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By J Mukhopadhyay, J Gutzmer

Most world-class high-grade (60 - 67 wt per cent Fe) hematite iron ore deposits are the product of enrichment of Precambrian iron-formations but processes responsible for enrichment are still unclear. Different models, ranging from syngenetic and diagenetic (King, 1989), deep-seated hydrothermal (Powell et al, 1999; Barley et al, 1999; Taylor et al, 2001; Gutzmer et al, 2002) and ancient supergene (Morris, 1980; 1985; Van Schalkwyk and Beukes, 1986) to modern supergene (MacLeod, 1966) have been suggested. The high-grade hematite deposits stand in contrast to martiteûgoethite ores which are generally accepted to be the result of supergene enrichment of iron-formation because they are found along Cretaceous to Tertiary lateritic weathering profiles (Morris, 1980; Harmsworth et al, 1990). Uncertainties about the origin of the high-grade hematite ores appear largely due to the monomineralic composition of the ores. They are almost exclusively composed of hematite (as microcrystalline hematite and martite), a mineral with wide stability field and very simple chemical composition that reveals little about its origin. Second, many of the deposits have been overprinted by later deformation and chemical weathering obscuring primary ore characteristics and zonation (Taylor et al, 2001). Third, surprisingly few detailed geological studies have been undertaken on the deposits with the aim of unraveling ore genesis. Most studies focus on the present-day structure of orebodies and their general physical-chemical composition for mining and beneficiation purposes. A more thorough understanding of the origin of high-grade hematite iron ore deposits may be gained by combining available mining-orientated data with systematic petrographic-geochemical analyses of different ore generations and hematite phases. This paper presents a first summary of results of an ongoing study, started some two years ago, of high-grade iron ore deposits in South Africa, India and Brazil, including a comparison with the rather well studied deposits of the Hamersley Province in Australia.

Jan 1, 2002

By D Craw

A glasshouse experiment was set up to investigate arsenic uptake in rye corn grown in different arsenic rich substrates. Sods of material were taken from various locations and planted with rye corn seeds. The plants grew for 13 weeks after which time the above ground biomass was harvested. Analysis of the rye corn plants showed a narrow range of arsenic concentrations, which did not reflect the arsenic contents of the soil. Comparison of the results from this study with previous work showed the glasshouse rye corn to have lower arsenic concentrations in above ground biomass than rye corn grown in field conditions. The environmental conditions present on the tailings and water-rock interactions were considered the main factors involved with the difference in arsenic uptake between field studies and the glasshouse study. This suggests that bioavailability processes are influenced by a variety of factors and cannot necessarily be predicted by the use of soil factors or glasshouse trials alone as is often done when planning phytoremediation work and mine shut down.

Jan 1, 2007

A brief history of the significant haulage truck feature changes and the factors that influenced those changes during the 60's and 70's provide a basis for forecasting the changes that can be expected in the 1980's. A review of the impact factors and changing requirements that currently exist that will create changes. Define the critical requirements of a successful haulage truck design and discuss the availability of bigger engines and better electric drive componetry to provide deeper pit capability and improve reliability. The Unit Rig Trolley Assist System to provide improved productivity and diesel fuel savings and an economic analysis to evaluate the Trolley System is covered. The Unit Rig Automatic Truck System for a driverless truck is covered in concept and discussed from the point of view of the experience in a test in a New Mexico mine. INTRODUCTION A good basis for trying to forecast what is going to happen in the future is to go back a little bit in history, to see what the influencing elements were in different periods of time as a foundation for the forecast. INFLUENTIAL FACTORS IN THE 1960'S If you look at the truck development that occurred in the 1960's, there were some identifiable factors that give us insight. (See Fig. 1) Several things happened at the beginning of the 1960's. Mechanical drive haulage trucks were introduced that were

Jan 1, 1982

By A N. Terblanche, D S. Smit

The paper discusses the improvements achieved after an external sparger flotation column, 1.42 m diameter by 9.5 m high, was installed as a re-recleaner unit at the Northam Platinum LtdÆs UG 2 plant in South Africa. The paper also evaluates the pilot plant data prior to the industrial size column installation as well as the accuracy of scale up from pilot to full-scale operation. Since the installation of the PrepQuip flotation column, the final concentrate upgrade ratio improved from 83 to 105, the 3PGM+Auå recovery improved from 79.7 per cent to 81 per cent and the Cr2O3 content in the final concentrate decreased from five per cent to 2.8 per cent. The upgrade ratio can be improved to 125 with an overall 3PGM+Au recovery of 80 per cent. Conventional mechanically agitated flotation cells achieved only 74 per cent recovery at an upgrade ratio of 125.

