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By P Hunger, H Günter, F Heinicke

High pressure grinding rolls (HPGR) have been used for more than 20 years to grind iron ore pellet feed. Besides coarse comminution (crushing), where HPGR are installed upstream of the ball mill, there are numerous flow sheets where HPGR are used after ball milling and dewatering for re- or finish grinding.There is a clear growing interest in grinding of pellet feed with HPGR during the last few years. In addition to their known advantages of low specific energy consumption, high availability, low steel consumption and improved pelletising processes the lower environmental load (reduced or no water consumption) became a strong driving factor for the application of HPGR in pellet feed grinding.This growing demand increases the interest in better understanding of the HPGR grinding process with fine iron ore concentrates. One of the most important process parameters is the moisture content of the feed material which influences the performance of the HPGR enormously. The HPGR can react to fluctuations of the fresh feed properties to a certain degree by adjusting grinding force and roller speed. Nevertheless, there are limitations by the physics of the compression process and the capability of water absorption by the concentrate. The capability varies for different concentrates and different specific surface areas. This fact has to be considered during engineering of the beneficiation plant.The paper focuses on the influence of feed moisture content on the HPGR performance in view of throughput, increase of Blaine number and process stability on the basis of numerous pilot plant tests, modelling results and industrial experiences.CITATION:Heinicke, F, Günter, H and Hunger, P, 2017. Influence of feed moisture on high pressure grinding roll pellet feed grinding, in Proceedings Iron Ore 2017, pp 187–194 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

THE art of mine surveying has made very great progress in recent years, and is still advancing, perhaps faster than any other branch of surveying. The scope of the mine surveyor's duties has greatly increased, his instruments and methods have improved, the responsibility of his position is greater, and the end is not yet in sight.It might be supposed that such a steadily growing subject would have an adequate literature, but this is by no means the case and outsiders commonly judge mine surveyors by their text-books. Hardly any condemnation can be too strong for most of these books. The English books truckle to the antiquated and crude methods apparently still in use in England, and thereby largely aid in perpetuating them; they commonly in illustrative examples give the distances in fathoms, feet, and inches; they spend page after page discoursing on instruments that should have been forgotten long ago; they try to antagonize theory and practice by detailing such calculations as that a certain vein will contain 2,003.907 pounds of galena per square fathom, and then reduce this amazing quantity to hundredweights, quarters, and pounds. Nothing can be more unscientific, or, for that matter, less businesslike, than unwarranted assumptions of accuracy; it is, perhaps, the greatest curse of applied science. Here we have a calculation to thethousandth part of a pound, when there is probably an unavoidable error of two hundred pounds. What shall we say of a man who explains how to measure the depths of shafts to the hundredth part of an inch by means of short brass rods screwed together...

Jan 1, 1909

By M Dickie

During the 1980s and early 1990s low cost gold treatment plants were at the forefront of the Australian engineering and mineral processing business. This opportunity was the result of a high gold price and innovative design by emerging engineering companies in an expanding market. The low cost approach to gold plant design and project execution resulted in smaller and shorter life projects becoming viable and the multiplicity and fast track approach of the projects resulted in sharp learning curves. From the mid 1990s to the early 2000s the relatively low commodity prices and resultant reduction in minerals opportunities also resulted in innovative design in both small and large plants, albeit on a reduced scale. The innovation was associated with alleviating capital cost pressures for large capacity low-grade (eg NewcrestÆs Cadia) or small-scale (eg JubileeÆs Cosmos) projects to either improve NPV or to enable the project to be won and profitable in the competitive lump sum environment. Between 2004 and 2008 the engineering market became less competitive from an engineerÆs perspective due to the high demand for engineering services in a high price commodity market. The need for innovation remained but was driven overtly by shortages in water, power and personnel and long equipment lead times. This paper discusses some of the factors that contribute to the capital cost of a project and the scope for improving the likelihood of financing and increasing the project net present value (NPV). Case studies with recent large copper concentrator projects will be used to demonstrate how a value driven approach to project and plant layout can result in significant improvement in NPV.

Jan 1, 2009

By Neldon L. Jensen

Although ASARCO Incorporated, the only domestic producer, had terminated copper smelting operations and associated recovery of byproduct arsenic trioxide at Tacoma, WA, in 1985, it shipped small quantities of both trioxide and metal from its remaining stocks in 1986. Imports for consumption of arsenic trioxide increased significantly, owing to increased demand for arsenical wood preservatives and the decrease in domestic shipments of trioxide. Prices remained unchanged throughout the year. Development of gallium arsenide integrated circuits, important in advanced military and commercial electronics circuitry, continued to gain momentum during 1986. Domestic Data Coverage.-Shipments of small amounts of arsenic trioxide and metal from remaining stocks by Asarco were reported voluntarily to the Bureau of Mines.

