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By R Piper

The Yabulu Nickel Refinery commissioned in 1974, processes lateritic ore via a modified Caron process to produce high quality nickel and cobalt products. The Greenvale orebody provided the sole source of feed to the plant until 1990 and with well-blended mineralogy, it resulted in stable and predictable plant performance, allowing the operating focus to be on reducing energy consumption and increasing ore throughput. This approach provided better economics than pursuing increased reduction efficiency. From 1990, increasing quantities of lateritic ore were imported from Indonesia, Philippines and New Caledonia. This introduced considerable variation in ore blends and instability in plant operation but also provided the opportunity to treat higher grade ore blends which yielded higher reduction efficiencies. Ore reduction is conducted using 12 Herreshoff multiple hearth reduction furnaces, using heavy fuel oil as reductant. The æROASTERÆ Project was approved in November 2000 with the primary objective of improving Nickel reduction efficiency by: Stabilising Roaster Operation via a structured program including focused maintenance efforts, capital equipment upgrades, new process measurements, process re-design and improvements to operating skills and process troubleshooting. A structured technical program including laboratory and plant studies using one plant furnace as a pilot unit to develop improved knowledge of how the reduction process proceeds in the Herreshoff furnace. Armed with this knowledge, optimised process conditions and a reduction process model were developed contributing to a significant demonstrated reduction efficiency improvement. Technical input to the project was provided by QNI with Hatch providing the engineering and project management for the $8.5 M capital work. Execution of the work included extensive consultation with the plant operators and close cooperation between the Hatch project team and QNI operations personnel ensuring installations were completed with minimal production disruption. A strong focus on safety management resulted in a number of brownfields project relevant safety initiatives being implemented resulting in project completion without a serious injury.

Jan 1, 2002

The paper reviews winder rope inspection procedures at the Non Destructive Testing (NDT) Unit of Western Australian School of Mines (WASM) and outlines measures taken to adopt the world's best practice. The measures include acquisition of a new type of rope tester, adoption of comprehensive rope rejection criteria, adoption of a standard rope inspection procedure and formal training of the wire rope inspectors.

Jan 1, 1995

As defined by both the Australian and New South Wales Governments the Illawarra consists of the Tablelands, the Local Government areas of WingecarribPe Shire, Bowral Municipality and Mittagong Shire, the Wollongong sub-region consisting of Wollongong City Council, Shellharbour Municipality and Kiama Municipality and finally the Shoalhaven Shire. I intend here to concentrate on community development in the Wollongong sub-region.

Jan 1, 1976

By E Topal

There are presently no suitable underground mine production scheduling optimisation models available for application to sublevel stope mining. Scheduling underground production for maximum return is therefore still a manual process, which generally involves scheduling production from the next available highest cash flow stope within the operational constraints of the project. In most mining operations, the scheduling problem is too large and complex to guarantee truly optimal results through manual scheduling. This paper reviews some general optimisation studies that have been proposed for underground hard rock mining. Furthermore, an example of a mixed integer programming model is presented for a small conceptual sublevel stoping operation. Comparative results of a schedule generated by a mixed integer programming (MIP) production scheduling model and a manually generated model on a nine stope example is presented. Results indicate that the potential benefits of the MIP production scheduling model for the purpose of maximising NPV are significant. Finally, a new constraint was formulated to limit multiple exposures of fill masses for use in an existing MIP production scheduling model. Testing of the formulation took place on the central stope of the nine stope example, which showed that the formulation performed its task without breaking other operational constraints.

Jan 1, 2007

Lower Silesia Coal Basin/SW Poland/ is adjacent to highly gas saturated igneous massiv and since the beginning of this century more than 1500 outbursts have occurred in four existing mines, including 1295 in the most hazardous mine Nowa Ruda. Prevailing part of these are carbon dioxide/coal outbursts of ejected masses 50-5000 tonnes/av.200/t and gas volume released from 200 m3 to 800,000 m3 Magnitude of these phenomena is growing with the depth and for present extraction levels/ 375-753 m/ may be expressed by a formula: M = 4.25/H-400/, where M-masses ejected, t and H - depth of extraction, m. Regulations obligatory hitherto call for gas pressure measurements to be made in 3 m long and 42 mm dia. boreholes spaces not more than 25 m along the longwall face and taking sample of drillings for desorption testing. Criteria of a hazard are following: pressure higher than 30 kPa /for C02/ or 80 kPa /for CH4/ and desorption more than 1,44 cm3/g. These criteria are not satisfactory because many outbursts occurred in spite of low values of parameters measured and for several times no hazard was evident after very high values were obtained. Moreover, observations show that a huge majority of case outbursts occurred in coal weakened by local geological distortion.

