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By K C. Runge, E Tabosa, A Jankovic

Flotation recovery in geometallurgical modelling is usually predicted based on relationships developed from batch flotation testing of different ore types. These batch flotation tests are usually performed at a constant set of operating conditions and at a fixed feed grind size P80. Usually the laboratory feed grind P80 is that which is expected to be produced in the full-scale flotation circuit for that particular ore type.Flotation recovery will be a strong function of the valuable mineral particle size distribution, with lower recovery of ultra-fines due to poor flotation kinetics, optimum recovery for the intermediate sized particles and lower recovery for the coarser particles due to poorer liberation of this fraction. This valuable mineral particle size distribution is not characterised by the solids P80 parameter alone. The proportion of material in each class will also be a function of the slope of the size distribution and the degree of preferential grinding of the valuable mineral in comparison to the total mass of the ore.This paper will demonstrate (through example) how these other size distribution parameters can change with a change in grinding technology, the size and operating conditions used in a grinding unit and the characteristics of the classification technology used in conjunction with the grinding unit. Case studies will be presented that demonstrate how this can result in these parameters being very different in laboratory testing to that produced in the full-scale comminution circuit. A rule of thumb that laboratory rod milling rather than ball milling produces a size distribution most similar to that of the full-scale grinding circuit will be challenged. These differences can result in a significant change in flotation recovery. It is therefore important to consider these parameters when developing a laboratory geometallurgical program, to enable more accurate prediction of the flotation recoveries that will be achieved in the full-scale process.CITATION:Runge, K C, Tabosa, E and Jankovic, A, 2013. Particle size distribution effects that should be considered when performing flotation geometallurgical testing, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 335-344 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By H Ishikawa, R Halomoan, S Palaniandy

The Karara iron ore project is a magnetite operation consist of open pit mining and concentrator to produce high-grade magnetite concentrate. The concentrator has adopted three stages of comminution, ie fine crushing in the high pressure grinding rolls (HPGR), primary ball milling and fine grinding in the TowerMill plus magnetic separation in between these comminution devices. Since 2014, the concentrator has increased the plant feed rate by 18 per cent. Meanwhile, the ore hardness has increased by 13 per cent to a Bond work index value of 15 kWh/t that led to a coarser flotation feed. Karara Mine has decided to shift the comminution workload from the primary ball mill to the TowerMill circuit by bypassing the 100 µm fine screen in between the ball mill and TowerMill circuits. This action has increased the circuit feed particle size distribution with a top size close to 1 mm. The specific energy consumption of the TowerMill circuit was approximately 3.4 kWh/t, and the circuit product sizes (P80) were ranged between 38 and 45 µm. A joint process improvement exercise was carried out to reduce the circuit product size closer to the magnetite liberation size, ie 35 µm. Among the activities were circuit audit, recommendation for improvement, modelling and simulation, multicomponent analysis, implementation of recommendations and quantification of the improvement. One of the key findings was the density effect of multicomponent minerals in the hydrocyclone. The analysis revealed that the low density coarser gangue minerals were bypassed to the hydrocyclone overflow stream that has resulted in a coarser particle size distribution. Meanwhile, more than 20 per cent of fine (-35 µm) high-density magnetite particles were recycled back to the mill through the hydrocyclone underflow stream and increased the circulating load. Based on these outcomes, several recommendations such as conversion to bottom feed configuration, use of smaller grinding media, high operating hydrocyclone pressure and additional grinding power to the TowerMill circuit were made to improve the overall circuit performances. Karara Mine has prioritised to implement those recommendations that have a minimal financial implication. Full-scale plant trials with bottom feed configuration and 17 mm grinding media were conducted to evaluate its performances. These trials have indicated that the grinding efficiency in the TowerMill was enhanced by 10 – 30 per cent. In May 2017, all the five TowerMills were converted to the bottom feed configuration. This paper discusses the impact of shifting the comminution workload load from the primary ball mills to TowerMill circuit and the performances enhancement of the TowerMill circuit. CITATION:Palaniandy, S, Halomoan, R and Ishikawa, H, 2018. Shifting the comminution workload from the primary ball mill to TowerMill circuit, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 163–176 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

