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By D Morgan, D Sato, B Lumsden, S Senanayake

Laboratory flotation tests on fresh cyclone overflow samples are a useful tool to troubleshoot and indeed to improve plant performance; however, reproducibility between laboratory flotation test and plant performance is important for interpretation of the laboratory tests and hence their usefulness. Chemical reproducibility can be achieved with the addition of the required reagents; however, reproducing the physics of forces and energy in a 5 L cell compared to a 50 000 L plant cell or a 500 000 L plant cell is not generally studied or discussed. For some tests such as collector evaluation the physics of the flotation process may not be critical, but for some evaluations in the laboratory, it can be important.All flotation plants suffer from losses of valuable <20 µm mineral. Selective mineral aggregation has long been recommended to improve the poor flotation recovery of <20 µm sulfide minerals; however, successfully testing any type of selective sulfide mineral aggregation’s effect on flotation recovery in the laboratory on practical plant samples requires reproducing plant cell physics. The energy input per litre and the forces in a laboratory cell are vastly different to a plant cell. Reproducibility between laboratory and plant tests requires that these differences be minimised. The physics of the laboratory flotation cell is particularly important when fine mineral aggregation tests are carried out.This paper outlines a modified laboratory aggregation and flotation method that closely reproduces plant performance in a laboratory test.CITATION:Sato, D, Lumsden, B, Senanayake, S and Morgan, D, 2014. Development of a laboratory flotation method to test plant mineral aggregation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 173–178 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

TSL Concepts and Practical Examples of the Non-Reactive System - Meyco TSL 865 Thin Spray-on Liners (TSLs) have been intensively investigated by mining and chemical industries within the last decade. Apart from the basic concept of spraying thin liners, expectations of the product's performance vary, eg immediate active strata support is seen as a key to control the ground permanently. For many coal mines this is an important factor to reduce maintenance in their roadways and enable permanent production from the long wall. In opposition to a passive mesh system this technology offers immediate active support to the strata. But not only coal mines are interested in TSL technology, there are potential applications in hard rock mines, during shaft sinking, pillar support and as an anti-weathering sealant. This paper will explain the advantages and disadvantages of TSL concepts; it will give examples of successfully applied TSLs with a main focus on the non-reactive and flexible system MEYCO TSL 865 by BASF. Furthermore, it will indicate the limitations and discuss briefly the bearing capacity and reasonable lab testing of such systems.

Nov 25, 2010

By S Chaudari, T Ren, T Harvey

Management of respirable dust on longwall face remains a challenging issue for mine operators, particularly for the new generation of thick seam longwalls. A fundamental understanding of the airflow behaviour around the shearer is critical for dealing with the dust control issue on longwall faces. Computational fluid dynamics (CFD) modelling techniques have been used in this study to conduct a detailed investigation of the air and respirable dust flow patterns around the longwall shearer. Three CFD models have been developed to represent different longwall cutting heights. The results of these modelling studies tallied well with field measured airflow data from different mines. The validated thick seam longwall face model was then used for detailed parametric studies to simulate the effect of various parameters and dust control concepts. The dust control options investigated include various spray configurations, shearer clearer, modified cutting sequences and shearer scrubbers of various capacities to minimise the respirable dust migration towards the walkway area of the longwall face. This paper presents a summary of the results of these CFD modelling investigations.

