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By R Fury, I Skepper, D White, G Miller

Although the Pressure Acid Leaching (PAL) of nickel laterites has been conducted at Moa Bay, Cuba, since the early 1960s, the commissioning delays generally encountered by the æsecond generationÆ of PAL lateritic nickel producers in the late 1990s have demonstrated the potential complexity of the PAL process and the importance of technical risk management in maximising the realised project value. This paper describes some of the strategies used by the Ravensthorpe Nickel Project (RNP) to manage the technical aspects of the Ravensthorpe project risk. Central to these strategies is the use of Front End Loading (FEL) to deal with issues early in the development phase, when changes to the project structure can be made most effectively and cheaply. Such an approach requires a management philosophy that recognises risk as a potential cost, which accepts responsibility for dealing with risk, and which is prepared to provide adequate resources for risk management.

Jan 1, 2004

By Woodcock J. T, Jackson N

Wattle Gully Gold Mines N.L. of Chewton, Victoria, has decided to replace its present battery plant by a new mill to treat a free milling gold ore, after fine grinding, by concentrating coarse gold in a jig concentrate for amalgamation, and fine free gold and auriferous sulphides in a flotation concentrate for cyanidation. This paper outlines the economic justification and advantages of this step. In a review of the present position at the mine, a history of the company is followed by a description of the ore and its occurrence.Present treatment practice in two separate battery plants is described. Treatment tailings assay 1 dwt/ton gold and a substantial part of this gold is finer than 200 mesh.Experimental work showing how recovery may be improved is discussed and alternative methods of concentrating coarse gold mentioned. It is decided that the most suitable method for recovering gold from the ore is by jig concentration plus flotation.The merits of various flowsheets incorporating these techniques in the existing plant and in a new plant are assessed. It is concluded that there is no advantage in extending or converting the existing two battery plants, and it would be more economical and satisfactory to build a new plant.An economic study shows that for a capital expenditure of £120,000 a new plant could be erected to treat 70,000 tons p.a., working a 5-day week, and return an additional 14.2/- per ton, or £50,000 p.a., in revenue over the existing plant. It is estimated the plant cost can therefore be recouped out of savings inside three years. Probable ore reserves are sufficient to cover this period and additional ore will certainly be developed.INTRODUCTIQNSince 1934, Wattle Gully Gold Mines N.L. has been mining a lode gold ore at Chewton, near Castleniaine, and treating it by stamp milling and plate amalgamation, plus table concentration of auriferous sulphides. In 1954, following two years of unprofitable operation, a rehabilitation programme of all sections of the mine and plant was commenced. In the treatment section, two, major prospects for improvement...

Jan 1, 1959

By M J. Daniel

Mineral resources all over the world are often heterogeneous and have variable ore properties and ore grade. As a result the ore processed in concentrating plants varies over the life of mines. Consequently the circuits often suffer from bottlenecks typically at the stages of crushing, semi-autogeneous (SAG) and ball milling. Bottlenecks may be remedied with equipment retrofits, however, design engineers should consider a phased approach to the circuit design that delays initial capital expenditure over the life-of-mine. This paper deals with the debottlenecking of existing mineral processing plants by means of high pressure grinding roll (HPGR) applications. It also deals with the use of innovative flow sheet designs using HPGRs for the design of Greenfield plants by engineering or mining companies. In the case of Greenfield plant design an analysis with respect to energy efficiency and operating cost (OPEX) is presented. The analysis compares the performance of SAG based circuits against HPGR circuits that may be influenced by variable ore properties. Globally about 600 HPGRs are installed in various applications in the cement and minerals industries. In excess of 100 of these HPGRs are used since the mid 1980s for crushing and grinding of various ore types including æhard rockÆ applications. HPGR technology is mature enough to be considered as an ideal debottlenecking device. HPGRÆs are versatile, they have a low installation footprint and they are flexible in its machine settings (pressure, roll speed), which can be adjusted to react to ore variations whilst maintaining a high throughput. Examples for the benefits of using HPGR in terms of energy efficiency and operating costs are presented by this paper. æEco-efficientÆ flow sheets and sustainable development initiatives are linked to energy savings as an æenergy costÆ and benefit to the environment. Energy savingsÆ can also be analysed in terms of the ædollar costÆ (OPEX) savings. This paper demonstrates that HPGR is more energy efficient and may reduce the overall grinding energy requirements in the order of 16 per cent depending on the target grind size and ore properties. The HPGR is more cost efficient and may reduce overall grinding costs by as much as 19.3 per cent depending on the cost of energy, grinding media and the rate of grinding media wear in the comminution circuit.

