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Tailings management trade-off studies are done for all mining projects. There is wide variability in these studies as their approach, details and outcomes are determined by the experience and focus of the project team. While some of these approaches may consider the whole life cycle of the project others may focus only on capital and operating costs and direct environmental impacts. A complete life cycle approach is not standard practice. This paper describes an approach to implementation of formalised life cycle assessment (LCA) following ISO 14044 to tailings management trade-off studies. The paper describes the implementation of the methodological framework for the LCA, ie goal and scope definition, life cycle inventory analysis, life cycle impact assessment and life cycle interpretation. This standardised approach to implementing tailings management trade-off studies following the LCA approach will contribute to the state-of-the-practice in sustainable mine development.

Jan 1, 2009

By O Bascur, A Soudek

Large metallurgical complexes are substantial users of energy, water and assets. To improve the effectiveness of energy and assets the quality of the data and events become paramount for real-time operational management. A lack of resources at the local operations and at the enterprise makes it impossible to process the sea of information and many projects have failed. As such, a novel approach for implementation of continuous improvements at the local level and innovations at the strategic level was implemented at all operating plants at Anglo American Platinum. Sixteen concentrators, three smelters and two refinery process systems were integrated to scale the information for manufacturing services at the local and enterprise level. The new capability of an enterprise real-time monitoring and diagnosis software infrastructure was available to implement many business strategies in tandem. Mineral and metallurgical processing knowledge is used to simplify the implementation of the data model. As such, asset monitoring, energy, production and process control management were implemented in an integrated approach reusing the same data but with different context and time horizons to have a standard methodology for local root cause analysis. This paper will highlight a sustainability management approach to change and empower the local and strategic team to collaborate using a new approach for adaptive reporting and condition-based event management and notifications. The results based on the integrated and collaborative team efforts will be presented. OSIsoft Plant Information system was installed and configured to achieve a targeted reduction in energy consumption of 15 per cent by 2015.CITATION:Bascur, O and Soudek, A, 2014. Implementation strategies for energy effectiveness and sustainability – example of Anglo American Platinum, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 101–108 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By M I. Roberts

Corporate and workplace culture, as many owners, directors, executives and managers know, is by far the most powerful determinant of productivity. It’s much more significant than buildings and equipment. Yet although no one today would build a building or machine without a plan, few leaders have a plan for building and sustaining a safer and more productive culture.Using practical ways, culture can be planned and shaped as desired. Success requires implementing a project plan for changing the systems that drive behaviours that in turn shape attitudes. The combination of behaviour and attitude together with leadership largely shape culture.To improve performance, leaders need to:1. improve the organisational systems that drive behaviour2. action a project plan for improving specific performance metrics 3. demonstrate leadership that is conscious, disciplined, committed and passionate for purposeful use of human energy.This paper explains all three factors in practical ways with operational and corporate examples. It details understanding and applying the power of fundamental statistical analysis tools to recalibrate, focus and drive proactive leadership that takes responsibility for process improvement, supporting people and ensuring accountability.Experience and practical understanding of human and organisational behaviour confirm that the Measurement ? Analysis ? Reporting system combined with conscious leadership is by far the most powerful driver of behaviour. This wisdom produces profound changes in leadership style and behaviour. It develops outstanding leadership to create and sustain a safe and highly productive culture reliably producing consistently high quality products. It is the key to developing accountability, employee retention and a sustained competitive advantage.CITATION:Roberts, M I, 2016. Building safe, productive cultures and leadership, in Proceedings International Mine Management Conference, pp 163-178 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By T M. Nester, D J. Reardon, A N. Page, B J. Barsanti

