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By Pollard DM, Willis GM

The removal of bismuth from liquid copper in a vacuum furnace was studied over a range of pressures. The rate determining step changes from diffusion in the gas at pressures above 0.2 Torr to approach the Langmuir evaporation rate at pressures of 10-2 Torr. Oxygen and sulphur were found to have a negligible effect on the rate. Bismuth removal from copper sulphide was found to be considerably slower than from copper. This is consistent with the known thermodynamic properties of ternary sulphide melts.

Jan 1, 1980

By L Dyer, A Keith, G D. Corder

As mining activity moves to remote and less developed locations globally, a holistic approach to mine development is fundamental for achieving a balance between strong financial returns and corporate social responsibility and transparency. Key inter-related fundamentals such as social licence to operate, life-of-mine operational planning, minimising environmental impacts and, most importantly, attractive investment returns for the mining company all contribute to the viability of any new mining project.However, the typical practice in the mining industry is often to treat environmental and social/community aspects as separate compliance issues that are dealt with at minimum cost and disruption to the project and resulting operation. This often results in less than optimum environmental and social outcomes, and presents considerable liabilities at the time of closure when rehabilitation programs continue to require funding when all revenue has ceased.The five capitals model seeks to identify each of the key contributors to sustainable development as financial, manufactured/physical, social, human and natural to formulate a type of triple bottom line approach balancing these often competing project factors. The SUSOP® sustainability risks and opportunities framework, developed by the mining industry, bases its approach on the five capitals model and proposes an approach that breaks down enterprise silos to identify innovative solutions for life-of-mine sustainability. This framework has been developed with the nature of mining projects in mind in order to produce approaches and outcomes relevant throughout the life cycle from the planning phases, through project design and construction into operation and closure.This paper argues the need for a more holistic approach to the development and operation of mining projects, and presents case studies where a holistic approach has been applied, in whole or part, and discusses the lessons learned from these case studies.CITATION:Corder, G D, Keith, A and Dyer, L, 2014. A capitals based approach – leading innovation in planning for life-of-mine sustainability, in Proceedings Life-of-Mine 2014, pp 499–512 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By D Cooke

In 2010, Kalgoorlie Consolidated Gold Mines (KCGM) was Australia’s largest gold producer, with total annual production of 788 000 ounces. Of the gold produced by KCGM in 2010, 95 per cent was extracted from the Fimiston open pit, also known as the Superpit. The Fimiston operation encompasses the historic Golden Mile, from which more than 55 million ounces of gold have been extracted from the world-class Fimiston lode style mineralisation.The operational performance of the KCGM Fimiston open pit was reviewed for the period between 2005 and 2010. Key performance metrics reviewed included mined tonnes and grade, cost per ounce of gold produced and the mine to mill reconciliation trends. The years 2007 and 2008 were characterised by a decline in performance against key performance metrics. The ore zones were diluted, with the excess tonnes mined resulting in lower grade and an increase in the cost per ounce. Poor reconciliation between ore mined, the ore reserve model and the grade control polygons was also observed.A series of improvement initiatives were implemented in late 2008. As a result of changes made to the grade control and mining practices, the site performance recovered. Unplanned dilution was reduced, which had a positive impact on mined grade. The lower tonnes combined with higher grade reduced the cost per ounce to below budgeted levels in 2009 and 2010, enhancing the profitability of the operation. The operational performance between 2005 and 2010 was compared to the turnover statistics for the KCGM geology department over the same period. Turnover accelerated between 2005 and 2007, peaking at an annualised rate of 43 per cent. With the onset of the Global Financial Crisis and the implementation of retention initiatives, turnover reduced significantly between 2008 and 2010. A strong consistent correlation was observed between the turnover trends in geology and the performance of the grade control function and resultant site metrics.The cost of turnover is known intuitively, however, rarely quantified. To evaluate the benefit of the improved performance, a detailed financial model was used to quantify the impact of the grade control function. In 2010, the headgrade exceeding budget by just four per cent contributed an additional A$24 M of value to KCGM. In contrast, if the 2008 performance had been replicated in 2010 (-9 per cent on headgrade), the result would have removed A$61 M in value from the business. The KCGM experience between 2005 and 2010 demonstrates the value of human capital in a mining operation and the importance of a high performing geology grade control team to the profitability of a mining operation.

