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By P Cundall

Three-dimensional DEM (Distinct Element Method) simulations were conducted in order to examine the performance of screw conveyors, which are installed to transport bulk materials as parts of many industrial machines, including mining and construction machinery. To apply the DEM to the analysis of screw conveyors, we added a spiral object and cylinder objects, which correspond to the helical screw, the casing pipe, and the driving shaft of a screw conveyor. These objects are represented analytically to enhance the precision and efficiency when calculating the interaction between objects and particles. Simulations were conducted for some real applications: inclined and other types of screws, as well as the basic types (horizontal and vertical). Results were compared with previous work and empirical equations. It is concluded that this method is sufficiently well-developed and useful to analyse various kinds of screw conveyors.

Jan 1, 2000

By D Elder, S Bell

Over the last five years Solid Energy New Zealand (SENZ) has gone through a series of changes in response to both external and internal factors. These changes have included corporate reorganisation and funding restructure, as well as modifications to medium and long term business objectives. The nature and size of its coal reserves and markets requires SENZ to continue developing new mines as existing mines are depleted. As well, there are opportunities to develop new mines as coal markets change or to realise value from existing coal resources. To assist in this process, a set of mine project assessment guidelines which are relevant to the size and scale of anticipated mine developments have been developed for SENZ. These project guidelines are structured to operate from the early stages of project or resource review through to final feasibility study stage. The guidelines provide both a basis for planning and budgeting, and a control mechanism within the company. They also enable clear understanding of the status of individual projects and provide a framework for comparison between projects. SENZ now has a defined method to plan, monitor and control this important aspect of its business. The paper explains the development and structure of the guidelines, as well as providing examples of their application. and use. It demonstrates how SENZ integrates its long term planning, five year planning, annual planning, project planning and risk management to maximise the value of individual projects, business units and the company overall in a consistent manner.

Jan 1, 2002

By J Kleynhans, D Vermeulen, V Cogho

A number of rehabilitated open cast coalmines in SA are already decanting. The paper focuses on the situation at one of these mines where the following information exist: monthly decant rates and rainfall; sulfate concentrations of the decanting water; water level measurements inside the mine prior to decanting; ABA analyses; information about the rehabilitation (drainage slope, vegetation, soil used). A 2D-model was constructed for the mine and calibrated against six years of flow data. About 85 per cent of the decant outflow rate comes from direct recharge on top of the rehabilitated mine while the other 15 per cent is derived from lateral groundwater inflows. The estimated recharge value was 17 per cent of the rainfall. Measured sulfate values showed that the sulfate generation rate for the mine was in the order of 7 kg/ha/d. Conclusions from the study are:most of the water decanting from rehabilitated open cast coal mines is derived from recharge via rainfall; given a specific sulfate generation rate, then: the lower the recharge the less the decant rate but the higher the sulfate concentration of the decanting water and vice versa; future prediction of the decant rate must be stochastic according to expected percentile monthly rainfall values; and as a first assessment of the predicted sulfate concentration of decant water from rehabilitated open case mines, the 7 kg/ha/d sulfate generation rate can be used.

Jan 1, 2003

By Roberts JD

The design and installation of a major on-line stores and purchasing system, with built-in maintenance reporting and plant register capabilities, needs more than just close attention to computer design details. When the system must be available almost 24 hours a day to a number of mine stores sites, and is used by a variety of mining staff including engineers and stores clerks, as well as by remote purchasing and office staff, then simplicity of use, availability, fast response times, and other human factors become vital. Critical aspects include easy to use screen design, involving a change from the traditional hierarchical menu system, and fallback and recovery to the last transaction. Business, people and systems objectives need to be established at the preliminary design stage, so that results can be measured and corrective action taken. The amount and type of user involvement and training, at all stages from initial design to systems tuning, has a major effect on people wanting to use the system. Active user participation in systems design, data definition and collection, and use of relevant training material is needed. Project management and design problems can arise in working with database oriented computer staff, and certain design features are found useful in ensuring a responsive, robust overall system.