The load capacity of a friction bolt has long been regarded as 4 t/m of embedment for ground support design analysis and supported by in situ pull test results. In recent years, the authors have observed lower pull test results or inconsistent results which were rarely sighted in the early 2000s. The lower pull test results indicated in some cases that reliable friction bolt capacity (≥90 per cent of results) is closer to 3 t/m of embedment with some geotechnical engineers adjusting the ground support parameters in the design work accordingly. This can be in contrast with other mines which reliably obtain 4 t/m (or greater) using the same suppliers bolt in similar ground conditions. This raised several questions: • What is the effect of poor installation (bolt twist or bolt hole deviation)? • Does the performance of friction bolts vary in different rock masses? • Does bolt performance vary between suppliers? • What effect does increased jumbo feed/percussion/rotation settings have? • Have the bolt dimensions or steel strip width changed? • Have the physical bolt properties changed? • Have the steel properties changed? This paper was aimed to answer as many of these questions as possible and discuss each variable in detail. This project included friction bolt trials at various mine sites across Australia, multiple friction bolt manufacturers, steel manufacturers and laboratory analysis. The paper also includes discussion on what the authors consider best practice for pull testing. It should be noted, the terms ‘friction stabiliser’ and ‘split set’ used in this paper are used in a generic manner and is not linked to any specific ground support supplier. Whilst its acknowledged within the industry the term split set and friction stabiliser is used interchangeably, the authors acknowledge that the term split set is a trademark of Split Set Mining Systems and has been used in context in this paper.

Nov 29, 2022

By P Standish

Qualitative risk assessment methods are not well suited to considering complex systems and potential interactions of new technology. As part of supporting tier one mining organisations and international industry groups, the author and colleagues have innovated processes to help provide better solutions to sites/companies considering a move to implementing proximity detection and collision avoidance systems. The process identifies required operating states for the system. By applying a combination of research and team-based analyses, a rigorous identification of credible failure modes which could cause these states to be lost, is identified. Finally, required business inputs, expressed in practical terms are distilled from regulator, industry, organisation and site in a way which clearly addresses the failure modes and so retain the required operating states. These business inputs identify improvements for site arrangements (EMESRT levels 1 to 7) before identifying functional requirements for technological collision avoidance solutions (levels 8 for advisory and 9 for autonomous). The paper presents a case study synthesised from multiple sites analyses and will provide guidance on where to find additional resources to assist in making the best possible transition to better equipment and road network solutions.

Jun 22, 2022

By C Jacobsen, N Harries

Assessing and managing instability hazards is an essential activity when working with unstable natural slopes and excavated open pit mining slopes. Slope monitoring has become the standard technique for the management of geotechnical risks associated with mine slope instability hazards. In recent decades, a proliferation of new monitoring techniques such as terrestrial radar, satellite InSAR and LIDAR have become standard operational tools, complementing conventional survey-based monitoring solutions. A reliable monitoring system should identify and record incipient anomalous slope movement. Although the most obvious purpose of a monitoring system is safety related, slope deformation and performance monitoring also enhance the understanding of slope behaviour and assists in improving system design and implementation. For a monitoring system to be considered an effective early warning tool, it needs to operate in real-time and should be linked to the mine’s emergency communication systems. Terrestrial radar systems have been developed that can provide near real-time measurements, at a high level of precision and covering broad areas in all weather conditions. This has had a positive impact on the management of geotechnical risks in operational conditions. The technology adoption of RADAR in mine monitoring has significantly progressed in the last 20 years from technology enthusiasts, to visionaries, to pragmatists to conservative users. However, the increasing adoption of RADAR cannot reduce or remove other monitoring techniques that often have important benefits; even if these technologies cannot be used as a real-time operational tool. An increasing awareness on the importance of combining data from different monitoring techniques to develop a holistic picture of all possible geotechnical hazards is a current industry trend. This is proving to be an excellent foundation for managing hazards associated with slope instability in open pit mines, and is only expected to improve with time with the adoption of new technologies based on big data and Artificial Intelligence (AI).

