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By M S. Cassola

It’s expected that the world economy will face a stable and continuous growth in the demand of iron ore, reaching more than two billion tonnes per year within the next year. After decades exploiting resources with high content of iron ore, now the industry faces the challenge to exploit and beneficiate more complex ores.According to the industrial practice, the flotation technology is one of the most important and effective beneficiation processes to deal with low-grade iron ores around the world. However, even with this, it is still necessary to search for new processing routes or promote the optimisation of the existing circuits.The broad application of this technology is an outcome that deeply relies on the proper selection of flotation chemicals specifi cally designed for each system. New collectors are in continuous development as flotation performance significantly relies upon their optimisation.The reverse iron ore flotation in Brazil, mainly constituted by haematite and quartz, uses ether amines as collector for silica minerals and caustic corn starch as depressor for haematite. The process selectivity is highly impacted by the features of the etheramine, such as:• mono or di-etheramine,• neutralisation degree,• chain length,• branched or linear chain,• the flotation pH, and• the size distribution of the flotation feed.This paper describes the experience obtained from laboratory and industrial trials on different ores, conducted to improve the selectivity and recovery in the reverse iron ore flotation by selecting the required collector for low-grade ores.

Jul 11, 2011

During operations, mining and metallurgical processes may generate effluents such as tailings water, acid mine drainage (AMD) and seepage and process acid streams. Depending on the type of ore and the metallurgical process, these effluents may contain one or more toxic compounds (eg acidity or alkalinity, cyanide, ammonia and/or nitrate, heavy metals, total suspended solids (TSS), sulfate) in elevated concentrations requiring treatment before their discharge to the environment or recycle/reuse in the process. Natural oxidation of sulfide minerals present in mining wastes (eg tailings and waste rock) at mining sites may generate AMD, which is characterised as a low pH, high acidity effluent containing heavy metals and sulfate. If generation of AMD cannot be controlled and/or prevented, AMD needs to be collected and treated for neutralisation of acidity and reduction of metals and TSS to meet regulated water quality standards. It is important to note that some of these compounds may persist in run-off from mine sites, even after the mine and processing facilities are decommissioned. Treatment of mining and metallurgical process effluents can be accomplished by means of various physical, chemical and/or biological methods. The mode of process application may vary from the use of either specifically designed, controlled and automated facilities or passive systems. Lime neutralisation and precipitation is the most common method used in the mining industry to treat AMD. To reduce the problems associated with disposal and long-term storage of the resulting sludge, the use of a high-density sludge process (HDS) has become a preferred option. The use of other chemical reagents, waste or by-products from other industries, and biological sulfate reduction methods can also be considered as viable options for site-specific situations. Recently, several passive treatment systems have been designed and successfully operated, even in the cold North American climate. This paper will discuss available options and provide insights for selecting a suitable method for a given situation using case studies from projects conducted by Golder Associates around the world over the last decade.

Jan 1, 2006

By S Goff

The Northern Sewerage Project (NSP) is a $650 M infrastructure project that will increase the capacity of the sewerage system for Melbourne’s growing northern suburbs while also helping to protect the Merri and Moonee Ponds creeks by significantly reducing the number of sewage overflows that can occur after heavy rainfall. The NSP consists of two stages: Stage 1 (NSP1) will be owned and operated by Melbourne Water Corporation, and Stage 2 (NSP2) will be owned by Yarra Valley Water and operated by Melbourne Water Corporation.Glass-fibre reinforced plastic (GRP) was used on both NSP stages, however, since Stage 1’s schedule for installation of GRP was slightly ahead of Stage 2’s, this paper will only focus on Stage 1’s use of GRP.NSP1 involves the construction of 7.9 km of new sewer tunnel ranging in diameter from 1.6 to 2.5 m, five main access shafts at depths of up to 65 m, and connections to the existing sewerage system including several access manholes. Construction began in 2007, and project completion is expected in 2012.The original design for NSP1 specified the use of high-density polyethylene (HDPE-) line precast concrete pipes as the final tunnel lining and HDPE-lined reinforced concrete for the access shafts and manholes. During construction, the rising cost of precast concrete pipes and the introduction of an additional GRP pipe supplier in the market justified a review of the tunnel final lining material. The contractor-proposed GRP pipe alternative was accepted for the final tunnel lining based on time and cost savings that were possible without compromising the design intent. After gaining experience with GRP through this design change, Melbourne Water Corporation reviewed and accepted GRP as the final lining for five smaller connection manholes. The use of GRP for the manholes was particularly inventive as the redesign made use of the approved tunnel GRP pipes as both a structural and corrosion-resistant lining.This paper discusses the use of GRP on NSP1; how the change in material, from concrete to GRP, affected the design philosophies assumed during detailed design; and how construction methods were modified to handle the less rigid GRP material. Details on the structural, hydraulic and durability considerations for the design are included, as are details about the time and cost savings and the quality and safety improvements that were achieved during construction.