Jan 1, 1980

By M R. Davidson, M P. Schwarz

A model for column bioleaching is investigated to identify and understand aspects of bacteria in bioleaching applications, which have implications in heap bioleaching operations. The model is used to simulate scenarios that would otherwise be time consuming to perform experimentally. This study uses a model of bacterial transport and attachment/detachment to ore particles, with a bioleaching model for the depletion of a copper-sulfide, also accounting for liquid and gas flow and gas/liquid oxygen mass transfer. The model includes aspects such as oxygen and ferrous ion consumption, coupled with leaching of a copper-sulfide via the shrinking core model. The model is used to investigate how the rate of leaching is affected by the bacterial concentration in the columns, by the bacterial regeneration of the leaching oxidant ferric ions. The model is also used to assess the impact of oxygen limitation and inoculation method on the copper leaching. Some comparison of the model with experimental data will be shown.

Jan 1, 2004

By Jelenich L, Murray J. Rantanen J

The experience gained in the development of an Operator Guidance System (OGS) for on-line process control and fault diagnosis in a commercial scale sintering process will be discussed in this paper. The OGS development started with the specification of feasible control and support tasks, eg ratio control scheme, mass balance calculations. Next, minimum requirements for fault diagnosis and process control were defined and the adequacy of existing instrumentation was assessed. The OGS knowledge base consists of both quantitative and qualitative diagnosis methods. Quantitative models based on fundamental engineering principle are used first and any gaps in such quantitative knowledge are then filled with heuristic rules. The diagnostic rules for the knowledge base was developed based on the knowledge acquired from experienced operators and operations engineers and validated with plant data. A real time reasoning program was written using C language and data base software. The OGS has a human-computer interface which is the primary means of interaction between the OGS and process operator. The OGS development has been successful in assisting operators in decision-making in their routine tasks. Further enhancement to the existing system is currently underway.

Jan 1, 1995

By AJ LYNCH

Broken Hill metallurgists have been responsible for some of the most important developments in mineral processing technology. These occurred mainly in two periods, 1902 - 15 and 1955 - 70. Mineral flotation was developed as an industrial process during the first period and this happened in two stages, the recovery of zinc minerals from the tailings dump accumulated during the gravity concentration of the oxidised ores and the selective recovery of galena and marmatite during flotation of the primary ores. During the second period fast accurate analytical procedures were developed to provide rapid assessment of process performance, and new means of controlling the process were devised which improved throughputs, grades and recoveries. These technological successes were due to the skills of the metallurgists and the commitment of the companies. They brought large financial returns. They were achieved under difficult circumstance. There are important lessons to be learnt from these successes.

Jan 1, 1992

By McDonald K. J, Flann R. C

A liquid phase sintering (LPS) process for preparing basket anodes from nickel powder has been scaled-up and the innuence of compact green density and sulphur content, as well as sintering conditions (period and syngas now.rate) on the perfonnance of anodes has been evaluated. The product anodes have been tested in an industrial electroplating tank. It is concluded that if anode residues are to be minimised, then with a sintering temperature of 960"C, compact green density needs to be as high as economically achievable (85 - 87 per cent density of solid nickel) and the sintering period approximately 40 minutes. With these constraints, if residual sulphur contents of anodes are to be kept as low as those of commercial anodes, then the sulphur content of the green compacts would need to be less than 1670 ppm. At the same time, it is also found that residual sulphur concentrations as high as 2000 ppm are beneficial to anode pcrfonnancc and not detrimental to the quality of the electroplate. The ability of the LPS process to produce marketable nickel anodes for the electroplating industry is clearly demonstrated.

Jan 1, 1993

By J C. Furness, F S. Cannon

Metal casting operations are a significant source of hazardous air pollutants. In particular, high production iron foundries emit significant quantities of volatile organic compounds (VOCs) during pouring, cooling and shakeout of iron castings made in green sand molds. End-of-the-pipeline capture and destruction methods to reduce VOC emissions add crippling costs to foundries. Alternately, the incorporation of advanced oxidants (AO) into metal casting green sand systems has been shown to reduce emissions from high production iron foundries in the US, and at the same time reduce operating costs. Cost savings are driven by the benefits of AO in clay recovery systems. Emissions reductions are the direct result of cascading AO-based reactions taking place in green sand molds. This sustainable greening of the metal casting process is a prototype for the development of other AO and non-AO process-based solutions for sustainable high temperature processing of materials. Fundamentals of AO technologies will be discussed along with the performance characteristics of AO processing systems in the metal casting industry and the breadth of other processing and remediation applications for which AO technologies have the potential to be successfully employed.

