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By A Specht, A Müller, V Montenegro, S Winkler, E Klaffenbach, A Schmidt

In the process of primary copper smelting in flash smelting furnace (FSF), the ratio of iron to silica (Fe/SiO2 mass ratio) primarily determines the slag viscosity and magnetite formation. Viscous slag does not only cause difficulties in daily operation, such as in tapping, it also increases the copper losses to slag. Thus, keeping the Fe/SiO2 mass ratio at the desired level is an important aspect of FSF and slag cleaning furnace (SCF) operation. In this study, the improvement of the Fe/SiO2 mass ratio was conducted in two steps: First, the optimal Fe/SiO2 mass ratio was derived based on thermodynamic data. Based on this analysis, appropriate control limits were determined. Second, this range of favourable Fe/SiO2 mass ratios was implemented into operation by an advice-based control system, which suggests the addition of silica based on the analysis of SCF slag. As this approach was successful, the same advice-based control system principle was adapted for the coke addition to the SCF. After testing the new advice-based control for several months, the production data confirm the predictions by thermodynamics: since the prediction was implemented as an advisor, the copper and magnetite content in SCF slag is significantly reduced and viscous slag is reported less often by operations.

Aug 21, 2024

The high cost of sampling systems is largely due to the fact that indiv- idual mechanical type sampling units must be installed at the discharge end of ore/pulp pipelines, that is, at points where the pipeline discharges into pump sumps or the like. A considerable economic advantage may be obtained in the use of a samp- ling device that can be installed at any point in the path of the trans- porting pipe line. Initial tests on a vertical line with an injection sampler using iron ore concentrates reveal the validity of this type sample versus that taken with a mechanical sampler. A descrip- tion of the injection sampler shows its simplicity of installation, requir- ing minimum downtime on existing lines.

Jan 1, 1976

By Lynch AJ, Musgrove NH

The behaviour of chalcopyrite and pyrite in the rougher-scavenger and regrind-retreatment circuits in the Warrego concentrator is discussed. The effects of change in xanthate addition on the separation of chalcopyrite and pyrite is described. The effect of the regrind mill on the (flotation rate of particles containing chalcopyrite and pyrite is discussed with particular reference to the importance of removing sub-mesh particles from the feed to the regrind mill.

Jan 1, 1975

By X Hu, J Björkvall, L Sundqvist Ökvist

The metal production industry is a significant contributor to global CO2 emissions due to the use of fossil fuels such as coal and coke. To mitigate these emissions and meet climate goals, innovative and sustainable technologies are required. Molten salt electrolysis is a promising technology that directly produces metals from their precursor sulfides or oxides using electricity. When combined with renewable electricity and an inert anode, the electrolysis process can be carbon neutral. This paper presents the results of two pilot-scale studies on the electrolytic reduction of metal oxides and sulfides in molten salts. The first study focuses on the electrolytic reduction of chalcopyrite in molten NaCl-KCl salt. The results demonstrate that in situ separation of copper, iron, and sulfur is possible, enabling the extraction of all valuable elements without CO2 emissions. Furthermore, the findings underscore the capability to eliminate impurities like zinc, antimony, arsenic, and mercury from the electrolysis product. The second study investigates the electrolytic reduction of pure/synthetic chemicals of wüstite, hematite, and magnetite, as well as a magnetite-type iron ore in molten NaOH salt. The findings reveal a stepwise reduction of iron oxides from high valence to low valence, ultimately leading to the production of metallic iron electrolytically. Notably, this study underscores the challenges associated with the selection of an economically viable and durable inert anode material for efficient oxygen generation. These results indicate that molten salt electrolysis provides a sustainable and green route for base metal production. The use of this technology has the potential to significantly reduce CO2 emissions in the metal production industry, contributing to achieving climate goals.

Jun 19, 2024

This paper presents a resume of the likely profitable mining areas in New Zealand. It covers the main "minerals" - gold, coal, oil and gas, ironsands, silica sands, clays, lump silica, perlite, sulphur and limestone.The potential mining projects are depicted on a map of New Zealand together with the associated works involved in hydro-electric and geothermal power development requirement for industries such as aluminium, nickel ferro-silicon or silicon carbide production.The political need for mining development to relieve unemployment and reverse emigration is stressed. A case is made for exploration and development assistance by government in labour re-training, energy supply and transportation, if the tremendous losses through lack of use of human and industrial resources are to be rapidly reduced. These losses are currently estimated at $10,000,000,000 per year.The need for protection of the sanctity of contract and security of tenure of all mining operations is touched on briefly as is the need for a reasonably balanced view on conservation. However as both of these are more properly covered in papers on the legal and environmental aspects of the mining climate they are presented here only as they affect the economy of the mining operation.Finally there is a brief comment on the mining climate in New Zealand relative to Australia and South Pacific mining operations.

