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By Troman L, Groutsch J. V

The Kwinana Nickel Refinery began operations in 1970 processing sulphide concentrates from Kambalda using the Sherritt Gordon pressure leach and hydrogen reduction process to produce nickel metal as powder and briquette. Over the years a number of changes have seen the refinery capacity increased from the original design capacity of 15 000 tpa nickel on an all concentrate feed to its current design capacity of 42 000 tpa nickel on an all matte feed. This paper outlines the changes in plant equipment and process for the most recent refinery expansion from 35 000 tpa to 42 000 tpa which have been implemented since 1992.

Jan 1, 1996

A proved routine mapping practice is described involving detailed observations on grade and structure. The equipment and methods employed are giving good service under the conditions encountered. Stopes are mapped on every floor whether timbered or open, "Kodatrace" workplans and sections being used, and in addition all development whether in country or lode is mapped.INTRODUCTIONThe accumulation of geological data for application to current mining problems and to the search for new ore involves the necessity for close mapping of all available underground faces and backs. The technique which has been developed to suit conditions at the North and British mines of North Broken Hill Limited forms the subject of...

Jan 1, 1940

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 Tozawa K, Nishimura T, Sasaki K

Liquidus surfaces in a part of the systems ZnO-PbO-Si02 and ZnO-"FeO"-SiO 2 were constructed by the quenching method. The ex- periments were carried out in air in the system ZnO-PbO-Si02. In the part investigated the primary phases were three ternary compounds (PbO.ZnOòSiO2, 2PbOòZnO.2SiO2 and barysilite), three lead silicates, Zn2SiO4 and SiO2. Iso- therms on the liquidus surface of each primary phase field were determined from 750 to 1300¦C. In the system ZnO-"FeO"-SiO 2 the experiments were carried out in an atmosphere of purified nitrogen. In the part investigated the primary phases were Fe2SiO4, Zn2SiO4 and Si02. Iso- therms on the liquidus surface of each primary phase field from 1150 to 1300¦C and the ternary eutectic (1130¦C, 15.9% ZnO, 48.2% "FeO" and 35.9% Si02) were determined.

Jan 1, 1980

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

A thousand writers have harped upon the wondrous nature of the inventive faculty. They realise that man is a creator, and that capital and labour alike are, and will always be impotent without machinery and processes that is invention. What Bacon has said is echoed by them all, "the introduction of new inventions seemeth to be the very chiefest of human actions. The benefit of new inventions may extend to all mankind-they make all men happy without injury to 'any' they are new creations and imitations of God's own works." My remarks will occupy another field I will refer to some of those features of the Patent Laws of different countries, which prevent the use of new inventions, oppress the development or inventive' genius, and diminish human happiness and progress' Wherever Patent Laws are framed and administered upon wrong principles, these results are inevitably found. A concise, complete, common-sense comparison of the chief Patent Laws of the world cannot easily be found but to avoid seeing scrappy, misleading references to Patent Law in the press particularly the English-would be equally difficult. Writers who are considered authorities so frequently make minor issues prominent and so uniformly fail to give weight to fundamental principles that the effect on the public is to mislead.

