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At Copper Refineries Pty. Ltd., Townsville, two reverberatory furnaces of 420 tonnes capacity are used to melt 210000 tonnes/year of copper for subsequent anode casting. When the refinery commenced production in1959, these furnaces were of 300 tonnes capacity. The original furnaces featured a silica brick hearth, magnesite and chrome magnesite side 'walls, and a sprung silica brick roof, but were unsatisfactory because of thelow refractory life and high costs. With continuous expansion in production and the incentive to increase furnace life and capacity the design of these furnaces has changed greatly since that time.The present furnaces feature all basic brick, a flat suspended basic brick roof, very extensive use of watercooled copper sections, and are of substantially increased (420 tonnes) capacity. Particular attention has been concentrated on high wear areas such as the taphole, side walls, and charging door jambs. Each furnace in its 24 h cycle, is charged, the copper melted, impurities skimmed off, metal "poled" prior to casting, and cast.The service condition during each of these operations is important in considering furnace refractory life.The improvements in operating practices and furnace 'construction which enabled the capacity of the furnaces to be increased are discussed. The life between major repairs to side walls has increased from 90 charges to300 charges.The scope for future improvement is considered and areas for development are suggested.

Jan 1, 1977

By K Nilsson, D Connelly

Troy Resources acquired the Karouni Gold Project in Guyana, South America in 2014 and immediately proceeded to a Pre-Feasibility Study and project implementation. The study considered two open pit mines feeding a conventional carbon in leach (CIL) gold plant with a capacity of 1Mtpa. The study assumed a total of 2.61 million tonnes of ore with an average grade of 3.84 g/t gold with a recovered gold production of 303,526 ounces over a three year mine life.The project development involved drilling metallurgical test holes, securing second-hand major pieces of equipment where suitable, and arranging shipping to Guyana. The remote location meant logistical considerations were paramount. The plant consists of conventional two-stage crushing with single stage ball milling and a gravity circuit. The tailings circuit includes DETOX.The extremely high rainfall presented challenges with water management and the necessity to dispose of clean water to the environment. The DETOX was also mandatory due to the highly sensitive environment and past history in the area. The criticality of this meant that in the design, any cyanide in the tailings would precipitate in a plant shutdown.Lessons were learned and the project has been both profitable and successful for Troy Resources in a new operating location. In addition, the project has created jobs, delivered royalties and brought new skills into an area where previously there was little current mining activity.CITATION:Nilsson, K and Connelly, D, 2015. Karouni Gold Project from drill core to commissioning, in Proceedings MetPlant 2015, pp 197–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By A Maldonado, A Robert, K G. Mercer

The Hamersley Group in the Pilbara, Western Australia, consist of interlayered banded iron formation (BIF) and shale host rock formations within which a large number of open pit iron ore mines have been established. The slope stability of most of the mining excavations developed within these formations is controlled by the relatively low shear strength of the shale groups and shale bands, which are the weakest rock types. Shale formations range from fresh to highly weathered and are generally highly fissile when fresh, and clayey when weathered. An accurate understanding of the shear strength of these materials across the entire weathering continuum is therefore a key importance for assessing the slope stability of these mines.Historically defect laboratory testing results for the Pilbara mines have been analysed mechanically using direct shear testing (DST) to measure a number of geotechnical characteristics of the rock bedding and defects. This paper sets out the current practice in the industry in terms of the laboratory testing and presents a possible application of hyperspectral data to empirically correlate the shear strength of shale bedding with the relative mineralogy abundance on the bedding surface. This was achieved by creating both hyperspectral and geotechnical data sets for the same samples.In the study the shale samples were separated into three distinct assemblages: iron oxide + kaolinite, iron oxide + white mica + kaolinite, white mica + kaolinite, which had 40, nine and two samples respectively. Analysing these assemblages alongside DST data showed that samples with white mica had reduced non-variable shear strength, whereas samples with iron oxide + kaolinite had an overall higher shear strength but with a greater variance. It is inferred that the reduced shear strength in the white mica samples is due to the sheet (or plate) like structure of the mineral, giving it a weak stress plane. Confidence in the trends observed can be reinforced by expanding the data set in future works. The investigation also includes a discussion on weathering grade and addresses the question as to whether mineralogy abundances influence these characteristics in Hamersley shales.CITATION:Maldonado, A, Mercer, K G and Robert, A, 2017. The relationship between mineralogy and shear strength of Pilbara Hamersley Group shales across the weathering spectrum, in Proceedings Iron Ore 2017, pp 423–430 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By P Fullagar