Jan 1, 1990

By G S. Esterhuizen, M M. Murphy, T S. Bajpayee

The strength reduction method (SRM) has been implemented in the FLAC3D finite difference software and applied to coalmine entry support evaluations. The FLAC3D numerical models have been calibrated against instrumented field sites in varying geologies, depths and field stress conditions. The calibration between the field and model results obtained a satisfactory match for rock deformation and support response. Previous research has also developed good correlations between numerical model stability estimations using the SRM and empirically derived stability estimations using the analysis of roof bolt systems (ARBS) software and the coalmine roof rating (CMRR). The purpose of this paper is to further apply the SRM to investigate how specific geotechnical and support parameters can impact coalmine entry stability. Results from different studies demonstrate how the calibrated models were used to investigate a few of the well-known questions in both mine design and support design. For mine design the impact of strong and weak beds in the roof strata, rotating the principal stresses and weakening the floor on excavation stability is investigated. For support design the impact of support length, support spacing and adding cable bolts to the design is demonstrated. These scenarios are evaluated in developmental coalmine entries for a variety of geology and field stress conditions. Stability factors are calculated for each scenario using the SRM. The SRM allows the impact of each parameter to be quantified and allows the support system to be optimised for given geotechnical conditions.CITATION:Esterhuizen, G S, Murphy, M M and Bajpayee, T S, 2014. Analysis of geotechnical and support parameters on coalmine entry stability using the strength reduction method, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 383–392 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By Johnson M. W

Factual data about the sedimentation in the Newcastle Coal. Measures are presented. Data concerning the total coal measure sequence (isopachs, sand /shale ratio and total coal thickness variation), data about three coal seams (Borehole, Dudley and Victoria Tunnel) and data about interseam con- glomerate units are discussed. From this data conclusions are drawn about the coal measure environment. The western edge of the coal basin, the Lochinvar Dome, although a high feature was apparently stable during coal measure time. Despite its height it apparently supplied little sediment to the basin. The northern and north-eastern edge, which was unstable, suppl- ied most of the coarse detritus including the conglomerates to the basin. The conglomerates show patterns of fluvial origin but after a period of "normal" variations in pattern they become restricted to two parallel zones evidently tectonically controlled. Deposition of conglomerates is episodic and separated by periods of coal formation when deformation was apparently slight. Formation of each of the three seams considered followed a rather similar pattern - each shows development of thick coal around the basin edge and poor thin coal in the "axial" region of the present synclinal structure. Evidence of in-situ formation of some areas of the seams is discussed and periodic deformation of the basin during coal measure time is postulated.

Jan 1, 1969

By Waghorne E. P

The State Electricity Commission of Victoria is Australia's largest single coal producer. Approximately 19 Mt of coal will be produced in 1989 from the SEC V's newest mine, Loy Yang Open Cut (LYOC), which com- menced overburden stripping operation in October 1982. When the adja- cent Loy Yang Power Station is completed in the late 1990's, LYOC will supply between 35 to 45 Mt/a, depending on power station performance and demand of coal for non-power generation uses. LYOC has been a major challenge for the SECV. It is the biggest single open pit coal mining development undertaken in Australia, with a whole of life capital cost approaching A$1 billion. The mine has supplied a very rapidly growing demand for coal from the expanding power station while developing in breadth, length and depth. Coal demand has consistently been above the figures anticipated during the initial planning because of the substantially improved performance of the 500 MW units of the Loy Yang A Power Station. The superior performance of the LYOC and power station has generated additional electrical energy during the first 5 years of power station operation compared with the initial planning targets- at almost no additional capital cost. This has been a major benefit to the SECV. LYOC will continue to present major challenges for the SECV, particularly in achieving overburden removal and coal reserve targets as development of the open cut continues to full depth over the next 15 years.