Nov 29, 2022

HISTORIC SIGNIFICANCE OF EXPLOSIVES TO MINERAL PRODUCTION The ancient method of breaking rock was to build a wood fire against the face, heat the rock through and then pour water on the heated ore-bearing rock to cause it to break by tension. It was too slow and costly as the forests around the mines were cleared and transport of wood became difficult. Black powder had been used for 300 years as a gun propel- lant. ('Black' after Berthold Schwartz, a German monk, Figure 1, and the inventor of the gun who was given the epitaph `Here lies Berthold the Black, the most abominable of inhumans who by his invention has brought misery to the rest of humanity'). Only at the beginning of the 17th Century, black powder was introduced for loosening rock in European mines. In 1802 Dupont started black powder manufacture on the Brandywine Creek. The ignition train of powder was enclosed in goose quills, straws, rushes, paper or wooden tubes. The time interval between igni- tion and blast was pure speculation.

Jan 1, 1988

By Pina P, Pereira MJ

The increasing exhaustion of raw materials entails the exploitation of poorer orebodies where the target mineral occurs frequently in a very fine dissemination. Consequently it is necessary to grind more and more fine to achieve an adequate mineral liberation. In other words, it is of fundamental importance to know what size one should grind in order to avoid the following detrimental situations: 1. Excessive grinding - giving rise to the generation of ultra-fine slime particles which may be lost in the ulterior concentration process and simultaneously leading to higher energy consumption. 2. Incomplete grinding - giving rise to insufficient liberation and consequently leading to considerable losses of the valuable components in the tailings. Although this issue constitutes one of the most important steps in mineral processing, little research has been done compared to other processes, mainly due to the fastidious experimental work required. This paper describes a complete and integrated system of image analysis, where some algorithms to determine automatically the degree of li beration, for different levels of grinding, are proposed. These algorithms, mainly based on mathematical morphology theory were tested with images obtained from polished sections of different grain size fractions. Cases studies on a complex sulphide ore from an important copper and tin deposit located in the South of Portugal are discussed. Samples of the unbroken ore are also studied by image analysis to predict the degree of liberation obtained according to the fineness of grinding.

Jan 1, 1993

By R Berry, J Lett, C L. Harraden

"In the past decade, increased processing capacity combined with precision robotics in high resolution spectrometers has resulted in a new generation of high-speed hyperspectral core logging systems. The application of these multisensor automated platforms provides a key advancement in the characterisation of metal resources. The development of this technology has allowed for comprehensive, drill core-based, mine-scale rock mass characterisation studies. Here we propose a new method for the extraction of parameters that seek to more accurately quantify ground conditions, including quantified rock mass rating (RMR) and the Rock Tunnelling Quality (Q) Index. Data inputs include rock quality designation (RQD), number of joint sets, joint roughness, joint alteration and joint spacing. Geologists and geotechnical engineers have historically collected these inputs by manually logging drill core. With automated core scanning technologies, these parameters can be estimated from the acquired image data and used to objectively calculate RMR and Q-index values for oriented core.Corescan is an automated hyperspectral core scanner that uses a 3D laser profiling system to measure the height of the surface of drill core. This technology allows for rapid core analysis to produce detailed fracture and rock condition data. Through an integrated geometallurgical approach, the proposed methodology will test the accuracy of joint measurement using the height profile Corescan data from oriented drill core. This will be combined with joint roughness and alteration mineralogy measured from the hyperspectral images to calculate the RMR and the Q-index continuously downhole. The values obtained can then be compared to the traditional, manual geotechnical log data. If the precision is sufficient, these techniques can then be applied site-wide to automate the collection and modelling of key ground condition classification indices across an entire deposit. Compared to the laborious manual geotechnical logging procedures that currently form the industry standard, utilisation of core laser profile data and high resolution red-green-blue (RGB) images provide an opportunity to collect large volumes of consistent geotechnical data, which can increase the efficiency and accuracy of deposit scale geotechnical models.CITATION:Harraden, C L, Berry, R and Lett, J, 2016. Proposed Methodology for Utilising Automated Core Logging Technology to Extract Geotechnical Index Parameters, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 119–124 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By B Murphy

