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By M Bannear, C Stanton

Since 2008, Arrium has been developing and commissioning a new low-grade hematite ore benefication plant (or OBP) at its Iron Baron mine site.The Iron Baron mine, which was closed in the 1990s, could not consistently yield the high-grade hematite required for pelletising. However, in todayÆs market, the 12 Mt of waste dumps represent a significant low-grade hematite resource, ideal for benefication.Initially, an internal scoping study and several sampling campaigns were conducted to determine the ability to upgrade the available low-grade dump material to a product suitable for export. Test work was conducted at Mineral Technologies (formerly CPG), and included high intensity magnetic separation, spiralling and jigging. Due to promising results from a wet processing circuit, Arrium engaged Mineral Technologies to design a flow sheet that could provide 1 Mt/a of a mixture of high-grade lump (-32 + 8 mm) and fines (-8 mm) products for export.With construction of the plant completed in late January 2012, Arrium, in conjunction with Mineral Technologies, began two commissioning phases. Each phase ended with a toll gate to prove the plantÆs capacity to reach rate and desired grade. After an initial period of running on water, feed solids were introduced to the plant and troubleshooting of bottlenecks began. The first toll gate, whereby the plant was required to run for 24 hours at an average feed rate of 200 t/h (80 per cent of design rate), was completed on the 1 March 2012. Further troubleshooting and resolving of issues allowed the plant to steadily increase feedrate while maintaining good availability and grade. The second toll gate required the plant to run for 72 hours at an average feed rate of 200 t/h while meeting grade, yield and water consumption targets. Sampling campaigns were conducted during this period to track the performance of key equipment. Completion of the test, and full handover of the plant to Arrium, was completed on the 21 April 2012.Although the formal commissioning phases had been completed, ongoing optimisation of the OBP continued, ensuring that all major equipment was working to produce the optimum yield and grade. Sampling campaigns were conducted on the jigs and spirals, with results and correlations used for operations documentation.Overall, with successful completion of the final acceptance tests, the commissioning of the Iron Baron OBP has been established as a major success achieving all production and quality targets as per the original design intent.This paper will focus on the successful commissioning and ramp-up performance of the plant however reference will also be made to the key development stages involved with the development of the project.CITATION:Stanton, C and Bannear, M, 2013. ArriumÆs Iron Baron hematite beneficiation plant - a success from start to finish, in Proceedings Iron Ore 2013 , pp 547-552 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By T. Johnson

Hydrometallurgical processes can be exceptionally corrosive. This is particularly true in acid leaching processes for copper, cobalt, nickel and rare earth elements. In the last five years, several large hydromet plants have been built in North America (Vale - Long Harbour, Baja Mining ? El Boleo and MolyCorp - Mountain Pass). Hundreds of storage tanks, extraction vessels and electrowinning cells along with miles of piping were designed and fabricated to withstand the aggressive environments inherent in these processes. One key element all three projects had in common was the extensive use of FRP in equipment design. As a material of construction, FRP provided equal if not improved durability relative to alternative corrosion resistant alloys at a considerably lower cost. This paper will highlight the extensive use of FRP in these three world scale projects and why it was chosen for each process.

Jan 1, 2013

By M. Neven, R. A. Steane, E. Lam

"The Key Lake uranium mill is located in Northern Saskatchewan. It treats a high grade, complex uranium and metal sulphide ore. The plant and process are in many respects unique, because commercial treatment of this type of uranium ore had never been done before. The process and engineering design was based on extensive laboratory test results. A pilot plant testing stage was omitted because of confidence in the test results and time constraints to bring the plant into production.The bench scale testwork on exploration drill core samples along with preparation of the feasibility study and environmental impact statement were carried out between 1976 and 1979. The contract for detailed engineering was awarded to Wright Engineers of Vancouver in late 1980 and in August of 1981 following a public inquiry, approval to proceed with construction was granted.Construction began immediately, and during the winter the foundations for many of the plant buildings were poured and by the beginning of the following winter the buildings had been erected and installation of equipment began. Despite a six month construction worker strike in 1982, the crushing plant started up in June of 1983 and ore processing commenced in October of that year, approximately 3 months behind the original schedule.This paper describes the mill design and compares the expected performance, with the operating experience. Emphasis is directed towards flowsheet and equipment changes made since start-up, operational difficulties encountered and further improvements envisaged. Auxiliary systems are only discussed where they directly affect mill operation."

