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By Wymer DG

The concept of hydro power in deep mines is based on the exploitation of the hydrostatic head that can be gained as refrigerated cooling water descends in shaft pipe columns from the surface, to provide hydraulic power for machines at the working face. This paper describes the work done on two important aspects of the controlled distribu-tion of the high pressure water within a mine, namely the control of pressure under normal operating conditions, and the control of flow in an emergency situation following a pipe breakage. Suitable methods of control have been determined using theoretical techniques to model the steady and unsteady flow behaviour of the water in the pipeline, and taking into consideration the environmental constraints on the types of control devices that can be used. The preferred approach is one in which the high pressure water itself is used as the control medium. The control valves themselves can be fairly conventional in design, but in the case of pipe break protection it is shown that a less conventional approach based on the use of a hydraulic fuse gives improved control performance.

Jan 1, 1985

By A M. Nyembwe, A M. Garbers-Craig, R Cromarty

With the depletion of high-grade lump iron ore, concentrates have been identified as an alternative material for sinter making. Adding concentrates to the sinter mixture reduces sinter bed porosity and gas flow through the sinter bed. This will result in lower sinter strand productivity. A potential solution to this problem is to add concentrate in the form of micropellets. This study investigates the effect of concentrate and micropellet additions on the permeability of the sinter mixture. Permeability was measured on sinter mixtures containing ten to 40 per cent concentrates and micropellets at various moisture contents. The effect of concentrate and micropellet addition on the permeability–moisture relationship was examined. The results confirmed that the addition of concentrates into the sinter mix decreases the maximum permeability of the sinter bed. The incorporation of micropellets into the sinter mix reduced the permeability less than concentrate addition. The study also showed that the maximum permeability of sinter mixes containing concentrate is reached at the same moisture content as the sinter mixture without concentrate addition. For sinter mixes containing micropellets, additional water must be added to obtain maximum permeability. Parameters including the granule size, void fraction and angle of repose were also investigated to evaluate their effects on the sinter bed permeability.CITATION:Nyembwe, A M, Cromarty, R and Garbers-Craig, A M, 2015. Effect of concentrate and micropellet addition on iron ore sinter bed permeability, in Proceedings Iron Ore 2015, pp 69–76 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By N S. Weerasekara, S Town, E Lessing, J A. De Torres

Philsaga Mining Corporation (Philsaga) had three main aims in converting their lining system from steel to metal cap. They wanted to increase mill availability, minimise localised high wear and optimise particle breakage to deliver increased efficiency within the milling circuit. Combining Discrete Element Method (DEM) modelling and empirical interpretation of liner wear resulted in a rigorous approach to understanding the impact of mill liners on overall mill performance. This new understanding was subsequently used to not only derive a new lining design to optimise performance and thereby improve overall plant economics, but also to guide further lining development.In this work, detailed DEM modelling, developed from actual plant data, together with optimising liner design for wear paved the way towards the installation of a Metal Cap lining system at Philsaga’s Ø6100 mm SAG Mill. The results were a reported increase in SAG mill throughput of 16 – 20 per cent due to improved breakage through more efficient use of installed power, a reduction in localised high liner wear with overall increase in liner life and reduction in liner replacement time. Site also reported an increased gold recovery of 2 per cent which the improved breakage might have contributed to. This paper will present the design challenges and compare the Metal Cap lining systems performance against Steel lining system. CITATION:Weerasekara, N S, Lessing, E, Town, S and De Torres, J A, 2018. Metal cap versus steel lining system at Philsaga Mining Corporation’s Ø6100 mm SAG mill, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 653–664 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By J Foster

