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By J Wood

Steady depletion of the world’s primary copper reserves coupled with a meteoric rise in electronic waste (e-waste) generation has led to secondary copper processing assuming an ever-increasing importance within the global copper industry. Treatment of secondary copper feeds at existing smelting operations has traditionally been performed in the Blast furnace, Peirce-Smith converter and/or anode furnace. In the past decade or more, bath smelting technologies have been preferred for the processing of these materials due to their superior environmental performance and flexibility to operate under a wide range of conditions. This paper focuses on the pyrometallurgical processing of copper secondaries in the Outotec Ausmelt TSL Furnace and some of the unique issues facing secondary copper smelters and downstream gas handling/cleaning equipment.

Aug 8, 2011

By N Weerasekara, M Bird, M Yahyaei, M M. Hilden, M S. Powell, J Franke, P Toor

The combination of new tools with a more rigorous approach to understanding the interaction of mill liners with overall mill performance and economics, forms the basis of an integrated approach to liner management. Based on accurate liner wear measurements, some (limited) physical mill inspections and surveys, accurate calibration of the mill load and analysis of process data, a whole new approach to liner selection, relining intervals and mill control is proposed. Collection and analysis of this information in operating mills illustrates the mill performance improvement which can be attained through this careful measurement and modelling approach.A more holistic approach to liner management is proposed, including a broadening of the current work to cover the potential benefits of improved relining technologies and predictive liner wear modelling. CITATION:Powell, M S, Hilden, M M, Weerasekara, N, Yahyaei, M, Toor, P, Franke, J and Bird, M, 2012. A more holistic view of mill liner management, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 95-104 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

The Bradford Process, Australian Patent No. 11253, has had considerable application in the treatment plants of Broken Hill mining companies, and is at present being used by the North Broken Hill Limited for the treatment of weathered slime accumulations.The "Mining and Scientific Press," of 28th September, 1918, describes the Bradford Process at Broken Hill, specially featuring its application to slime material at the Proprietary mine-the home of the process.The points then stressed for galena flotation were acidulated slime pulp (0.025 to 0.030% H2S04) at temperature 85° to 90° F. and suitable time contact, with 1.5 to 2 lb. of sodium hyposulphite (per ton on slime) to permit the released S02 to "wet" or depressthe blende mineral. Also 1.0 to 1.3 lb. of crude sulphur (per ton on slime) was burnt, to supply S02 for keeping the lead concentrate clean during flotation. Pulp density varied from 23 to 26% solids. Since 1918 the process has been simplified in its application.Acidity of circuit, temperature, and sodium hyposulphite have been dispensed with, and now the S02 is practically all obtained by burning crude sulphur. I The plant units now employed for control and absorption of S02 gas constitute the main advance made in process, and these, with other details, are fully explained in this paper.APPLICATION AT BROKEN HILL NORTHThe existing North Broken Hill Limited gravity mill commenced operations on 9th September, 1909.

Jan 1, 1929

By Y-B Kang, W-Y Cha, Y-M Cho

Molten slag used in the secondary refining process (RH process) for the production of Ultra-Low C (ULC) steel is typically composed of CaO-Al2O3-MgOsat.-FetO with minor constituents. FetO in the RH slag is the main source of reoxidation of the molten ULC steel in the ladle by 2Al + 3(FetO) = (Al2O3) + 3Fe, thereby serving as the source of the alumina inclusions. On the other hand, FetO also enhances the fluidity of the slag, thereby increasing inclusion absorption capacity. Optimum slag chemistry design is therefore required to produce clear ULC steel. The reoxidation kinetics was investigated in the present study by employing high-temperature experiments and developing the reaction rate model. Initial compositions of slag ((% CaO)0/(% Al2O3)0 and (% FetO)0)) and reaction temperature were varied and change of [% Al] in the molten steel was measured. The rate-controlling step was analysed. It was found that the rate-controlling step in some cases changed during the reoxidation: from a mass transport of Al in the molten steel to a mixed transport including Al2O3 in the molten slag. The experimental data validated the reaction rate model based on the elucidated reaction mechanism and FactSage thermodynamic database. The model suggested that high (% CaO)0/(% Al2O3)0 suppresses the reoxidation only when (% FetO)0 is low (5 or lower in the present study).

