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By D Yan, D Connelly

Beneficiation of magnetite is an integral part of the future of iron ore processing. Historically, the focus of Western Australian producers has been on exporting direct shipping ore (DSO) namely haematite. The future for new DSO resources is limited so companies are changing their emphasis into processing the very large, undeveloped magnetite ores in Western Australia (WA), using beneficiation to produce shippable magnetite concentrates. These magnetite resources require higher cost processing techniques such as fine grinding and beneficiation to produce saleable concentrates. This distinct difference, from the DSO ores, has led to the development of a number of new technologies. This paper reviews: the different techniques used for magnetite beneficiation and provides some case studies in the WA industry; the use of mineral liberation analysis (MLA) to describe the nature, grain size, occurrence and associations of the mineralisation;the consideration of coarse cobbing as a critical upgrading; the application of high pressure grinding rolls (HPGR) to save energy; how the field of magnetic separation has resulted in new machines with higher field strength (SLon Separators); ultra fine grinding requirements of magnetite concentrates; andthe application of reverse flotation to reduce silica in the concentrates.

Jan 1, 2009

By H Kurth

High specification Prompt Gamma Neutron Activation Analysis (PGNAA) has been successfully applied to conveyed flows at iron ore operations since 2002 to representatively measure ore quality for improved quality management and process control. While the PGNAA technique has changed little since that time, significant improvements have been made in measurement capability. Elements previously unable to be measured well or at all using this technique are now measurable and one of these is phosphorus. Aluminium and magnesium are also key elements in addition to calcium and silicon in determining sinter basicity in ironmaking. Other elements measured routinely in iron ores include iron, carbon, potassium, sulfur and manganese. The benefits of representative measurement cannot be overstated as iron ore mining operations in South Africa, Europe, Australia, Asia and the Americas have discovered. The technology is applicable to any conveyed flow where elemental analysis in real time assists with quality management, from raw materials in ironmaking through to scrap steel in steelmaking and coal quality for coke-making. Major benefits are realised when raw material processing is optimised and this often includes diversion of material meeting a required quality so it can bypass unnecessary processing. This includes waste rock which can be diverted from a plant feed stream in 30 sec increments or ore that meets product quality being diverted to bypass beneficiation. Analysers are successfully utilised to identify ore types that assist with upgrade optimisation in jig plants; measuring feed, product and discard flows to also account for metal content. Product flows to stockpiles help manage production flows and stockpile qualities for different products and assist in blending ores into trains or ships to confirm specification compliance. Technologies can be used in magnetite processing but are predominantly used in hematite and goethite ore processing operations. The paper details examples of the above applications at various operational sites providing estimates of economic benefit as well as operational improvements.

Sep 18, 2023

The current talk of risk management as a separate discipline and management function is like earlier imposition of Quality Control (QC) as an overlay on shoddy production management. Risk management is vital, but is integral in the way we marshal our staff, make decisions, then monitor and review and make crucial secondary decisions. New leaders must not assume that hiring experts ensures good decisions. It is only the essential step one. The worst company I worked for had more expertise than the best. The difference was in culture and decision-making processes. Failed feasibility studies, persistent technical factions in a company that cancel each other, heaps of expert consultant reports piled up like a dump of bricks, even great but half-managers in large and small companies cancelling expertise at their disposal, are the worst manifestations. Just daily foul-ups are common even amongst smart people. We miners have made a great industry but are content to drift far below excellence, even where that word is bandied around. All the management literature and management courses will not right the situation û we have been sending budding managers to this good stuff for two generations and the effects are worthwhile but marginal. A few key ideals, ideas and slogans are not the way. These make inspiring books that work about as long as the Christmas spirit does in the real world. What we need is a coachesÆ manual and a standard of the essential package of culture and work processes that make excellence possible and show how to maintain it long term. It has not been written until now because most managers want to remain dilettante amateur managers without the discipline that creates excellence. First, believe excellence is possible and worth any effort; then commit to it.