Jan 1, 1983

The writers of these notes, having conducted some tests on the steam consumption of air compressors under varying conditions, believe that the detailed results of such tests will be of interest to the members of the Institute, and may lead to the contribution of further and more valuable information, of benefit both to manufacturers and users of this class of machinery-to the manufacturer in that he frequently has the opportunity of giving a very thorough test to the machine in the shop, and-tothe user or purchaser by making clear to him what may be reasonably demanded of a high-class machine. It must be remembered that, though of the highest importance, a low steam consumption is but one of the many features of a high-classmachine; for the present, however, it has been considered advisable to confine the paper chiefly to the first-mentioned aspect, with such information concerning the air ends as is obtained along with the steam consumption tests. Unfortunately, too few of these tests are conducted, and but few results are published, therefore the writers feel that no apology is needed in bringing their results before the members.Some nine months ago the Brilliant Extended G. M. Co. was supplied with a compressor by Messrs. Thompson and Co., of Castlemaine, and with the object of testing its actual performance.

Jan 1, 1907

By Happ J. V

Factors affecting the rate of arsenic removal from lead bullion during softening processes were studied. Very high rates of removal could be obtained under conditions of intense agitation and ready availability of oxidant. Reaction mechanisms were proposed to explain the sequences observed. Selective removal of arsenic with minimal loss of antimony from bullion was favoured by a low temperature Harris process and oxidizing via a caustic soda medium.

Jan 1, 1987

By A Thornton, D Engelhardt, J Woodg

Grinding is a critical part of nearly all mineral processing operations. It is the largest consumer of energy on the mine site (and thus indirectly a producer of greenhouse gas through the generation of electrical energy at the power station). Since comminution is one of the main consumers of electrical energy worldwide, efficient control of grinding mills is of paramount importance. Mill Auto-Pilot is a control system developed for SAG mills to stabilise load and power and improve the efficiency of control and increase throughput. A dynamic, mechanistic model of the grinding circuit is used to determine circuit parameters which can not normally be measured using conventional instrumentation. The circuit model is built from models of the unit operations (such as conveyors, SAG mills, cyclones, sumps, etc), and so captures the dynamic complexities and interactions of real circuit operation. CSA Mines at Cobar NSW accepted an offer to be the reference site for Mill Auto-Pilot and the system was installed in March 2004. In this application the model is used to predict mill load mass, mill solids residence time and cyclone underflow density. These parameters are used to control mill load, power and mill discharge density. The outcomes of the introduction of Mill Auto-Pilot at the CSA Mine are discussed.

Jan 1, 2004

By K Lee, K Fernando, S Rayner

Copper-gold ores have been technically difficult and uneconomical to process due to high consumptions of cyanide. Many copper oxide and sulphide minerals react with cyanide to form copper cyanide complexes, partly contributing to the high level of weak-acid dissociable cyanide in the tailings which is normally experienced during the processing of copper-gold ores. The cost for detoxification, if required for treating these tailings, would further inhibit the development of these copper-gold resources unless the cyanide used for leaching was recovered. Several technologies have been proposed to process copper-gold ores, aiming to recover copper as a co-product and cyanide for recycling in conjunction with the leaching process. A critical review of these processes reveals that a pre-concentration stage (solvent extraction or resin ion exchange) is required. Cyanide is recovered by the conventional Acidification-Volatilisation-Regeneration technique in most cases. A critical evaluation is also provided on technical aspects related to the use of Vitrokele Technology and a newly developed Elutech process in processing copper-gold ores, in particular with its application at May Day Mine.

Jan 1, 2000

By T Tran, F Lucien

Supercritical fluids (SCFs) have gained recognition as solvents for the extraction of a wide range of organic materials. Their principle advantages over conventional organic solvents are that they possess much more favourable transport properties and that such properties can be easily altered by adjusting the system temperature and/or pressure. More recently, SCF solvents have been employed in the extraction of metal ions. The direct extraction of metal ions using SCFs such as CO2 is normally not possible due to the charge neutralisation requirement for solubilisation. However, extraction can be achieved with a SCF solvent containing an organic complexing agent as a cosolvent (Laintz et al, 1992; Laintz and Tachikawa, 1994; Dehghani, 1996). The role of the SCF is therefore similar to the role of a diluent in conventional liquid-liquid or solvent extraction processes. In this regard, SC-CO2 is a particularly good diluent since it exhibits good solubility for many organic complexing agents. The extraction of metals with SCF solvents has been examined mainly in the analysis of environmental samples and the treatment of metal contaminated wastes. Nonetheless, some interesting results have been reported recently on the extraction of rare earth metals, which highlight the potential of SCF solvents in mineral processing applications (Laintz and Tachikawa, 1994; Dehghani, 1996).