Jan 1, 1989

Limnological processes are often overlooked when trying to assess the long-term water quality of pit lakes. It is essential to deal with these aspects, since they determine the geochemical and redox conditions around the submerged reactive rocks. Underground mining at East Sullivan (northwestern Quebec, Canada) stopped in 1966. Two adjacent stopes, 91 and 106 m deep, were left open to the surface, with roughly circular apertures of about 7700 and 18 000 m2. Water filling of the two glory holes went on over three decades and overflow began in 1999. Surface water pHs values were near neutrality as late as 1994 (6.3 - 7.0) but had become acidic by 1999 (2.6 - 3.5). Limnological processes were investigated in late-1999 and early-2000, with temperature measurements at 1 m intervals and sampling of the water columns before and after the late fall density inversions. A strong chemocline-thermocline was observed at 15 m. Above the chemocline, the water had low pH (3.2), no alkalinity, and low Na, Ca and sulfate. Below the chemocline, the concentrations of these parameters and the pH increased, with pH at 5.5 - 6. Consistent with the low pH values present in the upper 15 m, the concentrations of Al, Cd, Cu, and Zn were high near surface, and decreased below the chemocline. Dissolved oxygen concentrations as well as Eh decreased with increasing depth. Alkalinity integrated over the entire water column below the chemocline was at least six times larger than the acidity inferred from Fe2+ and Fe3+ concentrations. The temperature survey showed that seasonal density inversions do occur in the water column. The inversions do not involve the entire water body, since the surface to depth ratio is too small for a complete overturn. Oxygen from surface waters is carried to the bottom where it oxidises sulfides, until its depletion. Residual Fe2+, stable under anoxic conditions, is displaced upward by the next dense water incursion. It eventually reaches the thermocline, but only after many successive incursions. There, its oxidation to Fe3+ allows hydrolysis, which consumes dissolved and wall-rock alkalinity. It is only in 1999 that alkalinity was finally exhausted and that the pH shifts to acid values. The low pHs in the surface waters allow a build up of Fe3+ and Al3+, and desorption of metals from colloids. Buffering is assumed to be controlled by wall-rock oxyhydroxides in surface waters, and by carbonate minerals in the bottom waters. Because the seasonal overturns are far from being complete, the large amounts of alkalinity acquired from the wall-rock in the bottom waters cannot balance the acidity of near surface waters. Hence the surface water is acidic.

Jan 1, 2003

By K Williams

Marvel Loch South Pit has had a number of stages of open and underground mining activities before acquisition by Sons of Gwalia. The historical pit had achieved a completed pit depth of 150 metres and the shaft and decline mine had reached approximately 220 metres in depth using open stope mining methods. The various mining methods reflect the various economics and industry practice at the time. The South Pit ore zones are medium grade (~2.5 g/t) but have a regular geometry and large tonnes per vertical metre. A number of studies have been completed up to a pre-feasibility stage looking at options to extend the pit depth and to lower the unit cost of gold production. The options considered were the re-optimisation of the pit to determine further cutbacks or the innovative use of an in-the-wall ramp. The in-the-wall ramp (tunnel) would permit the removal of the in pit ramp to expose additional ore that was within the footprint of the ramp design and to provide the opportunity to increase the final pit depth. Similar mining method has only been used at Three Mile (Coolgardie, WA) and Chalice Mine (Norseman, WA). The tunnel would serve as a gateway for further extension of the south mine and the central ore zone via underground mining methods. The ultimate depth of the South Pit has been extended to 310 metres below surface and significant additional ore has been recovered. This paper will give an insight into the various studies to optimise the Tunnel mining method, the determination of the various tunnel dimensions, and the phases of mining to arrive at the completed design.

Jan 1, 2003

By E Vargas, A Egana, M Alarcon, X Emery, A Barberan, A Lopez, N Morales, C Friedrich

"As the cost in time and money of data from sensors and small-scale tests has reduced, additional challenges have arisen. Although many mine data sets are not big relative to those in other disciplines, they are complex in other ways, and becoming too large to manage efficiently on personal computers. In order to take advantage of the opportunity offered by increased data, a diverse team from Universidad de Chile and CSIRO Mineral Resources has developed a virtual geometallurgical laboratory to support the computational requirements linking data acquisition with data-driven business decisions. A particular focus to date has been the development of user-guided workflow ensembles to enable comparison between plausible geometallurgical hypotheses.A case study has been undertaken using publicly available data from the Rocklea Dome iron deposit in Western Australia. A hypothetical mining schedule was produced from geochemical and hyperspectral drill core/chips data via the following steps: data preprocessing, exploratory data analysis, geochemical interpolation, block modelling, ultimate open pit design and scheduling. The key outcome of this study was the integration of workflow stages through new plug-in methods or modification of existing software. Outcomes from this study will be described in the paper in terms of geological and metallurgical data quality, analytical software support and ongoing computing infrastructure requirements.CITATION:Lopez, A, Barberan, A, Alarcon, M, Vargas, E, Ortiz, J, Morales, N, Emery, X, Egana, A, McFarlane, A and Friedrich, C, 2016. Progress towards Data-driven Mine Planning via a Virtual Geometallurgical Laboratory, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 287–294 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By J Pease, P Cameron, D Drinkwater