Jan 1, 2007

MAXIMINE is a compiled, comprehensive, spreadsheet-based, macro- driven software package, written to aid in the rapid and early assessment and design of virtually any small, medium, and large mining or quarrying project. The system has been des

Jan 1, 1998

By D Reid

Many of the relevant engineering behaviours of tailings are controlled to a large degree by the density of the material. For example, loose tailings are prone to brittle strength loss, while dense tailings are dilative (i.e. gain strength) at large shear strains. The critical state framework has been successfully developed over the past few decades to assess whether in situ conditions are contractive or dilative, and estimate relevant engineering parameters on that basis. Tailings comprising primarily silt-sized particles, when subaqueously deposited, often form a particularly loose state compared to subaerially deposited material of similar index properties. Such subaqueous deposition occurs in the decant pond area, where the tailings typically pluviate in quiescent conditions within a pond of standing water. Silt tailings deposited in such a manner have been observed to be extremely loose in a number of TSF investigations. Of particular concern, the deposited material in such cases appear to be significantly looser than can be reproduced in the laboratory - even using moist tamping, the sample preparation method which can usually produce the loosest samples possible in laboratory conditions. While the loose density of subaqueously deposited silt tailings is clear, in a well-managed upstream-raised TSF the decant pond is usually small and far from the perimeter embankments, however there are a number of examples where the engineering performance of such materials becomes relevant – for example, when historical deposition practices were poor, resulting in subaqueous deposition near the perimeter embankment. This paper outlines the geotechnical characterisation of a number of such subaqueously-deposited zones, compares the in situ state to that achievable in the laboratory, and discusses options for assessing the expected engineering performance of such materials when comparable laboratory tests are unavailable.

Jul 1, 2021

By D J. Brake

The underground metalliferous mining industry continues to change under the influence of many factors including, to name a few, new mining techniques and equipment, new approaches to risk management, more stringent safety and health standards, new employment practices and orebodies become deeper and often lower grade. In addition, the same technological revolution and plummeting cost of technology that has brought the GPS, smart phones and digital cameras to the general population is also working its way through the mining industry impacting on communications, automation and process control as well as introducing major efficiency and productivity dividends. However, not all factors are positive including, in particular, the issues of carbon costs and electrical power. This paper explores some of the trends affecting ventilation in hard rock mines, some of the existing and likely future challenges and some of the potential future solutions to these issues.CITATION:Brake, D J, 2013. Ventilation challenges facing the metalliferous sector, in Proceedings The Australian Mine Ventilation Conference , pp 3-12 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By M S. Cassola

It’s expected that the world economy will face a stable and continuous growth in the demand of iron ore, reaching more than two billion tonnes per year within the next year. After decades exploiting resources with high content of iron ore, now the industry faces the challenge to exploit and beneficiate more complex ores.According to the industrial practice, the flotation technology is one of the most important and effective beneficiation processes to deal with low-grade iron ores around the world. However, even with this, it is still necessary to search for new processing routes or promote the optimisation of the existing circuits.The broad application of this technology is an outcome that deeply relies on the proper selection of flotation chemicals specifi cally designed for each system. New collectors are in continuous development as flotation performance significantly relies upon their optimisation.The reverse iron ore flotation in Brazil, mainly constituted by haematite and quartz, uses ether amines as collector for silica minerals and caustic corn starch as depressor for haematite. The process selectivity is highly impacted by the features of the etheramine, such as:• mono or di-etheramine,• neutralisation degree,• chain length,• branched or linear chain,• the flotation pH, and• the size distribution of the flotation feed.This paper describes the experience obtained from laboratory and industrial trials on different ores, conducted to improve the selectivity and recovery in the reverse iron ore flotation by selecting the required collector for low-grade ores.