Jan 1, 2000

By S C. Goel

The Obuasi Mine in Ghana, West Africa is the largest producing gold mine in Africa, outside South Africa. The mine has changed from a mine producing from narrow vein, high grade quartz orebodies to a mine producing from wide, lower grade sulphide rebodies. Traditionally mining methods were cut and fill and sublevel caving. Now the preferred stoping methodologyis long hole open stoping. Transverse or longitudinal methods are both used, dependent on the orebody characteristics. The change has been technically, socially, economically and politicallychallenging and at times has tested the abilities of those responsible for the operation of the mine. However, the benefits have been many. Safety has improved significantly, ounces from underground have doubled. Productivityhas doubled and underground unit costs have reduced bya third. These achievements have allowed the Obuasi mine to staycompetiti ve in this time of falling gold price. During 1999 and 2000 a full review of the mining and processing operations was undertaken, and as a result, the mine is now in a phase of restructure. Efforts are being made across the mine to improve efficiencies and to reduce costs. The future for the Obuasi Mine is an exciting one.

Jan 1, 2000

An efficient filtration plant can be designed only from an adequate knowledge of the filtration characteristics of the material to be handled; if these characteristics can be expressed in the form of an equation the work of design is simplified immensely. The literature of the subject contains numerous equations which have been developed by various workers to express their results, usually obtained from a 'Very limited class of material, and from moderately thick pulps. Such expressions have been found quite unsuited for use in the case of thin, very free filtering pulps.In 1926, Underwood put forward an equation having a general for m, and which, he was able to show, provided a satisfactory expression of the data obtained and published by a large number of earlier workers. This equation has been found a very satisfactory and useful tool for the study of a variety of filtration problems. As thel basis of the equation is of assistance to the understanding of subsequent discussion, a brief account of Underwood's derivation is given here.UNDERWOOD's FILTRATION FORMULAEThe following symbols are used:

Jan 1, 1932

Most of the copper deposits in the Lachlan Geosyncline fall within areas having either a common host rock, mineral assemblage, form of ore body or time and method of emplace- ment. On this basis a Cobar-type ore has been recognised in the deposits of the Cobar -- Mt. Hope - Melrose region. The copper ores in the Tottenham-Girilambone area to the east have a different mineral assemblage. In the more rugged Central Highlands nearer the coast copper deposits are generally concentrated either in one of several Ordovician andesite belts, particularly between Wellington and Woodstock, or within Silurian acid volcanics developed in irregular fashion over a considerable portion of this region. In only a few instances is copper known in the granite batholiths which adjoin these volcanic belts. Native copper and magnetite are characteristic of the deposits of the andesite province and it is possible that future mineragraphic studies will indicate significant differences in the base metal sulphides of both the andesitic and the more acid volcanic belts. Ores having similar mineralogy and form to the Captain's Flat deposit are known at various localities in the eastern segment of the latter belt. In the Gundagai area several small copper deposits with associated nickel minerals have been developed in the Coolac Serpentinite belt.

Jan 1, 1969

The first difficulty encount.ered in preparing this paper was to find a definition of the word "special" as applied to steel. The first thought is "obviously any grade not mild steel" but this is an over-simplification, because the term "mild steel" covers a series of carbon ranges, each found from experience to be especially suited to the production of a particular rolled section.Even if the Australian structural mild steels are excluded it is found that no part of the plant here is independent of special steel.The face-man on Iron Monarch makes his bench safe by barring down with a 0.6% carbon steel bar. He bores a hole into the ironstone with a 0.75-0.8% carbon steel drill, driven by a jackhammer which is built of a variety of special steels. After it is shot down, the stone is lifted by an electric shovel, very few of whose steel components fall into the general category of structural grades of mild steel.Further special steels are met with in the truck into which the stone is loaded, the hauling electric locomotive, and the rails on which these .run. Even the permanent way uses more than one grade, e.g., the crossings experiencing heavy service have their frogs built with austenitic manganese steel inserts.Special steels play their part in the overhead crane which tips these trucks, and in the crushers into which they discharge, and so they can be followed right through the production line, and they are still there at the seaward end of the ship loading boom at the head of the WhyalIa ore jetty.