Jan 1, 1986

Book review Proceedings of the Symposium on Mining Methods. London, Institution of Mining and Metallurgy, 1974. 160 pp. The Symposium was held from 30th October to 1st November, 1974, and the papers include an interesting range of subjects in coal-mining operations, covering the improvements achieved to date, current practice, and required development for the future. Salamon, M.D.G., and Oravecz, K. 1. Rock Mechanics in Coal Mining. 119 pp. NIM reports Report no. 1822 Stability constants and linear free-energy relations for the platimtm-group metals. (22nd Oct., 1976). Report no. 1852 A revised method for the dissolution of platiniferous materials by the sealed-tube technique. (18th Oct., 1976). Report no. 1828 y-picoline adducts of the nickel, copper, and zinc chelates of 2-thenoyltrifluoroacetone. (26th Nov., 1976) Report no. 1847 A pilot-plant investigation of a kinetic model for flotation.(19th Nov., 1976)

Jan 2, 1977

By Farzad Moradpouri, Kianoush Barani, M. R. Azadi

The aim of this paper is to assess the effect of microwave treatment on copper sulfide ore for ball milling and bed breakage. Liberation analysis of ground products in eight size fractions showed that microwave pretreatment liberated more chalcopyrite particles from the bed breakage product than the ball mill product. In bed breakage, microwave pretreatment caused a 2% increase in chalcopyrite liberation on average. Microwave pretreatment produces more elongated particles in ball milling and more rounded particles in bed breakage, respectively. Microwave pretreatment produces coarser chalcopyrite particles with a wide range of sizes. This effect is more significant in bed breakage compared with ball milling. Micro-flotation test results showed that in ball milling, treated and untreated materials have similar metallurgical performance and there is a little difference (1%) between the average Cu recovery values. However, in bed breakage, the average recovery for the treated materials is about 5% higher than the untreated materials.

Jul 8, 2021

By Manis Kumar Jha

Leaching studies were carried out for the recovery/ recycling of metals from PCBs containing 17.05% Cu, 0.74% Ni, 1.74% Fe, 4.35% Pb and 8.32% Sn using various acids such as H2SO4, HCl and HNO3. While sulfuric acid was not a suitable leachant for the dissolution of metals from PCBs, hydrochloric acid selectively dissolved tin. The nitric acid was found to be effective lixiviant with the recovery of 99.99% Cu, Fe, Ni and 36.7% Pb in 6M HNO3 at S/L ratio of 100 g/L and 90oC. The kinetic studies carried out with 2M and 4M HNO3 at 90oC showed ?Ash diffusion control dense constant size-spherical particles? model.

Jan 1, 2010

By R. P. King

The essential features of an image analysis system for the measurement of mineral liberation are described. Good procedures for image acquisition and image processing prior to image analysis are defined. The basic stereological methods for the measurement of volume fraction, surface area per unit volume, particle size distribution and liberation spectra are given. The appropriate methods for fractal correction when measuring perimeters of irregular features and for frame correction when measuring linear intercepts are developed. Practically useful and accurate procedures for the stereological correction of particle size and liberation distribution methods are given.

Jan 1, 1995

By D. M. Loring

Radon progeny have been a health and safety concern for miners since the mining of radioactive minerals began. Through the ?nuclear age?, it has become better understood and the regulations have become more robust. Ventilation and control practices have improved, thus reducing miners? exposures. This paper provides an overview of radon in mining, the progress of the regulations, and discusses some of the uranium miner studies that contributed to the knowledge of the pathology of radon.

Jan 1, 2009

By Michael Schmitz, Eugene Ahrenholtz, William A. Heitbrink, Jeanne A. Zimmer, Andrew B. Cecala, Ernest S. Moyer, Earle H. Andrews, Chris C. Coppock, John A. Organiscak

Many different types of surface mining equipment use enclosed cabs to protect equipment operators from health and safety hazards. The overburden removal and mining process can be extremely dusty and can cause excessive dust exposure. To study this issue, a cooperative research effort was established between the National Institute for Occupational Safety and Health, U.S. Silica Co., Clean Air Filter Co., and Red Dot Corp. in an effort to lower respirable dust levels in an enclosed cab on an older surface drill at a silica sand operation. Throughout this research effort, a number of modifications were incorporated into the drill's filtration and pressurization system, as well as in other areas, to improve its design and performance. An average cab efficiency of 93.4% was determined with gravimetric sampling instruments when comparing the outside with the inside cab dust levels on the final design. Although this study considered just one operation, the goal was to identify cost-effective improvements that could be implemented on all types of enclosed cabs to lower respirable dust concentrations. Two critical components for an effective enclosed cab system are having a properly designed, installed, and maintained filtration and pressurization system, along with a method for maintaining structural cab integrity, which allows the cab to be positively pressurized. Another important component is maintaining cab cleanliness. Although this research was originally directed toward the mining industry, it is also applicable to agricultural or construction equipment.

