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By Kershaw M. G

At the Risdon plant of the Electrolytic Zinc Company of Australasia Limited, impurities toxic to the electrolytic production of zinc metal, notably arsenic and antimony, have traditionally been coprecipitated when precipitating iron as ferric hydroxide. With the development of a new lead/zinc mine at Elura, New South Wales, it was anticipated that the concentration of impurities, particularly arsenic, in the zinc sulphide concentrates treated at Risdon would increase. This suggested that an increase in the capacity of the iron purification step in the Risdon plant would be required to cope with the higher input of these impurities.Laboratory investigations showed that the additional capacity would be achieved, either by a large increase in the amount of iron used as the "collector" in the process, or by a two-stage process. The latter approach was preferred as a increase in the amount of iron precipitated would lead to much higher operating costs and overloading of the existing equipment.In the two stage procedure, acidic iron bearing solution is added to solution feeding the first stage and most of the arsenic removed from solution when iron is precipitated from solution by neutralisation with limestone. Mter separation of the precipitated solids, acidic iron bearing solution is added to the solution, and remaining arsenic removed almost completely following neutralisation by limestone.This paper describes the laboratory and pilot plant results and the plant modifications required. Abrief account is also given of the operator training and acceptance in the use of the digital control facilities installed in the new plant.The new plant is working well and good solution purity is being maintained despite a substantial increase in the concentration of impurities in the raw materials.

Jan 1, 1990

By Nightingale RJ

A column (50 cm 4) provided with a bell charging mechanism and a rectangular perspex insert was used to investigate the inter-relationship between charging pattern, size analysis and velocity profile for a number of charging methods. It is shown that a strong correspondence exists between size distribution and velocity profile for bell charged ore and coke and that decreased coke volumes cause higher pressure drops and increased central flow in beds with "V" shaped layers. It is also shown that a bell charged mixed burden exhibits greater segregation than when it is bell charged as layers and that when uniformly charged the mixed burden shows least segregation and a virtually flat velocity profile. A relationship is derived for "V" profile charges showing the extent of central segregation with furnace size.

Jan 1, 1975

The products from beneficiation present themselves at opposite ends of the spectrum, and yet numerous synergies exist in the preparation of coking coal and hematite iron ore products for their common export markets. Returning to the coal side of the business with Anglo Coal following a five-year sojourn in WA with Hamersley Iron, has provided the opportunity for comparing and contrasting some of the key synergies of the supply chains of both bulk commodities.Comparisons include consideration of things like: resource evaluation (especially quality aspects), run-of-mine handling and preparation, beneficiation, product handling and transportation, quality assurance and customer awareness, value-in-use and impacts on iron and steelmaking, and supply chain environmental aspects.Inherent within these are several other notable contrasts including: æseamsÆ and æorebodiesÆ, rocks and minerals, rejects and tailings, oxidation and weathering, suppliers and users, and marketing and purchasing, to name but a few.This paper covers some of the more interesting of these synergies and raises some potential opportunities for sharing knowledge and innovation between the two areas of activity in the future.

Jan 1, 2005

By Brent A. D, Olsen a. H, Mayfield P. L J, Grazier P. E

Concentrates produced from MnO2 and Fe203 ore fines have been targeted as potential feedstocks for direct metallurgical processing. Prereduction of pyrolusite-rich Mn02 sands to MnO has been investigated in batch and continuous experimental bubbling fluidised beds using CO-H2 reducing gas mixtures. This process has been found to produce a high grade feedstock suitable for smelting to ferroalloys or acid digestion for chemicals production. Similarly, production of highly metallised direct reduced iron (DRI) from hematite ore fines has also been investigated in batch bubbling bed reactors. Programs to characterise the reduction kinetics, fluidisation behaviour and defluidisation phenomena for both feedstocks are currently in progress to enable optimum process conditions to be determined.

