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By R J. deMelo, A, V Suckal, R A. Vilela

Massive hematite ore (MHO) is a special high-grade iron ore used as lump ore in the process of obtaining direct reduced iron (DRI). The influence of porosity on the reducibility was investigated using optical and scanning electron microscopes. Hematite is the main component of the samples and occurs as granular crystals (10 ¦m), microplates (1 ¦m) and euhedral martite (10 to 30 ¦m). Quartz, maghemite, kenomagnetite and goethite are minor components. Primary micropores (+ to 1 ¦m) are associated with microplaty crystals that fill cavities between granular hematite. Secondary micropores (+ to 5 ¦m) related to euhedral martite crystals are the most important. The total porosity of weathered samples, measured using nitrogen adsorption and mercury injection, attains values up to 18 per cent, whereas unweathered samples have a porosity less than 2.5 per cent. Varajpo et al, 2002 showed that reducibility is strongly enhanced by porosity and this work shows that reducibility can be indirectly evaluated by bulk density.

Jan 1, 2002

Laboratory-Scale Magnetohydrostatic Separator for High Resolution Density Analysis of Plastic and Other Wastes Recycling and reuse of different plastic wastes is still a current problem to solve for process engineers and it is true for seeking industrial applications as well as for smaller laboratory-scale, where a given waste sample, plastic or even metallic, has to be precisely separated into narrow density fractions to gain data for industrial design or for scientific research. The principle of magnetohydrostatic separators are known even there are industrial size machines but our primary aim was the development of a laboratory-scale separator for analysis of particles of densities up to 6 kg/L and sizes up to 8 mm. Main parts of the built experimental equipment are the ferrite core with two high power coils. The shape of the ferrite core at the two sides of the separator channel was specially designed to produce isodynamic magnetic field. In these places the ferrite core was constructed from laser cut ferrite sheets. The development of the high power electric supply for the two coils was a real challenge because the high voltage and current (400 V, 30 A) and because it had to be precisely regulated for being able to set discrete relative forces on the particles. Two separator channels were made from transparent plastic. The magnetic fluid is circulated by a centrifugal pump, fresh feed is supplied by a vibrated feeder and products can be taken by built in samplers. The velocity profile in the separator channel is measured by an ultrasonic Doppler velocity meter. Paper reports about the development and itself of the magnetohydrostatic separator and about some fundamental and applied laboratory experiments with different reference particles and wastes from used cars and electrical appliances.

Sep 13, 2010

By T F. McConachy, B I. A McInnes, R A. Binns

Within the last decade, major research discoveries have been made in the submarine realm of magmatic and hydrothermal activity of arc-backarc systems in the southwestern Pacific. These include identification of numerous particulate-poor, gas-rich (CO2-CH4) hydrothermal plumes emanating from arc front volcanoes, actively forming porphyry-copper-gold style mineralisation, and new backarc spreading systems erupting alkali basalt-trachyandesite magmas. Major goals of these studies have been identification of modern analogs to ancient volcanogenic massive sulfide ore bodies, and quantification of the volatile fluxes though supra-subduction zone systems.

Jan 1, 2002

Kinetic Behaviour of Solid/Solid Separation of Ultrafine Particles in Aqueous Suspension

Sep 13, 2010

By D Kotzen

Online cyanide analysers have been successfully used to control free cyanide in the gold/silver leach process for over 15 years. Use of such analysers leads to cyanide savings and improvement in recoveries. Plants with leach cyanide analysers show both lower and more consistent cyanide levels in tailings. Cyanide code compliance requires meeting residual cyanide targets in tailings. Monitoring and logging of the residual cyanide in plant tailings and effluent is required. Meeting targets may require cyanide recovery/destruction processes to be implemented. The operating cost of destroying cyanide is often the same order of magnitude as the cyanidation cost. Various cyanide destruction and/or recovery processes are reviewed. Choice of a process consistent with the environmental and operational requirements is illustrated. Online weak acid dissociable cyanide (CNWAD) analysers have recently been developed and introduced on gold plants. The application of a WAD 1000 online CNWAD analyser at a large gold plant is presented. The analyser ensures code compliance, reduces cyanide destruction process operating costs and forms a historical record of CNWAD values in tailings.