Jul 11, 2011

By E du Plessis, J Kapusta, J L. Mauk

The world-class Bulyanhulu gold deposit (375 t Au) is in the Sukumaland greenstone belt, Northwestern Tanzania. The main mineralised quartz vein structure, termed Reef one, occurs at the contact of felsic metavolcanic rocks on the hanging wall and mafic metavolcanic rocks on the footwall. Reef one is dominated by massive quartz together with pyrite, pyrrhotite and minor chalcopyrite. Alteration in the footwall basalt is characterised by extensive chloritisation, calcification and silicification, which is strongest near the vein. Sericitisation also locally occurs adjacent to the vein. Metamorphic hornblende and plagioclase (albite) increase in abundance at a distance of 120 m from the vein and reflect the gradation into less altered rocks. The increasing abundance of chlorite, calcite, quartz and local sericite near Reef one, coupled by replacement textures suggests that most of these footwall minerals are the product of hydrothermal alteration, rather than regional metamorphism. Geochemical data shows slight enrichment in Ca, Fe and As towards the vein, whereas Zn in several drill holes becomes enriched away from Reef one. The Bulyanhulu gold deposit is a quartz-pyrite-chalcopyrite shear controlled vein with an adjacent extensive chlorite-quartz-calcite hydrothermal alteration zone (and a limited local sericite alteration zone) that passes to a hornblende-albite metamorphic assemblage further into the footwall.

Jan 1, 2002

By N L. Turner, K Ehrig, V Liebezeit, D J. Robinson, L L. Kuhar, N Francis

Conventional industry tests used to determine leach recoveries are often fully monitored and may be time-consuming and expensive. Such tests may be limiting in geometallurgical applications where large numbers of samples are required to be processed for characterisation of an ore deposit. BHP Billiton currently use a fully instrumented leach test for characterisation of Olympic Dam uranium-rich samples. Researchers at the Commonwealth Scientific Research and Industrial Organisation (CSIRO) were approached to develop an alternative to these full-scale leach tests that could allow for the ranking of samples in terms of their leachability. The novel geometallurgical test was required to use samples of small mass and be affordable and rapid.Three leach test protocols were pursued in developing the small-scale tests. Kinetic leach tests were performed using mild conditions at higher pH, low temperature and low oxidation reduction potential, moderate conditions at intermediate pH, temperature and oxidation reduction potential and aggressive conditions at lower pH, higher temperature and higher reduction potential.This paper presents results from 44 leach tests on 11 samples with varying uranium mineralogy. The developed small-scale tests correlate well with data from the more costly conventional industry laboratory tests, indicating the possibility of using this alternative test as a geometallurgical leach proxy. Simple regression analysis confirmed the importance of pH, reduction potential and temperature on uranium extraction. Experimental data were fitted to published leach models to predict uranium leach extraction for a range of operating conditions.The ultimate aim of the test work is to combine a limited number of large-scale calibration tests, a large number of small-scale geometallurgical tests and leach models for geometallurgical sample characterisation and evaluation of a wide range of scenarios or processing options.CITATION:Turner, N L, Kuhar, L L, Francis, N, Liebezeit, V, Ehrig, K and Robinson, D J, 2013. Development and testing of a small-scale uranium leach for geometallurgical applications, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 345-350 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By Hanaoka K, Ikeda K

Kakogawa Works, Kobe Steel, Ltd. has two pelletizing plants and one sintering plant, and the blast furnaces have been operated with 30 - 50% pellets. At Kakogawa Works, various improvements in pellet quality have been carried out since the beginning of operation of the pelletizing plant. Especially, dolomite-fluxed pellets developed in 1975, have superior high temperature properties. The fuel rate of the large blast furnaces at Kakogawa Works has been reduced to 450 kg/t- hn by using a high percentage of dolomite-flux ed pellets.

Jan 1, 1980

By T P. Medhurst

In many cases mine design is the most important driver of the profitability of a mining project, however to reach an æoptimumÆ mine plan many compromises have to be made. Some of the fundamental profit (and loss) drivers relate to stoping methods and stope design parameters. Inevitably trade-offs have to be made between the stability of underground openings, ground support costs and production efficiency. This paper looks at the role of geomechanics in the mine planning and design process. The concepts of æcontrollable lossesÆ and æuncontrollable lossesÆ are developed as a means of partitioning ground control costs. A stope design example is given which provides a method of examining mining costs, and includes a decision making element in order to quantify geotechnical impacts and select stope dimensions. The method also provides a general framework as a means of balancing ground control costs against maximising returns from an underground mining project.

