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By L Ding, B Xu, C Wang

In this paper, we introduce the term ‘LJC’ to refer to the LJC Automatic Magnetic Flotation Separator, which is an advanced technology developed by Longi Magnet, integrating various techniques such as hydro separation, magnetic flocculation, and magnetic columns. This technology combines gravity, hydro separation, and magnetic separation to achieve efficient and reliable separation processes. With its low maintenance requirements and high reliability, the LJC technology has proven to be effective in magnetite processing. The LJC technology offers two primary benefits when compared to traditional magnetic drum separators. Firstly, it can enhance the quality of the targeted or improved concentrate at a coarser product size by minimising the carryover of gangue minerals into the concentrate. Secondly, it can significantly improve the concentrate quality (eg achieving >67 per cent Fe) while maintaining similar liberation size and mass yield. In China, this technology has been widely adopted in magnetite processing, replacing traditional magnetic drum separators and fines flotation in the final stage of the process. Through collaboration with a magnetite producer in Western Australia, Longi Magnet successfully implemented the next-generation LJC Automatic Magnetic Flotation Separator to replace the original stage 3 magnetic drum separators. The application of the LJC technology resulted in an increase in product P80 from 32 μm to 43.1 μm, while maintaining a final concentrate grade of 65 per cent Fe. Additionally, the power consumption, measured in kWh per tonne of concentrate, was reduced by 10 per cent. By eliminating the bottleneck caused by the requirement of a coarser liberation size to achieve the desired concentrate grade, the plant’s throughput was increased by significantly. The LJC technology has demonstrated its ability to reduce the carbon footprint, improve concentrate grade and enhance mass recovery, offering an alternative solution for magnetite processing. The high-grade magnetite produced by the LJC technology is particularly suitable as a raw material for Directed Reduction Iron and green steel production. This paper introduces the principles of the LJC Automatic Magnetic Flotation Separator and provides details of its application in a magnetite operation in Western Australia.

Sep 18, 2023

By D Gerrard, J Begelhole, J Gerber

The Iron Magnet deposit has been mined since 2007 when Arrium (then OneSteel) commissioned the magnetite concentrator to supply feed to the pelletising plant in Whyalla. The concentrate quality requirement for the customer required consistent product with minimal variability. In the early stages of operation, it was identified that the feed variability introduced significant changes in the concentrate quality, which was outside the acceptable customer limits.In 2011, a geometallurgical regression model was developed that allowed for the estimation of concentrate quality produced from the feed material. This was based on a laboratory-scale Davis Tube Recovery (DTR) test performed on the feed material. The objective of the project was to characterise the raw ore in the pit to allow for blending prior to crushing. By blending the feed to the concentrator, minimal concentrate quality variation within the plant was achieved. The orebody was divided into geometallurgical classes, called ore types, based on the mineral texture and magnetic mass recovery. Each geometallurgical class consisted of material with similar metallurgical performances. For each individual blast pattern, the ore was grouped into the geometallurgical classes and a composite sample was created. The composite sample was put through the laboratory-scale DTR test and the results were used to estimate the metallurgical performance of the material.The characterisation process and feed pile build methodology was applied in early 2013 and went through an optimisation and streamlining phase. Since the implementation of the geometallurgical characterisation process, the plant has seen a significant reduction in concentrate variability and measurable throughput gains. The characterisation process has also increased the amount of material that is now classified as ore.CITATION:Gerber, J, Gerrard, D and Begelhole, J, 2015. Geometallurgy of the South Middleback Ranges magnetite deposit – predicting plant performance from the pit, in Proceedings Iron Ore 2015, pp 555–560 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

The optimisation and validation of shearer cutting methods is a time consuming engineering task. Many different parameters, of which not all can be controlled, can vary. The easiest solution, to increase the installed power and the longwall length, is not always the best. A different cutting method can increase the capacity without the need of new machines. The Department for Mining and Metallurgy Machinery at RWTH Aachen University therefore developed ProSL, the simulation tool for shearer and longwall operations. ProSL enables the engineer to create his own cutting methods and compare it with other methods. Machine-data can easily be varied to see the impact on the method. The research shows that sophisticated longwall methods increase the productivity of the system. The paper presents the results of the calculation with ProSL and shows how higher efficiency and lower costs can be achieved.