The cost of power is an important matter to mining companies generally and this thought that the members of the Australasian Institute of Engineers, as well as the engineering and mining professions generally would be interested in any proposal for the reduction of that cost has led to the presentation of this paper.The writer trusts that the description will be found clear and increase the interest in this interesting subject. In the up of the electrical arrangements touched on in this paper, the author has had the able assistance of his friend Mr. Mars, to whom he offers his hearty thanks. The selection of the best class of power plant for a mine is a very difficult and large problem and it is quite out of place to dogmatise that anyone of the many systems that offer is better than another, eg that the all electrical is better than the partly direct steam-driven and partly electrical, or that a gas plant is better than a steam plant. Such a selection is one that calls for very careful and close consideration, in each particular case, of a large number of before it is possible to arrive at a proper decision.

Jan 1, 1912

By S. R. Gilbert, C. O. Bounds, R. R. Ice

"Many ores are upgraded to produce auriferous sulphide concentrates (principally pyrite) which are not amenable to direct cyanidation. Often these refractory gold-bearing concentrates contain undesirable elements such as arsenic, antimony, etc., which present environmental and/or processing problems. The pretreatment techniques most often considered for processing these concentrates prior to cyanidation include roasting, pressure oxidation, chemical oxidation, pre-aeration, and recently, bacterial oxidation. In this paper, the technical performance and economics of bacterial pre-oxidation vs the classical roasting approach for treating a specific auriferous pyrite concentrate are compared. The results provide flow sheets, preliminary operating and capital cost estimates, and rates of return for the two processes and demonstrate the potential advantages of bacterial pre-oxidation. IntroductionThe increased attention that gold has received in the last ten years has prompted mining companies to look for lower grade orebodies. Many of these low-grade ores do not respond well to conventional direct cyanidation recovery techniques. As free-milling ores decline, gold is sought in refractory environments which, ultimately, drive up the treatment costs.There are a number of reasons for a gold ore to be termed refractory, most of which can be identified by thorough mineralogical examination. The mineralogical occurrence of gold can, to a great extent, impact the method by which the ore is treated and, consequently, the capital and operating costs. Gold in a refractory ore can often occur as discrete particles locked in a host of silicate or carbonate gangue, or associated with sulphides or sulphosalts. Depending on its particle size, gold can be liberated and recovered by mechanical size reduction such as regrinding. This approach is most effective for gold in the 10 - 50 micron range. Gold can also be associated with clay, iron hydroxides, or other minerals which tend to coat the gold surface and inhibit the penetration of the cyanide solution, resulting in poor plant recovery. Because of their resistance to cyanide dissolution, gold tellurides and other refractory gold minerals are also responsible for losses to the tailings. For these reasons, it is paramount that the mineralogical occurrence of the gold be thoroughly and accurately determined before selecting a final process flowsheet."

Jan 1, 1988

The dissolution of gold in cyanide has been studied, using both chemical and electrochemical techniques. The electro-chemical studies have confirmed that gold may become passive in cyanide solution if its potential becomes more positive than -O· 5 V v. saturated calomel electrode (S.C.E.). The results of the conventional solution rate tests suggest that, although the solution rate is controlled by the rate of diffusion of oxygen at low oxygen and agitation levels, when these are increased the gold may become passive and its solution rate approach a steady value, or even decrease with increasing oxygen level. The passivity of gold has been shown to be of importance in the solution of small spheres of this metal, and in the extraction of gold from a calcined auriferous pyrite concentrate.INTRODUCTIONAlthough it has been appreciated for many years (McLaurin, 1893, 1895) that dissolved oxygen is a necessary adjunct to the solution of gold by the cyanide process, attempts to quantitatively assess its effect have led to conflicting results. For example, Barsky, Swainson, and Hedley (1934) reported that an increase in oxygen concentration improved the solution rate, but Beyers (1936) claimed that such an increase would reduce the rate at which the gold dissolved.By using an electrochemical approach Kudryk and Kellogg (1954) showed that the diffusion rate of either the cyanide or the oxygen was a controlling factor, and that, if the mole ratio of cyanide to oxygen concentration was greater than 10, the solution rate was proportional to oxygen concentration.These results, although they represent some of the most careful work available, were in direct contradiction to the findings of Mills (1951), who found that gold may become passive in cyanide solution, with a resultant decrease in solution rate.