Aug 22, 2011

Risk management has become an essential tool for mining companies to ensure their projects are well-managed and profit expectations are achieved. Risk management has also become a mandatory corporate governance requirement in Australia for publicly listed companies and equally important to attract investors. This paper provides a brief overview of the essential tools needed to implement a practical risk management framework to comply with the internationally recognised ISO 31000:2009 risk management-principles and guidelines from the perspective of small or soon to be producing mining companies. To?successfully?deal with the unknown and to manage the opportunities and risks involved with a mining project requires a clear understanding of the basic risk management principles. These include how to develop a project risk register, how to develop a project risk treatment plan and how to manage and monitor project risks to take full advantage of the opportunities presented.The first step is to identify and fully appreciate the risks that face a mining project. There are many risk identification methods that can be used including checklists, brainstorming and hazard and operability (HAZOP) studies. These often lead to a telephone book full of risks which are near to impossible to manage. A risk library specifically designed?for mining?projects containing no more than 100 risks will cover the major showstoppers, is practical and can be readily implemented and successfully managed.A risk framework also needs to be established which is compatible with the companyÆs structure and objectives. Once each risk has been assessed in regard to consequence and likelihood and the risk control systems are in place they need to be assigned to the responsible manager. The extreme or high risks will require a risk treatment plan to be developed. Risks will change during the life cycle of a mining project. Hence, a reliable monitoring system is also required for compliance.CITATION:Jones, J A, 2012. Mine project risk management, in Proceedings Project Evaluation 2012 , pp 117-122 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By C Tapia, B Hay

There is a close relationship between the mining industry, economic growth, and technological and social development. Mining activities benefit all economic agents, but only during a timespan determined by available reserves, primarily driven by internal factors such as production rate, technology and costs, and external factors such as prices determined by the market and taxes and royalties controlled by governments (Gordon and Tilton, 2008; Henckens, 2021; Tapia Cortez et al, 2018). The intense use of Mineral Commodities (MC) needed to maintain the current lifestyle has placed ore depletion as one of the main threats to sustainable economic, social and technological development. However, ore depletion does not only arise due to the finite nature of MC, price fluctuations or technological challenges. It is also triggered by the ‘economic limits of extraction’, determined by the optimisation of financial factors and technical restrictions within the regulatory framework (Henckens, 2021). Most reporting standards – if not all – define ore reserves as ‘the economically mineable part of a Measured and/or Indicated Mineral Resources’ determined by the technical and economic viability of extracting, processing and commercialising MC having the NPV as the fundamental decision – making tool (JORC, 2012; Krzemień et al, 2016). However, is the NVP an ‘economically’ basis index able to capture the complexity of economic phenomena? No, it is not, and it is crucial to define what is economic and financial. Although related, they are different disciplines. Economics studies the behaviour of the different market agents, including human behaviour and policies and explains the factors involved in the scarcity (or surplus) of goods and services. Finance focuses on financial systems and managing funds considering the time, cash available, and risk. It involves banks, loans, investments, and savings and can be considered a small subset of economics (Simon, 1959; Tapia Cortez et al, 2018). Given the economic nature of ore Reserves, endorsed by governments (Figure 1), NPV is an incomplete tool to determine ore Reserves as it limits the problem to simply maximising cash flows instead of optimising the economic benefits for all economic agents. In addition, using the rigid scheme of controlling taxation – unable to adapt to new market or economic conditions and systematically increasing – within the NPV framework only increases the sub-optimisation of ore reserves, mainly due to the systematic taxation rise. Short-term benefits of higher taxes and royalties are unlikely to offset the impacts of reducing exploration and project development in the long-term, which not only boosts ore depletion concerns but also reduces competitiveness, threatening economic and social welfare (Fisher, Cootner and Baily, 1972; Gordon, Bertram and Graedel, 2007; Lilford, 2017; Mardones, Silva and Martínez, 1985; Radetzki, 2009; Rodrik, 1982; Tan, 1987; World Bank, 2000). Holistic methods and collaborative tools, able to dynamically simulate and assess how changes in the technical settings, regulatory framework (taxes and royalties), and financial factors affect the availability of ore reserves and the impact for all economic agents, should be incorporated into the evaluation process to fill the gap.

