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By E Jamieson

For a number of years, Alcoa World Alumina Australia (Alcoa) has been investigating opportunities to produce economically viable products from bauxite residues. Three of these potential products are described here, being Red Sand, ALKALOAM« and REDLIMETM.Red Sand has a nominal particle size of +100 micron and is physically little different to crushed bauxite from which it is derived. In AlcoaÆs Western Australian refineries, Red Sand constitutes up to half of the residue going to impoundment areas. Initial testing indicates that this sand could be processed to provide an acceptable general landfill material, a construction back fill or a material suitable for road base construction. ALKALOAM« is the fine-grained residue often referred to as red mud. A great deal of work has been done to show the benefits of adding this material to sandy soils, which are common in coastal regions of WA. ALKALOAM« has properties that can elevate the pH of the acidic soils and also retain phosphorous, reducing overall fertiliser use and protecting sensitive waterways. REDLIMETM is a by-product of the refining process. This material has a high acid neutralising value. REDLIMETM could be more effective at pH control than most available products because of the fine particle size and sodium carbonate that remains with the product.

Jan 1, 2004

By G Brooks

The control of phosphorus in steelmaking is one of the famous challenges of pyrometallurgy. It is well established that highly basic slags, the presence of FeO in the slag and lower temperatures (less than 1650°C) are favourable for phosphorous removal. The thermodynamics of this reaction have been extensively studied under laboratory conditions and the general trends confirmed through industrial trials. However, in general, phosphorus slag/metal distributions measured in industry are far from equilibrium and quite specific to the oxygen steelmaking technology being used. This variability was quantified by Urban, Weinberg and Cappel (2015), who found that the phosphorus partition ratio measured in plants varied with blowing practice, stirring intensity and even converter life. Some recent kinetic studies by Gu, Dogan and Coley (2017) have shown how the kinetics of these reactions vary with FeO content and dissolved sulfur at the droplet scale. A global kinetic model by Rout et al (2018) provides meaningful predictions of where dephosphorisation occurs in an industrial basic oxygen furnace (BOF) and some recent heat transfer modelling by Madhavan et al (2021, 2022) implies that temperature difference between droplets and slag has a role to play in explaining why equilibrium is not achieved. This paper will review the current state of knowledge and provide suggestions on predicting phosphorous removal for industrial operations and how greater removal could be achieved.

Jun 19, 2024

By H Han, d S. Hapugoda, L Lu

With the recent rapid development of Chinese steel industry, the world iron ore resources of good quality are depleting rapidly. As a result, iron ore deposits of lower quality have been or are being developed to meet the market demand and are becoming increasingly important to iron and steel companies. As concentrates have advantages of high Fe grade and less harmful impurities, they are ideal sweeteners to maintain sinter grade and quality when high proportions of low-grade ores are used in the sinter blends. However, due to their fine nature, addition of concentrates will inevitably increase the proportion of adhering fines and reduced the proportion of nucleus particles of the sinter blends, which can adversely affect the green bed permeability and sintering productivity. In the present study, lab scale sintering tests were carried out under the conditions similar to the sintering process to examine the effect of concentrates on the high temperature sintering characteristics of sinter blends and the structure and strength of the resultant sinter analogues.

Sep 18, 2023

By I H. Jung, W O. Choe

Gallium (Ga)-containing compounds such as Gallium Arsenide (GaAs) and Gallium Nitride (GaN) are widely used in electronic devices due to their superior electro-optical properties and their usages increase rapidly. For the sustainable supply of Ga to electronic industry, therefore, the recycling of Gallium becomes essential. Pyrometallurgical Ga recycling process involves the complex chemical reactions between slag, matte, liquid metal, gas, refractories, etc. Therefore, the accurate thermodynamic information and phase diagram data for the oxide system containing Ga2O3 is important. In the present study, new phase diagram experiments for binary SiO2-Ga2O3 and ternary CaO-SiO2-Ga2O3 system are carried out using Differential Thermal Analysis (DTA) and quenching experiments followed by Electron Probe Micro-Analyser (EPMA) and X-Ray Diffraction (XRD) phase analysis. Based on new phase diagram data and available literature data, the thermodynamic modelling of the entire CaO-SiO2-Ga2O3 system is performed for the first time.