"In the 1990s metal prices were trending in a long-term decline and the usual cost-cutting exercises were adopted. Cuts to research and development made innovation difficult and the outlook was grim. But necessity is a strong motivator, and these conditions spurred the Mine to Mill movement that optimised across organisational ‘silos’ and utilised new technology tools, innovative software and increased computing power. Many applications of Mine to Mill exploited the fact that comminution is usually the site processing bottleneck and blasting is more efficient at breaking rock than grinding. This approach sought to: understand and characterise rock breakage from mining to the milldevelop models and simulators for blast design, fragmentation, crusher and mill circuitsdevelop tools to measure in real time the particle size distribution of rocks on run-of-mine (ROM) muck piles, at the primary crusher truck dump pocket and on conveyorsensure effective communication across the silos between geologists, blast design engineers, mining engineers and metallurgists.These methods and the technology tools available in the 1990s were widely adopted at numerous sites around the world with significant benefits. Semi-autogenous grinding (SAG) mill throughput increases of 10–20 per cent were common. This was the advance the industry desperately needed. It was low capital cost; it was obvious. It was here to stay.Except, in too many cases, it didn’t. In the minerals price boom of the 2000s Mine to Mill was no longer necessary to ‘survive’, even though it was still good business. Some operations, including some of the early success stories, slipped back to old habits of optimising within organisation silos instead of across them. Fortunately, other operators still embraced Mine to Mill and developed new techniques. Mine to Mill was still successful, but not as widely adopted as we had expected it to be. Now the boom has ended and operations are again under cost pressure. Since these are the same circumstances that created Mine to Mill, it seems time to achieve the wider adoption. Since the 1990s many new or advanced technology tools are now available for Mine to Mill projects: blasthole sensors, new explosives formulations, new blasting techniques and modelling, ore tracking devices, improved image analysis to determine size, texture and colour of coarse ore, grade sensors, whole-stream simulation tools, and even more powerful computing hardware and data analysis software. If we could achieve so much in the 1990s, how much more can we achieve today when we have the same imperative, the same potential and a larger number of high technology tools?Citation:Cameron, P, Drinkwater, D and Pease, J, 2016. The ABC of Mine to Mill and Metal Price Cycles, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 349–358 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By D J. Williams

Tailings management is typically constrained by many factors that are taken as given. These include the tailings production rate that must be accommodated, the desire to deliver the tailings cheaply and easily as a slurry using centrifugal pumps, and a tailings footprint limited by the desire to minimise capital costs leading to a rapid tailings rate of rise and a low settled density. Other constraints include wall raises being delayed due to limited capital, inadequate tailings water and rainfall run-off management, and the net present value (NPV) approach to capital expenditure that puts off expenditure at the expense of performance. All of these constraints result in the tailings occupying much more volume than is necessary, being difficult to rehabilitate, and not being capable of supporting a beneficial post-mining land use or function. Ultimately, such constrained tailings storage facilities will assume very large dimensions, but each will typically be developed as a series of smaller storages that are filled rapidly and added to progressively. The optimal stage to efficiently recover process water is in the process plant, but this is limited by the desire to use centrifugal pumps rather than the more costly positive displacement pumps, which also require greater management of tailings deposition. Process water can also be recovered from the tailings storage facility (TSF) decant. Tailings water that is not recovered from the plant or the decant will be lost to entrainment within the tailings, seepage to the foundation or through the wall, or evaporation. However, tailings water is not always suitable for reuse in the plant, particularly when it becomes contaminated by the processing, and it may simply be stored on the TSF. This will exacerbate the seepage of contaminated water to the environment, and will limit the densification of the tailings that would otherwise occur due to desiccation of the tailings on exposure. If a larger tailings footprint were developed early, cycling of tailings deposition in thin lifts between a number of cells could occur, maintaining the dormant cells dry to enhance desiccation and densification, and ultimate rehabilitation. The end result would be a much reduced stored volume of tailings, the potential for upstream raising, and ease of rehabilitation to a high level. The higher initial capital cost would be overtaken by reduced ongoing capital, operating and closure costs.CITATION:Williams, D J, ?2014. An alternative whole-of-life approach to tailings management, in Proceedings Life-of-Mine 2014 , pp 285–298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

International tenders for contract mining opportunities require the Contractor to make an assessment of risk for an operation with a life span of up to twenty-five years usually based on data made available by the Client. This paper seeks to address how the Contractor assesses the data and quantifies the risks associated with the project. The areas of risk are common to most projects, but in the--Lontractor's case, risk assessment is carried out on the Client's data base and within a compressed time frame of usually less than six months. Incorporation of that risk assessment into the contract documentation is also discussed. Practical examples are given in a number of areas.

