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By Onal G, Celik MS, Dogan MZ

Chromite tailings assaying 21.2 per cent Cr2O3 was upgraded to 48.7 per cent Cr2O3 at a recovery of 72.0 per cent using column flotation with a mixture of anionic collectors at pH 11. Electrokinetic methods were used to elucidate the mechanism of collector adsorption and correlate the findings with the optimum flotation conditions. Multivalent constituent ions such as Cr3+, A13+, Fe2+ and Mg2+ were found to adsorb on chromite surface and shift the zpc of chromite in the direction of oxide form of the mineral. The anionic collectors also imparted a negative charge to chromite in the entire pH region. The higher zeta potentials obtained upon adding the anionic collectors is ascribed to the adsorption of anionic surfactant onto the positively charged chromite surface. The positive sites are generated through formation of significant amount of hydroxy complexes of magnesium at pH 11. Complementary infrared data reveal the absence of a shift in the spectra indicating the possibility of physical adsorption in the system.

Jan 1, 1993

By Cox A

A key concern both in public perceptions of the environmental performance of the mining industry and in the development of policy relating to mining activities is the state in which the areas may be left at the completion of mining operations. There is, in effect, concern that the transient economic benefits of mining are enjoyed by the few, while the 'scars' may remain for all. While the techniques of mine rehabilitation have improved rapidly in recent years, an important set of economic issues has generally been neglected.In this paper, the economic and policy aspects of mine rehabilitation are examined. The key issue addressed is how to determine when expenditure on rehabilitation should stop. The answer to such a question requires consideration of the full range of social, as well as private, costs and benefits of rehabilitation at a particular site. Clearly these costs and benefits will vary between sites. From both an economic and policy perspective it is important to establish whether the additional gain from more rehabilitation would exceed the additional cost.It is concluded in the paper that the technical feasibility alone does not justify a paeticular level of rehabilitation activity and expenditure. While more rehabilitation at a particular site may be technically feasible, the additional expenditure incurred in undertaking that rehabilitation may result in little extra benefit. This conclusion has important implications for government policy, particularly with respect to establishing the goals for rehabilitation, criteria for successful rehabilitation and enforcement of rehabilitation objectives.

Jan 1, 1992

This paper is intended to continue the subject in the light of recent work, from where it was left at the conclusion of the discussion on the excellent paper by the late Mr. Noel Haszard. The position then obtaining is briefly summarised below:-The points which received general agreement at that time were:-'(1) That the gold occurs, probably in an elemental form, in a state of very fine division in the pyrite.(2) That the aim in roasting of Kalgoorlie flotation concentrates should be to obtain the maximum porosity possible. The gold tellurides were amenable to treatment with either a' solution of high lime and cyanide strength combined with fine grinding, or bybromocyanidation without re-grinding.(3) That a low roasting temperature is essential during the elimination of the first atom of sulphur, if the final calcine is to give a good extraction by cyanidation.(4) Even with the best temperature conditions of roasting then determined, and after a period of cyanidation of the calcines until no further extraction was obtainable, the lowest calcine residues obtainable were equivalent to approximately 1·8 dwts. per long ton, based on an original concentrate of pure pyrite.There was some division of opinion at the time as to whether the temperature of the later stages of roasting was significant, and also as to the reason why the initial roasting temperatures had so marked an effect.

Jan 1, 1939

By M Kongas, K Saloheimo

Concentrating lower and more variable grade ore resources to meet acceptable concentrate quality criteria requires removal of significant amount of gangue minerals. Monitoring plant feed mineralogy and concentrate by on-stream analysis has significant economic benefits in concentrate quality and recovery optimisation. There is a need to develop a sensitive slurry on-line analyser for silica, aluminium, magnesium and other light elements.On-line XRF elemental analysis technology, which is a routine practice in base metal concentrators is not able to measure lighter elements than calcium from slurry. Too much of the X-ray fluorescence signal from lighter elements is absorbed by water. The limitations in the direct measurement of silica and other light elements have restricted its use in some applications. Some light element slurry analysers have been developed based on prompt gamma neutron activation (PGNAA) method but they have not performed up to the expectations. This paper describes a new on-line elemental slurry analyser and the results of on-line laboratory tests.CITATION:Kongas, M and Saloheimo, K, 2013. Online light element slurry analysis, in Proceedings MetPlant 2013 , pp 93-101 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

The relationship between the permeability of coal to a mixture of methane and carbon dioxide, and the permeability to methane and carbon dioxide separately is described in this paper, along with the analysis of the differences in permeabilities of coal to methane and carbon dioxide.