By M I. Pownceby, W J. Bruckard

A South African chromite sample was subjected to characterisation and physical beneficiation testwork in order to assess its suitability to produce an upgraded chromite product with a silica level of <1 per cent SiO2 and a chromite level of >46 per cent Cr2O3. Chemical analysis by XRF indicated that the bulk material had a Cr2O3 content of 40.5 per cent w/w and a SiO2 content of 7.5 per cent w/w. Combined XRF analysis with sizing data showed that the majority (~70 per cent) of the siliceous material was present in the +600 ¦m fraction while ~70 per cent of the Cr2O3 was in the -600 ¦m fraction. Qualitative mineral phase analysis by XRD indicated that the sample mineralogy was dominated by ferrian-magnesiochromite spinel ([Fe,Mg]Cr2O4) and aluminium-chromite spinel (Fe[Al,Cr]2O4), with enstatite (Mg2Si2O6), haematite (Fe2O3) and anorthite (CaAl2Si2O8) as minor phases. SEM and EMP characterisation showed that the silica was mainly present in discrete enstatite grains but lesser amounts were also present as the high silica phases plagioclase and enstatite on the edge of grains. Wet gravity separation performed on sized fractions (-600+106 ¦m size range) from the -2.0 mm (primary) ore as well as the ore that had been crushed to pass 0.6 mm (secondary) showed that stage crushing of the -2 mm +600 ¦m fraction followed by wet gravity separation upgraded the Cr2O3 grade at 70 per cent Cr2O3 recovery from ~44 per cent Cr2O3 in the primary material to 46 per cent Cr2O3 (the target grade specification) in the secondary sample. It also showed that the stage crushing of this +600 ¦m fraction at a cut-off level of one per cent SiO2 increased the cumulative Cr2O3 recovery from ~50 per cent in the primary material to ~63 per cent in the secondary sample in the same size range of -600+106 ¦m. The extent to which additional crushing could lead to improved chromite recoveries at the required chromite and silica grade target specifications was not determined. This experience demonstrates that prior to processing test work being conducted, a thorough understanding of the chemistry and mineralogy of the test sample promotes efficient and targeted processing research.

Jan 1, 2008

By J Joughin, D Kyan, L Rollin

In line with the 2015 Paris Agreement and corresponding climate disclosure requirements, many mining companies have publicly disclosed that they are developing and/or implementing ambitious decarbonisation strategies. Sometimes these strategies can be linked to the development of community programs and/or the creation of a positive legacy post-closure. Renewable power is key to most decarbonisation strategies – some mines will get this from external sources and others will establish on-site power generation and storage facilities. A range of options are available to develop renewable power generation (eg solar panel, wind farm, hydropower) and energy storage (eg battery, hydrogen, pumped hydroelectricity). Land access, impact assessments, planning and environmental approvals are required to establish new facilities. Host communities are more likely to be in favour of, or at least will accommodate, new power supply developments if these are planned with a benefit to the communities. Transitioning to renewables raises new challenges. Among these are high upfront costs and access to capital, energy demand variability, supply intermittency and variability, storage limitations, grid stability and reliability, transmission and distribution infrastructure constraints. Compounding these challenges are issues such as infrastructure resilience to extreme weather events (eg heat, wind), land use and access, lengthy permitting processes, community perceptions, skilled labour requirements, and meeting mine closure objectives. Renewable energy sources provide a more decentralised source of energy that reduces reliance on imported fuels, thereby increasing energy security and lowering production costs. On the contrary, implementing renewable energy could lead to potential negative impacts such as visual perception from the community, competitive land usage, electricity price raises due to upgrading infrastructure and the use of electricity storage capacities. As part of the definition of an environmental and social management plan, participative stakeholder engagement is required to identify benefits to the communities. For example, among the recognised benefits of developing solar panels (increase job opportunities, reduce soil erosion), various technologies have been experimented globally for the last ten years and are emerging due to their proven community benefits. Key findings to enhance those benefits can range from the development of innovative practices such as ‘agri-/aqua-voltaic’, ‘solar grazing’ to optimise land usage and stimulate the local economy (Table 1), to the implementation of technologies providing services to communities such as mobile water desalination plants or ‘smart grid’ systems to minimise energy clipping during peak-load of oversized renewable energy facilities (Table 2). While developing those synergies, careful management is required to avoid creating superfluous energy service needs from community programs. Energy sufficiency should remain a key principle according to the sufficiency, efficiency and renewable framework of the Intergovernmental Panel on Climate Change. Darby and Fawcett (2018) define energy sufficiency has ‘a state in which people’s basic needs for energy services are met equitably and ecological limits are respected’. Sufficiency tackles the causes of the environmental impacts of human activities by avoiding the demand for energy and materials over the life cycle of buildings and goods. Efficiency tackles the symptoms of the environmental impacts of human activities by improving energy and material intensities. The third pillar, renewables, tackles the consequences of the environmental impacts of human activities by reducing the carbon intensity of energy supply (Cabeza et al, 2022). Life of Mine Conference 2023 | Brisbane, Australia | 2–4 August 2023 34 This paper provides project developers, decision-makers and regulatory authorities with ideas on synergies between renewable energy options and community development programs. These can be considered to enhance stakeholders’ support for implementation of decarbonisation strategies.