Jan 1, 1988

By P G. Rutherford, A W. McOnie

A volcanic sequence is described from the Golden Cross Mine, Waihi, New Zealand. The sequence includes seven lithostratigraphic units comprising flow and pyroclastic units of Coromandel Group andesite and dacite and overlying Whitianga Group dacite and rhyolite which is intruded by the Golden Cross dacite porphyry and rhyolite dykes. The sequence is mineralised and is unconformably overlain by two post-mineral units, the lacustrine Waitekauri beds and Omahine Subgroup andesite.   Detailed structural analysis of mine data has identified four deformational events (D 1-D4) and related these to the gold-silver mineralising events. Faulting was coeval with the mineralization and directly controlled the development, localisation, style and geometry of the ore shoots. Mineralization developed in competent lithologies where dilation occurred during faulting. The Empire Fault is the master shear which controlled fluid flow. Mineralised veining developed in response to tectonic pulses occurring at slightly different stages as represented by the underground Empire vein complex and the open pit vein array. The mineralising events culminated with the deposition of barren calcite veins. Post-mineral movement along the Western Boundary fault appears to have offset the orebody.

Jan 1, 1995

By Charles H. Minott, Michael J. Markow, Robert D. Wyatt, Fred Moavenzadeh

The substantial investment in tunnels anticipated in the next twenty years has focused new attention on the economics of tunnel construction itself and on some costly problems associated with underground work: the uncertain geologic conditions, the performance and adaptability of men and equipment, and the need for quicker, more efficient excavation methods. There also exists a need to develop better ways of estimating tunnel construction. Inaccuracies in current bid estimates stem from a number of causes, among them (1) the effects of geologic conditions, which are not adequately known prior to construction, (2) the dependence of actual cost on the construction method used and on the interactions among the operations occurring underground, and (3) the reliability of tunneling equipment. Inability to estimate final costs for conventional tunneling more accurately has in turn caused difficulty in gauging the costs and benefits attributable to new tunneling technologies either under development or for which R&D programs are planned. ATTRIBUTES OF THE TUNNEL COST MODEL This paper presents a computer based Tunnel Cost Model (TCM) which quantitatively assesses the uncertainties inherent in underground work, and is detailed enough to aid in preparing estimates or bids. The model employs appropriate techniques of subjective (or "degree of belief") probability and computer simulation of tunnel construction operations to estimate distributions of total tunnel

Jan 1, 1974

Engineering education has become a matter of national concern, at last, so I would like to talk about the links between the mining industry, the universities and technological developments. The Australasian mining industry and the mining schools have collaborated closely since the first school was established in 1871 and during those years there were a series of remarkable technological developments. For example:In the late 1880s George AndersoIl Richard developed chloride leaching of gold at Mt Morgan. This made a large difference to the wealth of Mt Morgan Mining Ltd.In the mid 1890s Robert Sticht demonstrated that pyrite smelting was an economically feasible process at Mt Lyell and the wealth which came to Mt Lyell Mining Co from his outstanding work made it one of the great companies in the country.During the first 15 years of this century flotation was developed at Broken Hill and it has proved to be one of the great technological inventions of this century.In the 1920s G K Williams started his outstanding work on lead smelting and refining at Port Pirie, this was work which ultimately re-wrote the text book on lead metallurgy and established Port Pirie as the mecca for lead metallurgists.In the 1920s also Frank Stillwell, later joined by Austin Edwards, established the new science of mineragraphy at the University of Melbourne. They were both great geologists, both were superb scientists and oddly enough both were outstanding athletes.In the 1930s Dr Ian Wark, a man in the front rank of Australian scientists of any period, started his outstanding work on flotation, work which resulted in a text book which remains a leader in its field today.In the 1930s also Arnold Black at Broken Hill South Ltd picked up the work which had been done at Mt Lyell many years previously and eventually wrote the papers on hydraulic fill which demonstrated that he led the world in fill technology. What a remarkable story of achievement it was, it laid the groundwork for the great industry we have today. It was possible because the industry was well supported by outstanding university schools and I would like to talk about some of these.