Jan 1, 1963

The more than 40,000 mining industry professionals that are expected to attend the National Mining Association’s(NMA) MINExpo International2000 trade show and conference will be treated to the exhibition’s largest display ever. The exhibit is expected to cover more than 60,385 m2(650,000 sq ft) and feature more than 1,300 exhibitors. The event is set for Oct. 9-12, 2000 at the Las Vegas Convention Center in Las Vegas, NV. Richard L. Lawson, NMA’s president and chief executive officer, said, “MINExpo 2000 will showcase everything that mining is proudest of. This is the largest premier mining exposition in the world.” MINExpo is held every four years.

Jan 1, 2000

The Bureau of Mines is responsible for a broad spectrum of programs for meeting the diverse and changing mineral resource needs of the Nation. These programs are managed by the Director and two Deputy Directors, who formulate general policy and program direction from the Washington, D.C., headquarters. A senior advisory staff, consisting of the Chief Staff Officer, Chief Scientist, and Chief Mining Engineer, provides advice and consultation to the Director on a wide range of scientific and technical matters and acts on behalf of the Director to maintain liaisons with other government agencies, mineral industries, and professional societies. Bureau program activities are classified into two major functions: (1) Developing new and improved technology that will make the production and processing of minerals more efficient, safer and more healthful for mineral workers and the public, and more compatible with a quality environment.

Jan 1, 1979

By E. C. Morton

The Western Australian School of Mines (WASM) has developed a facility for the static testing of large scale ground support elements. The samples are loaded using a mechanical screw feed jack. Instruments measure the displacement and the load being applied. Methods have been developed for testing of mesh, shotcrete and membranes. Mesh samples are restrained on all sides and loaded centrally. A new large scale punch test method has been developed to evaluate shotcrete and membranes. These products are sprayed on to a sandstone substrate containing a centrally located isolated disc. The sprayed product is loaded by displacing the disk. The different test methods are described in detail. The test program involved two types of mesh, several shotcrete mix designs with different curing times and one membrane product. The force-displacement responses are used to directly compare the products. The implications for implementation of the different ground support products are discussed.

May 1, 2009

By Peter Chou

A total of 117 slope stabilization drilled piers were installed as part of a major hillside revitalization project. The 110-million dollar development, known as Stratford at Kenwood, included an 18-story upscale senior residential tower, a 3-story healthcare building, and 4-story condominium buildings, offering approximately 580,000 square feet of living space with panoramic views of Downtown Cincinnati, Ohio. In an effort to establish a flatter hillside plateau for the new 4-story condominium and to create a cut and fill balanced jobsite environment, an 800-foot long row of drilled piers and a 600-foot long multi-tiered shear key system was used to terrace existing 1.5H to 3H: 1V steep slopes and support the new fill. These slope stabilization features reduced the amount of spoils needed to be wasted off-site and mitigated the risk of slope instability. An ODOT/FHWA research indicated that spacing of stabilization piers and necessity of top-connecting elements are highly dependent on pier diameter, spacing, soil type, depth to potential failure surface, surcharge loads, and pier deflection. Due to pre-existing deep buried swales, various load combinations, and the complex mechanism of soil arching effects between adjacent piers, both analytical and numerical computer modeling was performed to estimate the loading on each pier. New generation multiplexed, 3-Dimensional, Micro-Electro-Mechanical-System based inclinometers were installed between selected piers to confirm the pier design, and monitor the fill placement, as well as long-term slope stability.

Jan 1, 2009

By Franklin D. Cooper

This Bureau of Mines report reviews in detail the foundry coke situation in the United States in 1975. It discusses intrinsic production problems and identifies opportunities for modifying operating practices so that the quality and yield of foundry coke can be enhanced without unnecessary investment in new equipment. Major topics include operating data and attendant practices and problems, the relationship of carbonization phenomena to coke quality and yield, environ- mental impacts of foundry coke plant operations, suggested research and development opportunities, and data on components of oven charges and on foundry coke production and shipments.