Dec 6, 2010

By G Collecutt, D Proud, D Humphreys

"The hazards associated with dust explosions are well known, and coal dust explosions present a significant hazard in the underground coal mining industry worldwide. In earlier work, we presented computational fluid dynamics (CFD) simulations and test results for coal dust explosions within a 2.5 m diameter circular gallery, along with CFD simulations and test results for the suppression of these explosions with finely atomised water sprays. In this paper, we present refinements to the CFD modelling that yield a significantly improved calibration with the test results, and proceed to investigate by CFD the requirements for suppression of a coal dust explosion in a typical underground roadway. This work was carried out under an ACARP project and we gratefully acknowledge their assistance. CITATION: Proud, D, Collecutt, G and Humphreys, D, 2015. Computational fluid dynamics modelling of coal dust explosions and suppression systems, in Proceedings The Australian Mine Ventilation Conference, pp 309–314 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 31, 2015

By H Q. Zhang, M C Chai, W Fu, H Y Chen, L M. Wei, Q J. Yang

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Fozichong deposit – located in the south-western segment of the giant Qinhang metallogenic belt, South China – is a large-sized lead-zinc polymetallic deposit. This deposit contains two main ore districts, termed as the Guyi ore district in the north and the Hesan ore district in the south respectively. We present an integrated data set on sulfide minerals, fluid inclusions and stable isotope (H-O-S-Pb) geochemistry to better understand the features and genesis of the Fozichong deposit.Field and paragenetic relationships indicate three mineralisation stages forming the early (Po+Sp+Gn+Ccp+Py+Di+Ep+Qtz), middle (Sp+Gn+Ccp+Py+Ep+Chl+Qtz) and late (Gn+Sp+Py+Qtz+Cal) sulfide assemblages respectively. Mineral chemistry – particularly S/Fe and Co/Ni ratios in pyrite, Zn/Fe, Zn/Mn and Zn/Cd ratios in sphalerite and Pb/Ag ratios in galena – indicates a magmatic association for the sulfide minerals.Quartz and calcite coexisting with the sulfide minerals of various stages host abundant fluid inclusions. Quartz in the early stage contains two- or three-phase CO2-H2O and liquid-rich aqueous inclusions, which have homogenisation temperatures of 162~365°C and salinities of 2.9~17.8 wt per cent NaClequiv, whereas quartz and calcite from the middle and late stages are dominated by two-phase, liquid-rich aqueous inclusions that have slightly lower homogenisation temperatures (153°C~320°C) and much lower salinities (1.0~6.0 wt per cent NaClequiv). Hydrogen isotopes (dD = -59‰~-41‰), analysed using fluid inclusion waters from quartz and calculated oxygen isotopes (d18OH2O = -5.47‰~4.00‰) for the equilibrated ore fluids, indicate that the ore-forming fluids may have been sourced from magma and mixed with groundwater in the late stages. Sulfide minerals have d34S values of 2.3‰~4.3‰, consistent with a magmatic-derived source for sulfur. Lead isotopes (206Pb/204Pb = 18.592~18.794, 207Pb/204Pb = 15.648~15.864, 208Pb/204Pb = 38.909~39.580) confirm that lead and, by inference, zinc were mainly derived from magmatic rocks, with subordinate contributions from sedimentary rocks.Various lines of evidence support that the formation of the Fozichong deposit has close genetic association with the granite porphyry intruded in the late Yanshanian period (106 Ma), and it can be classified as a magmatic hydrothermal type lead-zinc deposit. We propose that the Hesan and Guyi ore districts may represent the proximal and distal products of a magmatic – hydrothermal system respectively.CITATION:Fu, W, Zhang, H Q, Chai, M C, Yang, Q J, Chen, H Y and Wei, L M, 2015. Genesis of the large-sized Fozichong lead-zinc polymetallic deposit, Guangxi, south China – constraints from the sulfide mineralogy, fluid inclusions and isotope geochemistry , in Proceedings PACRIM 2015 Congress, pp 609–614 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By G P. W Suyantara, Y Tanaka, T Hirajima, Y Aoki, K Sasaki, H Miki

The effect of sodium sulfite (Na2SO3) on the flotation behaviour of bornite and tennantite is reported in this work. Flotation tests were performed using pure minerals of bornite and tennantite under various concentrations of sodium sulfite at pH 9. The flotation results indicated that sodium sulfite exhibited a depressing effect on the floatability of bornite in the presence of 0.1 mM PAX. However, tennantite remained floatable after the addition of sodium sulfite in the presence of 0.1 mM PAX. The flotation tests using mixed bornite and tennantite confirmed the flotation results of single minerals. Surface characterisation using X-ray photoelectron spectroscopy (XPS) was performed to explain the flotation results. A mechanism is proposed based on the XPS analysis results.