Jan 1, 2007

Electronic noses are being used in the processing industries and in fields such as environmental and occupational hygiene to detect a wide variety of problems from contaminated foods to toxic chemicals in soils. Recently, research has been conducted into the use of these devices for detecting spontaneous combustion in mines with the aim of producing a method for early detection of a developing heating. Gas samples were collected from both SimtarsÆ 16 m3 large-scale spontaneous combustion reactor and the University of QueenslandÆs two-metre column. The samples were analysed using an electronic nose. GCMS and HPLC were used to identify some of the components present. A number of issues both from a practical mine situation and a scientific standpoint have been identified that need to be addressed before these devices can be used to detect a developing heating. Aluminised bags routinely used in the mining industry to collect gas samples for analysis of the permanent gases are not suitable for use with electronic nose devices as they have a æfingerprintÆ from the polymer lining that interferes with the coal heating fingerprint. Tedlar bags used for environmental gas sampling are also unsuitable due to their fingerprint. Gas samples can be collected in glass gas bulbs with aluminium seals and successfully analysed. However the aluminium foil used to seal the bulbs is a restricted item in underground mines. It was also found that the volatile organic fingerprint of the coal heating was extremely weak at temperatures below 130¦C. Before a useful application can be developed, further investigation into the chemical species present in the off-gases from Australian coals is required.

Jan 1, 2005

In November 1969, New Zealand Steel Ltd pioneered the commercial use of the SL/RN solid fuel direct reduction process to make sponge iron as a feed material for electric arc furnaces. Serious process problems with the use of green balls and coal injection were progressively overcome. The process was developed by New Zealand Steel along a radical route, of feeding the fine grained raw ironsand concentrate and coal directly to the kiln. Contemporaneously with this development of direct reduction, steelmaking process innovations were made that enabled the arc furnaces to operate successfully with the high volumes of acid slag. The further expansion of New Zealand Steel's primary steelmaking capacity to replace the currently imported hot and cold flat rolled products is under consideration. The requirement to produce about 600 000 tonnes of steel slabs will be an opportunity to further modify iron and steel making plant and processes to optimise the economics. The conceptual and preliminary engineering selection of options is described.

Jan 1, 1980

By W J. Rankin

Metals are well suited to sustainable development goals. They are not biodegradable and have virtually an unlimited lifespan and the potential for unlimited recyclability. Thus metals can be considered as renewable materials. However mineral resources, the source of primary metals, are ænon-renewableÆ as their supply is finite, but this does not necessarily mean scarcity. In this paper the results from a series of Life Cycle Assessments of primary metal production processes for copper, nickel, lead, zinc, aluminium and steel have been used to examine how metals may contribute to societyÆs transition to sustainable development. Particular issues considered include:current metal reserves and how these may change in the future; some of the environmental impacts (Total Energy, Global Warming Potential and Acidification Potential) associated with primary metal production and how they will be exacerbated by declining ore grades; new processing technologies with lower energy consumptions and improved metal extraction efficiencies that will reduce reserve depletion and environmental impacts; increasing the utilisation of æmetals in useÆ by recycling, with particular reference to aluminium; and the potential impact of a carbon tax on metal prices and how this may influence the ways in which metals are used in the future.

Jan 1, 2002

The process of hydraulic transport through pipelines, worldwide well known for the transport of fine-grain solids is also being used to a greater extent in mining for the handling of primarily coarse-grain solid û water mixtures for the removal of, for instance û coal and waste mixtures after coal winning using hydraulic monitors, tailings for backfilling underground and washer tailings and flotation waste to the dump. A large-scale test unit was taken into service at the Bergbauforschung GmbH (Mining Research Company) in Essen-Kray, GFR, to further improve this technology. The unit was planned and built by Krupp Industrie- und Stahlbau of Duisburg in cooperation with Bergbauforschung GmbH. The paper deals in detail with the demands made on this test unit and the technical results obtained on it and with the planned experimental research work.