Jan 1, 1995

The recommissioning of the plant at Mary Kathleen involved several distinct phases. The previous plant process was modified significantly, the plant capacity was increased by the addition of new equipment and the exist- ing equipment was in most cases overhauled. This equipment was either reused in its original duty or relocated. Maintenance requirements after the plant was cmommissioned were high because of the amount of modified equipment and also because some old items of equipment were deliberately not overhauled during recommissioning. The equipment that was overhauled has operated reliably. However some new equipment has not been as satisfactory.

Jan 1, 1978

By B Stewart

The SRS-1200 concept came about following the recommendations from the Board of Inquiry into the 1994 Moura No 2 mine disaster with the aim of having a system to remove personnel from an unsafe environment underground via a shaft where no other means of escape is possible. It is a mobile rescue unit that utilises a winding system to operate a man cage. It can descend the cage up to 1200 m into a vertical shaft. This operation is managed from the winder control compartment located on the non-driver side at the rear of the vehicle.

May 5, 2022

By P B. Swart, P D. Erskine

Despite an increasing focus by media, communities and activists driving an elevated regulatory focus in Australia and indeed some other mining jurisdictions, the mining industry globally has had limited successful mine lease relinquishments and transfers to support a next land use.Critique from anti-mining lobbyists frequently uses the large estimates from historically abandoned mine sites to influence risk-averse regulatory reforms to improve environmental performance. The mine rehabilitation regulatory processes in Australia, and specifically in the State of Queensland, are thus largely in place to prevent mining operators from abandoning their obligations.Regulatory responses to the lack of mine rehabilitation and closure performance in the last five to ten years have primarily focussed on compliance and enforcement of rehabilitation conditions in environmental approvals. Additionally, financial assurance measures have been tightened to protect against abandonment of rehabilitation obligations by the Industry, including the Chain of Responsibility legislation (Queensland Government, 2016b) in April 2016, to hold to account those who have benefitted from mining and processing/refining projects, and then avoid their environmental obligations.CITATION:Swart, P B and Erskine, P D, 2018. Are our closure planning and regulatory processes adequate to identify, quantify and appropriately transfer residual risks after successful mine rehabilitation?, in Proceedings Life-of-Mine 2018, pp 155–158 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By Floyd J. M

The recovery of gold from refractory ores and concentrates can be achieved in a number of ways using roasting and leaching procedures. The Sirosmelt system introduces a new approach to the recovery of gold from these materials using smelting procedures. Laboratory studies were carried out to establish procedures for operating the Sirosmelt system for recovery of gold and associated valuable elements from an ore containing 17.5 g/t gold and a concentrate containing 22 g/t gold as well as substantial copper levels. Copper, iron, lead and matte were evaluated as collecting phases for the gold. The ore smelting procedure recovered 80-90% of the gold whilst smelting concentrate gave 98-99% gold recovery.

Jan 1, 1987

Some only types of bank finance are appropriate for mining development, with conventional fixed rate finance having significant limitations of flexibility. New, innovative and flexible instruments have recently been utilised within project financing packages. A strictly limited number of specialist project finance banks exists, with the necessary specialist personnel able to address project cost-competitiveness, cost and commodity forecasting, joint venture negotiations, and completion and sales undertakings. Different techniques of internal bank appraisal are applied, with the usual equity investment project valuation criteria being seldom useful for loan assessment purposes. Company attention paid to the preparation of a sensitively structured bankable presentation can prove most effective for securing development project finance. Substantial scope is possible for savings of time and money.

