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By J N. Farrell

Metallurgists frequently use a small number of large samples to characterise expected mill performance, with the a priori assumption that these few samples are representative of the entire deposit. Geometallurgical sampling is becoming more prevalent as a way to use many smaller samples to indicate the expected recovery as part of the Mineral Resource or Ore Reserve estimation.Recent increases in prices for iron ore, together with the potential to produce high iron and low contaminant concentrates, have resulted in a renewed interest in recovering magnetite from banded iron formation and other deposits.Geometallurgical evaluation of magnetite involves approaches to sample preparation, sample analysis and resource estimation that are different from the methods commonly used for haematite iron ore. The magnetite sampling protocol is specific to each deposit, and is typically designed around a specific metallurgical flow sheet.The sampling protocol will typically include the use of Davis Tube analysis. The Davis Tube is a bench-scale test that is used for determining the mass magnetic recovery from a small amount of sample ground to a specific size. The magnetic concentrate may then be analysed and together with the mass magnetic recovery, may be used to simulate the expected mill recovery.During resource modelling, the mass magnetic recoveries and concentrate grades may be assigned to a block model using regressions with other chemical constituents, or may be estimated directly. For estimation of the concentrate grades, a weighting can be applied to account for the different mass magnetic recoveries from each sample and the impact of these differences on the concentrate estimates.This paper presents an overview of the use of metallurgical test data in resource evaluation for magnetite deposits.

Jul 11, 2011

By C M. MacRae

The characterisation of high-P iron ores by field emission gun electron probe microanalyser (FEGEPMA) was carried out to determine elemental associations in iron oxides sensus lato and, using this knowledge, to speculate on possible P incorporation mechanisms in goethite. Quantitative data was collected from two goethite-rich bulk ores and results showed that in both samples goethite was the main repository for phosphorus. The P-rich goethite also contained elevated levels of both aluminium and silicon.To understand the mechanism of P incorporation in goethite, high-P grains were located by coarse mapping of polished blocks with the FEG-EPMA. Analysis of element distribution maps collected on the P-rich grains showed that low-P regions within grains were typically associated with low-Al and high-Si, whereas high-P regions were associated with high-Al and low-Si. Based on follow-up quantitative analyses, a coupled substitution mechanism for phosphorus incorporation within goethite was proposed: 2Si4+ = 1P5+ + 1Al3+. Additional quantitative analyses on further examples indicated the mechanism was only valid for Si contents in goethite of <1 wt per cent.Preliminary transmission electron microscope (TEM) studies confirmed the presence of P, Al and Si in goethite.

Jul 11, 2011

By C Simpson

In 2011 the forecasted world demand for iron ore continues to grow, and during this time Australia is looked upon as a reliable supplier of high quality ore. The expansion of the current Australian mines is unlikely to meet the forecast demand. New mines are therefore being actively explored for and when discovered, are quickly being developed into mines in order to meet the world’s hunger for steel.The Solomon Project area is a large new iron ore discovery, located in the central Hamersley Ranges of the Pilbara province in Western Australia. The first Fortescue exploration drill holes commenced on the project in 2007 and to date three billion tonnes (Bt) of iron ore have been defi ned within the project area. Fortescue is fast-tracking the development of the ‘Solomon Stage 1’ project, with rail and mine construction commencing during 2011, and ore to be railed to Fortescue’s existing shipping operations at Port Hedland commencing in 2012. At a designed production rate of 60 Mt/a, the Solomon operation will be one of the biggest production centres of iron ore in the Pilbara.Deposit types include the three dominant mineralisation styles of the Pilbara province, being bedded iron deposits (BID), Channel iron deposits (CID) and detrital iron deposits (DID). All these mineralisation styles are present in large concentrations within the Solomon project area, and when mined will produce two product streams. These are a single product of CID, and a combined product from a blend of BID and DID material.This paper defines the geological characteristics of the Solomon iron deposits as recognised through the exploration and development of this vast resource over the three years since exploration commenced on the project.

