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By T A. Carter

In 2010 Agnew Gold Mine (AGM) struggled to produce the required tonnages from its stopes. The longhole rises used to create void in stopes were unreliable and often failed to gain the designed rise height. The number of firings per stope was having an adverse impact on the ground conditions at the stope brows, impeding stope productivity.Through practical experimentation with longhole drill rigs, box hole rigs and development drill rigs as well as trialling new methods in conjunction with reviewing drill hole data, drill hole accuracy was observed to be an issue on-site. Innovative dragging methods such as the reverse drag, combined with a slope instead of a vertical face on the rear of stopes, have improved dragging and a reduction of firings per stope, enabling larger production blasts.The methods trialled and subsequently implemented at AGM have facilitated the mine achieving budgeted targets for six consecutive quarters. This paper documents the use of these methods in a key lode of AGM’s operations to improve drill and blast practices in order to achieve production targets.CITATION:Carter, T A, 2014. Improving production drilling and blasting in the Kim South orebody at Agnew Gold Mine, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 251–258 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By Y B. Kang, Y J. Park

Ti-added ultra-low carbon (ULC) steel is produced by adding Al and Ti during the secondary refining process to deoxidise molten steel and to bind C and N which are detrimental to the deep drawing quality of the steel product. However, the production of Ti-added ULC steel faces challenges, including submerged entry nozzle clogging and surface defects on cold rolled coils. The troubles were often attributed to ‘Al-Ti complex inclusions’ in the molten steel. However, the evolution of oxide inclusions including their stability has been still unclear. In the present study, the evolution of these inclusions in Ti-added ULC steel was investigated by phase diagram measurement, CALPHAD thermodynamic modelling, high-temperature stability test for the oxides, and observation of transient behaviour of oxide inclusions in the steel. The phase diagram of the Al-Ti-O system was elucidated with an emphasis on oxygen potential, which significantly controls the stability of the oxides. CALPHAD thermodynamic models and a self-consistent database were developed. The transient behaviour of Al-Ti complex inclusions in Ti-added ULC steel was observed in situ using a confocal scanning laser microscope. This was additionally validated by the new thermodynamic model. The equilibrium phases of the oxide inclusions were investigated using a high-temperature resistance furnace, and were analysed using a secondary electron microscope, energy dispersive spectrometer, and electron back-scattered diffraction. By considering the morphology and crystal structure of these inclusions, the evolution of Al-Ti oxide inclusions was elucidated. Various behaviour of Al-Ti inclusions and their influence on steel cleanliness are discussed.

Aug 21, 2024

By O A. Aladejebi, S Mitra, T Singh, D O’Dea, S, T Honey

Granulation of the iron ore blend and the additives is the foremost step in the agglomeration of iron ore fines to achieve a permeable bed during sintering, which is crucial for sinter productivity. This study investigated the granulation of four types of blends to determine the impact of granulation on bed permeability. The blends were granulated in a rotating drum at various moisture contents and their JPU permeability was measured at each moisture content in a permeability pot (diameter 95 mm and height 500 mm) at various flow rates. Several independent experiments were carried out to investigate the changes in permeability when mixtures of different particle size range (-1 mm and +1 mm) were introduced into a packed bed with a larger particle size range (-6.3 mm to +4.0 mm). The results revealed that the addition of particles in the -1 mm size range had a more pronounced negative impact on permeability compared to particles in the +1 mm size range. This can be attributed to the relatively higher energy losses (mainly inertial) associated with the presence of -1 mm particles in the mixture. The findings were used to quantify the granulation process based on the -1 mm particle size fraction in the granulated mix and their utilisation (denoted by UI-1 mm). For achieving optimal permeability in a specific blend, it was found that a UI-1 mm (utility index of -1 mm particle size) ranging from 0.82 to 0.92 was required. However, exceeding a UI-1 mm value of 0.95 resulted in weaker granules prone to deformation and led to decreased bed permeability. The study also showed that the UI-1 mm was highly dependent on the water addition per kg of -1 mm in dry feed and suggested adding ~80 to 110 mL of water per kg of -1 mm in dry feed to attain the best possible permeability. Additionally, the research proposed a mechanism involving the melting of granules at high temperatures and highlighted the influence of -1 mm particles on bed permeability during the sintering process.

