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By A D. Pradana, D R. Pradana, Y H. Putra, Z Zulhan, T Hidayat

The high temperature processing of nickel laterite ore is currently dominated by the Rotary Kiln- Electric Furnace (RKEF) technology. The ratio of SiO2/MgO (S/M) in the ore is one of the critical parameters that determines the success of the RKEF process. Incompatible S/M ratios in the ore can cause aggressive chemical interaction between the slag and MgO refractory. The slag-refractory interaction at conditions relevant to nickel laterite ore smelting was investigated in the present study. Synthetic mixtures representing the slag compositions of nickel laterite ore smelting were prepared by mixing MgO, SiO2, Al2O3, CaO, Fe2O3, and Fe and heating the mixtures in steel containers at 1300°C under an argon atmosphere for 3 hrs. Pure MgO crucible were used as containment material in the melting process of the mixtures to represent the MgO refractory. The kinetics of the slagrefractory reaction were investigated using samples with selected initial S/M ratios of 2.0 and 3.0 (wt/wt) (with constant CaO = 3 wt per cent, Al2O3 = 5 wt per cent, FeO = 10 wt per cent) by performing melting at 1500°C in MgO crucibles for 5, 30, and 120 mins under an argon atmosphere. The effect of the S/M ratio in slag on the slag-refractory interaction was also investigated by performing melting of mixtures with different initial S/M ratios of 1.75, 2.0, 2.5, and 3.0 (wt/wt) in MgO crucibles at 1500°C for 120 mins under an argon atmosphere. After the melting process, each sample was quenched in water, mounted in resin, ground, polished, and coated. The interaction between the slags and MgO refractory was then evaluated by analysing the polished samples using a scanning electron microscope equipped with an energy dispersive spectroscopy (SEM-EDS). Thermodynamic simulations using FactSage™ 8.0 thermochemical software were performed based on the experimental slag compositions, refractory, and conditions to support the evaluation process. The results show that a higher S/M ratio in slag leads to a higher tendency for the refractory component to dissolve into the slag. A higher S/M ratio in slag also leads to an increasing extent of solid-state diffusion of iron oxide into the remaining refractory grains. The dissolution of MgO into the slag is rapid; the MgO concentration in the final slag increased by 2.4 wt per cent and 5.7 wt per cent at initial S/M ratios of 2.0 and 3.0 wt/wt, respectively, within 5 and 30 mins of the melting process.

Aug 21, 2024

By Redman P. G, McMahon B. K

A simple technique for evaluating the field stress ratio is presented, based on the results of extensometer or convergence tape measure- ments taken in an advancing tunnel. This tech- nique also yields a value for the rock mass modulus, provided Poisson's Ratio is assumed. The results of two case studies are presented illustrating the effectiveness of the method.

Jan 1, 1981

By S McKnight, L Koroznikova, S Hall

Mineral sands represent an important new resource being developed in the Murray Basin, including parts of western Victoria. This paper will outline a simple methodology for mineral sands characterisation, developed as part of the AMIRA-managed project P777 æThe Development of Heavy Suspension Techniques for High Density Separations (Replacement of ClericiÆs Solution)Æ. This project is currently sponsored by three multinational mining companies (De Beers Consolidated Mines, Iluka Resources Limited and Rio Tinto Limited) and is developing an innovative laboratory mineral characterisation procedure that will allow the replacement of the currently employed highly-toxic chemicals.Mineral sand resources almost always contain more than one valuable (and relatively heavy) mineral. Titanium minerals are found with a large range of titanium contents, giving rise to density variation and often subjective mineralogical descriptions. Companies tend to rely on laboratory heavy liquid separation in the evaluation of samples arising from exploration, mining or metallurgical processes. Unfortunately, there are only a limited number of high density (æheavyÆ) liquids and these tend to be more toxic as their density increases. Low-toxicity inorganic solutions, based on tungsten compounds, have been developed that can be utilised at relative densities (RD) up to 3.0. However, beyond this value currently only organic liquids can be used. Diiodomethane (methylene iodide) having a relative density of 3.31 is commonly used; however, this presents significant health and safety hazards. Mixtures of thallium formate and thallium malonate were found in the early 1900s by Clerici to provide liquids having specific gravities between 4.0 and 5.0, hence æClericiÆs solutionÆ. For the characterisation of the heavy components of mineral sand deposits (eg anatase sg 3.9, rutile sg 4.2, ilmenite sg 4.4 û 4.7 and zircon sg 4.6 û 4.8) there is currently no heavy liquid alternative to ClericiÆs solution. ClericiÆs solution is highly toxic and testing is now conducted by very few laboratories worldwide with costs reflecting the chemical costs (though extensive efforts are made to recover and reuse the liquid, plus the requirement of its removal from the mineral samples), the infrastructure costs and health and safety regimes (eg blood testing of exposed staff, inventory management). A simple laboratory technique of density fractionation is being developed, employing suspensions of fine tungsten carbide particles in lithium heteropolytungstate (LST) solutions, that can replace ClericiÆs solution in the evaluation of fine mineral sands samples (eg -250+150 microns). The developing methodology that can achieve low-cost, low-toxic separations at relative densities above 5.0 will be outlined and the comparison of results with ClericiÆs solution presented.