Jan 1, 1980

By M Maguire

The purpose of this paper is to provide an illustration of the Resource Management Act processes at their best. Many of you will be aware of the Martha Mine situated in the middle of Waihi Township in Hauraki District. Underground mining ceased on Martha Hill in the 1950s. A new mining licence was issued in the late 1980s and since that date open cast mining has continued at the site. The Hauraki District Council notified its proposed plan in October 1994. Prior to that date numerous discussion papers and draft sections of the plan had been disseminated in the community. Considerable consultation was undertaken with all interest groups. As an indication of the success of that consultation process only 17 references to the Environment Court were lodged following the making of decisions on submissions and further submissions. Those references, which included a number from the Minerals Industry, were all resolved by consent. Out of the reference and consent order process EMMA (Extended Martha Mineral Area) was born.

Jan 1, 1998

Zircon producers are often required to lower impurity levels to meet customer specifications as most of these impurities adversely effect the end use. For example, zircon sand in foundry applications needs to be free of any surface impurities (eg clay, gibbsite and goethite) which otherwise could cause sintering or fusion between cast metal and the zircon mould. Light coloured ceramic grade zircon, typically low in iron oxides and titania, is preferred in ceramics applications. The presence of impurities in zircon sands is a problem in the magnetic and electrostatic separation stages of their concentration. Previous work (Aral et al, 1997) showed that impurities in zircon sand concentrates occurred in the form of stains on grain surfaces, discrete gangue minerals and in the mineral grains. The gangue minerals such as rutile, garnet, xenotime, monazite, spinels, ilmenite, and aluminium silicates in the concentrate in some cases (Aral et al, 1997) contribute significantly to the impurity content of the concentrate. A careful hand picking of the impurity grains from a Western Australian zircon sand showed that the impurity content of the concentrate could be lowered significantly as a result of the removal of the surface stained grains and gangue minerals. The hand-picked ædirtyÆ fraction, comprised about eight per cent by weight of the concentrate, and consisted mostly of iron-oxide/hydroxide-stained zircon, silica grains and rutile, and occasionally ilmenite, monazite, gahnite and other (unidentified) coloured grains. The chemical analysis of the remaining æcleanÆ fraction showed that the major impurities (Fe and Ti) were reduced significantly (Table 1). The reduction in the uranium content was about 30 per cent. The other measured impurities, P, Mg, Al, Th, and Ca remained mostly unchanged as shown in Table 1. The contribution of ilmenite to the overall iron content of æcleanÆ zircon was insignificant as it comprised about 0.1 per cent weight of the æcleanÆ zircon. Rutile was the major source of titanium contamination (about one per cent by weight). Recent work (Aral and Calle, 1999) on zircon sand concentrates from the Murray Basin showed that, under the electron microprobe, the bulk of the impurities occurred in the dark back scattered electron (BSE) regions of the zoned zircon grains. The impurity contents of the light BSE regions and unblemished (unzoned) grains were low. The impurity content in zoned zircons has been investigated on single, relatively large, crystals (McLaren, Gerald and Williams, 1994; Smith et al, 1991; Romans, Brown and White, 1975). These studies generally aimed to investigate the incorporation of U in zircon as zircon is used extensively for U-Pb geochronology owing to its relatively high content of uranium. Smith et al (1991) identified a striking difference in composition between the areas of lower (dark BSE) and higher (light BSE) average atomic number in the zoned zircon. Their work showed in particular that the zones of lower atomic numbers contained very significant amounts of trace metals such as Y, REE, Nb, U, Al, Fe, Ca, Ba and, by difference H2O. In this paper the impurity distribution in zoned zircon grains was investigated on statistically significant number of grains before and after a leach treatment. The distribution of impurities was also measured in unblemished areas to compare the results.

