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By M S. Powell, M P. Bueno

The commonly used SAB, SABC and run-of-mine (ROM) ball mill circuits can achieve high throughputs with good operating stability. However, these circuits consume a substantial amount of grinding media, which can have a substantial impact on the OPEX and the æcarbon footprintÆ, specifically when viewed as an æembodiedÆ energy input. On the other hand, fully autogenous (AG) circuits can operate at much lower operating costs, but with limited throughput. The control of AG mills, fed by ores with hard and soft components, can also be challenging, due to the sensitivity of the mill to the ratio of hard to soft components.In this paper, a multi-component modelling approach was used to demonstrate that the harder component should be used as grinding media, and its use should be kept to a minimum to avoid reduction in the mill throughput. There is an optimal blend of hard to soft, and any optimal blending condition is both ore-dependent and mill-specific. Establishing this blend is challenging, and consequently discourages the use of autogenous mills. The new modelling approach addresses this challenge by providing a quantitative prediction of the influence of blending soft and hard components in a mill. This prediction can then be used to establish the required blend for maintaining a stable and efficient operation in autogenous grinding mode.CITATION:Bueno, M P and Powell, M S, 2012. How to use hard ore components as grinding media, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 31-36 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

The traditional concept of optimum drill and blast is that it is achieved when ore is produced at the lowest unit cost and, because of the complexities of most mining operations, represents a band which extends either side of an overall cost m

Jan 1, 1998

By X Hu, J Björkvall, L Sundqvist Ökvist

The metal production industry is a significant contributor to global CO2 emissions due to the use of fossil fuels such as coal and coke. To mitigate these emissions and meet climate goals, innovative and sustainable technologies are required. Molten salt electrolysis is a promising technology that directly produces metals from their precursor sulfides or oxides using electricity. When combined with renewable electricity and an inert anode, the electrolysis process can be carbon neutral. This paper presents the results of two pilot-scale studies on the electrolytic reduction of metal oxides and sulfides in molten salts. The first study focuses on the electrolytic reduction of chalcopyrite in molten NaCl-KCl salt. The results demonstrate that in situ separation of copper, iron, and sulfur is possible, enabling the extraction of all valuable elements without CO2 emissions. Furthermore, the findings underscore the capability to eliminate impurities like zinc, antimony, arsenic, and mercury from the electrolysis product. The second study investigates the electrolytic reduction of pure/synthetic chemicals of wüstite, hematite, and magnetite, as well as a magnetite-type iron ore in molten NaOH salt. The findings reveal a stepwise reduction of iron oxides from high valence to low valence, ultimately leading to the production of metallic iron electrolytically. Notably, this study underscores the challenges associated with the selection of an economically viable and durable inert anode material for efficient oxygen generation. These results indicate that molten salt electrolysis provides a sustainable and green route for base metal production. The use of this technology has the potential to significantly reduce CO2 emissions in the metal production industry, contributing to achieving climate goals.

Jun 19, 2024

By Lovett EP, Johnson CR, Dunlop GA

Seven streams of a low tonnage pilot plant operation on Cu/Pb/Zn ore from the Golden Grove Project were continuously assayed using an AMDEL In-Stream Analysis (ISA) system. The ISA instrumentation is briefly described as is the calibration procedure employed. The successful application of this instrumentation in the dynamic environment of a pilot plant operation is discussed. The operational sequence of the Golden Grove pilot plant is outlined along with the original project objectives and how they were achieved by the implementation of ISA. Results for the different complex flowsheets used are discussed, followed by the perceived benefits of installing such equipment in this operation.

Jan 1, 1986

The highland region of Papua-New Guinea is relatively rugged terrain where stream gradients are steep. In areas where porphyry copper deposits outcrop the streams commonly expose primary sulphide mineralization in unoxidized rocks. Stream sediment geochemistry combined with float examination and broad geological mapping proved to be an effective tool for detection of outcropping bodies of mineralization. After discovery, detailed stream sediment sampling, soil sampling and rock chip sampling, together with detailed geological mapping proved adequate to delineate drilling targets. Reconnaissance stream sediment sample density was dictated by geology and access and a density of one sample per 25 Km2, or less, was desirable to ensure a high degree of confidence in the programme. Research indicated that the base metals occur in sulphide form in stream sediment and that the -80 mesh size fraction gave the most reliable results. The evaluation of results from any one area relied on the interpretation of the local geology. Basic histogram methods for determining background and threshold values for metals in stream sediments were

