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BHP is the world's largest copper concentrate producer with production from mines at Escondida (Chile), Ok Tedi (Papua New Guinea), and Island Copper (Canada). The entire concentrate production is further processed into refined copper by third-party smelters around the world. In anticipation of an expansion in the global copper concentrate production capacity and a corresponding increase in treatment and refining charges by copper smelters, BHP has continuously evaluated various opportunities for downstream copper processing. An expansion in the Escondida mine production, combined with BHP's interest in processing some of its concentrate production on-shore in Chile, ultimately resulted in the development of the Escondida Leach Process. This process was specifically developed for higher grade concentrates, such as from Escondida. An ammoniacal lixiviant and air are used under ambient conditions to leach less than one-half of the contained copper values. After solid-liquid separation, the solution is subjected to solvent extraction regenerating the ammoniacal lixiviant and the copper loaded organic phase is stripped in spent electrolyte returned from the electrowinning plant where ultra-high quality SX-EW copper is produced. The solid leach residue can, if required, be upgraded by flotation to produce a high-grade copper concentrate with improved fuel values and a pyrite tail for disposal. After an 18-month bench and pilot plant scale program and an engineering feasibility study, Minera Escondida Limitada decided to build an 80 000 tonnes of copper per year facility near Antofagasta, Chile. The installed investment cost amounted to around $160 million. The plant went into commercial production in November 1994 and better than 99.9995 per cent Cu cathodes were produced right from the start. BHP believes that the process and the commercial plant are an excellent example of a novel approach advancing the science of copper metallurgy in harmony with present demands for environmentally sound processes and high quality products.

Jan 1, 1995

By Hermulheim W

In the Federal Republic of Germany hard coal is mined underground only. The coal mines reach down to 1 500 m deep, recently having an average depth of 900 m. The commonly used winning system is long- wall mining with face lengths up to 250 in. The gate roads, which separate the seam into single panels, have an average length of one kilometre with a cross- section up to 20 m2. These single entries are usually supported by yielding steel arches. The installation of steel arches can hardly be mechanized. The choice of heavier support, caused by increasing depth and roadway cross-section, results in high cost for labour and material in gate roads. Furthermore, the heavy steel arch is acci- dent-prone, not only during installation but also during transportation and ship- ment. Rock bolts combined with a suitable lagging offer a way of mechanizing support work in headings. The aim is to decrease cost and to increase mine safety and pro- ductivity. Over the last ten years, 50 km of gate roads have been reinforced by a combination of rock bolts and weld mesh. Nevertheless, there are still differing opinions on the feasibility of rock bolting in gate roads. In Germany a long tradition and experience with steel arch support exists, whereas the function of an anchorage is a closed book to miners, preventing this new technique from spreading more quickly. Advantages and shortcomings of both steel arch support and rock bolting are compared. The experience with rock bolting up to now is reported. Possible improve- monts arm discussed.

Jan 1, 1986

By Petersen V, Potke W, Polthier K

The paper reviews some of the aerodynamic factors in the blast furnace process and outlines the areas requiring further study. Detailed discussion is given to the pressure drop in both the dry and the wet zone of the furnace and an optimum coke size is suggested for minimum pressure drop. The effect of various charging sequences on the distribution of the gas in the furnace shaft is treated and notes on stack injection included. Flow phenomena limiting blast furnace output and the influence of aerodynamics on the movement of the bed in the furnace are outlined and these include fluidisation, flooding and raceway formation. A mention is made of alkalis, sulphur, zinc, softening, and oil injection and the mixed effect in blast furnace economics of increased tuyere velocity as problems requiring further research.