Jan 1, 2005

By C G. Ryan, D R. Cooke

The Thames gold-silver deposits are part of the Hauraki goldfield, situated within the Miocene to Pliocene calc-alkaline Coromandel Volcanic Zone (CVZ). The Waitangi vein system is one of the mineralised ore shoots in the Thames district. The Thames gold deposits are characterised by shallow-level epithermal vein mineralisation with phyllic to advanced argillic alteration assemblages and abundant sulphide minerals including pyrite, arsenopyrite, chalcopyrite, galena and sphalerite. Gold occurs as electrum in association with sulphide minerals. Sulphur isotope analyses of mixed sphalerite-galena and sphalerite-galena-chalcopyrite samples yield a narrow range of δ34 SCDT values (-1.0 to 0.9 ë; n=5), whereas late spongy pyrite gives unusually light sulphur isotope values (-16.7 to -27.9 ë; n=4). Vein quartz from the mineralised zone at Waitangi yields δ18OSMOW values from 6.8 to 12.7 ë (n=23). Fluid inclusion studies indicate a homogenisation temperature range of 190¦ - 296¦C and salinity range of 0.2 - 3.0 wt per cent NaCl equivalent. Similar temperature and salinity ranges have been recorded for the other gold deposits in the Coromandel Peninsula. PIXE (Proton Induced X-ray Emission) analysis revealed that the Waitangi ore fluids have 1090 - 2700 ppm K (average 1600), 145 - 205 ppm Ca (average 180), 80 - 100 ppm Mn (average 90), and 80 - 200 ppm Fe (average 120) but no detectable Cu, Zn, Br, Rb, Sr, Pb and Bi (only one fluid inclusion contains 28 ppm Zn). The sulphur isotopic values of base metal sulphides from Waitangi suggest that the sulphur was derived from a magmatic source (either directly, or by leaching of igneous sulphides). The calculated oxygen isotopic composition of ore fluids is between -2.1 to 3.8 ë at 250¦C and -0.1 - 5.8 ë at 300¦C. Oxygen isotope analyses have revealed significant variations in δ18O values with elevation and gold grades. Zones of gold enrichment coincide with a zone of variable oxygen isotope values at the top of the vein system, where boiling and/or fluid mixing most likely occurred. Mixing of ore fluids with convective ground water is a likely mechanism for gold deposition in a shallow environment for the Waitangi vein system and there is also lack of fluid inclusion evidence (eg liquid-rich and vapour-rich inclusions in the same growth zone) for boiling of ore fluids. Oxygen isotope values varying with gold grades within the Waitangi conduits suggest that δ18O values may be useful in targeting bonanza grade gold mineralisation in epithermal vein systems.

Jan 1, 1999

By P Tobar

The development plan (long-term plan) of El Teniente Mine, Codelco-Chile, includes 100 per cent primary ore, located at increasing depths, which may involve several difficulties related to the application of the current panel caving method, such as a high seismicity level, a coarse fragmentation and ore pass damage. Therefore, it is a strategic priority for the El Teniente mine, to design and to test alternative mining methods, at similar or lower costs to ensure an efficient and safe ore extraction. In this context, the Macrotrench method is developed, as a competitive alternative to the current method. The document describes the panel caving method, the experience achieved in the primary ore exploitation from the geomechanical point of view. It also describes the æmacrotrenchÆ method as an alternative to the current exploitation method. Finally, the comparative advantages of macrotrench in relation to panel caving are presented. The results obtained during the engineering stage include the following aspects:the mining design, the material handling, a geomechanical evaluation of the method, and a comparative analysis.

Jan 1, 2000

By Jankola W. A, Delong O. J

Historically, the silica content of zinc concentrates treated at Cominco's Trail Operations has been low. Silica in the roaster calcine seldom exceeded 1.5 per cent because of the low silica content of concentrate from Cominco's Pine Point mine. With the shutdown of Pine Point, alternate sources of concentrate were required and it was anticipated that calcines containing greater than two per cent silica (with excursions above three per cent) would have to be treated. Previous experience indicated that the existing leaching circuit could not tolerate such high levels. Therefore, a research program was undertaken to identify the key factors affecting silica precipitation; to compare different process alternatives; and to make recommendations for modifications to the existing plant. A project to modify and upgrade the leaching circuit has now been completed. Calcines with higher silica contents are successfully treated, but the upper limit of the circuit is unknown. The results of the research work will be discussed and the new leaching plant will be described. Recent operating results will also be presented.

Jan 1, 1993

By J S. Laskowski

Froth flotation process requires the use of frothers. These important flotation agents are commonly characterised as either æselectiveÆ or æpowerfulÆ and are chosen following general guidelines and verification by laboratory and/or pilot plant tests. Fundamental properties of the flotation frothers have been extensively studied over the last few years. These studies have led to the development of standardised procedures to characterise frothers in terms of their ability to reduce bubble size and to increase foam stability. In this research project, the performance of five frothers in flotation of coal is evaluated and related to the fundamental properties of these agents. Since the recovery of water in the concentrate is closely related to the non-selective transport of solid particles by entrainment, the tested frothers are also assessed in terms of their ability to promote the transport of water towards the froth collection zone, both in absence and in presence of solids.