Jun 19, 2024

By G King, Q Shu, W Cao, F Gyakwaa, H Singh, S Wang, M Huttula, T Fabritius

Metallurgical slag, such as refining slag, is essential to enhance or promote steel cleanliness. The CaO–MgO–Al2O3–SiO2 system is the primary source of oxides-based inclusions. It plays a vital role in applications in various pyrometallurgical processes. Numerous thermodynamic databases and physicochemical properties of slag studies mainly focus on quenched samples and measurements at room temperature. Consequently, the present study explored the physicochemical, structural properties and crystallisation evolution for CaO–MgO–Al2O3–SiO2 glassy slags via in situ hightemperature Raman spectroscopy and synchrotron X-ray diffraction. The study was carried out by synthesising CaO–MgO–Al2O3–SiO2 slag with varying Al2O3/SiO2 ratios. The results from the in situ high-temperature measurement demonstrated a pattern showing a transformation of a broad peak from the glassy matrix to crystalline peaks. The study showed crystallisation of dominant phases such as Ca2SiO4, Ca2Al2SiO7 and CaAl2O4 that correspond and are attributable to changes of structural units during in situ high-temperature measurements. The results further showed a correlation between an increase and transformation in crystalline phases observed from the spectra obtained from non-isothermal heating of the samples.

Jun 19, 2024

By J H. Park, M J. Lee

Because the environmental problems are occurred by greenhouse gases such as CO2, the industries have tried to increase electric motor efficiency to reduce CO2 emissions. A core material of electric motor is high-silicon electrical steel. The ferrosilicon (FeSi) alloy, a raw material for the production of electrical steel, affects the electric properties of silicon steel. The main impurities such as Ca, Al and Ti make inclusions or precipitates that causes core loss. The slag treatment has been widely used to remove impurity elements. Thermodynamic principles for the refining of several impurities, specifically Ca and Al, have been investigated, whereas thermodynamic behaviour of Ti has not been fully understood yet. Therefore, in the present study, the titanium distribution ratio () between ferrosilicon and CaO-SiO2-Al2O3 slag system at 1773 K was investigated. The results show that is influenced by both the basicity and stability of titanium ion in the slag. Specifically, exhibits a minimum value at about C/S=0.7 indicating a shift in the titanate structure unit from [TiO5]-square pyramid to [TiO4]-tetrahedron because of lack of Ca2+ ions in a C/S<0.8 region, contributing to an increase in titanate capacity and .

Jun 19, 2024

By Kokubu H, Moro-Oka A

Gaseous desulphurization from hot metal- lurgical slags containing sulphur mainly as sulphide and(or) sulphate was measured under `low at four different oxygen pressures. The total gas rate was from 1.7 to 2,8 litre/min. Crushed slag samples weighing 2 to 12 g were used for the experiments. The amount of SO2 gas evolved from samples kept at 15500 was rieasured over tires ranging from 20 to 300 min. The gaseous desulphurization rate of sul- phide sulphur becomes high as the oxygen part- ial pressure is increased, while that of sul- phate sulphur is high under low oxygen pressure. The effect of basicity on the desulphurization rate of sulphide sulphur in oxygen atmospheres is not obvious in the range of basicity from one to three. Changes in the ratio of sulphide to sulphate sulphur during the run in oxygen axe analysed. Desulphurization reactions and the rate controlling steps are discussed. De- sulphurization phenomena can be explained by inte.-¦ucia.l chemical reaction rate control.