The role of a project metallurgist is diverse and covers input into the resource definition, mining studies, metallurgical test program development, process engineering and plant design, cost estimate preparation and financial analysis aspects of project feasibility studies. Mining project schedule and cost overruns can often be attributed to cutting short metallurgical test work, engineering and cost estimating leading up to commitment to development. In a significant number of cases this may result from the lack of understanding and commitment by the project proponent to the requisite metallurgical and processing studies required during the various pre-commitment stages of a mining project. Metallurgical test work, process development, engineering and cost estimating requirements for each stage of pre-commitment development are described together with a summary of the ongoing role of the project metallurgist during detailed engineering and commissioning of a process plant.

Jan 1, 2008

By C Swamydas

VV Mineral (VVM) group of companies is the largest and the first private producer and exporter of beach sand mineral products in India. During 2010, the company produced and marketed around 750 000 tons of saleable products. Their operations are mainly in the state of Tamil Nadu and Andhra Pradesh, India. Almost all the wet pre-concentration plants use sea water as the concentration medium, since there is no fresh water source available near the deposits. The mines are located along the south-east coast of India in the states of Tamilnadu and Andhra Pradesh. The orebody varies in terms of mineral assemblage, slime content, grain size, and surface coating resulting in different behaviour of the minerals. Three different deposits containing ilmenite of different TiO2 content were studied. The study shows that there is no significant impact of using sea water for wet concentration prior to high tension separation of ilmenite. There is no significant variation in recovery and purity of ilmenite produced from these deposits when wet concentration of the deposits were carried out with sea water as the concentration medium and whether the concentrates were washed with fresh water or not before dry separation using High Tension Roll Separators (HTRS).

Oct 5, 2011

By V Lawson

Vale’s Sudbury Clarabelle Mill processes Cu/Ni ores from a number of mines in the Sudbury basin in Ontario, Canada. Bulk sulphide flotation produces a copper-nickel concentrate with pyrrhotite as the major diluent. After successful commissioning of the Voisey’s Bay Cu/Ni Mill (VBN) in Labrador, a miniplant campaign on Clarabelle ore with the VBN flow sheet produced a significant recovery improvement over current performance. In 2001, the Mill Redesign Project moved grinding energy into rock/sulphide and pentlandite/pyrrhotite separation and in 2006 Cu/Ni separation was re-introduced to Clarabelle Mill to produce a saleable Cu concentrate. The projects were a great success. What remained was to simplify the Clarabelle flow sheet by introducing the missing components found in the VBN flow sheet. This project known as CORe has evolved through many stages including the mining boom and surviving the 2008 economic downturn and it is scheduled for completion in mid 2013. This paper outlines some of the challenges faced in this major brownfields project – organizational, technical, financial and operational.

Aug 8, 2011

There is no doubt that the mining sector is considered to be the backbone of many countries. Furthermore, it has played an important role in the prosperity of nations, whether developed or developing. Saudi Arabia is one of these countries that has a large variety of metallic and non-metallic mineral resources that range in size and value occurrences of limited potential to deposits large enough to sustain profitable exploitation. Therefore, the Saudi government needs to reinforce the capacity of the sectoral institutions to better regulate and promote the sustainable development of the sector. The ability to overcome the administrative and legal complications that constrain private sector participation in the minerals sector, through new mining code which will streamline the procedures for obtaining licenses and will add more predictability and transparency to the application process, are proposed for increasing the sustainable development. This paper will outline how the Saudi government is tackling the major challenges that face the minerals industry. This paper provides the background to the Saudi Arabian mineral sector and its industrial base. Finally, the paper identifies the problems and constraints that face the minerals sector in Saudi Arabia and provides an assessment of the effects of government policies and planning efforts in the minerals sector, particularly during the period of the development plans which started in 1970.