Jan 1, 2005

New Celebration Gold Mine is located 35 km SE of Kalgoorlie, Western Australia, in the Archaean Kalgoorlie-St Ives Greenstone belt. The leases total 119 sq kms and arepart of a joint venture between Newmont Australia Ltd (as manager) and Mt Martin Gold Mines N.L. Mining commenced in August, 1986 and is now producing over 115,000 ounces of gold per annum. A variety of gold mineralisation styles with a total resource of 23.5 million tonnes at 2.19g/t are associated with shear zones at New Celebration. Gold production is co-ordinated from 7 open pits with others planned to com- mence soon. A large scale underground trial mining operation has com- menced with a decline on the hanging wall of the main producing orebody, Hampton Boulder. Millfeed produced is classified on the stockpile according to grade and metallurgical performance and blended tomaximise throughput while main- taining grade through a CIL treatment plant currently operating at 1.7 million tonnes per year.

Jan 1, 1991

By I Zulkarnain, H Permana, R A. Binns

Through an ambitious but relatively low-cost program of marine fieldwork, laboratory investigations and technology-transfer and training activities, three Indonesia-Australia-led marine expeditions were undertaken aboard KR Baruna Jaya VIII between 2001 and 2003. These IASSHA (Indonesia-Australia Survey for Submarine Hydrothermal Activity) cruises have sought to discover and investigate a variety of potential ore forming hydrothermal systems in a range of tectonic settings. All cruises have been successful, both scientifically and from the point of view of training, creation of capabilities and capacity building for such research in Indonesia. Over 60 scientists and technicians from Indonesian and Australian institutions and agencies have been involved. Three new sites and a possible fourth site of hydrothermal activity were discovered in the Sangihe arc in northern Sulawesi. Surveys in the Tomini basin tested a hypothesis based on previous data which suggested this might be an isolated anoxic, brine-filled basin over 2000 m deep where igneous heat sources existed to generate hydrothermal mineralisation. The bay, however, was found to be open to adjacent deep ocean circulation, and there was no evidence of massive base metal sulfides. Subdued evidence of hydrothermal activity was found in the Sunda Strait associated with the famous Krakatau volcano and the extension of the seismically active Semangko Fault. The BANDAMIN program (Indonesia-Germany) covered a portion of the Banda arc in eastern Indonesia, and also found evidence of recent hydrothermal activity and epithermal sulfide mineralisation.

Jan 1, 2004

By D Q. Zhu

In this paper, the pretreatment of concentrates by roller press was present to improve the granulation of blends comprising some 30 per cent iron ore concentrates and enhance the sintering performance. It is shown that by pretreatment of fine concentrates through roller press, the content of +3 mm fractions of granulation mixture and sinter mixture permeability are elevated by ten per cent and 35 per cent. In the meantime, a sinter productivity increase from 1.51 - 1.62 t.m-2.h-1 is attainted in pot tests with similar sinter tumble index and at lower coke rate. The mechanism of the pretreatment of concentrates process to improve sintering performance of fine iron ore concentrates was demonstrated by mineralogy that better permeability help form more calcium ferrite and good microstructure of sinter, further proven by the better metallurgical performance of sinter.