Jan 1, 1977

By Mohamed Ourriban, Stéphanie Somot, Éric Proulx, Jean-Sébastien Marois, Marjolaine Drouin, Paul Blatter, Ahmed Bouajila, Claude Gagnon

"The mining industry has to face increasing restrictions concerning the use of fresh water in Québec and throughout the world. Increasing recirculated water usage could lead to a better control of the quality and the quantity of water supplied to the mineral processing units. Furthermore, it could reduce the volume of waste water to be managed and treated before its release to the environment. However, process water may have a negative impact on mineral processing operations, thereby limiting the incentive for sustainable development initiatives. As a first step into selecting and testing remediation strategies, one of which being blending local waters, a mapping of process water quality (inorganic and organic fractions) allowed to locate zones in an industrial case study where fresh water is introduced into the circuit and to detect dissolution and precipitation zones. A complementary hydro-geochemical modeling study on water blends was also performed showing encouraging results towards the objectives of the project.INTRODUCTION The industry has to face increasing restrictions on the use of fresh water in Québec (Quebec Government, 2009) and throughout the world (Brown, 2003; UNESCO, 2006). The cost for the use of fresh water and for water management is highly variable and case-dependent (from 0.2 to up to 7 million dollars/year according to available private estimations, excluding the capital expenditure). It may be, or may become, significant for any plant; thus, risk assessment is of concern here. Using recirculated water could lead to a better control of the quality and the quantity of water supplied to the mineral processing units. Furthermore, it could reduce the volume of waste water to be managed and treated before its release to the environment. However, process water may have some positive and negative impacts on mineral processing operations (Janssen, 2003; Johnson, 2003; Rao and Finch, 1989). Negative impacts could limit the incentive for sustainable development initiatives. Water management strategies at mineral processing sites are supported both by a strategic plan and a water management plan. The strategic plan includes legal aspects, investment costs, potential benefits and various risk levels (Corder and Moran, 2006; Côte et al, 2006; Evans et al., 2006; MacIntosh and Merritt, 2003; McLellan et al., 2008; Merritt and MacIntosh, 2006; Robinson and Keddie, 2006; van Beers et al., 2007a; van Beers et al., 2007b; van Berkel, 2007). In practice, the strategic plan evaluates technical possibilities and costs of various scenarios, such as for example: bringing fresh water to the plant or recirculating waters, or using blends of both. Two important factors to consider in order to enhance the future production efficiency and to minimise risks are: the durability and the stability of the resource, both from quality and quantity points of view."

Jan 1, 2012

By P Lindsay, J B. Hughes

Underground and opencast coal mining has been ongoing since 1896 on the Stockton Plateau, West Coast, New Zealand. Acid Rock Drainage (ARD) from historic and current mine workings has had an adverse environmental impact on the surrounding aquatic environment. The two main catchments affected by ARD are those of the Mangatini and St Patrick streams. These catchments flow into the Lower Ngakawau River, which holds high amenity value for the local community. Water quality targets set by Solid Energy for 2010 in the Ngakawau River include increased pH and clarity and a decrease in certain dissolved metals.   At-source ARD minimisation options are the first stage in mitigating the effects of mining acid forming rocks and reducing acid loads in the Mangatini and St Patrick stream catchments. ARD minimisation techniques reduce the quantity of acidity generated and thus reduces the treatment required. Treatment will be required for many years at Stockton due to current and historical acid formation. This paper looks at the treatment options that Solid Energy has been investigating including limestone leach beds, engineered wetlands, oxic limestone drains, and limestone dosing of catchment drainage. Particular focus is given to fine limestone dosing of the Mangatini stream and subsequent water quality improvements.

Jan 1, 2007

By A van Jaarsveld

Environmentally-friendly, safe and cost-effective technology for stope drilling has successfully been introduced at TauTona mine. It has enabled the problem of inadequate compressed air pressure and its downgrading impact on production capability to be overcome. The paper traces the development process which culminated in the conversion of the entire stoping operation at TauTona to electric drilling. Background work which took place at other mines is also described. Statistics of performance improvements are provided. 1. Introduction Holman?s Silver series and the Seco S215 were drills that had a measurable impact on the South African gold mining industry. It is too soon to say whether Hilti will join those great names. However, there is no doubt that the introduction of electric drills into the harsh and unforgiving world of deep level gold mining is a significant development. History has shown that being the first to enter a new technology is no guarantee of long-term success. The pain and suffering which accompany the birth of anything new can deplete the energy of the innovator while at the same time creating opportunities for competitors to leapfrog him. In addition to commitment and enthusiasm, the innovator must therefore also possess, or have access to stamina and resourcefulness to overcome the unexpected difficulties which will inevitably arise. All of these were needed for the Hilti project.

Jan 1, 2008