Jul 11, 2011

By J M. F Clout

The Roy Hill Project is an independent integrated port, rail and mine development in the Pilbara region of Western Australia. The bankable feasibility study for the project was completed in January 2011 by Roy Hill Holdings Pty Ltd, a wholly owned subsidiary of Hancock Prospecting Pty Ltd. The Project will deliver 55 Mt/a of premium quality iron ore to a rapidly growing market with a mine life of over 27 years. This study is based on exploiting a 1.2 Bt bedded resource of microplaty haematite-rich Marra Mamba, from which 562 Mt of reserves has been delineated to date. A further 1.1 Bt resource of detritals and low grade bedded is proposed to be mined once the bedded high grade resource is depleted. Roy Hill lump and fi ne ore products will compete strongly with other Pilbara products. As a low cost producer, Roy Hill is on track to capture four per cent of the global seaborne traded iron ore market. The project decision to proceed is targeted for Q2 2011 to enable first ore on ship by Q2 2014.

Jul 11, 2011

By P J. Howard

Atlas Iron Limited’s McCamey’s North project lies at the eastern end of the Hamersley Basin, approximately 50 km east of Newman, Western Australia, and 3 km northeast of BHP Billiton’s Jimblebar Mine. The presence of significant surface iron mineralisation identified during field reconnaissance, has subsequently been further defined by detailed mapping and RC drilling.The project area is dominated by outcrops of moderate to steeply north and south dipping banded iron formation, cherts and shales of the Boolgeeda Iron Formation overlying rhyolites and rhyodacites of the Woongarra Volcanics. In lower lying areas recent colluvium and alluvium mask the Archaean geology. Drilling and downhole geophysics has allowed a composite stratigraphic section to be compiled through almost the entire Boolgeeda Iron Formation.Surface orientations and subsurface stratigraphic correlations using natural gamma logs indicate large scale open folding about east-west trending fold axes across the project area; while small scale tight to isoclinal folding with similar fold axis orientations are visible at the outcrop scale. These folds are cut by a number of moderate to steeply south-dipping normal faults defining a series of north-dipping fault blocks which repeat the stratigraphy across the project area.Bedded iron mineralisation consists mainly of haematite-martite and goethite ores with best results of 78 m @ 60.5 per cent Fe. Vitreous goethite is observed at the surface of the mineralised horizons. The mineralisation exhibits a strong stratigraphic control and extend down-dip up to 120 m below surface. The strike extent of the mineralisation is still to be determined. An inferred resource of 39 Mt at 58 per cent Fe has been defi ned to date (ASX: AGO 3 February 2011).The fi ndings at McCamey’s North indicate that there is potential for economic iron mineralisation to exist in other areas of Boolgeeda Iron Formation within the Hamersley Basin.

Jul 11, 2011

By T Belligoi

Diamond cores and drill chips provide the only direct physical evidence for ore containing rocks. Early characterisation of cores and drill chips is important as it provides critical information for downstream processing. Traditional characterisation techniques include visual logging by a geologist or analytic and spectroscopic methods but they are time consuming and can miss some important textural or geomechanical features.The goal of this work is to evaluate the application of image analysis to iron ore cores and drill chips and to suggest improvements to existing core-scanning and chip monitoring systems. Two samples of massive ore differing by their mineralogy and texture, as well as two different batches of drill chips, have been imaged and analysed. Results are compared in function of the imaging system and the classification algorithms.As a conclusion, despite the necessity for more testing and improvements in calibration and lighting, it is obvious that image analysis technologies can bring a lot of useful information in the perspective of a geometallurgical mapping of the deposit.

Jul 11, 2011

By C I. Edwards

Phosphorous is typically present in iron ore either in the mineral apatite, Ca5(PO4)3OH, or associated with the goethitic fraction of the ore. In this paper, we present results that show that phosphorous associated with the goethitic fraction can be removed with a heating pretreatment around 300 176;C for 1 h, followed by a caustic leach with 1 - 5 M NaOH, or a leach with sulfuric acid at pH 0.5. The heating pretreatment is considered to dehydroxylate the goethite to form a haematite intermediate phase, ‘protohaematite’, that reacts during the leach making the phosphorous accessible to the leachant. In the acid leach, ten to 15 per cent of the sample was dissolved to obtain a leach product with 0.08 per cent P. In the caustic leach, as no weight loss occurs, it is proposed that iron species associated with the protohaematite have either not dissolved or have reprecipitated at the high pH values of the leach.For an ore containing apatite as the source of phosphorous, a leach with sulfuric acid dissolved the apatite, lowering the phosphorous levels in the sample. The sample treated contained carbonate minerals (including siderite) that also reacted with the acid, and in practice a balance between the dissolution of the apatite and the carbonate minerals may be needed to minimise acid consumption.