The Lanfranchi Nickel mine is located approximately 48 km south of Kambalda in Western Australia. Mining first commenced in the mid-1970s under the previous owner, Western Mining Corporation Ltd. After two years on care and maintenance, Panoramic Resources (previously known as Sally Malay Mining Ltd) purchased the operation in November 2004. The site currently produces approximately 10?000 tonnes of nickel metal annually from approximately 430?000 tonnes of ore. The Ore is mined from four main orebodies; Deacon, Helmut South, Lanfranchi and Schmitz. The Helmut South orebody is situated approximately 790 m below surface and extends to a resource depth of 940 m. Horizontal thickness of the orebody ranges from 10 m to 45 m in width, with the average being 30 m. Previous mining at the Lanfranchi operations specifically the Helmut orebody, had a history of seismic activity. When Panoramic Resources acquired the operation it was decided that seismicity was going to be an issue and therefore a mining method needed to be selected that could effectively manage this potential risk. The dip of the orebody is quite shallow at 45º, with a 30º plunge to the south . The hanging-wall comprises of very weak ultramafics. Due to these factors the orebody posed several mining challenges. To safely and effectively mine the Helmut South orebody in the Lanfranchi Nickel mine, underhand cut and fill mining was selected as the most appropriate mining method. Paste fill comprising of cemented gold tailings was the backfill of choice. This paper is intended to convey some of the key learnings from the use of a mining method that has not been commonly practiced in Australia.

Mar 21, 2011

By K Aikawa, M Ito, K Mitsuhashi, Y Ebisu, J V. Satur, I Park, N Hiroyoshi, T Suto

Copper concentration using flotation is becoming more difficult, because of an increase in ore complexity accompanied by smaller grain sizes of copper minerals than usual, requiring finer grinding in order to liberate them. Project Arqueros, located at the mid northern part of Chile, is a copper mine project with an orebody consisting of various sulfides such as chalcopyrite, chalcocite, and bornite. Some of the copper minerals in Arqueros show low floatability mainly because of their fine grain size and resulted fine grinding size, and also because of the complex mineralogical composition. For example, chalcopyrite in Arqueros floats less than the other copper sulfide minerals. In this study we carried out some kinetic flotation tests with the Arqueros ore using a laboratory-scale forced air type flotation machine by varying the regrinding size. The products were assayed and mineralogically analysed to compare the minerals in their flotation behaviour with respect to size classes and liberation classes. The results were compared with a model calculation according to bubble size measurement. From the flotation testing and mineralogical analysis, it was found that copper minerals of the same size and liberation class floated at the same rate even with different regrinding size. At the same time the comparison between experiment and calculation showed that the fine particles of less than 5 µm size floated faster in actual than in the model applied. These results suggested that interactions among minerals of different species and of different sizes had positive impacts on the flotation rate of the fine particles. It indicates that this phenomenon can be applied to improve copper recovery in the project.

Aug 24, 2022

By C A. Chaves

During most of its history, the metallurgical industry has been seen as a source of pollution for the environment. However, during the second half of the 20th century, as the world environmental legislation became more protective and the global environmental conscience consolidated, this landscape began to change. Metallurgical activities have become increasingly related to the social and environmental impacts caused by human activities. With the adoption of environmental management in steel plants, there has been a significant change in steel-related activities which have begun to introduce modern plants, managed with environmental, social and productive efficiency. More and more, steel companies search for a decrease in negative impacts of their industrial operations on the environment, fitting them to the current environmental legislation and even increasing productivity and profitability. The steel industry has started to become a clean and more efficient industry. This work presents a case study of a sustainable steel plant project, located in an environmental preservation area. The project includes treatment and reuse of industrial liquid effluents, air emissions control, noise control, recycling, recovery and adequate waste management. It also incorporates production processes using clean technologies, capable of coproducing energy resources which may be used in the plant showing how is it possible to produce steel with environmental and social responsibility and even increase the enterpriseÆs profitability.