Jan 1, 1989

By G. Bonnell, W. Lidkea, M. C. Bétournay, E. Edwardson

"Hydrogen fuel cells are a known technology, having been applied to stationary (e.g equipment, buildings, and power plants) and vehicle applications (e.g transit buses and space shuttles). There is currently a growing need to provide alternate power systems to diesel fuel for underground mining vehicles to improve underground air quality and reduce production costs and greenhouse gas emissions.To date, however, fuel cells have not been exposed to underground mine air and physical conditions. A testing program was carried out to provide information on the vulnerabilities of fuel cells as part of a number of proof-of-concept projects to apply hydrogen power to underground mining vehicles. The fuel cell type of choice for the industry, the proton exchange membrane, would function at the range of temperatures encountered in underground and surface operations, and use hydrogen that is stored under low pressure and risk.A small fuel cell stack was tested in a cooperative project between CANMET, the Fuelcell Propulsion Institute, Inco, the Ontario Ministry of Labour, Sandia National laboratories, and H-Power. This article will review the tests carried out to measure the effects from high humidity, mineral dust, diesel emission gasses and diesel particulate matter, as well as from shock and vibration provided to the unit in underground conditions at Inco’s 175 Orebody minesite and Stobie mine. The test results provided will show that the unit was not affected by the underground conditions; physically and electrically, the unit performed without any reduction in operation or adverse effects imposed."

Jan 1, 2005

By V. Kecojevic

The objective of this research was to establish the relationship between production, consumption and energy cost in the surface mining of bituminous coal. Specific energy sources such as diesel, gasoline, electricity, explosives and bituminous coal were considered in this study. Gain in net energy, proportion of the cost of energy consumption and total energy cost relative to total revenue of extracted coal were determined, and a new energy efficiency index and a new energy-cost ratio were established. A case study on an operating surface coal mine was carried out to demonstrate the application of the newly developed method. The results of this study can be used by the mine operators in establishing strategies for the optimization of energy production and consumption, and for reducing the cost of bituminous coal extraction.

Jan 1, 2014

By F. M. L. Mulaudzi

Behaviour studies of metal dusting processes and associated filamentous carbon formation were undertaken on Alloys 600, 601, and 800 using a simulated metal dusting environment of 25C0-70H2-5H20 (vol.%) at 650°C. These samples were studied visually and by optical microscopy, scanning electron microscopy with energy-dispersive X-ray spectroscopy (SEM-EDX), transmission electron microscopy with energy-dispersive X-ray spectroscopy (TEM-EDX) and x-ray diffraction (XRD). Visual examination and SEM surface observation showed that Alloy 800 suffered metal dusting attack at an early exposure reaction period. The coke deposit amounts increased significantly with reaction time from 168 hours to 336 hours in Alloys 600, 601, and 800. Alloy 800 showed pitting after 168 hours' exposure, and the degree of pitting increased after 336 hours. XRD showed all these alloys had a common austenitic phase, with Alloy 800 also having ferritic metal particles. Alloy 800 after 168 hours' exposure had a complex phase mixture on the surface, consisting of ferritic Fe and austenitic FeNi phases. For coke deposit, there were also Fe304, Fe3C and graphitic carbon. The existence of Fe, Ni, and Cr metal particles, and also graphitic carbon in coke deposits, was confirmed by EDX analyses.

Jan 1, 2013

By O&apos, M. W. Neill

Mini-piles have been found to be a practical, technically correct remedial underpinning method. They can be constructed in limited access areas with very little disruption. Experience indicated that mini-piles installed using a down-the-hole soil displacement hammer would be particularly effective in the "bottomless" Beaumont Clay formations in the Houston, Texas, U.S.A. area. The University of Houston Foundation Testing Facility was ideally suited to perform tests on mini-piles. The availability of extensive geotechnical data and previous pile test results was invaluable in evaluating the mini-pile test data. As expected, the mini-pile test results were consistant with test results from large sized driven piles in the same soil formation.

Jan 1, 1989

By A. B. Hazar-Yoruç

Ferrochromium produced by smelting chromite ores is an important alloying component in the steel industry. Ore, coke and fluxes are mixed and reacted in an arc furnace for a smelting process of ferrochromium. In ad-dition to this process, pre-reduction of chromite ore with carbon is an important industrial process. In all these processes, the mechanism and kinetics of reduction of chromite with carbon play an important role. In this study, the reduction of Turkish chromite ore with carbon was investigated. Chromite and carbon were ground to three different particle size groups. Chromite was mixed with carbon in stoichiometric and excess ratios. The samples were reduced under argon atmosphere at temperatures between 1,200° and 1,350°C. The formed phases and alloy compositions of reduced chromite samples were analyzed by optical microscopy, scanning electron microscope (SEM) with EDAX and X-ray diffraction analysis (XRD). Experimental results showed that the degree of reduction and the reduction rate increased with increasing temperature and decreasing particle size. The highest degree of reduction, 61.4%, was obtained at 1,350°C. The reduction took place in three stages: Stage 1: transformation of Fe3+ to Fe2+ and formation of metallic nuclei, Stage 2: formation of metallic crust around the particles and Stage 3: growth of the metallic crust and coalescence of the metallic phase.