Jul 11, 2011

By X Dahe

SLon vertical ring and pulsating high gradient magnetic separators possess excellent mineral processing ability and have been widely applied to process oxidised iron ores. SLon centrifugal separators are applied to clean the SLon magnetic concentrate and remove quartz and other gangue minerals associated with a small portion of magnetite.This paper introduces the application of this technology in Hai Nan, Da Hong Shan and An Shan for processing oxidised iron ores.

Jul 11, 2011

By M S. Reston

The Tonkolili banded iron formations (BIF), Sierra Leone, host extensive iron ore deposits which are of economic signifi cance to the seaborne iron ore trade. The deposits are dominated by a strategic JORC compliant mineral resource of 11.6 Bt grading 30.1 per cent Fe comprised of primary magnetite mineralisation in the form of a fresh metamorphosed BIF featuring a uniform mineral assemblage of quartz-magnetite ± ferro-silicate minerals. Pilot plant metallurgical test work has demonstrated that the production of a magnetite concentrate is achievable using the established beneficiation techniques of magnetic separation and flotation. The concentrates arehigh-grade, and suitable for blast furnace or direct reduced iron pellet feed. The major challenge facing the development of such magnetite deposits at industry competitive production rates is the significant capital investment required for process plant and associated infrastructure.Two well-developed weathering zones exist within the deposits, and are associated with the progressive development of a tropical weathering profile overprinting the primary BIF. These zones feature a near surface hard indurated duricrust up to 60 m thick, and a soft progressively developed saprolite between duricrust and fresh BIF. These zones have been found to be amenable to producing iron ore products including DSO lump and sinter fines from the duricrust, and concentrate from the saprolite. Mineral resources sufficient to support commercial production of such iron ore products were defined by an intensive exploration program in 2010.African Minerals Limited has developed a three phase production strategy to progressively self fund the development of the Tonkolili strategic magnetite project by:• commencing a Phase I 12 Mt/a DSO operation in Quarter 4 2011,• increasing production in Phase II to 35 Mt/a with the commissioning of a saprolite beneficitation plant and associated infrastructure upgrades, and• developing a 45 Mt/a Phase III operation producing high-grade magnetite concentrate.The comparatively low capital and operating costs of a duricrust DSO lump and sinter fines operation coupled with its proximity to ground surface make it highly attractive for the generation of early cash flow for the Tonkolili project. Revenue from this early production may be used to selffund the subsequent development of phases requiring progressively more significant beneficiation plant and infrastructure.

Jul 11, 2011

By G Cooper

The Société Nationale Industriel et Minière (SNIM) is expanding its ore and concentrate production capacity in Mauritania, West Africa. This government-controlled mining company has been in production since 1963 and currently exports some 12 Mt/a.SNIM is presently doubling its magnetite concentrate production at the Guelb el Rhein mine. An existing processing line will have a second parallel production line of 4 Mt/a added. The mine is located some 600 km inland from the Atlantic coast in the heart of the Sahara Desert.The metallurgy of the ore is reasonably straightforward. It is a magnetite banded iron formation that is amenable to magnetic separation. While the existing plant uses semi-autogenous grinding and dry magnetic separation, the new processing line will use HPGRs, dry magnetic separation, and a wet milling and magnetic separation circuit for treating middlings.The process choices refl ect the scarcity of water in the region, the high cost of locally generated power and the operating experience and preferences of SNIM. Dust control in the desert environment has been a particular challenge.The metallurgical design aspects as well as the infl uence of the environmental and commercial aspects of the project are presented.