Jan 1, 2005

By A McGann, P J. Coghill, D Miljak

"It is widely accepted that bulk ore sorting could provide a step change in processing of low-grade ores. For this to be achieved a rapid, accurate bulk sensor of grade is required as well as sufficient natural variation of grade in the ore stream. CSIRO trialled a magnetic resonance (MR) sensor capable of measuring chalcopyrite, and by inference total copper grade, on the 1300 t/h Ridgeway portal conveyor. The gauge produced an unprecedented set of data down to a 1 t scale for months at a time. This paper analyses the measured variation and compares it to a simple model derived from the bore core data and mixing within the block cave mine.The model of the small-scale (<1000 t) variation is developed using fractal methods which have successfully been used in the past for copper porphyry deposits showing a power law or near power law distribution of copper grade and vein sizes. These fractal distributions have two features highly favourable for segregating ore, a large proportion of low-grade pods and the large-scale spatial clustering of grade. We show the presence of fractal ordering in bore core data at short range in the Cadia Ridgeway porphyry deposit and measure its persistence in the crushed rock produced by the Ridgeway block cave mine over one month. The model is then extended to demonstrate the effect of varying head grade, mixing and pod (or diversion) weight on bulk sorting efficiency.CITATION:Coghill, P J, Miljak, D, McGann, A, 2016. Modelling Grade Variation in Crushed Ore at Cadia Ridgeway and Its Potential Consequences for Bulk Ore Sorting, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 77–88 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By J Ferreira

To speed up multivariate geostatistical simulation it is common to transform the set of attributes into spatially uncorrelated factors that can be simulated independently. One decorrelation method is the method of minimum/maximum autocorrelation factors (MAF), where a two structure linear model of coregionalisation is assumed. The transformation decorrelates the theoretical model exactly, but the actual data are only approximately decorrelated. The MAF transformation can therefore be seen as a special case of a non-orthogonal approximate diagonaliser of a set of symmetric matrices. A more general approach for approximate joint diagonalisation (AJD) has been developed in the context of blind source separation. For these AJD algorithms no assumptions are made beyond symmetry of the individual matrices and so they can be applied to a family of experimental semivariogram matrices. In their application there are no restrictions on the number of structures in the linear model of coregionalisation (LMC) thus removing one of the conditions placed on the subsequent modelling of the spatial structure of the factors. In this paper the general background for the U-WEDGE AJD method is presented. It is shown that the U-WEDGE method achieves better spatial decorrelation than the MAF method. The factors derived from U-WEDGE are simulated using conditional turning bands simulation and then backtransformed to attribute space.

Sep 26, 2011

Laboratory studies of batch and continuous screening of ferrous sinter mixtures (4-0.5 mm) are described. The results are analysed by an equation derived from the first-order rate law for the condition of decreasing screen residue.The results of the studies show that the two screening operations are comparable in all respects if deck length in continuous screening and time in batch screening are interchanged.It is shown that the general screening process is determined by the numerical values of the screening rate constants of each of the particle sizes in the feed mixture and that the relationship between these constants and the particle size/screen aperture ratios is related to the appropriate probability function of the same ratios.It is also shown that the screening rates decrease exponentially with the amount of near-mesh material present in the feed and that oversize particles can increase these screening rates for some screen motions and decrease them for others.