Sep 18, 2023

By Gillies A. D S

The active history of foreign investment in the mining industry has resulted in Australia emerging as a major world producer of a range of mineral commodities. The current contribution to the national economy represented by mineral production and export revenues would not have occurred without both capital and expertise provided by foreign investors in the past. The initial foreign investment has led to the formation of Australian majority owned and controlled multi-national mining groups such as BHP Limited, CRA Limited and MIM Holdings Limited. These Australian companies, and others, are playing a significant part as foreign investors in the mining industries of Papua New Guinea (PNG) and Indonesia. The study examines issues of importance in foreign investment in each of the countries. It concludes that in Indonesia, the nationalisation of the Dutch mining industry in 1957 did much to deter foreign investment. The remarkable degree of policy stability brought about by the Contract of Works system since 1967 has gone a long way to restoring that confidence. The level of investment in the Indonesian mining sector is steadily increasing. Its attraction to Australian investors is a combination of policy stability, favourable fiscal terms, geological prospectivity for a range of commodities and proximity to Asian markets to the north. PNG has a stable policy regime which until recently has been free from political interference at the administrative level. As such, investors were developing confidence in the system and investment was progressively increasing as evidenced by growing exploration expenditures up to 1988. The 1989 Bougainville revolution caused a re-assessment of PNG's investment and country risk. The recent Mt Kare incident has further raised concerns over the government's ability to guarantee internal security. Foreign investors are faced with weighing concerns with the risks of operation in PNG against the undoubted geological prospectivity of the country. The fiscal regimes of Australia, Indonesia and PNG were compared by means of a simulated open pit gold mine in each country. The effect of taxation is examined by reference to the relative change in project internal rates of return (IRR). The comparison of the relative differences between pre-tax and post-tax IRRs provides a measure of the relative attractiveness of each fiscal regime.

Jan 1, 1994

By T Suwa, S Ishida, J Xue, S Fuchida, H Shimada, Y Aoki, C Tokoro

Pyrite depression with prolonged pre-conditioning treatment in high salinity water has attracted much of researchers’ interest in recent years considering the increased utilisation of multiple stage flotation, closed water circuits, clay minerals, and sea water in flotation plants. In this study, the role of calcium (Ca)/magnesium (Mg) precipitates in stabilising the dissociative ferric hydroxy-xanthate (FHX), and its effect on modifying the balance of hydrophobic/hydrophilic species on the pyrite surface were primarily investigated. The total amount of extractable Fe-bearing species on pyrite concentrates and tailings after floatability test was quantitively determined using ethylenediaminetetraacetic acid (EDTA) extraction tests combined with inductively coupled plasma optical emission spectroscopy (ICP-OES). A more evident accumulation of extracted-Fe in pyrite concentrates rather than it in pyrite tailings was observed at both pH 9 and 10.5 when pyrite was pre-conditioned in Ca/Mg-bearing solutions for 360 min. Fourier transform infrared (FTIR) spectroscopy showed the main xanthate derivatives changed from di-xanthogen (1155 cm-1 ) to FHX (1167 cm-1 ) on the oxidised pyrite samples that were preconditioned in Ca/Mg-bearing solutions. Scanning electron microscopy-energy dispersive spectrometry (SEM-EDS) suggested the preferential accumulation of FHX upon secondary Ca/Mg-bearing precipitates as reflected by the higher Fe/S ratio together with the decrease of O element herein after xanthate conditioning. Although the hydrophilic secondary Ca/Mg/Fe-bearing minerals on the pyrite surface generally deteriorate pyrite’s floatability, the upper section of these secondary hydrophilic aggregates is partially covered by FHX alongside with further multilayer-adsorbed di-xanthogen. The precipitated Ca/Mg-bearing precipitates promotes the immobilisation of dissociated FHX derived from the reaction among iron oxyhydroxides and xanthate anions upon the localised secondary Ca/Mg/Fe-bearing minerals via acid–base complexation. Therefore, this phenomenon alleviates the hydrophilic modification of secondary Ca/Mg/Fe-bearing minerals to pyrite considering the immobilised FHX upon localised precipitates shows a slight hydrophobicity, and meanwhile, the upper FHX benefits the multilayer adsorption of di-xanthogen via the interaction among their inner hydrophobic alkyl chains.