Automated multi-sensor core loggers (MSCL) measure petrophysical properties of diamond drill cores, including gamma density, P-wave velocity, electrical conductivity and magnetic susceptibility. A Geotek MSCL system has been used to record petrophysical data on archival drill core from Cadia East Au-Cu porphyry deposit, New South Wales, Australia, for correlation with metallurgical parameters. P-wave modulus, calculated from density and P-wave velocity, exhibits a correlation with small-scale crushability (A*b) test results, and hence offers a means for æcontinuousÆ characterisation of ore crushability at Cadia East. Magnetic susceptibility has proved to be a good indicator of alteration styles, and is a possible indicator of crushability.

Jan 1, 2009

Possibilities and Working of the Specific Agglomeration of Fibrous Materials and Residues Plant based fibrous materials are becoming of increasing interest in a multitude of industrial applications. Main advantages are the specific lower energy demand and virtually closed CO2 cycle, excellent mechanical properties based on low density as well as a high level of recyclables. In contrast, processing and handling of such materials is associated with a number of challenges. These challenges are mainly related to specific morphological characteristics in correlation to fibre length and structure (branching and splices). Specific problems in further processing steps including transport, dosage or storage for natural fibre compounding, result from form-locking bonds leading to burling, clusters or plaits. Technologies of fibre processing are well known, but other than textile based technologies they generally result in intermediate goods which do not allow direct industrial application. The investigation to be presented is based on results of recent research activities and shows two possible technical solutions of innovative fibre agglomeration procedures. These methods allow the conversion of middle to long fibres into a form, which eases further processing and dosage significantly and therefore allows free flowing too. The procedures are based on the working principles of rolling and winding technology. Within the work, both of the patented methods and their respected lab-scaled devices will be described. Further, results will be shown for an up-scaled rolling agglomeration unit applying the developed principle and consisting of multiple process zones. Possible variations of the resulting product characteristics and the impact of different process parameters will be discussed based on the trials with natural fibre (hemp and flax) agglomeration. As a main outcome of the research, product qualities can be supplied according to the requirements of the specific application in correlation to agglomerate strength, porosity or form. In conclusion, recent developments for specific methods of characterization will be depicted.

Sep 13, 2010

The beach sand industry is the only Australian mineral industry which, so far, has used electrostatic separation on a full commercial scale. The main application of the process is for the separation of rutile from zircon. Laboratory work has demonstrated that electrostatic methods are effective for ilmenite-monazite and cassiterite-zircon separations, thus facilitating the production of high grade monazite and cassiterite products from top-strip table concentrates, but the commercial application of these processeshas been rather limited so far. Overseas, electrostatic methods are becoming more widely used for the treatment of granular material which is not amenable to flotation. The use of electrostatic separation for the treatment of ores other than beach sands has been investigated in this laboratory 1, 2, 3, and two pilot separators were built during i953 to carry out field tests. Of these, the first was an inclined feed plate separator for the removal of silica from granular lime-sand in Western Australia, the second a conductance roll separator for the removal of diamonds from alluvial gravel in New South Wales. In both cases the whole of the ore passed through the separator, not a gravity concentrate only as in beach sand practice. The two types of separator mentioned are shown diagramatically in Figs. 1 and 2.