Jan 1, 1985

By J Butler, N Patel, S Narendranathan, S Rastogi

The Yallourn Mine (YM) commenced mining of brown coal in the 1920s under operation by the State Electricity Commission of Victoria (SECV), prior to it becoming privatised in 1996. The present owners of the YM, Energy Australia Yallourn (EAY), acquired the site in 2000 and intend to continue operations until scheduled closure in 2028. Brown coal extracted from the YM is fed into the Yallourn Power Station which supplies approximately 22 per cent of Victoria’s electricity. Water within the YM is collected and stored in the Township Field Fire Service Pond. Water levels within the Fire Service Pond (FSP) may fluctuate considerably depending on the requirement for storage at the site. With due consideration to the stability performance of mine batters adjoining the FSP, the authors performed slope stability assessments to evaluate the risk and consequence of batter instability during the potential pond filling as it approaches the ‘critical pool’. The critical pond is defined as the level at which the driving forces (destabilising forces) are at their greatest and the resisting forces (lake forces, friction) are at their lowest. This assessment was undertaken using the Mine Geotechnical Risk Index (MGRI) approach.

Aug 2, 2023

By Misra V. N, Spottiswood D. J

In recent years the column flotation process has gained worldwide acceptance for processing various types of minerals under different circuit configurations. In an age when real prices of many mineral commodities are in decline and mining and labour costs are rising in real terms, it is more important than ever that concentration processes be not only efficient but also cost-effective. The column flotation process can give better metallurgical performance as well as involve lower capital and operating costs compared to conventional mechanical cells.This paper reviews the literature on columns and the effects of various column parameters on performance of the column flotation process. The history and principles of operation of the column flotation process are briefly discussed by way of introduction.

Jan 1, 1995

By R G. Reddy, A Yahya

The sulfur distribution ratio (Ls) is an expression of the amount of sulfur in slag to the amount of sulfur in molten metal. The sulfide capacities calculated from Reddy-Blander (RB) model were used to calculate the sulfur distribution ratio (Ls). A new Reddy model for sulfur distribution ratio (Ls) was developed for modelling Ls for ironmaking, steelmaking, and secondary steelmaking conditions. Besides calcium oxide, the major component in the ladle furnace (LF) slags is alumina. The Ls was calculated for typical LF slags as a function of temperature and composition. The model calculated Ls values are in good agreement with the experimental and industrial slags data. The extremely low oxygen potential in these furnaces after fully-killed steel is favourable for desulfurisation. For any given slag’s composition and temperature, its sulfide capacity can be calculated a priori. The equilibrium sulfur distribution ratio between this slag and liquid metal in a particular vessel can also be calculated a priori. The Ls for ladle furnace (LF) slags is about twice those for blast furnaces (BF) slags and ten times those of basic oxygen furnace (BOF) slags. The desulfurisation of pig iron in BF and desulfurisation of steel in LF during secondary steelmaking are recommended. Steel desulfurisation in steelmaking furnaces is not effective. Since the model used to calculate the sulfur distribution ratio (Ls) is a priori, it is a useful tool for the iron and steel makers in improving the product quality and optimisation of the industrial furnace operations.

Aug 21, 2024

By Pinczewski WV, Nowak LP, Tanzil WBU, Jenkins DR, McCarthy MJ

An experimental and theoretical study has been made of the drainage behaviour of two-dimensional packed beds drained from an outlet in the sidewall of the bed in order to identify the fundamental me- chanisms involved. Under these conditions a grad- ient develops in the air-liquid interface in the direction of flow with the interface tilting towards the outlet. This results in a significant volume of liquid being retained in the packing on completion of draining when the interface first reaches the bed outlet. Residual liquid volume and the shape of the air-liquid interface as a function of time were det- ermined experimentally in a two-dimensional packed bed where the packing consisted of glass spheres ranging in size from 0.6 to 10 mm dia. and the bed was drained at superficial liquid velocities rang- ing from 0.007 to 0.32cm/s. The test liquids used were water, glycerine/water solutions and kerosene resulting in a viscosity range of 1 to 10 mPa.s and a surface tension range of 0.0243 to 0.072 N/m. Assuming laminar flow within the bed, a compu- tational model was developed to predict both the liquid residual ratio and the temporal evolution of the drainage profile within the bed. The computed results were in good agreement with the experimental data over the entire range of conditions invest- igated. the computational model was used to estimate the relative importance of the effects of changes in hearth conditions on residual slag volume for typ- ical blast furnace operating conditions. On the basis of the computed results it is concluded that coke quality is a major parameter affecting hearth drainage performance.