Jun 19, 2024

During the last 12 years the dominant theme at Mount Isa has been production expansion. Production rate of 3,200 tons per mine day in 1953 increased to 11,000 tons per mine day in 1960, completing the first stage of the programme. The second stage is still in progress. It is planned to increase production of lead and copper ores to 19,500 tons per mine day in 1968.Current mine workings comprise an area 2 miles long and 1/2 mile wide, the deepest production level being 2,000 ft below surface. During the next 10 years it is anticipated that mining will be carried out to a depthof 3,200 ft below the surface. The rapid extension of the mine has necessitated frequent re-appraisals and modifications to the primary ventilation system, and a system with considerable in-built flexibility has gradually evolved. Since 1953, volume circulation has increased eight-fold to approximately 2,400,000 c.f.m.To suit various mine operating requirements, a combined pressure-exhaust system of ventilation was adopted.The usefulness of this system is at a maximum when the fans installed permit ready changes in the location of the boundary between adjacent spheres of fan influence.Air flow through openings to the surface can be controlled or used as required. This feature is considered necessary for a mine where underground workings are comparatively shallow and caving to the surface willoccur.A major heat problem exists due to climate conditions, high geothermic gradient (one degree Fahrenheit in 95 ft), and oxidation in leached and brecciated areas.Because of this, quantities of air far in excess of the minimum requirements for dust removal are required to ensure satisfactory environmental conditions. In assessing fan pressure, consideration was given to 1. the mine resistance, and the requirement for pressure differential capability,2. the pressure requirement for deeper mining, with due allowance for booster fan use where appropriate,and3. the desire to avoid fan operation at pressure duties above the region of peak fan efficiency.The latter feature provides a safety margin between maximum operating pressure and the stall point of the fan.

Jan 1, 1967

By Richards BG, Komdeur W

Instability in spoil piles and in high wall slopes in natural overburden has been ex- perienced at Utah's Goonyella Mine since com- mencement of operations in early 1971. Annual production targets, although gener- ally met since the commencement of operations, required modifications to stripping and mining techniques and the rapid re-scheduling of oper- ations around unstable areas, but culminated in the earlier than planned acquisition of addit- ional stripping equipment. An understanding of failure mechanisms was developed within a collaborative study of pitwall instability between Utah Development Company and the C.S.I.R.O. Division of Applied Geomechanics. Results showed that pitwall instability occurs as structurally controlled deformations along planar failure surfaces; spoil pile failures are precipitated by moist- ure ingress and subsequent loss of strength of base layer materials; highwall failures de- velop over areally extensive bedding planes in conjunction with inclined and subvertical fractures caused by overburden blast damage.

Jan 1, 1978

By M Darby, B Burdett, F Lovell

The results of the process control improvement project aimed at improving the quality of Australian Bulk MineralsÆ (ABM) iron ore pellets produced by four vertical shaft furnaces are very positive. These results are achieved through process stabilisation and optimisation, improvement in process monitoring and taking early corrective actions when operating variables were outside the target ranges. A number of benefits are obtained from this project. These benefits include: More consistent and improved pellet quality. The average cold compression strength (CCS) value of pellets produced during the eight-month trial is 260 kg/pellet, which is 16 kg/pellet higher than that produced during the 12 months prior to the trial (244 kg/pellet). Reduction in the heat input by eight per cent, from 727 MJ/tonne to 668 MJ/tonne. Reduction in bentonite rate by six per cent, from 7.1 kg/tonne to 6.7 kg/tonne. Increase in the furnace throughput rate by four per cent and additional production of 10 000 tonnes per annum through process stabilisation. Better understanding of the process behaviour. This knowledge is valuable not only for setting the target operating conditions but also for developing the ABM expert system to control the process.

Jan 1, 2005

By D Maldonado

BlueScope Steel’s Port Kembla sinter machine underwent a major upgrade during mid-2009. The mixing and rolling drum (MRD) was thoroughly cleaned during the upgrade. Space factor measurements taken in October 2009 showed that the drum was operating in the cataract regime in the dry mixing section and the cascading regime in the rolling section, which is optimal for granulation. Sampling carried out during an entry into the MRD showed that both the Sauter mean diameter and the predicted bed voidage increase rapidly during wetting, and then decrease in the wet mixing section. In the rolling section, the granule properties remained constant untilthe drum discharge. Frozen particle analysis, using liquid nitrogen as the quenching agent, were carried out on material collected from the MRD discharge. The results, expressed as a Granulation Index, showed there had been a significant improvement in the granulating performance of the MRD following the upgrade. The plant studies were also complemented with laboratory scale experiments which aimed to optimise the granulation process. The effect of burnt lime on green feed permeability was quantifi ed using the laboratory scale drum at different moisture contents. A significant increase in permeability was apparent once the burnt lime dosing rates doubled from 1.1 - 2.2 per cent w/w (feed basis). The capacity of the burnt lime system at the sinter machine will be increased in order to benefi t from the expected higher permeability, permeability, which will enable the machine to sinter at deeper bed heights.

