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By C Zschiesche, alam, A Abadias Llamas, A K

Lead has the ability to collect and carry valuable metals such as copper, bismuth, antimony, tin and precious metals for their downstream recovery. Therefore, lead metallurgy is key for the raw material supply that our society demands. Lead smelters, excluding lead-acid battery recyclers, tend to process more complex primary and secondary raw materials, which are mostly processed via the pyrometallurgy route. Accordingly, understanding the slag system of these metallurgical processes is key for the efficient industrial operation and recovery of minor elements. Glencore Nordenham is an integrated lead and zinc smelter in northern Germany with a production of 92 000 t of lead and 164 700 t of zinc in 2022. The lead production line processes complex leadbearing raw materials through the direct smelting process. Firstly, the feed mix is smelted in a Top Submerged Lance (TSL – Ausmelt®) furnace, where a lead bullion containing minor metals and a lead-rich slag are produced. Then, the lead-rich slag from the TSL is tapped (via launder) into a Side- Blown Furnace (SBF), where lead oxide is reduced to produce lead bullion (with minor elements) and discard slag. The lead bullion from both stages is refined to produce lead (>99.9 per cent) and recover the minor elements (Cu, Ag, Au, Sb, Te, Bi etc). This paper reflects the experience of operating the SBF after the first five years of operation and describes its ‘PbO-SiO2-FeOx-CaO-ZnO’ slag system. Firstly, the slag system, the furnace operating region and the potential solid phases present are discussed from a theoretical point of view. This theoretical study has been performed using FactSage™ 8.2 and the database developed by the Pyrosearch group at the University of Queensland, Australia (UQPY). Then, the FactSage™ simulations are compared with industrial slag measurements. Finally, some examples on how the slag knowledge gained at Glencore Nordenham can help the industrial operation of the SBF are discussed.

Jun 17, 2024

An empirical method of estimating dense rock (D.R.E.) equivalent volumes erupted as airfall tephra, described in a companion paper in this volume, is elaborated, and its accuracy discussed. Estimates obtained from a single eruption can be classified as to whether they show positive, negative, or constant relative dispersion. For positively dispersed tephras (estimated volumes increasing with distance), this procedure improves the accuracy of the method. The technique is applied to selected andesitic tephras erupted from Egmont Volcano, New Zealand, during the last 28 000 years, which are found to range in volume from about 1.5 x 107 m3 up to about 2.4 x 108 m3 D.R.E. With a factor of about 16 between the smallest and largest volumes, this contrasts sharply with the rhyolite volcanoes in New Zealand, where the difference factor is usually of the order of 100. The largest tephra eruptions at Egmont are small compared to the largest debris avalanches, which have exceeded 1010 m3 (10 km3) in volume.The magnitude versus frequency relationship, calculated using a maximum likelihood method, establishes the limits of eruption magnitude at Mt Egmont as 107 to 109 m3 D.R.E. For some volcanoes, the magnitude-frequency relationship changes with time, owing to clustering of eruptions, separated by long dormant intervals. Ngauruhoe Volcano, New Zealand, is an example. Within eruptive episodes, the mean interval between eruptions of >_ 105 m3 is about 0.9 ¦ 0.65 years. The mean interval between eruptive episodes in which >_ 106 m3 is erupted, including episodes in which this volume is erupted gradually, is about 25.8 ¦ 6.6 years, and the mean dormant interval between all episodes is about 5.2 ¦ 3.0 years. At present Ngauruhoe is in an unusually prolonged dormant period, 50% longer than any in the historical record, since 1839.

Jan 1, 1990

By Egan J. R

Changes have recently been applied to the Sullivan Concentrator lead and zinc circuits to treat fine-grained ores which make-up the majority of ore reserves in the mine. Pilot plant testwork conducted in 1990 - 91 indicated that concentrate grades would be substantially improved by reducing the particle size (Pao) of the lead from 38 to 15 ¦m and the zinc from 45 to 24 ¦m. Circuit revisions involved installation of major new equipment including: two 600-kilowatt Vertimills for regrinding, a four metre diametre column flotation cell and a four metre diameter hyperbaric pressure filter for dewatering. Duties of the existing regrind mills were Reassigned.