Aug 2, 2023

Two key elements in the design of a pastefill or high density hackfill system are the preparation of the backfill material and its distribution underground. This paper examines these two areas. Owing to the essentially impervious nature of total mill tailings, preparation of pastefill and high density fill from current tailings involves a physical dewatering process. There are currently three methods available for this process: I. Vacuum or pressure filters. These represent the 'traditional' approach to the preparation of pastefill. 2. Paste production storage mechanism. This is a thickening/storage mechanism developed with the specific objective of producing paste/high density backfills. 3. Fluidization. This system utilises silos fitted with simple dewatering devices and nozzles. Recently developed by CANMET, it provides the simplest and most economical approach. This paper describes and compares the three preparation methods, from a practical and an economic point of view. Once the pastefill/high density fill has been prepared and binder added, the backfill must be distributed underground into the stopes. A fundamental factor in the design of a distribution system is the rheology of the material- No two materials will exhibit the same properties, and a sequence of rheological and related testing is required prior to the completion of the design of the underground distribution system. This paper covers the testwork normally required and discusses the fundamental design parameters of pastefill distribution systems. The final section of this paper summarises the use of pastefill at three mincsin Canada.

Jan 1, 1998

By Hommert P. J, Brown B

Early attempts at estimation of stress wave damage in blasting by use of finite element analysis met with limited success due to numerical instabilities that prevented calculations from being carried to late times. An improved damage model based on microcrack growth in tension allows finite element calculations which remain stable at late times. Estimation of crater profiles for blasting experiments in granite demonstrate successful simulations with this model.

Jan 1, 1990

Autogenous and Semi-Autogenous grinding has become an accepted method of reducing primary crusher product to micron sizes in a single or a two-stage grinding circuit. The elimination of secondary and tertiary crusher circuits and sometimes rod mills helps to lower overall operating costs and, in many instances, can make uneconomical projects viable. Selecting AG/SAG Mills have been rather a "hit and miss" affair over the years, but now with the many different types of tests available, accurate mill size predictions can be made, provided the test data is evaluated correctly. This paper endeavours to simplify the process of evaluating test data and sets down some guidelines for designers to follow when selecting AG/SAG Mills.

Jan 1, 1991

By R Sterk, B Reid

The Konongo Gold Project is located on the western margin of the 125 Moz Ashanti Gold Belt in Ghana, West Africa. It is situated 60 km along strike of the world-class mineral system at Obuasi and is interpreted to lie on the same controlling regional shear system.The project is operated by Signature Metals, a subsidiary of the Liongold Corporation, and is managed and funded by the Liongold Corporation.Historic underground operations at Konongo produced 1.6 Moz Au at a head grade of 11.8 g/t Au, from eight operations spread along 16 km of the shear system. Mining focused almost exclusively on free-milling gold in quartz, ignoring the gold-bearing sulfide mineralisation associated with the quartz veins. Underground mining ceased in 1986.In 2013, Signature Metals re-focused the program at Konongo to assess the viability of mining the sulfide ore sustainably. This led to the first campaign review of the historic underground data and resource potential since mine closure. The Obenemase mine was the first of the eight operations to be assessed as part of this campaign.Large amounts of legacy data have survived for Obenemase and several historic resource estimations have been completed based on these data. The data typically consisted of hand-drawn sections and plans, and ledgers of commonly incomplete drilling and sampling data. Some drill core have been lost over time, but a large amount of quarter-core and half-core as well as pulps and rejects are still available. Previous resource estimates had a low confidence value because all the available assay and geological data were integrated effectively with the estimates, resulting in a lack of understanding of both grade and geological continuity.This project built a new geological model for Obenemase that greatly enhances the understanding of the controls on mineralisation using a thorough approach of re-surveying, re-cataloguing and re-logging. This model led to an increased degree of confidence and a subsequent upgrade of resource classification, and created several previously unrecognised strong exploration targets. The resulting resource estimates increased the value of the project by 100 per cent.This paper emphasises and highlights the importance of a well-understood geological model on the confidence of a resource estimate and how this may directly impact on the project’s ‘bottom line’.CITATION:Sterk, R and Reid, B, 2014. The Konongo Gold Project, Ghana – an example of how geology makes all the difference to a resource estimate, in Proceedings Ninth International Mining Geology Conference 2014 , pp 467–476 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By J W. Dong, Y M. Li, J L. Tian, Z H. Jiang