Jan 1, 1981

By L H. Chapman, I J. Kelso, N H. S Oliver

Utilisation of modern 3D visualisation tools, can improve our ability to correlate between different datasets, and thus to produce more accurate geological models. Here, we present an application of such techniques to the Century Zinc Deposit, northwestern Queensland, Australia. This stratiform orebody is the second largest Zn resource in the world (167.5 Mt at 8.2 per cent Zn, 1.2 per cent Pb, and 33 g/t Ag). It is hosted in the Page Creek Syncline affecting Mesoproterozoic shales and siltstones of the Wide Supersequence of the Isa Superbasin. As in other deposits, (eg McArthur River, Lady Loretta, George Fisher and Dugald River), the mineralised sequence is bound by an important regional structure, the Termite Range Fault, which partly intersects the deposit along its Eastern side. This fault is thought have been active during sedimentation and probably also during mineralisation of the lowest part of the Wide Supersequence. The anastomosing geometry of this fault system and crosscutting relationships with other NE trending structures indicate that it was reactivated several times from Mesoproterozoic to at least late Devonian times (>1000 million years in total); as a result, the ore sequence is subdivided into several fault blocks.Using two different computer modeling packages (GOCAD and 3ds max), we have reconstructed and restored the stratigraphic horizon with the highest Zn content, realised a series of isopach maps for each mine scale stratigraphic unit, plotted the three-dimensional distribution of Zn, Pb, Ag, Fe and SiO2, and have begun to evaluate the degree of correlation between thickness changes and sulphide zoning. With this approach it is possible to better understand the timing of mineralisation from a genetic perspective, because the origins of the orebody are controversial. Three-dimensional reconstruction is a vital tool for identification of syn-sedimentary and post-sedimentary fault activity. In conjunction with sulphide precipitation, these are factors that greatly influence the stratigraphic thickness distribution. Post-sedimentary deformation can be recognised directly by core logging and pit mapping, but the effect of tectonic movements during sedimentation (growth faults in particular), that represents a substantial variable when we attempt to reconstruct basin evolution, is difficult to evaluate without this methodology. The 3D models improve our understanding of the local basin architecture, identifying similar grade characteristics at different structural levels and thus suggesting that much faulting and folding are post-mineralisation events. In addition, we identified several growth faults adjacent to thickened layers, representing two possible sedimentary depocentres. These thicker domains apparently relate to the highest Pb content. If further analysis of rocks, thickness and grade distributions support this preliminary correlation, then a syn-sedimentary model for mineralisation might be applied, and would contrast with the sub-surface model for mineralisation of Broadbent et al (1998).

Jan 1, 2003

This paper discusses some topical issues on the mining administration and legislation fields including:  1. Licensing û Administration and associated specialist functions including:Processing and volumes of mining privilege applicationsFuture organisation and possible decentralisationSpecialist staffFacilitiesGuide to the Mining Act 1971 2. Mining Amendment Act 1981 Transitional procedures 3. Planning Tribunal First hearing of objectionsPoints of principle resulted there from 4. Quarries and Tunnels Bill Currently before Parliament û implications for metallurgical mining

Jan 1, 1982

About 20 percent of world gold production has been contributed by gold deposits in Archaean greenstone belts, of which ca 2100 tonnes of gold has been produced from Archaean greenstone belts in Western Australia (Phillips, in press). These deposits are, therefore, important exploration targets and an under-standing of their nature and genesis can help to formulate exploration strategies and delineate potential targets.A literature survey of Archaean granitoid-greenstone terrains indicates that a wide variety of lithologies host gold deposits. The major part of production from the Yilgarn Block, Western Australia, has come from mafic volcanics andintrusives (70% of production),with significant contributions from BIF-hosted ores (15%) and low production from sediments, felsic volcanics, porphyry intrusives and granitoids (Groves et al., in press). Similarly, most