Jan 1, 2000

By J Evans-Wheeler

"The mandate of the 2005 VALMIN Code to provide ‘(all) reliable, thorough, understandable material information required by investors and their advisers when making investment decisions’ requires that due diligence for tenure be full and thorough. Yet a published due diligence would often appear to be simply a list of tenures allegedly held without any commitment as to the standing of the tenure as safe and secure or otherwise.The value of due diligence for tenure, as mandated in the 2012 JORC Code and the 2005 VALMIN Code, must focus on compliance rather than simply on ‘vital statistics’. Enforcement in every jurisdiction in Australia focuses on penalties (some more harsh than others) for non-compliance, which, in turn and most importantly, reflects directly on security of tenure. Some 22 Acts (on average) impinge on security of tenure and fundamentally underpin the security of any mineral asset.This paper will outline regulatory processes to demonstrate how tenure compliance is achieved and argue that the rigorous application of good practices in tenure evaluation will lead to more of this information being made available on a regular basis.The paper will then focus on further practical examples of tenure compliance failures, the application of these to the requirements of the JORC and VALMIN Codes and due diligence that failed to fulfil the mandate. Examples will be given that alerted other professionals using the JORC Code to complex geological and mining situations of which they were unaware in their valuations.Finally, the author will make a personal plea for tenure to be considered at the commencement of any reporting process.CITATION:Evans-Wheeler, J, 2016. The VALMIN code and tenure compliance – not just a list, in Proceedings Project Evaluation 2016, pp 112–121 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 8, 2016

By J V. Mehrabani, A R. Sayadi

Adequate estimation of equipment costs is a key factor in a feasibility study and in evaluation of design alternatives for mining and mineral processing projects. Inaccurate early cost estimation could lead to the elimination of investment benefits. However, this estimation is complex and time consuming because of data accessibility problems and consequently access to a rapid, up-to-date and accurate tool is desirable for carrying out cost estimations.This paper describes the development of models for estimating capital and operating costs for a jaw crusher, which is used as the primary crusher for a wide variety of mineral beneficiation plants, applying single and multivariate regression analyses, together with the design of experiment approach, based on principal component analysis. Explanatory variables include gape size, length of feed opening and power as numeric (quantitative) variables and toggle type (single or double) and the existence of extra heavy duty construction as categorical (qualitative) variables. The performance of each model has been investigated and comparing the estimated R-squared (R2) of each model, the best was selected and its validity examined. The cost models include the capital and operating costs along with the operating cost components. The results indicate that the suggested best cost model is sufficiently accurate for use in feasibility studies.

Sep 26, 2011

Completion of a project requires two separate money-focused activities, namely economic evaluation of the cash flows underlying the project (before financing) and if the economics look promising, how it can be financed. Economic evaluation might be best led by a person with a technical-operating background, whereas financing might be best led by an accountant. Both should be presented in simple language with easy to understand models. Economic evaluation has a sad and bad history because it evolved from the fringes of accounting. Anyone can become a self-appointed practitioner. Some still take pride in mathematical complexity without realising that they distance themselves from the decision-makers and alienate other team members. Today there is no evaluation modelling consistency across the mining industry and this reflects poorly on our discipline. It is not tolerated amongst our peers in engineering and accounting. In 2009 æbest practiceÆ economic evaluation modelling is well defined. It is:easy to follow;tailored to its purpose;transparent;discipline, rigour and consistency;recording of all source data; and hencequick to audit. Mantra: If you cannot readily understand my model you do not have a problem, I do! The task of the economic model is to make the range of business cases underlying the decision easy to understand. Intellectual power is used to simplify the decision to its key issues and risks and to present the full range of possible business outcomes in readily understood terms. Project team members, management and the board must be able to make their decisions with æeyes wide openÆ. A steering committee should be established to develop a set of standards and practices that could be adopted for economic modelling within the industry. The industry needs to purge itself of the undisciplined economic evaluation modelling that now characterises the discipline.

