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By S Hapugoda, M Kilburn, M Adam, L Lu

Lump ore is one of the key ferrous materials used in the blast furnace ironmaking process, typically accounting for 5–25 per cent of the blast furnace ferrous burden. Like other ferrous materials, the characteristics of lump ore have an important impact on stable operation and productivity of a blast furnace. As the cold burden lands on the top of the hot burden in the furnace and descends, it is inevitably subjected to thermal shock, which will likely lead to breakdown of the lump particles, or decrepitation and affect the gas permeability inside the blast furnace adversely. An ISO decrepitation test has therefore been developed to assess this behaviour of lump ore. However, the results obtained according to the existing standard decrepitation test method vary considerably between laboratories even for the same lump ore. To improve the test procedure of the existing decrepitation test, this paper first discusses the mechanisms leading to decrepitation and then studies the factors affecting lump ore decrepitation. Understanding the key factors affecting lump ore decrepitation is particularly important to improve the existing test procedure that enables researchers to achieve a higher degree of precision when conducting the decrepitation test.CITATION:Lu, L, Adam, M, Hapugoda, S and Kilburn. M, 2017. Decrepitation of lump iron ores, in Proceedings Iron Ore 2017, pp 91–96 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By MáAndrusiewicz, M M. Hilden, M S. Powell, P D. Kay, B Foggiatto

Circuits with unconventional and potentially more complex designs are predicted to become more common in the future as plant designers and operators look to process ores more efficiently. Ideas have been presented on how circuit design may be changed to utilise todayÆs technology to address tomorrowÆs challenges (Powell and Bye, 2009; Powell, Benzer and Mainza, 2011a). High pressure grinding roll (HPGR) installations in various configurations; application of preconcentration plants eg sorting, magnetic or gravity separation; and preweakening devices eg microwave processing; are all examples of technologies having the potential to deliver a significant reduction in comminution energy for ores amenable to these processes. Not only will future novel circuits contain equipment for which models are not as well developed (if at all), many will likely require the ability to respond to variations in feed, and interact with geometallurgical models requiring process adjustments when the ore characteristics change.In order to confidently simulate more complex circuits and accommodate variations in feed type, a significant advancement in modelling and simulation capability is required. This includes dealing with multiple components in the feed, accommodating different competencies of ore, utilising physical separation opportunities and tracking the grade reporting along the different potential processing routes. Developing the means to simulate complex circuits has been a key priority of a collaborative group of comminution researchers working to solve these challenges.Simulations are presented utilising a new configurable simulation interface called the model developers kit (MDK). The MDK is designed to accommodate multi-components and incorporate new models under development. These will be used to demonstrate the potential of flexible circuit design, based on measured ore properties and equipment performance.CITATION:Foggiatto, B, Hilden, M M, Powell, M S, Kay, P D and Andrusiewicz, M, 2012. Simulation of flexible circuits, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 291-298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By Manqiu Xu, Peter Wells, Gord Bacon

"A methodology is proposed for milling flowsheet design using flotation rate, selectivity and residence time distribution data. The flotation rate data and the difference in flotation rates between the main minerals to be separated are determined from laboratory batch tests. The residence time distribution (RTD) data is calculated using the tanks-in-series model assuming each flotation cell is a perfect reactor. The rate, selectivity and RTD data can be used to calculate the optimum flotation cell number in a bank for rougher/scavenger in a commercial plant.This methodology is demonstrated in a case study of a nickel sulfide ore. It is shown that miniplant rougher/scavenger data can be closely predicted from a batch test using the proposed methodology.INTRODUCTIONIt has been the trend in the past several decades that large flotation cells are increasingly used. This is largely driven by the economics as ore grades are getting lower and the rate of ore processing must be increased in order to keep mining operations economically viable. The development and evaluation of 250 to 500 m3 WEMCO SmartCell and Outokumpu TankCell flotation machines are well in progress. There are many advantages in using large cells: fewer cells, less floor space, lower power cost (although this is now being questioned for fine particle flotation), simpler circuit, simpler control, and lower auxiliary equipment cost (Arbiter, 1999). As flotation cells are getting larger, the importance of cell hydrodynamics, namely, air/slurry dispersion, power intensity, froth transfer, residence time distribution (RTD) and short-circuiting are being fully recognized (Jonaitis, 1999; Weber, et al., 1999; Gomez and Finch, 2002). It is not the intention of this paper to discuss flotation cell scale-up. The intention is to answer what is the optimum number and size of cells in a flotation bank for a given throughput. Figure 1 illustrates this problem facing design engineers. The same mean residence time required for a given throughput can be achieved in a single large cell, or many smaller cells in a row. A few cells of large size may be more cost-effective but they may not be as effective as more cells of smaller size in achieving the optimum metallurgy."