Safescape Laddertube provides an improved system for emergency egress in ventilation shafts. The addition of Laddertube in a rise has very little impact on ventilation flow, studies have indicated that the difference in flow velocities are difficult to measure due to the minimal impact. Due to the size and open-ended nature of Laddertube, the air velocity inside and out of the Laddertube is mostly linear. Laddertube can be used either permanently or during an emergency as a secondary ventilation duct. One project involved a 385 m ladder installed in a surface return air raise that could be made to bypass the primary circuit and supply fresh air to a sea container fresh air base at the bottom of the raise. Laddertube has been designed to be installed to any feasible length and can be fitted with a climb assist system ensuring enhanced speed and reduced fatigue during ascent. The climb assist used in association with Laddertube is a Tractelift system which applies a weight relief of up to 36 kg off the climber’s body weight when using the ladder. This system has successfully been tested for ladders up to 600 m in length and is currently in use for a ladder of 185 m length. The use of refuge chambers in underground coalmines has long been a contentious issue due to the concern that while it may provide temporary shelter, the risk of being exposed to high heat or the inability for rescuers to access them due to fire or explosive atmosphere means that they may be effectively trapped. The additional application for coal environments includes Laddertube installed alongside a refuge chamber concealed behind a blast proof door ensuring a secondary means of emergency egress. In certain operations designs may allow for this chamber to be provided withpositive pressure fresh air.

Oct 12, 2022

By T Ladinig

Raise caving is a novel cave mining method, which has been proposed for mass mining at increasing mining depths in LKAB operations. The method makes use of the raise mining technology and an active stress management approach. For the implementation the method is split into two phases, namely a de-stressing phase and a production phase. In the de-stressing phase, a slot-pillar system is established. The purpose of slots is to provide stress shadows and the purpose of the large pillars is to control stress and seismicity. The production phase follows after the de-stressing phase. Required infrastructure in the production phase is developed delayed in stress shadows and bulk extraction takes place in de-stressed zones. Eventually the pillars crush and they are extracted in the production phase. A comprehensive research and development program has been launched to develop the raise caving method towards implementation. As part of this program a full-scale test site of raise caving will be conducted as well as raise caving operations are planned for depth extensions in LKAB mines. This paper discusses the design of raise caving operations in practice at the LKAB mines. In particular, the purpose of the paper is to focus on requirements for the development and design of a raise caving operation. The development of raise caving is discussed from a systems engineering perspective as well as from a management perspective. The functional requirements in the destressing and production phase are outlined and discussed in the paper. The discussion is on basis of the main elements of the raise caving system, such as slots, stopes, pillars and infrastructure. Critical rock engineering design requirements in the de-stressing and production phase are highlighted and dependencies between individual main elements are identified. The analyses show that pillars are especially important for the success of the mining method. Overall, the analyses show that raise caving is a complex system and that its development demands a multidisciplinary approach.

Mar 29, 2023

By Z Lubosik, S Prusek, M Plonka, B Syrek

"The most commonly used method of thick coal seam extraction in Polish deep mines is multislice longwall (MSL). In MSL stability of goaf in the roof as a result of previous extraction in upper slice is a major geotechnical consideration that must be managed.This paper outlines the results of a wide range of investigations carried out in three longwalls that were in operation in a multislice system using caving with additional fly ash goaf stowing. The longwalls were operated by Katowicki Holding Weglowy SA (KHWSA) in the Upper Silesian Coal Basin of Poland.Examinations were completed on the properties of goaf at the roof of longwalls ie measurements of strength parameters of the goaf material by means of a borehole hydraulic penetrometer, determination of the goaf condition by means of a borehole endoscope and laboratory testing of the caved rock. The results of underground examinations of the loading on yielding arches in the gate roads associated with these longwalls and measurements of vertical and horizontal convergence are also presented.CITATION:Prusek, S, Lubosik, Z, Plonka, M and Syrek, B, 2014. Multislice longwalling for thick seam extraction – properties of goaf in the roof and gate roads behaviour, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference, pp 359–366 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 5, 2014