Electroslag remelting is widely used to produce various special steels, mainly because of its ability to provide high cleanliness and excellent homogeneity of ingot. Undoubtedly an optimal slag plays a key role in removing inclusions and enhancing the mechanical properties of a specific special steel. In order to improve the metallurgical performance of the slag in electroslag refining of die steel, a variety of slags have already been developed using traditional trial-and-error methods. Nonetheless, these slags may not be inherently optimal for the specific requirements of actual die steel refining processes. In this work, we have designed a CaF2-CaO-Al2O3-SiO2-MgO quinary slag system using genetic algorithms method aiming to remove the existing large size inclusions (D and Ds type) in high quality die steel. The comprehensive effects of five components (CaF2, CaO, Al2O3, SiO2 and MgO) were studied based on existing fundamental theory. The slag composition was screened considering the parameters such as melting point, electrical conductivity, calcium ion concentration, and appropriate viscosity etc. Furthermore, the candidate optimal slag was applied in the industrial production of die steel by electroslag remelting method. The detection results indicate that majority large inclusions (D and Ds type) have been successfully removed, showing significant advantage to traditional slags. This result has demonstrated the genetic method to be efficient and reliable. In addition, depending on the personalised demand of other steel and alloys, this method allows for the adjustment of the screening frameworks and processes to develop the candidate optimal slags. This method has not been reported previously in the field of electroslag composition design, and compared with the traditional trial-and-error method, the new method will save a lot of time and experimental costs.

Jun 19, 2024

By N L. Turner, K Ehrig, V Liebezeit, D J. Robinson, L L. Kuhar, N Francis

Conventional industry tests used to determine leach recoveries are often fully monitored and may be time-consuming and expensive. Such tests may be limiting in geometallurgical applications where large numbers of samples are required to be processed for characterisation of an ore deposit. BHP Billiton currently use a fully instrumented leach test for characterisation of Olympic Dam uranium-rich samples. Researchers at the Commonwealth Scientific Research and Industrial Organisation (CSIRO) were approached to develop an alternative to these full-scale leach tests that could allow for the ranking of samples in terms of their leachability. The novel geometallurgical test was required to use samples of small mass and be affordable and rapid.Three leach test protocols were pursued in developing the small-scale tests. Kinetic leach tests were performed using mild conditions at higher pH, low temperature and low oxidation reduction potential, moderate conditions at intermediate pH, temperature and oxidation reduction potential and aggressive conditions at lower pH, higher temperature and higher reduction potential.This paper presents results from 44 leach tests on 11 samples with varying uranium mineralogy. The developed small-scale tests correlate well with data from the more costly conventional industry laboratory tests, indicating the possibility of using this alternative test as a geometallurgical leach proxy. Simple regression analysis confirmed the importance of pH, reduction potential and temperature on uranium extraction. Experimental data were fitted to published leach models to predict uranium leach extraction for a range of operating conditions.The ultimate aim of the test work is to combine a limited number of large-scale calibration tests, a large number of small-scale geometallurgical tests and leach models for geometallurgical sample characterisation and evaluation of a wide range of scenarios or processing options.CITATION:Turner, N L, Kuhar, L L, Francis, N, Liebezeit, V, Ehrig, K and Robinson, D J, 2013. Development and testing of a small-scale uranium leach for geometallurgical applications, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 345-350 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By J J. Cilliers, K Hadler