Jan 1, 1986

By R Bertuzzi

Permanent rock bolts in civil engineering are taken as having to serve their design purpose for at least 50 years. In many projects the design life is specified as greater than 100 years. A review of recent Australian tunnelling projects shows that substantial differences exist in the level of corrosion protection provided for permanent steel shafted rock bolts. This paper reviews the current state of practice and sets out what the authors consider to be appropriate requirements for corrosion protection.

Jan 1, 1999

By M Thompson

"The Jaguar concentrator, 60 km north of Leonora, Western Australia (WA), consists of a standard closed circuit semi-autogenous grinding (SAG) and ball mill producing a float feed of approximately 60 micron at 70 t/h. Following comminution, separate copper and zinc concentrates are produced by differential flotation. These concentrates are subsequently dewatered by thickening and then filtration.Separate audits of the Jaguar Operation’s copper and zinc concentrate thickeners were conducted to evaluate their performance, following occasions where site personnel had identified unnecessary loss of copper and zinc concentrate to the thickener overflow. The feedwells were identified as the source of the observed problems due to the following issues with their design/duty:lack of retention time in the feedwell as current design is completely opennot conducive to effective mixing required for efficient flocculationdiameter of the zinc concentrate thickener feedwell was undersize for its duty.To improve the performance of the thickeners, it is planned to replace both concentrate thickener feedwells with a high rate design for their respective duties in February 2016. The audits also identified that the feed system requires modifications with particular importance placed on minimising air entrainment of slurry into the thickener feedwell. Minimisation of air entrainment is hoped to be achieved by providing constant head pressure through installation of weir arrangements in the feedboxes and redirecting each feed pipe so that it feeds tangentially into the feedwell. In addition, improvements to the control philosophy of both thickeners will be made with the installation of an ultrasonic bed level probe and bed mass sensor, in order to make real-time adjustments to the underflow pump speed to maintain steady state operation.Following the feedwell replacement and modifications to both thickeners it is expected that losses of recovered copper and zinc will decrease to undetectable levels. Subsequently it is anticipated that a more consistent, homogenous underflow can be produced for downstream filtration.Citation:Thompson, M, 2016. Concentrate Thickeners Feedwell Replacement, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 273–278 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By S Jayakumari, E Ringdalen, V Canaguier

Silicomanganese (SiMn), containing approximately 16–30 per cent Si, is produced in submerged arc furnaces using various Mn sources and quartz as the primary raw materials, along with fluxes and reductants. In the high-temperature zone known as the coke bed, a silica-rich slag is formed. SiMn is produced through the reduction of SiO2 from the slag. Dissolution of quartz into slags with different compositions, the primary slag formed from the Mn sources and flux before any MnO reduction occurred, representing conditions at the top of the coke bed, and dissolution of quartz into a partially reduced slag to simulate conditions inside the coke bed has been investigated. Experimental investigations were carried out to study the dissolution of quartz particles of varying sizes, 5 mm and 25 mm in synthetic slags with different compositions at temperatures between 1400°C and 1600°C, with varying holding times. Observed results are compared with liquidus compositions and equilibrium phases for original and formed slags. Particle size has been shown to be of little importance for the dissolution. Quartz dissolved more easily in slag at top of the coke bed than slag in the coke bed. Complete dissolution was observed after 30 mins at 1600°C in all cases, but not after 0 mins.