By J Light

Since 2019, the mine planning team at Olympic Dam has been establishing and maturing a shift from deterministic to probabilistic scheduling techniques. This paper outlines this journey undertaken by the mine planning team, key learnings from implementation and further work required to increase the level of planning maturity. Olympic Dam (OD) is a highly variable, polymetallic orebody with a vertically integrated value chain from operations to final product. The processing plant has a tight set of quality constraints which are managed through timing of stopes from varying parts of the orebody. Value is eroded for the operation when forecasted quality of the mine feed encounters disruptions from unplanned changes to the timing of stope starts. As production has moved from the historic Northern Mining Area into the more geologically complex Southern Mining Area, average stope size has reduced, resulting in increased mining fronts required to meet production targets. This has created a problem of increased schedule complexity and difficulties in identifying and communicating resource priorities within a large set of individual stope critical paths. The problem was approached by considering each stope as an individual project constructed by teams working across multiple projects at any one time. The operation could then be considered a multi-project environment with shared resources and enables the application of Critical Chain Project Management (CCPM) to the mine plan. Key to CCPM is the addition of time buffers to protect the critical path of a project form upstream or downstream processes. Implementation of time buffers protects the stope start date against compliance to plan variance. The monitoring of each time buffer consumption, as a proportion of total construction activities completed enables proactive prioritisation of resources. This resulted in an increase in the number of stopes starting in accordance with the mine plan, simplified communication of priorities to all levels of the operation, increased compliance to plan and a clear measure of schedule risk during planning routines.

Mar 29, 2023

By H J. J Boshoff

Mine closure planning integrated into life-of-mine (LOM) planning during the operational phase consists of many subcategories. One of these subcategories that needs to be fully integrated into the LOM planning is that of water management planning. Issues arise when mine water management infrastructure, which is required post-mine closure, is only considered closer to the end of LOM. Once the mine is closed monitoring is focused on water quality as an indicator of closure performance, hence inadequate upfront post-mining water management planning or integration into operations will result in environmental harm. The lack of considering post-mining water management is not uncommon in LOM planning. Poor mine site water management and planning are a wide reaching problem for the mining industry. Numerous active mines have been issued with environmental notices and penalties for contaminated water discharge; including issues with abandoned mines now being cared for by governments all over the world.Mitigating sources of water contamination caused by existing and closed mine sites that are leaching pollutants might be impractical, due to inaccessibility to the contaminants or final landform topography. The opportunity to consider and introduce post-closure required mine water management infrastructure is lost once the waste facilities are constructed. Mitigating contamination is made more problematic with mines located in remote areas, serviced by dedicated roads, water supply, electrical supply, etc. It is expected that these services will be decommissioned or drastically reduced, once closure is reached making remedial work much harder. Inadequate planning, to ensure access and easily maintainable water management infrastructure, could lead to erosion and contamination going unnoticed. There are numerous examples of poor mine water management practices in Africa, Asia, Australia, South and North America. In the United States more than 23 000 km of streams are affected by pollution sourced from some 50 000 abandoned or mature mine sites (DeGraff, 2007).CITATION:Boshoff, H J J, ?2014. Inadequate water management planning resulting in long-term closure liabilities, in Proceedings Life-of-Mine 2014 , pp 233–246 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By D Morton, G Wallace