Jan 1, 2009

By Beer G

The recent re-emergence of an Integral Pressure Stripping system which operates with both cell and column in closed circuit at elevated temperature and pressure, requires no cyanide in the eluate solution and has greatly reduced carbon reactivation requirements in seen as a progressive step in this area. Several of these re-configured IPS systems have been placed in service in Australia and overseas in the last three years, with the first of the new generation units constructed and commissioned by Como Engineers Pty. Ltd. at Mt. Fisher in the East Murchison of W.A. in September 1987. This plant was relocated to a new ore body at Darlot W.A. in February 1989. Use is made of a data base of raw plant performance figures from both Mr. Fisher and Darlot and its performance compared with other operating plants. Initial commissioning difficulties of the Mt. Fisher prototype and dis- cussed together with the modifications and operational procedures required to overcome these problems. Stripping times of less than 6 hours at 145 degrees have been achieved with barren carbon values less than l O ppm from loaded carbon values above 3000 ppm and with cell pass efficiencies reaching 90 per cent.

Jan 1, 1991

By Mahyera A, Sakashita B, Ahmed U, Abou-Sayed AS

Gas in U.S. coals is primarily composed of 90 to 99 percent methane and up to 10 per- cent carbon dioxide. In composition and heat- ing value, this coal-bed gas is similar to natural gas and can be introduced directly into commercial pipelines after standard condition- ing. The high permeability cleat system in the virgin coal can be exploited in order to drain the coal gas well in advance of mining. Two premining drainage methods have been extensive- ly evaluated in the U.S.; they are 1) horizon- tal boreholes collared from within the mine, and 2) vertical drilling from the surface with fracturing. Limited-size fracture treatments are advocated in order to prevent potential roof damage and the need for added support. An engineering approach to predicting gas flow for different drainage techniques near mining locations is presented. Results can be used in design, i.e. pipeline, compressor. Coal gas drainage from a horizontal borehole and a treated (contained fracture) vertical well for a 6 foot seam have been evaluated. Based on these results, it was concluded that selection of gas drainage techniques will depend primar

Jan 1, 1982

By T Baumgartl, D Mulligan, R Haymont

Mining at the Mt Leyshon Gold Mine in semi-arid north Queensland stopped in 2002. Newmont Australia has recently initiated a thorough post-closure water management study of the site by revisiting the existing information and conducting new water-related investigations. The focus of this paper, which is the first publication on post-closure environmental management of the site, is an overview of the site water quality in view of the sources and spatial distribution of polluted mine water, and also the performance of cover systems in controlling water flux though mine wastes. Since the mine closed the rehabilitation of waste rock dumps and tailings dams have significantly improved water quality in the surface receiving waters. However, the Scats Stockpile, the Heap Leach and Old Plant areas, which can potentially produce acidic waters, enriched with heavy metals and arsenic, are the top management priority. Modelling of the potential transport of contaminants in groundwater needs further investigations. A detailed examination of the waters in seepage sumps showed high concentrations of manganese, cobalt, nickel and selenium, which were previously overlooked. The study also showed distinctive chemical signatures for waters at different locations: the waters draining from scats, supergene materials and waste rocks have distinctly lower pH and higher concentrations of dissolved iron, sulfate, heavy metals, Mg, Mn, U, Se and As. While, the tailings sumps are more alkaline, and are enriched in Na and Cl. The southern tailing sump is characteristically As rich. The waters draining from the supergene materials have higher Cu concentrations. Assessment of the cover monitoring systems showed that although covers pass the design criteria, automated recording of data may ignore any failure of the monitoring system. Recalibration of the moisture sensors not only showed realistic moisture values compared to rainfall data but also showed that the permanently installed system records values that are higher than those of the mobile system. Event-driven recording of data overlooks infiltration events. Besides, with a higher time resolution (daily measurements) the breakthroughs could be clearly detected. Modelling of the water balance in covers is underway and an example is given here. Newmont is currently reviewing water management options and is willing to share the lessons learned.

Jan 1, 2006

By Adams R. W

A commercial scale strong acid leaching plant was commissioned at the Risdon plant of the Electrolytic Zinc Company of Australasia Limited, a member of the Pasminco group of companies, in February 1988. It was designed to upgrade the lead/silver residue product from 26% to 37% lead, thus improving the realised value and increasing overall zinc recovery. This in turn enables the lead smelter treating the lead residue to improve its productivity. The equipment consists of two 250m3 bricklined leach tanks and two 6.5m diameter stainless steel high rate thickeners operating with counter current washing at 95¦C and 120 g/L H2SO4. The present filtration and drying equipment is also being replaced. Two 35m2 squeeze action filter presses equipped with horizontal plates are being installed, together with ancillary drying equipment to ensure that the final product complies with the transportable moisture limit. The new filtration plant is due to be commissioned in mid-1989.