Jan 1, 2002

By B Oostendorp, R van der Merwe, P

In order to assess whether polysaccharide depressants are strongly or weakly and reversibly bound to the surface of talc, a series of experiments was conducted on New York talc in which the floatability of the talc in a microflotation cell was determined. The talc was conditioned in solutions of carboxymethyl cellulose (CMC) or guar gum in 10-2 ionic strength Ca(NO3)2 or Mg(NO3)2. The talc was then washed with four successive aliquots of water, or cation solution, to try to remove the polymer and the flotation response of the talc was assessed. CMCs of different charge (DS) were used to assess the effect of charge on the strength of bonding. The results show that CMC and guar gum could be removed to a large extent from the talc surface by washing with water (the floatability was restored), however very little could be removed from the surface by washing with cation solution. The higher charge CMC was easier to remove from the talc planes in the absence of cations than the lower charge CMC. Thus CMC bonding to talc has been shown to be irreversible or very slowly reversible only if cations are present, implying that cations are necessary to keep the polymer bound to the surface of the planes to effect depression. The presence of ions in solution also had the effect of maintaining surface coverage of the talc by guar gum.

Jan 1, 2005

By K Kuganathan, Y Potvin

Enterprise Mine at Mount Isa is to expand ore production from the current 1.4 to 3.5 mtpa by mining the 3500 Orebody, from which production is scheduled to start in February 1998 making this the deepest underground mine in Australia with its lowest mining horizon at nearly 1.6 km below surface. The following fill requirements were defined for the 3500 Orebody during the feasibility study: a minimum filling rate of 250 m3/h, a curing time of 28 days, and minimum free fill water. This paper mainly describes the investigation of high density and paste fills for the 3500 Orebody. The investigation covered all the key issues relating to fill option selection, including design criteria, material supply and demand assessment, drainage modelling, tailing dewatering method, mix design and a pump loop test. Results of the investigation indicate that both high density fill and paste fill are technically feasible. The investigation has led to the selection of a blended tailing paste for the 3500 Orebody as the paste option has significant advantages over high density fill in stope filling rates and fill reticulation. The blended tailing for paste fill is finer than Isa deslimed tailing but coarser than full plant tailing. The paste fill selected has minimum binder and tailing dewatering requirements while a relatively high filling rate is achieved.

Jan 1, 1998

The advancements achieved in rapid tunnelling in the 60's and 70's have been notable. It is unfortunate that shaft sinking has not enjoyed equivalent advances and there are many good reasons why this is so. Technical and commercial considerations have held back development and continue to do so despite the increasing urgency in the search for minerals and energy. By the careful selection of an appropri- ate project and the application of specialist engineering the Bdard took advantage of a unique opportunity to apply a mechanised shaft borer in field conditions.

Jan 1, 1981

By A J. MacDonald, M P. Raffield

The South Deep massive orebody consists of 20 to 30 m of payable conglomerates ranging in dip from 11¦ to 20¦ and at depths of between 2400 m and 3400 m. The mine design process selected a mining method with a proven record of application that could be adapted to overcome the inherent difficulties associated with the depth, thickness and structural influences of the South Deep orebody. A modified cut and fill mining method provides a concentrated and highly flexible method of extraction. An integrated destressing cut will enable the modification of the stress environment such that it is suitable for massive mining operations. The choice of backfill type and stoping width in the destressing cut ultimately determines the characteristics of the stress modification and, as such, is critical to the success of the cut and fill operation. This paper discusses the decision process undertaken to determine the optimum backfill type and stoping width combination in terms of, conditions in the destressing cut faces and in the massive mining environment. Numerical modelling has been extensively used to analyse various scenarios to aid in the decision process.

Jan 1, 1998

By A Xenidis, N Papassiopi, I Paspaliari

Acid generating sulfidic tailings covering a surface area of approximately ten hectares have been deposited in the historic mining area of Lavrion in Greece. For the development of a remediation strategy, the performance of three alternative acid generation control techniques was assessed under actual field conditions. The techniques involved the application of dry covers, including a synthetic HDPE liner and a compacted clay layer with capillary barriers. Furthermore, the potential formation of a low permeability hardpan layer at the sulfidic tailings surface by limestone addition was investigated. The field tests covered an area of 2500 m2, which was divided in equal quadrants, corresponding to the control plot and the three alternative remedial options. To monitor the amount and quality of percolated water, lysimeters were installed beneath the four plot areas. Based on the monitoring results over a period of six years, due to the dry climate encountered in the Lavrion area, a low amount of water percolates through the pyrites if no action is taken (control area), corresponding to 20 - 25 mm per year. This water is highly acidic, pH = 1.2, and contains a heavy load of contaminants, eg Fe 40 g/L, Zn 15 g/L, and As 1.5 g/L. The HDPE cover eliminated the percolation of water into the material for a period of five years, whereas thereafter the volume of leachates increased to values similar to those recorded in the control plot. The water collected in the lysimeter of the clay cover has been minimal corresponding to approximately five per cent of the drainage volume produced in the control area. In the fourth plot, which involved limestone addition to sulfidic tailings, the volume of drainage initially collected was almost double compared to the control area. After three years of monitoring, significant reduction in the amount of percolated water was observed, attributed to the formation of a cemented layer (hardpan), at a depth of 40-80 cm from the testpad surface.

