Search Documents

By D O’Dea, B Godel, T Honeyands, G Evans, T Harvey

The pores within iron ore sinter are important for producing a high quality material that is strong and easily reduced. The complementary methods of mercury intrusion porosimetry (MIP) and X-ray computed tomography (CT) were used to characterise the structure of industrial and pilot scales sinters across a wide range of pore sizes (3 nm to 100 µm for MIP and 50 µm to 5 mm for CT). The inhomogeneous nature of sinter and the variation in the measurements make it difficult to compare samples. The generalised additive modelling (GAM) approach, using the open source statistical software package, R, has been applied to highlight where there are peaks in the concentration of pore sizes. Importantly, the shape of the GAM-fitted function and the heights of the peaks show statistically significant differences between samples. For the samples investigated, the GAM-fitted functions for the MIP volume distribution of pore diameters were found to have a common set of distinctive peaks at 0.005, 0.6 and 20 µm. The GAM approach was also applied to the X-ray CT measured pore wall thickness, highlighting a single peak whose position varies between samples. The cause of these distinctive peaks and their implications for sinter quality are discussed. Correlation was found between the volume in peak 1 (0.005 µm) and the concentration of primary hematite. No correlation was found between the pore wall thickness and the strength of the sinter, suggesting the composition of the pore walls may be more important. Future work will focus on small-scale sinters produced under tightly controlled conditions to study sinters with a wider range of quality values.CITATION:Harvey, T, O’Dea, D, Evans, G, Godel, B and Honeyands, T, 2017. Highlighting key features of the pore structure of iron ore sinter using mercury intrusion porosimetry and X-ray computed tomography, in Proceedings Iron Ore 2017, pp 39–48 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By K Pery, J Leahy

Established metallurgical plants operate in a complex environment of interdependent drivers including technology change, operating and maintenance practice, evolving markets, HSEC requirements, statutory and plant requirements, personnel turnover, ore supply, and financial conditions, to name a few. A successful optimisation program should comprehend these factors and drive towards not only lower operating costs, but also higher rates of return for a given level of investment. Optimisation programs have the potential for very high rates of return on capital that Greenfield projects rarely have. This paper presents a robust strategy and methodology for plant optimisation initiatives as well as a case study of how it was implemented at the QNI Yabulu refinery in Queensland, Australia by an integrated team of researchers, engineers and operators. The methodology is premised on the fact that nobody knows the production asset as well as the current operating team. It covers the optimisation process from ideas generation, various stages of selection against the agreed criteria, development, including testwork, funding approval and implementation. It highlights the benefits in the use of integrated teams, the establishment of a sound project basis, and a diligent, phased approach.

Jan 1, 2004

By Misra V. N

Upgrading of a Koolanooka magnetite iron ore sample provided by Kingstream Steel Ltd was investigated using low intensity magnetic separation (LIMS) and reverse flotation. The ore contained 38.6 per cent iron, 37.8 per cent silica, 6.5 per cent magnesia and 0.54 per cent alumina, with the main minerals in the ore being amphibole (42 per cent), magnetite (39 per cent) and quartz (14 per cent). The concentrate obtained after low intensity magnetic separation contained 66.6 per cent iron and 6.34 per cent silica with an iron recovery of 72 per cent. This concentrate was further treated by reverse flotation to increase the iron content and reduce the silica content to meet the requirements for direct reduction iron (DRI) feed grade.

Jan 1, 1999

By R Lethlean

The mining industry in its drive to optimise equipment use and minimise cost simply to remain profitable in an uncertain commodity market needs to develop a greater understanding of equipment capabilities and cost. The factors influencing mobile equipment fleet cost and performance commence at the time of mine planning and continue to exert an influence over the life of the mine. These factors must be understood at the early stages of any operationÆs planning process as they continue to impact both positively and negatively on fleet performance and operating cost throughout the life of the mine. The key factors examined in this paper include: grades; rolling resistance; fragmentation and truck loading.

Jan 1, 1998

The works of Metal Manufactures Ltd are situated at Port Kemblam NSW, within a few hundred yards of a deep-water harbour. At present they occupy about 26 acres, and ample provision has been made for future extensions. Rail connection exists between various parts of the Works and the main South Coast Railway, the harbour jetties and the adjacent copper refinery of The Electrolytic Refining and Smelting Co Ltd. A plan of the works is shown in Fig 1.The company was incorporated in March 1916, and commenced production of copper wire in June 1918. Early in 1920, tube manufacture was undertaken, followed by telephone cable mnufacture in 1923. Today the Works consist of five principal sections: Founrdy, Tube Factory, Wire Factory, Cable Factory and Case and Drum Factory. Whilst the last four are engaged in producing the finished materials for despatch from the Works, the first-mentioned is engaged in producing copper, brass, and other non-ferrous billets for use in the Tube and Wire factories. In addition, there are Engineering and Metallurgical Departments supporting the manufacturing sections, and in these, as well as in all other sections of the Works, extensions have been carried out from time to time to provide for increased output and new types of products.