Jan 1, 1980

By D Smith

The Broken Hill deposit is located in Australia in the far western region of New South Wales. The deposit was found in 1883 and has been mined continuously since its discovery. It is considered the largest lead, zinc, silver deposit that has been discovered in the world and originally contained around 340 Mt of ore at a grade of around 12 per cent lead, ten per cent zinc and 150 g/t silver. The material remaining in the deposit represents only a fraction (perhaps ten per cent) of the original resource. Several of the world’s largest mining companies can trace their origins to the Broken Hill Field. The remaining resources on the CML7 consist of two large lower grade resource lodes that have not been subject to mining, some scattered areas of zinc lode material and the pillars and remnants of the main lead lodes.The deposit occurs in metamorphic rocks of the Broken Hill Group a division of the Willyama Super Group contained within the Curnamona Craton. The Broken Hill Group rocks have undergone multiple phases of deformation. Metamorphism is granulite grade with major shears cutting through the deposit having been retrogressed to mica schists. The deposit lies in an antiform associated with the second phase of deformation.The resultant proposed mine is situated on Consolidated Mining Lease 7 (CML 7) which occupies a strike length of 3.6 km in the central part of the 7.8 km long footprint of the orebody. Underground mining on CML7 ceased in 1975 with surface mining of silver chlorides in the weathered zone continuing until 1991. CBH Resources has been continually working to define and evaluate the remaining resource since 2002. This work has included four surface drilling programs, two underground drilling programs, an exploration decline, enormous amounts of compilation of historical data and detailed three- dimensional (3D) modelling of historical mining and the resource lodes. It is currently planned to commence production at the Rasp Mine in late 2011. The operations will produce from previously unmined lodes and from remnants and pillars.This paper primarily aims to encapsulate the processes involved from information acquisition through to resource estimation and also to highlight some of the challenges encountered and the specific techniques and practices used to overcome them. Many of the experiences at Broken Hill are applicable to all brown field sites.

Aug 22, 2011

By J Lyons, M Hasan, D Pepper, C Vadeikis

Processing of large volumes of ultrafine ores has long challenged mineral processing operators because of lower recoveries and increased tailings. This has led to many deposits, or parts of existing deposits, being viewed as uneconomic. As the mining industry can no longer afford to overlook resources that require finer sizes to achieve liberation or result in high tailings losses, the need for technologies to address these issues has increased. Mineral Technologies (MT) worked with a prominent Australian iron ore producer over five years to implement an innovative gravity separation technology for the beneficiation of ultrafine magnetite. The magnetite mineralisation requires a liberation size of <40 μm and selective rejection of ultrafine silica prior to magnetic separation. Through collaboration with the client, MT applied their Lyons Feed Control Unit (LFCU) technology for the beneficiation of finely grained magnetite. LFCUs are widely used in the mineral sands and iron ore gravity plants, and in tailings applications, to recover water and provide constant high density process streams. This project was an extension of knowledge gained from these applications. Test work was conducted on-site, using 1 t/h pilot and 300 kg/hr laboratory scale units. This test work showed that the LFCUs could reject 20 per cent of feed mass to tails whilst recovering >94 per cent of Fe to product. This upgraded the feed from 53.7 per cent Fe and 19.7 per cent SiO2 to 63.8 per cent Fe and 8.8 per cent SiO2. Recovery by size data showed a minimum 88 per cent Fe recovery to product for <8 μm material and up to 98 per cent Fe recovery for the -38+25 μm fraction. The LFCU rejected 70 per cent of <25 μm SiO2. The information obtained from the test work was utilised in the design of the full-scale units which are due for installation at the project site in 2021. This paper outlines the results of this laboratory and pilot scale test work and how the data obtained was used to design the full-sized units.