Jul 11, 2011

By M Schmid

German hard coal mining operations have decreased for more than 40 years. Current political decisions are leading to a discontinuation of subsidised black coal mining by the year 2018. This decision will, however, be reviewed once again in the year 2012. The enormous increases in productivity, which were achieved in previous years, have so far not led to an achievement of market requirements. Coal mining at depth of more than 1200 m in multiple seam environments is not yet competitive in global comparison. In 2008 the 24 faces left in eight mines produced about 20 million tonnes of usable steam coal. Management and the workforce will be reduced in parallel; from today until 2012 by more than half. The average age of personnel is increasing dramatically and nearly no new personnel are recruited. With this background in mind, increasing continuously coal mining productivity becomes more and more difficult. Above all, this goal was reached by mechanisation, then by increasing the mining machine power and then by enhanced machine control systems. The first attempts to automatically operate full face equipment from above ground were in the early 1980s. After successful automation of the face equipment, the emphasis is now on mine logistics. Autonomous monorail transport was introduced and tested in 2007. Since the development rate of machine improvements has its limits, the focus is on the full interaction of the total production system. Here information technology (IT) becomes important; the driver for more productivity. Actual developments aim for the complete and general homogeneous IT infrastructure both above ground as well as underground. The explosive environment needs high level investments in safe technology, eg access points for WLAN and fibre optics for underground use (ATEX certification). New technology availability also drives the enhancements of management and process control systems. Innovations in the mining industry often comprise technology advances through the adoption of well-known technologies. With virtual reality (VR) teaching and training systems advanced computational instruments, both in software and hardware development, were applied in the German coal mining industry for ten years. Widening lists of applications as well as the encouraging achievements show the economical benefits of investing in virtual reality technology both for teaching and training and for knowledge management. The paper discusses the actual technical achievements as well as in IT infrastructure utilisation and also in employment of virtual reality based systems. Special focus and deeper insight will be given to the fibre optics and WLAN hardware integration as well as software developments. The pocket personal computer (PC) is used to enhance underground material transport and data acquisition. The knowledge-based maintenance system (KBMS) integrates real-time virtual reality knowledge elements, such as repair process descriptions. It gives access to expert documentation by intelligent search algorithms and 3D representations of major mining machinery.

Jan 1, 2008

By Falbo A, Quarestima S, Cozza C, Barbaro M

A new synthetic reagent of the mercaptobenzoxazole class, 5- methyl-2-mercaptobenzoxazole, has been studied. This reagent exhibits powerful selective collecting action towards copper sulphides present in several complex ores, as demonstrated both by laboratory and pilot plant tests. Industrial production is expected to start in the near future. The way this reagent reacts with pure chalcocite has been studied utilising in situ FTIR techniques, adsorption tests, electrokinetic potential measurements and Hallimond cell flotation tests. The FTIR studies have indicated the nature of the surface phase. Adsorption isotherms obtained by the rest method have revealed the quantitative evolution of surface products, permitting the determination of surface coverage at various reagent concentrations. The electrokinetic potential has been utilised to verify the stability of individual species in diverse concentration ranges. Correlation of the results obtained has provided indications on the chemical interaction of this reagent with the surface and on the surface Arrangement.

Jan 1, 1993

By M Saghaeian, M Zare, V Sheikhzadeh, R Hejazi

High-Pressure Grinding Roll (HPGR) is one of the efficient methods for increasing the specific surface area (SSA) of iron ore concentrate for pellet feed production. HPGR grinding mechanism implies that material should compressed between the two rolls, therefore layer of material must be able to resist required pressure for achieving suitable grinding conditions. In this study, by doing SSA increasing tests with pilot HPGR, the effects of silica reduction on SSA increasing results were investigated. For this purpose, HPGR tests were performed on an Iranian magnetite concentrate before and after reverse flotation silica reduction tests. Based on the laboratory test results, silicates have been concentrated in two fraction sizes of the sample comprises coarser than 150 microns in form of quartz and finer than 7 microns in form of iron silicates. These silicates have been effected on reduction of concentrate bed pressure resistance by creating a pasty and sticky mud. In this condition, HPGR cannot work properly and operation results are not acceptable. According to flotation silica reduction tests, with 90 per cent weight recovery, concentrate Fe grade is increased from 67.8 per cent to 69.5 per cent and SiO2 content is reduced from 1.98 per cent to 0.9 per cent and especially for lower than 7 microns fraction size, as a critical fraction, SiO2 content decreased from 4.45 per cent to 2.35 per cent. HPGR tests were performed on 8 per cent moisture in 4 N/mm2 specific force and according to the results after silica reduction HPGR operation conditions are optimised. Results showed that the working gap increased from 7 to 10.5 mm and specific throughput of material raised from 180 ts/hm3 to 250 ts/hm3 , and SSA increased by 300 cm2 /gr in a single pass.