Aug 2, 2023

Anglo Platinum recognised with its expanded operations the need to change its evaluation strategy due to increased sample volumes and the pressure it created at laboratories. The sender/receiver analytical scenarios had to change in order to curb costs and to prevent substantial investments in new sampling and analytical facilities. Given the high cost associated with correct sampling systems and sampling protocols and the shortage of technical resources a strategy of single point sampling and analysis was introduced. The analysis was then done at an ISO17025 accredited laboratory with ten per cent checks, subjected to careful statistical scrutiny. Logistical problems increased with respect to weighbridge congestion, maintaining sampling quality, throughput of samples in the sample preparation areas, manual quality control systems in place, audit trails and analytical capacity throughout all operations. This required the expedited improvement of existing sampling practices and the development of new sampling methods and equipment. Anglo Platinum is classifying and standardising sampling equipment, sample preparation and analytical procedures for all process streams with the view to minimise overall uncertainties. Major investments were made into a customised LIMS and automated equipment for data management, reduction of manual transcription errors and streamlining of sample processing. Anglo Platinum is committed in rolling out the enhancements to all sites as priority dictates.

Jan 1, 2008

Mining of copper ore is still the most important business in Chile. In order to mine ore with a copper content of less than one percent at Minera Los Pelambres in an economical way, opencast mining is mandatory. Due to the prevalence of avalanches at the mine, the concentrator was located in a stable area, some distance from the mine. As a consequence, the material has to be transported between mine and concentrator by conveyor. A downhill conveyor system has been implemented for more than ten years as the most suitable and most economical ore transport alternative. Due to the length (12.6 km) and inclination (1300 m drop) of the conveyor system, the stresses in the steel cord belt are the dominant design criterion, resulting in a belt quality of ST 7800. Additional dynamic belt stresses during transient operating conditions are avoided by the installation of high capacity adjustable frequency drives. The rating of a single drive unit is 2500 kW. During ten years of operation, several capacity increases have been implemented, from an initial 5800 t/h up to the current capacity of 9900 t/h. This presentation describes the engineering challenges of the implementation of the world's strongest belt conveyor system. Capacity increase measures like the development of new control and breaking strategy, proved by dynamic simulation of belt forces and belt speed scenarios are explained. During this long-term partnership of RWE Power International, the former Rheinbraun Engineering, with Minera Los Pelambres, RWE has been engaged continuously for development work, safety checks, expert opinions and maintenance audits, and giving new impulse to conveyor technology.

May 1, 2010

By P Scholtz

Sustainability is one of those fuzzy words like innovation: everybody has an idea what it means, but if one starts asking for concise definitions then it becomes clear that everybody puts their own nuance on the meaning of these words. It’s not because these are difficult words per se, but rather because our understanding of them is highly dependent on the environment we work, live and play in. To remove any ambiguity and aligned with the risks that are faced by the human population today, the definition for sustainability that will apply for this paper is: generating value in the short term without destroying value in the long term.CITATION:Scholtz, P, 2018. Sustainable post-closure development – is it achievable?, in Proceedings Life-of-Mine 2018, pp 58–59 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By A E. Levett, J Durbin

The environmental, social and governance (ESG) obligations of mining companies promote the consideration of water and land resources as well as the post-mining employment opportunities following the cessation of mining operations. This work aims to outline the potential for a mining operation to use their brackish mine water resources to support microalgae production, generating high-quality organic carbon sources to support their mine rehabilitation and closure outcomes. Microalgae production is an established commercial process for high-value products including vitamins, cosmetics and food supplements. On mine sites, microalgae production offers several major environmental and social opportunities: (i) carbon capture, (ii) metalliferous water treatment, (iii) acid mine drainage prevention, (iv) beneficial reuse of brackish mine water, (v) accelerated soil formation and (vi) post-mining employment (Levett et al, 2023).