Nov 8, 2021

By B Smith, R Gelson

Springvale Colliery is an underground longwall mine situated approximately 10 km north-west of Lithgow in the western coalfields of New South Wales. Following a full-scale review of the mineÆs ventilation system in mid-2010, it was clear that the mine by early 2013 would become ventilation constrained as a result of the increasing size of the mine workings, the predicted worsening tailgate conditions and plans to introduce a fourth continuous miner unit. This realisation led Springvale to embark on a major upgrade of the mine ventilation system that would meet short-term and life-of-mine (LOM) requirements.Included in the upgrade project was the installation of a new high pressure centrifugal main exhaust fan that is capable of overcoming the high resistances imposed frequently on the circuit by restrictions in the tailgate airway. The new fan featuring a 2.5 MW motor is designed to be capable of operating at a quantity of 250 m3/s at a pressure of 7.9 kPa, a substantial improvement over the previous system, which had an operating duty of approximately 145 m3/s at 1.9 kPa. The new fan is of a centre hung design and features a backup diesel motor to maintain ventilation in the event of a power outage.Structural engineering analysis determined that under the operation of the new main fan the existing standard of ventilation control devices (VCDs) at Springvale would not be adequate to withstand the increase in differential pressures. As such, an upgrade of critical VCDs was undertaken utilising a novel high flexural strength (9 MPa) shotcrete and thin spray-on liner, which help serve to safeguard the structural integrity of the appliances and prevent increased leakage as roadway conditions at VCD sites deteriorate over time (a serious problem in many areas of the workings at Springvale).In addition to the main ventilation system upgrade, a separate upgrade focusing on improving development face ventilation was also undertaken. This upgrade included the purchase of two high capacity (22 m3/s) variable inlet vane (VIV) auxiliary fans to facilitate comfortable development face ventilation.The upgrade of the mine ventilation system at Springvale has been three years in the making, but has removed a major business risk in that it has afforded mine planning and operational flexibility (a fourth unit can now be introduced) for the LOM, and importantly provided unprecedented levels of comfort to operators at the working faces where previously ventilation and heat issues were frequently reported. The impact of this on the morale of the workforce, and hence their output, should not be underestimated.CITATION:Gelson, R and Smith, B, 2013. Life-of-mine ventilation system upgrade at Springvale Colliery - A case study, in Proceedings The Australian Mine Ventilation Conference , pp 79-86 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

By S M. J Koleini, F Hedjazi

The purpose of this research was to study the calcination of lead-zinc flotation tailings from the Angouran lead and zinc flotation plant in Iran as a pre-concentration step prior to hydrometallurgical processing of the oxidised tailings. There is an abundance of these tailings in the Angouran region and making use of these tailings would help preserve national wealth and also reduce the serious problems of environmental pollution caused by the tailings. At the optimal conditions of calcining at 750 - 800¦C for 45 minutes, the sample showed a mass loss of about 19 per cent. Mineralogical analyses showed that under these conditions the carbonate minerals including smithsonite (ZnCO3), calcite (CaCO3) and dolomite (Ca Mg (CO3)2) decomposed to their respective oxides. Hemimorphite (Zn4Si2O7 (OH)2.H2O) converted into willemite (Zn2SiO4) and this transformation postponed the formation of silica gel in the leach solution. The grade of zinc increased from 22.20 per cent to 29 per cent. These mineralogical changes resulted in desirable reactions in the acid leach process.

Jan 1, 2004

By J Aitchison, G Clarke

A reappraisal of the stratigraphy, new regional kinematic analysis and thermobarometric data allow a new interpretation of the metamorphic zoning and tectonic structure of the Upper Eocene high-pressure metamorphic core complex of northernNew Caledonia allow a three steps evolution to be proposed: 1. subduction and understacking of previously thinned continental crust elements; 2. subduction blocking due to the crustal thickening; and 3. crustal thinning and extensional detachment during the diapir-like uplift and unroofing of the eclogitic core. Steps 2 and 3 may be partly contemporaneous. Such a model accounts for the thermobarometric and radiochronologic data, and also for the weakness of substratum deformation during the emplacement of the ophiolitic nappe