Jan 1, 1973

By D J. Bradshaw, E M. Wightman, B Newcombe

Flash flotation plays an integral role in many of the gold and sulfide mineral concentrators around the world, and yet despite this widespread use, very little information on this unit process is available in the published literature. For operations to maximise the performance of their flash flotation circuits, understanding how these cells operate, the nature of the particles they target and how to predict whether a flash flotation cell should be used on a specific ore type is of vital importance. This paper provides a summary of the key findings of a large flash flotation research project based in the operating environment of a refractory gold concentrator. The influence of key flotation performance criteria including gas dispersion, residence time and particle segregation within the cell will be discussed and recommendations for process improvements will be made throughout. The nature of the particles within the flash cell will be examined, as will the impact on the type of particles that are passed to downstream processes when the flash flotation cell is taken off-line. The development of a laboratory method to determine whether an ore is suitable to undergo the flash flotation process is also presented for its potential to aid in flow sheet development and optimisation for new ores.CITATION:Newcombe, B, Bradshaw, D J and Wightman, E M, 2012. Into the belly of the flash à Insights into the mechanisms at work within a flash flotation cell, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 163-170 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

Within the Ross River Basin, the following types of water were collected and analysed; 19 streams, 24 wells and bores together with 19 samples from the Ross River Dam. The waters were found to contain up to 269 ppm of silica and, although they meet the requirements for industry in all other respects, this extremely high figure means that two basic guidelines should be followed. All steam generation units, except those less than 150 psi should employ hot lime zeolite softening, demineralization or evaporation to remove silica. Cooling systems should only operate on a once through basis.

Jan 1, 1978

Underground mechanized excavation in New Zealand has become more commonplace in civil and mining applications during the last three years. At one stage up to seven Dosco Road- header machines were being used on different projects around the country. The Huntly West Mine Drifts inclined at one in four were by far the most severe grade conditions that the machines were subjected to; however, other operations posed their own particular problems for the machines. Two major interrelated factors became evident as soon as the machines commenced at Huntly. These were traction problems on the grade and control of water, particularly on the invert.

Jan 1, 1978

Subsurface development requires some geotechnical conditions and challenges. Most of then are related to the compatibility between tunnelling system and surrounded ground conditions, and design criteria. Design criteria usually involve lining pressure and ground control of displacements. In order to fulfil these requirements, geotechnical parameters have to be obtained as well as construction aspects have to be taken into account for predicting the tunnel behaviour. The Brasilia Metro is presented as a case history illustrating the geotechnical conditions and challenges for its implementation. It is 42 km long, including tunnels excavated in collapsible porous soils by the New Austrian Tunnelling Method. The Brasilia porous clay presents some characteristics, which may lead to large deformations due to structural collapse. Empirical methods were calibrated for collapsible porous soils and then applied to predict tunnelling-induced settlements. Settlements due to soil structural collapse modify completely the expected settlement profile, increasing their values from the tunnel crown to the ground surface. Consequently, surface settlement trough volumes were also greater than the ground losses around the tunnel. In this case history, structural collapse of porous soils played an important role and must have been taken into account to predict correctly the settlement trough and profile. Numerical simulation has shown that settlement magnitudes due to structural collapse are strongly dependent on the soil stiffness reduction after collapse and the extent of the collapsible zone.