Jan 1, 1984

Western Mining Corporation began shaft sinking operations at it's Foster orebody, south of Kambalda, on the 20th June, 1984. The top levels of the orebody are currently being mined via a decline some 1.5km away.Long term plans require the shaft and decline to combine and produce 400,000 tonnes of nickel ore per annum. Eventually all of the ore produced will be hauled up the shaft.The shaft is 4.5m in diameter and the target depth is 760m. Ground conditions to date suggest there will be no further need for concrete lining beyond the oxidised zone. As such, the sink is an open-shaft development in competent basalt rock. Shaft furniture will be installed on completion of the excavation to the target depth.This paper summarises the experience in the project to date, along with comparisons to conventional shaft sinking methods employed in previous years at Kambalda Nickel Operations.

Jan 1, 1985

By K G. van den Boogaart, U Mueller

"An accurate prediction of benefit for some types of ore may require not just the ore grade, but a whole compositional characterisation of the estimates; that is, its full mineral composition including waste composition and nuisance elements. An example is Nickel laterite ores, where Ni/Co content must be complemented by estimates of many other elements, as these might have a notable impact on ore processing.Estimates are often obtained with (co-)kriging or co-simulation; however, geostatistics applied to compositional data may yield spurious and inconsistent results because of the constant sum constraint. The log-ratio approach avoids such problems. It proposes a three-step procedure: data are mapped to a set of log ratios of components; for example, the additive log-ratio transformation (alr) transformed scores are modelled with an appropriate fully multivariate geostatistical toolbox; for example, direct/cross-semivariograms and co-kriging or co-simulation results are back-transformed to the original units.Some practical aspects may make the application of this technique difficult: the assumption of Gaussianity and the high dimensionality of the compositions combined with the need for using multivariate methods. This contribution compares several ways of treating compositional data (combining normal score transformation, log-ratio transformations, and minimum/maximum autocorrelation factor (MAF) decomposition) with respect to their ability to generate sensible simulations. The various approaches considered are illustrated with a Nickel laterite data set for which ten variables are available. Both theoretical considerations and illustration results suggest that the best combination is (log)ratio-normal score transform-MAF, in this order. The factors so obtained are closer to Gaussian, approximately spatially decorrelated and can be simulated independently. Simulations can later be recombined to alr-simulations, which in turn may be converted back to point compositions. The resulting simulated compositions are compared with a full Gaussian co-simulation of the raw data. The log-ratio methods show reasonable to good reproduction of mean values, and distribution of the data set and by construction satisfy the total sum constraint, in contrast to the simulations based on raw data for which the total sums fluctuate strongly.CITATION:Mueller, U, Tolosana-Delgado, R and van den Boogaart, K G, 2014. Approaches to the simulation of compositional data – a nickel-laterite comparative case study, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 61–72 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By C McGuire

As mobile equipment electrification in underground mining continues to gain popularity, control ofheat and humidity in the workplace is becoming a key driver in sizing of ventilation and mine aircooling systems. For design and sizing of ventilation and cooling systems to be accurate, and for themine mobile equipment fleet to be sized appropriately to meet production goals, vehicle productivitymetrics, heat modelling, and energy balances for electrified fleets need to consider operation througha realistic duty cycle that is reflective of various tasks performed during a shift.The authors conducted a real-world comparison of two 8 cubic yard (14 metric tonne) class Load-Haul-Dump (LHD) machines – one diesel and one battery-electric vehicle (BEV) – performingidentical muck-haul-dump operations on consecutive days at an underground nickel/copper hardrock mine in Ontario, Canada.The battery-electric LHD averaged 8.9 per cent faster cycle time than the diesel vehicle (gross,without accounting for charging time), and was able to transport 25 per cent more material per cycledue to a larger bucket capacity. When including the charging time, average net cycle times wereequivalent for the two vehicles over the 200 cycles. The BEV carried more payload over the eighthour period due to the increased capacity per cycle.The testing identified an approximately five-fold reduction in heat output from the BEV in comparisonto the diesel LHD on a basis of heat output per tonne of rated bucket capacity. Heat output from thefast charger was found to be approximately 4 per cent of the charging rate, with negligibletemperature change observed in the main drift. External noise levels in the mine were found to be14 dB lower for the BEV during transit and 11 dB lower during bucket loading. Fuel/energy costs forBEV electricity input were approximately four times lower per operating hour than diesel fuel costbased on typical 2021 electrical and diesel unit rates for a grid-connected mine in Ontario, Canada.