Jan 1, 1993

Digitally enhanced Landsat MSS images are being used'in delineating the structural and tectonic features in the Arabian Shield as part of a project funded by King Abdulaziz City for Science and Technology (KACST) of Saudi Arabia. The delineated features together with statistical modeling and structural analysis are to assist in an improved understanding of the evolution and mineralization of the Arabian Shield. Specific emphasis is to be given to relating the extracted linear features to the location of known mineral occurrences and areas of potential geologic hazards. A number of textural (spatial) and spectral enhancement techniques have been applied, to the MSS data covering selected areas, in selecting the most optimal enhancement product for visually delineating the structural geologic .features.

Jan 1, 1988

By J Shillabeer

Paste backfill has been adopted by many underground mines in North America and a growing number elsewhere. Paste offers a number of advantages. This paper suggests wider applications of paste technology to surface tailings disposal and water management. Advantages include improved overall stability, potentially easier permitting, smaller water inventory and earlier reclamation. It may be feasible to use the same plant to prepare backfill and to dispose of surplus tailings. Example cost models are given to illustrate potential applications.

Jan 1, 1998

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 D Readett

The most critical variable in the successful establishment of the Murrin Murrin Heap Leach plant was the effective agglomeration of the Ni laterite ore. This paper describes the test work undertaken to establish the key agglomeration parameters including state of the art testing and analysis procedures. These parameters were then utilised to establish the key design and operational concepts for the world’s first commercial scale Ni laterite heap leach. Following the technical and economic success of the operation, the actual operational data is compared back to the original test work data.

Aug 8, 2011

By G Capes

A novel open stope design approach is presented that delivered improved performance in a mining area with poor ground conditions at the Olympic Dam mine. During 2019, a large open stope had an unplanned caving event resulting in the inability to extract the planned tonnes and subsequent sterilisation of nearby stopes. A design limitation was the lack of data and understanding around the alteration domain extents, the rock mass strength controls and limits, the failure modes controlling stope stability in the local area, and the use of conventional stope shapes. From the available data and failure observations, it was inferred that the dominant caving failure mode resulted from a blocky rock mass impacted by structure and alteration causing an unravelling failure mechanism. Numerical and empirical analyses were conducted to test this hypothesis and establish strength limits for design. The strength limits for the design were then used to provide a range of outcomes from which future stope design shapes such as chamfered backs could be selected. Three alternate chamfered geometries were selected to trial the innovative designs. The application of this methodology in 2020 resulted in overbreak reduction from >100 per cent in the initial caved stope to

Mar 29, 2023

By Keyte SG

Gravity methods of recovering alluvial gold are not very efficient at particle sizes below about 0.1mm. Whereas such gold may not have been economic to recover in the past, the same may not be true today. Centrifugal concentrators, like the Knudsen and Knelson bowls, are showing promise after an inauspicious start, at least in New Zealand. The large proportion of heavy mineral in many auriferous beach sands and the natural hydrophobicity of fine gold should make flotation an attractive contender for its recovery. The conventional mechanical flotation cell is effective, but roughing, scavenging and cleaning are necessary to achieve both high recovery and low mass yield. More problematic is the difficulty of maintaining coarse and dense sands in suspension. The air sparged hydrocyclone is effective at recovering fine gold from a fine Colarado River sand, but is not effective for the coarse and dense beach sands of New Zealand. The flotation column shows much promise for these sands, when recoveries of over 80% and mass yields of less than 1% can be achieved in a single pass. The froth separator of the USSR and flash flotation could also be worthy contenders. It is felt that flotation could be limited to naturally and artificially de-slimed concentrates.

Jan 1, 1990

By Dendyuk TV

The possible use of combined (flotation/magnetic separation and magnetic separation/flotation) technologies involving the new flotation reagent systems for upgrading the iron ore concentrates, low grade manganese products and beneficiation of graphite-bearing dusts from integrated iron-and-steel works has been shown. It has been found that the absence of magnetic flocculation phenomenon worsens the reverse cationic flotation of oxidised iron ore concentrates and direct flotation of low-grade manganese products which require the use of modifiers possessing the flocculating properties. The synergetic mixtures of polymers have been proposed to be used as modifiers, ie polyacrylamide (PAA) with carboxymethyl cellulose (CMC) and polyacrylamide with industrial lignosulphonates (LST)

