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Agitation leaching data has generally not been analysed to extract the maximum amount of information that is available. Analysis of heap leaching systems has been developing over the last five years to include the underlying rate determining process. This has been found to be diffusion control for all copper leaching; irrespective of whether they are oxide or sulfide minerals. Extension of the diffusion model has enabled better scale-up protocols to be developed. Acid consumption in copper heap leaching operations has been found to be a first-order chemical controlled system. The analysis of the data is relatively straightforward. However the interpretation and scale-up is not as direct as for agitation leaching. The differences in the residence time distributions (RTDs) are required to properly account for the scale-up between test columns and field. The leaching of oxide copper in agitated systems has also been found to be diffusion controlled. However, there are significant differences in the control mechanisms. Initially the leaching control is the supply of acid to the mineral surface. This is limited by the diffusion through the surface boundary layer and is thus subject to the level of agitation. Higher agitation provides thinner boundary layers and faster diffusion rates. Similarly, higher grade material creates a thicker concentration boundary layer and relatively slower leaching. Acid consumption in agitated leach systems is also a first-order system. However, the interpretation of the RTD is easier from batch testing to continuous multiple CSTR series plant operations. Altering the method of acid delivery can significantly reduce acid consumption rates. Predilution of the acid minimises the local acid concentration near the addition point and can reduce the consumption by up to 50 per cent. Modelling of the combined leach rate(s) and acid consumption rates in agitated systems allows comparison of various leaching strategies and selection of the most appropriate. Similarly, the model allows the identification of economic limits to leach recovery; where the cost of acid consumption is greater than the value of the copper recovered. From this analysis selection of residence times for agitation leaching can be determined. The modelling tools are useful in identifying optimum conditions for the leaching process.

Jan 1, 2005

By D Monaghan

Pumping water for dewatering and water supply is a major component of electricity consumption at mining operations and hence is a significant contributor of greenhouse gas emissions. Pump systems at a typical mine site can be broadly split between above ground centrifugal pumps (generally used for water transfer) and submersible borehole pumps (generally for dewatering and/or water supply). In contrast to above ground pumps, submersible borehole pumps can be subjected to varying duty points (total pumping head and flow requirements) as a result of changing bore water levels and yields, particularly in mine dewatering bores. Typically, much higher pumping rates are required at the commencement of dewatering to remove groundwater storage and to intercept sufficient groundwater throughflow to achieve target drawdowns. Once target drawdown levels are reached it often only requires much lower pumping rates to maintain target drawdowns. Pumps sized to remove the large initial volumes of stored groundwater often end up too large for the lower flow rate required for æmaintenance pumpingÆ. This often results in pumps operating inefficiently, a problem which can be made worse when pumps are throttled to reduce the pump output to better match the reduced bore yield. Current standard operating practice places little emphasis on the electricity consumed by pumps, with the focus often being on minimising capital expenditure (æIf it ainÆt broke donÆt fix itÆ). Submersible pumps can have extended service lives of ten to 20+ years. However as the capital cost of a pump typically represents only five per cent of the life cycle cost, the vast majority of the life cycle cost is energy usage.Through the implementation of a regular review of the operation of borehole pumps, significant reductions in electricity use and associated greenhouse gas emissions can be achieved without impacting the dewatering schedule. In most cases, the capital cost of replacing pumps is more than offset by savings in operating costs. These potential savings become even more significant when considering proposed future carbon tax levees.This paper presents examples of the opportunities for significant reductions in energy, greenhouse gas emissions and overall costs that can be achieved for a range of dewatering scenarios.

Jan 1, 2009

The story of the rise, progress, and development of our modern railway system is a long but an exceedingly interesting one. The phases it has passed through, the discussions that have arisen from time to time on the most economic modes of construction and working, and the final result these various discussions have led to, are full of importance and interest to the engineer. It is not my intention to deal historically with the subject. I desire simply to speak to the requirements of the hour in Australia. It will not be disputed, I think, that these colonies have reached a point in railway construction and management when, if additional lines to any extent are still to be built, a different principle must be adopted. There are yet large tracts and areas of country to be tapped by the rail and the locomotive, which for years to come must remain untouched if the same expensive gauges and modes of construction are continued. We have yet to see clearly the necessity of introducing a system of light lines that will pay their own way and at the same time augment the traffic of our main lines. This question really no longer remains an unsolved problem. It lies, in a few words, in the acceptance of the, narrowest gauge and the simplest mode of construction that can constitute a pacticable railway. I fear it is hopeless to suggest that private companies should be legally permitted to construct such lines. It seems as if it were next to impossible to move official authorities to enter upon the construction of lines on this principle. It is, all the same an undoubted fact that if private companies could obtain Acts of Parliament, that in several of the colonies a new impetus would be given to railway construction.I may point out that not only has the principle of narrow gauge light railways been adopted in India but private companies are obtaining power to build them. Outside of :England many narrow gauge lines have been made, and in France, Denmark, Italy, and Sweden they have been highly successful.