Jan 1, 1938

Pressure drops were measured in a column packed with glass spheres and wax particles, both in random and preferential distributions. Variables investigated included wax content, gas flow rates, and temperatures.It is shown that for random distribution of wax, pressure drop is exponentially related to wax content above the melting point of wax and that below this it increases with increasing gas rate and temperature.For preferred distribution of wax the highest increase in pressure drop is obtained with horizontal distribution of wax and the least with vertical distribution.Comparison with operating blast furnace data and application of results to practice are also included.

Jan 1, 1970

By S Dykes, R J. McCarthy, B Klein

There is growing interest in the mining industry on the application of ore sorting. While many are familiar with particle sorting, including the limitations that technology presents (e.g. throughput), bulk sorting, with its higher throughput potential, is less understood. Despite the potential to sort at higher throughputs, few operations have adopted bulk sorting processes, certainly not at large scale. It is suggested that the inability to reliably predict outcomes from bulk sorting may be limiting its adoption in mining projects. Consequently, an evaluation approach for bulk ore sorting has been developed such that mass pulls and grade upgrades can be predicted in the context of a mining study. The approach allows for evaluation of drill core assays and application of the consequently derived heterogeneity relationships to the block model for estimation of sorting outcomes. These processes were applied to conveyor-based bulk sorting for the CuMo project in Idaho, USA and are described in this paper.

Nov 10, 2020

By T Haskell, Y Joe, S Dickie

A current trend amongst producers is the increase in dewatering of iron ore fines (<0.5 mm), due to an increase in wet beneficiation processes used to upgrade lower quality ore deposits, increased water content in orebodies located below the water table, and increasing focus on transportable moisture limits (TML). Vacuum filtration is commonly used for dewatering of iron ore fines, and as with all filtration processes performance decreases with particle size. Significant improvements are possible with the use of filter aids, usually anionic surfactants and flocculants. Anionic surfactants reduce the surface tension of the associated water, which is then removed more readily leading to improved filtercake moistures. Anionic flocculants used correctly can improve cake permeability, in turn, decreasing cake formation times and increasing filtration rates. In addition to increased throughput, savings and benefits for producers can include: moisture limit penalties, improved handleability, along with energy and water savings.The effect of filter aids on two iron ore fines samples from the Pilbara region were evaluated using a lab scale vacuum filtration unit. The first sample showed a reduction in the filtercake moisture content by 2.3 per cent weight/weight (w/w) with the use of BASF’s Drimax® 1234. For the second sample a reduction in the filtercake moisture of 3.4 per cent w/w along with an increase in filtration rate of 20 per cent was achieved by using a combination of Magnafloc® 5250 and Drimax® 1239 NF, as both filter throughput and cake moisture were considered important by site.CITATION:Haskell, T, Dickie, S and Joe, Y, 2017. The use of filter aids on iron ore fines, in Proceedings Iron Ore 2017, pp 183–186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By A Turichshev

The synthetic rock mass (SRM) approach for modelling jointed and veined rock has been at the forefront of caving geomechanics research for years. A well-constructed and calibrated SRM model can capture the full rock behaviour at a macroscopic scale. Traditionally, SRM technology employed bonded particle models (BPM) due to their ability to model rock’s response to loading without prior specification of behaviour. The SRM modelling process requires the BPM to simulate intact rock and the subsequent introduction of fractures or veins by changing bonding characteristics between the particles. However, bonded particle materials have difficulty reproducing both the compressive and tensile strengths of intact rock. This and other limitations of BPM have been the driving force in exploring the potential of grain-based (2D) and bonded block (3D) models (BBM).This paper reports on recent work exploring the applicability of both BPMs and BBMs in 3D to the modelling of intact rock. The advantages and limitations of both BPMs and BBMs are addressed based on the results of numerical simulations using the PFC3D and 3DEC distinct element codes. The preliminary results suggest that BBMs are better suited for simulating intact rock behaviour than BPMs. Ongoing work aims to better qualify the applicability of BBMs under different conditions. This has significant implications for our understanding of rock mass behaviour in a caving environment.CITATION:Turichshev, A and Hadjigeorgiou, J, 2016. Simulating intact rock behaviour using bonded particle and bonded block models, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 453–460 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By W Newns

This paper describes laboratory and in situ tests and determines a set of parameters for stiffness and strength properties for a weak sedimentary rock mass, the East Coast Bays Formation of Auckland. The parameters derived are discussed in relation to peak strength and in respect of deformation limits associated with sequential excavate and support (SEM) or conventional tunnelling.