Jan 1, 1951

The resource sector is conservative industry and people are resistant to change. The methods and procedures used to implement changes in process plants ultimately determine the success of such changes. The financial managers have a large say in where money is spent and the technical personnel must justify the cost and benefits for any expenditure. There are also others who believe it canÆt be done û æwe tried thatÆ. Implementing change needs a æChampionÆ who can assess the risks, plan, define the objectives and scope, set the goals, determine the key performance indicators (KPIs) and stay focused. This also requires preparing a budget and schedule and measuring against this. Contract management, reports and reviews are part of the implementation. Several case studies are given as examples of the implementation of process design changes to highlight the critical aspects involved.

Jan 1, 2009

By J J. Cilliers, E Ventura-Medina

Mineral froth flotation is used to separate particles of valuable mineral from its associated gangue. It involves the selective separation of the hydrophobic particles from the slurry into the froth. As air is blown into the slurry, the hydrophobic particles attach to the air bubbles, while the waste particles remain in suspension. While the froth rises up, bubbles start to coalesce and burst, allowing the entrained liquid surrounding the bubbles to drain and return part of the gangue to the pulp. Mineral separation is therefore a function of the amount of valuable material loaded on the bubble shells, as well as the amount of gangue material entrained in the liquid channels separating the bubbles (Plateau borders). As a result, the separation performance of the process is affected by mineral attachment and drainage or bursting in the froth. This study aims to establish the relationship between solids loading, froth stability and separation performance. For this purpose, a series of industrial experiments were carried out to measure mineral attachment as well as bubble bursting by combining direct sampling of the bubble films and video image analysis of the froth surface. This work suggests that the solids loading on bubbles strongly affects the separation performance. The results generally showed that solids loading and concentrate grade are closely related, while froth bursting rate can be linked to the drainage of gangue from the Plateau borders and also to the overall recovery of valuable mineral. It was shown in particular that higher loadings, usually associated with higher froth bursting rates, are indicative of more selectivity in attachment and therefore a higher mineral grade in the concentrate. Additionally, this work suggests that bubble solids loading and froth stability are essential parameters to include in froth flotation models as they allow control and optimisation of the flotation performance.

Jan 1, 2005

By Lawson F

Arsenic-containing waste was dissolved into molten slags and the leaching behaviour of the quenched arsenic-doped slags (containing up to 2.3 wt per cent arsenic) was ascertained to evaluate the potential of this method as a means for arsenic disposal. The leaching behaviour was evaluated using acetic and sulphuric/nitric acid based solutions.From short-term (18 hour) leach tests, the amounts of arsenic in the leach solutions were found generally to decrease with an increase in the Fe(III)/Fe(total) ratio of the slag or an increase in pH of the leach solution. The amount of arsenic in solution increased with an increase in the slag basicity, the slag arsenic concentration or the surface area of the slag exposed to the leach solution. From longer term leach tests (up to 40 weeks) in the pH range 5 to 8, the arsenic remaining in the leach solution was believed to be controlled by sorption processes. The sorbent was an iron oxide-rich material which had the capacity to lower the arsenic concentration in the leach bottles to well below 1 ppm in some cases. At a leach solution pH over 9, the arsenic concentration in the solution increased with time, although the rate of solubilisation was much slower due to the high pH.Slags have the potential to stabilise arsenic and prevent it entering the environment provided attention is paid to the slag chemical composition and oxygen potential.

Jan 1, 1996

Modern, high-output, continuous process plant requires heavy capital expenditure and is exroected to achieve a high rate of return upon the investment made, thus its high utilisation is an economic necessity. Downtime is extremely expensive not only in terms of idle capital but also in terms of lost production and revenue. A sound maintenance management system can alleviate the problem of unscheduled stoppages and a key document in the maintenance system is the Work Order because it both initiates work and conveys maintenance control information back to the administrator. This key document must be supported by an information base that provides technical data, job procedures, spare parts, history and costing. To be effective this information must be easily and immediately available to all concerned. Computer technology has developed extremely rapidly over the last ten years and with it a wide variety of on-line computerised maintenance systems. Selection of the most appropriate system for a given industrial plant is not a straight-forward process. Computer requirements for hardware and software must be matched to the requirements of the maintenance system and such matching must be carried out in an ordered and rational way. At Kalgoorlie Nickel Smelter, time was taken to review the existing maintenance system, select, study and test the new computerised maintenance management package and plan its implementation. As a result, the initial target of equipment recognition has been achieved on schedule and within budget.