Aug 2, 2023

By E J. Coyle, L A. Millington

Tailings storage facilities are geotechnically complicated structures that develop heterogeneous strength profiles and varied porewater conditions. The monitoring of porewater pressures is one of the only direct measurements that can be performed to monitor the performance of a facility throughout its life and is of particular importance in upstream facilities. Foundation underdrainage, continuous and staged tailings deposition, climate inputs (rain, snow, humidity, evaporation, etc), and stratified tailings permeabilities can complicate this critical measurement that introduces uncertainty to stability analyses. These difficult conditions manifest in vibrating wire piezometer measurements as very low or negative pressure readings, both of which are within the instrument’s range of accuracy. However, the data can be difficult to interpret, and a range of interpretations are adopted from optimistic low phreatic surfaces to conservative fully saturated tailings. Where tailings are potentially liquefiable, these very low readings introduce further uncertainty regarding the pore space saturation ratio and liquefaction potential above the estimated phreatic surface. This area of uncertainty is the vadose zone, and its affect on tailings behaviour is not well understood. The two facilities analysed in this paper are upstream, raised embankments with tailings classified as clayey, sandy silt that have been found to be potentially liquefiable. The vibrating wire piezometers (VWP) at both sites show very low or negative readings when they are initially installed near the surface and then go through cycles of re-saturation and de-saturation. Eventually the readings settle as the VWPs are buried deeper within the tailings. The instrumented sections within the tailings column do not show consistent readings that would be indicative of a hydrostatic phreatic surface at either site. Rather, they are highly variable and can be interpreted as either representing a high phreatic surface within the tailings or as a ‘perched’ phreatic zone within the tailings layers. How the VWP data is interpreted has a significant impact on how the facilities are raised and operated. The design outcome for Site 1, which adopts a lower phreatic surface, results in an embankment that meets factor of safety (FoS) requirements under residual strength conditions without any buttressing. Conversely, a conservative (high) phreatic surface has been adopted for Site 2 and has resulted in the facility requiring a significant buttress to meet FoS under residual strength conditions.

Jul 1, 2021

By H Zhang, Y Wang, S Sukenaga, H W. Ni, H Shibata, W Z. Mu

The crystallisation behaviour of low melting point CaO-SiO2-Al2O3-MgO inclusions greatly affect the deformability of inclusions during the rolling process. The crystallisation characteristics of CaO-SiO2- Al2O3-MgO melts representing the oxide inclusions in Si-Mn killed steel were systematically investigated. The effect of Al2O3 and MgO contents on the crystallisation change were analysed under a fixed CaO/SiO2 in the complex inclusions. The continuous-cooling-transformation (CCT) and time-temperature-transformation (TTT) experiments were conducted. The results showed that the increase of MgO content increases the crystallisation ability of CaO-SiO2-Al2O3-MgO inclusions, while the increase of Al2O3 content has the opposite effect. The viscosity, liquidus temperature of oxide melt and also the initial crystallisation potential might be the reasons for the change in crystallisation behaviour. Also, the crystallisation activation energy could semi-quantitatively characterise the crystal growth during the crystallisation of inclusions. To obtain low melting point plasticized CaO-SiO2-Al2O3-MgO (CaO/SiO2=1) system inclusions, the Al2O3 content of the system needs to be controlled larger than 15 wt per cent and the MgO content should be kept at a small amount.

Aug 21, 2024

By D Zielinski-Nicolson

The emergence of affordable, portable and versatile wireless devices has enabled a new frontier in mine safety equipment. Existing solutions provide methods for tracking personnel and assets in underground mines but are not designed to optimally integrate into existing and emerging systems. Mine management are often required to coordinate primarily independent emergency, personal protective equipment (PPE), tracking and collision avoidance systems from multiple vendors. These systems involve a variety of wireless technologies that require separate integration projects that discourage adopting new services and policies.

May 5, 2022

By J H. Wood, I Gray

This paper examines the occurrence of outbursts, coal bursts and rock bursts in underground mining. It then examines them from the viewpoint of the failure mechanism and velocity of particles. The presence of gas is extremely important as it can both act as the fluid pressure component of effective stress leading to failure, and as a substantial energy source in projecting material during a burst. For gas to drive a dynamic event it must be present as free gas held in voids within the rock or coal mass. This can pre-exist the burst event or be released from desorbing gas during it. The latter is typically part of a multi-stage outburst event which can reach very large proportions. Rock and coal bursts are driven by strain energy release and can vary in form. These tend to be single events associated with failure and strain energy release. It is also possible to conceptually have hybrid events where the failure of the mass and the energy release are due to both stress and expanding gas.