Mar 8, 2011

Two key elements in the design of a pastefill or high density hackfill system are the preparation of the backfill material and its distribution underground. This paper examines these two areas. Owing to the essentially impervious nature of total mill tailings, preparation of pastefill and high density fill from current tailings involves a physical dewatering process. There are currently three methods available for this process: I. Vacuum or pressure filters. These represent the 'traditional' approach to the preparation of pastefill. 2. Paste production storage mechanism. This is a thickening/storage mechanism developed with the specific objective of producing paste/high density backfills. 3. Fluidization. This system utilises silos fitted with simple dewatering devices and nozzles. Recently developed by CANMET, it provides the simplest and most economical approach. This paper describes and compares the three preparation methods, from a practical and an economic point of view. Once the pastefill/high density fill has been prepared and binder added, the backfill must be distributed underground into the stopes. A fundamental factor in the design of a distribution system is the rheology of the material- No two materials will exhibit the same properties, and a sequence of rheological and related testing is required prior to the completion of the design of the underground distribution system. This paper covers the testwork normally required and discusses the fundamental design parameters of pastefill distribution systems. The final section of this paper summarises the use of pastefill at three mincsin Canada.

Jan 1, 1998

The uptake of zinc, lead, and copper by the flora of the Tui Base Mine area near Te Aroha is described.Vegetation and soil samples were taken from two traverses across the Raukaka Lode. Results. after statistical analysis, indicated that Beilschmiedia tawa was a suitable species for biogeochemical prospecting for lead and that SchefJlera digitata was satisfactory for zinc.The tawa showed a negative anomaly for lead over the vein itself but not over the adjacent dispersion halo. It was concluded that lead concentrations greater than 230 p.p.m. in the wood ash of the tawa and zinc concentrationsgreater than 540 p.p.m. in the leaf ash of S. digitata denoted threshold values for anomalous mineralization in the soil beneath. Although both species contained copper, neither indicated a soil anomaly for this element.

Jan 1, 1969

By Nakahiro Y, Wakamatsu T

In the present study, from experimental results, a new concept of possibility of flotation separation of quartz from feldspar is presented. The effect of the nonionic surfactant Brij 58 on the flotation behaviour of quartz and feldspar has been investigated. The effect of the surfactant adsorption at the solid-liquid interface was also studied. The results demonstrate that maximum flotability of quartz occurred at low concentration of surfactant. Feldspar is not collected by this surfactant. Flotation tests with feldspar that had previously been subjected to leaching by hydrochloric acid yielded similar flotation response as that of quartz. The effect of removal of alkali cations from feldspar surface on its flotability was investigated. The effects of inorganic and organic additives on the flotation recovery of quartz are discussed in terms of the slating-out or salting-in properties of these additives. KEYWORDS: Alkyl polyoxyethylene; feldspar; flotation; nonionic surfactant; quartz; salting-in; salting-out; separation; silanol groups.

Jan 1, 1993

By D Craw, I M. Turnbull, R J. Norris, N Mortimer

The Otago Schist is being subdivided on a regional scale into structurally, metamorphically and lithologically distinct blocks. Differences between blocks are subtle, and difficult to map in the field. Boundaries are late-metamorphic or immediately post-metamorphic in origin, and are different from later brittle faults which disrupt the schist. Mapping of late-post-metamorphic structural discontinuities has direct application for basic grassroots exploration in the Otago Schist. The mineralised (and currently mined) Hyde-Macraes Shear Zone forms a regional scale boundary between a block dominated by politic schist and a block with massive psammitic schist, pelitic schist, and minor greenschist and chert. The HMSZ forms a metamorphic discontinuity, with garnet and biotite in the underlying schist, and neither index minerals apparent in the overlying schist. The HMSZ is also a structural boundary between domains with differing lineation orientations. The HMSZ can not yet be traced along strike to the northwest to the Rock and Pillar Range, where the only major discontinuities recognised are the Caples-Torlesse boundary and a normal fault separating low grade from high grade schist. Structural and lithological discontinuities in the Dunstan Range break the range up into distinct structural blocks, two of which are separated by the gold-mineralised Rise and Shine Shear Zone.

