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By R. M. Reynolds

Engitec Impianti, S?.p.A. of Milan, Italy has successfully designed, constructed and has in operation state-of-the-art battery breaker systems at two European locations. A third facility i:s partially completed in Toronto, Ontario, Canada. The CX system crushes whole batteries, separates the various components and desulfurizes the battery paste. The system also produces sodium sulfate from the sulfuric acid and lead sulfate contained in the batteries. Actual plant operating data indicates that the desulfurized paste contains less than 0. 6 percent sulfur and less than 0. 5 percent antimony. The CX system utilizes mechanical screening and an up-flow hydrodynamic separator to accomplish the component separation. Sodiwn hydroxide or sodium carbonate is used for desulfurization. The sodium sulfate brine is evaporated and crystallized to produce clean anhydrous sodium sulfate suitable for use by detergent or glass manufacturers. Plant data also indicates that an increase in furnace productivity of about 25 to 30 percent is achieved using feed from the CX system. The desulfurized paste is very suitable for electrolytic processing as an alternative to pyrometallurqical processing.

Jan 1, 1990

By L. A. Roe

Magnetic separation occupies an attractive position in the field of ore beneficiation. It is a simple yet effective method, used for some 150 years and steadily growing more important. This type of beneficiation orginated in 1792, when William Fullarton was issued a British patent covering the separation of iron ore by magnetic attraction. What is magnetism, and why are some materials capable of being magnetized and others not? The study involves many unknowns, and even a partial answer to these questions would be a dissertation in solid state physics and perhaps other fields of science. But the last two decades have revealed basic facts as to why certain materials are magnetic and what happens to them when they are magnetized.

Jan 12, 1958

By D. Cantali

This paper will be presented in two parts. The first part will present the latest advancements in pile installation techniques using state-of-the-art press-in piling technology by Giken. By pressing in sheet piles and large modulus contiguous steel tube pile walls – as opposed to the more traditional installation methods using percussive hammers or vibrators – retaining structures can be constructed effectively noise and vibration free. For over water and coastal projects with limited access, this provides significant environmental benefits in the form of minimising the construction foot print and the impact to surrounding communities and the marine natural habitat. Typical noise and vibration data will also be presented. The second part of this paper will review the current manufacturing techniques for sheet piles and introduce innovative new materials used in the current piling market for embedded sheet pile walls. Materials include long service life non – ferrous materials such as new age plastics and fibre reinforced polymer piles. Their excellent long term performance and durability make them an effective solution in the marine environment. For steel piles, a number of steel grades with reduced corrosion characteristics will also be discussed including a newly developed steel to combat corrossion in the low water zone, an area often exhibiting the highest moments in a retaining wall. A number of project case studies will also be presented to reinforce their relevance in today’s changing construction landscape.

Nov 1, 2022

By T Raynlyn, R J. Holmes, J R. Manuel, A Poliakov, L Lu

The prediction of sintering performance of iron ore fines and the possibility of targeted optimisation of specific sinter properties are very important for both the iron ore industry and related research organisations. Physical pilot-scale sinter runs require large amounts of raw materials and are expensive, so it is critical to target large test work programs with many different sintering parameters effectively. To predict values for sintering performance parameters such as tumble index (TI), low temperature reduction disintegration index (RDI) and productivity, a comprehensive database of pilot-scale sintering experimental results has been established and empirical modeling conducted. Similarly to earlier work, physical, chemical and mineralogical characteristics of the iron ores have been considered. However, in contrast to the previous work where only one textural parameter was taken into account, namely the proportion of dense haematite ore texture, the current model includes the abundances of several different textures which were combined into different textural factors corresponding to different sinter properties. Coefficients for the variables within specific regression equations can provide a better understanding of the effect of the variables on the corresponding sintering performance. The modelling results have also been used for predicting the sintering performance of mixtures that were not part of the database used for establishing the models. Comparison of experimental and modeling results for the verification test data is also reported in this paper.

