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By Hyslop W

It is shown that coke has a major influence on the pattern of operation and on the aerodynamics of the blast furnace and that the physical and chemical characteristics of coke, at each stage in the furnace, determine its ability to satisfy requirements for iron production and coke economy. Analysis of coke sampled from operating furnaces is compared with furnace behaviour. The available data suggests the importance of segregation, strength, size change and chemical degradation of coke on furnace performance. Correlations are presented for coke breakdown ratio as a function of coke rate and hearth diameter which shows that breakdown increases with hearth diameter and with decreasing coke rate. It is also shown that the Micum tests do not reflect the coke strength in a predictable way and that solution reactions appear to play an important role in giving rise to a pitting effect on the cell walls of the coke with the resultant deterioration in coke properties. The catalytic effect of activating substances, such as alkalis, is noted and results are presented which show the effect of carbon solution on the coke strength. The importance of coke in the stack and in the bosh is discussed and flooding results are presented for BSC furnaces which show the probable driving limits for the furnaces considered. It is also shown that coke sampled from different tuyeres in a furnace gives quite different flooding limits. Other applications of the coke test work at BSC are also noted and the relevant objectives listed.

Jan 1, 1975

By A Horn

Mineral processing is characterised by a constant adaptation to changing raw materials and market conditions. It is the link between the mined raw material and a marketable product. As a lot of high-grade reserves are exploited, a steady deterioration of raw material quality can be observed. At the same time, the customer’s requirement for product purity and consistent quality increases.Over recent years beneficiation techniques for iron ore fines have become more important in order to achieve a maximised utilisation of ore resources and to produce competitive products according to international standards.Many high capacity iron ore beneficiation plants that target the production of fines focus on gravity separation processes using fluidised bed classifiers and spirals or wet high intensity magnetic separators as an alternative. This paper demonstrates the suitability of utilising the allflux® two-stage fluidised bed classifiers to treat iron ore particles up to 2 mm in size as well as showing how the high capacity gaustec® wet high intensity magnetic separation (WHIMS) technology offers several advantages compared to other WHIMS technology.The combination of the allflux® and gaustec® technologies offer the following benefits:The two-stage fluidised bed classification extracts a significant amount of concentrate from the feed. This in turn reduces the feed capacity required for the gaustec® WHIMS located downstream.The second classification stage produces a -0.5 + 0.1 mm product and a -0.1 mm product. The efficiency of the magnetic separation on these classifi ed products is high due to optimised settings for each size fraction.

Jul 11, 2011

By M Boon, M Franklin

This paper outlines the journey of cultural maturation and management system development at the Mt Rawdon (MRO) gold mine from its acquisition by Evolution Mining Limited (Evolution) in late 2011 to 2016.Evolution embarked upon a series of projects that aimed to improve the operational consistency and implementation of change on-site, while leveraging off the existing strengths of the operation. This document describes the gaps that were identified, the processes used to close them, and the resulting cultural change and production outcomes, with a specific focus on how to optimise the culture at any mining operation.MRO had a history of four owners in less than three years when it became a key asset of Evolution. The site leadership team (SLT) decided to influence the culture at MRO by reviewing and upgrading the existing management processes.The first priority was to improve transparency and collaboration at the SLT level, followed by improving competency in project management. The next phase was to strengthen the internal communication using a deliberately designed network of meetings, communication screens and other initiatives. Once there was some traction, the focus moved toward increasing production volume and decreasing cost per unit by improving short-term planning and execution capability. Together with other initiatives, this resulted in improved collaboration between all functions, which in turn netted over 37 per cent mining production uplift.Following solid success, a process of prioritisation and alignment management was implemented. This supported the ‘Mine to Mill one operation’ ideal and allowed the SLT to decide month-by-month what actions were to be prioritised. These priorities incorporated production realities and longer term imperatives of the balanced business plan.Much of this work was completed during a period of declining gold prices and a relentlessly strong Australian dollar, making it difficult to justify spending money on improvement projects. This work proved critical for the operation’s long-term survival.CITATION:Boon, M and Franklin, M, 2016. Improving consistency of delivery at Mt Rawdon Operation, in Proceedings International Mine Management Conference, pp 305-320 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By J J. Boshoff

