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By S Natsui, Y Goto, S Kawanishi, J Takahashi, H Nogami

The demand for copper increases yearly, and further improvements in copper smelting efficiency using flash furnaces are required. This study was conducted to understand and promote the interfacial reaction associated with the collision of silica flux and iron oxide particles, ie the formation reaction of fayalite slag, in the reaction shaft of the flash furnace. High-temperature microscopy was used to observe the reaction behaviour of a 2 mm granular SiO2 reagent in contact with micrometreorder- sized FeO reagents in situ. When the amount of FeO was lower than the stoichiometric amount with SiO2, the molten slag formed at the interface between FeO and SiO2 diffused into the SiO2 particle before dissolving the remaining FeO particles. It did not contribute to the subsequent reaction, and despite having the lowest amount of FeO among the samples in this study, many unreacted FeO particles remained on the surface of the samples after testing. On the other hand, under conditions with high FeO content and close to the eutectic composition of the FeO-SiO2 system, a liquid phase formed from low temperatures, gradually increasing in volume and eventually completely dissolving the 2 mm SiO2 grain. These results indicate that the early-stage slag is essential in increasing the interfacial area between FeO and SiO2 and facilitating the supply of FeO to SiO2. In other words, the FeO/SiO2 determines the amount of liquid phase and significantly influences the subsequent interfacial reaction rate between FeO and SiO2. Therefore, the local FeO/SiO2 of the particles falling down the reaction shaft should also be optimised to ensure early slag formation. Meanwhile, the time required for 2 mm SiO2 to complete the reaction for the temperature history employed in this study was significantly longer than the particle residence time in the reaction shaft. Further detailed investigation of the effects of silica flux particle size, composition, and reaction temperature on the reaction time will help find the conditions under which the reaction of silica flux can be completed in the reaction shaft. These kinetic approaches could contribute to future innovations in the copper smelting process using flash furnaces.

Jun 19, 2024

By G R. Ballantyne, A N. Mainza, M S. Powell, M Evertsson

Quantifying the performance of a comminution circuit relative to the potential that can be achieved is a standard requirement in justifying operating practice (the stick) and seeking operational upside (the carrot). Historic measures tend to focus on performance relative to laboratory design tests that provide a direct measure of specific grinding energy, such as the Bond Work index; or use dropweight breakage tests calibrated to a substantial database of operating sites, such as the SMC methodology. Although of value, such approaches are flawed in significant aspects. The assumption is that the laboratory prediction is correct and the single sample it is based on is representative. The database benchmarking methods are, by definition, locked into current average operating practice. These approaches do not illuminate upside; can ‘punish’ operations that are actually more efficient, such as grinding finer than standard operation; and reward poor operation that may comfortably produce a coarser grind than optimal for recovery or excess slimes that reduce recovery and increase water consumption and tailings volume. The authors present a set of established and easily applied measures, that draw together daily operation, highlight areas of opportunity and inefficiency, use simple samples and data, and can be used to provide the ‘size of the prize’ in pursuing specific areas of process improvement. These tools include size specific energy (SSE), overall operating effectiveness (OEE) which includes product quality, theory of constraints, and links this to the end objective – maximising the efficient production of valuable metals. Feeds into objective function driven by economics – financial return, energy, environment.

Aug 24, 2022

By V Ser, R Crosbie

To date, Anglo American Research Laboratories (AARL) has carried out several projects, based on the techniques developed in AMIRA International LimitedÆs (the mineral industries research association) AMIRA P9 project, to develop models for several Anglo Base Metals flotation plants. Further detailed analysis of the data which was generated has realised additional benefits: the various hydrodynamic measurements were useful in comparing cell operating parameters to literature sources, while the laboratory batch tests give an indication of plant recovery potential. A detailed cell by cell mass balance, which is a critical feature of the modelling process, is in its own right a valuable diagnostic tool. Several examples of how this can be used to highlight potential improvement areas in the plants are presented. The added understanding gained from sampling each cell is clear and this is shown to more than compensate for any necessary modifications needed to allow sampling to take place. The model fitting process generates an ore floatability distribution, which is used in the JK SimFloat simulation package to assess the effect of possible changes to each of the circuits. An example of an actual circuit change as a result of this approach is presented. The current limitations of and the potential improvements to the modelling process are also briefly discussed. Future models will be extended to include enhanced size and mineralogical information where the basic models suggest this has potential to improve understanding.

