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By B Roache

Ground support installation into the face of development headings has become an accepted practice at many Australian hard rock mines. Ground support is installed in the development face to reduce personnel exposure to rockfall while conducting work tasks such as marking up, installing lifter tubes, charging, and face sampling. The ground support system installed in the face is typically friction bolts and mesh. This support system can be effective at reducing rockfall occurrence, but it also increases the cost of development per metre, in terms of capital for the ground support, jumbo and operator capital allocation and the installation time slowing each drill and blast cycle. Other issues associated with meshing and bolting the development face include management of rock bolts and mesh sheets in the fired dirt of every cut, damage to services such as vent duct, geometry issues when installing ground support onto irregular development profiles and operator error. Fibrecrete installation onto the development face for support is an option considered by many mines, but it can be difficult to manage due to the removal of visual indications of misfires and slowing the mining cycle due to the wait time for fibrecrete curing. The use of Thin Spray Liner (TSL) products in underground hard rock mines has been relatively infrequent in the past, mainly due to issues with cost, health and safety, and liner strength. Kanmantoo Mine investigated the use of TSLs for the purpose of development face support, while collecting data on the costs and practicalities associated with their use. Several TSL products were trialled and a preferred TSL product was selected for use as face support. Cost savings, drill and blast cycle timing improvements and other benefits were achieved while meeting the requirement to reduce rockfall risk.

Mar 29, 2023

By D J. Thobaven

Project financing challenges caused by declining commodity prices have heightened the need to improve project metrics such as minimising capital payback and maximising net present value (NPV). Khnaiguiyah Mining Company (KMC) recognised the need to improve early cash flows at their Khnaiguiyah zinc-copper project after initial studies showed the project could not provide the desired financial outcomes necessary to compete for investment dollars in the current market.A significant improvement to the project cash flow in early years was realised through simultaneous optimisation of cut-off grade, mining sequence and strategic stockpiling. This improvement was achieved by accelerating mining in the pits, stockpiling lower value material and feeding higher value material directly to the plant. The schedule required higher mining and stockpile capacities than the sequential mine plan although minimal change occurred in the definition of ore and waste as measured by tonnes and grade. The practicality of the strategic schedule was demonstrated by implementation in the production plan with excellent conformance.CITATION:Thobaven, D J, 2014. An application of simultaneous optimisation – improving the payback period of a zinc-copper open cut project, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By J Hutchings

An essential component to the management of any process is the measurement of key parameters, used to monitor, control, and provide the feedback necessary for improvement. This paper discusses how data collection and analysis can provide a better understanding of the blasting process, as well as additional control and improved outcomes.The drill and blast process involves the generation and use of information at a number of levels. Comparison of historical parameters and results provides a starting point for the development of ongoing blast designs and a baseline against which future results can be compared. The collection of data during implementation provides a quality assurance/quality control (QA/QC) function where potential defects (such as under-drilled or over-charged holes) can be rectified prior to firing. Actual quantities and production rates allow the development of realistic plans and schedules, rather than using inaccurate estimates and targets that lead to unscheduled changes to equipment paths. Over?the past several years there have been a number of technological advances in data collection technology. Drill monitoring instrumentation on blasthole drills provides location information and feedback on rock properties as drilling occurs. Hand held ‘data logger’ technology has also overcome the challenges of working on the bench, such that blasthole measurements can be collected and forwarded directly to the explosive truck. Mine sites are becoming wireless network-enabled allowing the seamless data transfer from the field back to the office, in near real time, as that information is collected. Great strides have also been made in the development of drill and blast software systems which are more user friendly, and yet provide far greater capability to manage the quantity of data generated. The blasting process is critical to the overall mining process and the delivery of a successful blast outcome requires that the blasting process be ‘in control’. The measurement of key parameters can provide the data with which to measure and maintain control of blasting, and allows the validation of performance improvement measures and identification of improvement opportunities.