Mar 8, 2011

By L Gobbo

X-ray diffraction (XRD) provides useful information about the composition of an ore sample in terms of quantification of crystalline phases and amorphous content. The use of new, fast detection systems implemented in CubiX FAST industrial diffractometers creates the opportunity to use this technique in exploration and modern process control. Besides the chemical composition of iron ores, their phase composition is also an important factor for exploration, quality control and processing. In the analysis of iron ore, XRD can identify the phases containing iron, such as haematite Fe2O3, magnetite Fe3O4, and goethite FeO(OH), and any other mineral phases present, especially silicas. Quantitative analysis is possible by various classical methods such as straight line or polynomial calibration with standards, but modern quantification analysis techniques such as Rietveld analysis or full pattern autoscale analysis are attractive alternatives, as they do not require any standards. These methods offer impressive accuracy and speed of analysis. Another analysis technique offering great benefit to ore exploration and process control is cluster analysis. This technique greatly simplifies the analysis of a large amount of data, eg from drill core samplings, and automatically sorts closely related scans of an experiment into separate clusters and marks the most representative scan of each cluster as well as outlying patterns. This can facilitate multi-dimensional compositional mapping of ore deposits, identifying regions of favourable mineral composition and allows fast and reliable tracking of the process. It is the most economic procedure to have automatic data evaluation without involving any dedicated personnel in the process. Details of the techniques used, sample optimisation methodologies, results, data precision and limitations will be discussed. The approaches have enormous potential as an inexpensive, reliable tool, useful in the characterisation of iron ore materials in an industrial environment.

Jan 1, 2009

By McGhie R. R

The general structural features and the principal mineral relationships of the Black Star ore body, Mount Isa, Queensland, have been described in several previously published papers. But particular reference may be made to the work of Grondijs and Schouten, whose examination of over 200 polished sections revealed some remarkable features in the process of ore deposition. The observations by the present authors are based upon the study of a smaller ·set of specimens complementary to those examined by Grondijs and Schouten and are intended to elaborate certain aspects of the mineral relationships, more particularly those affecting the ore-dressing processes.The work described applies to the primary sulphide ore only, and to the present milling practice of fine-grinding and selective flotation.GEOLOGICAL FEATURESThe Black Star is one of several economic mineral concentrations in the Mount Isa series of thinly bedded carbonaceous shales, which are considered to be of preCambrian age. The nlineralization is apparently connected with pegmatite intrustions located within some miles of the ore bodies, and has been Gontrolled in the main by major folding of the shales and by a shear system which follows approximately the strike and dip of the beds. The detailed "The investigations described in this paper were made in the Metallurgy Department, University of Melbourne, where the senior author was formerly Senior Lecturer in Mining and Metallurgy. A report on a section of the work was submitted by the junior author as a thesis requIred by the University of Queensland.

