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By P Trotta

The paper provides a structured methodology to investigate metallurgical problems within the operating concentrators. The strategy uses classical metallurgical data analysis as well as pulp, solution and surface analysis to determine the reasons for particular behaviours. The approach applies equally to all mineral-processing operations. To demonstrate its effectiveness a case study, based on work conducted at Pasminco Rosebery Mine, is described. In this work, the classical metallurgical analysis indicated that a significant amount of sphalerite reporting to the lead concentrate occurred as liberated particles. A combination of pulp, solution and surface analysis supported the hypothesis that the liberated sphalerite was recovered by inadvertent activation by lead ions. Laboratory studies have indicated that the use of sodium carbonate, by itself and in combination with zinc sulphate and sodium cyanide, when added to the lead regrinding mill can depress sphalerite flotation, resulting in an improvement in the lead grade/recovery curve. When this approach was tested in the plant other more dominant issues masked any positive effect the addition of sodium carbonate may have had. The plant trial highlighted the real need for additional regrinding capacity.

Jan 1, 2002

The main factors controlling the electro- winning of zinc from impure aqueous sulphate electrolytes are reviewed. Zinc, hydrogen and impurities are deposited at the cathode. The current effic- iency for zinc is increased by increasing zinc/ acid ratio and current density and by decreas- ing temperature; and may be unchanged, increased or decreased by the presence of impurity ions. A qualitative comparison of observed and predicted impurity effects is in reasonable agreement. Quantitative treatment of the effects of impurities and cell additives is not available. A tentative explanation of the time dependence of current efficiency in the presence of some impurities is provided. The forms in which impurities are deposited is substantially unknown. Impurities may be classified according to the extent of cathodic deposition. Procedures for control of cathodic deposition of impurities are outlined. The main anodic reactions are the forma- tion of oxygen, manganese dioxide and sulphuric acid. Minor reactions include the oxidation of lead, silver, cobalt and chloride. The site of the anodic reactions and the reactions generat- ing manganese dioxide are uncertain and may change with time of operation. The anode behaves crudely as an oxygen electrode with

Jan 1, 1977

In planning and operating mining projects, managers must take into account economic conditions in foreign markets in addition to Australian conditions. As the manager has little influence over the price or the demand for the product, it is particularly important that close attention is paid to the control of costs to ensure that the mining operation remains competitive with foreign producers. This is not necessarily true for some sectors of the domestic manufacturing industry where foreign competition is restricted and costs can be passed on to consumers because of the protection afforded by tariffs. The effects of protection on the cost structure of Australian industry are more pervasive than is commonly understood. The issue of protection is particularly important to the Australian mining industry management because the cost burdens imposed by local protection must be absorbed within profit margins. Furthermore, because protected industries are effectively subsidised to use scarce resources such as skilled labour, the development of more efficient industries such as mining is inhibited. The mining industry has much to gain from any relaxation in protection policy, and hence the issue is of considerable importance to all managers in the mining industry concerned with costs.

Jan 1, 1980

By S C. Goel

The Obuasi Mine in Ghana, West Africa is the largest producing gold mine in Africa, outside South Africa. The mine has changed from a mine producing from narrow vein, high grade quartz orebodies to a mine producing from wide, lower grade sulphide rebodies. Traditionally mining methods were cut and fill and sublevel caving. Now the preferred stoping methodologyis long hole open stoping. Transverse or longitudinal methods are both used, dependent on the orebody characteristics. The change has been technically, socially, economically and politicallychallenging and at times has tested the abilities of those responsible for the operation of the mine. However, the benefits have been many. Safety has improved significantly, ounces from underground have doubled. Productivityhas doubled and underground unit costs have reduced bya third. These achievements have allowed the Obuasi mine to staycompetiti ve in this time of falling gold price. During 1999 and 2000 a full review of the mining and processing operations was undertaken, and as a result, the mine is now in a phase of restructure. Efforts are being made across the mine to improve efficiencies and to reduce costs. The future for the Obuasi Mine is an exciting one.