Jan 1, 2009

By S Whitton, W Wimmler, L Wimmler

“Given the increasing scrutiny of the mining industry and its relatively poor record with regards to mine tailings management, increased requirements to minimise water usage (often accompanied by very high costs of water) and the need to demonstrate achievable long-term closure strategies, it is likely that the option of a filtered tailings system will need to be considered in many operations in future.” (Australian Centre for Geomechanics, 2018). Given such a statement as a conference introduction, it is only appropriate that a range of potential technologies are investigated and compared, to create awareness for even underrated but appropriate technologies. The advantages and disadvantages of all technologies need to be considered and analysed. Suppliers are swift to promote their technologies advantages; however aspects of sustainability are not always fully understood. Perhaps a combination of two filtration technologies is appropriate. This paper delves into the technical details, good or bad, of four mechanical dewatering technologies in tailings dewatering and provides insight on an undervalued and, in the author’s opinion, young technology – the screw press.

Jul 1, 2021

By M Rauer

With a worldwide growing population the demand for higher living standards, food and the development of new technology is rapidly rising. To allow for a continuous growth, larger quantities of minerals and raw materials are needed at a faster pace. Different methods have been developed to access or tap ore more quickly, such as improved drill and blast operations, mechanical mining methods using equipment such as roadheaders (RH), longwall miners and other technical equipment. Another possibility to access and develop mines faster is the use of a tunnel boring machine (TBM).The historical usage of TBMs is surprisingly long, but the opportunity for technology adoption by the majority of worldwide mining companies remains largely untapped. Dozens of full face TBMs have been used by mines around the world, including two that will begin operation soon in Australia. TBMs have been used to safely and rapidly gain access to the orebody, or to expand access to the orebody to increase output by running a TBM along the edge of the orebody for several kilometres. These machines have also been used for ventilation and for conveyor tunnels for ore removal. They have been used to quickly excavate long and winding declines giving access to an orebody at several levels in a short period of time.Tunnel boring technology can be used for mine declines, mine access tunnels and all sorts of different mine designs and set-ups. TBM technology simply needs to be adapted to the mine conditions and, if manufacturers are involved early on in the planning process for mine development, the operation can be very successful. In some cases, historically typical mine designs may need to be re-thought.One mine, the Stillwater Platinum mine in Nye, Montana, is currently employing its fourth TBM in 25 years. Two were used to create tunnels running alongside the orebody, rapidly expanding access to the orebody in many locations for increased output. Two were used to create parallel access tunnels to a mine expansion at the East Boulder orebody; one tunnel is for conveyor haulage and the other for vehicular access. TBMs have been employed successfully many times to rapidly drive vehicular decline tunnels to multiple mine levels, such as at the San Manuel – Magma Copper mine in the USA. While TBM technology may not seem to be optimal for every mine, these success stories show that the method can provide vast benefits for the right projects.Early use of TBMs in extremely hard rock metal mines, in the 1960s and 1970s, had limited success since performance was low. However there have been great improvements made over the years in the strength of rock which can be excavated by TBMs with high performance. Other important improvements involve the provision of a safe work environment, safely and rapidly supporting the rock and predicting geology ahead of the TBM.This paper will briefly note the more than 20 TBM mining projects and highlight some notable successes. It will then go on to give a status report on the two active TBM mining projects in Australia and the difference between a TBM operation versus other excavation methods such as drill and blast (D&B) or RH excavation.CITATION:Rauer, M, 2014. Tunnel boring machines in mines – a?brief review of past use with a status report on use today in Australia, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 663–670 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By S B. Fitch, S A. Wilson, A J. R Barr, P R. Searle