Jan 1, 1999

By K Esmaeili, S Aziznejad

Impact-induced rock fragmentation is a mechanism that is commonly used for rock breakage in drilling and crushing. Additionally, rock fragmentation by blasting is frequently used in rock excavation operations. Experience shows that the presence of discontinuities can significantly influence the impact-induced damage and fragmentation of rock. Quantification of the response of jointed rock masses to impact loads is complicated by the fact that the available laboratory tests are mainly designed for aggregates or intact rocks. It can be argued that neither of these tests adequately represent a jointed rock mass. This paper presents the results of a series of numerical simulations used to investigate the influence of pre-existing discontinuities on the impact-induced fragmentation of rock masses. The methodology includes determination of the static and dynamic mechanical properties of a rock unit by conducting a series of laboratory tests on intact rock samples collected from a quarry in Canada. A 2D distinct element code, Particle Flow Code, was used to generate a bonded particle model in order to simulate both static mechanical properties (uniaxial compressive strength, elastic modulus, Poisson’s ratio and indirect tensile strength) and dynamic mechanical property (drop weight tensile strength) of the intact rock. The calibrated numerical model was then used to construct large-scale synthetic rock mass samples by incorporating discontinuity networks of different intensity into the bonded particle model. Finally, the impact-induced fragmentation inflicted by a rigid projectile particle on the jointed rock mass samples, simulated by a synthetic rock mass model, was determined. More fragmentation was observed for the rock mass samples with higher joint intensity.CITATION:Aziznejad, S and Esmaeili, K, 2015. Effects of joint intensity on rock fragmentation by impact, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 377–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By R P. Langford, T A. Moore

Over the last 15 years Indonesia has experienced a surge in coalexploration, which has led to the development of a major export industry. This coal exploration has improved the understanding of the geology of the Indonesian coal deposits. The main economic coal deposits are of Eocene and Miocene to Pliocene age, which mainly occur in Kalimantan and Sumatra and were formed from peat deposits in an equatorial paleoclimate similar to that prevailing today. Some of these peats were domed peats, which grew above the normal water tables, under a climate of year-round rainfall; these peats grew above the level at which waterborne mineral matter can enter the system, resulting in low ash and sulphur, and locally very thick coal. It is believed that such peats have formed the unusually thick, low ash, and low sulphur Miocene coals of Indonesia. Coal deposits of Eocene age are typically characterised by thinner seams, with relatively higher contents of ash and sulphur. The Miocene coals and Eocene coals both appear to have formed in lacustrine, coastal plain or deltaic depositional environments, similar to the modern peat-forming environments of eastern Sumatra and parts of Kalimantan. The Eocene coals formed mainly in extensional tectonic settings. Miocene - Pliocene coal deposits formed in a range of tectonic settings.

Jan 1, 1999

Recent geological mapping has indicated changes to the stratigraphy of the Pine Creek Geosyncline. The new stratigraphy and interpreted depositional environments are examined in relation to the distribution and genesis of stratabound mineral deposits. Basinward correlations are made with near-shore carbonate and psammite-rudite units in the Rum Jungle region. Most other units in the same region are condensed, indicating long- lived supratidal, intertidal or shallow conditions during most of the depositional cycle. Units containing most of the mineralisation represent the earliest near-shore developments of strongly reducing partly pelitic and evaporitic conditions and contain mainly uranium and base metals. Restricted distal, strongly reducing facies with associated felsic volcanics are also well mineralised, and mainly contain gold, silver and base metals, although some deposits are probably genetically related to synorogenic or postorogenic granites. Mineralisation in other facies is almost all epigenetic hydrothermal in origin, although minor mineralisation is related to volcanics, or dolomitic parts of the sequence. Areas of potential mineralisation include near-shore environments in the north, and carbonate reefs along growth faults. Two suites of postorogenic felsic volcanics and related sediments deposited in shallow water within and around northwest and east-northeast rift systems, overlie the metasediments of the Pine Creek Geosyncline in the south. The suites have potential for volcanogenic deposits, mostly of uranium, gold and copper.

Jan 1, 1984

By Griffin P

The project is the result of a European Commission supported collaboration between Surpac Software International, the Technical University of Berlin, and the industrial partners Exploration and Bergbau GmbH (E+B) and Taylor Woodrow. The object

Jan 1, 1998

Fluid bed sulphation roasting followed by leaching at low pH was developed as a means of separating copper and bismuth from a mix- ture of flotation concentrates and flash fur- nace flue dust. A 65 tonne/day plant was established and typically achieves 89 percent copper extraction with negligible bismuth and iron extraction. Acid-chloride leaching of bismuth from copper leach residue was then established, with bismuth oxychloride being precipitated from solution by dilution with water. A small scale batch plant presently in operation typic- ally achieves 80 percent recovery of bismuth to bismuth oxychloride.

Jan 1, 1986

The reasons for using SFRS, including the way a SFRS performs in comparison to plain shotcrete as a support element in mining tunnels, are discussed. The mechanisms by which steel fibres reinforce shotcrete and the need for specifying performance criteria are highlighted. A description of current testing procedures, including an overview of æquantitativeÆ design recommendations provided from various international authorities, is provided. A summary of international recommendations on suitable æqualitativeÆ performance classifications is also reviewed, including a critique of their suitability. Finally recommendations on the practical considerations necessary to ensure good quality, in-place SFRS, are made, including a calculation method for determining minimum steel fibre dosages.