Jan 1, 2006

By Z Li, Z Yan, T Htet, S Zhang

During the pyrometallurgical processes, a substantial quantity of high-temperature ironmaking and steelmaking slags, generated at temperatures ranging from 1400 to 1600°C, is wasted, as the heat contained in these slags is released into the environment during the tapping process without effective utilisation. On the other hand, a significant amount of energy is required to reheat the cold materials for the manufacturing of glass and mineral-wool, often necessitating the addition of high-silica materials to facilitate the production process. In this study, an innovative approach is presented to harness the heat present in molten metallurgical slags to directly produce new raw materials for glass and mineral-wool manufacturing while simultaneously reducing energy consumption and mitigating CO2 emissions. The theoretical amount of waste glass that can be effectively added in the process has been estimated via thermodynamic calculation. Experimental assessments were conducted to examine the impact of high-silica waste materials on the dissolution, melting and fluidity. Potential recipes for glass and mineral-wool manufacturing were suggested and an assessment of the energy savings, and reduction in CO2 emissions with manufacturing of glass and mineral-wool using this innovative approach were included. It was determined that the processes could lead to a reduction of over 26 kg of CO2 emissions per 100 kg of new material used, primarily due to the utilisation of heat from slag and the accelerated smelting process.

Aug 21, 2024

By D Capstick, M B. Ebell

This paper describes the test work, process design, commissioning and operation of a processing system at the Ergo gold operation that improves the extraction efficiency from gold tailings material. The improvement in recovery is derived from the separation of the gold contained within the sulfides of the tailings material and a dedicated process stream to recover that gold.The sulfides are separated by means of a flotation circuit and that resulting concentrate is subjected to a regrind of below 20 ¦m to enable a greater liberation of the gold. The ultra-fine material is then subjected to a dedicated leach circuit to recover the now exposed gold particles.The case study is an example of the challenges of introducing new technology and methodologies to a well-established operation and thereby attaining improved efficiencies and tangible business benefits.CITATION:Ebell, M B and Capstick, D, 2013. Improving extraction efficiency from Witwatersrand gold tailings using flotation and ultra-fine grinding of concentrates, in Proceedings World Gold 2013 , pp 301-306 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By D Andrew, G Stanway, P Mahoney, C Griebel

The iron ore mining industry is currently going through an adjustment from high to more moderate growth as China’s economy transitions from capital-intensive investment to a more services-oriented economy. We are now witnessing a renewed focus on productivity improvements and cost savings as planned expansions are completed. Despite the scale and importance that the mining industry plays in the global economy, innovation literature is generally more targeted at faster-moving industries with shorter innovation timeframes and lower capital requirements. To fill this gap, VCI set out to understand the state of innovation in the mining industry in 2014. This State of Play report aims to give an objective appraisal of the strengths and weaknesses of innovation in mining. The report has three sections covering both the structure and delivery of innovation in mining:Ecosystem – focused on understanding how the iron ore mining innovation ecosystem system works, including the roles of large and small miners, service companies, researchers and governments. Our recommendations focus on what is required for the system to work well and improve the level and quality of innovation in the industry.Strategy – how do companies define their innovation strategy in relation to their corporate strategy? How are these related to prevailing global and industry trends? How do they communicate this with their business? How successful are they? These are among the questions that this section attempts to answer. Our recommendations are pitched at the executive leadership of iron ore mining and service companies.Delivery – focused on how companies develop and deliver innovation, looking at the success of different structural options, leadership and culture, partnerships and the best approaches to change. Recommendations are aimed at improving outcomes within the iron ore mining value chain, including the role that suppliers play.CITATION:Stanway, G, Mahoney, P, Andrew, D and Griebel, C, 2015. Understanding the state of innovation in the iron ore industry, in Proceedings Iron Ore 2015, pp 631–646 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Savage E. N