Aug 24, 2022

ABSTRACT' The first references to gold in New Guinea were by the Portuguese in 1525. The first significant discovery and gold rush was on Sudest Island in 1888 and was a natural extension of the rush that surged up Australia's eastern coast and ended at cook- town. Prospectors made a series of minor discoveries in coastal regions before the first large discovery at Wau/Edie Creek/Bulolo in 1925. Major post war gold discoveries were made at Bougainville, Frieda River, Porgera and Ok Tedi. On Misima Island a large bulk low grade deposit has been recognised surrounding old gold workings. Gold exploration has increased drama- tically since the lifting of a 3 year moritorium on new exploration areas in Noverrber 1982. A new bulk low grade gold discovery has been made on Lihir Island, north of Bougainville and a number of other promising areas are being drilled. Gold production is also expanding dramatically from current levels of 600,000 ounces to an anticipated 1.3 million ounces in 1985 with the opening of Ok Tedi. Other potential developments are likely to increase output above 2 million ounces by 1990. Papua New Guinea's world ranking as a producer is likely to move from 9th to 7th in 1985 reflecting the favourable geological potential, stable political environment and attractive development terms offered by the Government.

Jan 1, 1984

By I B. Miller

Magnesium International Limited (MIL) has broken new ground in their desire to integrate their mineral development activities in the Southern Flinders Ranges of South Australia in to the communities of the region, despite there being no statutory requirement to do so. In their efforts to define a magnesite resource adjacent to the proposed site for a magnesium metal processing facility, MIL opened their exploration program up for public consultation. In conjunction with the Port Pirie Regional Development Board (PPRDB), a community group was formed to review the impact of exploration and mining on the ecologically sensitive Southern Flinders region. This voluntary move towards full community consultation for mineral exploration was a first in South Australia and probably in Australia. The Community Focus Group (CFG) worked closely with MIL, Primary Industries and Resources of South Australia (PIRSA) and the Department for Environment and Heritage (DEH) in the development of an exploration program and Declaration of Environmental Factors (DEF) acceptable to all stakeholders. Collaboratively, the community concerns were discussed and addressed, with the community gaining a very comprehensive understanding of the exploration process and possible future mine development. A balance of social, environmental and economic factors was developed that was accepted by all parties and encapsulated in the final DEF for approval by the regulatory authority. The consultation process was a new experience for all of the stakeholders, each of them effectively exploring new ground in addressing information dissemination, risk management and the social versus economic equation. MIL developed not only a viable and acceptable exploration program but also substantially reinforced its position as a responsible corporate citizen with the Southern Flinders communities.

Jan 1, 2004

By J Zhang, L Klemettinen, A Jokilaakso, J Biswas, J Partinen, H O’Brien, A Klemettinen

Waste lithium-ion batteries (LIBs) are important secondary sources of many valuable materials, including Critical Raw Materials (CRMs) defined by the European Union (EU): lithium, cobalt, manganese, and graphite. Additionally, LIBs typically contain nickel and copper, which are classified as Strategic Raw Materials for EU since 2023. In recent years, great effort has been made to develop efficient recycling processes for waste LIBs. Pyrometallurgical processes have been essential in industrial production of metals for many decades. These technologies are relatively mature, with high adaptability for different raw materials. Pyrometallurgical treatment in LIB recycling typically involves the use of smelting processes, in which waste batteries are heated above their melting points and metals are separated through a reduction reaction in the liquid phase. Through this recycling route, cobalt, copper, and nickel can be efficiently recovered in the form of a metal alloy, whereas lithium and manganese are lost in the slag phase. The goal of this work was to increase the recoveries of valuable battery metals through a combination of hydro- and pyrometallurgical unit operations. First, industrial Li-ion battery scrap underwent a selective sulfation roasting stage, where the aim was to transform LiCoO2 and Mn-oxides into Li, Co and Mn sulfates. After roasting, the battery scrap was leached in distilled water with a solid to liquid ratio of 100 g/L at 60°C and recovered 95 per cent of Li, 61 per cent of Mn and 35 per cent of Co. After leaching, the solid leach residue was mixed with industrial Ni-slag and biochar, followed by reduction at 1350°C in argon atmosphere. The high-temperature smelting experiments were conducted as a function of time (5–60 mins) to investigate the reduction behaviour of battery metals. The results show that Co and Ni from the slag and leach residue can be efficiently recovered in the slag cleaning stage.

