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To gain further understanding of the operating efficiency of the BHP Slab and Plate Products Division (SPPD) RH vacuum degasser, physical and mathematical model studies of the process have been undertaken. The purpose was to investigate how the various process parameters affect the liquid circulation rate, to visualise the flow patterns, and to identify and eliminate the cause of localised wear in the downleg. In the physical model mixing times were measured using an acid tracer technique. The results were applied to predicting trends in times required to obtain homogenous melt composition under varying conditions. A 2-dimensional mathematical model describing the liquid metal flow has been developed using the PHOENICS fluid-flow package. The physical model results were simulated and incorporated into the mathematical treatment and an improved design for vessel geometry is proposed. The effect of rounding the downleg entrance or installing a baffle between the legs is discussed.

Jan 1, 1987

By P Andrieux

By 1996 ground control-related problems at Brunswick Mine had raised serious concerns regarding the safe and economical extraction of large portions of the reserves. These difficulties were mainly caused by high stress levels in pillars, instabilities resulting from wide spans supported by ageing support elements, and chronic difficulties supplying rock fill from the surface quarry to the underground workings, which resulted in many large voids remaining open for long periods of time. Significant changes have been implemented at the site since 1996, amongst which were a change of mining method, the introduction of paste backfill, the establishment of stress management measures, and the introduction of shotcrete on a large-scale. This paper focuses on the regional ground conditions associated with both the previously used primary-secondary mining method and the newly implemented pyramidal pillarless technique, as well as on some of the stress management measures implemented at the mine.

Jan 1, 2000

By Staunton W. P

The presence of cyanide soluble copper in gold ores can give rise to serious operational and economical difficulties in CIP and CIL operations. Cyanide consumption can result in the ore being uneconomic to treat by conventional means. Loading of copper onto carbon can also have deleterious effects on gold recovery and subsequent stripping and bullion recovery. The recovery of gold from high copper ores has been previously reviewed by Muir, LaBrooy and Cao (1989). Work undertaken for Mt Gibson Gold Project by Australian Mining Advisors with the assistance of the Chemistry Centre (WA) resulted in the patenting of a process and subsequent construction of a plant at Mt Gibson to overcome some of the difficulties encountered with copper. This paper discusses some of the work which was undertaken during laboratory investigations prior to commissioning of the plant and some further considerations for the treatment of high copper gold ores.

Jan 1, 1991

By Hengst B

The first production stage in any mining operation is the breaking of whole rock into fragments small enough for loading and subseq- uent handling. This primary fragmentation is most frequently accomplished with blasting. The maximum fragment size and the fragment size distribution have an influence on the subsequent loading, handling and crushing costs. It is assumed that total rock fragmen- tation in practice is a result of an interact- ing array of radial cracks from various blastholes. The representation for the basic pattern of radial cracks emitted from a particular blasthole is first described. A model is then developed simulating the interaction between blastholes at various burdens and spacings, and in simultaneous and delayed modes. The resultant picture is analysed and a fragment size distribution calculated. Methods of incorporating the existing faults in the rock are also discussed. Finally application of this model to various facets of mining are considered.

Jan 1, 1977

By Thompson P, Sharma Y

The paper describes the methodology and results from a study carried out by Telfer Gold Mine to optimise the materials and costs involved in construction of the pad for their dump leach operations. The investigation involved large-scale field testing of five different types of liner and a number of different cushion and drainage layer configurations. The aim was to identify the most cost effective construction methods to allow the final dump height to be increased from 45 in to 60 in without causing significant damage to the liner. The effects of dump height on permeability were also investigated. These methods are described and results presented. The findings indicated that modifications to the existing liner/cushion layer/drainage layer configuration used previously at Telfer would actually reduce overall construction costs rather than increase them despite an increase in overall dump height. Relative construction costs are presented.