Jan 1, 2005

By May P. M

The role of chemical speciation in alkaline cyanide solutions is discussed by reference to recent experimental data from the authors' laboratories. It is shown that serious gaps exist in our present knowledge of the thermodynamics of cyanide complexes in solution. Nevertheless, using the available data and the JESS suite of computer programs it has been possible to develop a simplified chemical speciation model for alkaline cyanide solutions under conditions relevant to the gold extraction process. Some possible implications of the model for plant operations are Discussed.

Jan 1, 1991

By Grano S. R, Lauder D. W

Investigations on the oxidation behaviour of chalcocite and its rejuvenation by hydrogen sulphide ion have been undertaken. Chalcocite oxidation was measured using X-ray photoelectron spectroscopy (XPS), zeta-potential and by dissolution in et

Jan 1, 1997

By W Curlewis, D Hake, Z Cuthbert

The South Island Line (East) will be a medium-capacity railway covering approximately 7 km from Admiralty Station to South Horizons Station on the south side of Aberdeen Harbour in Hong Kong, with intermediate stations at Ocean Park, Wong Chuk Hang and Lei Tung.South Island Line (East) Contract 904 project is located on the island of Ap Lei Chau at the southern side of Hong Kong island and requires extensive construction works to be completed in close proximity to the existing residential estates of South Horizons and Lei Tung. The project also has areas of significant cultural heritage, including 18th and 19th century temples and historical gravesites. Owing to the site access constraints and location for the project, detailed planning and methodology innovations have been required to ensure the most effective and responsible means of delivering the project works. To excavate the tunnels using drill-and-blast techniques in these restricted locations, the maximum instantaneous charge weight that could be fired while blasting was severely limited. To overcome these restrictions, the project team developed and pioneered the use of ‘deck loading’ in Hong Kong to minimise the impact of blasting operations and has successfully implemented double- and triple-deck blasting operations during the completion of tunnel excavation works.Upon completion of the drill-and-blast excavation, the tunnel lining works were completed using both in situ concrete lining with travelling forms and permanent shotcrete works.CITATION:Curlewis, W, Cuthbert, Z and Hake, D, 2014. SIL904 Hong Kong – Drill and Blast Tunnels, station blasting innovations (double- and triple-deck blasting) and lining solutions, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 21–28 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By T Purvis, J Calverd, A-K Greve

The Ernest Henry Mining (EHM) underground mine is situated adjacent to the Great Artesian Basin in North Queensland and within a fracture zone. Underground development commenced in February 2008 and has extended to approximately 1000 vertical metres below the surface.Groundwater has been encountered in numerous locations throughout the mine, predominantly on the eastern side of the orebody and often related to fault structures. Most of the groundwater encountered has been managed with conventional pumping systems; however, on occasions large water inflows have been encountered, which have had a significant impact on the planned development of the mine. Some of the intersections encountered had the potential to compromise the mine from a combination of high temperature (over 45°C), high pressure (3500 kPa) and high flows (50–100 L/s).This paper describes three case studies where significant water inflows were encountered and then controlled by the injection of cementitious grout into the rock mass. The case studies are the 1650 mid-shaft heading, the 1325 shaft access decline and the 1625 to 1475 fresh air rise (FAR) raise bore. Each case study includes a brief description of the event that occurred and the grouting equipment and techniques developed to enable mining to continue.The paper also describes the development of a hydrogeological map of the mine, the probe-hole regime used for high-risk headings and the required processes and systems to inject both cementitious grouts and polyurethane resin into the rock mass.CITATION:Purvis, T, Calverd, J and Greve, A-K, 2014. Management of high-pressure groundwater in underground development at Ernest Henry Mine, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 217–226 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By G du Toit, P L. Gillot, M Swanepoel