Jan 1, 1989

By Szpindler G

The results of pot-furnace tests with 35 bituminous coals from 20 seams in New South Wales and Queensland were used to establish the relationship between coal properties, as determined by standard laboratory tests, and the combustion process. The rate of combustion is influenced chiefly by the expansion of the fuel bed, but this cannot be accurately predicted from the crucible swelling number of the coal.The effects of various other factors, such as calorific value and ash yield, were investigated and statistical analysis of the results shows that the coals could be classified satisfactorily according to two experimentally derived parameters, namely heat-release rate at an air flow rate of 260 lb/sq.ft/hr and air flow rate giving stoichiometric combustion. The grouping obtained is shown to be related to ash yield and swelling number.INTRODUCTIQNThe rate of heat release from the fuel bed of a travelling grate stoker and the efficiency with which the heat is used depend upon the design and method of operation of the furnace as well as upon the properties of the fuel. It is difficult to draw general conclusions concerning the influence of fuel properties from tests on a single stoker installation. In the pot-furnace test, on the other hand, a part of the same combustion process as occurs on a travelling grate is carried out in isolation, uninfluenced by furnace design variables, and consequently the effects of coal properties and of the method of pretreatment can readily be demonstrated.While the combustion pot provides a rapid method of assessing the combustion characteristics of a fuel during the ignition and burn-out stages under standard conditions, and of predicting changes in performance with changes in fuel or in air flow rate, it is unable to simulate certain features of furnace design and operation. Data from combustion pot...

Jan 1, 1962

By N Slade, D Kennedy

Optimal throughput is a key objective for the successful operation of any manufacturing or processing business. In the mining industry in particular, in order to obtain maximum return on the significant capital investment in the physical assets involved, ensuring continuous throughput is a major focus for the complete leadership team. Failure to meet throughput objectives becomes a major source of distraction for management which too often attempts to solve shortfalls by æforcingÆ and æenforcingÆ production targets. This focus on the short term and the lack of attention to addressing root causes frustrates operators who attempt to satisfy unattainable short-term targets and lose sight of the long-term goal. Mount Isa Copper Operations, Xstrata Copper, North Queensland, had ambitious plans to increase throughput volume by ten per cent within a four month period to allow budgets to be achieved within the financial year. To achieve this, the process had to overcome the interplay of a multi-node (æsiloedÆ) production system and its associated inventories, each node, of which on the face of it at least, had more than enough ænameplateÆ capacity to meet these plans. However, the actual volume achieved at the end point of the system was well below this nameplate capacity and the system operated with an extraordinarily high standard deviation. The key issues in terms of making or exceeding plan were: how to substantially reduce the variability of the system and managing the inventories between nodes, how to synchronise throughput between the production nodes, and how to improve the decision-making ability within the process. In this paper, the implementation team has shown that a revolutionary process view of the operation together with appropriate planning decisions allowed increased throughput to be achieved without further capital investment.