Nov 29, 2022

By N J. Grigg

Gekko Systems has developed an underground pre-concentration plant (Python) to reduce mine operating costs. Many ores liberate favourably using either high pressure grinding rolls (HPGR) or vertical shaft impactors (VSI). Using these comminution circuits for mineral liberation; rather than for the final recovery process and by utilising a high mass pull, high recovery process route (gravity/flotation), a narrow, low head, compact processing plant was developed that can sensibly be operated underground. The Python underground processing plant can provide a number of advantages for narrow vein mines including lower haulage costs, improved mine call factor and lower operating costs. The focus on fine crushing reduces the power requirement of the plant to approximately 8 kWh/tonne. The Python underground processing plant has been designed to be towed down the decline or lowered down a shaft, and is capable of being installed in sloping, non-linear drives for placement close to the working face. The overall benefit to mining companies of this concept has been estimated to be a saving in mining costs and a significantly smaller environmental footprint.

Jan 1, 2008

By H J. J Boshoff, A J. Karrasch

Mine planners frequently face the challenge of mitigating the impact of climatic events on mining operations, such as floods and droughts. Specific water management infrastructure can be implemented to meet operational requirements in response to these events. However, the effect of flood protection, for instance, may reduce the resilience of the site to drought. The probability and duration of unfavourable climate sequences significantly influences the net present value (NPV) of implementing specific water management infrastructure.Good life-of-mine planning will consider the incremental development of the project, and provide staged development plans. Water management infrastructure and the timing of implementation are facets of this process.CITATION:Boshoff, H J J and Karrasch, A J, 2016. A decision-making framework for water supply and flood protection options in net present value terms, in Proceedings Life-of-Mine 2016 Conference , pp 196–199 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By S Ellis

In January 2008 Chirano Gold Mines Limited committed to expansion of the Chirano Gold Project from its existing design capacity of 2 Mtpa ROM ore to a new design value of 3.5 Mtpa. In addition to increased throughput, the design had to contend with increasing ore hardness and competency, while at the same time make cost effective use of existing equipment with minimum disruption to existing production. The solution adopted involved some novel approaches including tertiary crushing and operation of the SABC circuit in overflow ball mill mode and parallel elution with a common acid wash column. This paper describes the approach taken to the design of these elements to achieve a cost effective and safe capacity expansion.

Aug 8, 2011

By H Kim, M J. Sun

In order to reduce carbon emissions from the steelmaking process and achieve carbon neutrality, global steel companies are establishing their own medium to long-term strategies and implementation plans using competitive technological advantages held by each steel company. At this point, Hyundai Steel has formulated a product-oriented carbon-neutral strategy based on innovative processing that makes use of Hyundai Steel’s own strength. Based on our experience in electric arc furnace product manufacturing and blast furnace operation in an integrated steel mill, Hyundai Steel is driving the Hy3 (Hy-cube) project, which involves a unique hybrid production system utilising hydrogen and hydrogen-based renewable energy sources. This initiative aims to achieve carbon-neutral production and eventually specialise in producing premium carbon-neutral automotive parts. The project has originality in that it involves not only designing processes using electric furnaces to produce premium steel products such as car body panels and electrical steel sheets, but also aims to reduce carbon emissions from the process, developing carbon-neutral products based on market demand. To assess the feasibility of the Hy3 project, Hyundai Steel conducted two pilot productions. The first pilot was producing a prototype of lower-arm part using electric arc furnace with three different kinds of raw materials: molten iron, HBI (hot briquetted iron), and scrap. Successful performance evaluation of auto parts with 1 GPa strength was achieved. The second pilot has been focused on tire cord steel, with the first-phase tests yielding a 33 per cent reduction in carbon footprint (CFP). Using the advantages of operating experience in electric arc furnace, Hyundai Steel is preparing for test operations producing various automotive parts using an electric arc furnace (EAF) to advance the Hy3 concept. From a medium to long-term technological development perspective, Hyundai Steel’s blueprint includes producing high-end carbon-neutral steel products using hydrogen-reduced iron as raw material.

Jun 19, 2024