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By James D, Dawson N

The alternate mineral dressing tech-niques for the production of ilmenite roaster feed from heavy mineral concentrate and the reasons for the selection of wet high intensity magnetic separation (WHIMS) at Richards Bay Minerals are outlined.Initial flowsheet studies were under-taken using laboratory scale equipment followed by on site pilot testing. Flowsheet development culminated with an extensive test programme conducted at Readings of Lismore in 1975.

Jan 1, 1986

By Bronson B

The geotechnical and environmental aspects of heap leaching are very closely tied during design, operations and closure. Potential environmental impacts from heap leaching are mostly due to land disturbance and water quality issues, including both groundwater and surface water. Water quality issues are mostly related to containment design, which is primarily a function of proper sizing of the facilities and site specific liner design. Geotechnical analyses is the dominant discipline in providing cost efficient, operationally effective and environmentally sound heap leach facility designs. Much has been published on geotechnical aspects of heap leach design, for example Van Zyl, Hutchison and Kiel (1988) and Van Zyl (1987). This paper will emphasize a few specific aspects related to the geotechnical and environmental consideration for heap leach projects. These aspects are: ò site investigation; ò containment design; ò slope stability; ò heap flow dynamics; and ò closure design. Design of a heap leach project must consider not only the operating life but also closure and post-closure considerations. As a matter of standard practice, designing for closure is an extremely important concept. Not only is it important for environmental aspects, but experience also shows that projects designed for closure will be overall more economical for the total life cycle of the project. Closure considerations are also important during project feasibility evaluations to ensure that total life cycle costs are evaluated.

Jan 1, 1994

By L Vimercati, R Williams

Transitioning to a green future requires the mining industry to adopt sustainable practices. Filtered tailings are become a key expectation of the communities we operate in and are growing in a number or mining commodities including bauxite, nickel, gold and iron ore. The filtration technologies required range from dewatering screens to vacuum and pressure filters. Particular challenges faced in iron ore applications include large scale which means several units of large size are often required. In addition, a high specific gravity that cause sedimentation issues and a high abrasion level make demands on achieving reliability level at above 90 per cent. This paper describes the testing, selection criteria and specific features required to provide a rational option for equipment and plant design. An example of how this has been applied in an iron ore application in Brazil is used to demonstrate a successful outcome. This project installed four overhead beam filter presses each producing around 200 t/hr utilising a recessed chamber plate, feed pressures up to 15 bar, cake thickness of 5 mm. The moisture lower than 20 per cent that was produced was considered to provide material with handling and geotechnical properties to guarantee a safe stacking. Regular high pressure washing at 100 bar was considered imperative to maintain cloth life and process performance. The correct management of the system (OPEX control) by PLC control ensures a balance between machine potentials and plant needs. With this equilibrium it is possible to limit mechanical wear preserving equipment lifetime.

Sep 18, 2023

The geotechnical and environmental aspects of heap leaching are very closely tied during design, operations and closure. Potential environmental impacts from heap leaching are mostly due to land disturbance and water quality issues, including both groundwater and surface water. Water quality issues are mostly related to containment design, which is primarily a function of proper sizing of the facilities and site specific liner design. Geotechnical analyses is the dominant discipline in providing cost efficient, operationally effective and environmentally sound heap leach facility designs. Much has been published on geotechnical aspects of heap leach design, for example Van Zyl, Hutchison and Kiel (1988) and Van Zyl (1987). This paper will emphasize a few specific aspects related to the geotechnical and environmental consideration for heap leach projects. These aspects are: ò site investigation; ò containment design; ò slope stability; ò heap flow dynamics; and ò closure design. Design of a heap leach project must consider not only the operating life but also closure and post-closure considerations. As a matter of standard practice, designing for closure is an extremely important concept. Not only is it important for environmental aspects, but experience also shows that projects designed for closure will be overall more economical for the total life cycle of the project. Closure considerations are also important during project feasibility evaluations to ensure that total life cycle costs are evaluated.