Jan 1, 2005

By John V. Beall

Since the U. S. Metals Refining Co. works was established, around the turn of the century, near the town which is now called Carteret, N. J., it has grown to be a major producer of refined copper and the main source of that special brand known as "oxygen-free high-conductivity copper." Owing to the complex metallurgical problems arising from handling a variety of raw materials such as copper concentrate from Matahambre, Cuba, copper and brass scrap from the New York area, and domestic blister copper, the organization is geared from top management down through its 2000 employes to maintain a high degree of flexibility in plant operation. The Company is a subsidiary of The American Metal Co. Charges for the smelter furnaces, one reverberatory furnace and one blast furnace, are made up in. bedding bins so that they may be tailored to the production of a constant grade of blister copper. The reverberatory furnace smelts the .sulphide charge, which may be a blend of ten different materials but principally the Cuban concentrate, and the matte from the process is poured into a converter. This reverberatory is 80 by 20 ft, silica lined with a slag bottom, fired by pulverized coal, and continuously side-charged from the top by bottom-dump cars which keep the side walls covered. It produces a 40 to 50 per cent copper matte. The fuel-charge ratio is 4.35 tons of solid charge per ton of coal. The furnace has a capacity of 10,000 tons of charge per month and produces from 5000 to 6000 tons of slag per month which must be disposed of. About 5000 tons of converter slag is produced monthly and returned molten to the reverberatory furnace. The converter gases go through a spray chamber to a Cottrell precipitator and thence to the flue system. Smoke from the

Jan 1, 1948

By Richard J. Mainiero, James H. Rowland

When most people think of explosives transport they think of a hazardous operation. We all know that we aren’t allowed to transport explosives through tunnels and are discouraged from traveling through heavily populated areas. Popular opinion suggests that explosives transport is a very risky operation. The authors decided to look into this a little more thoroughly and found just the opposite to be true. While there have been some disastrous world-wide accidents involving the transport of industrial explosives, this is not the case in the U.S. Over the past 10 years, accidents related to the transport of explosives used in mining and construction have resulted in 5 major injuries, 11 minor injuries, and no fatalities. Explosives and ammonium nitrate (AN) transport outside the U.S. has not had such a good record; there have been 4 major explosives or AN transport accidents resulting in a total of more than 300 deaths. Most of these fatalities could have been prevented if the accident site had been evacuated once the explosive or AN cargo began burning. The safe history of explosives and AN transport in the U.S. is due to diligent efforts by government, labor, and industry. However, accidents will become more common and disastrous if we become complacent.

By G Mark, K L. Blake, G de Jong, J F. Rotherham, N D. Adshead

Magnetite deposits with distinctive ¦ actinolite ¦ apatite-bearing gangue and spatially-extensive sodic-calcic wall rock alteration occur in both Proterozoic metamorphic terrains and Mesozoic-Tertiary magmatic arcs. Examples from both settings constitute significant sources of iron ore (egKiruna, Sweden; El Romeral, Chile) and some host major Cu-Au deposits that have a local association with K-silicate alteration (eg Cloncurry district, NW Queensland; Copiapo district, Chile). A growing body of evidence points to a hydrothermal origin for these systems involving high temperature, low S oxidised fluids. The Cloncurry magnetite-Cu-Au deposits are products of the local structurally channelised influx of a specialised high salinity ore fluid into larger-scale alteration systems developed during pluton emplacement at greater depths than those associated with subvolcanic (porphyry) Cu-Au deposits. The geological characteristics of deposits in magmatic arcs are consistent with a similar mode of origin albeit in rather different tectonic settings.

