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By S Basu, S L. A Gowravaram

CaF2 has been a common constituent in a wide variety of welding fluxes, including those used for submerged arc welding (SAW). The widespread use of CaF2 stems from its role in lowering the liquidus temperature as well as the viscosity of the molten slag that covers the weld pool. However, the harmful effect of fluoride evaporation from molten flux, on the environment as well as the health of the users is becoming increasingly evident over the years. This has led to increasing attention towards reducing the CaF2 concentration in the fluxes. The fluoride-free formulations face the challenging requirement to maintain the thermo-physical properties (viscosity, liquidus temperature etc) like those observed in fluoride-containing fluxes. In the present work, three fluxes with compositions in the CaO-MnO-SiO2-Al2O3 system have been identified as promising alternatives to the CaF2-rich fluxes. However, the thermo-physical properties of any such flux need to be comparable to CaF2-based commercial SAW fluxes before it can be adopted for regular use. The single hot thermocouple technique (SHTT) has been used by several researchers in the past as a tool for observing the melting and solidification characteristics of fluxes. This device has been developed in the present work and is used to characterise the melting behaviour of the fluxes. The measured solidus and liquidus temperatures from SHTT were compared with the results from differential thermal analysis (DTA) and simulations using the FactSage™ software for a comprehensive understanding. In spite of having a slight deviation in the measured values from the multiple techniques, the results obtained from these multiple methods show that the selected compositions could be potential CaF2 free alternative welding fluxes.

Jun 19, 2024

By Griffin PT, Espinosa-Gomez R, Jameson GJ

Two major issues are to be addressed in the Copper Concentrator of Mount Isa Mines Limited. The first of these is the need to increase concentrator flotation capacity to increase copper recovery, while the second is the need to reduce the iron sulphide dilution to meet future smelting requirements. Extra capacity in the cleaner and retreatment sections of the concentrator have been identified as key target areas, with additional copper recovery of at least one per cent identified from plant trials. Extensive pilot plant tests have been undertaken to evaluate the performance of the Jameson cell compared to conventional mechanical cell and column circuits. This work has shown that Jameson cells present an opportunity to achieve the desired grade and capacity specifications at lower capital cost than available alternatives. This paper outlines metallurgical results of work undertaken in the Copper Concentrator, together with a summary of pertinent Jameson cell operating parameters investigated during the period.

Jan 1, 1993

By Magne L, Barria J, Castro O, Menacho J, Gonzalez GD

An extensive experimental campaign was developed in a continuous 6 x 2' (D x L) pilot scale SAG mill. The effect of the feed flow rate, feed solids concentration, ball filling fraction and feed size distribution, over the mill performance was investigated. The residence time distribution (RTD) for the fine material was measured in every test, in order to detect changes in the mixing characteristics of the mill under different operating conditions. Based on phenomenological considerations a state model of the SAG mill was developed, which independently incorporates mechanisms such as: grinding, mass transport and classification in the grate discharge. These can be parametrised using information and optimisation software. This comminution model extends the compensation condition, which is a conventional hypothesis for ball milling, to the semi-autogenous mill grinding. The mathematical analysis of this hypothesis, applied to SAG mills, allow the reduction of the number of parameters in the model, using the relationship Ki = (1-bii)Si, where b and S have the conventional meaning. Therefore, the distribution fracture matrix bij and the specific fracture rate SIE are grouped in just a single diagonal matrix Ki.

Jan 1, 1993

By W Midgley, M Torok, I Canbulat, J Katupitiya, S Saydam, S Akdag

The green energy transition is expected to require a range of valuable minerals, which could be supplied through deep-sea polymetallic nodule mining. Deep-sea polymetallic nodules are mineral deposits with a composition well suited to produce lithium batteries, which are expected to be a necessary energy storage solution (Diouf and Pode, 2015; Paulikas et al, 2020) for the energy transition. By 2050 the annual demand for both cobalt and lithium is estimated to increase by around 450 per cent from 2018 levels (Hund et al, 2023), with the annual demand for nickel being greater than 2 million tons, and copper greater than 1 million tons. Polymetallic nodule mining is well positioned to provide these minerals in the near future. An intricate and comparatively unexplored ecosystem thrives within and surrounding the nodule fields (Smith et al, 2008). Deep-sea mining operations have the potential to disrupt and permanently damage this ecosystem through introduced pollution, artificial noise and light, and habitat destruction. Hence, there is a pressing need for new engineering and scientific endeavours to focus on developing new technologies to reduce any environmental impact from mining.