Jan 1, 1975

By T P. Tafirenyika, K C. Corin, C T. O’Connor

There is a growing demand for copper driven by its applications in renewable energy and electric vehicles. Sulfide ores are an important source of copper. Flotation is a critical front-end process used to remove gangue minerals and concentrate the copper minerals. The electrochemical activity of sulfide minerals contributes to their overall activity in the flotation pulp. The mineral rest potential dictates how collectors interact with the mineral surface, and hence ultimately on the flotation response. Dissolved oxygen, (DO), pH, redox potential (Eh) and water composition and ionic strength are also significant in controlling flotation performance. The aim of this investigation was to determine the influence of the electrochemical environment both during milling and flotation on the flotation behaviour of bornite and chalcocite. For this investigation, the interactions of collector with bornite and chalcocite were studied using synthetic plant water (SPW1) and deionised water (DIW) at 5 different pH levels. Sodium isobutyl xanthate (SIBX) was used both in microflotation, collector adsorption and zeta potential tests.

Aug 24, 2022

Goodenough and Fergusson Islands, in eastern PapuaNew Guinea, lie in an area of crustal extension on the western end of the Woodlark Basin seafloor spreading system. The islands are made up of a number of mountainous domes of complexely deformed basement, and these are intruded by large bodies of granodiorite. The domes are bounded by curved shear zones and faults dipping outwards at angles of around 25 to 45¦. The cores of the domes contain lower crustal rocks of eclogite and granulite facies, these rocks have undergone retrograde metamorphism in the outer sheared zones. Movement indicators on the shear zones indicate a complex moverm.-It geometry which does not fit the models proposed by earlier workers. These dome-like structures are similar to the metamorphic core complexes of the western United States Cordilleran region, however there are a number of aspects which do not fit with the models proposed for the development of metamorphic core complexes. Uplift of the metamorphic basement probably resulted from a combination of forces associated with the extension of the crust and the intrusion and emplacement of granodiorite plutons.

Jan 1, 1990

By R Graber, R Johnson

North American steelmaking practices have evolved based on access to iron ore raw materials containing very low phosphorus contents, typically less than 0.025 per cent P. Cleveland-Cliffs managed Tilden iron ore operation produces iron ore pellets exceeding 0.030 per cent P, which by global standards would be considered low phosphorus, but has limited penetration in the North American iron ore market due to phosphorus content. Recently cathodoluminescence microscopy has augmented more standard ore characterisation techniques enhancing our understanding of the genetic history and process mineralogy of TildenÆs complex martite ore. This paper highlights the unique capabilities that cathodoluminescence microscopy provides for phosphorus mineral identification in fine-grained iron ores.

Jan 1, 2005

Geostatistical analysis, resource estimation and three-dimensional modelling of the gold grade distribution was undertaken using exploration drillhole data taken from the Mt Leyshon gold mine. The main aims of the project were to provide an independent estimate of the primary gold resource and to improve the estimate by better understanding the statistical distribution of gold and the establishment of more robust variograms. These criteria have been achieved by the removal of low grade sub-populations, increased sample size and access to data from the most recent drilling program. The outcome of this statistical study has led to a lowering of the sill and nugget variance of the variograms used. Distinct geometric anisotropy was identified in all the resource estimation zones and was used to model gold grade distribution.Two independent resource estimates were established from the primary gold resource, one based on a geostatistical estimator (kriging) and the other on a traditional estimator (inverse distance weighting). Both methods were compared with a contemporary kriged estimate by Mt Leyshon Gold Mines Ltd.

Jan 1, 1993

By A Winchester, D Grant

The massive 1100 Orebody in Mount IsaÆs X41 Copper Mine has been extracted over the last 40 years form north to south utilising sublevel open stoping methods.De velopment has continually stepped ahead of production to provide access to new primary stoping blocks. The remaining secondary pillars contain stopes with one, two or three fill mass exposures and were constrained by access requirements and stope extraction turnaround time.The remaining southern mining areas consist of large 40 m wide by 300 to 400 m long east-west transverse pillars that have been left to provide access for ventilation and service requirements. Three large transverse cross-cuts or transverse pillars û 4180 x/c, 4010 x/c and the Panel pillar now remain. The 4180 x/c was the last major transverse pillar to be successfully broken.This transverse pillar is being extracted in a retreating sequence, creating 3SLOS stopes due to the surrounding backfilled stopes.In recent years the extraction of the first, and most critical, stopes in the transverse pillars have resulted in large changes to the induced stress field. This paper describes the extraction of the 1.1 million tonne stope P418 in the 4180 x/c pillar.T echnical challenges that were faced and how they were overcome to allow for the successful extraction of the stope are described.Critical to the success of the P418 stope extraction were the rehabilitation methodology used; extraction strategy modifications to address deteriorating ground; mass firings with multiple directional changes; managing the exposure of backfill of variable strengths; and geotechnical monitoring prior to, during and after extraction.