By C Yeung, N Swa, D Gribble, R Reupana

BlastLiteÖ is a low density explosive developed by Dyno Nobel and has been in use at BHP Billiton Iron OreÆs Mt Whaleback Operation since March 2004. The Mt Whaleback Operation utilises BlastLite because it offers an attractive alternative to ANFO in soft to medium strength rock types. Its use also reduces the amount of liquid fuel oil consumed and is well aligned with BHP BillitonÆs corporate Energy Excellence initiatives to reduce greenhouse gas emissions. This paper presents the:results of characterisation work completed on-site as a fourth year mining engineering thesis, and application and benefits of the product at Mt Whaleback. One of the key features of low density products is that the detonation is non-ideal. That is, the explosive does not react fully in the detonation driving zone. This manifests itself in that the product is highly dependent on charge diameter and confinement conditions. Dyno Nobel has access to the Vixen suite of detonation codes for characterising the ideal and non-ideal behaviour of explosives. The objectives of this work were to use the Vixen_i code to characterise the detonation performance of BlastLite, in order to understand the role of the bulking agent and to allow modelling of the explosive. The detonation performance was established by detonating a series of unconfined charges at various diameters and measuring the velocity of detonation (VoD). The work program consisted of sourcing and preparing cardboard tubes of various diameters (80 mm to 305 mm). The tubes were loaded with explosive at the BHP Billiton Iron Ore Mt Whaleback test range and detonated one at a time. Over the past three years BlastLite has been used in various applications across the site. Initial findings illustrate that shovel productivity from BlastLite shots was comparable to the baseline ANFO blasts. The study results were also backed with visual inspection and feedback from shovel operators. A work program is currently in place to develop different blends of BlastLite and TITAN« BlastLite to tailor the explosives to various blasting applications. The trials at Mt Whaleback are leading to future opportunities of BHP BillitonÆs satellite orebodies.

Jan 1, 2007

Stringent environmental benchmarks imposed by governments and successful legal challenges in the country of origin have changed the risk profile for all mining companies over recent years. In developing countries, however, where high government standards may not always be in place, direct community action has often made worthless substantial investments in otherwise viable mining operations. Real limitations are therefore imposed from these risks on all areas of mining activity, wherever they may be. Thus, the bar has been raised for all companies developing or operating mines. This paper argues real financial and global industry reputation benefits accrue when all known environmental risks, where practical, are managed. In response, among major international mining companies, as the industry moves towards greater global consolidation, senior management teams have increasingly adopted corporate governance standards including æTriple Bottom LineÆ (shareholder/government/community) sustainability reporting. Sustainability reporting is encouraged by improved international stockholder and financial investor perceptions by contributing to lowered social, community and geopolitical risk which lowers the cost of access to funds as well as improving staff morale and productivity. New mines must not only be primarily financially viable but must operate throughout in a sustainable way. Case studies of some recent mining operations, who have not foreseen or proactively managed major environmental risks, demonstrate the dire financial and personal implications for managers, directors and shareholders from not identifying and managing these environmental risks. Merely having a corporate policy statement on environmental standards or high level Government approvals process for a mining activity does not preclude mining operations from the risk of direct action by local populations or future adverse legal implications from risks which were perhaps identified but not mitigated effectively. Methods and processes for the identification and active management of environmental risks in the global arena are discussed to add a practical element to sustainability, based on the authors recent strategy development processes with governments and major mining houses such as BHPBillition, Rio and Xstrata. Emphasis is placed on proactive, innovative yet practical solutions which, where possible, show positive contributions firstly to the financial bottom line but also the community at large.