Jan 1, 1989

By M I. Pownceby, M A. Rhamdhani, S Palanisamy, D Fellicia, B Satritama, G A. Brooks, A Ang

Metal production have long been using carbon sources as both reducing agents and energy sources. Consequently, the global extractive metal sector contributes significantly to greenhouse gas emissions, accounting for approximately 9.5 per cent. Hydrogen gas offers as a promising ecofriendly alternative to carbon in metallurgical processes, serving as both a reductant and energy supplier with a by-product being only water vapour. However, the implementation of molecular hydrogen faces certain challenges related to the thermodynamics and kinetics of metal oxide reduction. In addressing these challenges, researchers have explored the application of hydrogen plasma, generated by subjecting molecular hydrogen to high energy to produce atomic, ionic and excited hydrogen species. Hydrogen plasma offers thermodynamic and kinetic advantages over molecular hydrogen and carbon-based reductants, exhibiting lower standard Gibbs free energy of reaction and activation energy. Therefore, hydrogen plasma can produce metal in fewer steps, process any oxide feed and feed size and even be used to refine metals. Despite these advantages, challenges exist in utilising hydrogen plasma in extractive metallurgy, including electricity costs, potential reverse reactions and industrial-scale implementation. This study provides a mini review of prior research on hydrogen plasma for metal oxides reduction, particularly iron oxide, as well as state-of-the-art techniques for its use in extractive metallurgy applications by mentioning several reactor types. Future prospects and scale-up possibilities of the hydrogen plasma in extractive metallurgy will also be presented.

Aug 21, 2024

By D Cliff, B Belle

Trigger action response plans (TARPs) are inherent to managing multiple hazards such as high gas content with multiple coal seams, high spontaneous combustion propensity, heat and ventilation. TARPs aim to provide assurance and guidance when the situation deviates from the original plan or there is a change in conditions that could be hazardous. Over the years, learnings from various incidents have continuously required coal operations to revisit the TARP trigger values that were based on historical data or guidance values from the industry. In most cases, the background to the basis of TARP statistical data (ie average, maximum, hourly or daily for the monitoring or sampling location) is unknown. The introduction of real-time monitoring devices to monitor gases and airflows has provided greater understanding of the hazard scenarios and their controls. This paper analyses the carbon monoxide data from operating longwall mines and compares these with the historical trigger values to understand the changes and identify improvement opportunities while setting trigger levels in the TARPs. As an example of setting trigger values, those used during the sealing of a panel are explored in terms of setting values based upon the sampling location and the level of risk. It is envisaged that the learnings shared herein will further enhance the understanding and management of multiple hazards in Australian coalmines.CITATION:Belle, B and Cliff, D, 2015. Improved trigger action response plan development based upon mine-specific data, in Proceedings The Australian Mine Ventilation Conference, pp 73–78 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

The paper describes the geotechnical as- pects of design and construction of two 12 m diameter concrete lined tunnels from the start of design to completion of construction. Prob- lems occurred due to delay in supply of essen- tial rock support materials from overseas and alternative methods using locally available materials were developed. Several major rock- falls and rock movements occurred and remedial measures are outlined.

Jan 1, 1981

By Lloyd F, Bayley F. J

The new South Mine in the Western Deep Levels complex is destined to become an ultra deep project extending to depths of 4 200 m below surface and where rock temperatures are likely to exceed 65 ¦C. Initial estimates put refrigeration requirements at 133 000 kWR. A surface refrigeration plant with an initial capacity of 42 000 kWR has been commissioned and will be used for mining the upper levels.

