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By T Atchison

The Vale Ferro Carajßs S11D project in northern Brazil is based on the movement of unprecedented volumes of waste and ore for mobile in-pit crushing and conveying or ætrucklessÆ systems. In peak years, the system is intended to handle a combined 160 Mt of material.The planning and implementation of the first such system for Vale, in a remote greenfield site, utilising the services of a range of international study, design and supply partners has provided a unique set of technical and project delivery challenges. The lessons from these are of value to the industry as the trend to remote and high-volume operations continues.This paper describes the key features of the mining system and documents the challenges and mitigations for important technical, cultural and project delivery issues that have arisen. It is a combined description of the journey taken by both Vale (as owner) and SKM (as delivery partner) over the course of many years.CITATION:Atchison, T, 2013. Lessons from the S11D truckless mining project, in Proceedings Iron Ore 2013 , pp 177-184 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

Development of the Boleo Process Flow Sheet and the Direct Solvent Extraction (DSX) Circuit for Cobalt and Zinc Recovery The metallurgical process designed to treat the El Boleo Cu-Co-Zn-Mn ore involves a sulphuric acid leach in seawater under oxidative and then reductive conditions to maximise metal extraction. Copper and cobalt are recovered as cathodes by electrowinning, zinc and manganese as zinc sulphate monohydrate and high quality manganese carbonate, respectively, by precipitation after a number of separation and purification stages. One of the key purification stages of the Boleo metallurgical process is the CSIRO DSX circuit. The DSX circuit was developed using the synergistic solvent extraction (SSX) technology. Initially, a synthetic solution was studied, and by adding 0.4 M LIX63 to 0.5 M Versatic 10 in Shellsol D70, large synergistic shifts were obtained for cobalt (?pH50 4.24) and zinc (?pH50 1.62). After a single contact, the separation factor of metals over manganese reached over 6,000 for cobalt and over 380 for zinc, indicating excellent separation of cobalt and good separation of zinc from manganese, magnesium and calcium. The SSX system was further optimised with the modified synthetic pilot plant solution. The extraction of cobalt and Zn after a single contact was 93 per cent and 70 per cent, respectively, while the Mn concentration in the loaded organic solution was only 0.28 g/L. A proof of principle pilot plant operation was conducted in 2004 and a demonstration pilot plant for final engineering design in 2006 with outstanding performance of the DSX circuit. For the demonstration pilot plant, the overall recovery of cobalt and zinc exceeded 99 per cent with a raffinate containing only 4 mg/L Zn and 1 mg/L Co. The DSX organic system showed no sign of degradation during the pilot plant operation, indicating good chemical stability under the anticipated commercial operating conditions. The DSX circuit will be implemented in the future Boleo processing plant.

Sep 13, 2010

The work described herein is the opening phase of an extensive system of underground excavation undertaken under contract with a Malayan authority.The specifications called for the lining of all tunnels in earth or broken rock with circular segmented cast iron lining, similar to that of the London tubes, and it is the installation of these linings which it is proposed to discuss.Owing to the long deferred delivery quoted and the obvious need for speed of access to the internal installation, it was decided to defer driving the completed circular section and substitute two small timbered headings.These could later be opened out in turn to full section and lined without prejudice to traffic, since both of them had access to the internal workings.NATURE OF ROCKThe rock series through which the circular sections were driven consisted of:(a) A wide zone of intrusive porphyritic granite, consisting generally of orthoclase phenocrysts in a ground mass of micro pegmatite. This area showed advanced weathering, varying from a stage showing slightly tinted kaolin containing approximately 20% of small boulders to one of ultimate decomposition to pure kaolin;(b) A narrow zone of weathered augite diorite, consisting of rock masses of a maximum weight of some 100-150 tons, isolated by clay seams up to 1 ft. 6 in. in width.The whole area was in a state of quasi-hydrostatic equilibrium, which resulted in heavy pressure immediately after excavation. Freshly broken faces would appear to be quite solid but, within a few minutes, would commence to sweat and "slab off" under pressure and, unless support was placed promptly, the whole face would burst out and run from above. Mucking was slow, owing to the plastic nature of the clay and the ease with which it puddled into slurry.In zone (b) a good deal of trouble was experienced because of the fact that the somewhat heavy blasting necessary tended to cause movement of the large rock masses. Subsequent scouring out of the supporting clay bands by the waterflow permitted settlement of the ground on to the timbers and many reinforcing sets were therefore required.The timbering of the pilot headings and its relation to the cross-section of the circular tunnels is shown in Fig. 1. Top and side spiling was driven in the ordinary way, but in bad ground intermediate sets and breast boards had to be placed. These sets were usually withdrawn after the...