Nov 8, 2011

By D P. Murphy, R F. Dewhirst

Traditionally closure has been seen by the Resource sector solely as a green or an environmental issue, focused primarily on the requirement to rehabilitate the site following cessation of production activities. In addition to operational, maintenance and production aspects of processing plant design, future design teams will need to take a more holistic view and consider an increasing number of sustainability issues including safety in design and cleaner production as well as closure itself. Sustainability principles being adopted by industry such as the Minerals Council of AustraliaÆs Enduring Value Framework are now broadening our understanding of closure. While issues around the closure of tailings dams and associated infrastructure have been widely studied, few investigations have looked closely at the implications of closure on the design of minerals processing plants. It is likely that design teams may be able to make a significant contribution to meeting industry objectives by adopting innovative designs which, in addition to meeting production objectives, deliver sustainable and cost effective plant closure outcomes. This presentation explores the opportunity for innovative design of mineral processing plants through the assessment of alternative closure objectives. This assessment specifically looks at current industry standards and statutory requirements, as well as potential risks and opportunities associated with each objective. Alternative design strategies to meet these objectives are discussed.

Jan 1, 2006

By E Philippa, J Vitanza, C Hawtin, B Miller

B Miller , E Philippa , C Hawtin and J Vitanza

Mar 22, 2022

EnergyAustralia is a state-owned corporation in the state of New South Wales, whose responsibility includes ownership and management of an electricity distribution network. Expansion of the high voltage distribution network in the Sydney central business district (CBD) includes the requirement to run an additional five 132 kV feeders over 1.7 km from south of the CBD to a new 132 kV substation in the northern section of the CBD. A driven tunnel is currently being excavated in Sydney sandstone beneath Darling Harbour to contain the new 132 kV feeders. Tunnel construction methods involve both roadheader and tunnel boring machine (TBM) excavation. This paper describes the design development of the cable tunnel, discusses the use of a geotechnical baseline report as an integral part of the contract documentation and provides an update of the current construction works.  

Jan 1, 2008

By B Saunders, J Carpenter

PanAust’s Phu Kham copper-gold operation (Phu Kham) in Laos is currently limited by throughput in the Semi Autogenous Grinding (SAG) mill. The ability to accurately predict SAG mill throughput (throughput) is therefore critical to accurately forecast copper and gold production. During the fourth quarter of 2016 the proportion of hard unweathered rocks in the mill feed increased, resulting in a period of lower than expected throughput. These low throughput rates prompted a study with the aim of identifying a practical solution for throughput predictions. The study identified an empirical modelling approach based on actual SAG mill throughput rates. The empirical model was then optimised by linear programming to identify the ideal feed blend of unweathered rocks to achieve a maximum SAG mill throughput.Rock strength was the initial focus of the throughput study at Phu Kham because previous studies had identified a strong link between rock strength and throughput. It was determined that there was insufficient valid data to adequately model but sufficient data to qualitatively characterise rock strength. The data identified that the weathering and lithology had a controlling influence on the rock strength. Complicating throughput predictions were operational improvements (changes to blasting and mill settings) implemented in response to the lower than expected throughput. This created uncertainty with the throughput equations. A self-learning empirical modelling method was developed to predict the throughput by incorporating fundamental rock properties with operational practices and improvements. The method is based on the proportion of mill feed with similar weathering and lithology (a proxy for comminution performance) and the actual mill throughput using the SAG mill as the analytical instrument. The modelling method simultaneously incorporated the sum and interaction of unmodelled influences including blasting, crushing and mill settings. The empirical modelling method worked at Phu Kham because the lithology and weathering has an intuitive and observable controlling influence on SAG mill throughput. The modelling method is described along with a worked example of feed blend optimisation using linear programming.CITATION:Carpenter, J and Saunders, B, 2017. Empirical mill throughput modelling and linear programming for blend optimisation at the Phu Kham copper-gold operation, Laos, in Proceedings Tenth International Mining Geology Conference 2017, pp 291–296 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By O Joneydi, J Viljoen, R Funnell