Jan 1, 2005

By R N. Lamb, A N. Buckley

Experiments have been carried out to establish whether time-of-flight secondary ion mass spectrometry (ToF-SIMS) is able to differentiate monolayer and multilayer coverage of thiol collectors on sulfide minerals. The systems investigated were those for which x-ray photoelectron spectroscopy is able to provide an independent determination of the extent of coverage, and included diethyldithiophosphate (DTP) and 2-mercaptobenzothiazole (MBT) on chalcocite, DTP on Ag2+MS prepared by sulfidising metallic silver, and isobutyl xanthate (BX) and MBT on galena. For monolayer adsorption of MBT on chalcocite, peaks from MBTû but not Cu(MBT)û ions were evident. For multilayer coverage, Cu(MBT)2û ions were clearly present, notwithstanding the fact that other data had identified the principal multilayer species as Cu(MBT). For adsorbed DTP on copper and silver sulfides, DTPû and metal(DTP)Hû peaks were observed for monolayer and multilayer coverage. Although the multilayer species was expected to be predominantly metal(DTP), metal(DTP)2û ions were evident for multilayer (but not monolayer) coverage. For the PbS/BX system, intact Pb(BX)2 or Pb(OH)BX ions were not detected for multilayer coverage, although Pb-containing ions heavier than PbBX were. Indeed, for all the systems studied, ToF-SIMS was able to differentiate monolayer from multilayer coverage. In general, however, the SIMS evidence alone might not be sufficiently definitive to effect the differentiation. In the case of collector adsorption on copper and silver sulfides, if the multilayer species detected had been the metal monothiolate only, and had not involved the formation of some metal dithiolate, then ToF-SIMS might not have been able to provide an unequivocal differentiation of the two coverage conditions.

Jan 1, 2005

By R Morrison, P Owen

Particle breakage is an essential part of mineral processing. The aim is to reduce run of mine mineral ore to an optimal size for liberating target minerals and for subsequent recovery by separation processes such as flotation. This size reduction is typically accomplished in a series of stages in a grinding circuit tailored to the properties of the particular mine ore. Commonly this involves two or more classes of equipment starting with crushers, followed by SAG mills and then sometimes ball mills. Occasionally, high pressure grinding rolls or other novel devices are substituted. Broadly, energy consumption increases and energy efficiency decreases with the fineness of the material produced by each piece of equipment. For many operations, up to 50 or 60 per cent of total greenhouse gas emissions from a plant arise from the operation of the comminution circuit with the majority produced by the finest grinding parts, such as the SAG and ball mills. Wear of mill liners and grinding media also add to greenhouse gas emissions generated by their manufacture. The need for continual cost reduction and increasing regulatory and social pressure relating to greenhouse emissions create a strong need for improvements in comminution energy efficiency. Traditional experimental and modelling approaches are not well placed to create the required insights into comminution fundamentals or facilitate radical step changes in performance. This paper discusses the role that advanced modelling (based on coupled DEM and CFD) can play in improving the energy efficiency and performance of existing mainstream grinding equipment and in the development of new ones with radically superior performance. Achieving this goal will also require an improved understanding of ore breakage and methods to include sufficiently realistic breakage models within the DEM models. Developmental issues for the modelling and the critical need for validation of the advanced model features are highlighted.