Sep 1, 2024

By A I M Ritchie

The pyrite oxidation rate is a process central to both the performance of bio-oxidation heaps, used in the pre-treatment of some refractory gold ores, and to the levels of pollution in acid rock drainage (ARD) from pyritic waste rock dumps. A goal in bio-oxidation heaps is to achieve high oxidation rates in the heap as a whole. In comparison, one way to mitigate the environment impact of ARD, is to reduce the overall oxidation rate in the waste rock dump since pyrite oxidation is the primary pollutant generation process. In both bio-oxidation heaps and waste rock dumps the overall oxidation rate of the pyritic material (the intrinsic oxidation rate) at these sites. Much research has been conducted over the last 40 years or so on the oxidation rate of pyritic material with particular emphasis on the catalytic role played by bacteria. More recently mathematical models and field measurements have clarified the extent to which oxygen transport rates are rate limiting, what the dominant oxygen transport mechanisms are and the physical properties of the heaps which have most impact on these transport rates and on the overall oxidation rate. How the performance of bio-oxidation heaps can be optimised and how the pollution load in drainage from waste rock dumps depends on gas transport mechanisms is briefly reviewed. The sensitive of the overall oxidation rate in bio-oxidation heaps and waste rock dumps to details of the intrinsic oxidation rate is quantified.

Jan 1, 1994

The knowledge in the field has been reviewed by literature studies, and using experience from personal research in sublevel caving. There is a lot of material regarding gravity flow of fine grained materials in bins, but the theory of flow for these materials are normally not applicable for coarse blasted rock. This study was therefore concentrated towards coarse rock fragments created after blasting in orebodies. The goal for this study was to make a report of known knowledge, and identify what we have to learn more about. The Bergmark-Roos theory, which was a paradigm shift in the science of gravity flow, is today the best mathematical theory for calculation of the drawbody for a homogenous material or when we wish to simulate the mean drawbody for a large number of draws. The Bergmark-Roos theory must however be improved, so it can take into account the flow pipe effect. When this is done it will be possible to construct a 3D computer model for calculation of ore extraction versus amount of loaded ore and waste. It is also necessary to find the 3D shape of the flow cone to be able to calculate the 3D ore rest that normally develops on footwalls. Calculations should be done for the draw on several sublevels including determination of the ore losses and temporary ore rests. First when this computer model is developed optimisation of ore recovery and waste rock dilution can start for a given orebody. The author points out the importance for international co-operation and standardisation of methods for determination of material properties. More field tests and model blasting tests should also be done. When enough knowledge is gathered, a handbook of the optimisation of sublevel and block caving should be written.

Jan 1, 2000

By G W. Wilson

Net solar radiation is one of the key factors affecting evaporation from soil covers on waste rock dumps. While net solar radiation is normally taken as a uniform parameter over a site for modelling purposes, there can be significant variation in the radiation actually received on various portions of the dump. These variations are a function of the difference in the cover slope and direction of exposure. A predictive model has been developed to calculate the actual radiation received on the dump surfaces, based on the net radiation data measured at a weather station on a horizontal surface. The model has been designed for application at any mine site in the world, and can be used in conjunction with evaporative flux models to help estimate the effect of three-dimensional variations in the cover surface exposure. The waste rock dump at Equity Silver site (located in British Columbia, Canada) has a barrier-type soil cover system to limit oxygen entry and water infiltration. This cover has been monitored for the past nine years. The new net solar radiation model has been applied to this site and the predicted net radiation was compared to the values of actual net radiation measured on the site. The predicted variations in net radiation over the three-dimensional surface of the waste rock dump have been applied to calculate spatial variations in potential and actual evaporation (or evapotranspiration) from the site. Preliminary analyses indicate actual evaporation from a site at this latitude could vary by a factor of two for exposed versus shaded slopes. The implications of these variations for the site are considered.

Jan 1, 2003

The words ""Uncertainty"" and ""Risk"" pervade every discussion about mining exploration and investment. Perhaps these terms are subjectively understood by industry professionals, but objective portrayal of these concepts outside the industry is a woefully undeveloped science. This paper addresses current industry understanding and practice regarding quantitative risk assessment techniques, and provides examples of the application of three of these techniques. Probabilistic techniques for financial risk assessment are valuable adjuncts to conventional financial analysis, and address a range of issues not assessable by any other means. The value of whole-of-project probabilistic risk assessment is currently debatable for decision-making purposes, but is seen as important as a mechanism to focus attention to the critical issues that ultimately impact on project success. The dissection of project capital into risk and non-risk components provides valuable insights into risk characteristics not readily quantifiable in any other way. This technique also provides a framework for more objective ""what if?"" scenario evaluation and for the capital structure of resource projects. Finally, mechanisms for the valuation of undeveloped reserves are examined, and guidelines suggested. The importance of reliability in production cost estimates is highlighted and the impact of early development on reserve valuations is discussed. The importance of economics throughout all stages of the evaluation process is fundamental.