Jan 1, 1983

By H Kim, M J. Sun

Global steel companies are actively combating climate change by reducing carbon emissions. Traditional steel production, using the blast furnace (BF) – basic oxygen furnace (BOF) process, heavily depends on coal and emits substantial CO2. To mitigate this, companies are transitioning to the more eco-friendly DRP (direct reduction plant) – EAF (electric arc furnace) process, which lowers CO2 emissions. This study quantitatively evaluates the impact of increased hydrogen consumption on the carbon footprint of product (CFP) through an analysis of direct reduction process heat and mass balances. The study prioritises a comprehensive material balance based on mass conservation principles. The heat balance is calculated using differences in enthalpy through state energy properties, avoiding heat consumption. Validation using operational data from Hyundai Steel Dangjin works’ blast furnaces shows close alignment between calculated results and actual data, with less than 1 per cent error. This methodology facilitates a detailed analysis of the direct reduction process, offering insights into its feasibility and efficiency. Analysis of the operational impact by increasing the hydrogen ratio demonstrates reduced CO2 emissions and increased heat requirements due to the endothermic nature of hydrogen reduction, in contrast to the exothermic CO reduction. Possible solutions include raising reducing gas temperature or enhancing flow rate. The study effectively utilises designed heat and mass balances to assess material quantities and thermal balance under different operational conditions. It lays the foundation for the initial direct reduction process design, aiding in deriving and optimising operational parameters. Additionally, it provides valuable insights into the challenges of increased hydrogen, contributing to the production of greener steel by addressing these issues.

Aug 21, 2024

By E du Plessis, M Rowley, M Fallon, F Golenya, R Swanson, I Robertson

"Check sampling programs were undertaken at Barrick Australia Pacific LimitedÆs Lawlers and Plutonic mine sites in Western Australia. The programs identified that the sampling, sample preparation and assaying protocols required modification to ensure acceptable precision (reproducibility) for each gold mineralisation type. These case studies describe the processes used to identify the: inconsistent precision different types of test work programs that were conducted to quantify the appropriateness for each mineralisation type steps used to modify the protocols.The type of test work conducted included: a duplicate series heterogeneity test for particulate gold mineralisation in the Lawlers gold deposit screen fire assay test work on duplicate subsamples for arsenopyrite associated mineralisation at the Plutonic gold deposit.Each test work program required a detailed scope specifying the sample selection criteria, sample preparation and assaying steps. The aim of the test work flow chart design was to ensure the assay precision between the different particle sizes or duplicate sample pairs could be measured and calculated. In the screen fire test work the true grade of the primary sample was calculated and compared against each subsample.A high quality assay laboratory was utilised for the test work. All samples were fire assayed and the gold grade determined using a gravimetric finish. The assay results were validated and the data was analysed using tables and graphs in spreadsheets. Following data analysis a modified sample preparation and assaying protocol for each mineralisation type was designed for use by the principal assay laboratories. Following implementation of the new protocols, routine check samples were collected during the sample preparation and assaying stages to monitor the performance of the new protocol.CITATION:Fallon, M, Rowley, M, Du Plessis, E, Golenya, F, Robertson, I and Swanson, R, 2012. Confirming the sampling, sample preparation and assaying protocols used at two Yilgarn gold deposits, in Proceedings Sampling 2012, pp 47-62 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 21, 2012

By Saint-Smith J. C

The anode, tank house and wire bar plant and operations are described with particular reference to those features of design and methods which are characteristic of this refinery at its inception.Reference is also made to auxiliary equipment, transport and materials handling facilities.The work of commissioning the plant late in 1959 is discussed and comment is made on the organisation of construction and origin of the equipment.LOCATION OF PLANTThe site chosen for the copper refinery is on level ground adjacent to the junction of the Mount Isa and the main north-south railway lines at Stuart near Townsville, Queensland. Blister for refining is received by rail from Mount Isa. Refined products are taken 10 miles by road to Townsville Harbour for shipment to other Australian ports or overseas, or despatched by rail direct from the plant.Adequate room for expansion was provided to cover copper refining and any associated industry. The layout of future extensions was planned and space reserved for them before detailing the original units of the main refinery.The initial plant also provides convenient storage facilities and is laid out to derive the greatest benefit from prevailing northerly breezes during the humid tropical summer.As far as possible, the working areas are located so that the prevailing winds cool them as they traverse the buildings.These factors are of very great importance since this is believed to be the only copper refinery in the tropics operating with all white labour and in any case the Company set out to provide the best possible conditions for its operating personnel.