Jan 1, 1995

By C Samuelsson, Q Shu, A Lennartsson, F Gyakwaa, A Andersson, J Isaksson

The physico-chemical property, viscosity, is essential for pyrometallurgical processes and influences the settling rate of valuable metal droplets in slag, affecting the metal recovery. The copper slag from smelting furnaces typically contains between 1 and 2 wt per cent Cu, which equals to or is higher than in most sulfidic copper ores mined today, meaning the slag is a valuable resource for copper extraction. A low viscosity is desirable for slag-cleaning through a settling furnace where entrained droplets settle under gravity. One approach to control the viscosity is through the slag composition. The literature has limited data on the correlation between viscosity, slag structure, and optical basicity of iron silicate slag with FeO/SiO2, CaO, and Al2O3 as factors. Therefore, the present study evaluated the influence of these factors on viscosity and correlations with slag structure and optical basicity. The FeO/SiO2 ratio (at%/at%) and the CaO and Al2O3 content were altered in two levels, resulting in a two-level full factorial design with three factors. The study was done by synthesising FeO–SiO2–Al2O3–CaO–MgO–Cr2O3 melts, followed by water granulation. The melt structure of the samples was analysed with the help of Raman Spectroscopy. The viscosity was then estimated with a high-temperature rheometer using a Mo spindle and crucible. The results showed a correlation between the optical basicity, FeO/SiO2 ratio, and viscosity, where a high optical basicity and FeO/SiO2 ratio were beneficial for achieving a low melt viscosity.

Jun 19, 2024

This paper describes the planning mechanism and implementation of a progressive rehabilitation programme at Hunter Valley Mine in the Upper Hunter Valley of New South Wales. Hunter Valley Mine is a large open cut coal mine which produces approximately 7.0 million tonnes of coal (run of mine) annually for export. This production level involves the movement of some 60 million tonnes of waste and coal each year.The rehabilitation programme at Hunter Valley Mine has been developed to provide a combination of pasture, based on improved pasture species and timber belts to enhance the visual characteristics of the rehabilitated landform, whilst creating amenity in the form of shade for livestock.The operational philosophy for the rehabilitation programme is that of progressive rehabilitation. The best time to undertake rehabilitation is now.&apos; As a result, planning for the rehabilitation programme is continuous, so that all site works are completed in time for vegetation establishment during the critical periods each year.

Jan 1, 1992

By M D. Raine, J K. Bartlett, S C. Dominy

The Bendigo Goldfield is located in the state of Victoria, Australia, and is one of a number of fields that make up the Central Victorian Goldfield. Since 1993, Bendigo Mining NL has been carrying out an extensive re-evaluation of the goldfield and is currently well advanced in developing an underground mine. The sediment-hosted auriferous quartz reefs are structurally complex and closely associated with anticlinal axes and reverse faulting. The gold within the quartz reefs is characterised by both its coarse nature (100 up to &gt;5000 ¦m) and its erratic distribution; as a result, the Bendigo Goldfield is classed as an extreme nugget effect system. This characteristic ensures that the Bendigo mineralisation is very challenging to sample and evaluate. In this case, diamond drilling is a good measure of structure and geological continuity, but a poor measure of grade and grade distribution. Drilling, combined with on-reef development, bulk sampling and detailed geological studies are required for resource evaluation. For grade control a balance has to be sought between sample representativness, cost, turn around time and practicality. Extreme nugget effect deposits like Bendigo, require the use of bulk samples in order to be representative. However, the cost and turn around time is significant. As a result, a micro-bulk sampling system has been introduced that attempts to overcome these problems by providing a fast, practical method that can define ore from waste. Bulk sampling and on-vein development are still necessary for resource and reserve estimation.

Jan 1, 2003

By K Williams, G M. Evans, S M. Iveson, K P. Galvin, C E. Loo

The Australian Research Council (ARC) has recently established an Industrial Transformation Research Hub in the area of iron ore, focused on iron ore characterisation, beneficiation, materials handling and end-use functionality. The research hubs are part of a new initiative aimed at building stronger relationships between industry and universities, while addressing issues of national significance. The ARC Research Hub for Advanced Technologies for Australian Iron Ore will focus its attention on developing innovative approaches for creating enhanced value across the full value chain through the characterisation of different ore types, beneficiation and materials handling and transport. This hub brings together five industrial organisations and a research team formed from well-established research groups based at the Newcastle Institute for Energy and Resources. These groups have a record of working closely with industry to create opportunities. Examples include new beneficiation technologies such as the Reflux Classifier for achieving gravity separation, the expertise of TUNRA Bulk Solids in materials handling and the Iron Making Centre at Newcastle, which is a capability maintained by BHP Billiton following the closure of its Technology Centre in 2009. The purpose of this paper is to provide an outline of the research hub and its objectives, some background on the research groups that now form the hub and an insight into the strategy adopted for developing and implementing new technologies. The paper also describes a range of novel technologies that have the potential to be developed and applied to iron ore beneficiation.CITATION:Galvin, K P, Roberts, A, Loo, C E, Evans, G M, Williams, K and Iveson, S M, 2015. Australian Research Council research hub for advanced technologies for Australian iron ore – an introduction, in Proceedings Iron Ore 2015, pp 7–12 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