Jan 1, 2009

By B E. De Gee, N Viviers, A Naidoo

In 2013 the Mopani Copper Mine Mufulira plant in Zambia embarked on a project that was aimed at improving concentrator recoveries. The project commenced with the automation of the milling and flotation circuits. This involved the installation of new instrumentation, namely measurement devices and actuators, and the connection of these to new programmable logic controllers (PLCs).The infrastructure changes were followed by the implementation of basic proportional-integral-derivative (PID) controllers on the PLCs. Supervisory control and data acquisition (SCADA) interfaces were also implemented to allow for switching between controller modes, inputting of setpoint variables and to provide a visual display for process monitoring. The final phase of the project involved the installation and commissioning of advanced process control (APC) solutions on the milling and flotation circuits. This work was carried out by Mintek over 21 on-site days. The APC solutions included the MillStar and FloatStar suites of advanced controllers.The MillStar control suite focused on stabilising the mill feed and mill discharge on the two primary mills as well as the flotation circuit feed. Mintek’s CyLas instruments, which provide a measurement of the hydrocyclone underflow angle, were also installed. The measurements were incorporated into the discharge stabilisation control on both milling circuits. The FloatStar level stabiliser controller provided flotation cell pulp level control on fourteen cells, including two columns.Performance tests showed that the Mintek APC system stabilised the mill feed and mill discharge while ensuring the process remained within operational constraints. The MillStar control system utilised the CyLas instrument to prevent roping on the hydrocyclone underflow. This was not always achieved under normal operation. Additionally, the flotation section was stabilised as a result of improved level control by the FloatStar control system.Performance comparisons showed that the Mintek control system improved the operation of the milling and flotation circuits resulting in a greater copper recovery.CITATION:Naidoo, A, De Gee, B E and Viviers, N, 2014. Implementation of an advanced milling and flotation control system at Mopani Mufulira copper mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 363–368 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

This paper describes new research and development currently being undertaken by the CSIRO Mining Technology Group to advance the automation capability of continuous mining equipment in underground coal mining operations. The effort aims at increasing the overall rate of roadway development as well as providing a safer working environment for underground mine personnel. The activity is funded by the Australian Coal Association Research Program (ACARP) and forms part of a larger underground development initiative, known as the CM2010 project. The CM2010 is managed via a consortium of leading mining industry representatives through the Roadway Development Task Group (RDTG). The Task Group has identified three research areas requiring new development in order to realise the CM2010 project objectives: self-guiding (autonomous) continuous miner capability, an enhanced drilling and bolting process and improved mesh deployment. CSIRO's primary role in the CM2010 project is in the development of the autonomous continuous miner guidance capability.This paper reports on outcomes achieved at the half-way mark of a three year research and development project. It details the technical developments undertaken towards demonstration of a 'self-steering' capability to enable a continuous miner to automatically maintain a given mining heading and mining horizon under production conditions. A primary technical requirement of this automated functionality is the means to accurately determine both the location and orientation of the continuous miner in real-time. Testing and validation of the guidance system solution has been implemented using a combination of an instrumentation-grade inertial navigation unit and radar technology. Comprehensive performance evaluations have been conducted using a scale skid-steer mobility platform known as the Phoenix. Results achieved to the present stage of the project are highly promising and suggest that an automated self-steering functionality is achievable under production conditions. This new outcome represents an important move towards implementing a step change improvement for future underground roadway development.

Dec 6, 2010

IN the irregularly shaped ore-bodies of the North Mount Lyell mine by overhead stoping, the method of filling the is a special feature.The situation of the mine two miles from the smelter and mill at an devation of 1000 ft. above the latter, precluded the economical use of granulated furnace or the mill tailings, even if these materials were as suitable for the purpose as the rock nowquarried at North Lyell methods at Mount Lyell have already been described in Proceedings of the Institute.*The breaking the ore in large dome-shaped stopes is still the rule, but the slope or "rill" is much flatter now than formerly. Owing the greater fluidity of the filling now in use, it is sometimes necessary to resort to square-sets, both at the ground floor and above, the roofs and walls are generally enough to permit stoping without timber, except for ground and occasional stacks on the rills.Sufficient area of ground floor has been beaten out to start overhead stoping, the dome back is partly formed, with its apex a rise which connects with the mullock-pass reticulation.(Sce 1 showing this reticulation in diagrammatic form.)