Aug 24, 2022

By S Gomez-Hernandez, P D. Munro

Filtered dry stack tailing storage facilities offer many advantages over thickened tailing storage facilities and yet, most of the mining companies still prefer the latter.Some of the advantages of filtered dry stack tailing storage facilities are: increased structural integrity of the tailing storage facility, which is even more critical in areas of high seismicity, close to nearby communities or environmentally sensitive areas; maximised water recovery which is particularly important in arid environments where water is an extremely valuable resource and its supply is regulated; optimised recovery of valuable metals in the process water, avoiding high cyanide concentration going to detoxification (both aspects haven’t been emphasised enough in technical papers on this subject); optimised space to store the tailings in mountainous regions; minimised elevation of embankment height, providing a safe option to store the tailings in places where there is limited area available; simplified license approval to operate where the tailing facility is a big issue; and avoidance of potential problems with nearby communities.Filtered dry stack tailing storage facilities have some disadvantages such as: technology limitations in operations that process high throughputs (eg >50 000 tpd) as they require many filters resulting in high maintenance and operating costs; higher capital cost; low efficiency in the filtration process, particularly in ores with high clay content increasing operating problems and capital cost; the new technology risk with possible debottlenecking issues and a longer time to achieve the design throughput; and the need to treat larger water flow rates when the water balance is negative.This paper analyses: the operating practices of Mexican gold and silver operations using filtered dry stacking storage facilities; implementation issues, advantages and disadvantages; quantifiable reductions in gold and silver losses and actual lower detoxification cost; and current trends to use filtered dry stacking storage facilities in new projects. The data gathered raises questions about (a) the need to collect data on tailings filterability, and; (b) reducing the current high operating cost of tailings filtration.CITATION:Espinosa-Gomez, R, Gomez-Hernandez, S and Munro, P D, 2018. Tailing filtration practices in Mexican gold and silver mines, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 275–282 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By E L. Kotova

Completeness of extraction of a mineral from ore depends on many reasons. First of all it is a function of quality of disintegration of ore. It is supposed that two basic factors: character of structure and texture of the ore aggregate and a disintegration technique influence the quality of the mineral aggregate destruction, æopeningÆ of its internal boundaries. In this paper, the problem of technological mineralogy from the point of view of genesis of the mineral aggregate, its typomorphical features and methods of their quantitative description are discussed. The purpose of this research is to provide information for technologists. It should enable the development of a rational flexible scheme of disintegration of ore with full extraction of a useful component, without its losses and without unnecessary expenses of energy. For achievement of this purpose the mineralogical information should have ½number and a measure+. By the authors, the technique of the quantitative analysis of fabric of the mineral aggregate based on several models û thermodynamic, crystallographic and geometrical is offered and discussed. The leading role in the quantitative analysis of a fabric of ore belongs to internal bounders. But internal bounders of the mineral aggregate by bounders or faces of the mineral individuals or mineral grains are formed. Their geometry, orientation concerning own (mineral grain) crystallographic lattices, orientation and distribution in space of the ore aggregate are proportional to the energy accumulated at origin and the further growth. These characteristics of mineral individuals are consequences of conditions of their formation. That is why the named triad of models is used. From crystallography it is known that faces of different stability and mobility form borders of crystals. They also contain different quantity of energy. Mineral grains also are faceted by different energy borders. They form intergrowths with each other according to a principle of balance or unbalance. That is why in addition to traditional parameters of the description of a fabric of the mineral aggregate (mode and grainmetrical composition) it is necessary to add new. For example, length and the square of intergrowthing bounders of mineral individuals differentiated (in couples), crystallographic symbols of borders, their roughness and so forth. Consequently, solving a problem of the geometrical characteristic of borders, we define also its power characteristic. In this paper experience of application of our technology in studying ores of one of deposits of Urals Mountains is presented. For realisation of these types of the analysis technologies of measurement, the program of calculation and the devices, which are carrying out the analysis in a semi-automatic mode, are possessed. Structure and texture of rock or ore aggregate reflect its formation and transformation conditions. It is important to understand that disintegration energy cannot be more than aggregation energy, the energy of intergrowths formation. The square and orientation of mineral individuals borders vary at pressures or stresses of mineral aggregate evolution. These phenomena often cause selective increase in the square of borders at constant average grain size, ie the granulation. Granulation presents the increase in quantity of mineral individuals while their modal share remains constant. At the same time their average mineral grains size. Some mineral individuals increase in size at increased pressure. When lithostatic or lateral pressure drops the majority of mineral grains increases in volume at the cost of intersticial or film solutions or fine grains. These are only special examples of the ontogenesis of the mineral aggregate. They illustrate our statement that all changes in fabric of the mineral aggregate are a reaction on varying external (ie geological) conditions. It is possible to consider that structurisation of totality of mineral individuals as a whole is a process of adaptation of the mineral aggregate, which forms and exists in varying force and energy fields. Differential and integrated geometry of total internal boundaries of the mineral aggregate serves as adaptation mechanism of the mineral grains system. Boundaries form intergrowths of the mineral aggregate. Thus, it is possible to consider that the most informative parameters of the stereometric analysis for restoration of the ontogenesis of the mineral aggregate are the following. First of all, it is a quantitative estimation of the volumetric shape of the ore mineral in crystallographic coordinates, a total area of borders of all mineral grains in the aggregate, the specific square of their boundaries, the specific square of intergrowth boundaries of the ore mineral separately with grains of each minerals of the matrix of the mineral aggregate as well as traditional grainsmetric and modal composition. For realisation of these types of the analysis technologies of measurement, the program of calculation and the devices that are carrying out the analysis in a semi-automatic mode are possessed.