Computational Fluid Dynamics (CFD) modelling is a useful tool that can assist engineers in designing effective ventilation systems for the control of airborne dust generated during mining operations. Thistechnology can save time, effort and the costs associated with re-work or the traditional on-site experimental field trials by running desktop 3D simulations of the various proposed scenarios using state-of-the-art CFD analysis tools. Before implementing a dust management system, an understanding of the behaviour of airborne dust particles in the face zone can be achieved, which can improve the confidence in the secondary ventilation and dust management design. Usingadvanced numerical models, suitable dust extraction strategies can be foreseen, and multiple scenarios can be simulated and investigated quickly. As a case study, dry drilling operations in Kimberlite orebodies produce large quantities of fine dust which poses health and safety risks. An effective dust management system is required to achieve acceptable face conditions. A possible practical solution is a ducted exhaust ventilation system with a force fan in the face zone. This paper demonstrates how CFD analysis can be used as a tool to assist the design engineer with validating and optimising the proposed ventilation design by tracking the trajectories of different size dust particles, to determine the best equipment layout and appropriate flow rates which minimises airborne dust.

Oct 12, 2022

By H Kusumi, A Nishio, K D. Halim, Y Yun

In Japan, evaluation of rock mass is crucial in mountain tunnels that are constructed using the NATM (New Austrian Tunneling Method) to determine the support pattern that in turns determine the final support structure of the tunnel. The current evaluation method is highly dependent on the observations of on-site expert engineers that grades the rock mass in four levels across nine criteria: A. Condition of tunnel face. B. Condition of excavated surface. C. Compressive rock strength. D. Weathering. E. Spacing of discontinuity. F. Condition of discontinuity. G. Orientation of discontinuity. H. Spring water. I. Water degradation. However, in recent years, the number of said experts are decreasing rapidly due to labour shortage caused mainly by an aging population and declining birth rates. This is one of the biggest challenges that the construction sector currently faces, and this may affect the efficiency of tunnel construction projects in the future. Thus, this study proposes the implementation of a deep learning tool called the convolutional neural network (CNN) to quantitatively evaluate rock fractures on tunnel face. In addition, Gradient-weighted Class Activation Mapping (Grad-CAM) is applied to visualise CNN, as well as verify the applicability of CNN to the evaluation of rock fractures. In other words, by creating heat maps of tunnel face images, CNN is utilised to evaluate rock mass in categories that are associated with discontinuities. The CNN model is most accurate when six convolution layers, four pooling layers, and three dense layers are used. This yields an accuracy of 75.0~88.0 per cent. Thus, the CNN model is verified to be feasible method to evaluate rock fractures.

Nov 29, 2022

By M E. Watson

Minimising dilution and ore loss is an important part of ensuring profitability of a gold mining operation. White Foil open pit gold deposit is a low-grade deposit and therefore managing ore quality is a high priority. Ground movement through blasting can displace ore and waste boundaries up to 10 m from their in situ location and therefore requires stringent ore movement monitoring and adjustment. There are currently only two options for monitoring blast movement – utilising visual targets (commonly lengths of polypipe) but this has widely been replaced by electronic blast movement monitors (or BMM). Regardless of the technology used, the basic principle is to compare the pre- and post-blast locations of the targets to determine the movement of the rock mass during blasting, which is then used to determine the final location of ore and waste boundaries.The Blast Movement Technologies (BMT) BMM system has been used at White Foil since June 2014. The system has been effective and reliable during that time; however, the annual cost of using the BMM system is greater than other monitoring alternatives. As such, the open pit geology team conducted a study comparing the BMM system against the conventional polypipe technique. The objective was to quantify the profit and loss that would occur based on the ore block transformations from both methods. Eight blasts were selected where polypipes were installed in additional holes adjacent to the BMM monitoring holes. The resulting movement vectors from the respective methods were used to create post-blast ore blocks by transforming the in situ ore blocks. While polypipe is a cheaper alternative, the BMM system tracks ore and waste boundaries more effectively resulting in better quality control, enhanced ability to minimise dilution and ore loss thus maximising profit. For these eight blasts, it is calculated that the BMM system resulted in A$664 978 extra profit through a reduction of ore loss. The total cost of a yearly BMM package was recovered in the first two blasts of this study. The primary reason for the difference is that polypipe had a poor recovery rate of 32 per cent compared with 92 per cent for BMM at White Foil. Therefore, the data used to transform the ore blocks was less representative, resulting in inaccurate post-blast ore block boundaries when using polypipe.CITATION:Watson, M E, 2017. Blast movement monitors or polypipe? A study into cost-effective blast movement monitoring at White Foil gold mine, Western Australia, in Proceedings Tenth International Mining Geology Conference 2017, pp 433–440 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By G Burton, S Fityus, J Li, S Vaughan, D Payne

