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By F van de Venter, J Monama, T Kale

For a multitude of years fine iron ore, -1 mm, across the world has been deposited as discard material in tailings facilities. This contributes to environmental problems, decreases plant yield and increases the cost of processing. Fine iron ore recovery processes are often deemed unfeasible or uneconomical, due to the complexity of the reclamation thereof in comparison with high-grade ores. However, recent advances in the recovery of fine iron ore using the Optima Classifier® has shown great promise. The Optima Classifier® is a new hindered settling separator that makes use of an upward current of water for density separation. It’s unique design combines three different separating zones for increased efficiency and recovery. In this study the potential of the Optima Classifier® to produce a +63 per cent Fe concentrate from -1 mm feed material was evaluated from a standalone and process perspective. It was found that a +63 per cent Fe product can be produced from a single stage, using the Optima Classifier®. Fine iron ore feed with an average head grade of 50 per cent Fe was upgraded to average concentrate grades of 63.2 per cent Fe. Displaying upgrade ratios of up to 1.26 in a single stage. A three-stage, rougher, cleaner and scavenger system did however show the best performance with recoveries of up to 70 per cent, yielding 56 per cent of a 63 per cent Fe product. Furthermore, the dewatering of the product and tailings was evaluated using the UltraG ultra-fine dewatering screen ensuring dry, stackable material. The tailings could be used in codisposal, while loads on thickeners and filter presses are significantly reduced. The high throughput of the Optima Classifier® ensures a small plant footprint, minimal civil and structural requirements and low operating utility consumption such as electricity, minimising the carbon footprint of a fines beneficiation plant. The Optima Classifier® in combination with the UltraG dewatering technology has provided a platform for economical recovery of fine iron ore, both current arising and historical. Providing opportunity to lower plant operating costs, reduce environmental liability of tailings facilities and increasing immediate process water recovery

Sep 18, 2023

By V Matousek, A Sellgren, R Visintainer, G McCall

A 4-component model for settling slurry pipe flow has been previously described by Wilson et al (2006) and Sellgren et al (2014) to predict pipeline friction loss (hydraulic pressure gradient) over a range of slurry compositions: from fine to coarse particle size, narrow to broad particle size distribution, and low to high solids concentration. The method applies a weighted average of established pipeline models for various settling slurry flow regimes, according to the volume fraction of solids falling within the applicable size range for each model. Further development of the model was undertaken by Visintainer et al (2017a, 2017b), based on a comprehensive set of laboratory tests in 203 mm (8 inch) and 103 mm (4 inch) pipelines, and it was also adapted to the modelling of slurry pump performance derates. However, this work was all performed with solids having a specific gravity near 2.65, as is typical for many mineral processing and dredging applications. The goal of the present work is to test the applicability of these models for settling slurries having a higher solids specific gravity, as may often be seen in the mineral processing of iron ore deposits. To that end, a test program was carried out in a 103 mm (4 inch) pipe loop using various compositions of an iron ore product having a solids specific gravity of 4.75 and containing both coarse and fine solids. By screening and flushing operations, a range of particle size distributions were created having different proportions of the coarse and fine elements. In all, 19 tests were performed with d50 particle sizes ranging from 50 μm to 3.2 mm and delivered solids concentrations from 10 per cent to 43 per cent by volume. Particle size distributions varied from very narrow to very broad, with d85/d50 ratios ranging from 1.75 to 26. Pipeline pressure gradient and pump performance data were collected and used to test the applicability of the previously developed 4- component models and to propose improvements to the models for the handling of high-density solids.

Nov 8, 2021

By Watters R

Modem open cut and underground mining in the tropics inevitably expose partially weathered and unweathered rocks to oxygen and water, leading to weathering and the release of solutes and often acidity as well. Historical monitoring data can demonstrate these phenomena. Three case studies from open cut mines in the north of the Northern Territory illustrate the deterioration in quality of pond water receiving drainage from waste rock dumps. The potential for deterioration of water quality was not recognised in many mine Environmental Impact Statements prepared and accepted in the 1980s. The examples documented indicate the importance of adequately planning for this near inevitable process. Retrofitting a mine water management system to 'no' or minimal release can be very difficult and expensive, and may not be feasible, leading to downstream pollution. The characterisation of acid and solute production potential of ore and waste rock, and improved dumping strategies and water management are very important to minimise the environmental impact of mining in the tropics.