Air is fundamental to flotation; not only is it required to collect the valuable particles, but it also controls the froth stability and consequently the separation performance for a given feed. Froth stability can be described and quantified in numerous ways, which are subtly different. Air recovery is one such measure of froth stability which accounts for both the stability of the bubbles and the mobility of the froth. The benefit of using air recovery as a measure of froth stability is that it exhibits a peak as air flow rate is increased, and this corresponds to the air rate at which the optimal separation performance is obtained. As such, it provides a single target value for optimising air flowrate for a given set of feed conditions. Use of air recovery, however, has one potential drawback: accurate measurement of the inlet air flow rate to a flotation cell is required. This can be problematic for operations, particularly where calibration of air flow rate is carried out infrequently or where there is no air flow rate measurement, such as for many self-aerated flotation cells. To this end, we present an alternative method for determining the peak in air recovery (PAR) air rate.We introduce a simplified method for determining the PAR air rate using trends in froth velocity and overflowing froth height, both of which are readily measured using existing froth image analysis systems. We will show, using industrial data, the application of this simple technique to find the optimal air flowrate for flotation cells. We will also discuss other alternative techniques for air rate optimisation that have the potential to improve separation performance using existing technology.CITATION:Hadler, K and Cilliers, J J, 2018. How to find the optimum air rate for flotation cells, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 377–384 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By R L. Brathwaite

The rocks of New Zealand can be grouped into three main elements: the Early to Mid Paleozoic Western Province, Late Paleozoic to Early Cretaceous Eastern Province, and several overlying Late Cretaceous to Cenozoic sedimentary basins. The Western and Eastern provinces were formed on or near the margin of Gondwanaland, whereas the Late Cretaceous to Cenozoic sedimentary basins developed after the separation of New Zealand from Gondwanaland in the Late Cretaceous.   The Early to Mid Paleozoic Western Province rocks are exposed in Nelson, Westland and Fiordland and include metamorphosed sandstone, mudstone, limestone, and volcanic rocks, intruded by granite batholiths and maficultramafic igneous complexes. The main associated mineral deposits are gold-quartz lodes hosted by Paleozoic greywacke and argillite. Other type of deposits present include: volcanogenic massive sulphide lead-zinc; vein and greisen tungsten and tin; and magmatic nickel-copper sulphide, platinum group element, and magnetiteilmenite deposits. Granite stocks and batholiths, intruded during the Cretaceous, have associated porphyry molybdenum deposits.   The Late Paleozoic to Early Cretaceous Eastern Province includes the greywacke rocks forming the axial ranges of the North and South islands, and a belt of schists in Marlborough, the Southern Alps and Otago. The schists host many shear-zone related, gold-quartz lodes and, in the Southern Alps, lenses of serpentinite with talcmagnesite and nephrite jade. Volcanogenic massive sulphide copper deposits and volcanogenic manganesechert deposits, occur in both the schist and greywacke, and a belt of Permian age ultramafic rocks (Dun Mountain Ophiolite) has associated copper, chromite and chrysotile asbestos deposits.   The Late Cretaceous to Cenozoic rocks are found in a number of sedimentary basins onshore and offshore of the North and South Islands. Many of these basins developed during the rifting of New Zealand from Gondwanaland in the Late Cretaceous. They contain New Zealand's economic petroleum, coal and limestone deposits. Uplift and erosion of the mountain ranges shed gold into rich placer deposits in the South Island.   From the Miocene, volcanic rocks feature prominently on the eastern South Island (e.g. Banks Peninsula southeast of Christchurch and the Otago Peninsula northeast of Dunedin) and northern North Island (Northland and Hauraki), and volcanism continues today in the Taupo Volcanic Zone. The North Island volcanic rocks have associated epithermal mineralisation, mainly gold and silver, but also copper, lead, zinc, mercury, and antimony, as well as deposits of sulphur, perlite, pumice and zeolite. Porphyry copper style mineralisation is associated with subvolcanic intrusive rocks. Erosion of the volcanic rocks has shed titanomagnetite onto the west coast of the North Island forming significant coastal placer deposits. Similarly, erosion of the Alpine schists in the South Island has resulted in placer ilmenite deposits on the coast of Westland.

Jan 1, 1997

A new watersoluble binder for mineral ore pellets has been developed by the sulfonation of bituminous materials. A highly effective binder for iron ore pellet making is obtainable from bituminous materials produced in the hightemperature cracking of crude oils. This paper deals with production process and basic properties of this binder as well as new applications in the field of iron ore pelletizing.