Jan 1, 1993

By D Henderson, K Howie

In 2005, Glass Earth Limited (GEL) commissioned two large area detailed airborne geophysical programmes in the Taupo Volcanic Zone (TVZ). In the first survey Bell Geospace Ltd of Scotland conducted an Air-FTG« (airborne Full Tensor Gravity Gradiometry) survey covering 2338km2 at 300m line spacing. The second survey by UTS Geophysics, Australia included detailed airborne magnetic, radiometric and digital terrain data capture covering 5341km2 at 150m line spacing.   From the detailed geophysical data collected it is possible to identify major deeply penetrative crustal structures within the TVZ, as well as define subsurface geological features, such as intrusive bodies and alteration zones. These major deep crustal structures are thought to have a controlling influence on the distribution of epithermal gold mineralising systems, and along the corridors defined by these deep crustal zones, the chances of discovery of an economic epithermal gold discovery are greatly increased.   In this paper GEL gives some examples of the application of its integrated data driven approach to exploration in the TVZ at both regional and project scale. The paper focuses on how GEL identifies regional scale highly prospective deep crustal structures. Then, using the Horohoro epithermal gold system as an example, we show how GEL applies innovative geological and geophysical data processing to model and understand detailed subsurface geology, focusing subsequent exploration to ensure the best opportunity for a new economic epithermal gold discovery.

Jan 1, 2007

Since gold was first discovered, mining development in the West Australian goldfields has been heavily dependent on the location of groundwater both for potable and mineral processing supplies . The location of adequate and economic sources of water has been a constant challenge to both explorers and developers throughout the history of the goldfields. The provision of a piped supply from Mundaring in 1903 greatly alleviated pressure on scarce resources, lowered mining costs and permitted the orderly development of infrastructure. However, increases in the demand for water resulting from new mineral discoveries over the past three decades has led to renewed pressures for more local supplies to be established. Wide-ranging groundwater exploration took place in the late 1960's and early 1970's, also, more recently, in support of intensified gold exploration. The collation and interpretation of the hydrogeological data from the whole goldfields region indicates that despite a low mean annual rainfall of between 180 and 350 mm, quite marked differences exist between the rates of groundwater recharge in different parts of the area, In general, these can be shown to diminish in a southerly direction contrary to a trend towards increases in annual rainfall. Recharge rates are related mainly to differences in rock weathering pattern, geological structure and physiography. The same differences have controlled the pattern of groundwater salinity and the magnitude of groundwater storages associated with the palaeodrainages. In the vicinity of the northern and western watersheds with the Gascoyne, the superficial sediments tend to be thin, may have calcrete in the section and contain moderate storages of brackish or even fresh water. This contrasts with the lower regions of the palaeodrainages where calcrete is absent and deeper erosion has permitted the accumulation of relatively large thicknesses of fine-grained sediments which are saturated with hypersaline water and constitute substantial storages. Account must be taken of these characteristics if water supply sources are to be optimised to meet the growing demands for groundwater in the region.

Jan 1, 1988

The tankhouse of the electrolytic zinc plant at Nordenham is operating with a very high operating efficiency of 99 per cent. This has been achieved not only by strict control of the quality of the zinc sulphate cell feed solution but also by all the improvements in housekeeping in the tankhouse developed during the past years: aluminium cathode specification, cathode stripping cycle, edge strips, copper contacts, anode isolators, cell cleaning, fittings and washing devices. During 1987 to 1992 the casting department was completely remodelled in order to improve the quality of the zinc products, the safety of the operations and the flexibility. The remodelling includes the enlargement of the area for the casting shop, the storage buildings and the five casting lines on the same ground level. New lines for alloying products and for SHG25 kg zinc ingots have been constructed. The line for galvanising products has new equipment in some parts and the other lines have been modified.