Aug 24, 2022

By M Paine

Work to date has shown that the use of Al2O3:SiO2 ratios is suitable for identifying potential gibbsite bearing samples. Subsequent confirmatory XRD analysis helps to refi ne this initial identification. Based on these methods, gibbsite has been mapped in two common settings:1. along steeply dipping faults, or2. in association with stratigraphic contacts where one unit is aluminous (eg dolerite dyke).On a microscale, the samples studied illustrate an association between haematite, and to a lesser extent goethite, and gibbsite. In these samples the dominant forms of haematite are discrete crystalline phases of either microplaty haematite or euhedral martite. Two dominant forms of gibbsite were observed:1. vein style gibbsite that cross-cuts (or infill’s cracks) in goethite ± martite iron oxide associations, or2. gibbsite intimately intergrown with and forming a matrix to microplaty haematite.Some of the gibbsite microstructures observed suggest that it may have formed during a very hydrous, possibly hypogene, stage of the deposit genesis. The presence of this crystalline gibbsite, and in particular its occasionally euhedral form, suggests that aluminium was at some stage remobilised, at least locally, and then precipitated from solution as gibbsite. These observations suggest that these has been a phase of gibbsite precipitation that may have had a close but complex relationship with regards to the timing of the mineralisation processes, rather than formation as a result of late stage lateritic weathering.

Jul 11, 2011

By Z-Y Pi, B Zhang, S Wen

"The paper introduces the structure and work processes of outside auger hollow claw tipped mechanical sampler for coal. Twenty sets of claw tipped sampler performance tests show that: The design of inner hollow cylinder-type (?180 mm) can ensure to take a coal sample with nominal top size of 60 mm. Built-in self-cleaning piston pusher ensures no adherence and blocking of the sample. The operation practices show that the mechanical sampler can operate in order for taking coal sample with up to 16 per cent of total moisture. Claw closing design can avoid sample leaking or spilling during the claw lifting and ensure the integrity of primary increment. Ultrasonic positioning device makes the sampler capture the materials no less than 10 cm from the bottom of the wagons, basically meeting the requirement taking full depth of the sample. The precision and bias test indicates that the moisture and ash have no relative bias under the sampling process; the sampling precision is in accordance with the requirement in IS013909.At present, the spiral mechanical sampler is widely used for coal sampling but there are many limitations during application, for example: It is difficult to capture a large size sample, so the size range of a coal sample taken is limited. There is easy adhering or blocking for high moisture coal, which will result in the mixture of different increments, wear of sampler and the difficulties for cleaning and maintenance of sampler. It is difficult to capture the coal sample at lower than 30 cm from the bottom of the wagons, in order to avoid damage of the vehicle. It is possible for coal sample loss and spilling during the sampler lifting, due to the unsealed sampler.For the outside auger hollow claw tipped mechanical sampler designed for solving the above problems, the opening distance of the claw is the opening size of the sampler and makes the size range of the coal sample to be taken wide. During sampling, the two pieces of claws open and the sampler rotates vertically downward to capture an adequate coal sample after reaching the specific point. Then the two pieces of claws close tight automatically to ensure there is no coal leaking or spilling. The inner pusher of the sampler will prevent from the adherence and blocking of the coal sample effectively.CITATION:Zhang, B, Pi, Z-Y and Wen, S, 2012. Outside auger hollow claw tipped mechanical sampler for coal, in Proceedings Sampling 2012, pp 41-44 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 21, 2012