Jan 1, 1941

Flotation of Smithsonite by Using Siloxane Cationic Surfactants as Collectors

Sep 13, 2010

An Innovative Process for Comprehensive Utilisation of Clay-Vanadium Ores By adopting conventional processing technologies such as flotation, gravity concentration, and magnetic separation, it is difficult to enrich vanadium mineral effectively. At present, vanadium extraction process usually has not the mineral processing enrichment procedure, but rather uses direct hydrometallurgical process: roasting - leaching - precipitating vanadium for obtaining high quality V2O5 product. But it results in problems, for instance, high consume of auxiliary materials like acid and alkali, serious pollution and high cost of vanadium extraction. In the project study on the ore of a certain clay vanadium mineral, by adopting the test process: scrubbing raw ore with reagents added in - dispersing and segregating with reagents - grading enrichment, vanadium concentrate product with higher grade was made by virtue of reagent's selective inhibiting, and the purpose of upgrading the raw material used for vanadium extraction with hydrometallurgical process is achieved. The process technology obtained from project study features simple process structure, low equipment investment, low cost of mineral processing and pollution-free to environment. It provides high efficient and practical technology for the comprehensive utilisation of clay vanadium mineral, and has a prominent prospect for its popularisation and application.

Sep 13, 2010

Few, if any, reliable thermodynamic data are available for the activity of tin oxide in slags. In this work, the activity of the oxide in silica saturated iron silicate slags has been measured at 1573 K using the equilibrium Sn (alloy) + Y2O2-SnO (slag).Slag and a Ag-Sn alloy were sealed in a zirconium oxide crucible to prevent the escape of volatile tin oxide, and the oxygen pressure at equilibrium measured in situ using the zirconium oxide as a solid electrolyte. Activity of tin was calculated from known data for the Ag-Sn system and activity of tin oxide calculated from free energy data. The results have been extrapolated to predict the industrially important distribution of tin and iron between Fe-Sn alloy and iron silicate based slags.

Jan 1, 1983

Removal of Arsenic in Fluorite Ore by Simultaneous Grinding-Leaching with NaHS Generally speaking, a high-grade fluorite ore is converted into hydrogen fluoride (HF), which is essential for the semiconductor manufacturing. With the continuous depletion of resources, novel technologies for processing low-grade fluorite ores are urgently needed, in order to lower the arsenic concentration to less than 100 mg/kg. In this study, a low-grade fluorite ore was upgraded by removing arsenic, which is difficult to remove by conventional method. The mechano-chemical leaching of fluorite ore (i.e. the sample was ground in presence of NaHS, using a beads mill) was carried out to investigate the removal of arsenic from the low-grade fluorite. Experimental results showed that the arsenic concentration was reduced to 73.2 mg/kg.

Sep 13, 2010

By Warren L. J, Horsley R. R, Meagher L

Mineral concentrators often use process water that is very saline and/or hard. In this paper the effect of increasing concentrations of sodium chloride and calcium chloride on the rheological properties of 70 wt% quartz suspensions (d5o - 10.6 ¦m) is reported. The apparent viscosity at 100 s t in 5 mol dm -3 sodium chloride solutions (approx. 300,000 ppm) was nearly 500 times the viscosity of water without salt or particles present. Part of the increase in viscosity is caused by aggregation (coagulation) of the suspension.

Jan 1, 1989

Today computers are accepted as a standard item in industry and they perform a variety of tasks over a wide spectrum of activities from mine planning and CAD to data processing and spreadsheet work. However many problems particularly in the. area of decision making where there are no clear mathematical models available and usually the output or answer is dependent to some extent on a heuristic approach, don't lend themselves to conventional solutions using standard procedural algorithms. Recently a number of techniques have evolved primarily from the enhanced capabilities of modem equipment, which are capable of solving these problems. This paper is a brief overview of these rather unconventional developments of computer technology in the area of artificial intelligence with reference to their application in mining.