Improving the safety culture and performance of any operation is a fundamental goal of every mine operator. Methods of implementing, or changing a culture have developed from the early methods of operant conditioning, for example rewarding crews for achieving nominated safety milestones i.e. 3 months Lost Time Injury (LTI) free through to the current model of engaging a workforce through education and empowerment. As a large scale and mature operation with multiple contractors, Telfer has been exposed to numerous programs throughout its history. This has provided the opportunity to build on and complement these systems by integrating key elements from each. SAFE 360° is a new approach developed to engage the workforce in a holistic approach to encourage positive behaviours across all facets of an individual’s life which results in a focus on situational awareness at all times, rather than being workplace specific. It is based on three key modules: • Emotional Intelligence • Mindfulness • Situational Awareness Each module has a series of modules that help enhance the individual’s sense of self, leading to an ability to self-reflect and self-manage whilst empowering them with the moral courage to challenge their peers to raise standards. Since commencing this SAFE 360° behavioural safety risk management journey in November 2017, we have witnessed a change in the way our workforce engages with each other, their workplace and with management. There has been an increase in hazard perception, identification and ownership of issues, and we have seen a significant decrease in site TRIFR rate from 13.7 to 5.7 (as of April 2019). This paper will provide an overview of the program, how it has been implemented, case studies to demonstrate outcomes and KPIs used to measure effectiveness.

Mar 15, 2021

By C Hedemann, N Silveste, H Davis, C J. Moran

For nearly two decades water scientists have been debating the need to use appropriate models for the questions being asked and the data available. This paper puts forward a rationale for a hierarchical framework for water balance modelling as it applies to mine sites. The hierarchy is based on the complexity of models and their data requirements. Scientific models are the most complex and require the most data; next is engineering models, then systems models and the simplest representations are given by conceptual models. A position is put forward that systems models have a range of uses that the others do not provide. A systems model, called SiteMiser, is described and its calibration illustrated. The model is applied to seven coal mines from the Northern Bowen Basin in Central Queensland. Currently, there is little relationship between total water use and coal production. This relationship is not any stronger when fresh (raw) water is compared to reused water. Leading practice water use levels are simulated for all sites. The simulation results demonstrate that there is considerable opportunity to reduce water consumption and, in particular, to import less fresh (raw) water to the sites.

Jan 1, 2006

The paper describes data from test work programs on a range of magnetite ores in Australia and overseas. The analysis looks at the behaviour of material of different sizes fed to the rolls and the change in product size as a result of that, the conclusion being that there is a logarithmic relationship. The paper develops a form of equation to predict the product size from a given feed size distribution. The behaviour of the various magnetite ores is compared to more standard test methods such as crushing work index and unconfined compressive strength.

Jan 1, 2009

By A Kondratiev, A E. Moiseev

Viscosity of oxide melts is one of the fundamental physicochemical properties that plays a crucial role in important technological and natural processes like slag flow, slag/metal separation, volcano eruptions etc. However, many oxides melt at extremely high temperatures and are highly corrosive in the liquid state, which makes experimental measurement of melt viscosity by traditional experimental techniques a difficult and expensive, if not unachievable, task. In this case it might be useful to employ other methods of viscosity determination such as modelling or simulation. In the present paper the shear viscosity coefficients of selected pure refractory oxides (CaO, MgO, Al2O3 and others) have been simulated at temperatures above their melting points via the classical molecular dynamics and compared to the available viscosity data (eg experimental viscosities, other model predictions) collected by the authors. The simulation has been carried out using the noncommercial molecular dynamics simulation package LAMMPS and the Born-Mayer-Huggins potential, which parameters for the selected oxides were taken from the literature. Several viscosity calculation techniques (the Stokes-Einstein and Green-Kubo equations, the so called Einstein relations, and the non-equilibrium molecular dynamics methods) have been applied to ensure a more reliable viscosity calculation. It has been demonstrated that the simulated viscosity of the selected melts agrees with the available experimental data. It has also been shown that the simulated viscosity of a number of the oxide melts investigated is close to that calculated by phenomenological viscosity models, which supports viscosity extrapolation from the corresponding binaries and ternaries, if no experimental data is present for unary systems. In general, it has been demonstrated that the molecular dynamics simulation could provide a reasonable estimation of viscosity if no other viscosity data is available.

