine feed to final copper concentrate. This review would be done concurrently with surveys of both the crushing/grinding and flotation circuits being performed at the same time. The outcome would be a steady-state model of the complete flow sheet allowing the crushing/grinding model to interact with the flotation circuit model, such that overall process optimisation was possible. This was to apply both by exploring the operating limits of the currently installed plant, as well as looking at the logical next stage of capital plant expansions. Surveys of the crushing and grinding circuits were conducted at the Osborne concentrator in May 2008. The main objective of the surveys was to review the potential of increasing grinding throughput whilst maintaining the flotation feed 80 per cent passing size. This would also require improving the efficiency of the crushing circuit which was already operating in excess of 80 per cent of the time. Steady-state simulations were performed using the developed circuit models to identify opportunities to increase throughput and alleviate high circulating loads in both the secondary crushing and grinding circuits. Due to operational changes, the recommendations resulting from this project were considered by Osborne but have as yet only been partially implemented.  This paper covers part A or the crushing and grinding component of the project. A separate paper discussing part B or flotation is also being presented at this conference. The results of interactive simulations between the flotation and grinding circuit models are included in part B of this paper.

Jan 1, 2009

By Brotzmann K, Turner RE, Philp DK, Rusden RC

New approaches in the last decade have led to the supplemental use of raw coal as a direct energy source in several iron and steelmaking processes. The dependence on more expensive coke and electricity is being progressively reduced. The Technology Venture of Klockner Werke and CRA has pionered several of these developments and is pushing ahead to processes for scrap melting and direct smel- ting of iron where coal is the ONLY energy source. Such complex developments depend strong- ly on the experience gained in the simpler but related processes for coal use already in operation. The longer term implications of a successful coal-based direct smelting process for the world steel industry are substantial.

Jan 1, 1986

By G Baiden

The removal of rock blockages in mining operations has long been a risky undertaking, especially in high overhead conditions. Moreover, the assessment of where to put charges and the placement of them has been difficult due to the lack of visibility and safe access to the area. Traditionally, wedging long poles with explosives on them to keep the operator at a relatively safe distance has been the tried and true method of attempting to remove the blockages. Unfortunately, this is not a perfect system as it usually takes several attempts to remove the blockage. Each successive attempt results in even more dangerous conditions for workers and/or damage to the mine due to the successively larger amounts of explosives used until the hang-up finally comes down.Over the years, different ideas have been proposed to improve this process and reduce the inherent safety risks. Some of the technologies that have been trialled include projectiles fired at the hang-up; large, cumbersome arms; and massive amounts of explosives, each of which come with their own inherent safety risks that result in dangerous situations for miners and the mine.After gaining a thorough understanding of the process, Penguin Automated Systems Inc has developed a robotic system that is capable of working in a rock blockage safely. The idea combines the latest in telerobotics technology with 3D scanning and underground geospatial positioning. The hang-up removal is performed by scanning the inside of the hang-up to rapidly develop a geospatially placed 3D model for the operator to use. The 3D model is detailed enough that the operator can attempt to pick the ‘keystone’. A blasting engineer or the operator can then determine the exact position where the explosive charge should be placed in the 3D model and thus at the actual hang-up. The operator, controlling the robotic arm, uses the 3D virtual reality model of the robot system and the actual drawpoint information model to display the location information, the arm can then reach into the hang-up to position the charge using the kinematic model of the robot system. The 3D model is used to provide views inside the hang-up so that the operator can move the arm safely and precisely. This process allows the operator to place the charge (using the 3D representation of the drawpoint) from a long distance away. As the process continues, the end of the arm drills the rock and precisely loads the explosives. The robot then returns the blasting cable to the command station, which is located in a truck at a safe distance from the blockage.This paper will review the development of the system and present the results to date.CITATION:Baiden, G, 2016. Robotic hang-up assessment and removal of rock blockages in mining operations using virtual reality for safety, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 745–754 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