Jan 1, 1974

By P Holtham, K Duffy, B, W Valery, E Tabosa, rade

Pre-concentration has potential to significantly improve Mineral Resource efficiency by removing gangue early in the process, before energy intensive and expensive comminution and fine processing. However, there are numerous options for pre-concentration and the performance and benefits of these are very case specific. To determine the best option for a particular deposit and to successfully integrate it into the overall mining and processing operations requires comprehensive evaluation. This needs to consider orebody suitability, technology capability and economic viability. The in-situ variability of a deposit and how it is influenced by mining methods and the liberation size of gangue are key factors which are generally not well understood. Geostatistical methods provide an insight into orebody variability, and the overall selection of any pre-concentration solution must be an integrated approach between geology, mining and processing. Many pre-concentration evaluations investigate the potential of just one option. Technology selection should start wide and may include: selective mining, pre-screening (with or without selective blasting), sorting (bulk and or particle), coarse gravity separation (e.g. jigging, DMS), coarse particle flotation, magnetic separation, etc. The upgrade performance of these processes is very ore specific and should be determined from testing, with detailed multi-component modelling used to determine the overall process performance. Many of these pre-concentration processes require significant ancillary equipment, feed preparation and materials handling. It is important to realistically estimate all costs to understand overall economics and select the best option. Some examples showing evaluation and comparison of pre-concentration options are presented in this paper. These include assessments of in-situ variability using geostatistical tools, process modelling of pre-concentration options and overall performance, preliminary layouts and cost estimates, and economic evaluations.

Nov 10, 2020

By Golubkov OL, Fedotov PB, Shkylar FR

One of the fundamental parameters of the race- way is its extent (a{ o), which has a significant effect on the distribution of gas and material flows in the lower region of the furnace. pp The known relationships for determination of aC o in most cases link the length of the raceway with the parameters of the blast, while the para- meters of the coke layer, in which the raceway is formed, are either ignored or else expressed in terms which are difficult to determine experimen- tally. Furthermore, the coke combustion propert- ies are not always taken into account in current blast furnace operating practice with combined blast. A complex dimensionless parameter, which re- flects the properties of the interacting media, is the ratio of the kinetic energy of the hot, com- bined gas stream to the potential energy of the coke flow, burning at the tuyere in a gas of known composition. Statistical processing of experimental data on the extent of the raceway zone, obtained from literature and our own work on operational furnac- es, has led to a working formula of the following Form:

Jan 1, 1981

By D Davis

The prediction of ground-borne noise levels from tunnel construction activities requires knowledge of the input vibration forces from the vibration source(s) into the cutting face, knowledge of the vibration transmissibility through the surrounding medium, and knowledge of the receiver building’s vibro-acoustic response. The conversion of this vibration energy into sound pressure within the receiver building depends upon the vibration coupling of the soil and the building’s foundations, the structure’s response including floor-to-floor attenuation and amplifi cation due to resonance, the radiation effi ciencies of the internal structural elements, and the room’s acoustical properties. Beginning with a known input vibration spectrum at the cutting face, it is possible to predict the resultant ground-borne noise levels within a receiver building using either analytical and/or empirical techniques, or by numerical modelling. This paper presents an overview of the various methods available to estimate ground-borne noise levels from tunnel construction activities and discusses the advantages and limitations of each.

Mar 8, 2011

By Weber W

Methods of calculation of the reliability of process computers are getting more and more important. The paper presents long period observations of 21 process computers with online applications in the iron and steel industry. About 5000 failure events during 10 years have been systematically recorded and evaluated. On the basis of these long time observations it is possible to develop a probability model of the failure behaviour of process computers.This failure model is constructed with four different states of the process computer:Working phase, working phase with undetected reasons, repair phase, failure phase resulting from external influences.The model is defined by differential equations for the probability of one of these four phases. Long time observations show, that all of these four phases are closely correlated with the capa-city of a process computer, restarting without detection of failure reason, changes of programs and software, costs and time of repair. So the result of this analysis is a model of failure for process computers, which allows to predict breakdowns of process computers on the basis of external parameters.