Jun 19, 2024

By M Badawi, Y Foucaud, C Veloso, J Laine, A C. Araujo

Iron is one of the most exchanged commodities worldwide. Its use for steelmaking explains the growing demand in the metal which remains mainly produced by the mining and the beneficiation of iron ores. Flotation is the most used mineral separation technique worldwide, processing several billion tonnes (Bt) of ore annually, including, in some cases, hematite and magnetite ores. Based on the physicalchemical properties of mineral surfaces, flotation aims to selectively adsorb molecules that render mineral surfaces either hydrophobic or hydrophilic, known as collectors and depressants, respectively. Hydrophobic particles are then recovered in the froth by the injection of gas bubbles travelling up in the cell and attaching the hydrophobic particles. However, despite the popularity and the good performances of flotation, mining industry faces new challenges of decreasing grades and increased mineralogical complexness in ores. Many flotation variables, especially when related to reagent adsorption, remain poorly understood and it becomes necessary to gain knowledge to enhance the existing processes. Molecular modelling techniques like the density functional theory or molecular dynamics simulations (ie Classical molecular dynamics or Ab initio Molecular Dynamics) currently represent powerful tools for different applications in material sciences, like catalysis or depollution purposes. They have recently been successfully applied in the flotation area, with an increasing number of publications dealing with this topic every year. These tools provide crucial information on bulk and surface properties as well as on the adsorption mechanisms of reagents on mineral surfaces, key step in the flotation process, and synergetic effect of collector mixtures. A better understanding of the adsorption mechanisms of flotation reagents, provided by molecular simulations, will help to finely choose flotation reagents, and even lead to the development of new reagents formulations. Overall, these tools enable the discovery of practical and industrial solutions to improve the flotation process, which will undoubtedly help the mining industry to face its future challenges.

Nov 8, 2021

By S Coward, C Xu, P A. Dowd

"This paper provides an assessment of the current challenges in strategic mine planning and design and suggested approaches for addressing them. The specific challenges covered are: realistic quantification of downstream processes applied to orebody models to provide an integrated approach to mine design and optimisation modelling, estimation and simulation of geometallurgical variables and their integration into resource and reserve estimation and mine planning modelling, estimation and simulation of new variables for new forms of mining – deep mining, particularly block caving, and solution mining flexibility in planning and design to manage risk and minimise its impact information technology (IT) infrastructure and platforms for rapid online data collection, storage, access and processing.Most of these challenges require new types of data, variables, modelling and estimation methods. Foremost among the new types of variables and data are geometallurgical and dynamic rock mass characterisation variables. New types of data and data collection include rapid generation of very large amounts of online sensor data and the consequent need for rapid processing and modelling of these data.This paper outlines the challenges and strategies in each of these areas and uses examples of models and outputs to illustrate approaches and potential solutions.CITATION:Dowd, P A, Xu, C and Coward, S, 2014. Strategies for mine planning and design, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 41–50 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By P Walker, I Crnkovic, D Bennett

The Phu Kham deposit represents a copper-gold porphyry system, with mineralisation present in skarn, stockwork and disseminated styles. Significant folding and alteration events have created a complex heterogeneous mineralogy horizon. Weathering and water table contact have created a leached zone, overlying transition zones with supergene chalcocite- dominant secondary copper mineralisation and clay-rich gangue. Primary ore copper mineralisation is mainly chalcopyrite with minor bornite. The major challenges to the copper-gold flotation process are a wide size distribution of chalcopyrite mineralisation and poor primary grind liberation, a high pyrite content in skarn ore requiring aggressive pyrite depression conditions, clay-rich gangue and non-sulfide copper mineralisation in weathered zones, and a significant association of gold with pyrite.The Phu Kham concentrator has been developed as a conventional semi-autogenous grinding (SAG) and ball milling circuit followed by selective rougher flotation, regrinding and cleaner flotation to produce a copper concentrate containing payable gold and silver values. The concentrator flow sheet design offered a capital efficient compromise between high copper recovery bulk sulfide flotation with large cleaning capacity, and lower recovery copper selective rougher flotation to ensure concentrate specification of 24 per cent copper grade could be achieved. This paper will examine and discuss concentrator flow sheet development, including projects implemented since commissioning to improve copper recovery, and future projects designed to maintain and enhance copper in concentrate production with decreasing copper grade and increasing pyrite content of ore feed, and increasing hardness of primary ore.CITATION:Bennett, D, Crnkovic, I and Walker, P, 2012. Recent process developments at the Phu Kham Copper-Gold Concentrator, Laos, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 257-272 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By D P. Blair