Oct 12, 2022

Just as geophysics, in the form of 3D seismic and wireline logging, plays a key role in petroleum reservoir management, so too will geophysics play an important role in mining of coal, metals, and minerals in the 21 st century. The commercial and social imperatives driving greater use of geophysics are reduced costs, increased revenues, and enhanced safety. In short, superior utilisation of capital and management of risks. In relatively undeformed sedimentary environments it is possible to adapt petroleum-style 3D reflection seismic to image mines. This has been demonstrated most impressively in the Witwatersrand. Anglo-American, for example, completed a $1 million 3D seismic survey at Western Deeps in order to site a new $300 million shaft with confidence. Likewise, 3D seismic has gained rapid acceptance at Australian coal mines in recent years. Encouraged by these successes, metalliferous mining companies are supporting research in Canada and Australia, as well as South Africa, to adapt 3D seismic for more highly structured, metamorphic terranes. Because the mining industry is far more diverse than the petroleum industry in terms of commodities and geological environments, 3D seismic is not always cost-effective. A plethora of other geophysical techniques can be applied, many of which are employed in mineral exploration. Mine applications of geophysics differ from traditional exploration applications in two main ways: time scales and length scales are shorter, and boreholes are more plentiful. Borehole geophysical techniques therefore play a more significant role, both for logging and imaging. Logging systems detail the variations of in situ physical properties down the borehole at scales measured in centimetres, while geophysical imaging techniques can map features located tens or even hundreds of metres from the sensors. While geologists tend to think of boreholes in terms of chips and core, geophysicists perceive them first and foremost as access paths for instruments. Borehole logging has been employed at iron and coal mines for decades, mainly to accurately define ore boundaries in delineation holes. In base metal mines, Outokumpu implemented logging widely for orebody delineation in percussion holes in the 1980s. The benefit was a direct cost-saving, arising from substitution of core drilling with percussion drilling plus borehole logging. The practice has since spread to other companies. INCO, for example, defines nickel boundaries in blast holes at Sudbury using conductivity logs. The benefits are in the form of reduced dilution and enhanced ore recovery, flowing from a more accurate mine model. Density, natural gamma radiation, magnetic susceptibility, and conductivity are the principal metalliferous mine logging parameters because they can be recorded in both dry and water-filled holes. Sonic velocity is the premier geotechnical logging parameter, given its sensitivity to rock strength, stress, porosity, and degree of fracturing. Sonic is recorded routinely in exploration and geotechnical holes at coal mines. With the advent of slimline dipmeter, full waveform sonic, and optical and acoustic scanner tools, the role of borehole logging in geotechnical evaluations is expanding. Monitoring of strain and micro-seismic activity enhances safety during mine production. While qualitative interpretation of logs is adequate for stratigraphic identification or definition of boundaries, a wealth of quantitative information, eg density, can be derived from properly calibrated, repeatable geophysical logs. Moreover, geophysical logs can sometimes serve as surrogates for geochemical assays, and not only for magnetite and uranium. At OutokumpuÆs Kemi chromite mine, for example, gamma-gamma logging provides the basis for grade control. By reducing reliance on assaying, three benefits can be realised: reduced reliance on core drilling; lower core handling and assaying costs; and shorter turn-around times. Conventional downhole EM and borehole magnetics are used for near-mine exploration, and for ground sterilisation. Inco has enjoyed considerable success with borehole UTEM in the Sudbury Basin, for example, and Geopeko has applied three-component borehole magnetics successfully in the Tennant Creek area. Electrical techniques such as applied potential and magnetometric resistivity (MMR) are also finding application at mines. For higher resolution, borehole seismic, radio imaging, and radar have been invoked, with varying degrees of success, to delineate orebodies and map structures, or to geotechnically characterise the rock mass and identify hazards. Success mapping nickel sulphide shoots with borehole radar has been reported by WMC at Kambalda. There are no universal geophysical panaceas, and each mine imposes different geological, logistical, and economic constraints. Geophysics will not always be cost-effective. However, the greatest single impediment to expanded use of geophysics at mines has been the low level of awareness of geophysics on the part of most mine geologists, engineers, and managers and, equally, the limited understanding of mine geology and engineering exhibited by the majority of geophysicists. This myopia will be remembered as a 20th century affliction! Blue Sky areas for mine geophysics in the next ten years include integration of geophysical data acquisition with drilling, enhanced grade estimation and rock mass characterisation, and the incorporation of geophysical information into mine models using geostatistical techniques. All these advances will be predicated on an expansion of petrophysical knowledge.