Jan 1, 2000

By R Sinclair, D Landwehr, I Hunter

"The Syama Gold Mine, located in southern Mali, was established in 1990 by Broken Hill Propriety Limited (BHP). The operation began treating oxide, and in 1994 it transitioned to processing hard and refractory ore based on ‘whole-of-ore’ roasting. In 1996, BHP was succeeded by Randgold Resources and the operation ran until 2001, when it was placed into care and maintenance.The Syama ore is classified as a double refractory ore with pyrite occluding the fine grained gold present in the ore and high levels of organic carbon presenting a challenge in terms of preg-robbing behaviour. The ore is extremely competent and this combination of metallurgical features was the main source of metallurgical problems encountered by the previous owners.Resolute Mining Limited (RML) acquired the Syama project in 2004. Following a feasibility study and the development of a revised processing flow sheet the plant was recommissioned in 2008 using a combination of old and new equipment. The revised flow sheet enabled primary sulfide ore to be treated by flotation and roasting of the concentrate to produce a calcine suitable for conventional carbon-in-leach (CIL) processing.Commissioning and ramp up of the plant was a troubled process, with monthly gold production being as low as 3000 oz in 2010. Poor availability of equipment and lower-than-forecast recoveries were the primary contributors.During the last five years, RML has utilised a systematic approach to improve production, focusing on mechanical reliability, metallurgical recovery and process bottlenecks. Modifications to the circuit have been as a result of both innovation and the application of technological improvements. Improvements have been made to the flotation, roasting and CIL circuits and RML has introduced a deslime circuit to treat flotation concentrate, in addition to the very successful commissioning of a new 1 Mt/a oxide circuit in December 2014. These changes have resulted in gold production increasing to more than 20 000 oz per month in 2015.This paper presents the processes, change implementation and outcomes of the modifications made to the sulfide circuit to address the availability and recovery problems.Apart from the expansion of an existing, world-class deposit and discovery of new resources, future improvements on the path to a class-leading gold mine include the continued reduction of the unit cash cost, increase in overall sulfide circuit gold recovery, increased throughput through continued innovation and consistency in the plant’s operation.Citation:Sinclair, R, Hunter, I and Landwehr, D, 2016. Syama Gold Mine - the Journey towards a Class-leading Gold Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 213–224 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By P Meehan, R McAree, Z Guan

Equipment maintenance is 30 - 50 per cent of the operating costs for a typical mining company. While this is substantial, its importance is beyond its significance as a cost heading. Modern mining requires large amounts of investment in capital infrastructure and equipment to produce a product sold at a low unit cost. To stay competitive, such a business has to focus on full realisation of its capital investment, ie sustained production at high levels. Maintenance plays an essential role in achieving this goal. Mining companies typically use a mix of breakdown or corrective maintenance, planned maintenance, and some condition-based maintenance. The share of breakdown maintenance has been coming down through more effective planned maintenance and better condition monitoring tools. Planned or preventive maintenance (PM) is playing an increasingly important role in todayÆs mining maintenance. This is the suite of inspection and repair/replacement actions performed at scheduled time intervals as part of a preplanned activity. The activities are scheduled well in advance and, usually, the current wear-state of the machine is irrelevant. For example, the replacement of a major gear may have been planned 18 months in advance; replacement is carried out when the time comes regardless of the actual condition of the gear. The PM costs are significant and include direct cost of parts and labour as well as the opportunity cost of lost production while the machine is under maintenance. It is important to identify the optimum PM effort because over-maintenance should be avoided as much as under-maintenance. A new concept called severity-based maintenance is introduced in this paper. We have seen that measuring equipment ageing in mining merely by counting the engine hours is a very imprecise way of planning and scheduling maintenance because the damage accumulated in one hour varies enormously from operator to operator and with changing pit conditions. We recommend continuous monitoring of duty on all major equipment. This is feasible without having to fit out the machine with an army of sensors because most of the physical sensors required by dutymeters are already installed and maintained as part of the existing performance monitors. While the investment is modest, the potential benefits are huge and can be grouped under three headings:Immediate benefits will come from providing operators with direct feedback on the effect of their behaviour on machine health and training them to use this feedback to correct their operating style. The equipment can operate closer to the limits of capacity, producing more without unduly sacrificing the availability by monitoring and controlling the severity of the operation, ie the duty on the machine. Longer term benefits accrue from establishing correlations between actual time to failure data and measured equipment duty and using these correlations to optimise maintenance effort as well as planning new equipment purchases and warranty conditions.