Jan 1, 1994

Continuous, steady-state laboratory flotation tests showed that the recovery of cha1copyrite from a naturally occurring ore, under conditions closely resembling those of plant practice, could be expressed in terms of a first order rate equation.Tests on full-scale plant flotation cells, using impulse tracers, indicated ideal mixing of the pulp in the cells.It was demonstrated that values of first order flotation rate constants can onlv be obtained from conventional methods of analysis in special cases.Analysis of a plant sampling campaign by the author supported a first order kinetic equation for two mineral species, and for the individual size fractions of one of these.The effect of stage-addition of reagents is interpreted in kinetic terms.

Jan 1, 1966

By R B. Wanty

Historically, most investigations of biogeochemical cycling in acid rock drainage systems involved synoptic sampling over longer time periods (one sample per week or month) or intensive time series studies over a few hours or days. However, many important episodic loading events, such as seasonal meltwater and storm events occur on timescales that are rarely observed by these traditional sampling approaches. Monitoring these transient processes, which may contribute the bulk of the annual metal loading, is essential for accurate assessment in acid rock drainage areas. Recent work also has demonstrated dramatic diel (24 hour cycle) variations in trace metal concentrations in response to diel changes in temperature, pH, oxygen, and photochemical cycling (Brick and Moore, 1996; Nimick et al, in prep). To characterise a system that may respond to diel, seasonal, and episodic events, a monitoring program must sample at a frequency that captures the details of these major forcing events. We developed two novel instruments, the Zn-DigiScan and the DigiSampler to examine low and high frequency temporal changes in acid rock drainage areas. The Zn-DigiScan is a battery powered real time in situ chemical analyser designed for long-term deployments with hourly analyses of Zn. Stream physical parameters (temperature, conductivity, dissolved oxygen, pH, turbidity, etc) were measured every 15 minutes with a water quality sonde. The DigiSampler was developed for the long-term daily sampling of biogeochemically active elements and can take either discrete samples or samples integrated over 24 hours. The DigiSampler collects 2 ml samples in a Teflon coil which are separated by 0.2 ml nitrogen bubbles. The sample coil is returned to lab and the 2 ml samples are diluted 1:10 and analysed for trace metals by ICP-MS. Initial results from a three-day deployment at Fisher Creek, MT, USA have successfully demonstrated the ability of the Zn-DigiScan to record Zn concentrations at levels below 100 ¦g/L. Zinc concentrations measured at 30 minute intervals in Fisher Creek showed a diel cycle with low values of ~25 ¦g/L in the late afternoon and increasing to ~60 ¦g/L by early morning. Zn concentrations were inversely related to temperature and pH, suggesting that temperature and pH dependent adsorption was the main factor controlling diel Zn fluctuations. Initial deployment of the DigiSampler also was successful, revealing diel cycles in Zn, Cu, and Mn. Comparison of trace metal samples collected by the DigiSampler showed good agreement with samples collected by an Isco automated water sampler, demonstrating that the DigiSampler can collect clean samples for trace metal analysis at the low ¦g/L range.

Jan 1, 2003

By N Mangadoddy, P Jampana, S Diddi

The study of air-core dynamics in hydrocyclone operation is essential for predicting separation efficiency in mineral processing. Electrical resistance tomography (ERT) allows non-invasive measurements of hydrocyclone internal flow dynamics. Existing regularisation methods such as Gauss-Newton and TV norms rely on optimisation techniques which have very high computational cost for very fine meshes. In contrast, the monotonicity method has much lower computational cost as it does not solve such minimisation problems. In this paper, results from the monotonicity method, Gauss-Newton (GN) (Tikhonov) and Total-Variation (TV) norm-based minimisation methods for estimating the air-core diameter in hydrocyclones are compared. We study these methods on the laboratory hydrocyclone experimental two-phase flow data. The results obtained are validated against High-speed video (HSV) imaging and Computational Fluid Dynamics (CFD) results. The results on different mesh sizes, in particular for very fine meshes with the number of cells ranging from 30 000 to above 100 000 are also investigated. The data used in this study is obtained from ITS Z8000 ERT system. This system does not measure the voltages on the current carrying electrodes. Since these voltage values are required for the monotonicity method, we implement an interpolation method to compute them. The results show that the monotonicity method provides a closer approximation of the interface between air and the water phases.