Jan 1, 2000

By B J. Monaghan, R J. Longbottom, S Prabowo, D Del Puerto, B Maisuria, C W. Bumby

The use of hydrogen as a reducing agent can substantially reduce carbon dioxide (CO2) emissions from the ironmaking process. Iron ore fines can be reduced in a fluidised bed (FB) using hydrogen (H2) at high temperatures (>800°C), although several studies have reported the sticking of particles which causes the bed to defluidise, effectively shutting down the process. Here, we report results from the reduction of New Zealand (NZ) titanomagnetite (TTM) ironsands in a small-scale laboratory FB (100 g) at temperatures between 800–1000°C using H2 flow rates up to 5 standard L/min. No sticking phenomena are observed under any of these conditions, which is attributed to the formation of a stable titanium-bearing oxide layer on each particle’s exterior, preventing iron-iron contact at the particle surfaces. Pre-oxidised NZ TTM ironsands have also been studied and shown not to stick. Interestingly, at lower reaction temperatures the reduction kinetics for pre-oxidised ironsands is faster than for as-received ironsands. This increased kinetic rate can be attributed to the preoxidation stage inducing micro-fractures that create a void for the hydrogen to diffuse into the inner regions of the particle. In addition, oxidation of TTM appears to segregate the particle into two distinct phases, a high Aluminium-Magnesium (Al-Mg) phase and a high Titanium (Ti) phase. The findings are important as increasing the operating temperature of the FB reactor results in a faster reaction rate and higher gas utilisation, making the process more economically attractive. Furthermore, oxidation of NZ TTM ironsands results in a faster reduction rate at lower temperatures (800°C– 900°C) opening the opportunity to reduce the reaction temperature which might be beneficial in a final commercial-scale process.

Sep 18, 2023

By M Zanin, E Chan, D Xu

An experimental design has been developed to investigate the relative influence of distinct pulp and environmental properties on froth stability in the flotation of a typical porphyry copper ore. In particular, factors such as frother and collector type, feed particle size (P80), solids per cent, composition (chalcopyrite and pyrite content), as well as grinding environment (mild steel versus stainless steel, high and low pH) have been varied in a controlled manner, and the resulting froth stability evaluated. A previously developed froth stability column, based on the Bikerman approach, was used to measure the froth height and half-life in each test. The relative effect of each factor is presented here on a comparative basis. It is shown that frother type is the most important factor, with marked difference in froth stability when switching from methyl isobutyl carbinol (MIBC) to glycol based frothers. Solids per cent and particle size also play a significant role. The grinding environment had lesser effect on the resulting froth stability, although mild steel grinding gave higher froth stability compared to stainless steel grinding. The experimental evidence supports the hypothesis that in porphyry copper flotation the grinding environment influences surfaces oxidation, pyrite activation and the extent of hydrophobic particles reporting to the froth phase. This has an indirect effect on the resulting froth stability, which is however small if compared to the other factors. This work is still in progress, and extension to other mineral systems is planned. However, some insights are offered to operators on the parameters which are more likely to have an impact on froth stability in copper flotation plants.CITATION:Zanin, M, Chan, E and Xu, D, 2014. Empirical evaluation of factors affecting froth stability in copper flotation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 193–200 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014