By S Henderson

The Otago Goldfield has produced approximately 8 million ounces of alluvial gold and over 2.5 million ounces of hard rock gold and is currently home to New ZealandÆs largest producing gold mine. In the eyes of explorers this production history makes the goldfield a good place to explore.   Modern exploration in the Otago Goldfield commenced in the late 1970s with the exploration for tungsten. However, a rapid rise of the gold price in the early 1980s saw the focus shift to the exploration for gold which lead to the discovery of the Macraes Gold Project in 1984, which since it came into production in 1990 has been New ZealandÆs largest producing gold mine. With the exception of the Macraes Gold Project, exploration continued in the Otago Goldfield for a further 20 years without further success.   In 2006, Glass Earth (NZ) Limited (Glass Earth) reviewed all the exploration technologies applied to the Otago region and available geological data, including the 1996 OceanaGold Helicopter Electro-Magnetic (HEM) data, and concluded that combined magnetics and HEM were able to delineate the Hyde Macraes Shear Zone (HMSZ) which hosts the Macraes Gold Project. Unlike previous explorers who explored the Otago region in a piecemeal manner, Glass Earth opted to collect a new, region-wide dataset which could be integrated with all previous collected geological information to come up with new exploration concepts and targets. As part of this process, Glass Earth applied in mid 2006 for New ZealandÆs largest on-shore gold Prospecting Permit, PP39-322 which was subsequently granted in November 2006. In mid January 2007, Glass Earth commenced acquisition of approximately 50 000 line kilometres of HEM data, making the Otago regional aerial geophysical survey (survey) the largest aerial geophysical survey ever undertaken in New Zealand.   This paper will report on the progress of the Otago Regional aerial geophysical survey and outline some of the preliminary findings from what is still a work in progress.

Jan 1, 2007

By S Pradhan, A Kuras, R Mahajan

This paper describes the design of the precast concrete segmental lining for the 13.1 m internal diameter and 450 mm thick, 2.4 km long mainline tunnels for the Waterview Connection project in Auckland for the New Zealand Transport Agency.The design and detailing of this segmental lining presented some noteworthy challenges, including an alignment that has sections of low cover in soft ground. Key points of interest are that this precast segmental lining is the largest to ever include steel fibres as the primary method of reinforcement and the lining includes cams on circumferential joints to control ring deformation.The paper describes some of the key design decisions that were made in a collaborative manner with the construction team, tunnel boring machine manufacturer, segment manufacturer and the designers.CITATION:Mahajan, R, Kuras, A and Pradhan, S, 2014. Design of segmental lining for Waterview Project, Auckland, New?Zealand, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 289–294 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By M A. Llano-Serna, D J. Williams, L Bu

Tailings dam failures continue to occur worldwide at an unacceptable rate, averaging two events annually over the last 100 years. Furthermore, tailings dams continue to grow in size, increasing the potential release of tailings and water should they fail. Tailings are generally deposited in a slurry state, with the potential to flow if containment is lost. Understanding the generation and propagation of excess pore water pressure on failure is critical to predicting the flow and run-out of tailings. This paper presents numerical modelling using the material point method indicating that tailings run-out processes may be self-enhanced by the excess pore water pressure induced during the collapse of the containment. Moreover, it is shown that geomorphological features, such as the slope and its surface roughness downstream of the tailings dam, influence the pore water pressure dynamics upstream of the advancing toe.CITATION:Llano-Serna, M A, Bu, L and Williams, D J, 2018. Excess pore water pressure induced during tailings run-out, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 377–383 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By A Sadri, S Smith

In the metal and mineral industry, different empirical techniques are used to estimate the remaining thickness of the lining within an operating furnace. The disadvantage and costly factor when using these methods is that production needs to be halted. Hatch has developed an accurate and reliable technique based on stress wave propagation principles to determine the condition of the remaining lining whilst the furnace remains online and operational.The technique involves test data collected and compiled to generate 3D imagery used to assist operators and maintenance planning personnel with valuable information showing areas of metal penetration in the lining, remaining lining thickness, exact location of voids, cracks, poor contacts and deterioration due to chemical attack. In this paper, the principals of the AU-E technique will be explained both theoretically and practically. In addition, the use of ultrasound technology for determining the condition of copper cooling elements will be briefly addressed.

Jan 1, 2006

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 S Maritsa, D Simbi, E K. Chiwandika, S M. Masuka

The steel industry is facing challenges on a global scale that include depletion of resources, huge energy consumption, and the emission of CO2. The demand for iron products is increasing due to the increased infrastructural development. Zimbabwe produced cast iron from scrap metals. However, there is currently a shortage of scrap, and yet Zimbabwe is rich in limonite ores that are currently being underutilised. The possibility of using limonite ore as a sustainable feed for pig iron production was investigated by preparing some limonite ore carbon composite pellets. The results showed that the addition of coal to the limonite ore and calcium carbonate mix to form the composite pellets resulted in a decrease in the drop number as well as the dry compressive strength of the composite pellets. This research aims to improve the physical properties of the green pellets by the careful addition of hydroxyethyl cellulose as a binder that was found to improve the physical properties of the green pellet. This is important for materials handling during the production process of the composite pellets. Results showed that the drop number was substantially improved by the addition of 0.4 wt per cent hydroxyethyl cellulose while the dry compression strength improved from 2.5 kg/pelIet to around 23 kg/pellet irrespective of the amount of binder added. The binder improved the physical strength of the iron-carbon composite pellets enough to allow for large-scale production of the pellets that can be an alternative and sustainable feed for cast iron production. However more results on the indurated compression strength and other properties such as the reduction degradation index, swelling index, and the reducibility test are required.