Jan 1, 2006

By Manlapig EV, Lawson F, Clarkson CJ

A low grade middling sample from Mount Isa, Australia, assaying 31.7 per cent zinc, 12.9 per cent lead and 14.5 per cent iron was leached under atmospheric pressure in sulphate and sulphate-chloride solutions with ferric ions as oxidants. About 96 per cent of the contained zinc was dissolved into a 0.5 M H2SO4 - 0.5 M Fe2(SO4)3 solution at 90¦C within three hours from a five per cent by weight slurry density mixture. The leaching process is very temperature-dependent, suggesting a surface chemical control. In the latter stage, the leaching rates levelled off and the leaching was most probably controlled by both surface chemical reaction and diffusion processes. The addition of chloride ions in the leach solution resulted in an increase in the leaching rate. About 95 per cent of the lead sulphide contained was converted to lead sulphate which precipitated and remained in the residue. Essentially no lead remained in solution and the low chloride concentration did not affect the precipitation of lead sulphate. Half of the iron orginally present remained in the residue as pyrite although essentially all the cadmium and 90 per cent of the copper initially present were dissolved. Some three per cent of sulphide sulphur was oxidised through to sulphate, about 67 per cent was converted to elemental sulphur which can be recovered by solvent extraction, the rest remained in the residue mainly as pyrite. Ferric sulphate and sulphate-chloride solutions can be used to effectively leach finely ground lead-zinc middlings and other bulk sulphide concentrates. A complete separation of zinc from lead and silver has been demonstrated.

Jan 1, 1993

In contrast to the '50s and '60s, the period of the '80s and '90s seems likely to have low growth in demand but much greater levels of technological change. In such a climate there will be pressure on costs, productivity will continue to rise and competitiveness will be closely associated with maintenance of the most effective technology. The penalties for inappropriate investments, whether short sighted or mistakenly based on a particular view of the future, will be greatly enhanced. Accordingly, there will be a need for significantly improved anticipation of technical change and thus for better planning. Study of the funding and direction of the world's R&D effort can provide a useful input to the planning processes within industries and individual firms. Such a study also suggests some insights into the characteristics of those countries which have achieved substantial growth and high standards of living over the past two decades. These characteristics may offer significant reminders for our own development. The particular implications for the Australian minerals industry include the need for direction that is sensitive to changing market requirements and customer practice. This is not simply "more of the same." In particular it appears essential for both basic and applied R&D to provide a sound basis for the purchase and ongoing development of the new technology required to achieve international Competitiveness.

Jan 1, 1986

By Han Kook-Nam, Lawson F

The recoveries of the three cobalt minerals in the Mount Cobalt deposit, cobaltite CoAsS, erythrite CO3(AS04)8H20, and new cobalt mineral with a composition approximating 2CoO.CaO.Fe203.2As205.11H2O were investigated using physical and surface-chemical processes.Over 80 per cent cobalt recovery was achieved by tabling a cobaltite-mineralized sample, while about 76 per cent cobalt recovery was obtained by dry feed magnetic separation of a sample containing erythrite and the new cobalt mineral. The resultant primary magnetic concentrate with a cobalt grade of 5.5 per cent, was able to be upgraded to 14.4 per cent cobalt by regrinding .and a further magnetic separation.Electrophoretic mobility - pH responses for each of the three cobalt minerals were found to be similar. Each mineral remained negative over the pH range 3 to 11 and was most negative at mildly alkaline pH values.Cobaltite was floated effectively with amyl and ethyl xanthate collectors under acidic conditions at collector concentrations of 10-2M to 10-5M. Erythrite showed a similar flotation response using 10-sM amyl xanthate. The practical application of these laboratory separations to an industrial process is suggested.