Jan 1, 2009

By J Jackson, M F. Young

"Ore is the economic portion of a mineral deposit that can be extracted economically. Hence an ore type is a classification of the ore based on one or more dominant characteristics in order to enable communication between unit operations and/or technical disciplines.In project evaluation, ore types are often defined early based on geological observations by geologists and initial metallurgical testing is based around this classification even though a number of processing options can be under evaluation. However, the geological drivers of performance for each of these processes can be very different and the ore type classification for one process may not be relevant for another. In operations an ore type, as either defined in the project evaluation phase or those that evolve with additional knowledge, is unlikely to provide the knowledge required across all the unit operations. The ore type has a meaning to someone but does not necessarily for all unit operations across the value chain.Geometallurgical or orebody knowledge has evolved through the consideration of multiple processes within the value chain, the improved understanding of variability of process performance within ore types and the effect on the complexity of the mineral extraction processes. Furthermore orebody knowledge has been moving from personal based knowledge and understanding to a more process oriented approach where measurement and spatial and process performance modelling is playing a greater role. Advances in mine planning and scheduling allow for both detailed analysis of the block model and the expected extraction processing attributes across various time scales. This capability of analysing and describing the complexity still requires to be communicated to the various unit operations, which may be beyond the traditional classification of an ore type.The limitations of an ore type and potential alternatives to enable the relevant information to be communicated to the relevant groups are outlined through a number of case examples across the value chain.CITATION:Jackson, J and Young, M F, 2016. Ore Type – Everything to Someone but Nothing to Anyone, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 267–274 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

The role of a project metallurgist is diverse and covers input into the resource definition, mining studies, metallurgical test program development, process engineering and plant design, cost estimate preparation and financial analysis aspects of project feasibility studies. Mining project schedule and cost overruns can often be attributed to cutting short metallurgical test work, engineering and cost estimating leading up to commitment to development. In a significant number of cases this may result from the lack of understanding and commitment by the project proponent to the requisite metallurgical and processing studies required during the various pre-commitment stages of a mining project. Metallurgical test work, process development, engineering and cost estimating requirements for each stage of pre-commitment development are described together with a summary of the ongoing role of the project metallurgist during detailed engineering and commissioning of a process plant.

Jan 1, 2008

By G R. Hancock, W D. D P Welivitiya

is placed in a waste rock dump, which is usually later reshaped to be erosionally stable, initiate and sustain vegetation and ultimately integrate with the surrounding undisturbed landscape. However, it is unclear how this exhumed material will weather and evolve for most sites. Also, there is a lack of data on the weathering of post-mining materials. If weathering is better understood, then there is the potential to improve rehabilitation outcomes. To improve predictions of the evolution of soil properties and weathering-limited erosion, estimating the rate at which fine, transportable material is produced from the weathering of larger, non-transportable particles and the resultant fragment size distribution and how that distribution evolves over time is necessary. This study examines the weathering process for four different coalmine waste rock materials for a Bowen Basin, Queensland site. Materials obtained from various areas of the coalmine were subjected to cyclic wetting and drying and heating and cooling. Particle size distribution and other material properties were explored after each experimental cycle to ascertain how the material changes during the experimental cycles. The particle size distribution data of wet and dry cycles were used as input data in a numerical weathering model to explore the dynamics of the weathering process for each material sample. A Monte Carlo framework was employed to assess the geometry of the weathering products, weathering rate and the number of daughter particles produced within a weathering cycle. Then the SSSPAM Landscape Evolution Model was used to evaluate the influence of weathering on erosion and landscape evolution of a post mining landform. SSSPAM simulations with: (i) active weathering and (ii) without weathering were run for each material. The erosion rate and the overall landform structure were then compared between weathering and non-weathering simulations.