Jan 1, 2003

Whether you are an employee, contractor or consultant working in the mineral industry, there are pressures to deliver the best possible performance. Technical professionals are usually driven by an internal desire to perform to a high standard because of personal pride in their profession, but there are an increasing number of external requirements to demonstrate that the actions taken were based upon reasonable grounds and that the work conformed to current best practice. People expect these best practice procedures to be followed and governments are now requiring those tendering for contracts to be registered in some way and to be participants in quality assurance schemes. One is not immune to these pressures just because you are working in a less legislatively sophisticated developing country in the circum-Pacific rim (Pacrim) region.

Jan 1, 1995

A Presidential Commission of Enquiry into the conservation of South Africa's coal resources was appointed in 1970. This Commission, in co-operation with the Chamber of Mines of South Africa, established a national inventory of South Africa's in situ and extractable resources and reserves of coal of various types and grades by several mining methods. South Africa's future demand for coal by all market sectors and the specifications of coal required, were also established by means of econometric models. A comparison of potential supply and anticipated demand indicated serious defi- ciencies of certain types of coal and the need for the conservation of others. This paper describes recommendations for alternate strategies for the optimum utilization of available resources. Con- sideration was given to various policies relating to pricing, exports, taxation and incentives, and to the possibility of the substitution of higher grades of coal by lower grades. The steps so far taken to develop a national coal policy in South Africa are described.

Jan 1, 1977

By Woods PW

Consulting Engineers have been used in the mining and metallurgical industries for many years. The traditional role of the consultant overseas has been one of assisting with conceptual design right through to con- struction and commissioning as well as on occasion acting solely in specialist fields. This role developed because mining companies wished to concentrate on building up the permanent organisation they require to operate their mines and treatment plants without the traumas of increasing staff for the design and construction period and reducing it on completion. In Australia where there have been few individual minerals projects of magnitude (until recently) companies have looked after their own detailed engineering and construct- ion management employing consultants mainly in specialised fields.

Jan 1, 1975

The Northern Mariana archipelago in the W.Pacific forms a classic intra-oceanic island arc system far from the influences of continental crust. As such it offers an ideal location in which to study many of the problems of subduction-related volcanism. Radiogenic (Sr, Pb, Nd and Hf) and stable (0, S and H) isotope systems have been applied to the question of the possible involvement of components from the subducting slab in arc magmagenesis. The results contrast with earlier studies based upon limited sample suites and suggest that fluids, derived from the slab and enriched in mobile elements, substantially modify the composition of the mantle wedge and contribute to the characteristic geochemistry of arc magmas. Trace element data, including the occurrence of negative Ce-anomalies in the lavas seem consistent with this conclusion. Major and trace element variations within the arc lavas can be modelled in terms of crystal fractionation of a gabbroic mineral assemblage and mixing calculations indicate that this has the approximate composition of PLAG:CPX:MAG:OLIV = 60:25:10:5. This observation is compatible with the widespread occurrence of gabbroic nodules in lavas throughout the arc. Consideration of Rare Earth Element and phenocryst data leads to the conclusion that many of the more basic lavas may be the products of cumulus enrichment. The results of this study constitute a model for magmatic processes occurring in simple island arc systems, and may be generally applicable to other, more complex settings. The recognition of a return flux of material with 'continental' affinity to the mantle, via sediments on the subducting slab, also places strong constraints on geochemical models of crust-mantle evolution.

Jan 1, 1987

By Haeussler P, Christie A, Bradley D, Skinner D

Mesothermal gold deposits of southern Alaska and Westland, New Zealand have both formed at the seaward edge of major collisional zones in the Pacific basin. In Alaska, production of large fluid volumes correlates in time with the addition of heat into the lower parts of the accreted terranes in the late stages of collisional orogeny. This heat was critical for driving both the metamorphic reactions that released the large volumes of fluid that carried the gold, and the contemporaneous widespread anatexis and magmatism. In Alaska's Chugach terrane, this heat was produced by subduction of a spreading ridge beneath the North America continental margin in the Eocene. The resulting products were the S-type granites and gold-bearing veins. The similar widespread S-type plutonism and gold veining in Westland's Buller terrane suggest that a similar tectonic event could have triggered ore formation along the southeastern edge of Gondwanaland. Based on the Alaskan model, a Devonian or Early Carboniferous age is favoured for high volume metamorphogenic fluid generation and gold vein formation in Westland.

Jan 1, 1995