Daunia and Caval Ridge coal mines, owned and operated by BHP, have been co-disposing rejects and dewatered tailings within spoil dumps from the beginning of their operations in 2013 and 2014, with the purpose of minimising environmental impact and geotechnical risk. Following the recent large failures of tailings dams around the world, BHP Coal, through its Coal Tailings Program, plans to transition other coal mines to deliver “dry” tailings and produce mixed plant rejects (MPR) for inpit co-disposal. This will materially reduce future tailings dam risk exposure. Previous laboratory shear strength testing was conducted on rejects with a maximum particles size of 20 mm, and some concerns were raised that this might not represent the mechanical properties of the actual full particle size distribution (PSD) rejects. BHP was also aware that using different technologies to dewater the tailings, such as belt press filters (BPF) and solid bowl centrifuge (SBC), could produce thickened tailings which could significantly modify the physical behaviours of the MPRs, particularly the bonding between particles. Therefore, laboratory testing on both coarse rejects and mixtures of the coarse rejects and dewatered tailings (MPRs), with full PSDs, was carried out. Testing was performed using the large direct shear machine developed by the Australian Coal Association Research Program (ACARP) project C20019 in 2017, as well as a 300 mm diameter triaxial apparatus at the University of Newcastle (UoN). This paper presents details of the laboratory testing program and results for the rejects from the first studied mine of the BHP Coal Tailings Program. It compares the shear strengths measured at full scale with those tested on modified (scalped or crushed) specimens in the past; and discusses the tailings dewatering technique selection from geotechnical aspects based on the testing results, and finally presents some dump and tip head stability analysis results using the testing results.

Jul 1, 2021

By Nikaido M, Kanda Y

A rotary type separator has been developed which separates particles on the basis of their shape. This separator was applied to a particle size range of about 50 - 120 ¦m, and to our present knowledge may be the smallest size range ever to be separated. A theory of the separation is given based on the difference of an adhesive force of the particles: the adhesive force between spherical particles and plate is more powerful than that of irregular shaped particles for the same particle size. These facts have been ascertained by the measurement of an adhesive force by a centrifugal method. US and Japanese patents have been obtained on this separator, which consists of a borosilicate glass cylinder of 150 mm outside diameter, 120 mm in width, and an AC electromagnet. The samples used in this study were mixtures of spherical glass particles and non-spherical shaped glass particles. The results are summarised as follows. In the case of mixtures of spherical particles and irregular shaped particles in the weight ratio of 1:1, the spherical content of the spherical product became 70 per cent - 75 per cent, and in the case of 3:1, the content became 87 per cent - 90 per cent, as the result of one separating operation. However, for a mixture of somewhat rounded particles and irregular shaped particles of weight ratio 1:1, the rounded content varied between 58 per cent - 73 per cent. The feed rate of the particles mixtures was about 0.3 g/min. Newton's Efficiency was 20 per cent - 60 per cent. The separator may find application in shape separation of ceramic powder, metal powder or industrial diamond powder.