Jan 1, 1976

Mining companies often view water quality as an environmental issue. The importance of water quality as a production related issue in mineral beneficiation is greatly underestimated at many mineral processing operations. While most mine sites have comprehensive water balance data for water quantity, the information regarding the quality of water supplies available on site is limited, inadequate or non-existent. The seasonal variations in process water quality and changes in the composition of various water streams are not known. Despite the fact that water represents about 80 to 90 per cent of the volume of mineral pulp processed in a flotation plant, the influence of process water composition on flotation performance is often poorly understood. The process water used at mineral processing operations is made up from a number of available water sources, which can be classified as recycled water streams or make-up waters. The recycled water streams are commonly the tailings and concentrate thickener overflows, filtrate from the concentrate filtration plant and tailings dam return water. Make-up waters can originate from a variety of sources: surface waters (rivers, lakes, reservoirs, dams), groundwater (wells and springs), mains water (potable water), treated and untreated sewage waters and industrial effluents. Mineral processing plants are increasingly recycling water to reduce demand for fresh water and minimise the discharge of wastewater to the environment. However, increasing water recycling can have adverse effects on process water quality and ultimately on the performance of mineral separation processes. The main reasons for reduced plant performance due to water recycling are the accumulation of organic and inorganic compounds in the process water and increased microbiological activities. Other detrimental effects of water recycling can be increased reagent consumption and inefficient dewatering of tailings and concentrates. Recycling of water also tends to accumulate very fine suspended particles. Excessive amounts of slimes in the process water can also have an adverse effect on mineral beneficiation processes. The main constituents of process water are dissolved gases (oxygen, nitrogen, carbon dioxide), colloidal and suspended solids of inorganic and organic nature (including micro-organisms: dead or alive), dissolved organics (natural organic matter, residual reagents, reaction and decomposition by-products of chemical reagents, impurities in the reagents and metabolites originating from microbiological activities) and inorganic compounds (acids, alkalis, inorganic salts, metal ions, anions and heavy metals). Inputs to the chemical composition of process waters are: dissolution of soluble mineral phases present in the ore, surface oxidation followed by dissolution of mineral particles during grinding and mineral processing, the chemical composition of various make-up waters and recycled water streams, and reagent additions during mineral processing. The beneficial or detrimental impact of process water quality on flotation performance can be attributed to a number of subprocesses: adsorption and/or precipitation of inorganic and organic species present in the process water onto the surface of mineral particles, chemical reactions between process water constituents and the chemical species present on the surface of mineral particles and interactions between the chemical and microbiological species present in the process water and the various reagent species added in solution during mineral processing. Dissolved chemical species such as calcium, magnesium, iron, copper, lead, zinc, nickel, sulfates, phosphates and carbonates can have a strong effect on the electrokinetic properties of oxide and sulfide minerals, at certain pH ranges. Several reactions can occur at the solid-liquid interface that can play an important role in determining surface adsorption of reagents. Solid-liquid interfacial properties of mineral particles can be significantly affected by the conformation of adsorbed and precipitated reagent layers, which in turn are determined by solution chemistry. The chemical and microbiological constituents of process water can have a significant effect on liquid-gas interfacial properties and have a strong influence on froth height, strength and stability during flotation. Water chemistry can play an important role in determining the interactions between minerals present in the ore and the chemical reagents added in the mineral processing plant by altering the reagent-solution and mineral-solution equilibria. These interactions can include dissolution, micellisation and precipitation of reagents, dissolution of minerals contained in the ore followed by hydrolysis, complexation, adsorption and precipitation of dissolved chemical species and reactions between dissolved ions and various reagent species present in solution. All of the above mentioned subprocesses can ultimately have a significant effect on the efficiency of mineral processing operations. In this presentation, a systematic approach for assessing the composition of water supplies available at the mine sites and for investigating the influence of process water quality on the efficiency of mineral processing operations will be discussed. The consequences of mixing different quality water streams to produce the required volumes of process water for some flotation plants will be highlighted. To substantiate the water quality issues described in this paper some examples are given from a metalliferous processing perspective. However, the topics described in the paper are not only relevant to metalliferous processing but to all other type of mineral processing operations as well. In fact the principles described in this paper have also been successfully applied to the coal flotation industry.

Jan 1, 2006

By Campain RA, Horner NJ, Limerick JM

The review covers the different concepts of automation which are appropriate to non-ferrous smelting and the degree to which the smelter, and the furnace in particular, is amenable to total automation. Due to the problems peculiar to a smelter, it is unlikely that a fully closed loop system could ever be achieved and that the smelter will continue to depend upon extended manual control supported by computer based information sorting and optimisation.Generally, loop control is performed using Taylor's Mod III process control system. For distinct plant systems involving a combination of process loops, sequencing, and data acquisition, the company has developed its own microprocessor based systems. Process optimisation using computer based analysis of operating data is well established. Utilising this data, computer modelling provides manual set point supervision for the furnace process control system.The impact of automation on the workforce and on operating costs is also examined. Predictions on future developments in the field of automation, optimisation and sequencing are propounded and related to the non-ferrous industry at large.