This iron ore mine site, located in the Pilbara region of Western Australia, commenced operations in 1998, with ore derived by mining of open-cut pits in Channel Iron Deposits (CIDs). A portion of the ore extracted at the mine is processed at wet processing plants that produce both ore saleable product and waste fines (i.e. tailings) slurry. The waste fines produced at the wet plants are presently stored within Waste Fines Cells (WFCs).Waste fines cells A (WFCA) and B (WFCB) are located within an Autonomous Haul System (AHS) area and consist of embankments that span the width of the pit in east-west alignments. Technical studies and design analyses were carried out to support embankment raises and ongoing development of the WFCs. During operation and development of the WFCs, a multitude of simultaneous activities took place to the immediate north and south of WFCA respectively. These activities included the construction of the embankment raises using the AHS fleet, mining of the CID to not only mine the ore but to also create future deposition space for WFCB, blasting next to the WFC embankments as part of the mining activities, seepage collection and dewatering of the pit in the vicinity of the WFC.This paper discusses the material characteristics, design approach, construction staging and equipment requirements, blasting near embankments, water management, facility consequence category and closure concept.CITATION:Boshoff, J J, 2018. A waste fines cell with a multitude of concurrent activities, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 39–49 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By Korsch RJ

Permian oroclines in eastern Australia must have formed by sliding on a detachment surface. It is identified as a westward- dipping Devonian and Carboniferous sub- duction zone. Major strike-slip faults probably sole out on the same surface. One major fault with an associated serpentinite belt was pulled away from the craton abd bent into loops. Basins formed in the loops.

Jan 1, 1987

By W Assibey-Bonsu

The paper provides a brief review of the multivariate uniform conditioning and the localised multivariate uniform conditioning techniques and presents a case study based on a porphyry copper gold deposit in Peru. Two other important scenarios have been investigated and will be particularly emphasised: The recovered selective mining unit (SMU)s depend on a combination of copper and gold content, which can be expressed by means of ænet smelter returnsÆ (NSR). Two approaches are compared. Firstly, the application of a composite cut-off on NSR on the joint distribution of each grade and the application of uniform conditioning to three variables is investigated, ie for the first approach NSR is used as the main variable. The second approach considers copper as the main variable. In the case of multiple domains the procedure used to apply the technique to process mixed panels is clarified and recommendations are made.

Sep 26, 2011

By T Takayama, M Matsumura, Y Konno

The steel industry accounts for 14 per cent of domestic CO2 emission in Japan, and iron ore sintering process occupies approximately three per cent. While Fe content in iron ore is gradually decreasing. So, the amount of concentrated iron ore will increase in the future. We have focused on magnetite concentrate as sinter materials, because magnetite can be easily magnetically beneficiated. However, it is experienced that blending magnetite ore resulted in increasing Fe2+ component in the iron ore sinter, which results in lower reducibility. Therefore, promoting the oxidation reaction from magnetite to hematite in the sintering process is countermeasure for reducibility. In addition, this promotion causes increase of oxidation heat, which results in high sinter strength and reduction of coke. It is assumed that the oxidation of magnetite tends to proceed in the cooling stage, where the oxygen partial pressure increases after the combustion of fine coke, but there are few studies on the effect of heat profile, especially cooling path. The purpose of this study is to design the effective sintering heat profile to promote oxidation of magnetite ore, especially, to investigate the effect of cooling path on sintered ore microstructure. In this study, magnetite ore and magnetite reagent were respectively mixed with calcium carbonate reagent. Then the mixed samples were pressed and formed into cylindrical tablets for simulating the adhesive layer of a pseudo particle. Through examining influence of maximum temperature and cooking rate on oxidation reaction of magnetite, we confirmed that the oxidation reaction of magnetite is suppressed at above 1350°C for maximum temperature, compared to 1300°C. Sintering at lower temperature is desirable because hematite is stable below 1350°C in the Fe2O3-CaO phase diagram.

Nov 8, 2021

By R Schlueter, H Mischo

The mining industry is facing a variety of geological, technological and social challenges. Future deposits show a general tendency towards increasing depth with complex ores and decreasing grades. One promising approach to deal with low-grade ores is bioleaching in the form of heap and dump operations. Bioleaching is already a state-of-the-art technique, especially for the extraction of copper from sulfide ores. The next step in the development of this technology will be its application as an in situ technology. First attempts to adapt this technology in underground mining in the form of stoping and block caving have already been made. Both methods have to be carried out adjacent to conventional mining operations and therefore require much effort regarding drift development as well as extraction and transport. The adaption of bioleaching as a borehole mining method is the next step to establish an innovative in situ technique to meet future challenges.The Freiberg University of Mining and Technology established the Biohydrometallurgical Centre for Strategic Elements (BHMZ) to foster interdisciplinary research along the whole biohydrometallurgical process chain. In general, 13 different university institutes and several associated groups with about 30 PhD students are mainly focusing on the extraction of indium and germanium from deposits, tailings and recycling material. One of the core projects within the BHMZ is the design and implementation of an underground in situ bioleaching testing facility.This paper demonstrates the potential of in situ bioleaching under technological aspects. Furthermore, different conditioning methods to increase the permeability of the orebody will be explained, and the BHMZ’s underground testing facility will be presented.CITATION:Schlueter, R and Mischo, H, 2015. Potential and applications of underground in situ bioleaching, in Proceedings Third International Future Mining Conference, pp 205–212 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By D Frost, G Harbort, T Lipiec, N Deonarain