Jan 1, 1994

By T Krull, T J. Donohue, D Ilic

"Problematic issues in materials handling applications are often amplified in the iron ore industry due to the relatively high density of the ore as well as the abrasive nature of the product. One of the main issues arising from the handling of iron ore is excessive wear, with two applications typically suffering accelerated wear issues being transfer chutes and conveyor belts. These wear issues are problematic due to additional capital costs, but mainly due to the associated downtimes resulting in the accelerated wear. This study will focus on the modelling of iron ore in practical applications where design work was undertaken in order to reduce the wear rates of different materials handling equipment.CITATION:Donohue, T J, Ilic, D and Krull, T, 2013. Modelling of iron ore in materials handling applications with a focus on wear, in Proceedings Iron Ore 2013, pp 355-362 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 12, 2013

By S Hancock, B H. Brady, H Muhlhaus

The aims of this paper are to present the governing science, verify the performance and demonstrate the potential engineering applications of a computational simulator for in situ leach mining of non-ferrous minerals. Assuming that the target mineral is deposited either uniformly within rock matrixes (matrix-hosted) or on fracture walls (fracture-hosted), in situ leaching can be treated as reactive flow and transport in geological media (porous media for matrix-hosted ore deposits and fractured media for fracture-hosted ore deposits). Under this treatment, the processes of in situ leach mining for non-ferrous minerals can be quantified through several sets of equations and these coupled equations have been numerically solved. The computational simulator has been applied to the simulations of one-, two-, and three-dimensional in situ leaching cases. The computational simulator, together with laboratory and in situ leaching tests, can be used to:optimise the leaching chemistry; optimise the in situ scale mining operations; scale up the in situ scale test operation to a full-scale mining operation; and evaluate the post-mining environmental restoration plan.

Jan 1, 2000

During the past three years Lurgi's Circulating Fluid Bed (CFB) technology has been successfully applied to roasting of refractory gold ores and con- centrates. In comparison with the so-called Stationary Fluid Bed roasting systems, a considerable improvement of gold recovery, to around 95 per cent, has been demonstrated and achieved on many occasions in pilot CFB units and in commercial CFB roasting plants as well. The major reason for such improved gold recoveries is the excellent controllability of the roasting process in the CFB reactor system. Here, temperature, gas atmosphere and solids residence time are more precisely controllable at optimal values during roasting operation in order to achieve the highest possible gold recovery in the subsequent leaching process step. Further dominant benefits of CFB roasting systems are their flexibility with regard to feed material, throughput capacity, dry or slurry feed, almost unlimited oxygen enrichment, direct fuel addition and in situ capture of SO2 in the presence of limestone and dolomite. The system will accept 50 per cent turndown ratio, large variations in feed composition and particle size, as well as a variety of different fuel types. The commercial applications of CFB roasting systems for gold con- centrates have been realized so far at Fimiston, Kalgoorlie/Westem Australia and for whole ores at Cortez, Nevada/USA.

Jan 1, 1991

By D J. Williams, S Islam

Worldwide production of black coal amounts to about 8 billion tonnes. Perhaps 20% of this annual production is washed to improve its quality, generating perhaps 250 million tonnes of coal tailings annually, generally in the form of a slurry. The coal tailings slurry is typically thickened to about 25% solids by mass prior to disposal to a tailings storage facility (TSF), and hence comprise mostly water (about 85% by volume), plus sand, silt and clay-sized mineral particles and carbonaceous material. While the tailings settle and consolidate on deposition in the storage facility, their high moisture content makes them prone to run-out should the tailings dam fail, and makes rehabilitation of the tailings difficult. Hence, it is important to understand the consolidation and shear strength of coal tailings. Laboratory consolidation testing of coal tailings from a slurry to a soil-like state has been carried out in a purpose-built, large-scale, slurry consolidometer, instrumented with load cells and pore water pressure (PWP) transducers. Laboratory vane shear testing of coal tailings produced at different gravimetric moisture contents has also been carried out. The test results have allowed a regression model to be developed relating the peak vane shear strength of the coal tailings to their gravimetric moisture content.CITATION:Islam, S and Williams, D J, 2018. Consolidation and shear strength of coal tailings slurries, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 62–71 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By J Palarski

Over the last 100 years in the Polish mining industry considerable work has been done to assess optimum slurry, develop flexible delivery systems and adjust the fill technology to a wide variety of mining and geological conditions. Sand or industrial mineral waste materials for the backfilling of underground voids are used to control ground movement and surface deformation. This paper discusses various criteria to he considered in the preparation of a fill, including slurry properties, mine infrastructure, mining geometry, placement methods and the purpose of the backfill. This paper presents laboratory and in situ test data on the influence of materials parameters on the slurry flow in a pipeline system, stiffness, permeability, binding time and strength of a backfill, on the distribution of mixture in underground voids or the penetration between roof fall Materials.