Jan 1, 1987

By Voorhees JS, Bureau G

To operate a mine in California requires compliance with State environmental regulations, including assessment of risks and associated financial assurances for postulated worst case catastrophic event scenarios. Carson Hill Gold Mine, an open pit, heap leach operation, completed new risk assessment catastrophic event analyses in 1988. The risk assessment was performed at the same time that a new leach site (Leach Site 3) was being designed. Leach Site 3 is located about 400 m upslope of New Melones Reservoir, which is a public recreation facility and a source of drinking water. Release of leachate (pregnant solution) or ore containing cyanide and metals from Leach Site 3 into New Melones Reservoir was considered to pose the largest risk of environmental damage.Flow failure of the ore heap, potentially induced as a result of liquefaction of the saturated portion of the ore, and/or overtopping of the leach site containment embankment due to excessive precipitation were found to be the most plausible leachate release scenarios. Yearly combined probabilities of various downstream release volumes were estimated. The release volume corresponding to a yearly probability of 0.05 percent was then used to estimate potential environmental impacts and mitigation costs. The costs include earthwork to restore the geometry of the ore heap and repair the fill slope below the Leach Site 3 containment, and impacts on New Melones Reservoir.

Jan 1, 1990

Having worked as a consultant for most of his 40-year working life, mostly as a mineral property valuer, the author has seen many poor valuations. Most were valuations of exploration tenements where the selection of the rather subjective, but necessary, geological inputs raised the main concerns. Those valuations involving iron ore prospects raise particular problems due to the special characteristics of such deposits. Iron ore is more like an industrial mineral rather than precious or base metals and Reserves are determined not by a traditional cut-off grade but by customer specifications. This is intended to be an overview/keynote paper on the current state of the growing (yet consolidating) Australian Iron Ore industry. It has now moved beyond Western AustraliaÆs æPilbara Big TwoÆ of Rio/BHPB (with the emergence of the irrepressible FMG and Hancock Prospecting) to include the YilgarnÆs æMidwest ManyÆ (including US re-entrant Cleveland Cliffs through Portman) and projects in other States. Ore types have moved from haematite Brockman to martite-goethite Marra Mamba (including the RobeÆs mesas and below water table Yandicoogina CIDs) and magnetite ore types. There are DSOs and secondary process feed. Mineral valuers have to reflect today upon these and many other determinants of value when choosing the most appropriate methodologies to adopt when technically assessing and valuing exploration tenements containing iron ore. Set against a frame work of the JORC Code (2004) and VALMIN Code (2005), the general valuation issues involved in using the cost methods (eg multiple of exploration expenditure), market methods (eg comparable sales, rules-of-thumb and joint venture terms) and income methods (eg synthetic discounted cash flow (DCF)/net present value (NPV) modelling) are discussed. Relevant factors when valuing iron ore properties are discussed, eg ore type, lump/fines ratio, stripping ratio, water table, impurities and grade, particularly the JORC confidence category of the identified mineralisation. Remoteness and access to existing rail infrastructure is a key consideration.

Jan 1, 2007

Detailed studies of mineral paragenesis, isotope and trace-element geochemistry, and physical mineralogy at Mount Morgan are compatible with deductions by Geopeko Ltd geologists concerning field relationships in the mine area. Considered together, field and laboratory data suggest that the Mount Morgan deposit originated from a shallow, intrusive, acid volcanic dome similar to those which produced the Kuroko-type deposits in Japan. At Mount Morgan, however, interaction with sea water was much less, the sulphides were concentrated rather than forming a group of deposits, and only the throat of a breccia vent is pre- served, so that only the lowermost parts of Kuroko-type deposits can be compared with the Mount Morgan mine. A final difference lies in the presence at Mount Morgan of a quartz diorite adjacent to the ore. Mineralogical data are compatible with post-ore intrusion, possibly up an earlier volcanic fissure.

Jan 1, 1974