Aug 24, 2022

By R McCarthy, P Hawke

FerrAus Ltd's Robertson Range and Davidson Creek Projects are located in the Hamersley Province about 100 km east of Newman, Western Australia. Significant iron mineralisation defined by an aggressive exploration program within the Marra Mamba Iron Formation is shallowly north dipping at Davidson Creek, and mainly shallowly east dipping at Robertson Range, forming part of a regional scale anticline with the granitic and greenstone basement of the Sylvania Inlier as its core. With minor exceptions, the stratigraphy is comparable with that seen in the main Hamersley Basin. Granite and greenstone basement rocks of the Sylvania Inlier are unconformably overlain by shales and volcanic rocks of the Fortescue Group. The overlying Hamersley Group is locally represented by interbedded chert, banded iron-formation (BIF) and shales of the Marra Mamba Iron Formation (Nammuldi, MacLeod and Mount Newman Members), and dolomites, cherts, BIF and shales of the Wittenoom Formation. Iron enrichment occurs predominantly in the Mount Newman Member, and to a lesser extent in the West Angela Member of the Wittenoom Formation. Enrichment varies from 20 - 30 m in thickness in elongate bodies up to 3 km in strike length, and generally thins down dip. At Davidson Creek iron mineralisation is a haematite-goethite-ochreous goethite assemblage, while at Robertson Range this assemblage is consistently overprinted by a later, goethitic alteration related to 'hardcap' weathering. Near surface hardcap alteration in both project areas comprises more siliceous, aluminous and vitreous goethite. Initial exploration completed by Rio Tinto Exploration between 1999 and 2001 indicated the potential for about 20 Mt of iron mineralisation at Robertson Range. Since 2005 a detailed exploration program undertaken by Australian Manganese Pty Ltd (a wholly owned subsidiary of FerrAus Ltd) has defined a global indicated and inferred resource totaling 164.4 Mt at 58.6 per cent Fe (ASX: FRS 17 April 2009).

Jan 1, 2009

By C Zschiesche, alam, A Abadias Llamas, A K

An integrated experimental and thermodynamic modelling study of the phase equilibria in the FeOFeO1.5- SbO1.5-SiO2 system in equilibrium with liquid Sb and Sb-Ag metal has been undertaken to develop thermodynamic model of the Na-Si-Fe-O slag system with S-Sn-Sb-Pb-As minor elements based on the experimental investigation of the selected sub-systems. New experimental phase equilibria data at 575–1600°C were obtained for this system using high-temperature equilibration of synthetic mixtures with predetermined compositions in sealed silica ampoules, Fe3O4 basket in sealed silica ampoule, or Re foils, a rapid quenching technique, and electron probe X-ray microanalysis of the equilibrated phase compositions. Experimental results on phase equilibria in the Fe-Sb-Si-O+Sb metal system obtained helped to produce initial set of model parameters in the slag. The primary phase fields of quartz/tridymite/cristobalite (SiO2), 2 high-SiO2 immiscible liquids, olivine (Fe2SiO4), wustite (FeO1+x), spinel (Fe3O4), schafarzikite (FeSb2O4) and valentinite/ senarmontite (Sb2O3) were identified in the binary Sb2O3-FeO, Sb2O3-SiO2 and ternary FeO-Sb2O3- SiO2 systems. Further refinement, particularly the distribution of excess Gibbs energy among the ‘FeO’-Sb2O3-SiO2 and ‘FeO1.5’-Sb2O3-SiO2 interactions, required the study at more oxidising conditions. Oxygen potential was increased using an inert metal (Ag) rather than using the gas flow due to the high volatility of Sb-containing gaseous species. Liquid Ag-Sb alloys with low concentrations of Sb of a few percent were used. At these conditions, the concentration of AgO0.5 in slag was below 1 mol per cent, which had a small effect on observed phase equilibria in the system. In addition, important information on the solubility of silver in slags is produced, which can be valuable when treating electronic recycling materials or primary silver-containing ores through the Pb process. Two main areas were addressed: the spinel-tridymite boundary (40–70 per cent SiO2 in slag) and spinel liquidus near 15 per cent SiO2 in slag. This allowed to deconvolute the separate contributions of the FeO-Sb2O3(-SiO2) and Fe2O3-Sb2O3(-SiO2) systems.