Jan 1, 1954

In this address I look back over the past 40 years of mineral exploration in New Zealand û essentially the period since the Second World War (ie since 1945). It was the period of my personal involvement, and indeed of the personal involvement of a number of you. Luckily it was aperiod of great interest and activity. In the previous 50 years, virtually nothing had happened, and it is kindest to draw a veil over that period. In the very important earlier 40 years (1855 - 1895) the New Zealand gold rush occurred. That must have been a fascinating, rewarding period, which has been thoroughly documented by better historians than myself. I will simply comment firstly that its mineral explorers (gold-prospectors) were very successful indeed, and found most localities of the minerals they sought, in spite of using very different methods from ours of today. Secondly, they were preceeded by one of Maori exploration, which searched for a much restricted list of minerals, but succeeded in finding virtually every locality we know of today. The explorers of both of these early periods were obviously highly successful, but, in the time available, I must restrict myself to the period since 1945. I am currently editing the effective up-dating of Gordon WilliamsÆ 'Economic Geology of New Zealand' (1974). It covers the last 12 years or so. Many of you are contributing to that volume û both as authors and as referees û and I would like to take this opportunity of thanking you all. Although this new volume excludes the energy field, many of us have been involved in it, and I am therefore including energy minerals in this review, as Williams did in 1974.

Jan 1, 1987

The Calypso geothermal field, mapped by the R V Sonne (cruise SO-135) in 1998, includes four main sites, the Northern Vent Area (centred on 37¦ 36.7'S, 177¦ 06.2'E, area 1.5 km2), Central Vent Area (37¦ 39.4'S, 177¦ 05.2'E, 1 km2), Southern Vent Area (37¦ 41.7'S, 177¦ 06.0'E, 1 km2) and Mercury Vent Area (37¦ 41.3'S, 177¦ 07.3 'E, 0.5 km2). Hydrothermal activity at the vent sites is controlled by minor, sub-parallel NE-trending normal faults. Gas bubble trails (C02) and shimmering hot water vent from fractures and joints between large blocks of silicified volcaniclastics and in depressions in the sediments at the base of these outcrops. Measured maximum vent temperatures are between 180¦C and 201¦C. Venting fluids are at, or just below, boiling for water depths of 200 m. Rock samples recovered by dredge from the sites include massive anhydrite, clay-altered pumiceous ash, silicified volcaniclastic sediments and volcaniclastic breccias cemented by sulphur. Clay-altered samples, dominated by randomly interstratified illite-smectite and accessory chlorite, indicate formation environments of 70¦C to 90 ¦C. Native sulphur is abundant throughout the samples. Fine-grained (<1 mm) disseminated pyrite and vein pyrite occurs in the clay-altered pumiceous volcaniclastics and argillites. In the Southern and Mercury Vent Areas, fine-grained orpiment, realgar and cinnabar have deposited in the sandy matrix of volcaniclastic breccias. Amongst the cinnabar, small (<2 mm) beads of native Hg formed on the surface of several rocks following their recovery. These samples also contained abundant light hydrocarbons, which coat the rocks with an oily sheen.

Jan 1, 1999

Stope back conditions in the cut-and-fill stopes at New Broken Hill Consolidated Limited often deteriorate to such an extent that, because conventional rockbolts are not able to maintain safe working conditions, square-set timber is installed. An attempt to eliminate this costly procedure has involved the use of long grouted rockbolts using high tensile prestressing wire. These bolts were developed in conjunction with the prestressing engineers of BBR (Aust.). This form of support has improved the back conditions, maintained safe working conditions, and delayed the introduction of timber in a number of stopes.Production from these stopes has been maintained at its previous level (at a rate approximately double that of a comparable timber stope).

Jan 1, 1974

THE object of the air-tight stopping is either to prevent a current of fresh air from getting into the fire area, or to prevent an escape of fumes and gases from the fire area into the workings of the mine. In the former case all is "plain sailing," but in the latter case there are certain difficulties to be overcome.In the Broken Hill Proprietary mine there were two styles of stopping used during the last fire-brick and bag and the following were the chief points that determined the use of one in preference to the other:-If the required stopping were to be more or less permanent, bricks were used, also if the area to be blocked were large-bricks being so much lighter and easier to handle than bags filled with -skimps. If, however, the air contained much gas, a bag stopping was put up. Great difficulty was experienced in getting essentially surface men, such as bricklayers, to work where there was the; slightest trace of gas; miners, however, would willingly do the work, and a bag stopping could be built without skilled labour.In old drives and gangways, where there was the liability of settlement, the bag stoppings were preferable to brick. The slightest movement around the sides or foundations of the latter would cause cracks, thus rendering the brick stopping useless;whereas, in the former, there was a certain amount of elasticity.