Jan 1, 1999

By R R. Lovel

In this paper, life cycle assessment methodology has been used to assess the variations in water use associated with different metal production and processing routes and provide insights into the value derived from water usage in the minerals sector. Using water consumption data derived from the literature it has been shown that the æcradle-to-gateÆ water consumption (or embodied water) for production of the various metals considered in the study ranged from 2.9 m3/t for steel up to 252 087 m3/t for gold. The results largely reflect the grade of the initial ore used to produce each metal, and can be approximated by the following equation:W = 167.7 G - 0.9039 where: W = embodied water (m3/t refined metal) G = grade of ore used to produce metal (per cent metal) The study showed that indirect water consumption in the metal production life cycle, in particular that due to electricity generation, can make a significant contribution to the embodied water value, eg aluminium production. When expressed in terms of m3/t ore, the results for all metals considered indicated that the embodied water is roughly, on average, three times the water consumption of the mining and concentration stage. It was also shown that the economic value per m3 of water consumed for the minerals industry exceeds that for the agricultural and industrial sectors, supporting the view that allocating water resources to the minerals industry has a strong underlying economic basis. Water reforms currently taking place in Australia aim to address issues such as competition for water access, reduced security of supply and increase in cost. Consequently the minerals industry, along with others, can be expected to come under increasing pressure to reduce fresh or raw water use and to integrate water use across sectors. While water recycling is an obvious candidate to help reduce water consumption in the minerals industry, issues such as water quality, among others, will influence the extent to which this can be achieved. In addition, wastewater volumes can be minimised using techniques such as pinch analysis to establish and use the minimum water requirement for the process. The use of dry or near-dry processing technologies, for which the demand for water is small or zero, may be a more radical solution to the water consumption problem; however, it is possible that the introduction of dry processing would bring with it a new set of problems, including dust.

Jan 1, 2006

By R R. Lovel

In this paper, life cycle assessment methodology has been used to assess the variations in water use associated with different metal production and processing routes and provide insights into the value derived from water usage in the minerals sector. Using water consumption data derived from the literature it has been shown that the æcradle-to-gateÆ water consumption (or embodied water) for production of the various metals considered in the study ranged from 2.9 m3/t for steel up to 252 087 m3/t for gold. The results largely reflect the grade of the initial ore used to produce each metal, and can be approximated by the following equation: W = 167.7 G - 0.9039 where: W = embodied water (m3/t refined metal) G = grade of ore used to produce metal (per cent metal) The study showed that indirect water consumption in the metal production life cycle, in particular that due to electricity generation, can make a significant contribution to the embodied water value, eg aluminium production. When expressed in terms of m3/t ore, the results for all metals considered indicated that the embodied water is roughly, on average, three times the water consumption of the mining and concentration stage. It was also shown that the economic value per m3 of water consumed for the minerals industry exceeds that for the agricultural and industrial sectors, supporting the view that allocating water resources to the minerals industry has a strong underlying economic basis. Water reforms currently taking place in Australia aim to address issues such as competition for water access, reduced security of supply and increase in cost. Consequently the minerals industry, along with others, can be expected to come under increasing pressure to reduce fresh or raw water use and to integrate water use across sectors. While water recycling is an obvious candidate to help reduce water consumption in the minerals industry, issues such as water quality, among others, will influence the extent to which this can be achieved. In addition, wastewater volumes can be minimised using techniques such as pinch analysis to establish and use the minimum water requirement for the process. The use of dry or near-dry processing technologies, for which the demand for water is small or zero, may be a more radical solution to the water consumption problem; however, it is possible that the introduction of dry processing would bring with it a new set of problems, including dust.

Jan 1, 2006

By B Belle

In a predrained gassy coalmine, ventilation control plays a secondary role to the longwall (LW) goaf drainage systems to safely manage panel return gas levels. Typically, the LW specific gas emission (SGE) estimation models provide anticipated goaf gas emissions and arriving at required gas drainage capacity for various coal production scenarios. A study comparing the various LW goaf gas hole spacing patterns with weekly production rates of up to 270 kt/w of an operating mine with high SGE rates (~20 m3/t) was carried out. The goaf capture efficiency of LW panels ranged from 64 per cent to 85 per cent. For the first time, gas content of upper seam data post LW retreat were used to verify the current SGE prediction models. This study has shown that an average of 50 m goaf spacing is optimal for management of high production retreat gassy LW panels in presence of multiple upper and lower seams with gas emission zone influence reaching up to 200 m above workings. Due to the horizontal stress direction related geotechnical issues, goaf hole failures just behind the LW face is a recurring challenge resulting in significant and immediate increase in LW panel return gas levels. This paper highlights the shortcomings of current SGE prediction models for goaf gas estimation, and evolution of 50 m goaf hole spacing embedded in design process in managing the LW tailgate gas levels.CITATION:Belle, B, 2017. Optimal goaf hole spacing in high production gassy Australian longwall mines – operational experiences, in Proceedings Australian Mine Vent Conference 2017, pp 15–26 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 28, 2017