Jun 17, 2024

By E J. Y Koh, G J. McLachlan, E Amini, N Beaton

Preconcentration greatly reduces the ore mass input to the processing plant while upgrading the grade. One of the commonly used methods of preconcentration is optical sorting. These methods rely on optical sensors which classify the material stream into “accept-reject” streams. Currently, it is common to use near infrared (NIR) or colour cameras to classify streams based on reflectance or colour thresholds set by experts. The imaging is done through line-scan sensors where the material is scanned on a belt or a chute. Then, a separation apparatus like a diverter gate or air jet is controlled to separate the streams according to the classification made by the algorithm. Separation efficiency is dependent on the classification algorithm. Existing classification algorithms rely on low-level feature discrimination like observing individual pixel values for reflectance or colour hues. This limits discrimination between minerals with low contrast in colour. Human experts perform mineral segmentation using texture, colour distribution and shape, but it is difficult to translate these visual rules to mathematical thresholds. Deep learning methods like Convolutional Neural Networks (CNNs) provide high-level feature discrimination similar to a human expert. Instead of relying on pre-defined features, the CNNs learn complex features from the dataset. CNNs can construct a hierarchy of features based on pixel clusters to learn texture, shapes, and colour spectrums of the mineral grain surface to provide better separation. In this study, a state-of-the-art deep learning instance segmentation method is used to outline boundaries and classify grains from the background (mineral segmentation). The algorithm is trained on images collected from a flotation feed of a gold deposit, where the gold is mechanically locked inside pyrite. This method can process on-line video inputs at 5 frames per second to provide a live grade. The proposed method is inexpensive as it only uses a camera and a desktop computer.

Nov 10, 2020

By M Field

Kimberlite pipes, as opposed to dykes, sill and secondary deposits, are the primary target for diamond exploration companies because they have simple geometries and can contain large volumes of potentially diamond-bearing ore. Once discovered, important decisions have to be made regarding the sampling of these geological entities to establish the total volume of ore present, and to define the internal geology, which can be complex in nature and controls the distribution of diamond grade. It is essential that as part of this process the uncertainty in constructed geological models are assessed. In this paper the Orapa AK1 kimberlite pipe in Botswana is used as a case study to explore a potential methodology for defining this uncertainty. The uncertainty of the rock volumes of different types can be characterised by a geostatistical approach. Geostatistical simulations, based upon a plausible representation of the geological bodies, provide different possible images of the orebody that can be considered as different realities. By testing different borehole layouts and drilling the orebody virtually on the computer, many different, but equi-probable realisations of the pipes can be produced. It is then possible to estimate the rocksÆ volumes and compare them with the actual ones. A statistical analysis of the relationship between estimation error and the number of boreholes can then be used to optimise the next sampling campaign. The rock volumes are obtained from a two-step simulation process. Firstly, the pipe geometry is simulated by means of introducing variations around the geological block model, by an original method called centre point simulation (CPS), which has been developed for this purpose. Secondly, the internal geology is then simulated within the pipe. The methodology for simulating the internal geological zones has to be adapted to the level of information and to the geological structure itself. The upper portion at Orapa AK1 is filled with sedimentary crater facies. Here plurigaussian simulation techniques can be applied that are adapted to the simulation of sedimentary facies. The central zones of the pipe are typically subvertically-oriented massive volcaniclastic deposits and breccias and the lower regions comprise a complex root zone. CPS is appropriate for these zones.