Jan 1, 1909

Drilling and blasting are an essential part of most mining operations, and are commonly major operating cost centres. The effectiveness of blasting can have a significant influence on all subsequent activities, and hence overall operating costs. Drilling and blasting systems must be compatible with the overall mining method, to minimise total costs and ensure operational efficiency. Selection of suitable equipment and techniques requires an understanding of the total operation, plus current skills in specialised technologies. This paper examines the contribution of drilling and blasting to total costs, including the balance between capital and operating costs. The use of computer modelling is discussed, to demonstrate how blast performance and costs can be predicted and alternatives analysed. Case studies illustrate how cost savings can be made in operating mines, and alternative systems evaluated to optimise new projects.

Jan 1, 1990

By D Jensen, L Riffo, S Yu, F Traczyk, D Meadows

With the steady increase of molybdenum demand worldwide and the favorable molybdenum market, many technological innovations on both process and equipment have been developed and applied in many modern molybdenum plants around the world. This paper introduces the most commonly used molybdenum flotation flowsheet, together with the introduction of the flotation chemistry. Many different types of flotation cells are used in modern moly plants, and each type of flotation cell has its own unique advantages suited for particular ore and process conditions. This paper tries to provide some insight and guidelines in flowsheet development and flotation cell selection in the molybdenum plants.CITATION:Meadows, D, Jensen, D, Traczyk, F, Yu, S and Riffo, L, 2013. Molybdenum flotation circuit and flotation cells, in Proceedings MetPlant 2013 , pp 387-398 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Yates C, Gillie E. W, Finucane K. J

During the year 1940 a complete investigation was made of the whole of the stoping operations throughout the Great Boulder Mine and, as a result, it was decided to convert some of the existing shrinkage stopes into cut-and-fill stopes, and also to mine many of the more recently developed ore blocks by the latter method. The necessity for filling was due primarily to the structure of the ore blocks, the character of the walls and possible excessive dilution, but was influenced also by the grade of the ore-block and by the fact that cleaner mining can be carried out by cut-and-fill stoping.The comparatively few cut-and-fill stopes in operation prior to 1940 had been filled mainly with waste rock from development work, but as the amount of this material available, or likely to become available, would have been wholly inadequate for future operations, it was proposed to construct a system of passes to supply filling material from the surface.Owing to the distribution of the stopes, no central pass or system of passes could be devised which would service all the stopes satisfactorily.However, work was commenced on two passes, one designed to service the cut-and-fill stopes in the Eastern Section of the mine, and another to service those in the Western Section. It was realised that these passes could serve only a small proportion of the total number of Stopes (Figs. 1 and 2). During the progress of this work experiments were undertaken to test the possibility of using filtered tailings underground as an adjunct to the above scheme, but for various reasons these were only partially completed.Early in 1942 it was suggested by the Mill Superintendent that an attempt be made to fill with wet classified flotation tailings as practised at Mt. Lyell in Tasmania and at the Triton Mine at Reedy, West Australia. For the purpose of testing this, an experimental stope was prepared on the 309-ft. level, "X" Lode. This was 100 feet long and averaged 4 feet in width. Water-tight rearings were built at each end of the stope and waste rock fill was spread to a height of 6 to 8 feet above the timber. Used filter cloths were laid on top of the fill and brought a few feet, up the walls of the stope. A two-inch victaulic drainage line was then placed in position, the end passing through a hole in one of the bearings and thence to a sump. In the central portion of the stope two vertical pipes were brought up from this line. These were bored with one-inch holes staggered on opposite sides of the pipe, the vertical interval between each hole being one inch. The holes were then stopped with...