Jan 1, 1994

By Rolfe PR, Ellis BA, Clements RJ

Associated Minerals Consolidated Limited (AMC) is constructing a 112,500 tonne/yr synthetic rutile plant at Narngulu, near Geraldton in Western Australia. Design of the plant is based on the technology developed by AMC and utilised in its two existing plants at Capel in Western Australia. Ilmenite Feedstock for the plant will be sourced from AMC's mine at Eneabba and coal obtained from the Collie deposits. The plant is scheduled to come on stream in the second quarter of calendar 1987. The rationale of the decision to construct the Narngulu plant is examined against the background of the world market for high-Ti02 content feedstocks. Also provided is a detailed description of the plant and an examination of the technology used in process Design.

Jan 1, 1986

By Ooms M, Scott OJ

This paper is concerned with the design and operation of storage and discharge facilit- ies for bulk solids handling. It presents an overview of the basic design philisophy emphas- ising the influence of bulk solid flow propert- ies and bin geometry on the flow patterns developed and how these, in turn, affect the reclaim efficiency and the bin structural in- tegrity and wear characteristics of both bins and chutes. The salient aspects of feeder design and operation will be discussed and the need to consider feeders as integral parts of the bin discharge system will be stressed.

Jan 1, 1978

By Langberg D, Gray N. B

The flocculation of hydrophobic magnetite with gold was examined as a possible means of recovering fine (95 per cent were possible for 1.5 - 3.0 ¦m and 5.5 - 7.5 pm gold sizes. The effect of process variables on the flocculation process was explained by variations in the adhesive force between the gold and magnetite.

Jan 1, 1991

As an Inspector of Mines in Queensland, my main responsibilities include the enforcement of the Mining Act 1968 - 1986, the Mines Regulation Act 1964 - 1983 and the Metalliferous Mining regulations 1985 to promote the safe and responsible exploitation of the States' mineral wealth. An important adjunct to this task is the offering of an advisory service to the mining industry. However, in the pursuit of my duties to this regard, I have sadly observed in some cases, numerous wrong doings and negative activities by miners which have led to their ultimate demise, not to mention that of others. Despite what I consider corrective advice, I have witnessed, again in some cases, disregard and blind pursuit for the wrong end. This then is a novel approach to get the message home in the form of a light hearted cartoon presentation relating the saga of an average Aussie battler entering the mining game unprepared, making the wrong decisions due to his own ignorance and the cleverness of others, leading finally to his and possibly others' downfall. It is not intended to insult any particular profession or group of individuals and only endeavours to impart to readers and listeners, the message of being prepared and alert when entering the gold mining industry. Even though the presentation focuses on the woes of a rookie alluvial gold miner, a similar analogy could be drawn with his hard rock counterpart since the basic issues that I have attempted to address are common. By no means is there a saga complete because there are many more traps a miner can inadvertently fall into and only time has prevented me from referencing them.

Jan 1, 1989

Nordberg has conducted extensive research, during 1982-85, on the effects of cone crusher variables such as speed, throw and cavity design on the productivity of the crushers. Simultaneously, Nordberg's engineers have developed advanced design and testing techniques that ensure efficient and reliable crusher designs. Combination of this knowledge has resulted in a design of the MPI000 (1000 hp) crusher which fits on the existing 7ft Symons foundation and yet is capable of producing twice the ton- nage of the 7ft. In this paper the development of the MP1000 crusher and its performance compared to the 7ft heavy duty and super heavy duty crushers will be discussed. Also, substantial cost savings resulting from the application of such a high performance machine will be presented.

Jan 1, 1988

HISTORIC SIGNIFICANCE OF EXPLOSIVES TO MINERAL PRODUCTION The ancient method of breaking rock was to build a wood fire against the face, heat the rock through and then pour water on the heated ore-bearing rock to cause it to break by tension. It was too slow and costly as the forests around the mines were cleared and transport of wood became difficult. Black powder had been used for 300 years as a gun propel- lant. ('Black' after Berthold Schwartz, a German monk, Figure 1, and the inventor of the gun who was given the epitaph `Here lies Berthold the Black, the most abominable of inhumans who by his invention has brought misery to the rest of humanity'). Only at the beginning of the 17th Century, black powder was introduced for loosening rock in European mines. In 1802 Dupont started black powder manufacture on the Brandywine Creek. The ignition train of powder was enclosed in goose quills, straws, rushes, paper or wooden tubes. The time interval between igni- tion and blast was pure speculation.

Jan 1, 1988

By M Nagarajan

Orica Mining Services (Orica) in partnership with Coal and Allied’s Hunter Valley Operations (HVO) has developed a risk management process to maximise mining efficiency whilst controlling vibration and maintaining critical electricity continuity to New South Wales (NSW) electricity grid in the Riverview Pit. The issue is a high tension tower which supplies electricity located within 40 m of mining and blasting activities. The process involved developing an understanding of the relationship between vibration, explosives, geology and the location of the blasting in the geological horizon. From this an optimum methodology for blasting in each region was developed.