The AusIMM came into being to foster the spread of professional knowledge within its client industry. It has evolved along with the Australian mining industry for more than a century. If the AusIMM is to become the world&apos;s premier mining professional body (whether by design, or by default), then draw up a strategic plan to get there. Define your strengths and market them Define the priority areas for professional competence which we most need, Target the groups within Australia who can produce the people, Create an industry peer group to speed technology transfer.

Jan 1, 1994

The Australian Mineral Industry&apos;s growth in the last two decades is directly related to the skill and experience of its consultants in mining, metallurgy, geology, finance, management, marketing, and engineering. The role of mining consultants needs to be re-examined, so that the quality of the service they deliver will continue to be adequate for the 1990&apos;s. One means of this evaluation is by examining Case Studies in the strategies and difficulties of developing contract and entrepreneurial research.

Jan 1, 1986

By A D. T Goode

Data Metallogenica (DM) is unique as a global mineral sample collection and deposit database with over 70 000 rock samples and a wide range of descriptive, photographic and measurement data. Subscribers have access to approximately four gigabytes of on-line data with many examples included on the public pages. DM commenced its life on the Pacific rim in 1971 and much recent growth has focused on countries of the Pacific margin, particularly Australia, Fiji, Chile, Indonesia and Peru. Approximately 600 separate deposits and mineral occurrences in this region are represented in DM. The sets of rock samples have been photographed at high resolution and included on the web site, together with unpublished descriptions, deposit cross-sections, bibliographies, field and mine photographs, petrology and reflectance mineralogy. Figures and abstracts from PhD theses are a new addition and the donation of proprietary databases by companies and individuals is an encouraging trend. DM increasingly is being viewed as an acceptable and important repository for æfragileÆ and irreplaceable personal and company data, it is also being recognised in its true light as a high level information system, not solely a collection of rock samples. Data Metallogenica is a not-for-profit venture of AMIRA International that requires self-funding from December 2004. Growth and development must be funded entirely out of subscription and sponsorship revenues because no government subsidy is provided. The Pacific rim is in the mainstream of mining and exploration activities worldwide and those involved have much to gain from a dynamically sustaining DM. The home page at www.datametallogenica.com contains much example data and details of subscription and membership rates.

Jan 1, 2004

The Mount Isa mine in North West Queens- land produces a total of nearly 10 million t/yr from separate copper and silver lead zinc orebodies. Sampling information is mainly obtained from diamond drilling on 30 to 40 metre centers in both types of orebodies. For the copper orebodies the majority of the core is analysed for copper content using a non-destructive bulk analyser developed by the Australian Atomic Energy Commission. The diamond drill core in the silver lead zinc orebodies is usually sam- pled as sawn half core and assayed in the com- pany laboratory using a variety of methods dependent upon the level of metal content and/or the elements required. Underground development is sampled where additional information is required to improve the ore reserve estimate. The copper areas are sampled using a standard 2.0 m by 2.0 m chip sample of the wall. The chips are taken on a 250 mm spacing. Lead areas are sampled using a 100 mm wide by 4 mm deep channel over intervals determined by the area geologists. The massive, irregularly shaped copper ore bodies are mined as large sublevel open stopes and pillars. Ore reserve estimation on both a production unit and global scale is routinely carried out using a geostatistical system developed in-house and running on a Sperry 1100 mainframe computer. Copper grade, tonnes and the Kriging var- iance are estimated at points on a user defined grid. The Kriging program uses 10 m assay composites from diamond drill core and underground chip samples. One average (rela- tive) variogram is used throughout the main copper orebodies. The validity of using an average variogram was verified by the original geostatistical study undertaken in the late 1970&apos;s.

Jan 1, 1987