Jan 1, 1985

By B E. De Gee, N Viviers, A Naidoo

In 2013 the Mopani Copper Mine Mufulira plant in Zambia embarked on a project that was aimed at improving concentrator recoveries. The project commenced with the automation of the milling and flotation circuits. This involved the installation of new instrumentation, namely measurement devices and actuators, and the connection of these to new programmable logic controllers (PLCs).The infrastructure changes were followed by the implementation of basic proportional-integral-derivative (PID) controllers on the PLCs. Supervisory control and data acquisition (SCADA) interfaces were also implemented to allow for switching between controller modes, inputting of setpoint variables and to provide a visual display for process monitoring. The final phase of the project involved the installation and commissioning of advanced process control (APC) solutions on the milling and flotation circuits. This work was carried out by Mintek over 21 on-site days. The APC solutions included the MillStar and FloatStar suites of advanced controllers.The MillStar control suite focused on stabilising the mill feed and mill discharge on the two primary mills as well as the flotation circuit feed. Mintek’s CyLas instruments, which provide a measurement of the hydrocyclone underflow angle, were also installed. The measurements were incorporated into the discharge stabilisation control on both milling circuits. The FloatStar level stabiliser controller provided flotation cell pulp level control on fourteen cells, including two columns.Performance tests showed that the Mintek APC system stabilised the mill feed and mill discharge while ensuring the process remained within operational constraints. The MillStar control system utilised the CyLas instrument to prevent roping on the hydrocyclone underflow. This was not always achieved under normal operation. Additionally, the flotation section was stabilised as a result of improved level control by the FloatStar control system.Performance comparisons showed that the Mintek control system improved the operation of the milling and flotation circuits resulting in a greater copper recovery.CITATION:Naidoo, A, De Gee, B E and Viviers, N, 2014. Implementation of an advanced milling and flotation control system at Mopani Mufulira copper mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 363–368 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By A D. Pradana, D R. Pradana, Y H. Putra, Z Zulhan, T Hidayat

The high temperature processing of nickel laterite ore is currently dominated by the Rotary Kiln- Electric Furnace (RKEF) technology. The ratio of SiO2/MgO (S/M) in the ore is one of the critical parameters that determines the success of the RKEF process. Incompatible S/M ratios in the ore can cause aggressive chemical interaction between the slag and MgO refractory. The slag-refractory interaction at conditions relevant to nickel laterite ore smelting was investigated in the present study. Synthetic mixtures representing the slag compositions of nickel laterite ore smelting were prepared by mixing MgO, SiO2, Al2O3, CaO, Fe2O3, and Fe and heating the mixtures in steel containers at 1300°C under an argon atmosphere for 3 hrs. Pure MgO crucible were used as containment material in the melting process of the mixtures to represent the MgO refractory. The kinetics of the slagrefractory reaction were investigated using samples with selected initial S/M ratios of 2.0 and 3.0 (wt/wt) (with constant CaO = 3 wt per cent, Al2O3 = 5 wt per cent, FeO = 10 wt per cent) by performing melting at 1500°C in MgO crucibles for 5, 30, and 120 mins under an argon atmosphere. The effect of the S/M ratio in slag on the slag-refractory interaction was also investigated by performing melting of mixtures with different initial S/M ratios of 1.75, 2.0, 2.5, and 3.0 (wt/wt) in MgO crucibles at 1500°C for 120 mins under an argon atmosphere. After the melting process, each sample was quenched in water, mounted in resin, ground, polished, and coated. The interaction between the slags and MgO refractory was then evaluated by analysing the polished samples using a scanning electron microscope equipped with an energy dispersive spectroscopy (SEM-EDS). Thermodynamic simulations using FactSage™ 8.0 thermochemical software were performed based on the experimental slag compositions, refractory, and conditions to support the evaluation process. The results show that a higher S/M ratio in slag leads to a higher tendency for the refractory component to dissolve into the slag. A higher S/M ratio in slag also leads to an increasing extent of solid-state diffusion of iron oxide into the remaining refractory grains. The dissolution of MgO into the slag is rapid; the MgO concentration in the final slag increased by 2.4 wt per cent and 5.7 wt per cent at initial S/M ratios of 2.0 and 3.0 wt/wt, respectively, within 5 and 30 mins of the melting process.

Aug 21, 2024