Jan 1, 1961

By Richardson F. A

Techniques for flotation optimisation were investigated at Cobar [lines Pty:Ltd., in anticipation of the proposed installation of a computer and on-stream analysis. Successful laboratory and pilot plant tests for flotation performance optimisation using the Simplex Evolutionary Operation Technique (Simplex) lead to a full scale plant test using this method. The index developed for" Simplex response evaluation of flotation performance was based on metallurgical and economic criteria. This index was further modified to minimise the effect of head grade fluctuations. The test program was carried out on one of two parallel copper flotation circuits to allow comparison with normal "manual" operating control, and was conducted for thirty eight shifts. Results from the test section operating under Simplex direction were superior to those obtained using normal "manual" operating techniques and demonstrated the use of the Simplex Evolutionary Operation Technique as a method of reducing reagent consumption in flotation but, at the same time, maintaining satisfactory metallurgical performance. Experience in the use of the technique indicated the need for modifications to the rules of Simplex operations. Modifications were proposed, tested and appeared satisfactory.

Jan 1, 1973

Minerals similar to the indicator minerals used in kimberlite exploration are widespread in the Cainozoic alkali basalts of north Queensland. Magnesian ilmenite, pyrope garnet, chrome diopside, chrome spinel, phlogopite and zircon were recovered from most of the localities examined. The occurrence of these minerals creates significant problems when indicator minerals are used for diamond exploration. Basaltic ilmenite is visually similar to kimberlitic ilmenite. Untransported grains are rounded and have pitted surfaces. Basaltic ilmenite grains often have exsolution lamellae and reaction rims of titanomagnetite. Although kimberlitic and basaltic ilmenite are chemically similar, basaltic ilmenite grains are usually less magnesian than their kimberlitic counterparts. Basaltic ilmenite contains very little Cr203. Pyrope garnet occurs as megacrysts and in a variety of xenolith lithologies in north Queensland basalts. Most basaltic garnet is Cr-poor and comparable with kimberlitic garnet from Groups 3 and 5 of Dawson and Stephens (1975). Wine-purple, chrome-bearing garnet is common in kimberlite but rare in basalt.

Jan 1, 1984

By K Sommerville

BHP Billiton’s Area C iron ore operation has been in production since 2003. During 2010, below water table mining in the Marra Mamba formation commenced and dewatered ore has been successfully processed through the plant.The ability to mine below water table material increases reserves. Pits can be dewatered using a combination of ex-pit and in-pit bores. Critically it is important to allow suffi cient lead time to dewater. For Area C, in-pit bores yield the most water which presents challenges in every day operations when mining around bores. Operationally there are steep learning curves in obtaining equipment, training personnel and setting up infrastructure. Core risks include lifting, refuelling and maintaining gensets. The pipework, extraction and re-establishment work can be very manual.The challenges include blasting, mining, stockpiling, processing, water balance and disposal. Maximising up time on bores whilst minimising impacts to blast practices have evolved. Blast practices now align bores to the edge of patterns. Protecting bores have evolved from stemming bores with rock and re-drilling to using gas bags which require no drills. Based on moisture and material properties, mining of dewatered material can be categorised into three groups:1. normal,2. sheeting, and3. sheeting and top loading.Ore can go straight to the plant ore to drying pads where it takes between one and three months to drain.Stock management of these piles is important to ensure efficiency of the plant. Rules have been established for blending wet material to maintain feed capacity and some modifications to plants have been made. Dewatering of pits poses a challenge for water use. Initially turkey’s nests were established to capture water and use for dust suppression. As water abstraction has increased methods of management include using exhausted pits for storage and evaporators. Managed Aquifer recharge and use in potable water are being considered. An over arching coordination of the capacity and use are required.Important elements in dewatering include:• capacity models,• capital,• long to short planning,• day to day coordination, and • water level monitoring and balances. Success in dewatering requires a cross function team working towards a common goal. *This is an abstract only. No paper was provided for this abstract.*

Jul 11, 2011

By Sullivan T. D, Lohe E. M

Geological structure is one of the main controls on ground conditions within mining. It has a significant impact on the mining conditions and productivity of coal mines within the Sydney - Bowen Basin. The three main types of faults common to this region, normal, reverse and strike-slip systems, each present distinct challenges to mining. These systems effect a wide range of geotechnical and mining conditions within the mines. These include coal quality, strata stability, goat and caving behaviour, productivity and maintenance schedules of mining equipment, mine design and mine-site stress fields. A better understanding of the regional, local and mine-scale structural setting, timing relationships of structural events and the mechanisms of fault formation will greatly aid industry's push for greater productivity and competitiveness.