Jan 1, 2006

By S Harris, A Bossilkov

The Kwinana (Western Australia) and Gladstone (Queensland) industrial areas are among the few dozens of heavy industrial areas globally that demonstrate significant levels of regional resource synergies. Such synergies are also referred to as æindustrial ecologyÆ or æindustrial symbiosisÆ. Fundamentally they involve the exchange of by-products or sharing of utilities between companies in close geographic proximity to achieve competitive advantage and environmental benefit. A concerted research effort is currently underway to foster greater realisation of regional resource synergies in minerals processing intensive regions, in Australia and internationally. This paper summarises current insights from the foundation research into engineering tools and technologies and enabling mechanisms for regional resource synergy developments. Regional resource synergy developments were reviewed for 16 international and two Australian regions. It was found that Kwinana and Gladstone compare favourably with the well-regarded international examples of regional synergy development. Given the fairly strong evidence that self-organisation is critical for regional synergy developments, an implementation model has been proposed that captures entry points for synergy developments at the level of platform (industry collaboration), process (developing synergy opportunities) and project (assessing and implementing specific synergies). It was also found that regional synergies have so far developed in the absence of specific methods for identification and screening of synergy opportunities. Moreover, very limited attention has been paid to the associated technological and engineering challenges. The current technical research effort therefore targets: the development of a toolset for the identification and development of potential synergy opportunities; and assessment of technology needs and opportunities for regional synergies involving water, energy and materials recovery and reuse.

Jan 1, 2006

By Sullivan T. D

The Lochiel Deposit is a large occurrence of soft brown coal about 130 km north of Adelaide. The deposit is undergoing continued evalua- tion of which an integral part was the excavation of a Trial Pit. The Trial Pit was deemed necessary to demonstrate that the deposit may be mined efficiently by draglines and the particular emphasis was on the geotech- nical and hydrogeological aspects of what may be termed difficult mining conditions. The dewatering of the Trial Pit was commenced in September 1986. After considerable planning and excavation was successfully completed in May 1987. The project is unique in terms of its size and technical com- plexity. It entailed excavation of over 230,000 m3 of overburden to an overall depth of 36 metres. The excavated material was utilised for experimentation in a Trial Dump. Included in the Trial Pit design were several novel techniques includ- ing depressurisation drains to improve mining conditions in soil strength materials and the use of vacuum to aid dewatering.

Jan 1, 1988

Underground mine ventilation is now com monly simulated on a digital computer. Such a programme, incorporating natural ventilation has been modified by others to account for methane emission and elevated local tempera- tures. At Wollongong University, the pro- gramme was further developed and extensive interactive graphics incorporated such that any view of the three dimensional mine could be viewed, and superimposed upon that view are areas where a nominated parameter has exceeded a particular value - generally at a nominated time after a particular event and usually a fire/explosion of one type or another. A further programme was developed such that up to 20 'times' could be examined at a particu- lar location after say, a fuel rich fire at some other place in the mine. The output from this programme includes a plot of methane 1, smoke 1, temperature, pressure and air flow versus time - a most useful graphic to observe the limits of safe attendance in a particular Airway.

Jan 1, 1983

By A C. Robertson

Over the past decade there has been continual change in the way that mines have been managed and the component roles of those people who make up the total mine management system. Major issues have included the change in the business structure of mining companies, the change in on-site infrastructure, increased personal liability of managers for the safety and health of employees and increasing social and environmental pressures on managers and their staff. This paper looks at the changing roles of two of the many groups of professionals associated with the mining industry - the equipment supplier and the mining consultant. The profiles of the ACME Group Pty Ltd, suppliers of ventilation equipment and ancillary canvas and plastic products to the mining and construction industry, and Tennent, Isokangas Pty Ltd, Consulting Mining Engineers, are presented.

Jan 1, 1998

By Siemon J. R

It is possible to use compacted anodes formed at low pressure for the direct electrowinning of lead from sulphide concentrates. An anode containing 5.5 per cent graphite, formed into a compact at 34 MN m-2, enables lead to be won at a current efficiency of about 80 per cent; the power consumption .at 150 A m-2 current density being 0.4 kWh per kg lead. It would be necessary to use diaphragm cells to obtain a sufficiently pure product. A conceptual design for a full-scale plant is presented, together with a cost estimate for the production of lead by a process based on direct electrolysis of compacted concentrates. It is unlikely that the proposed process will be economically competitive with the conventional lead smelting.

Jan 1, 1976

By Rolfe PR, Ellis BA, Clements RJ

Associated Minerals Consolidated Limited (AMC) is constructing a 112,500 tonne/yr synthetic rutile plant at Narngulu, near Geraldton in Western Australia. Design of the plant is based on the technology developed by AMC and utilised in its two existing plants at Capel in Western Australia. Ilmenite Feedstock for the plant will be sourced from AMC's mine at Eneabba and coal obtained from the Collie deposits. The plant is scheduled to come on stream in the second quarter of calendar 1987. The rationale of the decision to construct the Narngulu plant is examined against the background of the world market for high-Ti02 content feedstocks. Also provided is a detailed description of the plant and an examination of the technology used in process Design.