Jan 1, 1985

The activiltion of sphalerite with electrolytically generated copper ions from a copper electrode instead of the usual practice of the addition of copper sulphate was studied in the laboratory. A large surface area of copper was provided by lining three sides of a bench flotation cell with copper sheeting. The lining was connected to the positive terminal of a low voltage d.c. source, and the cell impeller to the negative terminal.Sphalerite was effectively activated by this arrangement and was subsequently floated using xanthate as the collector.Flotation results comparable to those obtained with 1 lb/ton CuS04.5H20 (0,255 lb/ton copper) were obtained using 0·1062 lb/ton of electrolytic copper and 0·488 kWh of electrical energy. The wastage of copper due to the formation of insoluble precipitates was found to be dependent on the length of time the current was passed. Maximum current was passed for the shortest time to minimize wastage.

Jan 1, 1973

By Sheridan GD

Fifteen samples 'of clays and shales from the Adelaide area were selected from a total of 84 as representing material of possible value for the manufacture of light-weight aggregate. A detailed examination of the bloating. characteristics of these revealed four likely to be suitable. for expansion.' in a rotary kiln. One of these, a Tapley. Hill shale., was-fired in an 8 in. diameter rotary kiln, but con-tinuous bloating without ring formation in the kiln was not achieved. Steam,,-oxygen,, sulphur dioxide and carbon dioxide have been, suggested. as the agents of bloating. An examina-tion of .. the evidence : `leads to the conclusion that carbon dioxide derived from. carbonate minerals is likely to be the principal bloating agent. Attempts to bloat clays by the addition of mica were.not successful.

Jan 1, 1963

By Moore R

An intensive safety campaign at Mount Isa Mines Limited from 1956 to 1966 saw the lost time accident frequency rate fall to half its original level. A review of the safety programme was carried out in 1967 and in 1968 the Five Point Safety System was introduced. The seven years since its introduction have been years of significant achievement both in production and safety. Improving safety is a fundamental part of Mount Isa Mines Limited's policy and this system has been a major tool in implementing that policy. To be successful personnel need to be prepared and trained for its introduction and subsequently counselled on its use. A carefully prepared programme is required to phase in various aspects of the system and to make use of complementary steps. The system has been a success and it is anticipated that the continued drive to improve the use of principles of the system will further improve safety. It is hoped that this paper will be of value to those personnel concerned with industrial safety in Australia.

Jan 1, 1975

By Holliday RJ

The Imperial Smelting Furnace (ISF) was developed in Britain during the 1950's as a process which could produce zinc from a blast furnace. Since then it has evolved into an efficient means of producing zinc and lead from lower grade raw materials, both of primary and secondary origin. These changes have been in response to the need to improve the cost competitive position of the ISF in a climate of decreasing metal prices. The improvements at the Cockle Creek smelter of Sulphide Corporation Pty Limited have resulted from work undertaken in four main areas: 1. Changes in plant design and operating practice to give more stable furnace operation. 2. Improvements to the quality of sinter being charged to the furnace. 3. Improved monitoring of process variables and the formulation of control strategies based on the improved data. 4. Increased understanding of the processes occuring within the furnace shaft to allow predictive modelling to be undertaken. Work in these areas is still progressing but the work to date has resulted in a significant improvement in the production rate and efficiency of operation.

Jan 1, 1984

By M McLean

This paper deals with change strategies on brownfield and greenfield sites in extractive industries. It draws upon contemporary experiences across Australian, Indonesia and Papua New Guinea (PNG). Change strategies can be used when owners of an extractive industry operation want to optimise their resource. This paper draws upon many tried and proven theories and practices, including the findings of the Tavistock Institute (Trist, Emmery, Bamford, Jaques), as well as the concepts of Adult Learning espoused by Malcolm Knowles and is supported by learnings of Australian based management consultants. This paper reviews a range of approaches that have succeeded in the integration of systems, machines and people, with the key corporate objectives of: increasing productivity; decreasing cost; improving on-time delivery performance and achieving long-term survival. Such integration needs to be measured to show the outcomes from the change strategies and the authors have worked within many measurement regimes and metrics but for the most part, found that JaquesÆ set of metrics being æquality, quantity, resources and timeÆ has gained currency across many Australian operations. This paper contends that investing money in machines alone without a commensurate investment into the people side is counter-productive. Further, if there is not an understanding of processes, ie stable and capable, core and support processes, then all that new technologies will do, is to make what is done badly, only quicker. Recent interventions for the most part, have been cognisant of this balanced approach towards change management. The change strategies described are across extractive industry implementations, using a number of tools and techniques drawn from Continuous Improvement and Six SigmaÖ (registered trade and service mark of Motorola Corporation, USA).