Jan 1, 1995

By Sylvain Létourneau

Help organizations maximize the benefits of the data that they collect ? perform scientific research in: machine learning, data mining, statistics, artificial intelligence, soft computing, information retrieval, information systems, and natural language processing ? preferred application areas: Equipment Health Management, Bioinformatics, Health, Web Mining ? today?s talk limited to Equipment Health Management While the aircraft is still in the air, IDS: ? clusters relevant WRN, FLR, and snag (pilot) messages ? identifies probable causes based on TSM and provide links to corresponding TSM pages ? assesses MEL conditions (GO, NOGO, GOIF, ?) ? displays relevant maintenance history, suggests fixes based on similar cases ? Commercialization with MxI Technologies Ltd and Air Canada in 2000

May 1, 2008

By J. C. Carrasco, M. Sánchez, R. Jara, F. Marquez, F. Parada, R. Parra, J. Palacios

In past years, Chile has been the largest copper producer in the world and for 2002 mining represented country average of 10 % of the GDP, accounting for 47 % of the total exportation. As copper sulphides are the main mining resources in the country, the metal is produced using the classical processes of flotation and pyrometallurgical extraction. Seven copper smelter plants, which extends from the northern Atacama desert to the central part of the country produced1,522,000 metric tons of fine copper in 2002, approximately one half of total copper concentrate production, with a notorious environmental impact due to the great amount of slag produced during these extraction steps. In this work, a global characterization of copper pyrometallurgical slags produced and disposed of in Chile and worldwide is done, and the concept of total project development is considered to explain the scopes of the study, recovering different compounds and generating new activities around mining. The presentation is completed with the proposal of various methods and techniques being developed today in a joint project between smelter plants and the University of Concepción, with the support of the Chilean government and mining companies, addressed to generate new materials from copper slag. Recovery of copper, molybdenum, precious metals, silica and iron, that is the most abundant component of the slag, are the goals for this research. Metals, commercial compounds, alloys and different forms of iron oxides for steel industry are proposed products.

Jan 1, 2004

By N. Aouad

Dump truck operators are exposed to whole-body vibration (WBV) levels that exceed the International Standard Organization (ISO) 2631-1. The WBV level measured by RMS acceleration value, for operator comfort, and long-term health and safety is under 0.315 m/s2 by these standards. However, fundamental research by Frimpong and Aouad (2009, 2012) and field experimental study by Kumar (1999) have shown that operators are exposed to extreme WBV levels exposing them to injuries and musculoskeletal diseases in the long-term. These extreme WBV values in the vertical direction are equal to 3.56 m/s2, 1.12 m/s2 and 0.87 m/s2 for the operator?s seat, lower-back and cervical regions, respectively. This paper will outline current research to solve these problems. Keywords: WBV, Truck Vibrations, MSC.ADAMS, Virtual Prototyping

Feb 27, 2013

By David Ziegler, John Babcock, Gregory Poole

On December 9, 2003 at 3:59 PM EST an earthquake with a 4.5 magnitude occurred in central Virginia. According to a survey on the US Geological Survey website, this quake was felt as far away as Bridgeton Missouri, approximately 683 mile from the epicenter1. We recorded the vibrations from this earthquake on 14 seismographs that were set up for monitoring vibrations from blasting activities in the area. Having this data gave us an opportunity to compare earthquake and blasting vibrations. The amplitudes, frequencies and duration were much different than vibrations from mining and construction blasting. A common question we get from homeowners when discussing vibrations from blasting activities is “How does that compare to the Richter scale?” The goal of this report is to provide some simple answers for that question. The Richter and Mercalli scale are compared to the particle velocities in order to show their relationship.