Rio Tinto’s Hope Downs Operations are currently mining iron ore in their South Central Pit. Prior to the commencement of mine operations, Hope Downs carried out an extensive archaeological investigation and identified an ancient rock shelter lying within the proposed mine boundaries. The site is significant to the traditional owners/custodians of the land in this part of the Pilbara, and thus the final pit design was changed to preserve the rock shelter, which now lies 30 m outside the mine boundary. In order to further preserve this ancient dwelling from blast-induced damage, blast design procedures were improved over time to minimise the vibration impact when blasting close to the shelter. Blasting and vibration monitoring commenced in May 2008 using pyrotechnic delay sequences and normal-direction firing. In October 2009 electronic delays were used to reverse-fire blasts close to the shelter in order to create a damage zone between the initiating holes and the rock shelter. A detailed statistical analysis of the vibration data shows a reduction in the higher levels of vibration for blasts fired after October 2009, which is most likely caused by the created damage zone. In May 2010, a site-specific vibration model was developed and implemented, and based on Monte Carlo waveform superposition. This model was used to give a further insight and improvement to the blast delay sequences when blasting close to the shelter. However, such models are expensive to implement and have limitations, which reduces their potential for estimating the probability of getting an excessive vibration due to a given blast design. In this regard, it is more realistic and significantly less expensive to use a recently developed probabilistic analysis based on simple charge weight scaling. This analysis shows that there was a higher probability of exceeding prescribed vibration limits at the rock shelter for blasts fired before October 2009 than there was for blasts fired after October 2009.

Nov 8, 2011

By R Cannings, J Wallace, M McCamley

The mining industry continues to have major disasters (Bingham Canyon, Pike River, Upper Big Branch, Mount Polley and Samarco), which often have a devastating effect on the enterprise, in terms of personnel deaths and injuries, environmental destruction, and financial and reputational loss. These disasters are not imposed from outside the business or organisation, they are almost always a function of loss of control of the management of the organisation’s critical assets and processes that they contain or to which they are exposed.Asset integrity is discussed as an effective response to business risks in order to mitigate, control and recover from loss scenarios that could expose a mining operation to significant property damage and business interruption, or even total loss. Vital to this process is the identification and control of risks to critical assets. Components of a critical asset assurance program are presented for discussion.Formal risk assessment has a longer history in industries other than mining, eg petrochemical, nuclear, military, aviation and space industries. Risk assessment is a structured, proactive approach to understanding and improving risks, as opposed to a reactive ‘fix-it-when-it-breaks’ mentality. Risk assessment techniques were triggered by major public disasters, such as the Flixborough chemical plant disaster (1973), Three Mile Island nuclear plant event (1979) and others.Today, most industries see risk assessment as an inherent part of their business, but do mining sites capture business risks that are related to major loss scenarios, which could have a significant impact on the operation?Does your risk assessment process:- involve a team having the right skill set so that the discussion is both stimulated and technically sound?- use generic assessment when a site-specific assessment is needed?- fail to consider all possible outcomes, including maximum foreseeable loss (MFL)?- fail to identify all hazards and controls associated with a particular activity?- fail to monitor controls effectively?This paper addresses the issues identified by these questions and provides some direction for developing a risk management process where business risk associated with critical asset integrity is integrated with other business and safety and health risk processes to provide a robust method for managing your business. Case studies and common findings from critical asset failures are used to support the need to include critical asset assessments as part of business risk management processes.CITATION:Wallace, J, McCamley, M and Cannings, R, 2016. How robust are your asset integrity management processes? In Proceedings International Mine Management Conference, pp 53-64 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By M Kim, J Park, I-K Suh, E Kim, J Lee