Jan 1, 1993

By L P. Trout, D G. Reid

PanAust Limited (PanAust) has successfully constructed and commissioned two mining operations in Lao PDR over the past decade and undertaken major studies for three new mine developments. The management of potentially acid generating mine waste and tailings in close proximity of local communities sensitive to water discharge quality have been recurring themes that have confronted PanAust’s project study, development and operational teams. Further compounding challenges, such as the effects of intense annual tropical monsoonal conditions, staging of embankment raises and regular lifting of spillway structures, integrating mine waste and tailings management into production plans and ensuring the long term stability of structures, have been addressed by implementing leading practice management solutions.A recognition of the criticality of managing the substantial business risks associated with these crucial activities led to the early establishment of a governance structure to ensure that the highest standards are embraced for planning and execution. Importantly, these are guided and monitored by a panel of highly experienced and qualified international specialists reporting directly to PanAust’s Managing Director – the Tailings Independent Review Panel. The stewardship process has been effective in identifying potential shortcomings in management systems and has led to enhanced executive commitment to risk informed designs, assurance and overall process rigour.CITATION:Trout, L P and Reid, D G, 2018. PanAust Limited’s approach to mine waste and tailings stewardship, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 135–155 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By B L. Dickson, E, M F. Lee, P A. Mikula

Computational techniques are needed to assist in the analysis and interpretation of the increasing amounts of geoscientific and mining related data and information that are routinely gathered at mine sites. New interpretation methods are needed to provide an integrated approach so as to establish relationships (cause and effect) or to be predictive about possible outcomes based on acquired data. Traditional multivariate statistical methods are often confused by variable relationships that are non-linear, data distributions that are non-normal, and by the data themselves that may contain missing values, text and both continuous and discontinuous numeric values. Modern data mining methods are available to understand the relationships within and between diverse data sets, and identify relationships or trends associated with processes, measurements and mine design parameters in mines. The self-organizing map (SOM) is a data mining approach with the advantage that all input data samples are represented as vectors in a data-space defined by the observations (variables). The SOM procedure is an exploratory analysis tool that highlights patterns and relationships. Results are internally derived, in an unsupervised fashion based on measures of vector similarity. Our SOM outputs are highly visual, which assists in understanding and illustrating the dataÆs structure and internal relationships. Two studies are presented. The first uses SOM to investigate the relationships between a range of measured and derived rock property parameters and their observed behaviours during mining. Our aim was to determine whether a SOM analysis would allow a better understanding of observed and predicted rock behaviours from their rock properties. The SOM analysis showed that there were indeed relationships between æbrittleÆ, æsugaryÆ, æslabbyÆ and æsqueezingÆ rock behaviours and a number of the input parameters. The computed SOM æstructureÆ was then used to assess the likely behaviour of unknown samples by assigning them into behavioural fields based on their measured and derived geotechnical responses. The second study was aimed at assessing whether a SOM analysis of microseismic data at the Kalgoorlie Consolidated Gold MineÆs (KCGM) Mt Charlotte mine can contribute towards understanding and potentially forecasting/minimising seismicity at the mine-design stage. The database comprised 40 sample æclustersÆ of microseismic parameters from the MS-RAP software package, which were derived from 2500 individual seismic events. The SOM analysis showed that some of the initial mining conditions are related to the seismic parameters. In each of the studies, the SOM procedures assisted in understanding the data and provided new insights. Because of its æordered vector quantisationÆ foundation, the SOM procedure is a substantial improvement over traditional statistical methods in three main areas:its ability to analyse data from disparate sources, including different data types; its ability to analyse sparse data sets with missing values; and its ability to analyse and visualise non-linear relationships within a data set.