Randgold Resources’ Loulo-Gounkoto Complex is one of the largest gold mining operations in Mali, West Africa. The mine, which is situated on the western border with Senegal, treats more than 4 Mt/a of ore through a conventional three-stage crushing and ball milling circuit followed by a carbon-in-leach plant. Ore supply is achieved by a combination of open pit and underground mining, with the majority of the ore supply sourced from the Gara and Yalea underground mines situated approximately 2 km and 6 km respectively from the gold plant.In 2011, Randgold Resources commissioned Golder Associates to perform an evaluation study for providing structural backfill to both the Gara and Yalea underground mines using the current gold plant tailings. The test work performed as part of the evaluation study concluded the need for a tailings cycloning and dewatering facility capable of producing slurry at a solids concentration of 65 per cent with a particle size distribution that had minimum 25 per cent passing 20 µm and less than 5 per cent of -5 µm material. Tailings desliming was required to ensure a consistent feed quality to the paste preparation plants and to ensure that the system would be capable of handling variation in the feed composition from the gold plant.WorleyParsons, previously TWP Projects, was contracted by Randgold Resources to complete the engineering design for the slurry preparation plant, whilst Golder Associates was retained to complete the engineering design of the two paste preparation plants.This paper discusses the test work, design considerations and engineering design of the slurry preparation plant, termed the ‘intermediate plant’, as well as all ancillary facilities required for the delivery of the deslimed slurry to the paste preparation plants located at the two underground mines.CITATION:Swanepoel, M, du Toit, G and Gillot, P L, 2014. Case study – engineering design for a slurry preparation plant for a paste application in West Africa, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 477–486 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Merwin RA

The recent development of rare earth permanent magnets has revolutionised the field of magnetic separation. The advent of rare earth permanent magnets in the 1980s provided a magnetic energy product an order of magnitude greater than that of conventional ferrite magnets. This has allowed the design of high-intensity magnetic circuits operating energy free and surpassing the strength and effectiveness of electromagnets. New applications and design concepts focusing on the mineral and metal processing industries have evolved. This technology also led to the development of various magnetic separators specifically designed for mineral processing applications. Applications which were not previously considered are now being applied to primary mineral upgrading and recycling and secondary recovery.

Jan 1, 1993

By H J. Dalstra

High-grade iron ore may be derived from banded iron formation (BIF) through four fundamentally different processes:1. syngenetic precipitation of chert free BIF,2. residual enrichment by removal of gangue minerals from BIF to form bedded (residual) ironore,3. mechanical erosion of iron oxide and chert from bedded iron ore or BIF and re-deposition andupgrading as detrital iron ore, and4. chemical removal of iron from BIF and precipitation elsewhere as a secondary (channel) irondeposit.Finally, the BIF itself may constitute iron ore if a high-grade concentrate utilised for pellets or sinters can be derived from it through mechanical (industrial) separation of iron oxide by means of crushing/milling and mineral separation.Historically, exploration for high-grade BIF hosted iron ores was focused on the residual (bedded) deposits and driven by supergene concepts. Exploration for detrital and channel type iron ores was mostly secondary to exploration for bedded deposits, but recently, a more focused exploration effort has led to the discovery of enormous moderate to low iron grade deposits in the Pilbara region of Western Australia. Exploration for high-grade iron ores using syngenetic concepts has been limited,but together with exploration using hypogene concepts offers the best hope of fi nding concealed deposits. Exploration for BIF sources suitable for concentrate ores commenced in the ‘old’ iron ore provinces after the high-grade resources were depleted and has only recently gained importance in Australian BIF provinces, mainly as a result of high iron ore prices in the last decade.