Jun 19, 2024

By D Brown, K Markovic, Z Tabor

From ancient times to the modern world, the mining industry has played a pivotal role in shaping the society that we live in today. It remains an integral part of everyday life and is a catalyst for both technological and economic growth. With finite resources on Earth, and growing pressures surrounding climate change and the environment, space mining opportunities have become of increasing interest. Recent discoveries have shown celestial bodies including the Moon and surrounding asteroids, contain an abundance of critical minerals, as well as resources necessary to sustain human life. These discoveries coupled with a transition into the digital and autonomous age, offer an innovative solution to solving some of the mining challenges currently being faced on Earth. Similarly, they also offer a pathway to enabling deep space exploration and off Earth exploratory missions. However, like with mining operations on Earth, space remains and immensely challenging and complex operational environment. The inhospitable nature of space poses new challenges, including communication barriers, lunar dust, cosmic radiation, and gravity. The challenges and risks are not just technological, as Environmental, Social, and Governance (ESG) factors must also be considered to prevent unintended consequences and hazards. Furthermore, future workforce, law, financial, and security systems must evolve to enable space mining to take place. These are all known aspects to begin with, but as the complexity of the space grows it becomes apparent that a holistic approach to assess and manage these factors will be required.

Sep 1, 2024

By A K. B Chigwada

Mining organisations grapple with the same problems year after year, wasting incredible amounts of time and money. According to estimates from the International Labour Organization (ILO), over one million work-related deaths occur annually, and hundreds of millions of workers suffer from workplace accidents and occupational exposure to hazardous substances worldwide. Many accident reports cite human failure as a primary cause (Busse and Johnson, 1998). The workers at the Bhopal chemical plant pumped methyl isocyanate into a leaking tank (Morehouse and Subramaniam, 1986). On 3 December 1984, more than 40 tons of methyl isocyanate gas leaked from a pesticide plant in Bhopal, India, immediately killing at least 3800 people and causing significant morbidity and premature death for many thousands more. The company involved in what became the worst industrial accident in history immediately tried to dissociate itself from legal responsibility (Broughton, 2005). Australia is not spared from safety problems either (Lucas, 2022). The ILO Convention 176 (1995) as a response provides that national law should inter alia provide for the supervision of safety and health in mines; the inspection of mines by designated inspectors of the competent authority; the procedures for reporting and investigating of fatal and serious accidents; the compilation and publication of statistics on accidents, occupational diseases and dangerous occurrences; the competent authority to suspend or restrict mining activities on safety and health grounds until conditions giving rise to the suspension are addressed; and worker consultation on matters related to safety and health in mines. This has assisted in getting enough data to define the magnitude of the problem to the mining sector.

Apr 16, 2024

Blasthole cone samples are used for grade control in most of the iron ore mines of the Pilbara of Western Australia. This method of sampling is straightforward when the target sampling interval matches the mining bench height but is problematic when the blasted bench is 'flitch' mined in two or more passes. Crucially, the sampler needs to decide which part of the blast cone represents the upper and lower flitches to be mined. This sampling selection decision is usually made by assuming a certain proportion represents the subdrill component of a sampling face in a blasthole cone and the two flitches are split equally from the remaining portion. In this study of a West Australian channel iron deposit, sampling experiments were carried out to determine the actual proportions of a sampling face in a blasthole cone by spray painting the blast cones at flitch and subdrill boundaries during the drilling process. Measurements were then taken to assess the differences between assumed sampling face proportions and actual proportions. A set of paired samples was also collected from a number of blastholes with one set using the assumed proportions of each flitch for each sample, while the other set sampled the actual proportions, which were identified from the cone painting process.