One of the key technologies in developing hydrogen-enriched ironmaking operations is the control of the carburisation, melting, and dripping behaviour of the iron ore burden materials. When a hot compacted iron (HCI) is charged in the blast furnace or the FINEX Melter-Gasifier, iron oxide reduction, the reduced iron’s carburisation, and the melting of iron and slag occur successively. This study investigated the reduction, carburisation, melting and dripping behaviour of HCI under a COH2 gas mixture using the high-temperature X-ray radiographic technique. Under 100 per cent CO gas atmosphere, the dripping temperature was 1410°C. When 5 per cent H2 was introduced, the dripping temperature slightly decreased to 1400°C. Furthermore, the dripping temperature gradually increased as the H2 gas composition increased. As 30 per cent H2 was introduced, the dripping temperature reached 1414°C. The carbon concentration in the drained metal samples gradually increased with increasing H2 composition. It is considered that H2 decreased FeO content in the slag, yielding the increased melting temperature and viscosity of the slag. On the other hand, H2 accelerated the carburisation of the reduced iron by CO gas, enabling the homogenisation of the oxide materials to form a liquid phase. Therefore, it is considered that introducing H2 in the reactor is helpful to increase productivity and energy efficiency by accelerating the liquid phase’s formation.

Aug 21, 2024

By P Navarra, R Kuhne

Dynamic simulation (discrete event simulation) is the preferred methodology to evaluate the impact of dynamic aspects of processing plants on the overall plant capacity. This tool can be used to: identify bottlenecks in the plant,justify upgrade and expansion projects by evaluating their impact, oroptimise maintenance and operating practices without disrupting the operation. Iron Ore Company of Canada's (IOC) pelletising plant is a complex operation because of multiple products, varying equipment capacity and shifting bottlenecks. Furthermore, with extensive capital requirements for projects and long lead times, a high level of confidence in project outcome is required. Therefore, a model of IOC's pelletising plant in Labrador City was constructed in 2007 by a joint IOC and Hatch team. The model includes both operational and metallurgical aspects in order to better capture the complexity of IOC operation. In this paper, the justification, boundaries, and functionality of the model are described. A comparison of simulation results to historical plant operation is given. It is observed that projects have interactions and that the benefits of combined projects are not equal to the combined benefits of the individual projects. Projects can have synergies that result in greater benefits when combined or can have overlapping benefits that result in lower benefits when combined. The power of the proposed modeling exercise lies in the ability to assess the impact of projects on overall performance.

Jan 1, 2009

By D Mcleod, S Brindley, S Green

The design and engineering of flotation circuits is driven by numerous inputs, including (in no particular order) testwork outcomes, site considerations, type of separation required, energy sensitivity of the flotation response, personal experience and preference for flotation machines, maintenance access requirements, operability, level of automation and capital constraints.This paper discusses these and other issues in the Australian context and covers the flotation of copper/gold ores and polymetallic (copper/lead/zinc) ores. The paper discusses aspects of the following: how should testwork be done and what are the important inputs and outcomes? how should testwork results be interpreted and how does this impact on equipment selection? what processes can have a critical impact on flotation circuit performance, eg thickening and regrind? what options are available with the typical æflatÆ Australia site? how do you minimise capital cost and what impact can this have on flotation circuit operation and maintenance? how should circuits be controlled and operated? Particular focus is placed on some practical aspects of process design and engineering and the potential impact that engineering decisions can have on flotation plant operation.

Jan 1, 2005