Jan 1, 1986

Sampling protocols and metallurgical flow sheets should be designed to suit the style of mineralisation in question. In support, the a priori need for evaluation programs is the characterisation of the mineralisation type(s) and domain definition. The proportion and size of gold particles has a direct impact on the effectiveness of sampling protocols and metallurgical processes employed. Within the coarse- to-fi ne gold spectrum, the samplability of a deposit ranges from relatively simple for fine-grained disseminated particles, through to difficult for coarse gold mineralisation. Conversely, metallurgical processing may be relatively simple for coarse gold ore and more difficult for very fi ne gold ores. Most deposits contain a proportion of both particle size types. The nature of mineralisation, mineralogy and associated gold particle sizing can only be determined by preliminary sampling to facilitate testing. Mineralogical studies, focussing on ore mineralogy and gold particle deportment, size and distribution are required as part of wider paragenetic and geometallurgical investigations. This paper discusses key issues and presents a methodology for the determination of gold particle size in coarse gravity-gold ores to support sampling optimisation and which also contributes to metallurgical characterisation.

Aug 1, 2010

By B Laidens, D Souza, W Bielefeldt

The CaO-MgO-SiO2-Al2O3 system, characterised by its intricate phases and thermodynamic properties, plays a pivotal role in steel secondary refining processes, encompassing desulfurisation, non-metallic inclusion capture, and refractory protection. Accurate predictions for diverse industrial applications, including metallurgy, ceramics, and materials science, are imperative. To address this challenge, a combination of machine learning techniques will be specifically applied to model the liquid fraction of the slag and the solid fraction of MgO. The development of an artificial intelligence (AI) system, leveraging various machine learning techniques, has gained momentum in this project. The focus of this work is on constructing an AI model, based on machine learning techniques, within the CaO-MgO-SiO2-Al2O3 system, utilising simulation results from FactSage™, version 8.1 (by GTT Technologies). The primary objective is to train the AI model using these simulation outputs to predict the percentage of liquid fraction and MgO saturation based on chemical composition parameters. The AI model will undergo training with a comprehensive data set of simulations within the CaOMgO- SiO2-Al2O3 system, covering a diverse range of compositional at 1873 K. These simulations, conducted through FactSage™ 8.1 software, provide a robust foundation for AI model training, ensuring generalisability and precise predictions for the liquid fraction of the slag and the solid fraction of MgO, the solid fraction of MgO in this case is determined by the difference between the total MgO and the MgO in the liquid fraction, so it is not the objective of this study to determine which phase of MgO is in the solid state.. The predictive capabilities of this AI model hold significant implications for process optimisation, quality control, and decision-making in CaO-MgO-SiO2-Al2O3- dependent industries. Precise estimations of the liquid fraction and MgO saturation empower researchers and engineers to enhance operational efficiency and quality. This paper explores the methodologies employed for AI model creation and training, achieved results in terms of prediction accuracy, and potential applications in the field. The development of this AI system signifies a notable advancement in utilising machine learning for better comprehension and control of complex chemical systems. Furthermore, to align the study with real-world steel production, we introduce FeO and MnO at concentrations of 2 per cent and 1 per cent at 1873 K, respectively, following the validation of model results using the CaO-MgO-SiO2-Al2O3 system. This adjustment aims to bring the study closer to the observed reality in steel mills globally.

Jun 19, 2024

MANPOWER RESOURCES The optimisation of human effort has been an ongoing and significant process in the coal industry since industrialisation as we know it began. The extent to which the changes sought have been achieved has, over the years, been in the main determined by the economic and political forces existing at that time and the determination and character of the individuals involved. The question of optimisation is therefore not new in our industry. Hopefully this presentation will demonstrate to the reader the effect of previous measures adopted by industry to optimise all facets of its operation and in particular that of the human Resource.

Jan 1, 1991