Jan 1, 2009

By R. Svensson

Mill linings play an important role in all comminution processes with tumbling mills. The selection of the lining profile and the lining material has a great impact on over-all grinding cost and mill throughput. The cost of the lining itself is minor in comparison with media cost, energy cost and the value of the material produced in the mill. The total scope must be considered when mill linings are selected. This paper presents case stories and explains the technology behind: -different lining profiles in rubber and steel -OREBED magnetic lining -Steel-cap rubber lining

Jan 1, 1994

By R. Svensson

Mill linings play an important role in all comminution processes with tumbling mills. The selection of the lining profile and the lining material has a great impact on overall grinding cost and mill throughput. The cost of the lining itself is minor in comparison with media cost, energy cost and the value of the material produced in the mill. The total scope must be considered when mill linings are selected. This paper presents case stories and explains the technology behind: •Different lining profiles in rubber and steel. •Orebed magnetic lining. •Steel-cap rubber lining. Introduction Grinding mill liner life has been a subject of extensive studies. Performance of mill liners in terms of wear life and how it relates to lining material and profile is abundant in the literature. The most economical liner material and design has been selected based on "cents per ton milled". The evaluation of the effect of liner design on power and grinding media consumption which is a far more significant part of grinding costs, has been less comprehensive (Fig. 1). Lining materials Steel. The most commonly used lining material is steel, calculated on a volume basis. Steel linings have a long tradition and a number of alloys is being developed. The main families are: •High chromium white iron. •Cr and Ni white iron (NiHard). •High chromium martensitic steel. •High carbon Cr-Mo perlitic steel. •High carbon Cr-Mor martensitic steel. •Manganese austenitic steel. Steel linings can be successfully used in most applications. Rubber. Rubber linings were introduced 25-30 years ago and are today commonly accepted to be the most economical linings for secondary and regrind applications. Rubber linings offer long service life in these applications and generally [ ] outlast steel in wet applications, where corrosion is a factor on the steel. The cost relation between rubber and steel has changed dramatically over the years. In the past rubber was more expensive than steel, but today, the cost of rubber is close to half the cost of steel, calculated on a volume basis (Fig. 2). The present cost situation has made rubber linings an economical alternative in several primary grinding applications as well. The wear rate of rubber in primary applications is higher than the wear rate of steel, thus giving a shorter wear life. This can be compensated for by making the rubber lining thicker. The cost advantage of the rubber allows for this, but care must be taken not to jeopardize the grinding performance. Rubber, as a lining material, offers some distinct advantages over steel lining, such as: •Ease of installation and removal. •Safer to handle, less risk of injuries. •Faster replacement. •Reduces noise.

Jan 1, 1996

By Jeff Kravitz, John Kovac, Wayne Duerr

Since 198 1, Federal mining law has required every miner working in underground coal mines to have a self-contained, self-rescuer (SCSR) available for use in emergencies. Some miners that have escaped from fires using SCSR's have reported that they had to remove their mouthpiece to talk during escape, thus compromising the protection afforded by the SCSR. If miners are in thick smoke during an escape, they may have trouble if they become separated from their group. The visibility can be so poor that separation can occur at very short distances. To address this problem, two-way, FM radios were built into the SCSR to improve the ability to communicate should the miners be separated over relatively short distances. The SCSR prototypes built and used in testing included both two-way radios and improved mouthpieces. Comparison studies were conducted using combinations of the new and old mouthpieces, and trials using the radio or not using the radio. Subjective judgments indicate that communication ability was significantly improved using the prototype devices. Communication problems have been encountered with teams using standard voice- powered communications systems. Mine rescue teams perform rescue and recovery work under extremely hazardous conditions, life lines are a standard part of mine rescue team equipment. Leaky feeder and quasi-leaky feeder life line communications systems provide significant improvements over standard systems. These improved systems allow all members of the team to communicate with each other and their base of operations. These innovations will significantly enhance the safety of mine rescue operations.