Jan 1, 2003

By J J. Plumb, P D. Franzmann

A study was conducted to describe the microbiology of the MICCL Monywa chalcocite heap bioleaching operation. Microorganisms were detected in the heap using culture-based techniques and cultureindependent PCR-DGGE analysis of the 16S rRNA gene. The metabolic requirements, temperature and pH optima were determined for selected strains isolated from the heap material. Six strains (BH1-BH6) were enriched and isolated from heap solids and leachate samples. Phylogenetic analysis of the 16S rRNA genes showed that strains BH3 and BH4 were closely related to the acidophilic bacterium Acidithiobacillus caldus and strains BH5 and BH6 were closely related to Leptospirillum ferriphilum. The optimum growth temperature for L. ferriphilum was 41.3¦C and the optimum pH range was 1.1 to 1.5. A new species of Archaea was isolated from the heap samples. Cells of the proposed species, Ferroplasma cyprexacervatum (æcyprusÆ L.n. meaning copper; æexacervoÆ L.v. meaning æto heap upÆ), are non-motile pleomorphic cocci, capable of chemomixotrophic growth with ferrous sulfate and yeast extract. Cells grow anaerobically on ferric iron in the presence of potassium tetrathionate and yeast extract as electron donors. Growth occurs from 14¦C to 63¦C, with an optimum temperature of 55.2¦C. The optimal pH for growth was 1.0 - 1.2. The species was phylogenetically most closely related to Ferroplasma acidiphilum with a 16S rRNA gene sequence similarity of 95 per cent. Molecular analysis of mine samples (16S rRNA PCR-DGGE) detected the above-mentioned cultured strains of microorganisms as well as species of Sulfobacillus and other unknown Proteobacteria. The microbial community of the Myanmar bioleach heaps contained similar levels of diversity to a dump bioleach operation in Chile, but contained greater amounts of biomass than another heap bioleach operation in Australia. The operating parameters of the Myanmar heaps (low pH and moderate temperature) have selected for the growth of moderately thermophilic microorganisms that are more commonly found in extremely low pH acidic mine drainage sites than in heap systems. The novel species of Ferroplasma is thought to be involved in the aerobic and anaerobic cycling of iron within the heap bioleaching environment.

Jan 1, 2004

By P Radulovic, W Y. Lui

The Mount Isa Mines (MIM) copper concentrator at Mount Isa processes both chalcopyrite ore from the MIM underground mine and rotary holding furnace (RHF) slag from the MIM copper smelter. There have been numerous changes to the processing practices since commissioning this concentrator in 1973. Current management of the concentrator extends from grinding and flotation to concentrate handling (thickening and filtration) and tailings disposal (fill plants, tailings thickeners and process water systems).Predominant mill feed through the concentrator is chalcopyrite ore. RHF slag is processed when concentrator production exceeds mined ore production. The chalcopyrite circuit has two stages of grinding in parallel lines (Line 1 and Line 2). Each line has parallel preflotation and rougher banks, combining into a common scavenger/retreat circuit (including regrinding) and common cleaner circuit. RHF slag may be milled in parallel with chalcopyrite, utilising Line 2 flotation roughers and a Jameson cell cleaner. All final concentrate produced is combined and pumped to the concentrate handling plant. The concentrate is thickened, pre-fluxed and filtered in hyperbaric disc filters. Fluxing specification is set by the copper smelter, and filtered product transferred via conveyor belt to the smelter concentrate storage facility.Wet fill and paste fill plants utilise flotation final tailings as hydraulic or cemented hydraulic fill for stopes underground. Cement ratios and fill plant utilisation are varied depending on underground stope fill requirements. Tailings from the adjacent lead-zinc concentrator are also processed at wet fill. All tailings that are not utilised for backfill are pumped via wet fill to three parallel tailings thickeners. Thickener underflows are gravity fed to the tailings dams with thickener overflows recycled for site process water use. In addition to summarising historical operations, this paper will provide a detailed outline of more recent changes in the concentrator flotation circuit, equipment upgrades, reagent optimisation as well as product and process optimisation at the final concentrate handling and fill plants.CITATION:Lui, W Y and Radulovic, P, 2013. Mount Isa Mines copper concentrator - An insight into current and historical practice, in Proceedings MetPlant 2013 , pp 553-574 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