Jan 1, 1993

Preparation of MgO Nano-Particles with Magnesite

Sep 13, 2010

By A Paz, H Lehto, M +stholm, I Roitto

Nowadays, the demand for a finer grind in minerals processing has set new challenges within the industry, particularly for grinding technology. Apart from a finer grind, energy efficiency is also a key driver in optimising comminution technology.Stirred milling technology, already proven in many other industries, delivers a modern, sophisticated, flexible and energy efficient grinding solution for fine and ultra fine grinding in minerals processing. Fine grinding technology is utilised particularly in concentrate regrinding to complete the liberation of valuable minerals after the first stage of concentration. Maintaining the correct particle and particle size distribution of the regrind product is crucial for downstream process performance. Stirred milling technology offers the unique possibility for online control and optimisation of the regrind product particle size. This paper describes the basis of this online control possibility and discusses the implementation of stirred milling technology in minerals processing, particularly in regrinding applications. The paper will also outline management and control of fluctuations in feed rate tonnages as well as particle size fluctuations in concentrate regrinding.CITATION:Roitto, I, Lehto, H, Paz, A and +stholm, M, 2013. Stirred milling technology - A new concept in fine grinding, in Proceedings MetPlant 2013 , pp 190-201 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

Ultrasonic Extinction for High Resolution Particle Size and Concentration Analysis

Sep 13, 2010

Recovery of Fine Gold Particles from Philippine Gold Deposits by Enhanced Gravity Concentration and Flotation The objective of the study is to determine the applicability of enhanced gravity concentration (EGC) and flotation for gold recovery. While gravity concentration methods have long been applied to gold ores, especially to free-milling types that requires minimal beneficiation, flotation for gold recovery has not yet taken hold as a major operation in the Philippine setting. In this study, the application of EGC and flotation for gold is applied and compared to the existing methods for gold recovery. Two samples, with assays of 7.315 and 5.333 g Au/MT (samples 1 and 2, respectively) are used for this study. These samples are subjected to mineralogical studies and is found to have a gold-particle size ranging 10 to 200 microns. To verify the separation size, the mesh-of-grind (MOG) is used as the primary parameter for experimentation. Initially, the samples are stage-crushed, ground, and subjected to EGC using a Falcon SB40 Concentrator. Based on the results, the two samples showed that recovery increases with a finer MOG. The ratio of concentration (K) decreases with a finer MOG. This shows that there should be sufficient liberation of the gold values for EGC to be effective. The effect of the enhancement is to pronounce the difference in specific gravity of the minerals, promoting better separation. This is validated by the high recovery values of 86.97 per cent and 98.73 per cent exhibited respectively for samples 1 and 2 (at 54 microns). For the flotation runs, sample 2 with an average particle size of 80 per cent passing 74 microns is examined using thiocarbamate-based collectors for roughing and subsequently exhibited a recovery of 96.32 per cent. At this point, the concentration ratio (K) is noted as an important efficiency indicator for flotation process since it yielded a very low-mass and high-metal content concentrate.

Sep 13, 2010

The Porgera Joint Venture commenced production during September 1990. A small tonnage underground mine extracts high grade gold ore using small scale stopes. Conventional drill and blast methods are used for development and production mining. Ground support is effected with Splitset anchors, grouted rebar bolts and grouted cable bolts. Splitsets and grouted rebar can be installed by mechanised means. Vertical crater retreat, slot and massfire, and modified VCR stoping tech- niques are used at Porgera. Stopes are backfilled with a relatively strong cemented rockf ill. Future stope sequences require recovery of pillars beside and under filled stopes.

Jan 1, 1991

A new lead refinery with a capacity of 230,000 tons per year commenced operation at Port Pirie in October, 1959. This plant superseded the refinery which had operated from 1933 with the advent of the continuous lead refining process. The incorporation of new equipment following local metallurgical developments, together with the overseas demand for lead of extremely low antimony content createddifficulties in operating the original plant. The new refinery project was undertaken to cover this disability and to gain the full advantage of the new processes.Desilverising and softening are carried out in units identical in size to those used previously. Metallic zinc is recovered from the entire output of desilverised bullion by vacuum distillation. Final refining is carried out by batch treatment with caustic soda yielding lead of purity previously unattainable at Port Pirie.These two processes replace continuous dezincing by oxidation, a high temperature process which caused large quantities of lead and antimony to be recirculated. The final stage is a batch process; therefore the product composition can be checked before casting. Individual batches can be adjusted to produce special alloys to consumer's specification.Improved casting equipment allows the quantity production of pigs of good physical characteristics either as 56 lb bars or 2000 lb pigs.This, together with the high purity of the lead, assures the Broken Hill Associated Smelters Pty. Ltd. (RH.A.S.) position in world markets.Automatic control systems are extensively employed, particularly on the vacuum dezincing unit.The anticipated financial benefits have been achieved mainly by a reduction in the tonnage of recirculated materials, a smaller labour force, and reduced maintenance requirements.INTRODUCTIONIn December 1956 a decision was made to build at Port Pirie a lead refinery on a completely new site, and in October 1959 the new refinery was brought into operation. This plant superseded the lead section of the old refinery which...