Jan 1, 2006

By G Love, S Maher

In Victoria’s onshore Gippsland Basin, geology is driving brown coal developments, and geologists are key decision-makers. Prompted by volatile energy prices and the likelihood of a carbon constrained future, significant work has been carried out on the next generation of technologies to be applied to this giant resource. These include new-generation gasification technologies, coal conversion processes yielding products as diverse as diesel and fertiliser, drying technologies producing thermal and metallurgical coals and in situ conversion processes. However, coals aren’t coals, and brown coal available for new projects will have different quality parameters and mining economics from that currently mined.New projects are likely to be developed on coals with moisture contents averaging 60 per cent and corresponding low energy values. Whilst ash values will be low, averaging just 5 per cent (dry basis), this will at times approach 10 per cent, which is a level that would challenge the installed-generation technologies. Sulfur values will average 0.4 per cent (dry basis), but at times exceed 0.6 per cent, requiring technologies that address the potential for sulfur dioxide emissions. Whilst localised high levels of the fluxes iron (>1 per cent dry basis) and sodium (>0.3 per cent dry basis) would increase fouling of installed technologies, they may be suitable for selected next-generation technologies.Project viability for this next generation of technologies will be strongly influenced by mining cost, and geologists are playing a role in identifying higher-value coal. At its simplest, this is being achieved for open cut mines through regional, vertical strip ratio assessments, which are considered a first-order proxy for mining cost. Follow up assessments are incorporating mining and processing cost, coal quality penalties and product revenues. At a regional scale, it is informing the likely location and relative timing of future mine developments, as well as thinking around rehabilitation strategies, infrastructure and land-use planning.For deeper coal, factors like macro permeability, the ability to isolate seams from aquifers, groundwater chemistry, pressure temperature conditions, connection with groundwater recharge and in situ biota are being used as vectors to in situ coal conversion opportunities.Matching coal to the next generation of technologies has benefited from regional-scale geological studies of coal quality and mining economics, and has benefited from early engagement between geologists, technology developers and project proponents.CITATION:Maher, S and Love, G, 2014. Matching brown coal to the next generation of Latrobe Valley projects, in Proceedings Ninth International Mining Geology Conference 2014 , pp 77–84 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By P Revell, B Adair, D King, L Keeney

Grade Engineering®, integrated across the mine value chain, has a pivotal role to play in achieving step change reductions in energy and water usage in mine operations. High levels of gangue rejection in the mine can significantly improve mineral head grades and overall productivity. A highly successful example is described at the Minera San Cristóbal (MSC) operation. The nature of the mineralisation in their “intrusive” ore domains in particular has facilitated high rejection rates (75 % of the mass), with significant upgrading of metal to the “accepts” streams (equating to a 2.6 times upgrade in the intrinsic Nett Smelter Return). Results from a series of production trials have confirmed these strong upgrades, resulting in the transformation of mineralised “marginal wastes” to high grade ore feedstocks. If new approaches to more energy and water efficient comminution and separation technologies can also realise gangue rejection at finer sizes in the concentrator, then preconcentration strategies across the value chain also offer the promise of no wet tailings treatment facilities and greatly reduced volumes of waste streams. This “No Tails” strategy is discussed, along with the integrated technologies needed to realise its effect. The work suggests a pathway and insights of a sustainable future for the Minerals Industry, unconstrained by Energy and Water, along with no requirement to produce problematic disposal streams. This strategy has the potential to significantly reposition the social, environmental, financial, and regulatory context of existing and new mining opportunities.

Nov 10, 2020

Tourmaline-bearing rocks are a rare rock type of Suites 3, 4 and 5 at Broken Hill. Minor laminated plagioclase-quartz-tourmaline rocks occur in association with the quartz- magnetite rocks of Suite 3 with the greatest abundance of tourmaline-bearing rocks present in Suite 4 intimately associated with lode horizon, scheelite mineralisation and zinc mineralistion - all approximate strike equivalents of the Broken Hill Pb-Zn-Ag deposit. Bedded quartz-tourmaline rocks, tourmalinites, tourmaline-rich pelite and tourmaline-bearing lode horizon have been recorded from suite 4. The bedded tourmaline rocks rarely display cross bedding, graded bedding, slump structures and small scale intraformational breccias. Minor tourmaline-gahnite-bearing pelites are present in Suite 5. The sedimentary structures, metamorphic textures, the stratigraphic position of the tourmaline-rocks and the presence of quartz-tourmaline-gahnite-spessartine (-fluorapatite) lode rocks indicates that the mineralisation at Broken Hill and the tourmaline-rich rocks are all products of submarine exhalative hot spring systems which were most active during deposition of Suite 4 rocks. Tourmaline is chemically different from that associated with granitic activity and from other submarine exhalative tourmaline-rich rocks because the premetamorphic alteration at Broken Hill involved addition of Fe, Ti and F and subtraction of Mg - a feature reflected in the chemistry of tourmaline from Broken Hill.