By Leslie McHattie

?Intelligent mine? conjures up a futuristic image of unmanned extractors and loaders working in harsh conditions in a remote lunar landscape. The promise of increasing mine fleet productivity and solving the problem labor shortages in mining regions can certainly be achieved today through remote controlled extraction and automated hauling. The technology is available and it doesn?t seem to be so much science fiction when Google?s self-driving cars hurtle down the freeway. ?Intelligent mining,? on the other hand, implies the application of information technology at every phase of the mining value chain, from exploration and geological modeling to equipment, operations and maintenance, and logistics and transportation. These are really industry-specific, enterprise-class software solutions focused on using information technology to support the business processes of mining and make them more efficient and effective. Overlaying the physical world with the digital or virtual world enables us to model and simulate our assets, giving us the ability to effectively design, build, and ultimately optimize the performance and reliability of our assets throughout the lifecycle. The digital asset, often a 3D model, is created initially during the engineering and construction phase, and is handed over to the operator before the mine goes into operation. Combined with geospatial or geographic information systems, the operator has a complete digital representation of the physical world, which forms the foundation for risk and performance management, along with compliance and regulatory reporting. Laser scanning and positioning technology can be used to create point clouds ? information models consisting of millions of data points ? which enable the visualization and representation of the ?as-operated? reality. But consider that once the mine is in operation, it throws off an endless stream of data in the form of performance and condition data from sensors and monitoring devices on fixed and mobile assets through networks, servers, and services. This ?big data? can be processed and analyzed to spot trends, help predict events, and formulate reliability strategies as early as the design stage (e.g., reliability-centered design). ?Intelligent mining? implies that massive amounts of data augment the reality of the physical mine, plant, and equipment. This embedded intelligence can be used to optimize operational efficiency, increase asset availability and utilization, improve safety and environmental integrity, and maximize return on investment. Lastly, the sweet spot for intelligent mining is seen in the convergence of consumerization and industrialization. The application of ?consumer? technologies that we use every day on our iPhones and Android devices, such as cameras, motion sensors, and positioning in an industrial context, are producing ?immersive? experiences. Overlaying the digital world on the physical world and connecting them accurately through intelligent positioning results in ?intelligent infrastructure,? which is safer and more sustainable. Bentley Systems works with many mining companies and engineering, procurement and construction companies involved in all aspects of mining infrastructure development. In fact, 10 of the top 20 mining companies ranked by market capitalization are users of Bentley software, including all of the top five. In addition, Bentley provides software solutions to the world?s leading engineering, procurement, and construction companies, as well as owner-operators, who design, build and operate the world?s infrastructure. Bentley?s solutions for mining and resource extraction industries help increase the efficiency of capital projects associated with the design, procurement, and construction of mines and processing plants, as well as the operation and maintenance of mining fleet and equipment.

Aug 1, 2013

By Morrison R. D, Davis J. J, Fraser B, Kojovic T

1991 saw the completion of a three-year $1.1 million research and development program in mineral sands beneficiation, funded in two associated projects by the Australian mineral sands industry through AMIRA, and carried out by the Julius Kruttschnitt Mineral Research Centre. It is believed to be the largest R&D project in mineral sands ever conducted by a university research group. It covered dry plant operation, and delivered several products to the industrial sponsors, including: ò A detailed characterisation of the radiation properties, mineralogy and size distribution of inhaleable dust arising in dry plants. ò New process models of magnetic and electrostatic separators. ò New on-line instruments for elemental assay (in association with AMDEL) and bulk conductivity measurements of dry process streams. ò Demonstration and evaluation of the Magstream magnetohydrostatic separation technology.