Jan 1, 2000

Estimation of operating costs in the nickel production industry requires a detailed analysis of material flows from mine to smelter to refinery. Despite the small number of nickel producers compared to other base metals, the existence of two very different ore types (sulphide and laterite) and a wide variety of mining and processing technologies make the identification of these flows of critical importance if an accurate global picture is to be obtained. Smelting and refining processes in nickel metallurgy have evolved with a high degree of adaptation to specific operating conditions in different locations. Overall costs are calculated by combining individual cost elements for each unit in production chains from mine to saleable metal product. The average cost of western world primary nickel production in 1995 was US$2.07/lb ($4560/tonne). Average operating costs remained virtually unchanged in the three years to 1995 after an 8.5 per cent fall in 1993, but a 3.9 per cent increase to $2.15/lb is expected for 1996. A major factor in this rise results from the lower prices of copper and cobalt this year, reducing the by-product credits available to major producers.

Jan 1, 1996

Mt. Whaleback, the property of the Mt. Newman Joint Venturers, contains more than one thousand million long tons of high grade hema- tite averaging 64% Fe, ranging from 70%, the grade of absolutely pure hematite, to 54%. The ore occurs in the Dales Gorge and Joffre Members of the Brockman Iron Formation. The interbedded shale bands common in other orebodies occurring in these horizons are seldom more than a few inches thick and are commonly partially enriched to about-35% Fe. In the generally hard, massive hematite orebody, the gangue minerals tend to break preferentially to the fines, or -6 mm product, and for this reason it is of a somewhat lower grade than the lumpy product. The control of the chemical qualities is concentrated on the fines product for it has been found that maintaining the iron and alumina levels in this product ensures that all chemical specifications are met in both the lump and fines products. Physical qualities are monitored to ensure that the physical quali- ties of decrepitation and degradation of the lumpy product are maintained at levels accept able to the buyers.

Jan 1, 1973

By Elber L, Whiten WJ, Cunningham KD, King GL, Bailey CW, Clay PA

The Savage River Mines concentrator treats magnetite ore at about 300 tonne/h, and produces feed for a pelletising plant. The plant incorporates two parallel grinding lines, each consisting of an autogenous mill, in closed circuit with a screen, a rougher mag- netic separator, a ball mill in closed circuit with parallel cyclones, and a finisher magnetic separator. Significant fluctuations in ore grade and grindability make it difficult to maintain pro- duct size in the narrow range desired, and to achieve maximum possible throughput at the same time, using the present largely manual control system. The present paper describes the develop- ment of a control system based on a mini- computer. It has been possible to implement a scheme of on-line estimation of product size which is sufficiently accurate for use in an automatic control system. The size estimation is essentially derived in terms of plant variables which control the ball mill cyclone cut size. Three control functions have so far been implemented and tested. These are control of the feed rate to the autogenous mill, control of water addition to the autogenous mill, and control of the ball mill sump level.

Jan 1, 1978

By West Coast Staff

Attention to the design of facilities for drainage, of both surface water and seepage, made it possible to attain, for a qam impounding residues from a concentrating mill, a more stable sand wall which can eventually be carried to a greater height.EXPERIENCE WITH No. 1 DAMResidue from the lead zinc concentrating mill, which treats the ore from the Rosebery and Hercules Mines, was pumped 3,600 ft. through a 5-in. diameter woodstave pipeline to the site of the dam. It was formerly delivered through a 4-in. steel pipeline.State laws prevent the residue being discharged to waste into the Stitt River. Furthermore, as a pyritic residue it is a potential source of sulphur.Between 1936 and 1956 more than 1,000,000 tons. of residue was paddocked. The run-of-mill product was roughly classified at the dam in a 6-ft. diameter cone classifier and the sand fraction was pumped by a 3-in. pump to the front wall of the dam across a shallow valley. The overflow gravitated to the rear of the dam (Fig. 1). Typical sizings were:

Jan 1, 1958

The application of single liquid cement for fracture grouting in base rock may have history more than 120 years. The disadvantage of it is difficult to increase the grouting efficiency, because the jelling time of it is very long and hard to control. The double liquid grout, such as chemical grouts and cement water glass grout was developed at the end of 1960.'s Although the jelling time of this kind of grout can be controlled, it mast adopt double liquid grouting technology, use complicated equipment and is not easy to control component's ratio of the grout. Another disadvantage for chemical grout is high price, and have pollution to environment. OCE series single liquid grout is the effective grout material developed recently by making large efforts in Ohina. Main feature of it is that the jelling time is easy to control, materials from cement and clay are very cheap and without pollution to environment, and the grout can be injected by single liquid technology. The effect of QCE series grout has been proven by its application in China. It can be believed that QCE grout has great economic efficiency and will give a push to develop grout material.

Jan 1, 1988

The word "optimization", refers to the search of an economic optimum, or, more precisely, to the choice of technical parameters which will define the more profitable mining project, knowing the values of the economic parameters. In fact, there is no direct way to perform this optimization, because the extremely large number of technical factors involved, from the type of working and its selectivity to the characteristics of the mill and its flexibility, makes it impossible to make a comprehensive survey of all possible projects. Beside, it would be meaningless to engage in such a task as the deposits themselves are not really known, but only estimated, with sometimes a high level of imprecision. Not to mention the numerical instability which would affect such a computation! In addition, the "best" project is not necessarily the one which strictly maximizes a given profit formula. There also exist human factors which have to be complied with, when choosing the cutoff grades for instance. Finally, there are other non-numerical factors which interfere with the choice between several projects: the shape of the bottom of a pit of the layout of the access road for instance.

Jan 1, 1986

ADDRESS BY THE PRESIDENT OF THE INSTITUTE (MR. C. H. MARTIN) IN PRESENTING THE CERTIF1CATE TO SIR GEORGE FISHER, C.M.G.Members of The Institute, distinguished guests, of which there are many, ladies and gentlemen, you are welcome.And might I add a special welcome to Lady Mawby and Lady Fisher and to Sir George's only son Peter, who with his wife, Betty and one of Sir George's three daughters, Helen, are present this evening, and also to Sir Maurice's son, Colin, and Colin's wife, Jay, also in our company.The family presence must surely be a great source of pleasure and satisfaction to all those so intimately concerned.It is hardly. necessary for me to state the sole and only rC'l.son for our presence here tonight, which is to conJer on Sir George Fisher and Sir Maurice Mawby Honorary Membership of The Australasian Institute of Mining and Metallurgy, and at the same time to acknowledge two people who have rendered great service to the mining industry albeit tinged with sadness to all of us in the knowledge that from now on their influence may diminish.

Jan 1, 1976

By F Cesnik, P Griffin, S Green

In July 2004 a flotation concentrate regrind circuit was commissioned in the æHigh GradeÆ Ridgeway concentrator at NewcrestÆs Cadia Valley Operations. This was the culmination of two years of project testing, process design and planning which commenced shortly after commissioning the concentrator in March 2002. During the two-year project evolution alternative grinding technologies were evaluated from conventional ball milling through to sand milling. A Detritor mill was eventually selected for the duty and the criteria on which this selection was based will be presented. As the project evolved so too did the equipment sizing with the concentrator quickly exceeding design capacity of 4 Mtpa and currently averaging 5.6 Mtpa, the process design had to accommodate this and future potential throughput increases. This paper will focus on the supporting testwork, circuit surveys and concentrate properties which were used as the design basis for the project. The economic evaluation which led to the project receiving board approval in November 2003 will also be presented. Detailed design and construction management issues will be discussed as will preliminary results and findings up to November 2004.