Jan 1, 1993

By K W. Mills, N R. P Baczynski, J Mylvaganam, D A. Prado, M F. Lee, I A. de Bruyn

"This paper presents the second part of a study of the assessment of rock stress inputs on the performance of various new mining designs at the Ok Tedi large open pit mine in Papua New Guinea. Over the years, four programs of rock stress measurement have been completed at Ok Tedi, each providing different interpretations of the in situ field stresses. Details of three of these programs and interpretations are provided in the precursor to this paper, entitled ‘Rock Stresses at Ok Tedi, Papua New Guinea’ (Lee et al, 2014).This paper explains how the various stress interpretations were utilised in the modelling of the proposed new open pit and underground mining excavations, comparing where possible their expected effects on stability. The modelled performance of three specific mine components have been discussed here as case studies, including: the below-pit drainage tunnel, as the floor of the open pit workings is mined down from 350?m above, to within just 75?m above the crown of the tunnel the stability of the 1000?m high slope of the proposed West Wall cutback the proposed sublevel open stoping extraction sequence in the Gold Coast orebody beneath the East Wall, for which only the likely ‘worst-case’ stress regime was used to assess sequencing and stability issues.The benefits of scheduling the collection of detailed rock stress measurements and other input data from a range of different sources at various stages of the projects are discussed.Alternative in situ stress models have less stability impact on open pit slopes than on underground mine excavations.CITATION:de Bruyn, I A, Baczynski, N R P, Lee, M F, Mills, K W, Mylvaganam, J, and Prado, D A, 2014. The application of rock stress inputs to stability assessments at Ok Tedi Mine, Papua New Guinea, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference, pp 43–54 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 5, 2014

The New Southern Railway (NSR) involves the excavation of approximately 10 km of single bore tunnel from Tempe Reserve, Tempe, to Prince Alfred Park (PAP). PAP is located just south of Central Railway Station in SydneyÆs Central Business District (CBD). From Tempe Reserve the alignment takes the tunnel under Sydney Airport including the main north/south runway. Sydney Airport is approximately 8 km south of the CBD. The NSR is being constructed by a private group, the Transfield Bouygues Joint Venture (TBJV). Transfield is a major Australian contractor and the French contractor, Bouygues, is providing the soft ground tunnel construction expertise and is also responsible for the design of the concrete segmental lining. This paper sets out to present in some detail the issues involved in tunnelling under the airport and in particular under the north apron, the main north/south runway and the new elevated roadway. The paper concentrates on these three areas on the airport with an emphasis on the following. The risks involved and measures taken to minimise the risks in tunnelling under the International Terminal north apron (with Jumbo Jets parked immediately above). Secondly, settlement predictions, settlement and runway operation criteria and the actual settlements that have occurred on the main north/south runway. Finally, the criteria that was developed during the construction of the deep bored piers for the elevated roadway at the Domestic Terminal as the TBM passed through this area of construction activity.

Jan 1, 1999

By Cunningham J. C

JUST prior to the war the Broken Hill South Ltd: raised, on the average, 6628 tons of ore per week, all of which was crushed and treated in the 4-section gravity mill and the slime flotation plant, for the recovery of lead concentrate carrying silver. The sandy residues from that treatment were railed to the treatment plant of the Amalgamated Zinc (De Bavay's) Ltd. for the recovery of zinc concentrate by flotation, on the joint account of both companies. Subsequent to that-since 1916-approximately 1000 tons of old dump slime were also treated weekly for the recovery of lead and silver as slime-lead concentrate.PLANT CAPACITYUnder this programme the Babcock and Wilcox boiler plant of 8 boilers was taxed to such an extent as to call for the installation of two additional boilers, each of 2690 sq. ft. of heating surface and 55 sq. ft. chain-grade area.The electric generators and the air compressors of the old powerplant were also loaded to their maximum capacity. In view of the fact that the old power-plant had been added to from time to time since 1901, and that further extension was notpossible, and as it was not, moreover, an economical arrangement, the whole question of power generation was reconsidered. The considerations that determined the installation of entirely new plant were as follows:(1) The need for more compressed air for underground work and more electric current for the extension of the slime-flotation plant for the recovery of zinc, as well as lead, as slime concentrates. Provision of additional power was also deemed advisable for the...