Jul 11, 2011

By A Simmons, R Longey, D Brett

The South Deposit Tailings Storage Facility (SDTSF), located at Grange Resources Pty Ltd’s (Grange) Savage River mine in north west Tasmania, has recently begun construction. The facility will provide storage for approximately 37 million cubic metres of tailings, equating to approximately 20 years’ tailings storage.The SDTSF embankment will be constructed entirely out of waste rock won from mining operations, and will feature a flow-through drain constructed from alkaline, non-acid forming (NAF) waste rock. This provides Grange with an economical storage solution for waste management (both tailings and waste rock) and maximises available space on site. The outflows discharged through the alkaline rock ‘flow-through’ will provide a long-term source of alkalinity to Main Creek, subsequently feeding into Savage River. This will provide environmental benefits to the downstream ecology that has long been degraded due to the effects of legacy acid and metalliferous drainage (AMD), caused by historical mining operations.CITATION:Longey, R, Brett, D and Simmons, A, 2015. Integrated mine waste management – South Deposit Tailings Storage Facility, Savage River mine, Tasmania, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 343–352 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By Takasaki Y, Ohzeki S, Hotta H

TO measure high temperature properties of blast furnace burdens ( the change of gas permeability accompanied by contraction, soft- ening and melting ) which govern the gas flow and its distribution, a series of experiments were carried out under simulated blast furnace conditions, using sinter, acid pellets and self -fluxing pellets. 1) The high temperature properties are affected by the ore's reducibility ( up to 1000 -1200¦C ), and the composition, and volume of gangue before reduction. Generally, the burde- ns with high basicity ( Ca0/Si02 ), high reduc- ibility and low volume of gangue have good high temperature properties. Good high temperature properties are : a high temperature at which the gas permeability rapidly decreases, a high melting point and a low maximum pressure drop. 2) Using acid pellets, slow-down of red- uction rate occurs around 1000¦C because the pellet forms a dense metallic shell, while its slag core, resulting from a FeO, Si02 and A1203 reaction, has a lower melting point. 3) The addition of MgO sources improves high temperature properties both of sinter and Pellets.

Jan 1, 1980

By Sorentino C

Mineral valuation may appear to be a special field of financial valuation when in fact it is a subset of general investment decision theory. The only significant difference in mineral valuation is that in the case of valuing an on-going mineral asset, ie a mine, often there is no initial capital outlay involved. One is required to determine what the mineral asset as it stands is worth. But this is the same problem as determining the maximum one could pay today and not incur a loss over the life of the asset. In other words one needs to determine the Net Present Value (NPV) of the asset. The two most widely used discounted cash flow methods, NPV and Internal Rate of Return (IRR) came of age with the rapid adoption of the personal computer and spreadsheet programs. The two methods are directly related as the IRR is a special case of NPV. NPV measures the absolute increase in real wealth that can be expected from a certain investment, which makes it particularly suitable for mineral asset valuation, but ignores the efficiency of the investment. In contrast, IRR gives the expected efficiency of the investment but ignores the increase in wealth aspect. IRR has two serious theoretical weaknesses; multiple IRR's and a very rigid assumption about the rate of return of reinvested proceeds, plus if no initial equity expenditure is involved there is no IRR. The choice of the ""hurdle"" rate can also be a problem and in certain circumstances one can obtain different rankings of mutually exclusive projects using IRR and NPV. Although NPV and IRR supposedly measure financial risk, in fact they only address a very narrow area of risk, namely the time value of money given the real discount rate. They side step the issue of what the real discount rate should be and varying degrees of risk. The classical way to establish the real discount rate is to use the weighted average cost of capital.

Jan 1, 1994

Mineral deposits in New Zealand whose origin can be ascribed to primary magmatic segregations are associated with mafic-ultra- mafic complexes related to two orogenic episodes which took place during Paleozoic and Mesozoic times. These mafic-ultramafic complexes are essentially of two types. One is ophiolitic and has podiform chromite mineralisation presumably formed below a spreading ridge. The other type occurs as intraplate layered intrusions in which Fe-Cu-Ni sulphides and Fe- Ti-V oxides have formed as a result of liquid immiscibility with the host magma, and have subsequently accumulated by gravity means. Generalised descriptions are given for some deposits in NW Nelson, Fiordland and Marlborough districts.