By A Whaanga, W Vigor-Brown

IGO Ltd’s (IGO’s) Nova-Bollinger Deposit (Nova-Bollinger) is a magmatic nickel-copper-cobalt (NiCu-Co) sulfide deposit found 160 km east-north-east of the town of Norseman in Western Australia (WA). The deposit is hosted by the Mesoproterozoic rocks of the Fraser Zone, which is part of the Albany Fraser Orogen (AFO). Since mining commenced in 2016, IGO’s Nova Operation (Nova) has mined and processed to 31 December 2020, 5.63 Mt of ore grading 2.04 per cent Ni, 0.86 per cent Cu and 0.07 per cent Co. Nova’s mine geology team (MGT) has used commercially available implicit modelling (IM) and general-purpose resource modelling (RM) industry software systems, to prepare the 31 December 2020 (CY20) update of Nova-Bollinger’s JORC Code reportable Mineral Resource estimate (MRE). This CY20 MRE update was predominantly based on ~386 km of diamond core drilling, with the drill holes having a nominal grid spacing of 12.5 by 12.5 m throughout the mineralised zones of the deposit. Using IM tools, Nova’s MGT interpreted and modelled 22 separate domains from the drill hole logging, assaying results, and the MGT’s underground mapping. These IM closed volumes were then used to control the estimation of MRE variables into conventional industry digital block models using RM and other ancillary software systems. During 2021, a commercial machine learning (ML) software was trialled by Nova’s MGT for preparing block models of Nova-Bollinger’s MRE domains. The motivation for the trial was that the ML process could expedite modelling through the direct creation of a domain coded block model from the drill hole logging. Compared to the industry standard approaches of wireframing or IM, where the modeller usually makes many subjective choices to produce the domain model, ML offers a more objective ‘hands-off’ process for determining the connectivity of domains defined in drill holes. Additionally, the ML process provides a quantitative confidence metric associated with its output that may have utility in mine production and resource classification. In this paper, the results of the Nova-Bollinger ML modelling trial are compared to the MGT’s current workflow for MRE work. The MGT’s conclusions as to the advantages and disadvantages of the IM and ML methods for preparation of MRE domains are discussed. The ML software was also tested as a method of rapidly interpreting geology outside the principal zones of MRE interest. These testing results are also presented in this paper.

Mar 22, 2022

The Golden Cross Mine will be the first underground gold mine in New Zealand to operate since 1952. The development plans, along with the conditions and circumstances presently found in the now ongoing mine development, will be discussed as well as a brief review of planned stoping activity and stoping results to date.

Jan 1, 1991

By P Nissen, T Jenke, M Ralph, M Cattani, M Quinlan

The West Australian Government hold an annual ‘Mines Safety Roadshow’ around the State’s regions and the capital city, Perth. Each year presenters provide an update on legislation and safetyrelated themes. A recurring theme is the mining industry fatality rate. Professor Michael Quinlan’s ‘Ten Pathways to Death and Disaster’ (Quinlan, 2014) has been referenced regularly to assist in structuring workshops and conversations concerning fatality prevention in the mining industry. The ‘Ten Pathways’ are the outcome of an analysis of fatal injuries in the mining industry, which identified a series of common themes to the fatalities: Pathway 1: Design, engineering, technical and maintenance flaws. Pathway 2: Prior warnings or causes for alarm ignored. Pathway 3: Failures in risk assessment. Pathway 4: Failures in management systems and hazard management plans. Pathway 5: Failures in auditing. Pathway 6: Economic pressures compromising safety. Pathway 7: Failures in regulatory oversight and inspection. Pathway 8: Worker and others expressing concern prior to the incident. Pathway 9: Poor management – worker communication and trust. Pathway 10: Emergency and rescue resources and procedures. To determine a fatality risk profile we asked participants at the Mines Safety Roadshows to indicate their perception of their employer’s performance in each of the Ten Pathways. We administered the questionnaire at the Mines Safety Roadshows in 2017, 2018, 2019 and 2023. In this paper, we report on the results of the questionnaires, and suggest how organisations can improve their fatality risk score.

Apr 16, 2024