Jan 1, 2008

By T N. Little

This paper is concerned with the influence of engineering geology on design of Wall Control Blasts. In the Introduction, the Blast Management Framework and the Blast Design Requirements classification system (previously developed by the author) is drawn upon to set the context. Blasting objective for all wall control blasts involves both profile and damage control. Four classes of approaches for blast design are outlined and briefly discussed. Five distinct wall control blasting techniques are summarised. The general relationship between geology and blast design is explored in the paper. Influence of geology on pre-split and post-split design and blasting direction is highlighted. Wall damage modelling from the closest row of blastholes is also introduced using the Analytical Damage Model (ADM). The relationship of rock properties and explosive selection and in particular the Mach wave generation is introduced to assist blast designer in this regard. Finally a Conceptual Model that relates vibration, damage and rock mass condition has been presented along with some applications that have been undertaken by the developer. Eight conclusions have been formulated based on extensive work in this area and the current study.

Jun 22, 2022

By V Chamberlain, M Appeah Owusu, M Aniawu-Asumakah, A Anyimadu, R Peattie

This is an integrated geology and plant improvement study arising from the heterogeneity seen in mineralogy and gold association at the Obuasi goldmine in Ghana. This heterogeneity comes from the two ore types mined, the one being a sulphide ore, mainly composed of gold-bearing arsenopyrites. This gold is refractory and exhibits a strong relationship between gold and As. The other is quartz veins, that are high grade and free milling. The installed circuit consists of comminution – Gravity -Flotation – BIOX – Leaching and Adsorption processes. The opportunity tested involved improved mass pull - related flotation recovery of Au in the Sulphide stream; while balancing the need for a minimum Sulphide grade for the Bio-oxidation process, occasioned by the removal of 25 to 30 % of the (quartz) stream through preconcentration by Ore sorting. The current circuit is then utilized for the sulphide route, while a smaller grind-gravity circuit is utilised for the quartz stream in a relatively inexpensive way, followed by a common leaching and adsorption circuit. Added advantages of the strategy includes faster recovery of gold from the quartz stream, with less consumption of reagents from saving on flotation and BIOX reagents for this stream. Screening and Ore sorting was successfully tested with laser technology, achieving over 98% separation of quarts (containing up to 40% of the gold). The plant schedule of Ore, the suggested circuit design for the Ore sorting, the results obtained from the different flotation regimes, as well as consequent financial modelling have been presented and discussed in this paper. This illustrates the opportunity that arises out of a detailed analysis of material versus installed circuits, even if the gains in pre-concentration do not necessarily involve rejection of gangue material. An added opportunity for future investigation, briefly discussed but not tested in this paper, would be to maintain current mass pulls but with increase in throughput (by the space created by the sorted material). This will of course require the mining ability. It could also add LOM value by altering the cut-off grade.