Jan 1, 2005

By Wright S, Jorgensen F. R A

The reaction between lead sulphate and a number of base metal sulphides (galena, sphal- erite, chalcopyrite and synthetic pyrrhotite was studied as a means of desulphurizing lead sulphate containing fumes and residues to levels acceptable as ISF feed. The reactants were mixed with 50% zinc oxide to act as a "basket" to contain the molten products of the reaction and pressed into small briquettes 20 mm in diam. Factors such as temperature, time and the composition of the atmosphere were investigated. Using the PbS/PbS04 system as an example it was shown that the reaction became rapid above 800¦C and that both sulphur dioxide and oxygen in the atmosphere were detrimental to achieving low sulphur in the product. In an inert atmosphere all the sulphides when roasted for 1 h at 1000¦C gave results corresponding to the elimination of more than 95% of the sulphur in the reactants. Leach plant residues were considered for use as the "basket" material. It was shown that the residual sulphide and sulphate components of the residues underwent similar reactions to those experienced by the pure systems.

Jan 1, 1987

By George G

The Circum-Pacific Map Project is a cooperative international effort to prepare and publish geological, geophysical and mineral resource maps of the Pacific Basin and adjacent land areas. Earth scientists representing 180 organizations from more than 40 Pacific Rim countries are participating in the work. The project is directed by a committee established 14 years ago as an activity of the non-profit Circuin-Pacific Council for Energy and Mineral Resources. Technical and cartographic support is provided by the U.S. Geological Survey. The Circum-Pacific Map Project is organized under five regional panels of experts on the geology and resources of the four quadrants of the Pacific and Antarctica. A series of five 1:10,000,000-scale regional maps and a 1:17,000,000-scale map of the entire Project area, the Pacific Basin Sheet, provide the cartographic base. Forty-eight individual sheets are planned and thirty have been published in eight different series, including base maps, geography, plate tectonics, geology, energy resources, mineral resources, tectonics and geodynamics. Additional special single-sheet thematic maps on the Pacific Basin base have been published and are planned for a total of more than 50 individual sheets.

Jan 1, 1987

By Kuruppu M

Geotechnical design plays a key role in mine design. A proper geotechnical design provides a safe working environment and facilitates efficient mining operation. There are mainly three design approaches: (i) judgmental, based on observational and experiential facts, (ii) empirical, based on empirical design formulae; and (iii) analytical, incorporating numerical analysis. Most design applications are based on the design methods one and two as mentioned earlier. However, complexities arise in deep underground mining operations and deep open pit mines. These complexities and difficult geological environment introduce more uncertainties and simple empirical formulae would not be adequate as a design tool. These situations require numerical modelling and analysis of the design problems including interpretation of the results obtained from the analysis. There are several tools available for performing the numerical modelling and analysis. A brief review of the available tools is provided. The authors selected ANSYS (a general purpose finite element analysis tool) for use in mining geomechanics and geotechnical design. This paper includes several examples demonstrating the applicability of this software in designing mining structures. The authors hope that the design examples will demonstrate the use of the numerical modelling and analysis applications in excavation design.

Jan 1, 1995

By Gillies A. D S

Replies to a comprehensive questionnaire on mine water resource management systems (WRMS), which were distributed to a selection of Australian mining operations in 1991, are analysed. Although the replies cannot be considered fully representative of the industry, they do provide a good qualitative indication of water resource management in the industry at that time.Within Australia's largely arid land mass, a majority of mines nonnally need to conserve water, a few need to dispose of water and a number face a seasonally varying position. An assessment of the importance of WRMS compared with management of ore extraction and processing is given. A risk assessment of failure is given; there is more acceptance of WRMS failure in the mine compared with the mill. An assessment is made of considerations in WRMS design. Managements are generally pro-active in the design of WRMS and in the setting of perfonnance standards. The operational characteristics of mine systems are examined in detail.Companies generally do not appear to allocate sufficient resources for the collection of basic WRMS monitoring data and knowledge of the water budget to efficiently manage the system. This indicates scope for considerable cost savings in most mines.