The porphyry copper minerals of Melanesia occur within a host of narrow veinlets in predominantly quartz diorite stocks or as contact metasomatic masses in skarns adjacent to the intrusion. Some 90 per cent of the constituent minerals comprise pyrite or marcasite, chalcopyrite, and magnetite with the remainder mainly bornite and hematite with accessory rutile and chalcocite together with several trace minerals. Gold is found mainly as inclusions in chalcopyrite, and minor molybdenite occurs likewise.Of particular significance is the persistent occurrence of accessory rutile of hydrothermal origin intimately intergrown with chalcopyrite. The rutile occurs relatively late in the hydrothermal sequence and upon weathering of the deposit may be released on a cumulative basis possibly in sufficient amounts to constitute a particulate pathfinder mineral which may aid in prospecting.Rutile is present in all the Melanesian occurrences studied and is also prominent in several American deposits.The porphyry copper mineralogy is characterized by the presence of accessory hydrothermal rutile intergrown with chalcopyrite.

Jan 1, 1975

By Tiu C, Sarmiento G, Uhlherr PHT

Fundamental rheological properties of slowly settling mineral slurries are reviewed. Slurry flow is discussed in terms of observed shear stress-shear rate behaviour. Particular emphasis is placed on establishing procedures for scale-up and design. Flow property measure- ments on red mud, a waste product from the Bayer alumina process, are presented and used to illustrate recommended design procedures.

Jan 1, 1978

By T Connor

Alkali emissions are one of the environmental challenges facing alumina refineries. Queensland Alumina Limited (QAL) is undertaking a number of initiatives to continuously improve its environmental performance. One of these is a program aimed at the reduction of alkali emissions. Alkali emissions originate from a number of sources (eg elevated open tanks), and its level depends on a number of process parameters/ mechanisms (ie splash filling, thermal currents in tanks, streams discharged from a pipe, tank temperatures, atomisation) and climatic conditions (eg wind speed and direction, rain, etc). Under normal operating conditions, there is a continuous low level of alkali emissions from the plant. Certain vessels within the plant have been identified as major contributors to this level of emission, while certain activities within the plant contribute to a temporary elevation (æspikeÆ) of alkali emissions. QAL developed a method using phenolphthalein-treated pads to measure emissions within and outside QAL boundaries. These provide no information about mass emission rates but are important for detecting if alkali material is present. Since mass emission rates are important for determining if improvements in emissions are made, QAL identified the need to design an improved sampling method. Following the development and implementation of a sampling and analysis method to monitor alkali emission concentrations, QAL is conducting a number of feasibility studies evaluating a range of alkali emission reduction options. The alkali measurement method will be used to track and demonstrate progress in this environmental initiative. This paper will discuss the measurement method and emission reduction options being evaluated.

Jan 1, 2005

By M G. Aylmore, L W. de Klerk

Roasting of refractory gold ores has been a commercial process for many years. Improvements in design of fluidised bed roasting technologies and low capital and operating costs compared with other refractory treatment processes can potentially make roasting a viable option.However, gold extraction from roasted ores carried out on laboratory scale equipment often invariably yields lower recoveries than other processes such as bio-oxidation or pressure oxidation. Non-optimal laboratory roasting conditions can incorrectly write roasting off as a process option.Low gold recoveries from the cyanidation of calcine products from roasting can often be attributed to roasting conditions not favouring gold liberation and agglomeration processes, particularly if lockups of elements such as arsenic are being pursued for environmental reasons.This paper reviews the conditions favoured for gold agglomeration and accessibility of gold to cyanide, test conditions to achieve gold liberation and agglomeration on laboratory scale and designs that incorporate staged decomposition and roasting to make roasting a more commercial option.CITATION:Aylmore, M G and de Klerk, L W, 2013. Conditions and design considerations for maximising recoverable gold in roasting of refractory gold ores, in Proceedings World Gold 2013 , pp 375-388 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By S O’Connell, M Scholz, A Robertson, M L. Bloss

The value created in any mining operation is a function of the mine plan. The quality of this plan is dependent on the strategies employed during definition drilling, resource estimation and mine planning. This paper presents opportunities to improve the value of an operation through better strategic management of these core activities. Case studies undertaken recently at Olympic Dam are presented to support the conclusions presented in the paper.CITATION:Bloss, M L, O’Connell, S, Robertson, A and Scholz, M, 2016. Do we maximise the value of our operations through our definition drilling, resource estimation and mine planning strategies? In Proceedings International Mine Management Conference, pp 9-20 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

The Barra Mine was the most significant mine of Australia's earliest mining era, which took place in South Australia between 1841 and 1851, the decade prior to discovery of gold in eastern Australia. Between 1845 and 1860, Barra was the largest metalliferous mine in Australia and employed up to 1000 men and boys, most of them Cornish.""Today the site is also important in a physical and archaeological sense as it contains extensive remains of mining and processing operations of the period 1850 - 70. Most significant are three cnginchouses which housed Cornish beam engines.