Jan 1, 1927

An integrated palynological and sedimentological investigation of four wells from the eastern margin of the Gippsland Basin has resulted in a scheme for classification of palynofacies in this area. Thirteen different palynofacies assemblages are recognised and assigned to particular environments based on the enclosing sediments, which range from alluvial, through coastal barrier to continental shelf environments. Close correlation is observed between the interpreted energy regime of the palynofacies assemblage, and that of the enclosing sediments. Assemblages characterised as reworking surfaces can be correlated with unconformity producing events (ie tectonic activity associated with the opening of the Tasman Sea), and some of the minor eustatic sea level Changes.

Jan 1, 1992

Individual specimens of sphalerite from the Broken Hill lode vary considerably in manganese and iron contents, even within the same orebody, so that study of the overall variation of manganese and iron content of the sphalerite calls for the analysis of a large number of specimens. This difficulty has been overcome by analysing a series of recleaned zinc concentrate products, prepared from stope samples and their equivalents, from most of the developed sections of the lode. The analyses reveal that during the formation of the sphalerite the concentrations of iron, manganese and zinc in the mineralizing solutions varied independently of one another from place to place in the forming orebodies, and also in time.The overall pattern of variation of the iron and manganese contents of the sphalerite in the several orebodies of the lode bears a general resemblance to the overall pattern of distribution shown by several other elements, notably, cadmium, lead, bismuth and arsenic. The iron content of the sphalerite indicates that it was formed at a temperature of 6000 C. or higher, but the variation in its iron and manganese contents demonstrates that Kullerud's method for determining the temperature of formation of sphalerite from its iron content must be used with caution if only single specimens of sphalerite are available.INTRODUCTIONThe four chemical analyses available of specimens of practically pure sphalerite from the Broken Hill lode (Table 1) reveal that the manganese content of the sphalerite varies considerably, and that there is a significant variation in its iron content. The variations revealed between individual specimens within the same orebody in the same mine suggest that specimen material is unsatisfactory as a basis for studying the overall manganese and iron contents of Broken Hill sphalerite, unless a great number of specimensis analysed.

Jan 1, 1956

In general, the metallurgical industry has so far been slower than the chemical industry to adopt ion exchange materials for industrial processes. The atomic energy industry presents a marked exception to this general situation, and the literature shows a rapidly increasing use of ion exchange techniques for the recovery of atomic energy metals on scales ranging from the ultra micro up to that of the largest mining operations. In many cases, the processes used would be equally applicable to more common metals and it is hoped that this review will be of interest to metallurgists outside the specialised atomic energy field. The review is intended to describe developments of ion exchange processes made during the last three years. Earlier studies have been summarised by Kunin and Preuss (1956) and Roland (1957). In order to restrict the number of references discussed, purely analytical procedures have been omitted and only those processes which have been conducted on a reasonably large scale or which, from their nature, areclearly capable of being upscaled, have been considered. The paper is divided into five main sections concerning respectively:Water treatment and effluent disposal.Metal recovery and purification.New ion exchange materials.New ion exchange equipment.Membrane cells.WATER TREATMENT AND EFFLUENT DISPOSALA high proportion of atomic reactors, and particularly those of American design, are cooled by water which is...

Jan 1, 1961

Situated in the Greymouth Coalfield, the Mt Davy Block contains a significant resource of high quality bituminous coal suitable for use in metallurgical coking coal blends. The coal, which is all low sulphur, is seen as a complementary deposit to export coking coal at Stockton Mine.   Previous drilling by State Coal Mines (1948 - 1953) and Japanese interests (1970's) have been supplemented by Coal New Zealand drilling (1992 - 1993) and surface mapping. A mining feasibility study was completed in late 1993 and approval gained for the driveage of an exploratory tunnel to the target seam.   Following construction of surface facilities, tunnel driveage on a 1:5 decline commenced from Rewanui in May 1995 and to date about half the required length has been driven. When the seam is intersected a comprehensive geotechnical testing programme will be undertaken to assess the in-situ mining conditions. It is expected that the results will confirm the assumptions made in the feasibility study.   The Mt Davy Mine, at depths of 500 - 700 metres, will be the deepest underground coal mine ever inNew Zealand and in-situ stresses (orientation and magnitude) will be important considerations for mining engineering. The coal has a high gas content and suitable techniques for gas control and prevention/mitigation of coal outbursts will be necessary.   Mine development is scheduled to commence in mid 1998 and an annual production level of 500 000 tonnes is forecast. The coal seams will be developed by continuous miner and coal extraction will be by hydraulic monitor. Coal will be pumped to the surface and from Rewanui transported five kilometres to Dunollie either by truck or slurry pipeline. At Dunollie a coal dewatering plant, coal stockpile and rail loadout will be constructed.