Nov 8, 2011

By Gupta A, Fung C. C

The hydrocyclone parameter d5Oc is estimated by the application of Artificial Neural Network (ANN). Results indicate that ANN performs equally well as compared to statically derived analytical formulae. Results also show that ANN will also be convenient in the on-line control of hydrocyclones.

Jan 1, 1996

By Jones KW, McClelland RA, Denholm WT, Taylor RN, OÆShea J

Associated Tin Smelters, Sydney, are developing tin smelting operations in a prototype commercial SIROSMELT plant comprising two furnaces of 5 to 8 tonnes capacity. Features of the plant and its operation are discussed and results of its application to tin slag reduction and high-grade tin concentrate smelting are presented. Development work is still in progress but experience indicates that the technology has potential for lowering the costs of tin smelting and relieving constraints on grade and iron content of concentrate imposed by conventional technology.

Jan 1, 1984

Having provided basic data in the main paper I would now like to move on to discuss these areas in broader terms and to examine the various coalfields in terms of their tectonic setting and depositional environment and ultimately to make some brief comments on the factors which may have controlled deposition.

Jan 1, 1975

The construction of mine headframes of reinforced concrete is not a new departure as many structures have been built of this, material particularly in Canada and South Africa. This type of construction has been satisfactorily tested in service and is now accepted by the mining fraternity.The two headframes at New Broken Hill Consolidated Limited are the first structures of this type to be built in Australia, and provide an interesting application of reinforced concrete design and construction.Reasons for Adoption of ConcreteDuring 1947 the writer visited D.S.A. and Canada and inspected three headframes, of reinforced concrete construction.Leading details are as follows:(i) Hollinger Gold Mines. (Timmins, Ontario) : Height of sheaves 110 ft. Shaft has provision for 4 skips each of 12,000 lb. capacity. Structure incorporates surface crushing plant.(ii) International Nickel Corporation-Murray Shaft (Sudbury): Height to sheaves 153 ft. 6 in. Shaft provides for 2-12 ton skips and 2 cages. Surface crushing plant built integrally with frame.(iii) Asbestos-Johns Manviae (Quebec): Height of sheaves 116 ft. Shaft provides for 2 skips 200 cu. ft.

Jan 1, 1956

By Hocking G

For some underground structures, the use of the plane strain assumption in stress analyses may not be justified. The finite element method and photoelasticity have been used to obtain complete 3-D solutions, but, for various reasons, neither method has found universal use. The boundary integral equation method (B.I.E.M.) can be more efficient and economical than the finite element method for 3-D problems involving large volume to surface area ratios. A B.I.E.M. program developed for calculating stresses and deformations in infinite elastic media has been used to determine the 3-D distributions of stress around T- and Y- junctions of circular tunnels in stress fields in which the ratios of horizontal to vertical stress are 0, 0.33, 1.0 and 2.0. For the T- junction considered,stress concentrations at the intersection are approximately twice the plane strain values. Except where horizontal field stresses are high, the stresses in both tunnels approximate the plane strain values at about two tunnel diameters from the point of intersection of the tunnel centre lines. The stresses in the two branches reach those for the corresponding plane strain, two parallel tunnel case two diameters from the point of intersection of thq inner tunnel walls. Very high stress concentra- tions occur in the pillar of rock between the inner tunnel walls near the point of intersection.

Jan 1, 1976

For the past five years the University of Queenslandhas, through its various workshops, been preaching to Australia that there was a potentially hazardous situation from earthquakes for urban Australia. A few people outside The University accepted this, but largely the warnings fell on deaf ears.The 1989 Newcastle earthquake changed that per-ception. The most important lessons to emerge from Newcastle were (i)the realization that in continental areas small earthquakes cause widespread damage:(ii)the local geology of an area is of great importance in the damage done by an earthquake.These two factors clearly indicate that, in the future, we must take far greater account of the "Urban Geology" of an area. This paper discusses the need for urban geology and its impact on seismic risk and compares that with the traditional methods of assessing seismic risk.