Nov 10, 2020

By B Green

With a focus on safe productive tonnes, there has been an ongoing drive to increase the productivity of the mining fleet across BHP Billiton. In response, a team from the Iron Ore business was formed to review all aspects of the end-to-end drill and blast process and to challenge conventional practices that limit production efficiency. As a result of the outcomes of this work, a number of initiatives were identified to improve operational practices that have also delivered significant cost savings.One such initiative was to increase pattern size to a minimum of 1 Mt where practicable, thereby creating ‘megablast’ as a new standard across all mines. To achieve blasts of this size, the team had to overcome the complex problem of integrating wall control into the megablasts.With traditional blasting techniques, the key strategy, which is also historically inefficient but was thought to be integral to having stable, safe walls, was to utilise the trim blasting/modified production blasts technique (ie narrow blasts along the pit wall designed to ‘peel off’ the material while minimising the effects of vibration and charge confinement on wall integrity).Small traditional trim patterns comprise three to four rows of production holes and one or two rows of batter/buffer holes of reduced diameter that require the firing face to be completely exposed before blasting. This is an extremely slow process that requires a lot of resources for very little tonnage while adding additional expense to the final cost per tonne.This paper will show how the megablast approach was developed to control damaging vibration and confinement effects, flyrock and fragmentation while having the largest possible blast that includes wall control. The new practice is based on a theory that involves the initiation point and control row being the second row of holes from the pit wall itself. Adjusted charges in vented batter and buffer holes help to achieve an optimal toe design, and at the same time create a zone of broken ground that absorbs damaging vibrations formed by the attached production blast of any size, whether it is a straight wall or a multi-angled complex pit shell design.Using the new style of blasting has allowed an increase in the size of the patterns from an average of 300 kt to over 1 Mt whilst maintaining pit wall integrity. Case studies will be presented showing drill, charge and tie-in designs with the presentation having additional blast videos, including overall shots of blasts and in-close footage of what happens behind the blast at the crest of the planned catchment berm.The paper will also demonstrate the flow-on effect of using this style of blasting to reduce operational costs associated with other downstream processes, such as the reduced requirements for pattern preparation, an increase in productive digging, reduced maintenance costs and a decrease in fuel burn for equipment.CITATION:Green, B, 2015. Megablasts – enabling technologies in BHP Billiton Iron Ore, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 599–606 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By M Spiteri, S Woth, J Caratti, K Henley

Blasting is an essentially violent process aimed to disrupt and loosen rock for productive excavation and downstream processing. Dilution of the orebody to some extent is the inevitable result, particularly in narrow vein gold mines. A small change in gold recovery is usually a strong lever on revenue generation. As a result blast designs are carefully engineered to both minimise and control the direction of rock movement. Traditionally blast designs in gold mines have used the minimum powder factor that will still permit rock excavation. This now conflicts with the recent industry trend to optimise the total process flowsheet from the mine to the mill. Numerous mines have achieved success in reducing total mining cost by increasing powder factors. Not only is explosive energy cheaper than mechanical comminution energy requirements, the increased blasting effect may deliver benefits across all downstream processes of digging, hauling, crushing and milling. Kalgoorlie Consolidated Gold Mines (KCGM) Fimiston operation is the largest gold mine in Australia, located in the heart of the Kalgoorlie Goldfields. Blast dilution has been reduced at KCGM by managing location of blast boundaries and by firing along strike to choked faces. Significant economies of scale have resulted from application of a bulk mining methods. The bench height of 10 m is the largest in the Western Australian Goldfields, and is typically mined in a single pass with large face shovels. Recent increases in production rates in both the mine and mill has been partly attributed to a 30 per cent increase in powder factor. KCGM then examined the benefit of a further 18 per cent increase in powder factor to 1.0 kg/BCM. A concern though was the impact of very high powder factors resulting in excessive blast movement and subsequently ore dilution. This was the subject of a project conducted with Orica Explosives. OricaÆsDMC(Distinct Motion Code) blast model was applied to understand the effect of not just further increases in powder factor but also blast geometry and explosive type. The modeling work demonstrated that high powder factors may be applied with minimal increase in ore dilution provided the combination of blast geometry and explosive type is optimised. These results are currently being implemented to achieve further reductions in total mining costs without a significant impact on recovery.

Jan 1, 2001

In considering the organization of research, it is necessary to know just what research is, what objects are in mind when setting out to conduct research, and what are the functional units which are required to enable a coordinated effort in research to proceed.The dictionary defines research in the following terms: Laborious and patient search, as for truth, diligent inquiry or examination in seeking facts or principles; inquiry, scrutiny; to search or examine with continued care; to seek diligently; to search again; to examine anew.This is, of course, simply a formal definition, but the reference to "labour", "patience" and "diligence" should be noted.The following quotation from an answer to the question "What is Research?", published recently in a technical journal, puts some life into the formal definition:- Essentially, it (Research) is nothing but a state of mind a friendly, welcoming attitude toward change. Going out to look for a change instead of waiting for it to come. Research, for practical men, is an effort to do things better... The research state of mind can apply to anything: personal affairs or any kind of business, big or little. It is the problem-solving mind as contrasted with the let-well-enough-alone mind . . . It is the "to-morrow" mind instead of the "yesterday" mind. Note the statements that: Essentially, it (Research) is nothing but a state of mind, and the research state of mind can apply to anything.