Jan 1, 1988

By P Ottenio, B CarrT

In the last 40 years, the froth flotation process widely spread in the paper industry becoming the dominant technology for ink removal from recovered paper slurries and cellulose fibres recovery. Most of current models used to describe the flotation deinking process are based on hydrodynamic and statistical theories of ink particles collision/attachment to air bubbles. The complexity of these theoretical models, together with the variability of the recovered papers composition, does not allow to define a set of æeasy to handleÆ equations to be used for modelling industrial flotation cells. This main limiting aspect makes that, in several deinking process modelling tools, basic parameters used to characterise the flotation unit, ie yield, ink removal efficiency, water loss, are constant parameters. Although in some process simulation tools the flotation yield/efficiency is adapted to process control parameters (air ratio, pulp flow, pulp consistency), physicochemical variables (namely the pulp frothing aptitude, the pulp surface tension and the ink adhesion energy to air bubbles) are not taken into account to adjust the flotation yield/efficiency. Data collected during recent laboratory and pilot plant experiments focusing on the role of surface active substances on the flotation efficiency were therefore interpreted and used to identify general trends that could be described with simple semi-empirical models. A set of model equations using surface tension and froth removal height as main variables was then defined in order to describe the behaviour of a pilot flotation cell. Trends obtained during the dynamic simulation of the deinking pilot plant were in good agreement with experimental data obtained under similar experimental conditions, thus indicating that developed equations can forecast with good approximation the behaviour of a flotation deinking unit.

Jan 1, 2005

By King RP, Kientzler P

In recent years, ultrasonic comminution technology has been developed at the Utah Comminution Center. An ultrasonic grinding device was assembled and investigated. An ultrasonic transducer system has been significantly improved by using a special type of piezoelectric ceramic and preloading to 4.1 x le kPa to obtain maximum strength. The improved system provides constant and rapid vibratory promotion of fatigue fracture resulting in more effective breakage. The design principles for an ultrasonic mill are developed in this paper. Size reduction was successfully achieved in the ultrasonic nip-roll device for a variety of materials. Ultrasonic comminution has repeatedly demonstrated the capability of producing fine particles from a variety of materials. A comparison between ultrasonic grinding and dry ball milling of limestone showed that the ultrasonic device produced much narrower size distributions than the ball mill. This trend is especially obvious in the coarse size range where few particles remain, and in the fine size range where overgrinding is prevented. This behavior might have some interesting applications in areas other than mineral processing like powder metallurgy or material science where narrow and controlled product sizes are required for the successful elaboration of high-technology ceramics and glasses. Ultrasonic comminution has a significant advantage in the accurate control of the product size.

Jan 1, 1993

By A Van den Bulck, K Verbeken, O Vergote, I Bellemans

Viscosity is one of the most important physicochemical properties during pyrometallurgical operations. In the sub-liquidus regime, an important factor is the presence of suspended solid particles, yet its influence is not well-described in earlier literature, despite the significance of this factor. This project aims to determine the influence of spinel particles (Zn(Al,Fe)2O4) on the rheology of a multiphase synthetic PbO-SiO2-ZnO-Fe2O3-CaO-Al2O3 slag system. Three data sets with a wellcontrolled methodology and three different spinel sizes (small (13 μm), medium (34 μm) and large particles (76 μm)) were published previously, using a custom-built high-temperature rheometer. This study presents an additional data set of slag viscosity measurements, performed using a different apparatus, the Anton Paar FRS 1800, to verify the consistency of the earlier determined viscosity behaviour. Within this data set, no consistent trend could be found between the predicted wt per cent spinel and the relative viscosity. Therefore, additional quenching experiments were conducted to identify the morphology and experimentally determined volume fraction of the spinel particles in the slag. These measurements revealed a difference in spinel size across the samples and corresponding viscosity behaviour, emphasizing the importance of spinel particle size on slag viscosity. Once the spinel size was taken into account, consistent viscosity results (relative apparent viscosity and flow index) were observed across the two devices. This study confirms that, once all parameters affecting slag viscosity are considered, the viscosity behaviour of a heterogeneous slag can be uniquely determined. The resulting optimised slag viscosity models can be used to predict viscosity before processing, addressing relevant phenomena such as slag tapping, slag foaming and copper droplet settlement.