Jan 1, 1994

The concentrated efforts now being directed towards the development and application of monitoring and control techniques have now resulted in their widespread use in UK mines together with evidence of benefits resulting from their application. There is little doubt that the longwall method of producing deep mined coal will continue but will be made more reliable and efficient with the aid of control technology. The major fields of research and development work are concerned with planning and design of mines and mining equipment; management and engineering information; and automation of coalface, tunnelling and transport systems. The principal achievements now in widespread use are: the standard computer system MINOS, widely applied to mine transport, coalfaces and mine environment; extensive use of machine condition monitoring leading to condition-based maintenance; underground automation of conveyor systems and guidance systems for ranging drum shearers and boom-type roadheaders are being widely introduced.

Jan 1, 1985

By Bogar D. V

Often dewatering of coal tailings is inhibited by the presence of clays, making it difficult to obtain a high concentration, handleable coal tailings. The net result can be a low concentration, chocolate mousse-like tailings which poses significant sedimentation problems in a tailings dam and represents a significant environmental problem. This paper examines the coal tailings from a Hunter Valley colliery where the tailings properties are influenced significantly by the presence of montmorillonite clay. The influence of the calcium ion on the rheology and sedimentation/compression behaviour of coal tailings . containing montmorillonite already dispersed in water was investigated and revealed that very little improvement in the properties is achieved through the coagulation. The preliminary investigations also indicated that the properties of the tailings were dominated by the presence of the montmorillonite clay. Thus investigations were carried out on the clay alone in water. Investigations into the effect of dispersing samples of the clay alone in water and then coagulating with calcium compared with dispersing the clay directly into calcium ion solutions at the same calcium concentration showed huge improvements in the rheology, compressibility, sedimentation rates and sediment solids concentrations for the second dispersion method, which can be called controlled dispersion. The sediment volume fraction solids improved by more than a factor of two by controlling the dispersion of the clay. The reason for the improved properties lies in the suppression of the initial swelling of the clay, which is initially in the sodium form, thus maintaining the parallel orientation of the platelets that is present before wetting. While swelling is being suppressed, ion exchange occurs with the calcium which results in permanent swelling suppression. In the uncontrolled dispersion case where swelling is uninhibited, the clay is allowed to break up and despite the powerful coagulating nature of the calcium ion, the random orientation of the high aspect ratio clay platelets inhibits effective coagulation. Results indicate that the initial electrolyte concentration of the washwater in a coal washery is the critical factor controlling the dewaterability of clay tailings and the handleability of the dewatered product rather than the actual act of coagulating with the calcium ion. The results presented are of clear practical significance and indicate how coal tailings problems where clay dominates the rheology can be improved considerably by knowledge of the surface chemistry.

Jan 1, 1995

By T Higuchi, K Fukada, K Takehara, Y Iwami, S Fujiwara

Following the Paris Agreement adopted in 2015 and the SDGs, reduction of CO2 emissions has been taken up as an issue worldwide, and the steel industry, which has a particularly large emission, is required to significantly reduce it. Most of the CO2 generated in the steel industry is generated from the ironmaking process, due to the use of coke and its raw material coal in the ironmaking process. JFE Steel Corporation has been considering the use of hydrocarbon-based gaseous fuels and liquid fuels as a partial alternative to coke breeze used in the sintering process since 2006, immediately after the Kyoto Protocol came into effect in 2005. In a laboratory study, a pot test was used to investigate the effect of the type of fuel, its amount and its injection method on the heat pattern in sinter bed. As a result, the authors developed a technology, in which a predetermined amount of gas fuel or liquid fuel was injected from the surface of sintering bed to extend the holding time of 1200°C or higher at which liquid phase sintering occurs in the layer, to improve the sinter strength while reducing the amount of coke breeze. The authors succeeded in putting this technology to practical use using hydrocarbon-based gas fuel in 2009 and achieved a maximum annual reduction of 60 000 tons of CO2 per sintering machine. In this report, the authors introduce the results of laboratory studies on the use of various energy sources, the practical application of the technology for injecting hydrocarbon-based gaseous fuel into the sintering machine, and the operational results.