Jan 1, 2002

By K Broadley

Risk and dispute resolution are linked. Dispute resolution techniques are brought to bear on a dispute - which is an outcome of a risk being wholly or partially realised. There has been an increasing awareness by business of risk as a component of doing business. There is an accompanying awareness of the need to manage risk - including legal risk. Many companies have undertaken a systematic review of their potential risks and endeavoured to put in place systems to help to avoid or manage risks. A legal risk management program will not prevent disputes arising. However, such a program should prescribe how that dispute will be managed. The management of the dispute will involve consideration of the dispute resolution procedure to be adopted. The most appropriate processes will take into account the practical, personal and commercial considerations surrounding the dispute and be as efficient, cost-effective and user friendly as achievable in the circumstances for the benefit of all the parties. Carrying on business in South East Asia, whether as an explorer or a mining operator, brings additional considerations to bear in legal risk management and the dispute resolution process. A significantly different perspective is required due to the varying nature of the legal systems in many South East Asian jurisdictions. These jurisdictions often have relative uncertainty as to the law. This impacts on the dispute resolution processes and also raises further timing and cost issues. The authors contend that this is all the more reason to endeavour, as practically as possible, to adopt a legal risk management and dispute resolution profile which will provide business with the greatest prospects of maintaining control of the dispute resolution process. This presents a greater chance of a successful outcome to the dispute. In these times of increasing pressures on profitability because of low mineral prices, all costs of a minerals business are being reviewed. In such times, a significant legal dispute may have even greater potential to adversely impact on the companies concerned, together with the careers of the people involved. In this paper possible approaches to managing disputes and a case study a legal dispute in which Freehill Hollingdale and Page were involved are discussed. The dispute concerned an international mining company developing a gold mine in Indonesia and one of its contractors in Indonesia. Described is how that dispute was resolved. This achieved a very satisfactory result for the client - all things considered. Given the æadditionalÆ problems associated with ascertainment and enforcement of ærightsÆ in South East Asia, the longer the parties can retain control over their dispute the better off they will be. For this reason, the authors set out in this paper the main additional dispute resolution tools available - that are appropriate for use throughout South East Asia.

Jan 1, 1999

By R Hoskings

Conceptual studies of the run of mine stockpiling and reclaiming requirements commenced in 1975. Final selection of equipment was made in 1978 and the equipment was commissioned in June, 1979. Equipment selection was made after extensive investigation and visits to existing facilities throughout the world. The equipment selected is described and compared with the alternatives. Foundations were designed to minimise cleanup effort and to ensure stability of equipment under design wind loading without storm bays. Programmable logic control enables the stacking and reclaiming facility to provide a blended feed to the coal preparation plant.

Jan 1, 1980

By L Torckler, R L. Brathwaite

At Neavesville gold-silver (electrum) mineralisation occurs in steeply-dipping zones of intense fracturing, brecciation and quartz veining within rhyolitic pyroclastics, carbohaceous shales and andesites. Hydrothermal alteration extends over an area of greater than 3 by 1.5 km. In rhyolitic tuffs, highly silicified zones containing quartz-adularia-illite assemblages are flanked by less silicified assemblages composed of albite, illite-montmorillonite and chlorite. The mineralogy and sequence of alteration are comparable with the alteration zones which envelop the steam-producing fissures of the active Wairakei and Broadlands geothermal fields. Primary fluid inclusions in quartz from five fissure veins in the Neavesville field show maximum homogenisation temperatures ranging from 220 - 260¦C and salinities of 0.0 - 1.1 wt per cent NaCl equivalent, which cover a similar range to actual measured temperatures and salinities in geothermal fluids at Wairakei and Broadlands. The age of the rhyolitic pyroclastics and related alteration and mineralisation is probably Pliocene and Neavesville therefore represents a fossil geothermal system. The intensely fractured zones containing the gold-silver mineralisation were probably produced by hydraulic fracturing generated by accumulation under pressure of hydrothermal fluid in blind fault zones. Study of fluid inclusions indicates that hydrothermal quartz associated with electrum was deposited under boiling conditions. High grade electrum mineralisation at Graces workings appears to be localised by reaction of hydrothermal fluid with sedimentary marcasite in black shale.