Jan 1, 1921

By D J. Brake

The importance of mine ventilation to health and safety in both coal and metalliferous mines has been long recognised. The primary and secondary ventilation systems in most metalliferous mines incur 50 per cent or more of the total mine electrical power consumption and frequently about 10 per cent of total underground mine operating costs. The requirements for ventilation-related horizontal and vertical development, fans and cooling have a significant impact on mine capital costs and also on mine schedules and start-up times and hence cash flows. There are increasing pressures on regulators and miners to reduce airborne contaminants such as diesel particulatematter, nitrogen dioxide and heat (wet bulb temperatures), and significant pressures to reducegreenhouse gases such as fugitive methane emissions from coalmines and the carbon dioxide footprint of both coal and metalliferous mines. Many previously Australian miners are now globaloperators and have extensive overseas mining operations where local ventilation standards and expertise may not be consistent with Australian practices. The role of the site ventilation officer is also changing with strict new requirements for the statutory position being introduced into Queensland metalliferous mines and the potential for this to become more widespread. Recent regulator and parliamentary review committees have identified systematic shortcomings in mine ventilation compliance, and statutory certificates in both Queensland and NSW now require continuing professional development to maintain currency. Public and investor support for mining are also increasingly contingent on safe, healthy and environmentally responsible practices and the standards for these are frequently tightening. Good ventilation design and operating practices that are consistently well executed therefore contribute significantly not only to a safe and healthy mine but also to a productive and cost-effective operation and the ongoing social licence to operate. There are a variety of ways of providing technical design and oversight into a mine’s ventilation systems; this paper explores some current trends in ventilation standards and statutory requirements, as well as ways to support and develop mine ventilation staff for both domestic and international operations and also the emerging senior technical roles of Group/Principal/Corporate mine ventilation engineer.

Oct 12, 2022

Lihir Gold Mine is situated in a dormant volcanic caldera on a small island off PNG. Not æextinctÆ but dormant. Current ground temperatures are up to 150 degrees Celsius with active geysers in the workings of the mine, pools of boiling ground water adjacent to low-grade dumps and hydrogen sulphide gas emissions. It is a unique mining environment by world standards. This paper will deal with the following issues encountered and managed by the operation:blasting in hot and reactive ground; management of sulphide gas emissions; disposal at sea of all mining waste rock; one dear to all Australian minerÆs hearts û dealing with landowner groups; and unusual human resource issues.

Jan 1, 1999

Forty years ago Dr Pierre M Gy, a metallurgist, introduced variography as applied to monitoring a process. Consequently, his followers used the variogram to elaborate meaningful process control charts, especially since 1993. The name æChronostatisticsÆ was suggested several times by Gy as a logical name for this new science. The intent was to draw a parallel between the variogram identifying the variability components affecting a process parameter as a function of time, and the variogram used in geostatistics identifying the variability components of a given mineral content as a function of space. Heterogeneity problems encountered have indeed strong similarities. However, there is a fundamental difference. The variogram used in geostatistics is often stationary within a given type of mineralisation. While investigating a dynamic process through Chronostatistics, there is no such thing as a stationary variogram. Still, the evolving variogram provides essential information about subtle, often overlooked process difficulties. Chronostatistics is especially useful for management to take advantage of existing data that are often a forgotten source of valuable information to pinpoint recurring structural problems. The superiority of Chronostatistics over conventional statistical process control approaches is that it links observations to the inherent heterogeneity of materials under investigation, therefore to the sampling theory. Chronostatistics is like opening a new world to the metallurgist, making the process variability speak in a more comprehensive and in-depth way. Several case studies are presented to demonstrate the potency of this new science. For each of them, observations lead to solutions for continuous process improvement, therefore attractive economic opportunities. The philosophy is this: if a control chart shows a process is out of control, it must also suggest logical and pragmatic directions for solutions. The intent of this presentation is to vastly expand on these valuable, almost forgotten ideas.

Jan 1, 2006

Comparatively recent Tasmanian legisla tion established a series of rigid control standards for environmental protection just as ma spectacular expansion of the mining industry was nearing completion. Upgrading existing protection to obtain the necessary licence to operate under these new regulations required further major works and involved a considerable outlay of non- productive capital at a time when escalating costs and falling metal prices were straining economic efficiencies to the limit. Late in 1974 a major environmental protection scheme was commissioned by the Electrolytic Zinc Company of Australasia Limited at Rosebery on the West Coast of Tasmania. This 4 million dollar project was specifically developed by the Company ahead of and to meet the new standards for control of total effluents discharged from its zinc-lead -copper-pyrites mine and concentrator.

Jan 1, 1977