Mar 1, 2010

By F C. D Michelin

As mines get deeper, the critical underground temperature limits will be exceeded, and an increasing number of mines will need to implement, expand or modify cooling systems. Surface cooling plants have many advantages over underground cooling such as efficient heat rejection, and lower relative capital cost; however the delivery of cooling through long underground distances can result in lost refrigeration capacity before the chilled air reaches the areas it is needed most. Refrigeration plants are therefore often overdesigned in size and capacity to compensate for underground losses.More mines are now utilising real-time monitoring and automated control of ventilation airflow and fan systems to ensure the conditions underground are safe and productive, and power consumption is efficiently managed. There may be significant opportunities to extend ventilation monitoring and control into the refrigeration delivery and control system.Energy reduction is an effective way to reduce costs and CO2 emissions, which is an increasingly important part of corporate governance. More efficient refrigeration control is a further step toward reducing energy consumption. This paper looks at an added step in how real-time monitoring can assist in controlling the output and chilled air delivery of a cooling plant. The requirements, implementation, benefits and challenges will be discussed.

Oct 12, 2022

By H Arvidson, A Walker, N Pollock

Following the recent tailings tragedy in Brumadinho, the Investor Mining and Tailings Safety Initiative was formed representing institutional investors in the mining industry. This Initiative, led by The Church of England (CoE), requested data from 726 mining companies on each of their Tailings Storage Facilities (TSFs). What this exercise confirmed was that there was no public database of TSFs, and that there was a clear gap in tailings management systems within the disclosing companies. We present an approach using technology to support best practice TSF management, governance and disclosure which was originally submitted as part of University of Cambridge Post-graduate studies in Sustainability Leadership in January 2020. The aim of the paper is to discuss how technology could be used to deliver a Tailings Management Solution (TMS) that is aligned with the Global Industry Standard on Tailings Management (GISTM), and supports rigorous governance leading to disclosure. Subsequently the goals of the plan are aligned with that of the co-conveners of the GISTM (the International Council on Mining and Metals (ICMM), Principles for Responsible Investment (PRI) and United Nations Environment Program (UNEP)) which is to facilitate operators’ trajectory towards zero harm to people and the environment. Most of the focus to date around tailings management post Brumadinho has been on monitoring technologies, of which there are many. It is obviously important to acknowledge the critical role of monitoring technologies; however, our approach is agnostic to monitoring technologies and assumes that all of them are relevant. Our focus is on the data management, reporting and governance leading to disclosure of the information. Critical components of developing the TMS include adapting existing software products and solutions, recognising a system thinking approach is needed, strategic partnerships to deliver an accessible solution faster and more cost effectively, and, new ways of collaborating. The TMS should also accommodate relevant regional geotechnical codes and standards. The industry need for a TMS is well established and urgent, with significant pressure from regulators and civil society for the industry to address this significant issue.

Jul 1, 2021

By O Arafat, K M. Bartholomew

A voracious consumer of energy and grinding media, the modern ball milling circuit has a huge direct cost impact on a mineral processing operation. Through optimisation, grinding also has the potential to unlock great improvements in recovery and throughput, but how can the complex interactions between mills, classifiers, tonnage, ore-type and downstream recovery be measured, understood and managed in a systematic manner?Functional performance analysis provides the tools and insights needed to measure, understand and improve the two key process efficiencies in ball milling circuits: classification system efficiency (CSE) and mill grinding efficiency.CSE measures the composite performance of the classification system as a whole. In short, the purpose of the classification system is to ensure that grinding mill energy is used to grind coarse particles while minimising overgrinding. CSE is simple to measure in the plant and it provides immediate feedback to the plant metallurgist, mill superintendent and management about the performance of the classification system and the amount of wasted energy in the grinding plant.Mill grinding efficiency measures the capacity of the grinding mill to convert feed-sized material into product-sized material on a tonnes per kilowatt hour basis. It is normalised based upon the ore resistance to breakage, so it provides feedback about the ‘health’ of the milling process under varying operating conditions and ore types. Mill grinding efficiency is measured at the same time as CSE through circuit sampling.Functional performance analysis combines CSE and mill grinding efficiency to provide a measureable, manageable optimisation objective. It also provides a link to tonnage, ore type and recovery. As a result, systematic optimisation of a grinding circuit is a measureable and manageable process to meet business objectives.CITATION:Bartholomew, K M, McIvor, R E and Arafat, O, 2014. Functional performance of ball milling circuits – a plant metallurgist’s tool for process characterisation and optimisation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 227–232 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014