Jan 1, 1996

This paper describes the behaviour, under creep conditions, of a cast lead creep specimen consisting of five crystals, the boundaries of these crystals being substantially at right angles to the direction' of tension, i.e., across the long axis of the specimen. This particular specimen was obtained in an attempt to produce a single crystal in the manner described in the appendix of a previous paper (1).Thus, the specimen was of the same shape and size, was composed of the same purity lead and received the same preliminary treatment as the single crystal test-pieces.The object of the experiment was mainly to observe the effect of the crystal boundaries on both the deformation of the test piece and the process of recrystallisation and to compare the creep rate of the test-piece with that of a specimen consisting of one crystal only.EXPERIMENTAL METHODThe specimen had an effective test length of 10 cms. and a cross $ection of 0·5 in. x 0·25 in. In Fig. 1 is given a sketch of the specimen to scale showing the positions of the crystal boundaries on all four surfaces. Except for those of crystal No. 4, which was confined to approximately one-half the cross section of the specimen, the boundaries of each crystal traversed the four faces.The specimen was mounted in exactly the same manner as the single crystal specimens. During the creep test, it...

Jan 1, 1941

Spreadsheet Based Modelling of Liner Wear Impact on Charge Motion in Tumbling Mills

Sep 13, 2010

By J Fraser, M Scoble

Within the past decade, incidents of mining–community conflicts have grown dramatically and represent one aspect of a phenomenon known as social risk. Research published in 2014 indicates that a lack of social acceptance is now a leading and costly cause of delays for mining projects.The rise of social risk, complemented by the need to earn the trust of an increasing number of stakeholders so that mining projects can be developed effectively, is problematic for the industry. Conflicts are occurring in situations where companies are fully compliant with regulatory and legal requirements, despite initiatives by mining companies to earn social acceptance and despite the proliferation of tools to support corporate social responsibility. Intensifying the impact of social risk is the fact that it has increased during a time in the global mining sector when companies have had to grapple with declining commodity prices, increasing capital costs and debt levels and the challenges of mining lower-grade deposits.This paper will explore a hypothesis that in today’s interconnected society, social risk in the mining sector constitutes a legitimate business risk that must be managed strategically. The reality facing mining companies is that information, once considered confidential, now travels quickly on social networks and via a growing number of groups and individuals that have earned a legitimate right to be classified as stakeholders in projects that affect their communities. To be successful, it is suggested that companies will benefit from increasing internal collaboration and providing training to equip teams to mitigate social risk to mining projects and protect reputation capital. The paper is based upon PhD research being undertaken to assess the points of intersection between social risk and social responsibility during the construction stage of greenfield mining projects.CITATION:Fraser, J and Scoble, M, 2015. Mining–community conflicts – can the future mining sector transform social responsibility?, in Proceedings Third International Future Mining Conference, pp 159–168 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By Sofoulis J

In the Archaean of the Kalgoorlie-Norseman area, the layered rocks have been subdivided into two sequences, both containing basic igneous rocks and sediments. The lower sequence is distinguished by the presence of acid volcanic flows and large acid sills. The upper sequence is unconformable on the lower one.In some areas, clastic sediments become coarser and pass into conglomerates. Th:s passage is accompanied by thinning of the beds.These features and their distribution suggest a basin of subsidence flanked by areas of shore-line conditions.Repeated igneous activity, including vulcanism, has occurred along the flanks of this basin. These different igneous and sedimentary environments have played an important part in the primary distribution of metals.A chronology of all basic and acid igneous activity, as well as sedimentat:on, has been established for the Precambrian of this area.INTRODUCTIONThe subdivision of Archaean rocks into those of basic igneous or of sedimentary origin has formed the basis for the nomenclature appearing in past literature. These subdivisions were distinguished as greenstones (predominantly basic igneous rocks) and whitestones (predominantly sediments), and it was generally accepted that the greenstones were stratigraphically lower in the sequence than the whitestones.Recent studies show that, between Kalgoorlie and Norseman, basic igneous rocks interfinger with and pass laterally to sediments, and that basic volcanic rocks occur at different stratigraphic levels. Younger Precambrian. units are also...