Jan 1, 1983

The operations management system at Olympic Dam has evolved over a two-year period to the state described in this paper. This evolution has been driven largely by the requirements of the recent expansion of the Olympic Dam operation from three to nine million tonnes of ore per year. Such a change process demands an holistic approach to mine management and several techniques have been employed including XPAC, Mine Works Planner as well as a basic philosophy of æjust-in-timeÆ completion. The philosophies, software and tracking mechanisms for managing a large tonnage operation are described, outlining a fully integrated scheduling system from shift to shift detailed activity planning to a 20 year production plan. Moreover, the vision of production exceeding the current limit of nine million tonnes means that there are to be further developments to this state-of-the-art system in use at the Olympic Dam mine.

Jan 1, 2000

By Y Cui, G Cao, H Zong, J Zheng, J Wang, S Yue, J Zhao, B Li

The iron (Fe) concentration in nickel slag is high, making its recovery and utilisation a hot and challenging topic. In the nickel smelting process, using CaO instead of SiO2 to adjust slag’s composition, and then directly reducing Fe from the output of molten slag is a more feasible method in practice for Fe recovery in nickel slag. The adjustment of slag’s composition in the nickel smelting process will have an impact on the distribution of impurity elements such as Pb, Zn, and As. In this paper, the slag adjustment of nickel smelting process was carried out with the oxygen-enriched topblowing system. The distribution of impurity elements in the smelting products with each composition slag was conducted by using thermodynamic software. Experimental verification was performed with rich oxygen top-blowing, and the distribution characteristics of impurity elements in the smelting products were characterised to explore the differences in mineral phases of impurity elements with each smelting conditions, elucidating the distribution patterns of Pb, Zn, and As in each phase. The results indicate that after slag adjustment, impurity elements are more easily to volatilisation and removal into the gas, reducing their total concentration in slag and matte. In the slag, the existence form of Pb, Zn is changed from silicate to ferrate, and As is changed from arsenate to low-valent arsenic oxide. It is easier to decompose the impurity-containing mineral phase and remove the impurity elements in the subsequent iron extraction process.

Jun 19, 2024

By J Pearce, M Barteaux, S Pearce

The prediction of how waste materials will evolve geochemically within waste storage facilities has been the subject of hundreds of thousands of hours researched by geoscientists globally. Despite the quantity of research there are a number of significant areas of uncertainty that remain as partially resolved issues. One of the most significant issues is the applicability of scaling laboratory test results to field conditions, and the use of laboratory data for predictive calculations to determine geochemical evolution of waste materials in the field. This issue has arisen predominantly as a result of the relative paucity of field monitoring data from waste rock storage facilities (WRSFs) and the fact that laboratory test methods are not typically linked to specific field conditions; rather they are based on generic standardised methods and designed primarily to simulate accelerated weathering conditions that do not relate to field conditions in a linear manner.To address these specific issues the authors have in the last two years made significant progress in the development and deployment of advanced field monitoring equipment within numerous WRSFs. O’Kane Consultants (OKC) has previously reported the findings from data collected from these monitoring installations in a number of papers presented throughout 2013–2014. This valuable site data has subsequently been used by OKC as the basis to design and engineer advanced customisable site-specific kinetic leach columns at OKC’s geochemistry research laboratory. These columns represent an important advancement in kinetic column assessment methodology as they have been designed to replicate the field internal conditions within waste facilities.Key features of the columns include their capacity, size and technical specifications; including fully programmable solenoid-controlled air supply with variable flow and pressure control and in-line heating option, automated temperature control and monitoring, automated oxygen consumption and carbon dioxide production monitoring, and soil moisture/matric suction monitoring.This flexibility of the design not only allows for more accurate field-based assessment of pyrite oxidation rates (POR) but also assessment of the potential effectiveness of waste management options such as deposition within a reduced oxygen environment, for example, as simulations of reduced net percolation rates or oxygen ingress rates can be accommodated.CITATION:Pearce, S, Pearce, J and Barteaux, M, 2015. Advanced customisable leach columns – a new kinetic testing method to simulate site-specific conditions, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015