Jan 1, 2005

By Wilson G. L, Lord J. H

A detailed analysis of faulting indicatcs that blocks of "greenstone" have been thrust beneath the southern end of the Mt. Isa orebodies.This "greenstone" basement is considered to be a major structural control in the localization of these orebodies.INTRODUCTIONThis paper is based on exploration carried out by Mining Corporation (Aust.) N.L. from 1956 to 1960 in the area immediately south of Mt. Isa, Queensland. During this period over 20,000 ft of diamond drilling was completed together with costeaning and geochemical exploration.Early in 1959, it became apparent that diamond drill information could not be correlated with the current geological concepts of this area and a detailed geological appraisal became necessary. In all, sixty square miles were mapped at a scale of 1 in. to 500 ft, using enlarged aerial photographs. All drill core was logged and sections re-interpreted.Professor K. C. Dunham of the University of Durham consulted on this project and contributed through valuable discussion. Dr. A. Day of the University of Sydney carried out a gravity survey in February 1960 and Dr. H. Wilshire of the same University undertook microscopic examination of rocks from the area. Certain sections of the area were investigated geochemically by Mr. K. K. Hughes of New Consolidated Gold Fields (Asia) Pty. Limited in 1960.In outlining a theory of ore genesis in the area the writers have drawn heavily on the invaluable data published by many previous workers on the Mt. Isa field, in particular...

Jan 1, 1963

"Blasthole deviation is a frequent, well documented and undesirable occurrence in mining operations. It is caused by the drill string mechanics, operating variables and the 'interactionbetween the drill bit and the rock mass characteristics. It is composed of three distinct components: collaring or marking error, alignment error and trajectory deviation. This study has focussedon the dependence of trajectory or natural deviation on the geological features of the rock mass being drilled."

Jan 1, 1996

Greymouth River Dredge û Birchfield Minerals Ltd Blackwater Gold Mine û Macraes Mining Company Ltd Globe Progress Gold Mine û Macraes Mining Company Ltd

Jan 1, 1996

By A. Habibi

A study has been undertaken on two 1.12 m diameter industrial booster fans operating under different blade settings powered by a 1200 rpm motor at the Missouri University of Science and Technology. The fans total pressure varies up to 1kPa forcingup to 25 m3/s through the workings. A pressure-quantity survey has been conducted inby and outby the booster fans with different blade settings. The study uses a variable speed drive (VFD) to determine the effect of rotational frequency on the system. The pressure drop across the bulkheads has been monitored during the experiments. The fans were operated with various blade settings to determine the optimal scenario that maintains the maximum airflow quantity and the lowest power demand at a particular ventilation station. Five scenarios were conducted with different blade setting and mostly with two different speeds. The experimental results show that alteration of fans? speeds by use of a VFD unit can reduce power consumption while maintaining airflow requirements. With the flow rate forced through the mine by the surface fan the blade settings 4 and 5 were determined as possible alternative for the mine ventilation system. In scenario 4, the airflow at the particular ventilation station for a number of speeds is over 20m3/s. The power consumption at 1080 rpm was measured to be 20.1 kW compared to 25.5 kW at 1200 rpm. The operating cost would be significantly less at lower speeds. Scenario 5 is the alternative making use of both booster fans and the main fan in series that meets the minimum airflow requirement at the particular ventilation station along with minimum power consumption. Reducing both booster fans speeds to 1054 rpm results in power consumption of both together dropping to 11.8 kW. Therefore blade setting 5 using two booster fans was determined to be the optimal setting. Separately it was determined that the combination with use of only one booster fan, the West booster fan, running in series with the main fan is the overall optimal scenario. The power consumption of the West booster fan was calculated to be 8.8 kW at 860 rpm with the minimum airflow requirement being met. Computational fluid dynamics is used for analyzing three dimensional flow structures in time domain and calculating the corresponding unsteady pressure fluctuations. The sliding and dynamic mesh techniques were used to study the unsteady flow interaction arising due to the rotation of the fan blades. The numerical predictions of the variables in the form of velocity vectors and contour plots detailing the flow characteristics are then analyzed according to the known physical situation and existing experimental data.