Jan 1, 1945

By Kelly E. G

NZ Steel's flushing slag typically contains 1.2 per cent V203. Extraction of vanadium from powdered slag using a salt (NaCI or Na2CO3) roast/leach process was investigated. With NaCl, optimum extraction conditions were a charge containing 10 per cent NaCI, roasting in air at 875°C for 4 hours, followed by leaching in dilute H2SO4. Extractions were typically 30-50 per cent. NaCI roasting did not chemically attack the slag; the phase transformations that occurred were due to high temperature oxidation. Slag particle size had a significant effect on extraction.Optimum conditions for extracting vanadium by Na2C03 roasting were 20 per cent Na2CO3 in the charge and roasting in air for 3-4 hours at 850-875°C followed by water leaching.Na2CO3 roasting involved chemical attack that resulted in the formation of perovskite (CaTiO3) and carnegieite (NaAISiO4).The extent of vanadium extraction depended on the amount of Na2CO3 added and the original slag SiO2 content.Compared to the separate roasting treatments, simultaneous treatment with NaCI and Na2CO3 gave lower vanadium extraction, while requiring considerably higher roasting times and temperatures.

Jan 1, 1982

Before presenting this address I desire to express my appreciation of the honour which has been conferred on me by my election as iPresident of The Australasian Institute of Mining and Metallurgy. At this stage it might not be out of place to recall that Broken Hill was the birthplace of The Australasian Institute of Mining and Metallurgy, originally formed as the Australasian Institute of Mining Engineers in 1893.In selecting for my address the topic of "The Broken Hill Mining Industry and its Contribution to the Economy of Australia" I realise it is impossible to cover fully every aspect of the nation's economy which owes all or part of its origin to the Broken Hill field. Nevertheless, I feel that some attempt should be made to give credit to the Broken Hill mining industry for its part in the progress which Australia has made over the past seventy years.. If we care to reflect for a moment it soon becomes apparent that, not only is the Broken Hill mining industry an important producer of base metals for domestic and overseas consumption, but its profits have provided the means whereby many of Australia's leading secondary industries have been established or built up. Examples which come to mind are the founding of the iron and steel industry by the Broken Hill Proprietary Company; the establishment of plants at Port Pirie in South Australia, and at Risdon in Tasmania, for the production of metallic lead and zinc; and also at Port Kembla for the smelting of copper ores. From profits derived from operations at Broken Hill, capital has also been provided to assist other new essential...

Jan 1, 1956

By Edmonds W, Jeffcoat R

The completion of the first two open hearth furnaces in the new No. 2 open hearth plant at Port Kembla will increase Australian production of steel by 350,000 tons of ingots per annum.The paper gives an outline of the essential features of open hearth design and auxiliary equipment required to operate the two modern open hearth furnaces at present being installed.INTRODUCTIONThe increasing demand for steel required by Australian secondary industries led to the decision to construct and operate No. 2 open hearth plant at Port Kembla. Two basic open hearth furnaces of the most modern design are under construction and it is anticipated that these units will be commissi.oned in September 1956. Australian steel capacity will thereby be increased by approximately 350,000 tons of ingots per annum.PLANT LAY-OUT AND CONSTRUCTIONIn the design and lay-out of this plant the emphasis has been on efficient material handling with simplicity of design and operation. Overseas methods were studied and these studies, together with experience gained at Newcastle and Port Kembla open hearth shops, enabled this plant to be built to a standard which compares favourably with any other in the industry.Initially two furnaces, each of 2,75 tons capacity, have been built, but provision has been made in. the design and lay-out to enable expansion to six furnaces.The location of the new plant in relation to the existing units will be noted in Fig. 5. It is one of the first units to be built in an area which will dovetail into a pattern for...