Jan 1, 2007

Observed mineral assemblages in the Mt. Lyell copper deposit can be correlated with phase equilibrium investigations in the systems Cu-Fe-S and Fe-Zn-S. The trend of crystallization (or paragenetic sequence) of the ores is reflected in a progressive increase in the Cu: Fe and metal: sulphur ratios of the assemblages. This trend agrees with the regional zoning of the district. Tentative relationships between the paragenetic sequence, sulphur vapour pressure, and temperature are presented graphically. The absence of a suitable geological thermometer prevents precise elucidation of the range of temperatures and pressures which existed during crystallization.INTRODUCTIONRecent phase equilibrium investigations of metal-sulphur systems at the Geophysical Laboratory, Washington, D.C. provide valuable information on the stability relations of a number of important sulphide minerals. This data, when applied to natural ore deposits, may be expected to clarify two special problems which confront the ore petrologist seeking to interpret observed data in terms of a particular physical and chemical environment of ore deposition. These two problems are the sequence of formation of sulphide minerals (commonly designated the paragenetic sequence) and an elucidation of the range of temperatures and pressures which existed during crystallization. The object of this paper is to make such an interpretation of the copper mineralization of the Mt. Lyell district, Queenstown, Tasmania.The following abbreviations are used in this paper:py = pyrite, cp = chalcopyrite, en = cubanite, bn = bornite,cc = chalcocite, cv = covellite, dg = digenite, id = idaite,po = pyrrhotite, v = sulphur vapour.GEOLOGICAL SETTING AND MINERALIZATIONThe general geology of the Mt. Lyell district is well known through the recent work of Wade and Solomon (1958). The host rocks are a series of quartz-chlorite-seri-...

Jan 1, 1963

The Leigh Creek Coalfield is owned and operated by the Electricity Trust of South Australia to supply fuel to the Northern Power Station. To supply electricity at lowest cost, a costing and decision process that establishes the role of the Leigh Creek Coalfield in the overall system planning and operation is required. The costing is integrated in that it is based not just on a particular mine plan but on the wider need to supply a particular electrical demand. The detail costing has evolved over time from manual to main-frame computer to microcomputer techniques. Now there is a choice between fast consistent costs and a slower but more detailed and flexible costing.

Jan 1, 1990

Two types of low-sulphidation epithermal mineralisation may be recognised in volcanic terranes. Chalcedonic Silica- Adularia-Illite type mineralisation is most common in rhyolitic terranes, whereas Crystalline Quartz-Illite-(Adularia- Kaolinite) type mineralisation is more typically formed in andesitic terranes. A third type of epithermal mineralisation, the high sulphidation or Vuggy Silica-Alunite- Kaolinite-Illite type, is also common in andesitic terranes. Episodic violent boiling, accompanying hydraulic fracturing and hydrothermal eruptions, characteristic of geothermal systems in rhyolitic terranes, is stressed for the formation of Chalcedonic Silica mineralisation. Such boiling of deeply circulating meteoric groundwater, with some magmatic fluid contribution, provides chalcedonic veining, episodic banding and brecciation textures, adularia stability, bladed calcite, and extreme loss of H2S from the fluid to cause major gold deposition. Crystalline Quartz mineralisation is probably caused by the mixing of shallow acidic groundwater with ascending deep geothermal fluids beneath andesitic strato- volcanoes. The cooling effect, oxidation, and increased acidity, overcomes the dilution effect, and results in quartz deposition, illite (and locally kaolinite) alteration, and precipitation of metals. Extensive formation of base-metal sulphides further enhances gold deposition. Violent boiling is restricted to local structural dilation sites, potentially producing high grade "bonanza" gold mineralisation.