"The use of flotation columns has remained a contentious issue among mill operators. There are those who consider them an essential part of any mineral processing operation, while others consider them a necessary evil, which should only be installed if there is no alternative. Lastly, there are those who believe they should not be installed, no matter how great the perceived benefit.This paper provides an analysis of over 4000 installed flotation columns, contained in the Amec Foster Wheeler flotation database. Changing trends in column flotation use by type, commodity and geographical region are discussed. The effect of changing commodity prices and the China ‘phenomenon’ are reviewed. Special reference is made to the changing face of column flotation in Australia.Of note is the fact that after falling to a 20 year low in installed flotation column capacity in 2014, flotation columns during 2015 went through a resurgence in popularity. This resurgence was in direct contradiction to depressed metal prices and was driven by brownfield optimisations to reduce off-site costs, particularly in base metals. A case study is presented comparing the benefits of column flotation at high commodity prices with low commodity prices.Citation:Harbort, G, Deonarain, N, Frost, D, Lipiec, T and David, D, 2016. Changing Trends in Column Flotation Use - Their Impact for Australian Mill Operators, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 93–104 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By O Ishiyama, L Lu

Sintering is the most economic and widely used agglomeration process to prepare iron ore fines for blast furnace use. Due to the depleting reserves of traditional high-grade iron ore, there have been considerable changes in iron ore resources available throughout the world, especially in steel mills in East Asia. Corresponding to the changes in the availability of iron ore resources, the amount of impurities in iron ore has been slowly increasing. Some of these impurities have been found to have deleterious impacts on sinter quality and sintering performance. In the meantime, an increasing number of large blast furnaces with inner volumes of more than 5000 m3 have been built that require more sinter and are often more demanding in terms of the quality requirements of the ferrous materials. Finally, sinter plants are facing increasing pressure due to more stringent regulations regarding their environmental impact. This paper gives an overall review of a variety of technologies developed worldwide to tackle the changing raw material characteristics and mitigate emissions from sintering operations.CITATION:Lu, L and Ishiyama, O, 2015. Recent advances in iron ore sintering, in Proceedings Iron Ore 2015, pp 61–68 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By W Stange

Assessing the risks in a mining project is a key aspect of project evaluation. This is an exacting and demanding task because of the complexity due to the need to deal with uncertainty over long time periods. The way risks are assessed and managed is critical to the long-term success of the projects and the business. Discounted cash flow (DCF) analysis is commonly used for project and risk evaluation. A discount rate is selected that accounts for uncertainties in the cash flows. However, it is difficult to determine an appropriate discount rate due to the large number of factors that need to be considered and the complex relationships between risk sources. Using a proven framework, ævalue at riskÆ (VaR), this paper proposes to rigorously model and quantify ærisk at sourceÆ. The approach was first employed to assess financial market risks and is now widely used in the banking sector for risk assessment. In project evaluation, all risk sources are identified and estimated separately to ensure the overall project risk is quantified accurately. A bottom-up approach has been proposed. Estimates are first carried out for risk factors at the bottom of the project structure. The assessment is then applied at increasingly higher levels until the overall project risk is estimated. Value at risk is a versatile methodology and can be used in a local or integrated manner. The final value is objective and the calculation steps can be easily justified and followed. Four case studies have been included to illustrate how the proposed approach can assist management in decision-making.