Feb 27, 2013

By A J. Rorke, U Chhika

"A series of tests was carried out on a dry blend of PPAN and LAN prills (LANFO). The objective of thetests was to determine detonation stability and VOD performance compared to ANFO. Heave andfragmentation results in the field were also evaluated visually. A number of factors were behind for.mulating this blend. A lower cost is combined with higher in-hole energies, but at slower reactionrates and lower peak borehole pressures. The resultant effect is improved heave characteristics andlower energy losses caused by inefficient crushing of the rock immediately around the borehole.The test results indicate that IANFO is ideally suited to blasting in softer midburden and overburdenrock types often encountered in coal strip mines."

Jan 1, 1995

Soil erosion is strongly related to soil hydraulic properties. Understanding how surface coal mining impacts those properties is important in developing effective management practices to control erosion during reclamation. Soils from undisturbed areas, roughly graded mine spoil, replaced topsoil before seeding, and revegetated areas at the Rosebud Mine in Eastern Montana were evaluated to determine impacts on soil hydraulic properties. Field and laboratory studies were conducted to determine soil hydraulic properties, including particle-size distribution, organic matter content, and saturated hydraulic conductivity. WEPP simulations and risk analyses were performed on the soil hydraulic property data to determine the impacts of changes on soil erosion. The hydraulic properties of the soils in each representative area have significant differences due to the mining and reclamation practices at the mine. WEPP simulations show that the potential for soil erosion increases due to mining activities disturbing the soil. WEPP simulations also indicate that the potential for erosion may return to pre-mining levels over time with effective revegetation practices.

Feb 27, 2013

By K. P. Davey

In 1998 an initial objective was given to the author, to process valuable off grade High Carbon Ferro Manganese (FeMn) metal fines profitably. The previous attempts that had been made to re-melt these metal fines through the furnaces had resulted in poor furnace operation, mainly to do with lack of electrode penetration and furnace bed permeability. It was decided that the method to resolve these problems was to agglomerate the metal fines. During the study on the agglomeration of the metal fines, a decision was made to use furnace baghouse dust and stockpiled furnace baghouse dust and sludge (DSF) as a ?filler? in the metal fines. The primary reason for using baghouse dust was to eliminate an environmental hazard, whereas the secondary reason for using the DSF was to utilize manganese units contained in the dust. The off-grade metal fines and dust were compacted using a brick press, with cement and aluminum rich plastic clay as a binder, to obtain agglomerate that was cost effective. Through the re-melting of the agglomerated off-grade metal fines, it was realized that this agglomerate concept could have other uses, that of replacing ores on the furnace, at a lower cost. The agglomerate recipe was changed to create an agglomerate that had a high manganese to iron ratio, this replaced Comilog ore on the furnaces, thereby reducing overall furnace unit costs. Future work concerning agglomeration, is to reduce furnace costs further through agglomerating .0.5mm ultra ore fines and .0.3mm Gloria and Nchwaning sludge. Using this agglomerate replaces a portion of the Gloria and Nchwaning lumpy ore on the furnaces at a lower cost. This would eliminate problematic material that exists at the ASSMANG Manganese mines.

Jan 1, 2004

By Emmanuel N. Zevgolis

Energy required for roasting and smelting of a nickeliferous laterite ore by the rotary kiln - electric furnace process is investigated. From this work it comes that thermal energy is about 65% of the total energy needed and the rest is electrical. Also, 61.3% of thermal energy input in the roasting step (of all combustibles fed into the rotary kilns) is used for pre - heating, 11.6% for pre - reduction and the rest (27.1%) corresponds to the energy of the remaining carbon in the rotary kiln products (i.e., calcine, dust and coatings). Carbon entering the system is used as follows: 57.9% for combustion, 37.1% for reduction and the rest (5.0%) remains unburnt. Exploitation of energy from gases of both furnaces, as well as the higher possible reduction degree, the optimum temperature of the calcine and also elimination of the excess air in the rotary kilns, improve significantly energy balance and economics of the process.