The AJ Parker Cooperative Research Centre for Hydrometallurgy is the focus of a world-class effort in providing technical solutions to the minerals industry. The 85 FTE staff are drawn from the CentreÆs five joint venture research partners comprising universities (Curtin, Murdoch and Qld) and government research agencies (CSIRO and WA Dept of Industry and Resources). There are also 12 industry partners, representing most of the leading mining companies in the world. Around 45 postgraduate students, mainly PhDs, make a significant contribution to the research effort. Total annual expenditure on R&D is around $17 million.Hydrometallurgy activities encompass both fundamental and applied research across the alumina, gold and base metal sectors. The Centre is now growing its client base into overseas markets, particularly North America, South Africa and Europe. Quality, strategic R&D by the Parker Centre is seen by the industry as an attractive investment. A recent survey of the industry revealed an estimated ten-fold return based on direct costs of research to the client. In addition, the Parker Centre has a strong commitment to education of postgraduate students wishing to enter the mining industry as well as providing specialist courses for those technical professionals already employed in the industry. The wide range of employment opportunities in the mining industry is reflected in the diversity of the disciplines amongst the CentreÆs research team, eg extractive metallurgy, chemistry, biotechnology, physics, engineering, molecular modelling, microscopy, geology and computational fluid dynamics. How does an atomic force microscope and molecular modelling improve our ability to control gypsum scaling or understand crystallisation of alumina in a Bayer plant? Can a biologist contribute to the problem of the slow leaching of copper from chalcopyrite? Why are computational fluid dynamics and lasers the basis of understanding how to make thickeners work more efficiently. Can you combine a PhD or Honours degree with industry experience? What is crud and why is nickel stressed? These are typical examples of the CentreÆs research activities and demonstrate the contributions of its multi-disciplinary teams which keep the Australian mining industry at the cutting edge of advanced global technology.

Jan 1, 2003

The mining industry is facing tremendous economic challenges. Fluctuating and depressed commodity prices, the ever-increasing pressure from environmental legislation and the competing global opportunities for capital investment are placing enormous strains on every aspect of the mining business. At the same time, mines are generally becoming older and deeper with all the logistical and rock mechanics difficulties that this entails. In the face of these new challenges the industry looks to technological advances to make operations more efficient and profitable. One approach is to develop and implement highly automated and computerised equipment as part of a trend towards major reductions in the underground workforce. This approach requires more capital investment rather than less and requires a more sophisticated and well-educated workforce with skills which are generally in high demand in society as a whole. It is difficult to see how the benefit that can be gained from such technology can justify the expenditures necessary to make it operate reliably underground on a daily basis. Nor is it easy to foresee how the mining industry, based as it is often in very remote areas, will be able to hire and retain sufficient numbers of people to maintain such fleets of equipment. Another approach, and the one which I favour, is the implementation of much greater control over the whole of the mining process. Mining is essentially a very simple process - we break rock and move it. The most cost-effective means of moving and processing the mining product depends entirely on the way it is broken - it depends on primary fragmentation by blasting. I propose that the way forward for the industry in the face of our present difficulties, is not new technology but is to utilise the level of technology which currently exists in ways which have traditionally been regarded as too difficult or too inflexible - improved fragmentation and the use of conveyors. The technical success of this approach depends on the complete re-design of the ore handling system from the face or stope drawpoint to surface. The fundamental issue which determines the success of this approach is designed fragmentation.

Jan 1, 1995

The Olympic Dam mining operation is some 520 kilometres NNW of Adelaide on the Roxby Downs Pastoral lease. The deposit containing copper, uranium, gold and silver was discovered in 1975 by Western Mining Corporation (WMC). A joint venture was formed in mid-1979 between WMC (51 per cent) and British Petroleum (BP, 49 per cent) for the development and exploitation of the deposit. WMC assumed 100 per cent ownership after acquiring BP's share in early-1993. Ore is won from a highly mechanised underground mining operation and processed to refined products. Current annual output from the mining of 3.0 Mt of ore is approximately 83 500 t of refined copper, 1400 t of uranium oxide, 750 kg of gold and 12 000 kg of silver. Conventional long hole, open stoping techniques are used to extract the production ore. Since stope production began in April 1988, full surveys and appraisals of stopes have been carried out to evaluate the integrity of the design and blasting techniques. This evaluation included the determination of the degree of dilution or non break that had occurred. Performance information also made it possible to re-design any adjacent stopes to retrieve remaining ore and conversely, avoid the chances of targeting backfilled material in the future. Performing stope surveys proved not only to be a time-consuming process but one fraught with access and line-of-sight problems. Occasionally it was not possible to obtain any stope survey data, and as was often the case with the mine pass system, rarely. In 1992 the sudden failure of the pillar between the fine ore and mullock passes and the subsequent delays to production, emphasised the need to effectively monitor pass wear. Initial information regarding the development of the Cavity Measurement System (CMS) prototype (Figure 1) indicated that it had the potential to solve these problems by the introduction of a remote scanning device into a cavity. Following a great deal of investigation, Olympic Dam Operations purchased the first CMS in Australia. This paper discusses its application for all underground void surveys and the procedures developed to manage both field and office requirements.