Jan 1, 1991

By D. Rutledge

Discrete (digital) signal processing techniques are proving to be very valuable tools for miners using the block cave method. Waveform analysis of different measured signals associated with active mining provides valuable information on production dynamics and safe operation of the mine. For example, correlation of the three-dimensional surface displacement velocity waveform and the production output waveform reveals a remarkably predictable time-varying physical process. In this paper, the authors discuss the signal processing techniques used to study these relationships, as well as the related implications for mining.

Jan 1, 2008

By M. J. Fairweather

"The development of means to maximize the selectivity between galena and sphalerite in lead zinc ores is extremely important to the lead-zinc industry. Two challenging studies recently undertaken by Cominco will be reviewed. The first required an unusually fine grind to achieve liberation between galena and sphalerite. The second contained partially altered galena which resulted in unusual early activation of sphalerite under normal flotation conditions. Means by which lead and zinc separation were optimized in these two ores will be discussed.There are two important factors in the separation of minerals by froth flotation: particle size distribution (grind) and pulp chemistry. Pulp chemistry includes a number of factors including pH, Eh, collector type and concentration, inorganic depressants, organic depressants and activators.Grind is important for two reasons. A sufficiently fine grind is required to optimize liberation. However, if the mineral dissemination is too fine, mineral selectivity in the flotation process is impaired. Due to the hydrodynamic constraints of conventional mechanical flotation cells, flotation works best over the single decade size range between 10 and 100 microns. The majority of new ores treated by Cominco until relatively recently were comparatively simple. The major factor in their treatment was defining optimum grind size. Accordingly, the focus within mineral processing at Cominco was on grind and supporting liberation studies. The relationships between grind, liberation and flotation response are intuitively easy to understand. An idealized relationship is shown in the first figure."

Jan 1, 1991

By Charles Pol Vuillier

Piling work for modification to the Charles Grimes Bridge in Melbourne, Australia required piles to be installed through 15 to 20 m thickness of very soft to soft silty clay overlying 10 m of stiff clays and sands in turn overlying siltstone. The presence of an old sewer founded at depth in the soft clays demanded that vibrations be kept to a minimum. Two pile type were used by Vibro-pile (Australia) to provide the client with the most economical piling price. The two pile types were CFA piles of 750mm diameter founded in the weathered rock and a full displacement concrete injected screw pile developed by Vibro-pile called the "Z" pile, founded on the rock. The development and features of the "Z" pile are briefly discussed, including the perceived applications and advantages of the pile type. On board instrumentation comprising a computer was used to monitor all aspects of the construction. The rig instrumentation provided an important quality control measure that gave confidence in the pile installed. Pile performance was proved on the cast in situ piles by dynamic load testing methods. Initially tests performed with a 120 kN drop hammer, which was not capable of mobilising the required loads. The performance was then satisfactorily proved by using a drop hammer of 20 tonne mass delivering blows drop heights of 1.5m. Low strain integrity tests on a number of piles were also used to confirm the structural integrity of the piles.

Jan 1, 2000

By Michael Gauna, Christopher Mark

"For decades, pillar recovery accounted for a quarter of all roof fall fatalities in underground coal mines. Studies showed that a miner on a pillar recovery section was at least three times more likely to be killed by a roof fall than other coal miners. Since 2007, however, there has been just one fatal roof fall on a pillar line. This paper describes the process that resulted in this historic achievement. It covers both the key research findings and the ways in which those insights, beginning in the early 2000s, were implemented in mining practice.One key finding was that safe pillar recovery requires both global and local stability. Global stability is addressed primarily through proper pillar design, and became a major focus after the 2007 Crandall Canyon mine disaster. But the most significant improvements resulted from detailed studies that showed that local stability, defined as roof control in the immediate work area, could be achieved with three interventions:• Leaving an engineered final stump, rather than extracting the entire pillar;• Enhancing roof bolt support, particularly in intersections, and• Increasing the use of Mobile Roof Supports (MRS)A final component was an emphasis on better management of pillar recovery operations. This included a focus on worker positioning, as well as on the pillar and lift sequences, MRS operations, and hazard identification. As retreat mines have incorporated these elements into their Roof Control Plans, it has become clear that pillar recovery is not ""inherently unsafe.""The paper concludes with a discussion of the challenges that remain, including the problems of rib falls and coal bursts.INTRODUCTIONPillar recovery has always been an integral part of underground coal mining in the US. When room-and-pillar methods are employed, large blocks of coal in the form of pillars are initially left in place to support the weight of the overburden. Unless these pillars are subsequently recovered, the coal they contain will never be mined."

Jan 1, 2016

The Detachment of Coarse, Composite Particles from Bubbles

Sep 13, 2010