Jul 11, 2011

By J Siliézar

The Ernest Henry Mine (EHM) is situated 38 km north-east of Cloncurry in the Mount Isa – Cloncurry mineral district of northwest Queensland. The EHM orebody is an iron oxide copper gold deposit with an average grade of one per cent copper, 0.5 g/t gold and 23 per cent magnetite, with current reserves of approximately 88 Mt.The copper concentrator is a single line plant with a nominal throughput rate of 1300 tonnes per hour. An average of 350 000 tonnes of concentrate is produced each year containing around 100 000 tonnes of copper metal and 120 000 troy ounces of gold.In December 2009, Xstrata Copper announced approval of a $589 M investment to extend the life of EHM to at least 2024, through the transformation of open pit mining operations to a major underground mine together with the construction of an associated magnetite extraction plant.The EHM magnetite plant extracts the magnetite from the copper concentrator’s tailings stream. It will produce approximately 1.2 Mt of magnetite concentrate per annum at full capacity for export to Asia, making EHM Queensland’s first iron ore concentrate exporter. Construction of the magnetite extraction plant commenced in July 2010 and was completed in January 2011.This paper gives an overview of the development of the EHM magnetite extraction plant flow sheet from the early mineralogy and laboratory test work through to the plant commissioning and early operation of the base plant. It has a major focus on the commissioning learnings from the plant start-up and includes a review of the operational performance of the plant versus original design and expectations.

Jul 11, 2011

By P Cooper

Continuous improvement using six sigma methodologies commonly follows the DMAIC methodology of define, measure, analyse, improve and control. A key requirement in the use of this approach is to ensure that data is trusted, validated and contextual. In today’s production environments it is common to find disparate technology comprising the system architecture and highly customised interfaces between the various technology layers. This complexity often leads to inaccurate data presented at the operations management layer or worse, data that is not trusted. Identifying defects and making corrective actions cannot be efficiently carried out unless trusteddata can be easily obtained with a production context. It is also common to find that disparate systems of this nature present information in multiple ways and through multiple presentation systems. This paper discusses how the use of web-based technologies in an integrated technology stack can aid the accessibility, accuracy and trust of data used in decision-making and also how a unified visualisation environment can lead to greater operator efficiency.

Jul 11, 2011

By D Matthews

With a brownfield project comes control integration challenges. The Khumani Iron Ore Mine’s second phase expansion posed a number of challenges as there was substantial brownfields work conducted. The fi rst phase was the compilation of the modifi ed process functional specifications for the project. The second phase was an audit on all of the operational sequences; this included a comparison between the SCADA sequences, sequential starts analysed from the historian data (with the potential for improvements made by the plant operators in manual start-ups) and what was proposed in the process functional specification. Differences, inclusions and missing equipment were highlighted. The third phase was the comparison of interlocking and control in the PLC with the updated process functional specification; this was done during the coding process. Running parallel to the three phases was the SCADA integration; tie-ins to the existing SCADA were conducted on maintenance days and shutdowns, in many instances with ‘dummy’ equipment to get the operational staff accustomed to the new interface. This paper details each of the phases, the success of this methodology as well as the pitfalls experienced.

Jul 11, 2011

By M A. Wells

The various mechanisms by which phosphorus (P) occurs and is distributed within banded iron formations (BIF)-derived iron ore are examined. In unenriched, precursor BIF P occurs predominantly as discrete grains of primary apatite. In high-grade ores hosted mainly by the Brockman Iron Formation, P occurs in three main forms:1. as secondary apatite;2. other submicron, P-rich phases (eg Rare earth containing minerals (REE), vivianite, strengite,wavellite) present in pore networks; and3. as P occurring with iron oxides, in particular, goethite.However, the presence of secondary P-bearing phases does not contribute signifi cantly to the total P level in iron ore, and it is P associated mainly with goethite, which represents the most common occurrence of P in these ores.No direct evidence for the replacement of Fe by P within the structure of synthetic goethite has been demonstrated. Therefore, it is most likely that in iron ores P associates with goethite in occluded form as adsorbed PO4 3- species or as discrete P-bearing minerals, such as strengite, wavellite or vivianite, in ultra-fine, micro-pores or within intra-domain regions of multi-domainic goethite. Such occluded P is not easily extracted with commonly used lixiviants, such as weakly alkaline leachates. Recent development of a low temperature-alkalie/water leach extraction method has been successful in reducing not only the P content, but also amounts of Si and Al inthe initial ore. Refi nement of such a method to commercial application will have enormous benefit in realising the economic potential of large tonnages of high-P (ie >0.07 wt per cent P) bearing iron ore.