"Evolution Mining is the sole owner of the Mt Rawdon open cut operation, located 75 km south-west of Bundaberg in Queensland, Australia (Figure 1). It is a massive, volcanically hosted, low-grade gold deposit that exhibits excellent characteristics conducive to low cost mining and treatment.In 2014, Mt Rawdon began investigating initiatives to deliver higher mill throughputs without any significant capital expenditure or modifications to the existing processing plant. Various studies have shown throughput increases are possible by applying more blast energy, essentially by reducing feed size through blasting and leaving less work for the comminution circuits (Brent et al, 2013; Ziemski, 2011; Workman and Eloranta, 2003).Given that 53 per cent of energy used on a mine site is consumed by the comminution circuit, with only two per cent being consumed by drill and blast (Smith, 2013), it makes logical sense for a mining operation to align their drill and blast with their processing plant. The term commonly used when exploring this relationship is a ‘Mine to Mill’ program.Over nearly 12 months, various blasting options and Mine to Mill methodologies were tested at Mt Rawdon. Throughout the journey, it was abundantly clear that the Mine to Mill initiative is not as simple as making one technical or physical change and expecting an improvement. Rather, true sustainable improvements demand a paradigm shift across both the mining and processing cultures, where all departments are aligned and working towards the one outcome. This true overarching Mine to Mill mentality, enabled by Vistis™ 250 high energy bulk explosive, ultimately led to a sustained increase in throughput and profitability of the Mt Rawdon operation.Citation:Wallace, G and Morton, D, 2016. High Energy Bulk Explosives and Mine to Mill Focus – the Mt Rawdon Story, in Proceedings Ninth AusIMM Open Pit Operators' Conference 2016, pp 60–69 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 15, 2016

By H Kurth, L Balzan

The potential for bulk diversion was identified and quickly implemented following the development of bulk sensing technologies applied to conveyed flows. In the early 1980s real time analysis of ash in coal was intended to improve the understanding and control of quality variability. By the end of the 1980s approximately 5% of coal analysers installed were being utilised for bulk sorting; diverting flows to create stockpiles to improve blending flexibility and boiler feed consistency, diverting waste material, or bypassing the beneficiation process when the coal met product quality criteria. In the 1990s bulk sensing and sorting utilising natural gamma detection was applied to conveyed waste in gold-uranium mineralisation and allowed ore to be recovered and processed that would otherwise have been discarded. Further applications developed in the iron ore sector where product quality ore could be diverted to bypass beneficiation and save significant unnecessary processing costs and improve recovery by avoiding process inefficiency losses. Plant capacity was freed up to be utilised by material that required processing. Similar benefits became evident in the phosphate industry and in base metals where multi-elemental analysis using Prompt Gamma Neutron Activation Analysis provides ideal opportunities to representatively measure 30 second conveyed increments at high accuracies. This has been successfully adopted in copper, nickel, platinum and lead-zinc to improve waste removal after primary crushing to eliminate unnecessary expense and improve plant efficiency. The benefits include increased output from existing operating capacity, significant reductions in consumable costs and generation of fewer detrimental waste streams. The paper outlines the technologies and discusses case studies covering the above commodities, demonstrating the immense value that representative real time measurement of conveyed flows can create. Measurement data concurrently provides multiple benefits in operational performance besides sorting, through ore reconciliation, ore blending, feedforward control and metal accounting, adding further value.

Nov 10, 2020

By K Hortin

Kidd Creek mine in north western Ontario is developing phase 1 of the deep mine project for mining between 2100 m and 3100 m below surface. Heat problems were experienced during the 2003 summer in working places about 2300 m below surface. At the time the mine had a æcold stopeÆ for cooling the air supplied to the mine below 1500 m from surface. The æcold stopeÆ is where during winter, ice is created in both the open pit and its connecting airways to the mine and used to cool air in summer. The operation and limitations of the existing cold stope were evaluated and led to the requirement for additional mechanical cooling to be available for the summer of 2004. The first stage of a surface refrigeration plant providing 7.5 MWR of cooling was approved, the compressor set was ordered in early January 2004 and the plant commissioned six months later in early July 2004. Based on the current modifications to the mining plan, further plant expansions are required in 2006 and 2009 leading to a total of 19 MWR of mechanical refrigeration and 8.5 MWR equivalent from the extended cold stope. The refrigeration system is described with emphasis on the specific adaptations necessary to suit Canadian conditions. Additional investigations were; using the refrigeration compressors in winter for heating and, extending the performance of either cold stopes or alternative ice storage systems. The winter use of refrigeration involve removing heat from the mine exhaust air to provide a cooling load and to use the hot water in the condensing circuit to heat the intake air and reduce reliance on mine air heating with natural gas. This paper follows on from an earlier one presented at the Seventh International Mine Ventilation Congress where the background and planning of the mine ventilation and cooling requirements were described for extending the mine at depth to 3100 m.