Jun 19, 2024

By Shklyar FR, Bokovikov BA, Gordon YM, Scherbatskii VB, Yaroshenko YG, Shvydkii VS

The paper presents, for the first time, a complete mathematical model of the flow of gases in packed beds which describes the processes of gas-mechanics in iron blast furnaces and other shaft type smelting units. Good correlation between calculated and experimental results was obtained confirming the adequacy of the model. It is shown that the uniformity of gas distribution is related to the tuyere size and the extent of its protrusion into the furnace and that these variables may be used to regulate gas distribution across the furnace diameter. It is also concluded that furnace height has no significant influence on gas distribution. The necessity for a mathematical description of raceway phenomena has been experimentally proved. Conclusions from theory are shown to have profound implication to furnace design and operation.

Jan 1, 1975

By J Pan

This case study assesses the application of Mine-to-Mill optimisation combined with Whittle Consulting’s Prober<sup>®</sup> economic optimisation for the purpose of economic value uplift in open cut base and precious metal operations. The study extends the application of these optimisation methods to incorporate the recent practice of Ultra High Intensity Blasting (UHIB) developed by Orica Mining Services. The case study deposit known as “Marvin” is a copper/gold porphyry resource that is commonly used in optimisation software training and industry case studies. It has many similarities to Newcrest’s Cadia Hill open pit mine in NSW. Prior desktop research and industrial trials employed static assessments of Mine-to-Mill effects. No prior work other than a Whittle Consulting client study, has sought to assess the impact of variable fragmentation on enterprise economic value. This study examines the use of variable blasting intensity as a driver of economic value maximisation over the mine’s life.CITATION: Howe, S and Pan, J, 2018. Application of enterprise optimisation considering ultra high intensity blasting, in Proceedings Complex Orebodies Conference 2018, pp 14–20 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By N Esmaeili, M Saghaeian, L Hosseini, V Sheikhzadeh, R Hejazi

Ore roasting has long been used for beneficiation and assay upgrading of different ores. In this process, which is mainly used for sulfide ores, the ore is heated to a high temperature. More specifically, it is a metallurgical process involving gas-solid reactions at elevated temperatures. Some types of Iron ore are weak in magnetic properties. Hematite, goethite and limonite are classified in this group. Unlike magnetite, which shows strong magnetic susceptibility, these ores are hard to beneficiate through magnetic separation route. Many researches have focused on gravity separation and flotation routes for upgrading these ores and these methods have also been utilised in the industry. One of the methods to whose industrial application less attention has been paid is magnetising roasting in which the non-magnetic iron ore is transformed to magnetite which is further beneficiated through magnetic separation. In this study, magnetising roasting tests have been performed on one goethite sample in order to check the feasibility of using this method for this specific ore in industrial scale. It is worth mentioning that high intensity magnetic separation have been performed on this sample before but the achieved results were not promising. Results have revealed that through magnetising roasting magnetite content of the ore could be increased from 1.7 per cent up to about 25 per cent. FeO content of the feed sample was increased from 1.03 per cent up to around 9.25 per cent. Also optimum size distribution for achieving the best results in magnetising roasting for this sample has been determined through this study. The best results were achieved when the ore size was 0–10 mm. The effect of coal ratio, time and temperature on the process have also be studied. A coal ratio of 5 per cent, time of 30 min and a temperature of 850°C were determined to be the optimum conditions. Finally, the technical feasibility of utilising magnetising roasting for this specific ore has been confirmed.

Aug 24, 2022

By D Kahler

Modern gold production from the Gympie Goldfield commenced in 1995 with the first production from the Monkland Mine. The primary ore target was the 2.5 m wide Inglewood Fault ore zone, which was initially mined using traditional narrow-vein shrink stoping. This manuallyintensive mining method allowed the mine to re-open with minimal capital cost, however the trade off was low productivity and high operating costs. As the mine has developed, access through 100-year-old, timber-lined, small shafts, and the high cost of delineating reserves, has restricted modernisation of the operations. In early-2000 a stockwork lode was discovered adjacent to the existing workings with an economic width of 40 m. In order to maximise the benefit of such an orebody, mining needed to be approached in a new way. This paper summarises the many changes implemented at the Monkland Mine, including the necessary cultural change, implementing long-hole stoping, de-bottlenecking and the application of mechanisation. The result has been a significant improvement in safety performance, higher productivity and a more secure future for all those involved in the project.

Jan 1, 2002