Jan 1, 1999

By Aziz NI, Bridgwood EW, Singh RN

One of the major impacts of using modern mechanised systems of mining is the production of large amounts of extraneous dirt intermixed with the Run of Mine output. The paper out- lines a proposed system of utilizing liquid tailings from coal mines to replace imported cementitious materials used in ground control and various other safety measures. A geotech- nical and cost assessment of the proposed system are also included. The paper concludes that it is possible to utilize processed tailings to cost effectively replace imported packing material for ground control.

Jan 1, 1986

By P J. Terbrugge

Many ore deposits have considerable vertical extent which is not always known at the time of commencement of mining. In many of these cases, initial mining is by opencast methods, and as ore reserves are proved to greater depths, the pits are often planned to go deeper than had been originally envisaged. In such cases, surface plants and critical underground facilities such as conveyer tunnels, access ramps, ore passes, hoisting shafts and ventilation shafts are often located much closer to the pit rim and the orebody than is desirable for the deeper mining situation. This usually raises the question of the stability of such underground excavations, which may be critical for the viable longer-term mass underground operation of the mine. In this paper the key considerations in the evaluation of the stability of the overall mining environment for ædeepened minesÆ are defined. Aspects which are dealt with are: open pit stability, shaft stability, dilution, mudrushes and airblasts, and selection of mining method. The necessary stability evaluations are put into the appropriate context by considering two case histories. Critical parameters and considerations which need to be addressed during the evaluation of excavation interaction are also discussed.

Jan 1, 2000

Mt. Whaleback is in the Pilbara region of Western Australia approximately 1200 kilometers north of Perth, the State capital. In this deposit the Mt. Newman Joint Venturers are mining ore reserves totalling 1500 million tonnes of high grade hematite averaging 64.0% Fe. In addition to Mt. Whaleback, 38 ore bodies have so far been identified outside Mt. Whaleback on the Company's remaining 75,000 hectares of lease area. These ore bodies contain major tonnages of iron ore. Extraction at present is planned at a rate of 37 million tonnes per annum at an ore-to-waste ratio of approximately 1 to 1.4. The ore is railed north to Port Hedland on the Indian Ocean where the different products are screened, crushed and blended prior to shipping. The purpose of this paper is to acquaint the reader with the facilities installed in the Mt. Newman operation to form a background to the sampling techniques employed, describe the precisions which were achieved in experiments conducted February through June, 1976 and also to assess the degree of blending which takes place during the various processes and to put a quantitative measure to the degree of blending. There have been many excellent papers written on the more theoretical aspects

Jan 1, 1976

Metal grades and contents of ore deposits should be measured in an unbiased manner, and with a degree of precision that reduces to an acceptable level the risk to put into production inviable prospects. The additive property of variances for metal grades and contents is used to assess the accuracy and precision characteristics of this measurement process. Each stage in the process of extracting different types of samples from ore deposits, preparing test samples from drill core sections, drill chips or crushed ore, and collecting and assaying test portions, contributes a variance component to the intrinsic variability of a metal's distribution in its matrix. Deducting such extrinsic variances results in more precise estimates for metal grades and contents of elementary units. The cumulative metal content for a set of elementary units of in-situ ore, and the sum of the variances for metal contents of all units in the set, can be used to calculate confidence intervals and confidence ranges at different probability levels as measures for risk.

Jan 1, 1976

By D Williams

Recent advances in global positioning systems (GPS), machine guidance technology and telemetry allow an unprecedented level of control of surface mining operations. GPS technology can now locate the bucket of a shovel or the blade of a dozer within 50 mm. Some of the outcomes possible are: precise selective mining û even when the ore is visually indistinguishable from waste; tracking grade and tonnage of every ore parcel through the mine; real time productivity monitoring; detailed post accident safety analysis; and tracking the movements of every piece of equipment. This paper will consider the contribution that GPS based machine control systems can make to ensuring that surface mining projects deliver the outcomes promised in the feasibility studies. Case studies of installations are presented.

Jan 1, 2003