Jan 1, 1992

By W. S. Szolga, M. Moser, M. D. Soderstrom, L. Cohen

"CYANEX® 272 is a phosphinic acid-based solvent extraction reagent used commercially since the early 80’s to recover and purify cobalt from sulfate solutions. Historically, the design of CYANEX 272 circuits has involved the selection of an optimal pH profile during pilot-scale testing using mixbox pH control. The desired pH profile is required to be carefully controlled in the same manner during commercial operation. To assist operators in the design and optimization of their circuits, Solvay developed CYANEX 272-specific solvent extraction modeling software, which has enabled determination of the ideal pH profile and staging configuration. Solvay’s recent advances in modeling capabilities have allowed the simulation of circuits without direct mixbox pH control. Modeling has indicated that circuits operated without direct pH control can achieve the desired metal separation while simplifying the commercial operation significantly. This paper reviews a number of potential circuit configurations for the use of CYANEX 272 and demonstrates the separations achievable under the right design and operational conditions, some of which have historically been considered too difficult.INTRODUCTION CYANEX® 272 is a phosphinic-acid based reagent designed specifically for the separation of cobalt from nickel by solvent extraction from weakly acidic sulfate solutions (Rickelton, Robertson, & Burley, 1982; Rickelton, Flett, & West, 1984; Rickelton & Nucciarone, 1997). Following commercial introduction in the 1980’s, CYANEX 272 has been used in a number of hydrometallurgical flowsheets for cobalt purification and/or recovery. CYANEX 272 metal extraction occurs by means of a cation exchange mechanism. Extraction of a divalent metal ion M2+ is represented by the following equation where RH represents the CYANEX 272 ligand and MR2 represents the ligand-metal complex."

Jan 1, 2017

Advances in Optical Image Analysis and Textural Classification of Iron Ore Fines

Sep 13, 2010

By S Hapugoda, M Peterson, A Haileslassie, A Poliakov, E Donskoi, L Lu

Most metallic iron in the world is produced in blast furnaces from different feed stocks – sinter, lump ore and pellets. Sinter is the main iron-containing feed to the blast furnace and can constitute up to 70–85 per cent of the total ferrous burden. As sinter quality is a key element for stable blast furnace operation, the textural, chemical and physical characteristics of the sinter are very important. Two major factors that affect sinter strength are mineralogy and porosity. This study utilised optical image analysis (OIA) to characterise sinter mineralogy, and the results were compared to those obtained by manual point counting under the optical microscope.Two major mineral characteristics of iron ore sinter are the presence of primary (unreacted) and secondary (derived from melt) hematite. Standard OIA, which is based on RGB thresholding, is not able to distinguish them as they have the same reflectivity; however, primary and secondary hematite in iron ore sinter have a different morphology. The CSIRO-developed OIA software Mineral4/Recognition4 has a unique feature to identify various textures/morphologies of the same mineral. Together with other capabilities of the Mineral4/Recognition4 software, this feature was used to identify different types of hematite and silico-ferrite of calcium and aluminium and other common sinter phases, such as magnetite, larnite, glass and remnant aluminosilicates.A visual comparison of the sinter mineralogy present in optical photomicrographs and that present in the mineral maps created automatically by the Mineral4 module of the CSIRO software confirmed the accuracy of the automated mineral identification.CITATION:Donskoi, E, Hapugoda, S, Lu, L, Poliakov, A, Peterson, M and Haileslassie, A, 2015. Advances in optical image analysis of iron ore sinter, in Proceedings Iron Ore 2015, pp 543–548 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By J Rubio