Jan 1, 2004

The Hall-Hoult process is likely to be the dominant method of aluminium production for the remainder of the century. The characteristics of the operation of a modern smelter are described and attention drawn to their disabilities which are due chiefly to the small production capacity of individual cells.The principal components of the Hall-H6roult cell - the electrolyte, the anode and the cathode - are discussed in order to identify the problems of scale-up. The factors influencing current efficiency and energy consumption are analysed and lead to the conclusion that the greatest potential for energy saving lies in reducing the anode to cathode distance (ACD).The most promising direction for major change is in the application of a new titanium diboride - carbon composite for coating of the surface of the cathode carbon. It improves the wetting of the carbon by aluminium and should permit the use of sloping cathodes and anodes. The deep metal pad would thereby be eliminated and, in the absence of magnetic perturbations, the ACD could be substantially decreased.The construction and testing of a full-size "Low Energy Cell" is scheduled for early 1986 and is expected to reduce energy consumption in aluminium production by about 15%.

Jan 1, 1985

The general principles of technical due diligence best practice that are involved in assessing a mineral property in the early stages of its development are described and a bibliography of relevant papers is attached. The issues specific to the evaluation of gold deposits are highlighted. The Australasian Institute of Mining and Metallurgy's (The AusIMM) initiatives in this area, dealing with the proper public reporting of Reserve/Resource information (JORC Code) and property assessment/valuation (VALMIN Code), will be used as a framework against which the illegal tampering with drilling samples to artificially boost their gold content (salting) from the Busang gold deposit (Kalimantan, Indonesia), owned by Bre-X Minerals Limited (Calgary, Canada), will be reviewed. While the Busang saga was based upon fraud, through salting the samples, the general lessons to learn from such a scam are worth documenting. In Australia, most of those working in the mineral industry belong to long established professional institutes and consultant associations (eg The AusIMM or Mineral Industry Consultants Association [MICA]) that require their members to work within their technical limits and to comply with best practice guidelines, or risk being judged and found wanting by their peers in the context of strong Ethics Codes. There is also a strong interface between such representative professional bodies and the corporate and financial market regulators (ASC/ASX), which closes the monitoring loop. Canada has only now seen the wisdom of having this type of early warning system in place. Fraud and deliberate deception will be always possible, but deception on the enormous scale that occurred at Busang is most unlikely with proper surveillance systems in place and the use of accredited technical professionals. There should have been more hard data available about so big and rich a deposit owned by a C$6Bn company.

Jan 1, 1997

By James CH

For drainage sediment to be used as a successful sampling medium in reconnaissance geochemical surveys, the length of any dispersion train from a typical target must be great enough for it to be detected by a widely spaced sampling pattern, and must also be homogeneous enough to avoid it being missed by the unfortunate selection of a random low value sample. Elements which occur in stream sediments in the form of discrete heavy minerals present two special problems in this regard. Since the element is concentrated into a few particles, the medium is extremely heterogeneous, which makes representative sampling impossible unless very large samples are taken, while the high specific gravity of such grains leads to their being concentrated in traps along the stream bed. Several ways of overcoming these difficulties have been suggested. Among these the "schlich" test, in which heavy material obtained by panning is taken for analysis is among the most popular. However, the results of the present study indicate that while this method improves the nature of the patterns obtained, they are still far from satisfactory. Alternative methods of sample preparation, including the taking of light material for analysis, appear to provide better answers to the problem. In the area studied this approach eliminated most of the "noise" associated with the data obtained by other methods, as well as giving an extended dispersion pattern.

Jan 1, 1986

By Barnett DW

Financial risk analysis provides the tools to examine the uncertainty of capital decisions in new mining ventures. This paper explores the methodology by which financial risks can be studied and quantified. The most commonly used risk evaluation methods, such as sensitivity analysis and discount rate adjustment, are presented as an introduction to a more comprehensive discussion of stochastic methods of discounted cash flow analysis using Monte Carlo sampling. The discussion is illustrated with examples of a stochastic discounted cash flow. The advantages of Monte Carlo sampling in risk analysis are discussed together with its problems, particularly those originating from the correlation amongst the variables that determine the economic output of a mining venture, and the difficulties created by insufficient data, imperfect knowledge and complexity. The paper also surveys the most commonly used software used in risk analysis.