Jan 1, 1939

By A Giyose, V Malysiak, K Davey

Batch flotation tests were conducted on a haematite-bearing Sishen iron ore slimes sample from South Africa using reverse cationic flotation. The effect of grinding on flotation performance, the flotation response of various key impurities in the sample, and the feasibility of increasing metal recovery by refloating tailings in a scavenger flotation step were investigated. The test results indicate that reverse cationic flotation is effective in rejecting impurities from the iron ore sample tested. From a head grade assaying 6.4 per cent SiO2, 2.14 per cent Al2O3, 0.402 per cent K2O, 0.082 per cent P and 0.194 per cent TiO2, the levels of impurities were reduced to 1.83 per cent SiO2, 0.88 per cent Al2O3, 0.095 per cent K2O, 0.066 per cent P and 0.174 per cent TiO2 in the final concentrate at a Fe recovery of 74 per cent. The flotation response of SiO2, Al2O3 and K2O were found to be better than that of P and TiO2. The testwork demonstrated that grinding to 80 per cent passing about 49 microns is essential for upgrading the Sishen iron ore to produce >67 per cent Fe concentrate grade. This grind size corresponds to about 80 per cent liberation of haematite from the gangue minerals. Fe recoveries up to 76 per cent were obtained by refloating the rougher tailings in a scavenger stage, with little effect on the final concentrate grade. Size-by-size Fe recovery data obtained indicated that particles below ten microns were mostly lost in the desliming stage conducted prior to flotation whilst some reported to the froth by entrainment. Some of the coarser haematite-gangue composite particles reported to the froth product by genuine flotation.

Jan 1, 2009

By S Whitton, W Wimmler, L Wimmler

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

Jul 1, 2021

By K Gardner, R Fraval, V Singh

Using new technology to create optimised infill drill programs in underground or open pit settings, it is possible to quantify the value of a drill program. The computer designed programs are optimised to uplift the most amount of resource possible into the specified resource classification, while honouring geological, spatial, equipment and budgetary constraints. When designing ‘by hand’ balancing all these factors is a time-consuming effort with no real way to determine metrics on ‘how good’ a program will be. The optimisation considers many factors allowing geologists to apply critical thinking and domain knowledge to constrain the optimisation, letting the computer do the heavy lifting of determining hole placement. Once programs have been created, they can be integrated into a production schedule. This is a critical step in determining the correct sequencing and balancing of resource availability and seeing how a program will interoperate with other tasks in the mine. For example, if drill drives are a requirement for part of the program, will they be developed in a time frame that is useful for the goals of the program? Do we risk drilling infill holes too late to add value? Do we put production at risk by not classifying parts of the model ahead of time, thus adding to uncertainty? Using software to assist with optimising and scheduling of drilling is a useful technique to save the geologists from the mundanity of manually designing drill programs and puts metrics around the effectiveness of a program and has the potential to add quantifiable value to a program. Examples will be presented that demonstrate the effective use of drill hole optimisation, comparing manual designs with optimised designs, as well as the examples that show the effective use of scheduling.

Mar 22, 2022

By A G. Sheard

Fire safety requirements inside tunnels have become more demanding as tunnel designers consider the impact of potentially larger fires. Tunnel ventilation equipment is required to clear hot gases in the event of a fire. This is vital to maintain smoke free escape routes for people trapped in the tunnel and to facilitate safe access for emergency services. As the fire becomes larger, the temperature of clearing hot gases increases. Traditionally, engineers have taken into consideration gas temperatures of 250°C when designing tunnels. Because of larger fires, engineers must now design equipment to clear hot gas up to 400°C.Increasing the temperature of hot gases to 400°C requires tunnel ventilation equipment that goes beyond historic limits. As temperature rises, material strength reduces, consequently mechanically constraining fan aerodynamic performance. Developing tunnel ventilation equipment suitable for clearing hot gases at 400°C requires a fan technology that is more typical of industrial turbomachinery. The standards EN 12101-3:2002 and ISO 21927-3:2006 defi ne the necessary design criteria and testing methodologies to verify that a range of tunnel ventilation equipment is capable of extracting hot gases.This paper describes the process by which the authors certified in accordance with EN 12101-3 and International Organization for Standardization (ISO) 21927-3 a range of powered ventilators suitable for clearing smoke and hot gases at 400°C for two hours. Proving the high temperature capability of the new range provided a challenge as a consequence of the large physical sizes and high motor powers involved. Additionally, the need to install vertically, as well as horizontally, imposed high thrust loads on motor bearings, further complicating both mechanical design and testing. The paper presents the methods by which the authors overcame these challenges.