Jan 1, 1993

By F Cesnik

The past few years has seen a concerted effort to improve the recovery of gold along with its co-product copper from the æhigh-gradeÆ Ridgeway concentrator at Newcrest Mining LtdÆs Cadia Valley Operations. A number of initiatives were identified and implemented, culminating in a sustained improvement in recovery of approximately three to four per cent for both metals. The key projects that contributed to this improvement included the installation of a 355 kW Metso stirred media detritor (SMD) to create a regrind circuit, installation of froth crowders on the scavenger circuit, installation of a Falcon SB2500SE gravity concentrator as part of the regrind circuit to improve gold recovered to bullion on-site and the optimisation of the grinding circuit to reduce the 80 per cent passing size (P80) of the primary grind from 160 to 121 ¦m for the same throughput via process control, cyclone and ball charge optimisation. This paper will focus on the supporting test work, where applicable, that was used as the design basis for the project, but more importantly the plant data before and after the changes to clearly identify the improvements to plant recovery.

Jan 1, 2007

By Z Tong, M Gao, X Wang

In response to the need for improved magnetic separators for beneficiation of fine grained iron ores that have been finely ground to liberate the iron minerals from the gangue, a series of high efficiency wet drum permanent magnetic separators (T-GCT) has been developed by Maanshan Tiangong Technology Co Ltd. These magnetic separators have high efficiency for separating superfine strongly magnetic minerals and the ability to produce high-grade concentrates with high recovery. They are ideal replacements for conventional drum magnetic separators, especially for treating superfine particles.

Jan 1, 2009

By D R. Seaman, B Adamson, F Burns, B A. Seaman, P Manton

The Telfer concentrator, located in the Great Sandy Desert of Western Australia, consists of a dual train gold/copper operation processing ore from one underground and, currently, two open pit mines with differing mineralogy. The flotation circuit of each train was designed to operate in several modes depending on the feed mineralogy. The majority of ore mined at Telfer is processed in a sequential mode where copper minerals are first floated into a saleable copper concentrate followed by the flotation of an auriferous pyrite concentrate which is treated in an on-site hydrometallurgical plant (carbon-in-leach (CIL)). Gold is recovered as a gravity product within the primary grinding circuit, to the copper concentrate, and to a lesser extent, the CIL circuit.Since Telfer was re-opened, with a new concentrator, in 2004, the processing plant has struggled with poor copper concentrate grades, partially due to the excessive entrainment of non-sulfide gangue minerals in the copper flotation circuit and, more recently, due to composite copper particles produced when processing ore from a supplementary satellite pit that has not previously been processed through the new Telfer concentrator. Gold recoveries in the CIL circuit have also been below industry standard. This paper presents the implementation of recent changes made to the circuit to address these performance issues. The reconfiguration of the circuit has involved the installation of the following major equipment items: two ISAMillsÖ in ultra-fine grinding applications (one in the copper circuit and one in the pyrite circuit), two Jameson Cells to improve fine gangue rejection and a bank of 5 + Outotec TC30s to recovery copper and gold from the reground pyrite stream. The equipment was purchased direct from vendors and an engineering firm contracted to design and install the multi-vendor reconfiguration upgrade.CITATION:Seaman, D R, Burns, F, Adamson, B, Seaman, B A and Manton, P, 2012. Telfer processing plant upgrade - The implementation of additional cleaning capacity and the regrinding of copper and pyrite concentrates, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 373-382 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By A Dal-Corobbo, R Zick

The coal mining industry is now faced with new regulatory requirements that limit the discharge of chlorides into receiving streams. To meet these new regulatory standards for treated mine water, a zero liquid waste approach was developed using advanced treatment technologies. The approach described in this paper will generate clean water for reuse in various energy endeavours or discharge to the environment, with no substantial liquid or solid waste from the treatment process leaving the site.CITATION:Dal-Corobbo, A and Zick, R, 2013. Zero liquid discharge in coal mining operations, in Proceedings Water in Mining 2013 , pp 221-226 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By S M. Denn