Jan 1, 2006

By R van Berkel

Regional synergies concern the capture, recovery and reuse of by-products, water and energy between industrial operations in close proximity. The Centre for Sustainable Resource Processing (CSRP) undertakes applied research to further advance regional synergies in the Kwinana Industrial Area in Western Australia in order to achieve greater efficiencies in water, energy and materials consumption and reduction in waste and emission generation. The Kwinana Industries Council (KIC) and its member organisations recognise water consumption and disposal as key environmental issues. Some 30 companies in Kwinana consume a total of more than 35 000 ML/yr of fresh water. Over the past years significant progress has been made towards the reduction of water consumption and improvements in effluent disposal. As part of the CSRP Kwinana Synergies Project, water balances for the ten major water consuming companies have been completed, including workshop sessions with company staff on water synergy opportunities. This work resulted in a set of synergy opportunities which are currently being pursued. In parallel to the Kwinana project, the CSRP has commissioned a supporting project that delivers a toolkit to guide a more targeted and less resource intensive way to identify feasible water synergy opportunities. One of these tools focuses specifically on water, and takes count of input and output water flows within a given industrial area to deliver listings of prioritised water synergy opportunities. This paper discusses the water mapping and workshop approach taken in Kwinana and its outcomes, which are to identify and evaluate water synergy opportunities. The results from the trial application of the developed Regional Eco-Efficiency Opportunity Assessment Toolkit are also presented.

Jan 1, 2006

By T Martin, M Martin

Mining of sulfide-based ore deposits typically creates a potential for release sulfate and acid to groundwater, and many operating mines are thus predicted to require long-term post-closure treatment of groundwater. Toward the goal of selecting an optimal treatment, this paper compares costs of four demonstrated technologies for long-term treatment of sulfate-contaminated groundwater: in situ biological reduction (ISR), in situ permeable reactive barrier (PRB) composed of compost and zero-valent iron (ZVI), and two ex situ æpump-and-treatÆ technologies ù ex situ biological reduction, and ex situ nanofiltration with lime precipitation. Costs for each technology are estimated for treatment of a model aquifer system containing sulfate-contaminated groundwater, with the goal of treating 1 m3/min of groundwater from 1500 mg/L sulfate to a target level of 500 mg/L. (Metal removal is typically achieved by these technologies, and thus excluded from this analysis.) Costs are estimated for each technology as a function of treatment duration (ten to 60 years) and, for PRB and ISR, required replacement frequency (ten to 60 years). Estimated costs include capital and operation and maintenance, using a seven per cent net discount rate. Results indicate that ex situ technologies (biological reduction and nanofiltration with lime precipitation) are the most expensive. In situ technologies may be much less expensive, with PRBs having by far the lowest potential cost, followed by ISR as the next least expensive. However, actual costs for the in situ technologies are very sensitive to poorly constrained parameters, particularly the ZVI content of the PRB, and the effective life of PRB and ISR systems. This large cost uncertainty supports delaying remedial actions where viable, and suggests that feasibility analyses are generally warranted for specific applications to focus on these sources of uncertainty.

Jan 1, 2003

By N Vagias, R Shaw, M Coghill, W Easman

Rio Tinto Technology and the Rio Tinto Foundation for a Sustainable Minerals Industry have funded the development of a practical floating module that can reduce water losses through evaporation from water dams at mining and mineral processing facilities by about 75 per cent. The modules, which are also suitable for use by farmers and communities, were designed for easy deployment, to allow the water to æbreatheÆ, harvest rainfall and resist wind speeds of more than 100 km/h. A large-scale demonstration trial will be conducted at the Northparkes Mine, located near Parkes (New South Wales, Australia). The objective of the trial is to demonstrate to Rio Tinto business units, community, farming and government groups the moduleÆs operating costs and water saving potential.

Jan 1, 2006