Aug 2, 2023

By J L. Merritt

Contour banks and waterways are standard soil conservation measures to assist farmers reduce the impact of gully erosion on sloping cropping land by reducing the slope length to the interval between the banks. The Universal Soil Loss Equation (USLE) developed by the USA Department of Agriculture Soil Conservation Service in 1930s predicts the long-term average annual soil loss (A).The equation is the product of the rainfall erosivity factor (R), the soil erodibility factor (K), the topographic factors of slope length and angle (L and S) and the cropping management factors (C and P). Contour banks reduce the slope length (L) only.Contour banks are a constructed earth embankment, incorporating a channel on the upslope side, typically traversing a slope on or close to the contour to control and/or prevent the erosion of that slope. The banks are also referred to as graded banks, terraces, or bunds (DSITI 2015). Contour banks are either broad based or narrow based. Broad based banks allow the passage of the machinery over the banks whilst narrow based bank batters are too steep preventing the passage of machinery. Waterways are a stable, longitudinally sloping water disposal area of sufficient capacity used to discharge surplus runoff from the contour bank and to allow it to flow to a lower level without causing erosion (DSITI 2015).The mining industry must decide what the role for contour banks and waterways is in each operation’s rehabilitation and closure plan.CITATION:Merritt, J L, 2018. Contour banks in spoil rehabilitation – a matter of timing, in Proceedings Life-of-Mine 2018, pp 147–149 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By M Berry, F MacCorquodale

The ownership, management and employment structures operating in the Australian minerals industry have dynamically evolved during the last 30 years. One of the most dramatic changes, from an exploration and mining geology perspective, is the reduction of in-house geological expertise and an ever increasing reliance on contract and consulting services.For all companies - big and small - two key issues resulting from these changes are the management of core geological intellectual property (IP) and competitive advantage. This is because there are less experienced geologists at exploration and mine sites, there are fewer head-office technical service teams to support mine sites, exploration teams are smaller with less specialists employed, and there is an ever-greater dependence on contract and consulting services.This paper reviews and explores these issues with an industry-wide geological context, then provides a case study of how Newcrest Mining Limited (Newcrest) has dealt with these issues in exploration. Newcrest has grown from a one-mine company with an Australian exploration focus, to a large global company with multiple operations and an extensive international exploration portfolio. NewcrestÆs management of its geological IP and competitive advantage has evolved as the company has grown and responded to market conditions, including its internal restructuring in mid-2013.CITATION:Berry, M and MacCorquodale, F, 2013. Managing geological intellectual property and competitive advantage - Newcrest Mining LimitedÆs experience, in Proceedings World Gold 2013 , pp 37-44 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By D J. Black

The process of excavating and mining coal causes fractures in the overlying and underlying strata. The fractures provide pathways for gas released from coal seams and other gas-bearing strata to flow into the mine workings. Coal seam gas typically contains high concentrations of methane with lesser concentrations of carbon dioxide. Low concentrations of other gases such as nitrogen, hydrogen sulfide and ethane may also be present in some coal seams. In certain geological settings, particularly in close proximity to geological structures, such as faults and dykes, the concentration of gases contained in a coal seam can vary significantly between methane-rich to carbon dioxide-rich.In mine design and planning it is vital that mining engineers gather sufficient information to accurately determine the content and composition of the gas present in the coal seam and develop an understanding of changes in these parameters within the planned mining area.The longwall method of mining coal causes fracturing of the overlying and underlying strata behind the retreating longwall face. Where coal seams and other gas-bearing strata are present within the caving zone, gas will be released from the strata leading to contamination of the mine workings. If the rate of gas emission exceeds the diluting capacity of the mine ventilation, the concentration of gas in the mine may exceed the statutory limit, resulting in production delays and potentially unsafe conditions.CITATION:Black, D J, 2016. Planning effective management of gas emissions in an underground coalmine, in Proceedings Life-of-Mine 2016 Conference, pp 44–47 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016