Jan 1, 1995

By L M. Lobato, J C. S Seoane, F J. Baars

The Carajßs Province presents several volcano-sedimentary sequences that comprise the Itacai·nas Supergroup. The rocks represent bimodal volcanism, and clastic and chemical sedimentation in relatively unstable basins subject to recurrent structural events with subsidence and volcanism. The Grpo Parß Group represents one of these sequences with mafic volcanic rocks that enclose discontinuous jaspilite lenses, with development of large high-grade orebodies (Fe >65 per cent). This unit is named the Carajßs Formation and presents peculiar characteristics compared to other iron districts in the world, thereby departing from the classic Lake Superior or Algoma iron formation types. Owing to the dense vegetation, lack of outcrops and harsh landscape, the structural analysis of the district can only be accomplished by combination of regional field work, detailed structural work on the open pits, and remotely sensed image interpretation, in this case Landsat ETM7, JERS-1 images and the SRTM digital terrane model. The regional trend of the several sequences of the area is approximately N-S and the structure is dominated by a flattened flexural fold system with axes moderately dipping WNW, intersected by several strike-slip faults subparallel to their axial plane. The Serra dos Carajßs represents an s-shaped synform-antiform pair, herein named the Carajßs Fold. This regional structure is partially disrupted by the Carajßs Shear Zone that divides it in the northern (Serra Norte) and the southern (Serra Sul) Ranges and also probably prepared the terrane with the development of pathways for mineralising hydrothermal fluids forming large high-grade massive iron bodies. Syntectonic granitic bodies played an important role in the structural evolution of the area as well. They caused localised ductile flattening deformation and thermal contact metamorphism in surrounding terranes. The Estrela pluton, for instance, was responsible for the discontinuity of the regional trend between the Serras do Rabo and Leste. The Carajßs Province is regionally the upper crustal product of a very shallowly eroded dome-and-keel geometry of Neo-Archaean volcano- sedimentary units intruded by syntectonic calc-alkaline intrusives and overlying pre-existing infracrustal rocks. The lithostructural data suggest continental-margin back-arc basin development and closure in an oblique collision belt, with N-S shallow crustal shortening, parallel to the inferred pre-existing strike of the stratigraphy.

Jan 1, 2005

By Siddall B

A brief review of the capabilities and practical limitations of blast simulation packages has been carried out. It is concluded that the simulators accurately reflect size distributions in the mid-ranges of 0.1 to 1.0 in, but are less reliable

Jan 1, 1998

By Childs G, Ritchie IC

This paper describes the principle and operation of small hydrocyclones for use in the coal, minerals and other process industries. The principles for selecting a hydrocyclone for an application are also discussed. Typic- al uses and installations in various industries are described.

Jan 1, 1984

By G Nicholas, S Coward, J Vann, R Wolff, S Jackson, S Moayer, A Bye

"A new approach to mineral project evaluation is described called Scenario-Based Project Evaluation (SBPE). SBPE incorporates well established æscenario planningÆ and æscenario thinkingÆ approaches, which are used extensively in other industries,?most notably the?petroleum industry. While most scenario planning is qualitative and non-probabilistic, the approach described here includes both quantitative and qualitative aspects. SBPE is complementary to optimisation approaches and allows mining firms to build and operate projects that are more robust in the face of adverse changes as well as proactively respond and exploit the upside offered by a realistic assessment of variability. The approach has potential to improve project performance and decrease operational risk. It also has important applications for currently operating mines.Conventional evaluation of metalliferous mineral deposits uses estimates of metal grades and deleterious attributes in singular æorebody modelsÆ, usually 3D block models, which fail to capture two critical aspects that underpin the realised value of mining projects: the inherent uncertainty of the estimated attributes the spatial variability of attributes, at the scale of mining selection, which impact on downstream processing steps and fundamentally drive realised value. While singular models are appropriate for estimating block averages, conditional simulation (CS) models of the relevant attributes are needed to represent uncertainty and capture spatial variability. Any attributes that can be either built into CS models and/or modelled in the envisaged mining/processing steps, can be evaluated fully through to highly ægranularÆ (ie detailed and un-smoothed) cash flows. A complete view of SBPE relies on selected strategies being tested against plausible æscenariosÆ of factors external to the project and thus outside management control. æExternalitiesÆ captured in such scenarios include market prices, costs and taxes. Via SBPE, project managers may demonstrate that there is material value in preserving or purchasing options that provide future flexibility to respond to the changing externalities or changes in orebody performance. Such flexibility generally comes at a cost but is very difficult to value. It is argued that full value chain evaluation using SBPE can help to value these options for a mining company. A case study for a gold mine is presented.CITATION:Vann, J, Jackson, S, Bye, A, Coward, S, Moayer, S, Nicholas, G and Wolff, R, 2012. Scenario thinking - A powerful tool for strategic planning and evaluation of mining projects and operations, in Proceedings Project Evaluation 2012, pp 5-14 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