Mar 8, 2011

By J Jardine

An improved ground support method for development intersections, wide spans and stope brows was implemented at Kanmantoo mine. The method uses a jumbo to simultaneously drill and install self-drilling anchors (SDAs) to depths from 4.5 m to 7.0 m. Resin is subsequently pumped into each SDA using a specially designed integrated tool carrier basket, with plating occurring within 10 mins due to rapid resin cure. This methodology means that SDAs can be installed rapidly due to reduced process steps and wait times with reduced hazards to personnel. Cablebolts are used extensively in underground mines to reinforce the ground in wide spans, such as at intersections and stope brows. The flexible cablebolt tendon allows for a long, continuous and high-capacity reinforcing element to be inserted into the rock. A common cablebolt installation practice at Australian underground mines that do not utilise a mechanised cable bolter, is for cablebolt holes to be drilled by a jumbo or longhole rig, hand installation and grouting by a service crew, then plate tensioning following a grout curing wait time of typically 12 to 24 hours. This process involves multiple separate labour-intensive work processes and results in reduced availability of priority headings. This paper discusses the development history of vertical SDA use in wide spans at Kanmantoo mine. The installation process is fully described, including aspects such as reliable in-hole coupling of SDAs, resin selection and pumping aspects. A cost benefit assessment, and a case for ground stability are presented to compare cablebolt use to SDAs in development intersections.

Mar 29, 2023

By M Brady, O Salisbury, C Claassen, B Beamish, H Baxter

Monitoring for signs of elevated spontaneous combustion in the active goaf behind the longwall face is crucial for early intervention of any potential heating incidents. Typically, trigger action response plans (TARPs) are established at the start of longwall mining and often are only reviewed when triggers are activated frequently and become ‘nuisance alarms’, or in the worst case scenario after a heating event. Narrabri Mine has adopted a proactive approach of reviewing the longwall active goaf spontaneous combustion monitoring TARP at the commencement of each longwall block and prior to reaching a known ‘mylonite zone’ of crushed coal, which is associated with increased coal oxidation. The review is based on information recorded from the monitoring data of the previous longwall blocks as well as interpretation of relevant spontaneous combustion propensity results for the coal. This has resulted in the mine implementing a zoned TARP approach for each longwall block covering both the longwall retreat through normal undisturbed coal and the zone where the goaf is influenced by the increased coal oxidation associated with the mylonite coal. The consequence of this approach is that it has removed the issue of having nuisance triggers being activated during mining through a known increased oxidation zone, while maintaining a high awareness of indicators of spontaneous combustion.CITATION:Baxter, H, Claassen, C, Salisbury, O, Brady, M and Beamish, B, 2015. Implementation of a zoned trigger action response plan associated with changing mine conditions at Narrabri Mine, in Proceedings The Australian Mine Ventilation Conference, pp 113–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By A R. McKinnon