Jan 1, 2009

By M G. Aylmore, L W. de Klerk

Roasting of refractory gold ores has been a commercial process for many years. Improvements in design of fluidised bed roasting technologies and low capital and operating costs compared with other refractory treatment processes can potentially make roasting a viable option.However, gold extraction from roasted ores carried out on laboratory scale equipment often invariably yields lower recoveries than other processes such as bio-oxidation or pressure oxidation. Non-optimal laboratory roasting conditions can incorrectly write roasting off as a process option.Low gold recoveries from the cyanidation of calcine products from roasting can often be attributed to roasting conditions not favouring gold liberation and agglomeration processes, particularly if lockups of elements such as arsenic are being pursued for environmental reasons.This paper reviews the conditions favoured for gold agglomeration and accessibility of gold to cyanide, test conditions to achieve gold liberation and agglomeration on laboratory scale and designs that incorporate staged decomposition and roasting to make roasting a more commercial option.CITATION:Aylmore, M G and de Klerk, L W, 2013. Conditions and design considerations for maximising recoverable gold in roasting of refractory gold ores, in Proceedings World Gold 2013 , pp 375-388 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By S Udayakumar, S Biswal, N Sarmadi, V Sahajwalla, F Pahlevani

Recent times have witnessed a notable momentum in the interest surrounding technology dedicated to harnessing waste as valuable resources, prompted by the mounting challenges posed by waste accumulation and the swift depletion of natural resources. The carbon dissolution process within a molten iron bath stands as a pivotal reaction within the metal processing sector. The current study explores the utilisation of waste graphite electrodes (WGE) (obtained after being utilised in an electric arc furnace) as a secondary resource of carbon for dissolution into liquid iron. Experimental investigations were carried out at 1550°C using the sessile drop approach. High purity iron powder was used and the carbonaceous substrates were prepared from the ground WGE. The carbon pickup was determined using a suitable carbon analyser. Furthermore, an examination of the interfacial area between the molten iron and the WGE substrate was conducted beneath the metallic droplet, which effectively represents the iron/carbon interface. This interfacial analysis was carried out on two different samples obtained after a varying period of heat treatments at 1550°C. The interface layer was investigated using scanning electron microscopy (SEM) in conjunction with energy-dispersive X-ray spectroscopy (EDS).

Jun 19, 2024

By M Camarda, A Pirson, F Vasconcelos, J Mesquita

ArcelorMittal Prijedor is a goethitic iron ore mine located in the north-west of Bosnia and Herzegovina, which mainly supplies ArcelorMittal’s European subsidiaries. Annual production of the asset stands at the level of 1.5–2.1 million tons of iron ore product which is sent to ArcelorMittal Zenica steelmaking plant. Two types of products with approximately 50 per cent Fe are generated in Prijedor through a process composed by crushing, screening, and magnetic separation stages. Within this process one of the tailings produced is called ‘ultrafines’. The ‘ultrafines’ product corresponds to the desliming hydrocyclones overflow in Prijedor plant, which is classified in a size fraction below 25 μm and corresponds to about 5 per cent of feed. This material is richer in iron than the coarser size fractions of the ore but do not present a good performance in concentration processes. In this way, several studies have been carried out during the last years to find solutions to use the ‘ultrafines’ material without success. In this context, the possibility of dehydroxylate the goethite contained in the material transforming the mineral into hematite and thus increasing the iron grade of the final product was investigated. During the research, several dehydroxylation tests with different temperatures and time of exposure were performed. Using dihydroxylation process at temperatures higher than 800°C it was possible to produce a material with 43 per cent Fe from the original 39 per cent Fe ‘ultrafines’ sample. In addition, the dehydroxylation tests confirmed that goethite becomes completely transformed into hematite at 400°C (with an exposure time of 60 mins) and material is completely sintered at 1200°C. A simulation study based on dehydroxylation tests results showed that it would be possible to use a ‘ultrafines’ product with Fe grade higher than 45 per cent to produce a material with 50 per cent Fe through a complete dehydroxylation process.

Sep 18, 2023

By Kwok S, Haemmerle A

Treatment methods for a low grade deposit at Mt. Fitch near Rum Jungle, N.T., were investigated. Physical beneficiation of the ore, sulphuric acid leaching, carbonate leaching and various methods of uranium extraction from the leach liquor were studied. Although the deposit occurs in a carbonate environment, acid leaching of the ore after beneficiation by radiometric sorting appears to be the most economic treatment method. Uranium would be recovered from the leach liquor by solvent extraction.