This work presents design features of an innovative in-line mixing helical (coiled) reactor for flocculation and flotation as a solid-liquid separation process for suspended particles (including liquid droplets). The device has been named flocs generator reactor (FGR), a compact system whereby the flocculation of particles is assisted by the kinetic energy transfer from the hydraulic flow through the reactor and/or by the injection of microbubbles (30 - 70 ¦m). The flow mixing presented a plug flow regime with a low dispersion degree, promoting the required hydrodynamic conditions to disperse the polymer flocculant (cationic polyacrylamide) and to generate æstrongÆ flocs of Fe(OH)3 or clays (as colloidal model systems) with aggregation using an anionic polymer, Al2(SO4)3 and poly aluminium chloride (PAC), and oil emulsions destabilisation with a high molecular weight cationic polymer. The solid-liquid separation of the flocs was then achieved either by settling or by flotation with microbubbles. This paper discusses advances in this new in-line flocculation-rapid flotation device to remove æaerated aggregatesÆ, aggregates with entrained and entrapped bubbles. Studies were carried out with different models of FGRs (varying the length:volume ratio) and process efficiency (mainly kinetics) evaluated as a function of polymer concentration and some operating parameters, namely, feed flow-rate, air:solids ratio and residence time. Results showed that the aerated flocs are readily floated with rising rates in the order of 120 mh-1, values higher than those obtained for the settling of the non-aerated flocs (18 - 24 mh-1). The FGR requires short residence times and generates dense, well structured flocs (with a mass fractal dimension, dF of about three) which withstand high shear forces. Mechanisms involved appear to include small bubble formation and their rapid occlusion (entrapment) within flocs, nucleation of bubbles at floc/water interfaces, polymer coiling as a result of æsalting outÆ effects at the aqueous/air interface and plug flow type of mixing (flocculation). Successful examples of emulsified oil and solids removal from water are shown and because in all cases high efficiencies were obtained (>90 per cent removal). Due to the high process efficiency and high loading capacity shown, the FGR appears to have good potential as an in-line flotation-separator device in applications requiring high rate solid-liquid or liquid-liquid separations.

Jan 1, 2005

A major tool in the search for petroleum is reflection seismic mapping. The period which has seen most of the exploration in Victoria is also one which has seen major advances in this technology, from 1963 try present day. Seismic mapping can be divided into three interlinked areas - acquisition, processing, and interpretation. In acquisition the major changes have been from an explosive energy source in 1963 to gas exploders in 1968 and airguns in 1970. The number of recording channels has increased from 24 to 192, with digital recording introduced in 1966, and floating point recording in 1976.

Jan 1, 1982

By Paul J. Sylvester, Yeonuk Choi, Mike Nelson, Louis J. Cabri, Mike Tubrett

"The development and characterization of sulphide standards containing as many as seven precious metals has increased the efficiency and comprehensiveness of micro-analyses for deportment studies using laser ablation microprobe inductively coupled plasma mass spectrometry (LAM-ICPMS). Because trace precious metals occurring in solid solution or as sub-micron inclusions in sulphides, arsenides, and sulpharsenides are often heterogeneously distributed, a significantly large number of analyses are required. Using well-prepared samples it is possible for up to 120 analyses per day, far more than by other comparable methods. Examples will be discussed from projects focused on the deportment of Au and the platinum group elements (PGE).INTRODUCTIONBecause gold and the platinum-group elements (PGE) occur as both discrete minerals and in trace quantities in a variety of minerals (mostly sulphide, arsenide, and sulpharsenide minerals), specialized trace analytical methods were developed and applied to determine the deportment of precious metals in ore deposits, requiring sensitivities ranging originally from about hundreds to presently tens of ppb for individual precious metal or less.In mineralogical studies, micro-analytical techniques such as the electron microprobe were first applied to obtain analyses for major elements in about 1959-60, but as the instrumentation improved early attempts for PGE in potential carrier minerals indicated that reasonable levels of detection (LOD) were of the order of 300-400 ppm, depending on analytical conditions, X-ray spectral lines, and mineral matrix (e.g., Cabri and Laflamme, 1976). Eventually, the lowest detection levels by electron probe micro-analyses (EPMA) obtained for some PGE were of the order of 10s of ppm using high accelerating voltage and current for extended measuring time on peak and background (Gervilla, Cabri, Kojonen, Oberthür, Weiser, Johanson, Sie, Campbell, Teesdale and Laflamme, 2004)."

Jan 1, 2010

By Alan Minchinton, Ian Kirby, Jim Chan

It has long been known that successful blasting in soft and hard rock can require the use of different explosives. While choosing an explosive of the right energy density is important, the dynamics associated with non-ideal detonation behaviour play an equally major role. Tuning the energy release rate of an explosive to optimise its blast efficiency can be likened to tuning an internal combustion engine to improve its performance.