Jan 1, 1990

By L Terrusi

The Bungaroo Valley hosts a concealed Tertiary channel iron deposit (CID) along a 17 km stretch of its length. Bungaroo Valley is approximately 0.5 km wide upstream at its easternmost extent, and 3.5 km wide downstream where it joins the Jimmawarrada Creek. The valley follows the axial trace of an anticline that plunges gently to the southeast, and the CID infills the valley. Mineralisation extends to a depth of 230 m below the surface, and almost the entire deposit occurs below the water table. Bungaroo Valley cuts through the Buckland Hills and is bounded to the north and south by steep scarps capped with the resistant Dales Gorge Member of the Brockman Iron Formation. Basement rocks are believed to be mostly Wittenoom Formation shales and dolomites, with Mount McRae Shale and Mount Sylvia Formation also present. Deep, localised depressions appear at the base of the CID sequence towards the north edge of the upstream section of the valley, while downstream the basal CID contact is relatively flat and shallow. In both cases the profile of the CID surface closely mirrors that of the basal contact. The localised depressions seen in the upstream basal CID contact produce significant variations in CID thickness of up to 100 m over short strike distances. This uneven palaeotopography is most likely due to eddying and waterfalls forming within the riverbed prior to CID deposition during a time when the water table was much lower than at present. It may also be associated with possible karsting in an underlying dolomite unit and subsequent syn- or post-depositional collapse of the overlying CID. The irregular basal contact of the Bungaroo CID sequence has implications for mining in terms of pit design and resource accessibility.

Jan 1, 2007

Dartbrook mine is a new greenfields thermal coal longwall mine located n the Upper Hunter Valley ten kilometres north of Muswellbrook Figure 1). Construction began in April 1993 with coal extraction starting n October 1994. Longwall production is scheduled to commence in the first quarter of 1996 with production expected to exceed 3.5 million onnes per annum. The permanent workforce will number 150 full-time ,mployees and productivity rates will be 22 000 per employee per annum m a ROM basis. Being a greenfield site Dartbrook has had the opportunity to develop and operate the mine using the best practices and latest technology available to meet high standards of safety, quality and production.

Jan 1, 1995

By Duncan GR

Having passed through a number of previous phases the best longwall results in Australia have shown a significant increase in the last two years. The results expected from a longwall face can be estimated from the ideal production rate, determined by the capacity of the equipment and the conditions in which it is installed, the utilisation, and the available operating hours. Back analysis of the results achieved suggests that, on average, recent improvements arise from the higher capacity equipment recently installed; the utilisation has in fact reduced slightly. Review of the constraints which limit the longwall results, i.e. shearer speed, AFC capacity, support, advance rate, and man travel speed, shows that little improvement can be expected in the ideal production rate in thinner seams. In thicker seams the AFC often proves the overriding constraint and further increase in equipment size could lead to increased future ideal production rates and is expected. In all cases a concerted effort to increase the utilisation achieved is likely. For deep mines with thin to medium seams this offers the most viable path to improvement; by contrast thick seams with highwall/shallow access may benefit from further increase in equipment size.

Jan 1, 1988

By S Robson, T G. Blenkinsop, S C. Dominy

Golden Pig mine is in the central part of the Southern Cross greenstone belt within the Archaean Yilgarn craton. The mine has produced approximately 2.5 Mt of ore at 5.7 g/t Au to yield approximately 450 000 oz. The majority of gold mineralisation is hosted within extensively deformed and quartz-veined BIFÆs. In addition to the BIF-hosted mineralisation, an increasingly important part of the resource lies in the Taurus Lode, which is a N-NNW-trending amphibolite facies shear zone. The Taurus Lode lies within a continuous shear-zone that has a moderate to steeply WSW dipping foliation, and a mineral lineation of biotite, amphibole and pyrrhotite plunging consistently 10¦ S. Drive faces, subperpendicular to the foliation and lineation, consistently show evidence for syn-mineralisation reverse shear. Exposures parallel to the mineral lineation and perpendicular to the foliation reveal both sinistral and dextral asymmetries. These characteristics suggest that the vorticity axis of the Taurus Shear Zone is parallel to the mineral lineation, and that the simple shear sense is reverse. This geometry can arise when there is a major component of flattening across the shear zone, which may be due to interference between two adjacent granite domes. The BIF-hosted lodes plunge consistently 15¦ NNW coincident with the intersection of the axial planar cleavage of the regional folds and the Taurus Shear Zone. However, where the penetrative shear characteristics control the orientation and geometry of the mineralisation, oreshoots plunge SSW, parallel to the stretching and mineral lineations within the shear. The SSW plunge of strike extensive and laterally confined high-grade, economic ore shoots within the Taurus shear is fundamental to defining the economic mineralisation within this lode. Identifying the zones of maximum continuity and establishing the optimal position for future development will maximise ore extraction.

Jan 1, 2003