Jan 1, 1995

By E R. Ramanaidou, M S. Piggott

Transport to and handling of iron ore at Port Hedland, Western Australia, results in the generation of airborne particulates that contribute to the atmospheric dust load, with concerns about potential local environmental impacts (eg mangrove swamps) and possible human health implications. Mineral and chemical characteristics of the Background soil samples were contaminated with particles of iron ore as martite octahedra and grains of micro-platy hematite as detected by scanning electron microscopy (SEM) in the 2.5 - 10 ¦m and 10 - 50 ¦m size fractions. Fossilized wood fragments similar to those observed in Yandicoogina fines ore were also detected in some background soil samples. With a predicted increase in demand of channel iron deposits (CID) ores and the inherently dusty Marra Mamba ores (eg West Angelas, MAC, OB29/30/35, Marandoo), in conjunction with particulate emissions from hot-briquetted iron and direct reduced iron (HBI/DRI) processing plants, there is the potential for additional sources of anthropogenic dust to contribute to background levels. Mineralogical and chemical characterisation of the entire range of particulates that could be produced is necessary for a complete understanding of their potential impact on the local environment.

Jan 1, 2002

By Robins R. G

The dissolution of metallic copper powder in aqueous solutions of cupric sulphate under the influence of ethylene gas was investigated. The dissolution reaction stoichiometry obtained was: Cue+(aq) + Cu(s) + 2C2H4(g) = 2(CuC2H4)+(aq) The rate of formation of the copper (I)-ethylene complex in the above reaction was studied in a laboratory autoclave and the effect pH, temperature, ethylene partial pressure and initial concentration on the dissolution rate was measured experimentally and expressed theoretically in terms of several simple conceptual kinetic models. The results led to the selection of optimum conditions for the reaction and the suggestion of an "ion-molecule reaction" mechanism to explain the very low activation energies for the reaction system. The area of application of this reaction lies in the direction of refining impure copper such as cement copper. Several experiments were performed in which an acidified solution of cupric sulphate under ethylene pressure was used to dissolve copper from the cement copper powder in the form of the copper (I)-ethylene complex, followed by the release of gas pressure to disproportionate the complex and precipitate a purer metallic copper.

Jan 1, 1987

By H P÷llmann

Calcium aluminates, calcium aluminate ferrate and calcium aluminate sulfate were synthesised by solid-state reaction, sol-gel method, a self-combustion method and by a polymeric precursor process. For chemical sintering methods the base chemicals CaO, CaSO4, Al2O3 and Fe2O3 were used. As precursors for sol-gel synthesis metal nitrate hydrates and Al2O3-Sol were used. In order to synthesise pure phases by a self-combustion reaction glycine was used as fuel and nitrates as metal components. In the polymeric precursor process metal nitrates and diluted H2SO4 were used as metal components and the resin was made using citric acid (C6H8O7) and ethylene glycol (C2H6O2). Precursor phases synthesised by these different methods were sintered step-by-step in order to investigate the crystallisation. Further on single phases were hydrated and their hydration behaviour was studied by heat flow calorimetry, X-ray diffraction and cryo-transfer scanning electron microscopy. Due to the different synthesis procedures different hydration reactions and microstructures of the phases will be shown.

Jan 1, 2008

By Richardson G. W, Yap L. C

Friction rock stabilisers (FRS) are the most common steel-based ground reinforcement used in underground mines in Western Australia. As with any other steel-based product used in underground mines they are susceptible to corrosion, particularly under aggressive minewater and mineral conditions. Because of their thin-wall tubular construction and large surface area, the potential damage resulting from corrosion is considered to be more severe for this type of reinforcement than for other forms of reinforcement made of solid steel bars. Because of the obvious safety problems which may result from corrosion, both mine operators and regulators have raised concerns regarding the long-term effectiveness of FRS installed in underground mines in Western Australia. Although corrosion has been recognised as an important safety issue, the controls of corrosion in varied underground mining environments has not been well understood. To improve the understanding of the corrosion behaviour of FRS, the Department of Minerals and Energy has initiated a research project focused on the mechanisms and extent of corrosion attacks, and their influence on the effectiveness of the reinforcement. This paper describes the research project and presents the interim results achieved To-date.

Jan 1, 1995