Jan 1, 1950

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

By C R. Ure

To substantially reduce, if not eliminate, carbon dioxide (CO₂) emissions from ironmaking it is necessary to convert from blast furnace (BF) ironmaking using coking coal as the reductant to direct reduction (DR) ironmaking using hydrogen (H₂) and green electricity. Currently, almost all natural gas (NG) based direct reduced iron (DRI) production utilises iron oxide pellets in shaft furnaces, as opposed to fines in fluidised beds. Also, these pellets are ordinarily produced from high-grade magnetite concentrate, rather than hematite and goethite with typically higher gangue contents. The use of high-grade magnetite concentrate is driven by the preference to melt DRI in conventional electric arc furnaces (EAFs), thereby avoiding the basic oxygen furnace (BOF) for making crude steel (CS). However, in replacing BF with DR ironmaking it is not economically feasible to source enough high-grade magnetite to replace the lower grade hematite and goethite currently consumed. That is not to say that hematite and goethite, or even low-grade magnetite, cannot be used in DR ironmaking. However, their higher gangue content, resulting in higher slag production, requires that the EAF producing CS be replaced with a submerged arc furnace (SAF) that will produce pig iron (PI) for the BOF as does the BF. Here, critical issues to be addressed are, what are the technicalities in replacing high-grade magnetite concentrate with hematite and goethite and NG with H₂ in DRI pellet production and melting? This paper summarises certain relevant published information on DRI pellet research, test work and production together with relevant information on Pilbara ores. It attempts to illustrate the inter- relationship of composition and processing conditions on DRI pellet properties. It is intended to serve as a rudimentary guide to understanding the complexities of formulation, testing, evaluation, production and goethite and offer insight into this challenge.

Sep 18, 2023

By J K. Claflin, S R. La Brooy, A M. Claflin

Rotary kilns have been in service in the gold industry to regenerate carbon for 65 years. At the time oxide ores with gold head grades of 8 to 10 g/t were being treated. Carbon could be regenerated adequately at 650°C and solution losses were less than 1%. Forty years ago, research indicated that heavily fouled carbon from flotation circuits had to be held at 750 to 850°C for ten to twenty minutes for full reactivation (Avraamides and La Brooy, 1987), gold head grades were typically 5 g/t and solution losses typically 0.02 ppm – still less than 1%. In 2017 it was determined (Claflin et al., 2017) that a residence time of less than 1 minute at 750°C can be adequate to reactivate carbon fouled with organics sufficiently to achieve 0.005 ppm solution losses in a flotation tailings leach plant.With the potential for discovery head grades to drop below 0.6 g/t, solution losses of 0.02 ppm represent over 3% loss. Tight operation of the whole carbon circuit is required to keep gold solution losses below 1% going forward.There are alternatives to a rotary carbon kiln, e.g. vertical kilns of which the Minfurn, Rintoul and Combustion Air kilns are examples. The alternative kilns can be heated using electrical heating elements, induction, and microwave. These kilns can operate successfully under the right conditions, however, they are almost exclusively for small carbon throughputs and are not suitable for the large carbon advance rates that are required to process low head grade ore deposits. Large throughput carbon kilns are are almost exclusively fossil fuel fired rotary kilns and the subject of this paper. In the view of the principal author, a fossil fuel fired vertical carbon kiln is preferred to a rotary kiln, however, it is not currently used in the industry.Thermal regeneration of activated carbon has a major impact on gold recovery in the carbon circuit. The carbon kiln and associated equipment constitute 3 to 5% of the capital cost for an oxide processing plant and up to 10% of the capital cost if flotation tails are leached. Despite the capital cost and impact on recovery, the carbon kiln is often poorly selected, operated and maintained.Six years ago Ausenco embarked on the Carbon Kiln Initiative to reduce solution gold losses. This body of knowledge has been published in a series of papers culminating in this paper on how to:1. Select a kiln appropriate for the flowsheet;2. Maintain the kiln to achieve design operation; and3. Operate the kiln to minimise costs and maximise reactivation.CITATION:Claflin, J K, La Brooy, S R and Claflin, A M, 2018. Carbon kiln selection, operation and maintenance, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 251–274 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