Jul 11, 2011

By William DeWit

When rivers are contaminated from industrial operations, as often occurs near repositories of spent mine tailings, decision-support tools can be critically important in evaluating the effectiveness of various engineering impact-management measures. Even where data describing river flows and quality are sparse, simple mixing-zone models can be constructed that can contribute greatly to understanding how impact-management measures can differentially affect existing river-chemistry regimes. There can be circumstances where accumulated surface waters near contaminated land can bear contaminant loadings that could be acceptable to river regimes if there were methods available to evaluate optional discharge rates and to predict post-mixing consequences on river chemistry. Nomographs can be constructed to evaluate discharge regimes that appear capable of releasing contaminated accumulated pond water without compromising water quality in a nearby river. River-mixing zone models also contribute to predicting rates of acceptable discharge and release to the receiving environment.

May 1, 2011

By Willemijn Husslage

Tata Steel Group At a glance ? Part of the Tata Group ?Tata Steel Group: ?Fortune 500 company ?Top 10 global steel producer ?Annual crude steel capacity of 28 million tonnes ?More than 80,000 employees ?Manufacturing operations in 26 countries across 5 continents ?Serving customers all across the globe ?Turnover 2009-10: $22.8 billion

May 1, 2011

By Graham Sim

Agenda ?The Water Challenge ?Examples from Three Case Studies ?Mine Drainage, 99% recovery ?Mine Drainage, 80% recovery ?Road Dust Control ?Technology Development ? Conclusion Global water challenges Assuring sustainable quantity Improving water quality Reducing energy consumption

May 1, 2011

By Timothy D. Dreger

In the spring of 2009, Suncor Energy Inc. technical personnel saw an opportunity to improve planning 0and mining of overburden material in order to address aggressive construction goals and increased mining complexity. By tying together current and historical equipment performance, geological model information, and material observation in the field new operating elevations for the shovels were developed. At the same time, methodology of recording and reporting overburden movement through the Modular Mining DISPATCH system was changed. The result of this first stage of improvements was an increase in construction-grade material available at the face. The personnel involved realized that other opportunities were available to build on the initial successes and establish processes that would stand up to attrition and experience levels. A cross-functional technical team was assembled to identify ways of further improving workflows around overburden mining. Some of the opportunities realized include greater alignment between planning, reporting and operations as well as development of reporting tools that help steward Mine Operations to the plan. All of which have resulted in Suncor meeting or beating its forecast overburden targets. The cross-functional technical team continues to seek out new and better ways of doing business so Suncor can continue to deliver on its commitment of outstanding performance and results.

May 1, 2011

By Louise Pearce

?Environmental and social impact assessments (ESIAs) are: ??process-driven and scientific processes ??The process entails a number of steps and procedures which result in obtaining a licenceto operate ?and moving more towards a social license to cooperate. ?However, the primary premise of ESIA is to facilitate the consideration of environment and the communities in planning and decision-making which would ultimately make it possible to arrive at decisions that are ?sustainable?. ?Hence, ensuring the development of the mining sector on a sustainable basis is a critical challenge that needs to be addressed by the global community.

May 1, 2011

By Gordon F. Scott

This paper considers a recently completed hoist project for IAMGOLD. Called the Westwood project, this mine utilises some of the largest drum hoists supplied to the North American Market in recent times. This project is an example of where many of the design features discussed the associated paper, (Robotham, 2011) were incorporated. Director of sales and marketing, Gordon Scott has worked at DavyMarkham for over 30 years in a variety of roles starting as a mechanical design engineer, moving to project management before joining the sales department. Gordon has an honours degree in mechanical engineering from Leeds University.

May 1, 2011