The recently opened Hera Au-Pb-Zn-Ag mine in central New South Wales has provided an ideal opportunity to demonstrate the calculation of sulfide ore mineralogy using normative methods. Normative mineralogy applies a set of sequential rules based on the species likely to be present to assign the chemical components of a sample to their respective mineral components. The dominant sulfide mineral assemblage present at Hera is galena, iron-bearing sphalerite, chalcopyrite, pyrrhotite and pyrite. A normative technique for estimating the relative abundance of each of these species from drill hole, grade control and metallurgical assay data sets has been developed. This includes a process for deriving a gangue iron value and differentiating pyrrhotite from pyrite using sulfur/iron ratios. A calculated total sulfide volume value has been utilised at the mine to improve interpretation of lode boundaries. Normative drill hole values have also been used for domaining within the orebody, with large scale mineralogical trends evident. Dry bulk density (BD) values calculated using a normative species-weighted method show good correlation with measured BD values (R2 = 0.895) and are a significant improvement on the Pb+Zn+Cu regression method (R2 = 0.646) previously used. Application of these calculations to identify errors in assay databases is demonstrated, with specific reference to the data set for the nearby Nymagee copper deposit. Validation of block model grades is also explored and a method to improve resource estimates using direct normative mineral interpolation is proposed. The integration of the normative data into the production and metallurgical data sets at Hera is described and the relationship of the normative minerals to other economic elements such as gold and silver is discussed.CITATION:McKinnon, A R, 2017. Application of normative ore mineralogy to geological and metallurgical data sets at the Hera Au-Pb-Zn-Ag mine, New South Wales, Australia, in Proceedings Tenth International Mining Geology Conference 2017, pp 63–74 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By D Brown, Z Tabor

Projects must be flexible to account for the rapid development of new technologies and changing stakeholder expectations. Coupled with calls for bleeding-edge solutions, customers, shareholders, and regulators demand robust, safe products and systems-of-systems. Developing and integrating these solutions is becoming increasingly complex and maintaining the flexibility required to ‘pivot’ to effective solutions can be a serious challenge. The necessary flexibility is fundamental to the Agile ethos, and this family of methodologies therefore offers a potential solution to this challenge (Beedle et al, 2001). These have traditionally been delivered with systems engineering applied through a Waterfall methodology. Agile Systems Engineering combines both approaches and presents a means to achieve these goals without compromising flexibility, quality or safety. A robust methodology for the application of Agile Systems Engineering is required to enhance practical outcomes and reduce risk for real-world mining projects.

Sep 1, 2024

By Y Pan

The recycling of steel is a crucial aspect of the shift toward a sustainable metals industry. The emphasis on steel recycling through the introduction of the scrap based mini-mill concept is also matched with a desire for greater product quality and reduced environmental impact, which, in turn, has generated important innovations. There have been significant advances in the technology for recycling steel over the last 20 years and this paper will provide an overview of these developments and discuss future directions in steel recycling including scrap management, control of tramp elements, electric arc furnace technology and ladle metallurgy.

Jan 1, 2004

By DJ McKEE

Process control emerged in the mid-1960s as a new and exciting method of improving the performance of mineral processing operations. The early Australian developments, principally in Broken Hill and Mount Isa, were based on pioneering work in instrumentation, the availability of small digital computers and a particularly effective partnership between companies with technological foresight and University and CSIRO research groups. Initial progress was rapid and within ten years many plants were committed to process control. Process monitoring is now routine and most circuits have some level of control. However, few plants have comprehensive optimising control systems as the difficulty of developing control strategies which can cope with the wide variety of conditions encountered in most mineral plants has been fully appreciated. This paper summarises past experience and assesses the degree of application of different forms of process control in metallurgical plants. Barriers to the effective utilisation of opt rising control are identified and some suggestions for advancing the application of control are made.