Aug 21, 2024

By F Phillips, E Deucker, J Kato

It is challenging to determine the optimal mining strategy to maximise value when a mine plan includes mineralised material which does not meet the full cost of mining but has value exceeding the variable cost of mining (‘marginal material’). Mining too much marginal material dilutes the operation’s head grade and undermines profitability. Conversely, leaving too much metal behind fails to achieve the full value of the endowment. Finding the balance between the two will maximise value delivered from the asset. This dilemma has traditionally been approached by calculating a suite of cut-off grades to define the grade of material that meets economic targets for an orebody (or zone within) and should therefore be included in the mine plan. A problem with this approach is that individual mining blocks within the zone have different costs, value and confidence levels, with each having economic co-dependencies between them. Blocks of identical grade but different mining contexts will have distinctly different economic outcomes. For example: • a block may be a low-grade increment or shell around a higher-grade stope; • a block may be available to be mined when there is spare mining capacity; or • a block may defer access to significantly higher cash flow material. Each of these circumstances would result in different value from the blocks if included as part of the mine plan. Cut-off grades calculated as averages over zones of material, or in isolation from schedule-based information, are missing the entire mining context that determines the ultimate economic outcome of making a mining decision. There are tools and techniques available to address this for open pit mining, however underground mining has different nuances. There are more intricate economic and physical dependencies between potential ore blocks, and importantly, the decision to leave material in situ can be made at any time. The case study in this paper explores a new methodology for underground mining, targeted towards strategic planning applications. It examines whether the economic logic usually applied via cut-off calculations can be implemented in the schedule so that optimal economic decisions can be made on a block-by-block basis, taking into account the mining context of the block, with the objective to maximise asset value. The results of the case study scenarios in Table 1 demonstrate the magnitude of the potential improvement in NPV that can be attained by a block by block valuation approach

Mar 15, 2021

By A R. McKinnon

The recently opened Hera Au-Pb-Zn-Ag mine in central New South Wales has provided an ideal opportunity to demonstrate the calculation of sulfide ore mineralogy using normative methods. Normative mineralogy applies a set of sequential rules based on the species likely to be present to assign the chemical components of a sample to their respective mineral components. The dominant sulfide mineral assemblage present at Hera is galena, iron-bearing sphalerite, chalcopyrite, pyrrhotite and pyrite. A normative technique for estimating the relative abundance of each of these species from drill hole, grade control and metallurgical assay data sets has been developed. This includes a process for deriving a gangue iron value and differentiating pyrrhotite from pyrite using sulfur/iron ratios. A calculated total sulfide volume value has been utilised at the mine to improve interpretation of lode boundaries. Normative drill hole values have also been used for domaining within the orebody, with large scale mineralogical trends evident. Dry bulk density (BD) values calculated using a normative species-weighted method show good correlation with measured BD values (R2 = 0.895) and are a significant improvement on the Pb+Zn+Cu regression method (R2 = 0.646) previously used. Application of these calculations to identify errors in assay databases is demonstrated, with specific reference to the data set for the nearby Nymagee copper deposit. Validation of block model grades is also explored and a method to improve resource estimates using direct normative mineral interpolation is proposed. The integration of the normative data into the production and metallurgical data sets at Hera is described and the relationship of the normative minerals to other economic elements such as gold and silver is discussed.CITATION:McKinnon, A R, 2017. Application of normative ore mineralogy to geological and metallurgical data sets at the Hera Au-Pb-Zn-Ag mine, New South Wales, Australia, in Proceedings Tenth International Mining Geology Conference 2017, pp 63–74 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

This paper briefly reviews the history of mine haulage trucks. It reviews producti- vity limitations with respect to size or speed. Changing haul requirements once again create the need for more flexible mechanical drive power transmission equipment. The new equip- ment however is designed to provide extended life between overhauls as compared with previous mechanical transmissions.

Jan 1, 1981