On 15 August 1998 the first section of the PUTRA LRT system was opened to the public as a free service prior to official commencement of revenue service on 1 September 1998. It is a remarkable achievement to open a highly advanced medium capacity urban railway scheme in four years after the outline concept began. Even more remarkable is the implementation of the next stage which is the underground section planned to be operational in mid-1999. The decision to build the first underground railway in any major urban centre is a technical challenge. The PUTRA LRT System can be likened to Hong Kong when the initial MTR system began in the 1970s and Singapore MRT in the 1980s. Prior to the PUTRA railway very little bored tunnelling had been undertaken in Kuala Lumpur. A few shallow sewer tunnels had been built but the main experience of tunnelling in Malaysia had been for water, hydroelectric and road tunnels usually through granite formations. The ground conditions in Kuala Lumpur were known mainly from experience of piled foundations and occasional deep excavations. The suitability and likely difficulties to be experienced during bored tunnelling could only be theoretically predicted. In both Hong Kong and Singapore, government owned corporations were set up to implement the scheme, but in Kuala Lumpur the whole project has been undertaken by a private company PUTRA, a wholly owned subsidiary of Renong Berhad.

Jan 1, 1999

By M Berner, N A. Sifferlinger, E Fimbinger

Today, the advance rate of underground roadway development by drill and blast operation is limited by the need to ventilate the toxic blast fumes after each cycle. In deep mines this usually is only possible during shift changes when the related mine sections are free of persons. This results in roadway development advance rates of 4 m per shift, or 12 m per day. For long roadways this is a limiting factor in mining development in deep mines. Companies like EPIROC, KOMATSU, ROBBINS and SANDVIK are making serious R&D efforts to disc-cutting mobile miners to overcome this bottleneck. However, today, the achieved advance rates are less than 12 m per day in hard rock. If we achieve full robotisation and/or teleoperation from a safe place for drill and blast operation of an underground roadway development section, we could eliminate this bottleneck. Poisonous blasting fumes do not affect robots and machines as long as these fumes do not create aggressive acids. If we can keep the blast fumes isolated in the roadway development section for the shift until the next ventilation opportunity (eg shift change or designated ventilation times), we can do the drill and blast cycle more often in a shift, which will significantly speed up the advance rate. This requires robotisation of all work steps in the section: surveying, drilling, charging of explosives, blasting, loading and transporting material, roof support, installation of infrastructure etc. Also, cache storage for the material is needed. Special care for the ventilation system to keep the blasting fumes under control in the section is necessary. The paper discusses the aspects needed to achieve this robotisation and the related technical and operational tasks.

Sep 1, 2024

By M S. Fenzel

Increased environmental regulations and pressures have created changing and new demands for tailings management strategies in a variety of mining applications. Critical among these items is the disposal of tailings as the pursuit of increased yields and lower costs have driven the application of different process technologies. With a number of technologies having a niche application focus, the belt filter press has been utilised for decades as a cost-effective and versatile option for dewatering different types of mineral tailings and other waste process streams. One of the critical advantages of the belt filter press is the technology’s ability to adapt and work in numerous plant designs, operating conditions and applications. As permitting and disposal options have become more stringent, plant designers, operators and equipment suppliers must develop comprehensive and site-specific economic, design and process evaluation techniques to ensure proper equipment selection and system design for belt filter presses or any other dewatering technologies. This paper will explore these techniques in relation to belt filter presses (with reference to other technologies) in a variety of different applications, along with other considerations to ensure a successful tailings dewatering system and disposal design. Summaries of equipment performance characteristics, operating and maintenance strategies and optimisation techniques will also be addressed in conjunction with the belt filter press’s adaptability to different plant designs and the resulting tailings characteristics.CITATION:Fenzel, M S, 2015. Analysis and adaptability of belt filter presses and other technologies for tailings dewatering over a range of mineral processes, plant designs, conditions, regions and operating philosophies, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 35–44 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By A Parbhakar-Fox, B G. Lottermoser, N Fox