Jan 1, 1994

By Nemick JA

Recent advances in computer simulation together with field measurements of caving and microseismic activity about longwall panels, has allowed a much better understanding of the caving process and the variability due to geology. The joint research between SCT Operations and CSIRO Division of Exploration and Mining has initiated new methods of computational modelling predicting various caving patterns and strata failure far ahead of the longwall face. This work was validated by field measurements of caving and microseismic activity at the longwall face.The rock fracture distribution and the caving characteristics of a range of strata sections have been simulated by computer methods. Validation studies of the method were addressed together with case studies. The interaction of caving with support convergence and face control is presented. The method allows the simulation of longwall support behaviour under various geological conditions. The system also allows a prediction of the monitoring data, which is best suited to give an early warning of weighting events or signal various key caving characteristics.

Jan 1, 1998

By L Yao, J Li, C Sammut, B Li

The underground mine environment is inherently complex and hazardous, which necessitates ensuring mining workers’ safety. With the fast development of AI techniques, human activity recognition has become a crucial task to enhance daily life, especially in such challenging settings. This enables automatic monitoring and detection of the mine workers’ activities and operations on a large scale, which leads to better support of workers’ safety and welfare. Existing traditional uni-modal approaches, which use data of one single modality, suffer from low data quality and noise, so they struggle to generalise effectively in such extreme conditions (Li et al, 2022). As underground mines have extreme and complicated environments, such as dust, low light, signal interference, and rugged terrain, uni-modal approaches could not resolve such obstacles and are not suitable for real-world deployment. Multi-modal human activity recognition approaches could use data from multi-modal sources, thus capturing complementary information and producing robust and effective performance in recognising and monitoring mining activities. In this case, designing suitable multi-sensor hardware and AI activity recognition models has become a pivotal task. Producing efficient multi-modal approaches for edge deployment is another problem worth exploring.

Sep 1, 2024

By B P. Banerjee, D Patra, S Raval

Roof bolts are an essential component of roof support systems in underground mines. They are used to provide structural support to the roof of the mine and prevent it from collapsing. Therefore, it is imperative to perform regular assessments of these roof bolts to avert any hazards. Manual investigations of roof bolts are done by surveyors in underground mines, which is extremely timeconsuming and challenging due to the low-light conditions in underground mines accompanied by stringent mine access rules. To this end, automated recognition of roof bolts in 3D point cloud data obtained through laser scanning in underground mines serves as a potential solution to aid roof bolt monitoring. With the continuous advancements in laser scanning-based 3D data acquisition systems, the feasibility of making such surface estimations from 3D point cloud data has increased severalfold.

Sep 1, 2024

By Drew GJ

Smelting is a process in which heat is applied to ores to produce metals. Impurities are removed by segregation in the slag, or converted to gases or sublimates and discharged up the flues. Mate- rials delivered into the smelter have generally been previously concentrated or processed at the mine, and the size of their particles, and also their chem- ical composition, greatly affect the smelting proc- ess. Some impurities are more difficult to remove than others, and are more objectionable in the finished product. The first metal mine in Australia was opened near Glen Osmond in South Australia in 1841, for silver-lead ore. It was followed by the Kapunda Mine for copper in 1844 and by the very signifi- cant Burra Mine, also for copper, in 1845 (Figure 1). A major part of their ores could not be exported profitably for smelting in England and Wales where the large smelters were then located. In addition to treating ores from Cornwall these also smelted ores from recently opened mines in Cuba, Chile, and Mexico. The Welsh smelting process (Figure 2) was developed over a period of years to utilise Welsh coal to treat copper ores particularly from Corn- wall. The first step consisted of a calcination to remove sufficient sulphur from sulphide ores so that subsequent melting operations would produce copper matte, a copper-iron-sulphide which melted at about 1050¦C. Subsequently refined to white metal with the addition of carbonate and oxide ores when these were available, and often through an intermediate step of blue metal, this matte was finally oxidised to pure copper, or as pure as it could be made in those days. The movement of metal towards greater purity was matched by a reverse flow of slag, carrying reducing quantities of copper, so that the slag rejected from the first melting process carried the minimum quantity of copper. Chemical analysis was virtually unknown. Materials were assayed in the laboratory by a small scale smelting process, and the purity of the final refined copper was judged b} the ease with Mhich it could be hammered into thin sheets.