Jan 1, 1965

During the latter part of 1937 consideration was given to the construction of a; local smelting plant for producing blister copper. Previously copper concentrates had been shipped to the United States of America. The proposition had the advantages of a saving in cost of realization, quicker financial return and reduced dependence on overseas shipping.The smelter was designed by the existing staff, who had difficulty in obtaining data on small plants, particularly on the reverberatory furnace. Construction was started in March, 1938, and the reverberatory was blown in on January 16th, 1939. One roaster had been operating for several weeks prior to this date.While results and operating technique on this new departure in small-scale smelting are barely beyond the experimental stage, it is felt that the experience gained to this time should be recorded to help fill the obvious gap in published information covering plants of this type.At present there are three copper smelters operating in Australia; the other two plants are equipped with blast furnaces.LOCATIONThe new smelter is situated in a position convenient to the concentrator and to the power plant. The site is traversed on two sides by a brick flue, from an old smelter plant, which connects with a 250-ft. stack. This stack and portion of the old flue are used in connection with the...

Jan 1, 1939

By D Pilone

The Tyrrhenian micro-nodules, findable at low depths (200/600 m under s l) are a reasonable reserve of manganese. They can be easily and cheaply recovered but do not contain valuable metals as in the case of oceanic nodules. In this work a hydrometallurgical process for manganese recovery from Tyrrhenian nodules is presented. The studied treatment includes the following operations: magnetic enrichment, reducing leaching, leach liquor purification and electrowinning . The study shows that the most important step in the process is the preliminary manganese enrichment. It can be done directly on the platform reducing not only the transport cost, but also the residue mud in the metallurgical plant. The leaching parameters such as status and size of nodules, temperature, composition of leaching solution and S/L ratio have been investigated. After purifying the leach liquor by iron precipitation as ammonium jarosite , the conditions to electrowin manganese have been investigated. The yields of both manganese leaching and iron precipitation together with current efficiency and specific energy consumption in the electrowinning step are given.

Jan 1, 2000

By KEITH BARRONI

In the proposed criterion for coal a distinction is made between brittle and "psuedo-ductile" failure. This criterion is the basis for the development of new equations for coal pillar strength, including a transition from brittle fracture to pseudo-ductile yielding. In addition the equations obtained allow the critical minimum pillar dimensions to be calculated to avoid "catastrophic" and "ultimate failure".The validity of these formulae can be tested by comparing their results with pillar case histories derived from the literature.

Jan 1, 1988

The Broken Hill orebody ,occurs in the Willyama Complex, a block of Precambrian rocks which have been strongly folded and metamorphosed at moderate to high grade. Although -the origin of the silver-lead-zinc mineralization remains obscure, recent investigations have substantiated the view that the orebody has undergone concomitant high grade metamorphism with the enclosing wallrocks. The mesoscopic structures produced by this metamorphism are described, and the possible processes Telating to their formation are disoussed.In the high grade ore, metamorphic structures which can be recognized are foliation and lineation, wallrock fragments, layering, flow folds, ore breccias, and sulphide bearing veins. These structures can be related to processes involving plastic flow and fluid phase transport of the mineral assemblage. 'In areas of low grade mineralization adjacent to high grade ore, the structures more closely resemble those produced in -the wallrocks-foliatlon, lineation, layering, folds, and sulphide injections. Within areas of high grade ore, lenses and pods of manganese silicates Probably represent original inhomogeneities in the ore, i.e., portions of manganese-rich and sulphide deficient rock which have been metamorphosed to manganese silicates.From the structures displayed, a sequence of events has been established for the plastic flow of ore during deformation.

Jan 1, 1975

By Conochie D. S, Grave N. C

Disposable-tip emf cells at present used in liquid steel can be used to measure the state of oxidation of high-iron slags produced in non-ferrous smelting. This provides a new tool for the control and evaluation of pyrometallurgical operations.An investigation of oxygen potential variations throughout a typical nickel smelter using the flash smelting technique gave a valuable insight into the process. Correlations of oxygen potential with ferric to ferrous oxide ratio and nickel content in slag were in reasonable accord with equilibrium data in the literature indicating that the probes may be used both as a plant investigation tool and possibly as a means of obtaining thermodynamic data for slags.

Jan 1, 1979

By Hannan J. C

In New South Wales, development applications for major coal mining proposals are determined by the Minister for Planning and Environment and applications for mining leases and other mineral titles are dealt with by the Minister for Mineral Resources. The environmental conditions placed on the development consent, the coal mining lease and the approvals and licences under the pollution control legislation, amount to a substantial component of any new project's planning and commissioning considerations.An outline is presented of the framework within which various approvals are granted and conditions for environmental management are imposed upon mining projects. The principles and concerns, as perceived by the regulatory authorities, on which the majority of approval conditions are based are also outlined.No attempt has been made to analyse the extent to which these principles or standards are achieved in practice, nor to discuss the degree to which some of the conditions are achievable with the current status of technology and economics in the coal industry.

Jan 1, 1987