May 24, 2012

By M Suzuki

Although several models for the surface tension of molten oxide slag have been proposed, suitably accurate predictions of this property are not yet possible. The surface tension, or surface excess free energy, of molten oxides is largely determined by the ionic coordination induced by surface relaxation. However, the associated mechanism of surface structural relaxation for molten oxide mixtures such as slag is complex and not yet fully understood. To allow a better evaluation of surface relaxation characteristics, the present work analysed the ionic coordination associated with the surface-relaxed states of several oxide mixtures. This work especially focused on calcium aluminate slags because these materials exhibit complex relationships between composition and surface tension. The effects of incorporating low concentrations of SiO2 as a surface active component on the surface ionic coordination were also examined. X-ray absorption techniques were used to assess oxygen and cationic elements in glassy samples after surface relaxation treatments, and molecular dynamics simulations based on a polarisable ion model of molten slag with vacuum/melt interfaces were also performed. The X-ray absorption techniques provided data related to electron yields (which are primarily associated with surface features) and fluorescence yields (which evaluate the bulk material). Thus, the ionic coordination characteristics of both regions were investigated. The results of molecular dynamics calculations allowed statistical analysis of the distributions of Al- or Sicentred polymorphs as well as the bond angles between cations and oxygen anions in the vacuumexposed and bulk regions in the equilibrated melt. The results indicated that bridging oxygen ions were preferentially distributed in the relaxed surface region rather than non-bridging oxygens. These bridging oxygen ions represented vertex connections between AlO4 or SiO4 tetrahedra. In the case of the calcium aluminate slags, the addition of one Ca2+ ion as charge compensation for two Al3+ ions was found to be necessary to form two AlO4 tetrahedra. This specific feature of surface ionic coordination could be responsible for the complex trends observed in surface tension data. The incorporation of low concentrations of SiO2 reduced the proportion of tetrahedrally-coordinated Al ions such that higher coordination states become dominant in the bulk of the material, whereas AlO4 tetrahedra were preferentially distributed in the surface region. SiO4 tetrahedra were the preferred Si-centred polymorph and were likely connected to one another to form bridging oxygen ions at the surface. On the basis of these results, a model to predict slag surface tension was proposed, and the energy of the formation of the ionic clusters resulting from surface relaxation was taken into account.

Aug 21, 2024

Hindustan Zinc Limited (HZL) is one of the leading base metal producers in India. It operates a two-smelter Complex at Visakhapatnam, Andhra Pradesh. At this zinc-lead smelter zinc is manufactured by the conventional hydrometallurgical route and lead is produced by Blast furnace technology generating residues or wastes which contain substantial quantities of metal values. Disposal of such wastes is a problem in any non-ferrous industry. Both the stringent environmental regulations and the changing industrial scenario emphasise the need for industrial research to find economically viable and environmentally friendly technologies to recover the metal values from these waste materials. The in-house R&D Centre at Vizag Zinc Smelter (VZS) thinking globally re-engineered its activities and major thrust was given for converting waste to valuable metals and metal compounds. Basic analytical chemistry with the hydrometallurgical concepts has been adopted in developing these innovative technologies. In this paper attempts are made to provide a clear history of the different waste raw material, the process developed for each raw material and their superiority of over other parallel work. Most of the processes described here are pilot plant tested and under patenting. The process flowsheet, results obtained and advantages of each process are presented. This paper provides a consolidated approach through which the varied smelter waste materials can be processed with cost effective and eco-friendly innovative technologies. In-house R&D efforts at VZS with its contribution and achievement in converting æwastes into wealthÆ technologies are presented in this paper on the following the major thrust areas:recovery of zinc from liquid effluent; recovery of zinc from effluent treatment plant (ETP) gypsum sludge; production of highly pure electrolytic zinc metal powder from zinc bearing gypsum residue/sludge generated at the effluent treatment plant; hydrometallurgical recovery of copper as copper sulphate solution which can be used for CuSO4.5H2O, copper cathode/copper metal powder from copper-cadmium cement; recovery of manganese, lead and silver from anode mud generated at Zinc Cell House and 4-metal extraction/recovery of manganese, cobalt, copper and nickel from Indian ocean bed manganese nodules; recovery of zinc, lead, silver and sulphur values from silver concentrate residue generated at the froth flotation process; recovery of silver and lead as lead-silver sponge/lead-silver sulphide concentrate from lead bearing residues; recovery of lead, silver and copper from copper matte; recovery of antimony as antimony metal or lead-antimony master alloy from antimony bearing dross; and recovery of nickel and dimethylglyoxime from Ni-DMG complex.