Jan 1, 1987

By R R. Anand

Recent research by CRC LEME from an Australian mineral exploration perspective, has focussed on regolith architecture and mechanisms of geochemical anomaly formation, within transported regolith. Methods have been developed for the rapid production of regolith-landform maps which is the starting point for understanding regolith architecture in the third dimension. Methods for development of 3D regolith models are less well advanced, and require integration of all available geological and geophysical datasets, but still with a heavy reliance on drill-hole information. The base of the transported regolith û the unconformity û remains the most important regolith boundary for geochemical sampling in transported regolith terrains. A new generation portable spectral logger, employing a broader spectrum can interpret important features from drill chips within the regolith. This allows internal architecture, redox fronts and the all-important interface to be objectively identified. Transported lateritic components can provide vectors to mineralisation in depositional regimes. Palaeomagnetic and new radiometric methods which date individual phases of the regolith provide evidence of different episodes, each characterised by different geochemical dispersion patterns in transported regolith. Along with lateritic residuum, calcrete is prime sampling medium. Calcrete is probably enriched in gold through physical and biological processes, rather than straight chemical processes. In South Australia, the lowermost calcrete layer buried within the depositional regime, especially where it lies directly over the silcrete layer at the buried interface, is the desired sampling medium. Certain gum trees, with deep roots in transported regolith have been shown to record anomalous values of gold and basemetals in leaves, twigs and bark. Anomalous metals in acid-sulfate soil seeps can also provide a window through sedimentary cover in respect of mineralisation in the basement. A number of Yilgarn occurrences of gold anomalies in transported cover, strongly infer hydromorphic and biological mobilisation of gold. This inference is supported by micro-analyses of regolith mineral hosts in hardpans and mottled sediments, which show gold and pathfinder elements prefer to reside in goethite and specific types of clay minerals. This creates anomalies in specific mineral phases. However the inference that that these are sites of mobile or labile metal ions remains enigmatic. Similarly there is inconclusive evidence that selective extractions will provide an anomaly not otherwise detected by conventional total dissolution methods. Hydrogeochemistry is a promising exploration tool for basemetal exploration. The importance of microbes in both the dissolution and precipitation of gold in the Australian regolith is demonstrated. We are on the verge of identifying the functional gene sequence of individual active microbes. A consideration of possible mechanisms for creating anomalies in soils above transported regolith, presents difficulties in facilitating upward movement of ions from the watertable to the surface. Perhaps the best avenues of research lies with surrogate soil gases, and biotic transfers.

Jan 1, 2004

By K C. Corin, N Ndamase, M Tadie

Mining operations in arid regions are compelled to reduce their consumption of fresh water. Closed water circuits are an attractive solution and, in addition to reducing freshwater consumption, have the added benefit of reducing reagent consumption as well as the environmental impact by eliminating effluent discharge. Accumulating ionic species have been shown to hinder collector adsorption which reduces the recovery of valuable minerals. Numerous studies have investigated the effect of degrading water quality on collector adsorption however there is very limited understanding as to how this takes place from an electrochemical perspective. This study therefore aims to investigate how the presence of accumulating ionic species at varying concentrations affects the electrochemical adsorption of sodium ethyl xanthate onto galena. The synthetic plant water used in this study comprised of single salt solutions to isolate the effects of the ionic species of interest. The ionic strengths were varied between 0.0242 M, 0.0727 M, 0.1212 M and 0.2426 M which correspond to University of Cape Town (UCT) Centre for Minerals Research (CMR) synthetic plant waters of 1, 3, 5 and 10SPW, respectively. Mineral rest potentials indicated how changing water quality affected xanthate-mineral interactions. Microflotation observed the impact of changing water quality on mineral floatability.

Aug 24, 2022