The following observations on the mineral composition of the lead-zinc ores at Captain's Flat, New South Wales, are based upon the examination of a collection of specimens made during a brief visit to the mine in January, 1942, in conjunction with earlier studies of specimens and mill products, which have 'been the subject of various Mineragraphic Reports, Captain's Flat is about 35 miles south of Canberra, and is connected with the main line from Goulburn to Bombala by a branch line to Bungendore, 23 miles away from the mine.The geology of the mine has been described by Kenny and Mulholland2 and by Harper.3 The country consists of Silurian sediments, which have been invaded by a composite sill of quartz-felspar-porphyry. Both sediments and sill have been folded gently, the axial lines of the folds trending north and south. In the vicinity of the orebodies the folds are steeper, and thru,st faults are associated with the anticlines. The intense compression and shearing that accompanied the faulting has converted the adjacent porphyry to schist. The Captain's Flat orebodies occur along such a zone of shearing and faulting, on the eastern limb of a steep, north-pitching anticline. At their southern end the orebodies are enclosed in the slates underlying the porphyry, but the northerly pitch of the fold carries the slate to greater depth in the northern part of the mine, where the orebody lies beween schistose porphyry on the hanging wall and massive porphyry in the footwall.THE OREBODIESThe orebodies occur along a N.-S. strike length of 4,200 ft., and from the point of view of mining, fall into three sections: the Elliot's Section to the north, the Central Section, and the Keating's Section to the south. The Keating's Section is separated from the Central Section by 500-600 ft. of mineralised ground of so low a grade as' to be called barren, and is offset about 125 ft. to the 'east of the Central body by an oblique fault striking N.300E. Elliot's Section and the Central Section are connected by persistent veins and stringers of lead-zinc ore, but although these are...

Jan 1, 1943

The latest outcome of science is that aII bodies are composed of vibrating atoms or molecules. In almost all mineral bodies when changing from the gaseous or liquid condition to the solid, if the vibrating molecules are allowed free play, they arrange themselves in a symmetrical manner, and at a definite angle to each other: This angle varies with each system of crystallization. In a great many bodies this process may be brought about artificially, and the growth of the crystal watched. The most common method is to dissolve some substance in water or some other liquid, on slowly evaporating the liquid, the substance dissolved will solidify and the molecules will arrange themselves in their particular crystalline form.The element carbon crystallizes in two forms; as graphite in the form of a short six-sided prism', and in the diamond generally as the octohedron in the cubical system of crystallization. Orystalline bodies, as a rule, have plain faces but what is remarkable in the diamond is that in a great many cases the faces are rounded. Its great beauty as a gem when cut, and the high artificial value placed upon it by fashion, as well as its value as a cutting and boring instrument-it being the hardest body in nature-has caused many attempts to be made to form it artificially. These attempts have met with fair success as a scientific experiment, but as a commercial speculation they have been a complete failure. The most noted of these experIments was carried out by Mr. Hannay, of Glasgow.Paraffin spirit with lithium was submitted td prolonged heating in strong wrought-iron tubes securely welded. In most of the experiments the tubes exploded; but in a few cases the experiments were successful, and on cutting open the tubes small crystals of diamonds were found embedded in a black mass.Despretz produced minute diamonds under the influence of a powerful electric current from coal.

By A R. Bye

Energy comes at great cost to our world and societies and therefore we should use it wisely and optimally. Societal pressure is enforcing this and the industry must respond by being proactive.The mine-to-mill approach to integrated mine and semi-autogenous grinding (SAG) mill optimisation demonstrated that throughput gains of up to 20 per cent could be obtained through a closer match of blasted run-of-mine ore to the feed best treated by a SAG mill. Since that approach was developed, new drivers have risen to prominence including environmental costs and impact of energy, water, waste. This is set against a backdrop of reducing ore grade and increasing demand that is pushing up our impact on the environment. The new challenges demand new approaches.This paper explores the opportunities in taking traditional approaches to optimisation to new levels of two-way integration and incorporating potentials for ore upgrade into circuit design. The new mantra may be æflexible circuitsÆ û designing and building for the present and the future by allowing for the uptake of new and future technology.