Jan 1, 1980

The mining industry continues to be a major driver of the Australian economy generating over A$130 billion in export earnings in 2008/2009. However, the industry has been cited as a significant contributor to green house gas emissions. Australia's proposed carbon trading scheme, the Carbon Pollution Reduction Scheme (CPRS) will financially impact on mining operations; this calls for a holistic planning approach for mining operations taking into account the impact of the emissions trading scheme. Since carbon trading is a new area of study, particularly within Australia, the quantitative effect of the CPRS on the mining industry is uncertain and current mine planning practices do not directly consider emissions. This paper presents results of the study into the impact of the CPRS on a hypothetical large scale open pit operation, using a spreadsheet model based on linear programming and simulation. By varying the production rates, life of mine (LOM), carbon price and ore grades among other variables several scenarios were simulated to determine the impact of emissions trading scheme on the net present value of the project. This study found that the adoption of the proposed Carbon Pollution Reduction Scheme could impact mining operations in Australia by a three per cent to six per cent reduction in net present value, for carbon credit costs of $25/t to $50/t respectively. While the six per cent reduction in net present value for a mining operation is significant, rising fuel prices have had a similar effect in recent years. The most energy-intensive processes are the milling circuit and the flotation concentrator circuit. These processes are jointly responsible for up to 60 per cent of the total emissions, depending on the production rate and the level of offshore processing conducted. Clearly, the introduction of the CPRS makes it is imperative for mining companies to assess the impact of carbon emissions on a mining project during mine planning.

Dec 6, 2010

By P Vix

A thermodynamic model of the copper Peirce-Smith (P-S) converter has been developed to predict the behaviour of magnetite in the converter slag, the amounts of slag and matte, the compositions of slag and matte, the volume of the bath, the bath temperature and the SEMTECH OPC signals. The predictions of bath temperature, slag and matte compositions and magnetite content in the slag have been validated by the industrial data. The effects of fluxing strategy, returns and skim charges, oxygen enrichment and temperature on the magnetite formation in the slag have been predicted and discussed. Some industrial applications of this model have been presented.

Jan 1, 2005

By L Langer, R Simcock, M Davis

Rehabilitation of mining sites helps to achieve the purpose 5(2c) of The Resource Management Act 1991 û æavoiding, remedying, or mitigating any adverse effects of activities on the environmentÆ. The environmental outcomes for recent and current mining operations on the West Coast are variable. There are some exemplary mining operations which are restoring or even improving land use and environmental factors in the region, particularly those operated by the larger mining companies. There are also examples of an exploitative mentality where the environment and land have been severely degraded by mining activities. Technology has been developed to prevent a repetition of the historical destruction of the environment through mining. Failure to rehabilitate mined land is no longer acceptable to the New Zealand public in the 1990s and damages the credibility of the mining industry. Examples of successful mine site rehabilitation to pastoral farming and to production or plantation forestry are illustrated from the alluvial gold mining industry. Planning, sequencing of operations, the utilization of sailor plant growth materials, and aftercare are key factors in successful land rehabilitation to these productive uses. There is also a recent focus on restoring indigenous forests and wetlands at both coal and gold mining sites, particularly for mines on or adjacent to the conservation estate. The results of scientific research and efforts by the industry on techniques for rehabilitating rainforest and pakihi wetland after mining are presented, particularly from the Giles Creek Dunoille Coal Mine. There is a need for further research and trials to apply and extend rehabilitation techniques to other geological and environmental situations, particularly to mines in mountainous areas and to difficult environments like the coal measures ecosystems of the plateaux above Westport.

Jan 1, 1996

South Africa has joined the league of other major Western World countries by officially adopting its own code for public reporting of Mineral Resources and Mineral Reserves. The recently published South African Code for Reporting of Mineral Resources and Mineral Reserves (SAMREC Code or Code) (SAIMM 2000) is presented here in its local and global context. The main aspects of the Code are listed and elaborated upon. The Code has been written with the participation of the major South African stakeholders in the field including Government institutions, the legal confraternity and the mining industry. Relevant foreign organisations, such as the Australasian Joint Ore Reserves Committee (JORC) and the United Nations contributed to its compilation, and supported it. The Code thus enjoys endorsement both locally and, to a large extent, overseas. The Code is modelled on, and is 90 per cent compliant with, the Australasian Code for Reporting of Mineral Resources and Ore Reserves (JORC Code) (AusIMM, 1999). The paper also elaborates on the duties and responsibilities of Competent Persons signing off resource and reserve reports and on the new listing requirements of the Johannesburg Securities Exchange (JSE), formerly the Johannesburg Stock Exchange, which has officially adopted the Code.

Jan 1, 2002