Jan 1, 1980

By H W. Wu

Occupational exposure limits for diesel particular matter (DPM) are progressively being adopted in a number of countries. Many of these follow the lead of the US Mine Safety and Health Administration initiated in 2008. In line with adoption of best practice it is accepted that all exposures should be reduced to as low as reasonably achievable. The management of diesel emissions and occupational exposures to those emissions requires an integrated strategy incorporating efforts from all key departments on a mine, including management, production, maintenance, supply and occupational health and safety.Australian coalmine longwall moves rely on the use of high-powered diesel equipment such as chariots and other machines that produce exhaust pollutants of gases and DPM. To reduce mine personnel’s exposure levels to DPM a hierarchy of controls can be followed. Minimising the use of diesel equipment, better operator positioning in relation to exposure source, using efficient engineering methods and adopting better ventilation to reduce concentrations through dilution are some of the controls that can eliminate exposures. Approaches generally adopted in Australian longwall mines currently rely on a combination of strategies such as optimisation of ventilation, use of diesel particulate filters and use of diesel tag boards that minimise the number of vehicles through recording entry and exit into working panels.A study has been undertaken into the mine ventilation systems currently in use during longwall moves within Australian modern longwall extraction mines. This paper reviews current longwall section ventilation systems and discusses evolving changes being adopted to address the more complex problems in dealing with section DPM during phases of the operational moves. The effects of DPM on crew members as well as the diesel equipment operators within a longwall section are examined. Issues that should be considered in designing the longwall section ventilation during the moves are discussed.CITATION:Wu, H W and Gillies, A D S, 2015. Review of ventilation optimisation strategies during longwall moves, in Proceedings The Australian Mine Ventilation Conference, pp 133–140 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By J Kinal, I Mitchell

Many flotation plants use pH to adjust the pulp chemistry of their system to achieve optimum separation. For example, in a sequential lead/zinc circuit the pH during sphalerite flotation is increased to 10.5 or greater to depress galena and pyrite, thereby improving selectivity for sphalerite. However, maintaining a pulp at a particular pH value does not necessarily provide the operator with an abundance of information regarding the chemistry changes occurring within a plant. This paper provides the reader with a number of pulp chemical observations in several plants, showing that the same trends are noted over time; however, the magnitude of the measured values do change. Further, the changes in magnitude are invariably associated with a change in mineralogy. Thus, is measuring pH enough? Can the Eh, dissolved oxygen and temperature be measured at the industrial scale reliably? And, are these measurements useful?

Jan 1, 2006

By E Nye and T Schroeter, B Muir, M Kitson, M Gonzalez, D Mares

The single track North Strathfield Rail Underpass (NSRU) consists of a dive structure either end of a 148 m long driven tunnel skewed under three live railway tracks. The tunnel is 8 m high, 9 m wide, with a horseshoe profile, excavated by full face using a road header. Ground cover varied between 2.5 m to 3.5 m. Settlements were 5 mm to 15 mm (the latter due to a dyke). A one pass synthetic fibre reinforced shotcrete lining was installed (no lattice girders or steel sets were used). A system of automated robotic total stations was used to provide real time monitoring of the rail track and associated ground formation. No disruption to train services occurred.CITATION:Gonzalez, M, Kitson, M, Mares, D, Muir, B, Nye, E and Schroeter, T, 2014. The North Strathfield Rail Underpass – driven tunnel design and construction, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 369–374 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By J H. Park, R R. Kim, H S. Park, H J. Kim

This study focuses on the recovery of valuable metals, specifically silver (Ag) and palladium (Pd), from copper-containing sludge (with copper content less than 20 per cent) generated during PCB processing and from spent petrochemical catalysts used in vapour decomposition during oil refining processes. The present results indicate that an increase in the mixing ratio of alumina-based spent catalyst leads to a decrease in the recovery rate of Ag and Pd. The recovery rates for Ag and Pd range from 84 per cent to 96 per cent and 80 per cent to 98 per cent, respectively. This trend is attributed to the increased emulsification of copper droplets containing Ag and Pd in the slag. The emulsification is caused by the decrease in the settling velocity of the copper droplets due to the increased viscosity of the slag as well as by the decrease in the slag-metal interfacial tension due to an increase in sulfur content at higher mixing ratio of spent catalyst.