Jan 1, 2014

By D. Robert Weir

The pioneers in pressure hydrometallurgy have provided a solid foundation during the past four decades. The pressure techniques are now capable of being used to push back the frontiers in the winning of metals. Pressure hydrometallurgy has been used to meet the objectives of extracting metals; purifying metal solutions, recovering metals; and rendering waste streams acceptable for disposal to waste repositories and the environment. Some examples of each of these functions are briefly reviewed. The applicability of pressure techniques to the recovery of precious metals is discussed.

Jan 1, 1985

By Mark Holdsworth

In 2002, Kennecott Utah Copper Copperton Concentrator installed an Expert Control system for optimization of their SAG and Ball milling circuits. The advanced process control has been well received and is utilized well over 95% of the time. In the years since, many lessons have been learned and many advances have been made. Improvements have produced millions of dollars of benefits and have included directly controlling feedrate with complex logic as opposed to using a bearing pressure controller, modifications to how sound is used for control, modifying logic for maximizing asset utilization and using advanced control for automating equipment restart.

Jan 1, 2012

By Jessica Hurst, Mark Holdsworth, Jeff McKay

"In 2002, Kennecott Utah Copper Copperton Concentrator installed an Expert Control system for optimization of their SAG and Ball milling circuits. The advanced process control has been well received and is utilized well over 95% of the time. In the years since, many lessons have been learned and many advances have been made. Improvements have produced millions of dollars of benefits and have included directly controlling feedrate with complex logic as opposed to using a bearing pressure controller, modifications to how sound is used for control, modifying logic for maximizing asset utilization and using advanced control for automating equipment restart. INTRODUCTIONRio Tinto’s Kennecott Copperton Concentrator produces copper, molybdenum, gold and silver. The mill has 4 SAG mills (SAG 1-3, 34 foot diameter and SAG 4 36 foot diameter), 8 ball mills and copper and molybdenum flotation plants, as seen in Figure 1. The 2010 average data is shown in Table 1.In 2002, a Metso Cisa OCS Expert Control system was installed at Copperton for SAG and Ball mill advanced control. The expert control was first placed on SAG 2; data from the first few weeks compared with operator performance indicated approximately an 11 percent increase in throughput. After full commissioning, the system was gradually refined further by plant personnel to develop key performance indices based on SAG feed size, refinement of the sound setpoint for control of mill speed and throughput, specific rules to help the adjustment of speed based on loss of a feeder, etc. With the addition of the pebble crushing circuit, the expert control began utilizing a model estimation of crushed pebble bin level to help stabilize the impact of returned crushed and uncrushed pebbles on the SAG mills. As the ore and limitations change, it is necessary to evolve the SAG logic to better handle any constraints."

Jan 1, 2012

By T. Negeri, M. Boisclair, A. Bouajila

CanmetMINING has been working on process development for separation and concentration of rare earth bearing minerals from various ores. Among others, the flowsheet development for the Montviel Rare Earths/Nb deposit, located at the north end of the Abitibi region in Quebec and owned by GeoMegA Resources Inc. (GeoMegA) is now at an advanced stage. The concentrate produced by a flotation-only process at the early stage of the project accounted for higher than 90% TREO and Nb recovery in 40% mass. This concentrate was submitted to SGS Lakefield for hydrometallurgical processing. Lixiviation of the concentrate using hydrochloric acid yielded approximately 99 % REE. An overall (from ore in ground to final precipitate) REE recovery of 80% was obtained through a series of selective precipitation steps. Recently significant additional developments have been made. CanmetMINING is steadily improving the quality of concentrate produced through a simplified, more efficient flowsheet which consists of flotation, magnetic separation, and a thermal treatment procedure. The paper discusses aspects of the process that allowed obtaining 82% recovery of TREO and Nb in 16% of mass, the best result to-date.

Jan 1, 2014