Jan 1, 1991

By J Szymanski, Y Hu

Excavation engineering involves complex processes for primary and secondary extraction of materials. The shovel excavators bear varying mechanical energy input and stress loading across the working bench during excavation. These varying mechanical energy input and stress loading effects cause significant wear and tear and fatigue failure in equipment components. These effects further result in unplanned downtimes, reduced efficiency and high production costs. In addition, the mechanical and electrical control systems must be operated in efficient profiles to generate maximum outputs and efficiency from these excavators. Efficient technologies are therefore required to solve these problems in order to reduce production costs and increase efficiency. In this paper, the authors develop a rigorous simulator for a hydraulic shovel in a surface mining environment. The finite element model is used to capture the stress profile within the shovel components during excavation, such as, the bucket, stick and boom assemblies. The profiles are classified into normal, critical and extreme ranges, with appropriate corrective measures to avoid extreme loading conditions. The loading capability of shovel excavators can be examined by assessing its structural strength against all possible maximum loads working on the equipment. The dynamic model is used to define efficient profiles of the critical structural components of hydraulic shovels during digging operation. This assessment is used to locate the maximum possible loads and the critical sections of the structures. The method presented in this paper forms the basis for developing comprehensive simulator models for efficient shovel operations in constrained mining environments.

Jan 1, 2003

By Martins V, Dunne R

A re-evaluation of the Hampton Boulder prospect in the early eighties resulted in a decision to proceed with mine development in December 1985. A 500 000 tpa gold treatment plant was commissioned in December 1986. The treatment facility was expanded to 1 600 000 tpa in July 1988. A tailings treatment plant to improve recoveries from harder gold bearing sulphide ores was built in December 1990. The development of an underground mine in 1991 meant that a source of sand for backfill was required. A sands plant to fulfil this requirement was commissioned during November 1991.As of June 1992 a total of 7 710 487 tonnes of ore have been treated through the New Celebration gold plant. Total gold production from inception of the new mine until June 1992 is 545 470 ounces obtained at an average recovery of 90.1 per cent from an average gold head grade of 2.4 g/t. The combined quoted ore reserves at the end of December 1991 was 14Mt grading 1.8 g/t gold

Jan 1, 1992

By D Lalor, N Goodman

The increasing demand for batteries is resulting in the development of large-scale projects for the production of key battery metals such as nickel and vanadium. Several of these projects plan to extract the battery metals from the ore via chemical roasting, leaving large volumes of waste iron oxides after fuming and/or leaching of the battery metals. These iron oxide wastes can be smelted in a HIsmelt furnace using biochar as the reductant, to produce clean, green pig iron with net zero carbon emissions. This green pig iron can then be added to basic oxygen or electric arc steelmaking furnaces to produce green, net zero carbon, steel. This paper describes the flow sheets and the economics for potential projects producing green pig iron via HIsmelt using waste iron oxides from nickel and vanadium production plants.

Sep 18, 2023

Detailed cash flow forecasts have always been almost essential as a basis for judging the viability of proposed new mining projects. In recent years attempts have been made explicitly to take account, in such forecasts, of the uncertainties surrounding the assumptions upon which they are based. With the risk analysis approach, Monte Carlo simulation of the cash flows indicates in probability terms the combined effect of these uncertain basic assumptions. While the use of risk analysis has been widely discussed, few specific applications to real projects have been reported. The application of such an analysis in the feasibility study of the large new Deelkraal gold mine presently being established on the Far West Witwatersrand gold fields by the Gold Fields Group in South Africa is described in the paper. The paper also indicates how one of the major sources of uncertainty, namely the gold content of the ore, can be`quantified in objective probability terms. This feature distinguishes the application fran other published accounts in which only subjective probability assessments have been utilised.

Jan 1, 1977