Nov 8, 2021

By X Hu, J Björkvall, L Sundqvist Ökvist

The metal production industry is a significant contributor to global CO2 emissions due to the use of fossil fuels such as coal and coke. To mitigate these emissions and meet climate goals, innovative and sustainable technologies are required. Molten salt electrolysis is a promising technology that directly produces metals from their precursor sulfides or oxides using electricity. When combined with renewable electricity and an inert anode, the electrolysis process can be carbon neutral. This paper presents the results of two pilot-scale studies on the electrolytic reduction of metal oxides and sulfides in molten salts. The first study focuses on the electrolytic reduction of chalcopyrite in molten NaCl-KCl salt. The results demonstrate that in situ separation of copper, iron, and sulfur is possible, enabling the extraction of all valuable elements without CO2 emissions. Furthermore, the findings underscore the capability to eliminate impurities like zinc, antimony, arsenic, and mercury from the electrolysis product. The second study investigates the electrolytic reduction of pure/synthetic chemicals of wüstite, hematite, and magnetite, as well as a magnetite-type iron ore in molten NaOH salt. The findings reveal a stepwise reduction of iron oxides from high valence to low valence, ultimately leading to the production of metallic iron electrolytically. Notably, this study underscores the challenges associated with the selection of an economically viable and durable inert anode material for efficient oxygen generation. These results indicate that molten salt electrolysis provides a sustainable and green route for base metal production. The use of this technology has the potential to significantly reduce CO2 emissions in the metal production industry, contributing to achieving climate goals.

Jun 19, 2024

By A B. Richards

Time window analysis that limits the explosive mass fired within a specified time window (commonly eight milliseconds) has been used for many years in blast design by explosives engineers. Despite several warnings in the past that this technique has limited practical or scientific basis and, in many cases, does not effectively control vibration, almost every textbook and blasting manual refers to time window charge mass limits as a primary vibration control technique. It has become entrenched in some blast vibration management plans, despite being inappropriate for the particular situation. With the flexible initiation timing available with electronic detonation almost a practical reality, and the 8 ms constraints in-built into the signal tube initiation system thereby lifted, it is timely to review the significance of the 8 ms time window in controlling blast vibration. This paper re-visits the original research that led to the development of the 8 ms criteria and the non-supportive conclusion of the original researcher. Because airblast was not measured, the 8 ms time window was never intended to be applicable for airblast control. Examples of blast designs are given in this paper that comply with the 8 ms time window limit that result in substantially increased air and ground vibration, together with examples of blast design that does not satisfy time window considerations, which results in reduced air and ground vibration. Techniques that identify wavefront reinforcement, due to the combined effect of drilling pattern and delay sequence, can assist explosives engineers to avoid high blast vibration situations that result from the inappropriate application of time window techniques and other adverse delay combinations.

Jan 1, 2003

A process was developed based on the thermal hydrolysis and precipitation of iron from solutions resulting from the leaching of zinc plant residue. A study was made of the hydrolysis of iron, at temperatures in the range 140-220°C, in both pure solutions of ferrie sulphate and in leach solutions derived from plant spent electrolyte.At 200°C hydrolysis of pure ferric sulphate solutions results in the precipitation of ferric oxide, Fe2O3, at low acid. concentrations, and a basic salt, Fe2O3.2S03.H20, at hIgher acid concentrations. At 180°C ferric oxide is precipitated at low acid concentrations, but at higher acidities. carphosiderite, 3Fe203.4SO.3.9H20, is the stable phase. Frequently a mIxture of ferric oxide and carphosldente IS produced at 180°C, the ratio of phases being dependent on the non-equilibrium experimental conditions.With solutions derived from plant spent electrolyte hydrolysIS at elevated temperatures results in the precipitation of jarosite compounds of the type NaFe3(S04)2(OH)6 The precipitation of natrojarosite jarosite, and ammonio-jarosite was studied in detail. Temperature, free acidity, and the concentration of sodium potassium, and ammonium ions are critical factors which affect the extent of precipitation.A process based on ammonio-jarosite precipitation was tested in a pilot plant.An alternative method of iron removal based on the addition of zinc oxide calcine, to neutralize excess acidity, and the precipitation of ferric oxide was also tested in the pilot plant. Both processes appear economically favourable...