Jan 1, 1992

By H Wright

Black Rock Cave (BRC) is a sublevel cave which was developed in 2018–2020 and has been in production since November 2020. BRC is part of the Mount Isa Mines complex and extracts a leached orebody comprising of high-grade chalcocite ore, situated below the historic Black Rock Open Cut workings. The mine is owned by Mount Isa Mines and operated under contract with PYBAR Mining Services. In 2021 a number of rockfalls occurred throughout the mine and were increasing in frequency. This culminated in a major rockfall on the decline in June 2021, after which the decision was made to withdraw all persons from the mine, initiate rehabilitation and conduct further investigations to deduce a safe method to provide long-term support. The rockfall investigations have shown that the corrosive nature of the highly leached rock mass can consume a split set in less than 18 months. A review of potential corrosion resistant ground support methods concluded that steel split sets have a safe lifespan of six months at BRC, and that all workings must have corrosion resistant support installed prior to exceeding the safe life of the friction bolts. The review recommended the use of 4 m cable bolts as the most suitable method of corrosion resistant support. This new support system, and the requirement to rehabilitate all mine workings within the leached orebody, had an impact to the schedule and an effect on both equipment and manning levels at BRC. Accelerated jumbo rehab allowed access to the production levels within two months of the rockfall. Cable bolting then followed the jumbo bolting in all leached areas. The direct impact has been ten months of reduced production, due to night shift closures of the decline to enable cable bolting. The impact to the mine has been minimised by the small flexible team that enabled the mine plan to change rapidly and often to accommodate the challenging conditions. In less than two months from the rockfall event, production had resumed. Within ten months of concluding that the mine required; full rehabilitation, a new support system and a full re-schedule, normal mining operations had restarted, with pre-event productions rates being achieved.

Mar 29, 2023

By S R. Williams

There is a sense of geometallurgy being new; a new methodology for mining project development and improved operational strategy. One of the main challenges that any ænewÆ technology faces is a validation of the value and the need to produce case studies. However, producing case studies can often be problematic particularly given the long cycle from mineral deposit project, through feasibility and construction to stabilised operation of a mine.However, the roots of geometallurgy go back quite some time. Successful practices with geometallurgy can be seen from as early as the 1980s. Many times those practices were not called geometallurgy but something else and, in other cases, what can be seen are various components of the geometallurgical ævalue chainÆ.This paper will analyse a selection of published past practices from a geometallurgical perspective to demonstrate the value realised from the application of this methodology. The paper will then make some general comments on where this history of work in geometallurgy has lead us to and what are the challenges today for the geometallurgical effort.CITATION:S R Williams, 2013. A historical perspective of the application and success of geometallurgical methodologies, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 37-48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

In 1997, the Australian coal industry through Standards Australia committee MN-001 Coal and Coke recognised the need to produce a Standard giving some instruction on how to inspect and audit mechanical sampling systems. A Guide was developed by sampling subcommittee MN-001-04 and in 1999 the Standard was released as AS4264.5 æGuide to the Inspection of mechanical sampling systemsÆ Coal and Coke. Since that time the author has assisted with other committees in developing the Guide for other commodities such as concentrates and a generic standard for particulate materials. (AS4433.6 released 2000). The Coal and Coke guide is also currently a work item for ISO Standards. This paper is focused primarily on auditing and inspection procedures for coal mechanical sampling systems. It highlights the need for at least a three level inspection protocol where the operators manning the system maintain operational checks, the operators are regularly supervised by the company managing the system and once per year an independent auditor inspects the whole system to ensure compliance with design and standards. It does not cover short- and long-term maintenance of individual systems. With companies already certified to the ISO9000 series, this guide forms the framework to bring the operation and inspection of their mechanical sampling systems into line with these principles.

Jan 1, 2005

By Iwu GO, Almond DP, Joasoo _

The gravimetric integral Knudsen effusion method was used to measure cadmium activity values in binary liquid In-Cd alloys in the range 523 to 573 K. The activity measurements together with other studies from the literature indicate that special bonding conditions exist in the melts near a composition corresponding to InCd3. Sound velocities in In-Cd melts were also measured using a precision pulse-echo over- lap method in the range 404 to 953 K. The frac- tional deviation of experimental and ideal isentropic compressibilities at 623K shows a functional dependence on composition with a pronounced maximum near the composition 75 at.%.

Jan 1, 1980

By L D. Munro, S A. Jackson

This paper provides a logical approach to developing a TSF design concept through: • Identifying key properties of tailings and containment structures; • Reviewing underlying principles for effective operation; • Showing how these apply to select an appropriate TMS; and • Demonstrating how to align the TMS to site-specific constraints and TSF design. This approach follows a path of rigorous data analysis independent of discharge parameters (whether low-density slurry, paste or cake disposal) to select the most cost-effective and sustainable approach for any given material or site.

Jul 1, 2021