Jan 1, 1957

ALTHOUGH the development of the various flotation processes during the last 8 years has been so revolutionary, this development has been, until recently, entirely confined to the separation of the gangue from the mixed metalliferous sulphides.The desirability of finding some method of separating the independent sulphides from such a miXture, by means of flotation, has long been recognized. ThIS need was emphasized when the slimes resulting from the grinding of Broken Hill sulphide ores were for the first time successfully dealt with by the Mineral Separation Company's process on the Central mine. This process proved the practicability of separating the sulphides of lead and zinc as a mixed concentrate from the gangue present in slime. Although this was a very notable achievement, the process has not been generally used, owing to the mixed lead and zinc concentrates resulting from the treatment being acceptable neither to the zinc nor the lead smelters.Although the introduction of eucalyptus oil in minute quantities as an emulsifying agent has simplified the work of the subsequent tabling of mixed sulphide concentrates, rendering unnecessary the burning off or removal of the oil, there will always be a considerable quantity of slimy product too fine to settle on the moving surface of the concentrating machines, and therefore requiring other means for its division into lead and zinc concentrates.

Jan 1, 1912

When the first rush of miners took place on the Molyneux River, in the Dunstan Gorge, the gold was won by means of cradling the gravel, which was shovelled from the various beaches and crevices in the rock-bound sides of the river.The above method of winning the gold was only practicable when the beaches were not covered with water, hence the work was usually carried on during the winter months, the ordinary level of the river during spring and summer months being some ten or twelve feet above winter level. The melting of the spow in the Lakes water-shed being responsible for the high summer level of the river.As the available beaches were worked out, other methods of winning the gold were proposed and worked with more or less successful results the first advance being to work the bed of the river by means of a spoon dredge. The spoon was made with a round lip or ring of iron, having a steel cutting edge on one half of the circumference, at the opposite side a socket being forged to take a long spar or boom, which was securely fitted thereto. At intervals round the hoop, half-inch holes were bored to enable. a bullock-hide bag to be laced on to same. The spoon was worked from a pontoon which carried a crab winch, tackles and the necessary washing appliances to treat the washdirt lifted. In starting to dredge, a tackle was attached to near the upper end of the boom, and a line or chain was carried over a cat head from the crab winch...

Jan 1, 1901

By B S. Utting, W J. Cowie

The alluvial gold industry of New Zealand is based on the placer deposits in Otago and on the West Coast. Production from these since discovery in the 1850s has been an estimated 480 t (15 Moz) of gold. Annual output has expanded continuously since 1980 and is expected to be over 2 t of gold for 1989. Following a historical review, the characteristics of typical operations, which use hydraulic excavators and mobile trommel units are discussed. Descriptions are then given of alluvial activities in Otago and on the West Coast.

Jan 1, 1990

By B C. Povey, K Lagutin, M Mryasov, V Noll

The current Stoilensky magnetite concentrator comprises a three-stage crushing circuit followed by three stages of ball milling, grinding and concentration to produce a magnetite concentrate with 66.5% iron (Fe). The plant is built in four lines, three lines having four mills and one line with five mills, to treat 32 Mt/y of ore and produce 13.9 Mt/y of concentrate.NLMK, the owner, is Russia’s third largest steel maker and while the ore from the Stoilensky Mining and Beneficiation Plant (SGOK) provides the bulk of their supply, they still must buy ore from external sources at world prices. A decision was taken to expand the SGOK operation to supply all the NLMK concentrate, including the production of pellets.To commence the expansion, high pressure grinding rolls (HPGRs) were introduced as a fourth stage of crushing ahead of the first ball mill. This was a relatively low capital cost expansion and increased production by 12 to 15%, the cost being much less than an additional grinding line. The importance of this development was that earlier introductions of HPGRs in Russia had presented several problems so there was some reluctance to the initial concept. The even greater significance was that nearly every magnetite plant in Russia had a three-stage crushing circuit so the successful introduction of HPGRs was of interest to many operators.The design was developed by a team, consisting of Worley Parson, Mineralconsult and PiterGORproject (PGP), for the first four units to fit inside existing building structures. The first two units were commissioned in March 2016 and the next two units in May 2016, and production improved by over 12%. The design of the installation of the final four units is in progress and the installation is expected in late 2017.CITATION:Povey, B C, Noll, V, Lagutin, K and Mryasov, M, 2017. Introducing HPGR quaternary crushers in a Russian magnetite operation – challenges and solutions, in Proceedings MetPlant 2017, pp 84–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017