Jan 1, 2000

By Hoberg H, Schnieder FU

The disposal of residues from coal preparation and processing will to an increasing extent require investigation and consideration of the environmental problems resulting as a consequence of this. Different authors (Diingelhoff and Plankert, 1983; Hasenpatt, 1985; Szczepanska and Twardowska, 1987) have concentrated primarily on the content and the mobilisation of inorganic contaminants such as chlorides, metals and heavy metals from spoil tips, while no publications have yet been found on the question of a possible emission of organic contaminants (PCB, PAH, HC HC) from processing residues. Here the flotation residues in particular are able to bind larger quantities of organic contaminants by physi-sorptive means because of their large specific surface and, after disposal, to be re-emitt than into the environment. The flotation agents used in coal flotation are mixtures of technical distillation products with a correspondingly fluctuating composition. As Hey, 1986 showed, they may contain, in addition to the main components (n-alkanes, alcohols, surfactants), over 50 individual trace substances. In conjunction with the structural-chemical similarity of the individual components, this complicates the quantitative analysis of individual components considerably. For the analysis of hydrocarbon content of flotation products by means of extraction with organic solvents in accordance with DIN 38408, H18, the difficulty arises, besides the insufficient sensitivity at low concentrations, that geogeonic hydrocarbons are extracted from the coal as. well and the analysis results are thus falsified. These problems were overcome by the application of the 14C radiotracer method where certain components of the flotation agents are marked with radioactive carbon (14C). By measurement of the radioactivity of solid and liquid samples, the concentration of the marked substance can be measured very sensitively and precisely, whereby the accumulative measurement of similar organic substances is ruled out. Thus the reaction path of certain substances in complex reagent mixtures such as flotation agents can be traced excellently and the conceivable environment burden resulting from flotation tailings disposal can be estimated. In this paper, the adsorption behaviour of typical components of coal flotation agents are investigated for different coals and types of gangue material, the reagent content of flotation concentrates and tailings, as well as the mobility of the reagents adsorbed onto solids. The knowledge of adsorption and desorption mechanisms of unpolar hydrocarbons emulsified in water to solids are also of particular interest for the understanding of processes of organic soil contamination and for the further development of washing processes for oil-contaminated soils.