Jan 1, 2005

Pike River Coal Limited is in the process of developing the Pike River Coal Mine in the Paparoa Ranges of New ZealandÆs South Island. The mine will be developed to extract a coking coal deposit of the Brunner Seam, some 46 km north-east of Greymouth, using a combination of continuous miners and hydraulic extraction. The mining area is located within Department of Conservation (DOC) land and is adjacent to the escarpment of the Paparoa Range and the Paparoa National Park.   As such, the major restriction to planned extraction is protection of: +        the western escarpment, +        vertical and sub-vertical rock faces, +        permanent water courses, +        significant vegetation, and +        steep slopes.   The mine will use its elevation advantage to hydraulically flume coal from the working faces to the pit bottom area where it will be slurried to approximately 35 per cent density of solids and pumps down a slurry line to the coal prep plant some 10.5 km down the Pike River Valley. The coal will be sold on the export market as a high quality coking coal for international steel making.

Jan 1, 2006

By P Kumar, J Safarian

Understanding how ore interacts with flux particles at elevated temperatures to create molten slag is crucial since it governs the dynamics of a chemical reaction. This study explores the smelting behaviour of pre-reduced Nchwaning manganese ore when combined with lime, with the objective of examining the evolving interaction between pre-reduced ore particles and lime over time. The research sheds light on the interaction between solid and liquid and the phases that emerge during this process. To achieve this, a sessile drop furnace was employed to rapidly heat the materials positioned adjacent to each other on an alumina substrate and to observe the smelting process as it unfolded over time. This method allowed for the direct observation of the melting temperatures and the flux-ore reaction progression rate, and the potential disruptive events that might occur. By comparing the molten interfaces of the fluxed materials at various time intervals, this study provides insights into the relative rate of slag formation from the two materials. The results indicate that the main slag formation initiated at approximately 1400°C and continued to advance with time, with complete mixing occurring around 1500°C. The possible phases formed were identified using Scanning Electron Microscopy and modelled using Fact Sage thermodynamic software. In addition, the iron particles in the pre-reduced Mn ore were separated and settled from a rich MnO-containing slag. It was found that the separation of molten iron droplets from the slag depends on the rate of solid MnO particles dissolution into the adjacent slag phase.

Jun 19, 2024

By M Neurohr, B Wacker, D Mensing, C Murphy, W Kitz

Mining operations have large power requirements. The biggest consumers of energy are the drives for the mills located in the concentrators. Assuming that the decision is made on how many mills are needed and how big these mills will be, it can be determined how these mills should be driven. The decision as to which drive should be applied depends on design limits for different mechanical or electrical drives, anticipated operation modes, capital expenditure optimisation and lifecycle cost optimisation.The task for the engineer specifying the drive equipment is to select a drive solution that can debottleneck the operation, avoid interruption of production and enhance the reliability of the process. At the same time, the engineer must choose a design that enables cost optimisation either in a single investment or in relation to the total cost of ownership (TCO).This paper outlines different mechatronic or electric drive alternatives for tube or horizontal mills applied in the mining industry, along with their advantages and disadvantages. The paper covers a wide range of applicable drive systems and provides a background to the benefit of applying integrated drive systems.CITATION:Wacker, B, Kitz, W, Murphy, C, Neurohr, M and Mensing, D, 2015. Application of different drive systems for horizontal mills, in Proceedings Iron Ore 2015, pp 205–216 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015