Jan 1, 2009

Pipe Flow Stability of Concentrated Coal-Water Suspensions in the Presence of an Electric Field

Sep 13, 2010

By J S. Dunlop

At its most basic level, minerals project management may be broken down into a series of logical chronological phases, described in this paper as: exploration, discovery; scoping and pre-feasibility; feasibility and approval; project financing and commissioning; operation; expansion and closure. Each phase has its own peculiarities and challenges, any one of which can potentially upset the forward progress of a minerals project.Reference is made to each of these project phases based on the authorÆs many years of first-hand experience, in an attempt to identify issues within the project management spectrum where additional caution may be warranted. Left un-addressed, these issues can cause undue delays in the project timeline, ultimately delaying approval at significant project cost.Finally, reference is made to the Mine ManagerÆs Handbook recently published by the AusIMM which is an excellent project management resource, considered to be very relevant for minerals treatment plant managers, whether the context be constructing, operating, expanding or shutting down.CITATION:Dunlop, J S, 2013. Mineral project management - A perspective from four decades in the industry, in Proceedings MetPlant 2013 , pp 13-27 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By G Small, A Lazamanana, C Greet

When conducting gold leach tests on free milling gold ores which method is the best, bottle rolls or the stirred beaker test? Recently, a client requested that gold leach tests be conducted using the stirred beaker methodology. When asked why, because the laboratory was set up to conduct tests using the bottle rolls technique the reply was that the stirred beaker leach test would replicate the plant more closely. Not wishing to upset the client, the instructions were followed. However, the opportunity was taken to complete additional tests so that the two leach procedures could be compared. Further, this comparison was completed on two different gold ores as well as a number of different grinding media types.This paper provides a description of the two laboratory techniques employed, and presents the results of these parallel tests. Interestingly, the assertion that the stirred beaker methodology more closely replicated plant performance was not validated. In fact, the results obtained using this procedure were noticeably different from those observed in the plant, with lower recoveries and significantly higher cyanide consumptions. The bottle rolls test however more adequately replicated plant performance in terms of recovery and cyanide consumption. The reasons for this are discussed in the paper.CITATION:Greet, C, Lazamanana, A and Small, G, 2015. Bottle rolls versus stirred beaker leach testing – which is best?, in Proceedings MetPlant 2015, pp 188–196 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By A J. H Newell

The background and the basis for conducting a Technical Due Diligence are discussed as well as the source information, typical studies and potential limitations. Typical short comings including ‘show-stoppers’ are presented for the metallurgical area, with examples. Issues found in other areas such as geology, mining, infrastructure and financial evaluations are briefly reviewed, highlighting the input and interaction required by metallurgists with these disciplines. A checklist is provided as a guide to maximise the success of a Due Diligence as well as a check on the quality of a Feasibility Study.CITATION:Newell, A J H, 2015. Fatal flaws in technical due diligences, in Proceedings MetPlant 2015, pp 61–77 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

Undisturbed minor sedimentary structures-cross-bedding, ripplemarking, scour-and-fill, slumping-are present in most of the rock types in the Willyama Series of the Broken Hill district and in the orebodies.This indicates that there has not been any significant movement of mineral matter within or into the rocks during or after metamorphism, that the rocks have not flowed during tectonic deformation or during metamorphism, and that the ore is an original sedimentary deposit in its sedimentary position.Sedimentary processes, depositional and mechanical, are indicated to explain the deposition of sedimentary metallic minerals and their concentration into large masses. The Broken Hill orebodies show evidence of these processes.INTRODUCTIONI visited Broken Hill for one week in May, 1958, at the invitation of Mr. Haddon F. King, Director of Consolidated Zinc Pty. Ltd. He asked me to examine the rocks and orebodies in the mines and outcrops at Broken Hill for:1. Sedimentary structures that might be used to determine the facing of the banding;2. Indications of the original nature of the rocks if I considered they may have been sedimentary; and3. Indications of any possible sedimentary origin for the ores.It has been stated (Gustafson et al., 1952, p. 30) that there was no indication, in the banding, of the facing of the banding, but recently B. P. Thomson had found examples of what he had interpreted as graded bedding (personal...

Jan 1, 1959