The Cawse nickel-cobalt operation is situated 50 km NW of Kalgoorlie in Western Australia, at latitude30o22'30'' south and longitude 121o08'30'' east on the Kalgoorlie 1:250 000 geological map sheet (SH 51-9) (see Figure 1). The project is owned and operated by Centaur Nickel Pty Ltd (CTR) and was the first in Australia to commercially produce nickel metal and cobalt sulphide through pressure acid leach (PAL) technology. Cawse has a total resource base (all categories of resources + reserves) of 213 million tonnes Mt at 0.7 per cent Ni and 0.04 per cent Co, comprising 127 Mt at Cawse Central which is 100 per cent owned by CTR and 86 Mt at Cawse Extended where CTR has a 80 per cent equity. Cawse Extended is located immediately to the northwest of the Cawse Central leases. All current reserves (proved and probable) of 30 Mt at 1.0 per cent nickel are contained within Cawse Central. In addition the Siberia project area 20 kilometres to the NW has a resource of 63 Mt at 0.7 per cent Ni. Cawse is a dry laterite deposit, with nickel and cobalt hosted by iron and manganese oxides. Cawse Central mineralisation extends over a ten kilometre strike length, with three pits currently being mined. The Bunyip pit has the premier nickel and cobalt grades within Cawse Central. There are seven dominant lithology types forming mappable units within current pit exposures. Four of these units are host to nickel and cobalt mineralisation. Ore types are defined as Upgrade, Grind and Non-upgrade, depending on their physical characteristics with respect to the treatment route. Mining commenced in February 1998. To the end of calender 1999 the operation has produced 2100 tonnes nickel plate and 470 tonnes of cobalt as a cobalt sulphide product. Future production will target 9000 tonnes per annum Ni metal and up to 2000 tonnes per annum Co, based on processing 500 000 tonnes of ore per annum.

Jan 1, 2000

The sinking of the new No. 3 Shaft being mainly concerned with providing for the continuation of mining operations north of the existing workings, requirements for the shaft and haulage equipment were assessed, having in mind the anticipated needs of the Company in future years, the .available knowledge and probable future trends of the orebody, and also that the shaft would be required to act as a downcast airway for the ventilation system associated with the northern underground workings.

Jan 1, 1957

By G Harbort, D Clarke, D Morgan, C Sola

Northparkes Mines commenced production in 1994 and the mine has significant reserves to allow operation into the future. There are a number of potential future concentrator feed sources with variable sulfide mineralogy and grades.In February 2012 a comprehensive flotation survey was conducted to allow mass balancing and evaluate the operation of the flotation circuit. A rudimentary, copper element only, unsized flotation simulator was developed to evaluate high level potential for optimisation and improvement. In 2013 this flotation model was expanded to produce a mineral based, floatability component model to estimate the effect of future concentrator feed source on metallurgical performance. This revised model allows various circuit configurations to be simulated to provide a high level blueprint for the long-term planning to maximise performance.This paper provides a review of the process followed to develop the model, including an analysis into the mineral floatability component model and its calibration against plant operations. The effect of varying feed mineralogy and feed quality on future performance has allowed an internal review of potential circuit changes needed to accommodate the changing future feed.CITATION:Clarke, D, Harbort, G, Morgan, D and Sola, C, 2014. Northparkes Mines – flotation and planning for the future, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 203–208 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By A Weston

Northparkes Mines is a joint venture between Rio Tinto and the Sumitomo group and is operated by Rio Tinto to produce copper concentrate from ore sourced from open cut and underground. Underground ore is mined with an owner operator workforce using the block cave method from the E26 deposit, with the first lift of the cave now completed. Development of the Lift 2 block cave commenced in March 2001 using a contract workforce. The Lift 2 Project required the mining of 14 700 m of decline and lateral development to establish a new mining horizon at the 9450 level and to develop two new conveyor declines. Also included in the scope was the excavation of a Crusher chamber to house the jaw-gyratory crusher. This paper describes the excavation of the hydroset chamber and orepass that sit immediately underneath the Lift 2 Crusher chamber. It includes risk assessment, planning, development of method statements and standard operating procedures, through to the excavation of the orepass and the installation of ground support in seismically active ground. There was a major ground failure in the backs of the conveyor feeder chamber during its excavation, which affected the excavation of the orepass due to its proximity to the breakthrough site.

Jan 1, 2005