Jan 1, 1970

By S Warden, T Neville, P Leckie

At its simplest, the classification and characterisation of an orebody is a matter of Where, What and When. Where and with what spatial resolution are measurements taken, What properties are measured, and When are the data acquired, processed, and delivered to create the most value. This paper delves into how existing and near-term advances in measurement technologies, field automation, and whole-system-digitisation are combining to open new routes for mine and exploration productivity improvement. Commencing when the initial exploration hole is dug, the advancement in deployment of survey technology—from expert-operated, to driller-operated, to driller-integrated—is used to demonstrate a template for adoption of higher technology measurements. We then introduce and discuss the multi-use measurement as offering outsized returns from a single measurement run, highlighting two new technologies that acquire rock strength while drilling and downhole assay data as examples. For rock strength, we highlight a novel approach to determining Uniaxial Compressive Strength (UCS) while drilling, its relationship to and advantages over Mechanical Specific Energy (MSE), and how it offers utility to multiple downstream processes. For downhole assay, we detail how a back-tophysics approach to Pulsed Fast and Thermal Neutron Activation (PFTNA) analysis offers significant advantages over other measurement methods and earlier implementations of PFTNA, generating a rich data set that can significantly extend and improve the information on which mining decisions are made. Finally, we discuss the possibilities enabled via optimising data delivery, collection, and curation— noting a fundamental limitation of historical systems and exploring the possibilities that will be unlocked by soon-to-market solutions that better enable Orebody Characterisation data to (virtually) move in space and time with rock material post-blasting. Ultimately, the value of optimising the Where, What, and When from point of measurement to the moment it generates maximum value will create greater life-of-asset production for a lower cost and energy input.

Sep 1, 2024

By M Yahyaei, P Knights, M S. Kizil, J Qu

Digital Twins (DTs) are transforming business operations across many industries through their accurate representations of physical entities enabled by IoT technologies.

Sep 1, 2024

In making any attempts to determine the depositional environments in which coal seams accumulated it would be useful to establish whether there is a pattern, or patterns, of development which the majority of the seams have followed. To this end, the distribution of types of coal seam sequences found in the standard petrographic profiles of about a hundred Australian coal seams of Permian and Triassic age has been examined statistically, using the "chi square test" with the limiting probability set at O·Gl.Results indicate that non-random conditions have probably prevailed during the deposition of most of the seams. More samples are needed for conclusive results.The plants, or some other internal feature of the swamp environment, have been the important controlling factor in the development of the seam sequences.Comparison has been made with some British Carboniferous coals.

Jan 1, 1972

By D Baas, D Bennett

This paper describes how Brisbane-based PanAust Limited develops process control strategies that are implemented at all operations and are used in functional descriptions for plant upgrades and new projects.The process control strategies are determined by operating management philosophies designed to maximise returns from the company’s assets.The approach is endorsed in the project planning and design phases to ensure facilities and equipment that form the major production assets are fit for purpose and capable of enabling the production managers and operators of the projects to maximise shareholder returns.PanAust’s process control approach has been to develop sets of process control standards which focus on two key areas. The first area covers hardware requirements and architecture, software objectives, control models and individual loop tuning methods. The second area defines control room layout, graphic standards and the alarm philosophy. The application of these standards in a new plant or upgrade decreases the time required to achieve design capacity and optimal performance.The PanAust process control strategy changes the operator’s role from one that controls a number of individual loops to one that sets the control objectives of the processing plant. To achieve optimal performance, all the process areas of the plant are analysed to identify opportunities to improve throughput, recovery and stability. Once a key opportunity is identified, a process control strategy is developed which defines the objective of the control, its functionality and how an operator will interact with it. After development of the control model the operators assist engineers to test and debug it. Once the model is robust, it can then be duplicated throughout the group and developed as a group process control standard.CITATION:Baas, D, Bennett, D and Walker, P, 2014. Developing process control standards for optimal plant performance at PanAust Limited, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 325–334 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By J Karlovšek

Civil engineering infrastructures are often subjected to different types of natural and mechanical activities. These influences may result in serviceability or even in stability of structures due to material deformations, increased water content within the materials used or the formation of internal or adjacent cavities that may threaten the infrastructure. Construction practices can lead to development of such defects in the form of cavities. In civil engineering it is crucial to detect these variations in material properties and to detect the presence of defects. However, as they are often hidden from view, these attributes may be difficult or impossible to target with traditional testing methods. For these reasons rapid geophysical methods, such as ground penetrating radar (GPR), are increasingly being used. At the University of Queensland (UQ) GPR is used for detection of voids and cavities which have been caused by an over excavation of the earth pressure balance machine (EPB) operating in a closed mode.A variety of numerical simulations using the finite-difference time-domain (FDTD) methods and preliminary experiments have been carried out in order to specify information about the nature, type, size, location and other characteristics of targets to be detected by GPR. In doing this the difficulty of interpreting GPR data, which is mainly due to the complexity of the factors involved in multiple possible solutions of the observed features, can be overcome.

Mar 8, 2011