Jan 1, 1967

By Kim M

Mukuk gold mine in South Korea produces a pyrite concentrate containing gold associated with arsenopyrite as a gangue mineral. The effects of Portland cement as a depressant on the flotability of arsenopyrite were studied to improve the separation of arsenopyrite from pyrite concentrate containing gold. A series of the fundamental flotation tests were performed using Portland cement as a function of pH and concentration of the collector. Flotation recovery of pyrite and arsenopyrite in the fundamental tests with amyl xanthate showed that arsenopyrite was depressed by the addition of a moderate amount of Portland cement, but pyrite was not depressed by it. In the flotation tests of the artificial mixture samples with arsenopyrite and pyrite, following pH were adjusted to be 10.5 by Portland cement, different amount of amyl xanthate was added. The results from these studies showed that flotation recovery of pyrite was 100 per cent under the condition of some addition of amyl xanthate, but arsenopyrite was not floating at all. Portland cement shows remarkable depression of galena, but its effect on the flotability of chalcopyrite is not as clear. In the pulp under Portland cement addition, chalcopyrite can be easily activated by the addition of sodium bisulphite, whereas galena is depressed more effectively. From the batch flotation tests with the pyrite concentrate, the galena concentrate and the Cu-Pb bulk concentrate from the mines, it was confirmed that the results of the batch flotation tests agree with the results of the fundamental flotation tests. The effects of depression by Portland cement on pyrrhotite, marmatite and stibnite are also discussed briefly.

Jan 1, 1993

By R-H Yoon

Increasing the upper particle size limit of flotation would allow operators to increase mill throughput, save operating costs, simplify flow sheets, and increase rate of return. However, coarse particle flotation is difficult for various reasons, of which bubble-particle detachment has been identified as the major limiting factor. In the present work, the process of bubble-particle detachment has been studied by directly measuring the forces required to detach air bubbles from hydrophobic solids. The measurements were conducted using a hanging balance apparatus. The measured forces were converted to detachment energies that can be compared with the work of adhesion, which in turn is a function of hydrophobicity, surface tension and contact area. The results were converted to detachment energies using the Young-Laplace equation for capillarity. In the present work, the solid surfaces were hydrophobised by coating them with octadecyltrichlorosilane and cetyltrimethylammonium bromide. The results show that bubble-particle detachment occurs in two steps. In the first step, air bubbles are deformed, while the three-phase contact (TPC) line is pinned, until contact angle reaches advancing angle. In the second step, the TPC line moves along the surface until solid/air interface is replaced by solid-liquid interface. In general, the energies of detachment measured in the second step are in good agreement with calculated work of adhesion. Thus, the energy required during the first step effectively represents an energy barrier for bubble-particle detachment. It has been found that the energy barrier varies with surface roughness and surface tension. The results of the present investigation suggest, therefore, that coarse particle flotation can be improved by control of particle hydrophobicity, surface roughness, and surface tension.