Jan 1, 1998

By I R. F MacCulloch

Bacterial oxidation of sulfide minerals is a familiar and commercially available process to enhance gold recovery with problem ores. Pintail Systems, a Colorado, USA based company had developed bio-processes for gold recovery based on natural mineral formation and transformation in a global mineral cycle. The biological recovery of precious metals from ore involves a number of mechanisms that are dependent on the metal-mineralogical association. These processes include: partial bio-oxidation of sulfide ores; oxidation of gangue minerals exposing gold to leaching; surfactant properties of bacteria/nutrient solutions that improve wettability of ores and solution contact with leachable gold and silver; and microbial production and excretion of trace amounts of gold lixiviants, and bio-fracturing or biological alteration of ore minerals. Pintail has demonstrated enhanced recovery of precious metals during cyanide detoxification of spent heaps at the end of mine life. Biological recovery processes also have the potential to be applied to in situ mining technologies. The in situ process application could recover gold from subgrade deposits, small deposits or those ore bodies with uneconomic stripping ratios for conventional mining. In situ biomining can be accomplished at a fraction of the cost of conventional mining and leaching and does not have the environmental liabilities associated with many conventional gold lixiviants.

Jan 1, 2004

By K Esmaeili, S Aziznejad

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

Aug 24, 2015

By N L. Turner, D J. Robinson, A J. McFarlane, N M. Chapman, L L. Kuhar, R L. Meakin, R Martin

A number of geometallurgical tests have been developed within the AMIRA P843A Geometallurgical Mapping and Mine Modelling (GeMIII) project, an interdisciplinary collaborative research project involving four research groups and over 20 global mineral companies. Researchers at the Commonwealth Scientific and Industrial Research Organisation (CSIRO) have been focusing on the development of predictive hydrometallurgical indices for the GeMIII project via rapid, small-scale, cost-effective tests and protocols for comparative ranking of attributes relevant to leach performance. One of the focus areas has been the development of a leaching scheme for determination of the mineralogical deportment of copper in a large number of samples for geometallurgical applications.Various leaching schemes have been used over the last 20 years to identify the mineralogical deportment of copper. Typically, weak sulfuric acid and cyanide are used to target copper oxides and æsecondaryÆ copper sulfide minerals, covellite, chalcocite and bornite, respectively. Residual copper is assigned to chalcopyrite and/or bornite. Adaptations of this scheme have included the use of a weak organic acid to target oxides or ferric sulfate to target secondary copper sulfides. Testing of the weak acid/cyanide scheme in the GeMIII project using head and residue QEMSCAN mineralogical data analysed with a statistically reliable comparison method indicated that the inferred mineralogical deportment from various leaches could differ markedly from the theoretical or assumed value. Based on this initial work, test development and leach tests on samples from multiple sites has resulted in the development of a scheme to target copper oxides, chalcocite, covellite, bornite and chalcopyrite. This paper presents results from leach tests conducted on a large sample suite from two pits in a Cu-Au ore deposit with results calibrated using mineral liberation analyser (MLA) mineralogical analysis. This study has assisted in the development of a protocol for determining the mineralogical deportment of copper in a large number of samples for geometallurgical applications.CITATION:Kuhar, L L, McFarlane, A J, Chapman, N M, Meakin, R L, Martin, R, Turner, N L and Robinson, D J, 2013. Calibration and testing of a geometallurgical leaching protocol for determining copper mineralogical deportment, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 177-186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By M I. Pownceby, N A. S Webster, A J. Studer, I C. Madsen, J A. Kimpton, M J. Fisher-White, L Lu