Jan 1, 2006

By D Craw

At Reefton, mesothermal gold deposits occur in the Ordovician Greenland Group basement and bituminous coal deposits occur in overlying Eocene Brunner Coal Measures. These different resource types occur in close proximity to one another in the same topography, vegetation and climate. Both types of resources have been mined for many years and as a result historic mining areas discharge water with chemistry reflecting the mineralogy of the deposits. Coal measures release natural acid rock drainage throughout the region due to oxidation of pyrite in coal and associated sediments. Levels of acidity are increased in mining areas, and pH near three is common. Gold mines contain pyrite, arsenopyrite and stibnite. Discharge waters from these sites have pH near seven because of the high acid neutralising capacity of the basement rocks. Both coal and gold mining sites have iron oxyhydroxide precipitates in drainage waters. These precipitates are more abundant at gold mining sites, and one deposit is up to 5 m thick. Iron oxyhydroxide at coal mine sites contain Zn (up to 89 ppm), Ni (up to 10 ppm), As (up to 163 ppm), Cr (up to 23 ppm), Pb (up to 16), and Cu (up to 11 ppm). Jarosite group minerals have been identified in the coalmine iron oxyhydroxide, although most of the material is amorphous. Gold mine iron oxyhydroxide contains Zn (up to 353 ppm), Ni (up to 592 ppm), Cr (up to 17 ppm), Cu (up to 72 ppm), Pb (up to 29 ppm), Sb (up to 230 ppm), and this material is particularly high in As (up to 20 wt per cent). Most of the material is amorphous but distinctive zones (mm scale) are As rich (up to 30 wt per cent As oxide). Pharmacosiderite, K2Fe4(As04)3 (OH)5.6.3H20, is a secondary mineral in one deposit. These iron oxyhydroxide deposits are useful indicators for the metals mobilised into the environment by oxidation in the historic workings.

Jan 1, 2003

By J. Diaz

"Antioquia region, in Colombia, is considered one of the areas with the highest mercury contamination in the world due to its use in gold recovery through artisanal mining, emissions to the environment between 100 and 150 tonnes of mercury are estimated by year. Therefore it became necessary to develop a project in which it was proposed aim to empower traditional artisanal mining community, or in different areas, such as gold mining in the region of Antioquia, in the implementation of safe mining practices and environmentally sustainable, from the introduction of clean technologies, in order to prevent or mitigate the impacts generated by traditional mining on the environment and the communities involved. In order to achieve this training to traditional mining community developed and technical visits to artisanal mining were performed in order to optimize operating processes and promote safe mining practices. In the project more than 1400 artisanal miners were trained.INTRODUCTION In the developing world, a combined 30 million individuals extract more than 30 different minerals using rudimentary techniques. Gold is the preferred mineral extracted by artisanal operators due to its high unit value and its market price, which has increased almost sevenfold over the last decade (Veiga et al, 2014). The artisanal gold mining sector in Colombia has 200,000 miners officially producing 30 tonnes Au/a. In the Northeast of the Department of Antioquia, there are 17 mining towns and between 15,000 and 30,000 artisanal gold miners (M. Veiga, 2010) (Upme, 2014). This production, however, has caused environmental problems, including high levels of river siltation and mercury pollution (Veiga et al, 2014) (UPME, 2007) (Cordy et al., 2013). The mercury contamination in Colombia by artisanal gold mining has been recognized by a number of researchers and local authorities for over a decade estimated that the annual mercury emissions from artisanal gold miners in Colombia in 2007 were between 50 and 100 tonnes, however given recent gold value increases and gold rush activity, current mercury emissions are likely much higher. Colombia is likely the world's 3rd largest source of mercury emissions from AGM after China (240 to 650 tonnes of Hg/a) and Indonesia (130 to 160 tonnes of Hg/a) (Telmer and Veiga, 2008) and is the world's highest per capita mercury polluter (M. Veiga, 2010)."

Jan 1, 2016