Jan 1, 2005

By S Vink, V Nanjappa, C J. Moran

Poor quality water resulting from interaction of surface run-off with saline mine spoil and soils can cause significant problems for water reuse on mine sites. Not only can this saline water lead to machine corrosion and increased maintenance costs, but may cause detrimental effects on the environment. Determining the geochemistry of mine spoil, and the likelihood of salt dissolution during rainfall events, may aid in more effective mine site management of water. Spoil samples were taken from three areas of the German Creek mine site, situated in the Bowen Basin coalfield, Queensland. Samples from two undisturbed areas on the lease were also collected for comparison. Analyses were performed using a variety of laboratory techniques: leaching tests, effective cation exchange capacity determination, X-ray diffraction, clay quantification, and total organic content determination. Results show that dissolution of surface (top 2 cm) salt minerals from spoil areas is an important contributor to surface run-off salinity during rainfall events. Equally, ion exchange with clay minerals appears to be a significant source of elevated ion concentrations in run-off waters. Findings from the undisturbed areas show undetectable quantities of salt mineral species, resulting in waters with low ion concentrations. More generally, monovalent cations (sodium, and to a lesser extent potassium) appear to be derived from dissolution of salt precipitated whereas divalent cations (calcium, magnesium) are more likely to be sourced from exchange reactions with clay minerals. Incorporating knowledge about the mechanism of cation mobilisation from spoil with the spatial distribution of spoil properties and understanding of the dynamics of water quality variations on the site will aid in development of integrated water quantity and quality management strategies.

Jan 1, 2009

By G V. R Goodman, G J. Chekan, J M. Listak

The extraction and transport of coal from underground coal mines can result in significant liberation of coal and/or silica dust into the mine atmosphere. Mine operators have long used ventilating air as a primary means of diluting generated dust, removing dust from the working faces and preventing dust from reaching the minersÆ working environment. As production levels have increased, mine operators continue to be challenged in maintaining dust concentrations below compliance levels. The need for maximising the effectiveness of available ventilating air in conjunction with other effective controls, such as water sprays and dust collectors, continues to be critical to the long-term health of mine workers. The National Institute for Occupational Safety and Health (NIOSH) has conducted full-scale laboratory and mine-site research to evaluate improved application of dust controls for both longwall and continuous mining methods. A summary of recent research results and recommended practices will be provided.

Jan 1, 2005

By M Dunglison, P M. Cameron

Simultaneous mass-balancing of a mineral processing flow sheet results in adjustments to each data point that reflects the accuracy and precision across the full set of data. In this way, all the good work that goes into designing the sampling and analysis protocol for each sample point is leveraged in order to produce a æbetterÆ set of balanced numbers for every sample point in the circuit. Few operating plants employ whole of circuit balancing techniques to produce reported operating results. This situation is changing with the application of mass balancing technology which utilises redundant data for production accounting and metal reconciliation from product to ore source across multiple phases and multiple time periods. Mine and plant data can now generate credible information to improve productivity. Mine and plant personnel can now use consistent data sets for review and planning. Decisions based on balanced data can be made quicker and with increased confidence.

Jan 1, 2005

Relationships between lead blast furnace performance and the composition and size distribution of sinter were determined from analysis of lead blast furnace operating data. Sintering plant practice was subsequently modified and substantially improved furnace performance resulted.

Jan 1, 1971

The paper presents the results of laboratory blasting and grinding experiments on a low-grade iron ore, investigating how blasting will influence the subsequent crushing and grinding operations. Increased blasting energy will lead to a reducti

Jan 1, 1998

By Griffin P

The project is the result of a European Commission supported collaboration between Surpac Software International, the Technical University of Berlin, and the industrial partners Exploration and Bergbau GmbH (E+B) and Taylor Woodrow. The object

Jan 1, 1998

By Partridge AC

In order to provide a'valid description of the performance of size classifying equipment it is necessary that a standard procedure be established for testing and for the subsequent expression of results. Such a standard would permit the valid comparison of alternative equipment and may provide a basis for the prediction of performance. An Australian Standard (AS 1634-1974) has been used as the starting point for an International Standards Organisation-(ISO) working group (of which the authors are members) charged with the preparation of an ISO Standard for the expression and presentation of the results of tests on coal size classifying equipment. The approach taken is applicable to all types of sizing equipment (cyclones, screens, dedusters, etc.) and should be suitable for adoption in the minerals industry as well as by coal preparation engineers. The background to the proposed Standard, is given,including a critical review of other frequently quoted performance measures, the procedures described in the draft are discussed, and an example given.

Jan 1, 1984