Jun 19, 2024

By J R. Robinson

Prior to mine development, exploration drilling within the Luise Caldera on Niolam Island encountered gold mineralisation to the northwest of the main Minifie and Lienetz orebodies. This mineralisation was referred to as the Kapit orebody, and ten diamond drill holes were subsequently completed over the area to investigate its economic potential. Several significant mineralised intercepts were returned. These were interpreted using the orebody model developed for Lihir at that time which invoked a strong horizontal control to mineralisation. Additional consideration was given to the elevated geothermal temperatures encountered, the proximity of the mineralisation to the ocean, and its perceived depth below sea level, resulting in the Kapit area being given a low priority for follow up investigation. As a result, no further work was completed over Kapit until recently. The Kapit orebody was the target of an intense diamond drilling programme during 2002/2003. Data from this latest round of drilling has significantly improved understanding of the mineralisation and associated geology. The significant orebody now delineated at Kapit substantially differs from past interpretations, and the latest data has upgraded its economic potential. A resource estimate and other critical studies completed in 2003 enabled an updated reserve statement to be issued in February 2004 including the Kapit mineralisation for the first time. Total Probable Reserves at Kapit stand at 25.2 million tonnes (Mt) at 5.28 grams of gold per tonne (g Au/t), for a total of 4.3 million ounces (Moz) of contained gold.

Jan 1, 2004

By S Farrokhpay, M Zanin

Although it is well understood that in flotation collection zone and froth zone are deeply interconnected, and reagents (and in particular collectors and frothers) cannot be selected without considering their synergistic effect, this concept is rarely applied in plant practice. The feed mineralogy also has an important role in how particles and reagents interact in flotation, which is sometimes overlooked by operators. In this work, a combination of batch flotation tests and froth stability measurements was used to optimise the collector and frother scheme for the flotation of a copper ore. The methodology was applied to an Australian copper plant which was experiencing high variability in froth stability in the roughers when the feed ore mineralogy was changing. It was hypothesised that chalcopyrite in the feed in combination with isobutyl-xanthate had a destabilising effect on the froth phase under the reagents scheme used. Froth stability was restored if a shorter chain length, less hydrophobic, xanthate was employed. It is apparent that the hydrophobicity of adsorbed films at the solid/liquid/air interfaces has a critical role in enhancing or reducing froth stability. Unstable froth causes a reduction in copper recovery in spite of a high collection zone flotation rate. The case study suggests that collection zone and froth zone can rarely be optimised independently of each other. With the laboratory procedure adopted, a more suitable reagents scheme was determined to respond to changes in the feed mineralogy, avoiding fluctuations in plant performance due to unexpected froth instability.CITATION:Farrokhpay, S and Zanin, M, 2012. Synergic effect of collector and frother on froth stability and flotation recovery - An industrial case, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 145-150 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By J Coveney, A Rich, D Grimsey, J Wood, S Creedy

In 2021, BHP and Metso examined processing of high-MgO nickel sulfide concentrates using Metso’s Ausmelt Top-Submerged-Lance (TSL) technology. Test work was conducted in Metso’s pilot test work facility in Dandenong, Australia to explore operability of the SiO2-FeO-MgO-CaO-NiO slag system across a wide range of compositions, temperatures and bath oxygen potentials. Pilot-scale testing aimed to define slag ‘operability limits’, representing the lowest bath temperature at which stable process and equipment operation could be maintained. This work was supported by FactSage™, version 8.2 (by Thermfact/CRCT and GTT-Technologies) thermodynamic modelling, slag viscosity measurements, physical characterisation of quenched slag samples performed by the University of Queensland and benchmarking of commercial-scale TSL nickel smelting operations. A wide range of slag compositions were examined, with Fe/SiO2 ratios varying from 0.4–1.1, CaO content from 0.8–7.0 wt per cent and MgO content from 6–19 wt per cent. Slag SiO2/MgO ratio, wt per cent CaO and matte grade were found to have the greatest impacts on identified operability limits. Operability limits were found to be influenced by both the solids content in slag and viscosity of the remaining liquid slag phase, with the relative contribution of these parameters heavily influenced by the slag composition. In the majority of trials, limits were defined by a theoretical solids content of 40–50 per cent, however in trials with a low Fe/SiO2 ratio and/or low wt per cent CaO, limits were characterised by a much lower solids content due to the increased effect of the liquid slag viscosity in determining the behaviour of these slags. The test work highlighted inherent flexibility of the Ausmelt TSL process to operate across a wide slag range of slag compositions and recover from process disturbances without an interruption to feeding. The trials also demonstrated the possibility for Ausmelt TSL technology to process concentrates with an Fe/MgO ratio as low as 1.4, which has important implications to the commercial-scale processing of high MgO feeds. Arsenic rejection across the trials was very good, with only 30 per cent of arsenic in the feed inputs reporting to the matte phase. Such high levels of arsenic removal provide the Ausmelt TSL process with a notable advantage over alternative smelting technologies.

Aug 21, 2024