In situ synchrotron X-ray and in situ neutron diffraction-based experimentation have been implemented to characterise the formation of the complex calcium ferrite iron ore sinter bonding phases silico-ferrite of calcium and aluminium (SFCA) and SFCA-I. Experiments were carried out using fine-grained (<20 ¦m) sinter mixtures containing ~77 wt per cent Fe2O3, 14 wt per cent CaO, 3.5 wt per cent SiO2 and 5 wt per cent Al2O3, with diffraction data collected during heating until 1300 - 1350¦C, which was enough to ensure complete melting of the SFCA phases. In the case of the in situ synchrotron experimentation, results showed that altering the nature of the starting sinter mixture (ie substitution of goethite for hematite; substitution of an amorphous Al2O3-based mineral for gibbsite) did not have a significant effect on the thermal stability range of the SFCA phases. It did, however, have a profound effect on the formation and rate of consumption of the calcium-rich ferrite phases C2F and CF, and on the formation mechanisms of SFCA and SFCA-I. The in situ neutron diffraction experimentation is the first described in the context of iron ore sintering, and the observation of both SFCA-I and SFCA formation in the in situ diffraction data represents the first step in achieving the goal of charactering iron ore sinter phase formation in large volumes of industrial sinter starting materials with a wide range of particle sizes (up to 6.3 mm).CITATION:Webster, N A S, Pownceby, M I, Madsen, I C, Studer, A J, Lu, L, Manuel, J R, Kimpton, J A and Fisher-White, M J, 2013. In situ x-ray and neutron diffraction studies of silico-ferrite of calcium and aluminium iron ore sinter phase formation, in Proceedings Iron Ore 2013 , pp 487-494 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By Chunbao Z, Zhenchuan Z

As known to the international mining sectors, Hunan province, called as ' Nonferrous Native Area ', is the main base of nonferrous metals Pro- duction in China. There are over 194 nonferrous mines in this province, most of them distribute over the basin of Xiangjiang River. The state of management of wastewater in Hunan's nonferrous mines is outlined.The experiences and economic benefit in the management and treatment of wa- stewater in Bofang and Mayang copper mines, and at Shizhuyuan polymeta- llic mine, are mainly introduced. It concludes with measures and recommendations for future management and treatment of wastewater in Hunan's nonferrous mines.

Jan 1, 1988

By S Serp, M Duchateau, P Chevreux

Molten salt reactor (MSR) is a promising advanced reactor system aiming to the transmutation of minor actinides such as americium in order to reduce the inventory of ultimate nuclear waste. The fuel is a molten salt in which actinides are homogeneously dissolved in the liquid phase. A chloride salt may be retained for this concept, as it provides low melting point, high solubility of actinides, harder neutron spectrum. To avoid corrosion and precipitation issues, molten salt composition has to be carefully controlled with impurity content as low as possible. Obtaining pure actinide chlorides without contaminants such as oxide, oxychloride, hydroxide and water is still a challenge. To prepare actinide-bearing salt, the chlorination of actinides oxides was investigated in an unstirred reactor under flowing gas as solid-gas reaction. The carbochlorination of PuO2 were performed in the temperature range of 600 to 800°C with chlorine gas as a chlorinating agent and the presence of solid carbon. PuCl3 was successfully synthesised by this method and characterised by X-ray diffraction measurements but some impurities such as oxide phase remain inside the formed product. Refinements of anhydrous and hydrated PuCl3 phases by Le Bail method were also performed for crystalline materials definition. Conversion mainly depends on the chlorinating temperature and the contact between the oxide and the chlorinating agent. A conversion value of 70–80 per cent was achieved at 700°C from PuO2 with quite high specific surface area. The conversion rate was not improved with increasing the chlorination time. The volatilisation of Pu was observed during the carbochlorination experiments. To avoid a loss of Pu caused by sublimation, the chlorination temperature should be limited to 650°C despite that the conversion of PuO2 to PuCl3 was enhanced by increasing temperature. Both carbochlorination and hydrochlorination of AmO2 were also carried out leading to the formation of AmCl3. These first results suggest that americium oxide was chlorinated more readily than plutonium oxide. The purity of produced PuCl3 and AmCl3 still deserves further investigations.

Jun 19, 2024

By W Newton, J Price

This paper outlines the design, justification and performance of a gravity circuit upgrade at the Marvel Loch treatment plant. The design of the upgrade was simple but effective. The key components of the upgrade were the addition of a sluice and a second Knelson Concentrator. The sluice was installed as a pre-concentration step. The upgrade also included the purchase of a Mineral Cone to treat the increased quantity of gravity concentrate. The cost was low because of the use of mostly second-hand equipment. The result was that for a cost of $75 000 the gravity recovery doubled and the overall recovery increased by over one per cent. This paper shows that you do not need to spend millions of dollars to be innovative and successful.

Jan 1, 2000