Jan 1, 1963

By A Golsby

Although much talked about, social licence to operate (SLTO) is a relatively new concept that has been deemed as one of the four biggest business risks to a mining project over the life-of-mine. There is no accepted single definition of SLTO and this author understands SLTO to be stakeholder perception of the legitimacy of a project, a company or an industry. At a specific site, and across different sites within the same organisation, SLTO ranges through different levels according to stakeholders’ degrees of acceptance in time and space. Management of SLTO is vital for the mining sector but is difficult as it is informal and intangible. Although there are no key performance indicators, there are certain indicators that enable relative measurement of the ‘level’ of the SLTO. Because of the importance of the SLTO, information management during the entire life-of-mine, from exploration to rehabilitation, becomes crucial for the continued operation of a project. This paper identifies ten basic principles for the management of information to support the SLTO.CITATION:Golsby, A, 2014. Managing information to support a social licence to operate, in Proceedings Life-of-Mine 2014 , pp 389–398 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By P E. H Gregg, R B. Stewart

Reclamation field trials commenced in 1985, two years before the granting of the Mining Licence. The level of pasture production on varying soil depths (0 cm, 5 cm, 15 cm and 25 cm) overlying both tailings and oxidised waste overburden was assessed.   After seven years, the rate of increase of N, C, P and S, losses of Sand P and pH changes were investigated on the plots where grass seed was sown into bare tailings. It was determined that on these plots it would take approximately 24 years to reach the original carbon and nitrogen levels at the mine site. Further tailings trials have been initiated to investigate alternative land use options for the tailings dam. Growth increases of 73% occurred in native species growing directly in tailings, and growth increases of 78% occurred in tailings amended with compost over the first six months. Pasture trials on tailings with and without a compost amendment have also been initiated. Research has commenced to investigate the restoration options for acid producing pit slopes. The early field trials have been put into practice with the restoration of oxidised waste on the tailings embankment. This is progressive with approximately 16 ha restored to productive pasture at present. Yields compare well with those of the most versatile and productive soils types investigated in baseline studies of the area before the tailings dam was constructed.

Jan 1, 1995

By Fookes R. A, Bunch K, Gravitis V. L, Watt J. S

The combustible volatile matter in coal mine roadway dusts (CVM) has been determined using x-ray backscatter techniques. The correlation between x-ray and chemical techniques is reasonably good for the 92 samples from collieries on the Bulli seam, and the maximum error expected at the maximum level of 11· 5 weight per cent CVM permitted in the N.S.W. Coal Mines Regulation Act, 1912, as amended, is about ± 2·5 weight per cent. This x-ray technique can be used only when the combustible volatile content of the coal matter (cvm) varies within a limited range, and a separate calibration is required for each coal seam.Portable equipment based on a radioisotope x-ray source ahd digital ratemeter makes possible simple and rapid analysis, and with adaptation to use in coal mines should lead to much more comprehensive testing- ofroadways and hence improved overall prevention of coal dust explosions.

Jan 1, 1977

Effect of Activated Carbon on the Leaching of Cobalt-Rich Ferromanganese Crust in Sulfuric Acid

Sep 13, 2010

Rio Tinto has embarked on a journey to use automation to improve the performance of its surface mines. The driver for automation is to improve the accuracy and consistency of mining processes and less to do with cost savings through labour reduction. A key task in most surface mines is blasthole drilling. The degree to how well this is done cascades through the downstream mining process. It impacts scheduling, excavation, slope stability, material handling, beneficiation and final product blending. Improved blasthole drilling was identified as an objective that has a significant business case in most of Rio Tinto's surface mines. This paper describes Rio Tinto's drill enhancement project that has developed a robust system for automating most of the functions on a Terex SKSS16 drill rig. Automated drilling is currently being used in production at the West Angelas iron ore mine in the Pilbara region of Western Australia. A description of the essential elements of the drill automation system is given together with an overview of how automated drilling is performed remotely from the mine office. A review of some of the benefits of the enhanced drill system is given together with the future plans to extend the functionality of the automated drill and the expected benefits.

May 1, 2010