"Determining the deportment of economic and environmentally significant elements in sulfidic mine materials (eg ore, gangue and waste) requires the use of advanced microanalytical techniques, including electron microprobe analysis (EMPA) and laser ablation inductively coupled plasma mass spectrometry (LA-ICPMS). Sulfidic boulders were sampled from an acid rock drainage impacted ephemeral stream adjacent to historical copper-silver workings at Baal Gammon, northern Queensland. The abundance and deportment of a range of trace elements and precious metals were analysed in these samples. Whilst many of these elements represent a potential environmental risk if leached from sulfidic rocks into streams in the surficial environment, significantly some of these elements (eg In, Sb and Co) represent specialised metals that are currently considered to be in critical supply.Sulfidic waste rock material at Baal Gammon is dominated by chalcopyrite, arsenopyrite, pyrrhotite and pyrite. Microanalytical investigations revealed that chalcopyrite contains significant quantities of In, Sn, Ag and Zn either substituted directly into the crystal lattice or occurring as discrete sphalerite and stannite inclusions. Arsenopyrite, which may comprise more than 50 per cent of some boulders, is notably enriched in Sb, Co and Ni but also contains inclusions of sphalerite, chalcopyrite and stannite. In contrast, pyrrhotite contains no trace elements of economic significance, but instead represents a likely contributor to acid generation during oxidation in the surficial environment. Trace metals (eg In, Sb, Co, Ni, Zn) are liberated during sulfide oxidation of these boulders in the surficial environment, generating a metal-rich, low-pH leachate.Fe-oxides precipitated as rinds on the surface of these boulders under low pH conditions also contain abundant As, Bi, Sn, Cu and Zn. Abandoned or historical mines represent potential sources of metalliferous drainage that poses potential environmental risks to water and habitats. However, sulfide-rich historical waste rock, stockpiles and processed waste (eg tailings) at abandoned mines may also represent significant sources of critical (eg indium) or other significant metals (eg Sn) that if liberated economically could improve environmental conditions in and around abandoned and historical mines.CITATION:Fox, N, Parbhakar-Fox, A and Lottermoser, B G, 2016. Critical and Deleterious Metal Deportment in Sulfidic Waste Rocks, Baal Gammon, North Queensland, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 173–182 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By G DeschOnes, M Fulton

The Eleonore property (James Bay district of Northern QuTbec), owned by Goldcorp, hosts gold within stockworks of quartz-tourmaline-arsenopyrite veins and veinlets contained within microcline (potassic alteration) and brown tourmaline replacement zones. The preliminary investigation to recover gold from drill core samples showed that flotation followed by ultra-fine grinding and cyanidation is the preferred option. Ultra-fine grinding is used to liberate gold finely disseminated in sulfides. The flotation concentrate used in the investigation had a P80 of 11 ¦ and contained 75.5 g/t Au, 5.0 g/t Ag, 10.3 per cent S, 0.07 per cent Cu and traces of antimony (0.03 per cent). The mineralogical characterisation showed the presence of 65 per cent gangue minerals, 23 per cent pyrrhotite (hexagonal), 9.6 per cent arsenopyrite, 2.2 per cent pyrite and 0.08 per cent chalcopyrite with trace amounts of galena (0.05 per cent) and sphalerite (0.03 per cent). Gold was in the form of native gold and electrum. A straight cyanidation conducted at pH 11.0, DO of 3 - 5 ppm, 2000 ppm NaCN, 20¦C and for 72 hours extracted 97.0 per cent Au and consumed 31.5 kg/t NaCN. The equilibrium was reached within 24 hours. Increasing the dissolved oxygen to 16 ppm reduced the consumption of cyanide to 22.0 kg/t with 96.7 per cent Au extraction. A 16-hour pretreatment with 2.0 kg/t lead nitrate, followed by a 24-hour cyanidation reduced the cyanide consumption to 6.0 kg/t with a gold extraction of 97.5 per cent. Increasing the lead nitrate addition to 6.0 kg/t reduced the cyanide consumption to 1.2 kg/t by passivating the surface of pyrrhotite. The gold extraction remained at 97.0 per cent. It was possible to decrease the concentration of cyanide to 800 ppm NaCN without compromising gold extraction. The associated cyanide consumption was 1.2 kg/t NaCN. The passivation of gold grains was an issue when the cyanide concentration was decreased to 550 ppm NaCN. The gold extraction decreased to 92.2 per cent. The average lime addition for all the tests was 7.4 kg/t and the average silver extraction was 80 per cent. Efficient cyanidation of an ultra-fine sulfide concentrate with only 800 ppm NaCN represents an advance in leaching of ultra-fine sulfide concentrates. The high addition of lead nitrate would certainly make cyanide destruction easier; consequently reducing the effluent treatment costs and making possible to meet the discharge regulations criteria.CITATION:DeschOnes, G and Fulton, M, 2013. Design of a leaching strategy to extract gold from Eleonore Mine ultra-fine sulfide concentrate, in Proceedings World Gold 2013 , pp 71-78 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013