Jan 1, 1993

By Georgi H, Farquhar J. W, Lorrigan A. N

The potential for major new lenses of Volcanic Hosted Massive Sulphide (VHMS) beneath the existing Rosebery Deposit is extremely high. Recent deep drill hole intersections of massive sulphides, including 22 in true thickness at 24 per cent Zn, may significantly extend the life of the Rosebery Mine. The Rosebery Ore Deposit is located within Australia's most prospective VHMS mining district, the Mount Read Volcanic (MRV) arc of western Tasmania (Figure 1). The MRVs are a 10 - 15 krn wide arcuate belt of lavas, related intrusives and volcaniclastics. Rosebery is a major Cambrian volcanic hosted Zn-Pb-Cu-Ag-Au rich deposit which has been over-printed by Devonian deformation and granitoid alteration resulting in local rcmobilisation of the ore. The Rosebery Mine Sequence is composed of an east dipping and east facing, predominately felsic sequence of rhyo-dacitic volcaniclastics, epiclastics, sediments and shale lenses more than 500 in thick. This sequence is bounded by two, low angle (35 - 40¦), east dipping thrust faults, the Rosebery Fault to the west and the Mount Black Fault to the cast. The Rosebery Mine lithologies are summarised in the following table: Hangingwall (HW) Polymictic, quartz, feldspar-phyric epiclastics. Black Slates Graphitic, pyritic mudstones. Host Rocks Turbiditic mudstones and sandstones. Footwall (FW) Feldspar-phyric, pumiceous, mass-flow breccias. Cambrian, quartz-feldspar, porphyritic sills intrude this sequence at all levels. Thin, Jurassic, dolerite dykes also occur throughout the mine. Widespread quartz, sericite and chlorite alteration occurs in the FW. This alteration is manifested as quartz-augen schists beneath the orebody. The Host Rocks are pervasively altered with silica, sericite, chlorite and pyrite. Intense carbonate alteration occurs within the orebody, whereas chlorite and pyrite alteration is commonly concentrated directly beneath it. Cambrian volcanogenic alteration is over-printed by three major Devonian, granite-derived, assemblages. These are massive to quartz veined tourmaline, pyrrhotite-pyrite and magnetite-chalcopyrite. Though the Devonian granite has not been intersected in deep drill holes or in mine workings, there is good evidence that it exists within a kilometre of the deposit. The Rosebery orebody is structurally complex when compared to many other VHMS deposits. Evidence for Cambrian growth faulting has been found at the North End of the mine (B lens) where displacement of ore lenses occurs without corresponding displacement of the overlying Black Slates. A well defined cleavage exists throughout the mine, dipping at 28 to 50¦E. East dipping shear zones are also obvious in all parts of the mine workings and reverse movement is evident on many of these.

Jan 1, 1993

The West Fork project is located in Reynolds County, Missouri, in the mineralized zone referred to as the Viburnum Trend. The West Fork orebody has a calculated ore re- serve of 13 600 000 tonne (15 000 000 st) con- taining 5.5 per cent lead, 1.2 per cent zinc, and recoverable values of copper and silver. A total of 64 600 tonne (71 200 st) of lead concentrate and 11 300 tonne (12 500 st) of zinc concentrate will be produced annually. The mill was designed to operate at an average capacity of 3450 tonne/day (3800 st/day), based on a 95 per cent availability factor. The mill will operate 24 hours a day, 5 days a week, with maintenance performed, as needed, on weekends. The mine will operate on an identical schedule; but the underground, pri- mary crushing will operate on a six hour/shift, three shift/day schedule. The 1.07m x 1.22m (42in x 48in) jaw crusher will produce a minus 20cm (8 in) material at an average rate of 191 tonne/h (211 st/h). The jaw crusher has almost twice the throughput capacity required, but the decision to install that size of crusher was based on the need to handle over sized rock in the ore.The coarse crushed ore will discharge into a 180 tonne (200 st) skip pocket, which will allow up to a one hour surge capacity prior to hoisting. Hoisted ore will discharge into a 900 tonne (1000 st) storage bin located adjacent to the headframe. The skip pocket and coarse ore silo comprise the total ore storage capacity. The concept of having no intermediate fine ore storage between the secondary crushing and grinding sections was borrowed from the Brushy Creek Mill of St. Joe Minerals, which operates adjacent to the West Fork property. Integration of the secondary crushing and grinding circuits has worked ' successfully for years at the Brushy Creek Mill. The most obvious advantage to eliminating the intermediate fine ore storage is'capital expen- diture savings. The capital expenditure savings include the cost of silos, feeders, and the cost of additional conveyor length and eleva- tion. Savings in operating costs will also be gained, particularly in reduced maintenance costs. Other factors which influenced the decision to eliminate fine ore storage were the simplicity of the secondary crushing sec- tion and the limited area available for con struction of the facility

Jan 1, 1978

By S Raval

The estimation of greenhouse gas emissions from coalmines is increasingly becoming a priority for both operators and regulators. At the same time, involved scientific challenges in the methane measurements is generating significant interest from global research community. Various technology providers are also actively engaged in improving their sensors and platforms to address the measurement challenges and capitalise the market opportunities. This presentation highlights rapidly evolving multifaceted landscape of coalmine greenhouse gas emissions. It covers the advances in sensors for the detections, including ground-based, airborne, and satellite-based systems as well as models for the emission estimations, including attempts to reduce the involved uncertainties.

Sep 1, 2024