Jun 19, 2024

By K Barns, H Law, T Whebell, P Scobie, T Perkins, J Siliezar, M Larson

With processing a variety of orebodies at Glencore’s Ernest Henry Mining (EHM) has come a changing mineralogy and more complex requirements for treatment in the concentrator. From mid-2013 and into 2014 the grind size required to achieve sufficient mineral liberation for production of a quality concentrate has reduced significantly. What was once a final P80 of 35–45 microns was forced to 20 microns. This has necessitated some creative changes to the flow sheet that previously had a 937?kW Vertimill regrinding a rougher concentrate to 40 microns. EHM is able to utilise an existing M10 000 3 MW IsaMill previously used for magnetite processing, to provide a quick convenient solution without large scale capital expenditures. Operating the Vertimill and IsaMill in parallel in closed circuit was successful at reducing the P80 of the regrind circuit to below 20 microns which increased the final concentrate grade by four per cent. This circuit and intermediate circuits used are discussed. Performance of the Vertimill and IsaMill is compared for efficiency optimisation to improve the overall circuit performance.CITATION:Siliezar, J, Whebell, T, Perkins, T, Law, H, Scobie, P, Larson, M and Barns, K, 2014. From magnetite to chalcopyrite – a story of versatility and efficiency at Glencore’s Ernest Henry mining?operation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 85–92 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By L J. de Lange

As a material asset for mining entities, the resources and reserves (RR) estimation processes are surprisingly underrepresented in the assurance landscape. When press reports expose them being inaccurately reported, or in merger and acquisitions processes, their importance becomes clear. The impact of erroneous RR numbers (both positive and negative) could have a material impact on an entity’s reputation and value.The technical nature and ‘black magic’ connotations of the RR estimation processes are possibly reasons why audit committees are not actively involved with it. Internal auditors avoid the RR processes for similar reasons. Also the traditional approach to obtain assurance on RR is expensive and is therefore only performed when it is absolutely required.However, stakeholders’ expectations of good governance are growing. Part of this increased focus is based on attaining a higher degree of certainty about the current and forecasted position of the entity. Stakeholders are also increasingly more interested in non-financial areas of entities, as the future success of an entity is more than a set of financial metrics.Consequently, the RR estimation processes should be visible on the agendas of audit committees. Monitoring of key controls is required as part of the governance obligations for senior management and the audit committee. So once it is on the audit committee’s agenda, the question then becomes, how will that agenda be supported by an assurance process that is cost-effective?The main objective of the paper is to describe a model of RR assurance that has been effectively applied in some mining companies. The paper discusses one particular approach that provides an audit committee with the required assurance regarding RR processes. The approach ties the assurance needs of the audit committee to the needs of the technical experts in the entity, therefore involving two important figures. It also offers assurance providers with a model to audit ‘through’ the RR processes rather than ‘around’ them. The paper then discusses top-down and bottom-up approaches that provide assurance at different levels of an entity.A governance audit that focuses on the RR processes is suggested as a top-down approach. A bottom-up approach assesses the design adequacy of internal control processes. A hybrid model is described which meets the needs of diverse stakeholders including the audit committee and the RR community.The hybrid model combines the expertise of professionals in both internal audit and RR. The right balance of these skills directed by a singular approach ensures that a credible result is achieved.This approach is not as expensive as some verification approaches used in the industry and can, as a result, be performed on a more regular basis.The last element of the paper looks at implementation of the reporting mechanism. An assurance process aimed at continuous improvement further enhances the robustness and reliability of RR reported by an entity.CITATION:de Lange, L J, 2016. Resources and reserve assurance processes – a framework for improved governance, in Proceedings International Mine Management Conference, pp 21-34 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016