Jul 11, 2011

By M R. Asef

Although generation of environmentally harmful hydrogen sulfide is considered to be related to sour gas fields, sweet gas reservoirs and waste fluids, travertine springs and geothermal fields may also produce acid gas (H2S and CO2) under certain conditions. The potential parameters influencing such a possibility need to be fully investigated to evaluate the extent of the consequences and predict hydrogen sulfide generation accordingly. Reports on hydrogen sulfide production at different regions and fields were gathered worldwide for the cases when some of them did not have such a problem previously. In order to inspect different aspects of these case studies, some other regions with no hydrogen sulfide content were selected as control. In all cases water samples were taken carefully for chemical analysis in the laboratory. Besides, mineral compositions were characterised in some cases for better evaluation. In order to give a thorough prospect of hydrogen sulfide production, a geochemical model was prepared. In situ engineering geological conditions, especially pressure and temperature, were assigned in the model to investigate the possibility of H2S generation using PHREEQC software. The results of modelling revealed that although many similarities existed between mineral compositions of the cases, certain formations were particularly prone to hydrogen sulfide generation. For better evaluation, important exchangeable cation ratios such as potassium/sodium, calcium/magnesium and ion proportions like sulfate and chloride were calculated as trends of the formations. As expected, the model could successfully monitor a higher ratio of SO42- and Cl- in potential H2S generator formations. Wide variation in percentage of HCO3- was considered as a secondary observatory parameter for better estimation. In addition, it was noticed that higher anion content created an environment ready to absorb any cations and this makes H2S generation easier. Finally, using correlations between predictors and estimators for low depth and deep samples defined the degree of effectiveness for every sample.

Sep 26, 2011

LIST OF CONTENTSAbstractIntroductionSelected Sections of the Broken Hill LodeLocality PlansPetrology1. Zinc Corporation Mine: DDH. 5.98, section 30, No. 26 level2. Zinc Corporation Mine: DDH. 838, section 30, No. 13 level3. Broken Hill Sonth Mine: 60 ft. cont01(r above 1170 ft. level4. Broken Hill South Mine : No. 7 shaft section, 1370 ft. levelOrigin of garnet sandstone5. Barrier Central Pty. Ltd.: DDH. tJ.93, Block 136. North Broken Hill Ltd.: Junction mine, DDH. 602, No. 10 level7. North Broken Hill Ltd.: Jnnction mine, DDH. 588, No. 11 level8. North Broken Hill Ltd.: North mine, DDH. through Southern ore body, 3370 ft. level9. North Broken Hill Ltd.: North mine, Northern ore body above 2300 ft. level(a) Southern end, section 27, 77 ft. above rails(b) Northern end, section 30, 6.9 ft. above rails(c) Miscellaneons samples, sections 27 and 28Relative time of ore depositionSericitizntionStructural significance of sericitizationGCLhnite OrthoclaseApatite GarnetManganese SilicatesAlteration of manganese silicatesRelation of zinc and lead to the silicatesZinc in manganese-bearing silicatesLead in potassium and lime silicates and apatite

Jan 1, 1959

The LeadtZinc Concentrator at Mount lsa treats all the lead-zinc-silver ore from the Mount Isa Mine and some of the ore from the Hilton Mine. This concentrator was commissioned in June 1966 and total lead-zinc-silver ore treatment was transferred from the Mount rsa's original No 1 Concentrator in May 1967. Plant capacity is around 5 x 106 t/y.There have been three phases of major plant modifications since commissioning:1. replacement and upgrading of the flotation section in 1979; 2. upgrading of the crushing plant and installation of a heavy medium hydrocyclone plant in 1983 for ore preconcentration, and; 3. doubling ball milling capacity and a further upgrading of the flotation section in 1992.Other developments have included the installation of flotation columns and Jameson cells.The evolution of milling practice since 1955 has been reported by Davey and Slaughter (1970), Bartrum, Dobrowolski and Schache (1977), Fiedler and Munro (1984) and Espinosa-Gomez el al (1989).Lead concentrate is smelted in Mount Isa while zinc concentrate and bulk concentrate (locally called Low Grade Middlings or LGM) are railed to Townsville and shipped to custom electrolytic zinc plants and ISP smelters.

Jan 1, 1993

By Manlapig EV, Lawson F, Clarkson CJ

A low grade middling sample from Mount Isa, Australia, assaying 31.7 per cent zinc, 12.9 per cent lead and 14.5 per cent iron was leached under atmospheric pressure in sulphate and sulphate-chloride solutions with ferric ions as oxidants. About 96 per cent of the contained zinc was dissolved into a 0.5 M H2SO4 - 0.5 M Fe2(SO4)3 solution at 90¦C within three hours from a five per cent by weight slurry density mixture. The leaching process is very temperature-dependent, suggesting a surface chemical control. In the latter stage, the leaching rates levelled off and the leaching was most probably controlled by both surface chemical reaction and diffusion processes. The addition of chloride ions in the leach solution resulted in an increase in the leaching rate. About 95 per cent of the lead sulphide contained was converted to lead sulphate which precipitated and remained in the residue. Essentially no lead remained in solution and the low chloride concentration did not affect the precipitation of lead sulphate. Half of the iron orginally present remained in the residue as pyrite although essentially all the cadmium and 90 per cent of the copper initially present were dissolved. Some three per cent of sulphide sulphur was oxidised through to sulphate, about 67 per cent was converted to elemental sulphur which can be recovered by solvent extraction, the rest remained in the residue mainly as pyrite. Ferric sulphate and sulphate-chloride solutions can be used to effectively leach finely ground lead-zinc middlings and other bulk sulphide concentrates. A complete separation of zinc from lead and silver has been demonstrated.

Jan 1, 1993

By G de Jong, W Sunyoto, M Cloos

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Ertsberg mining district is a 100 km2 area in the highlands of Papua, Indonesia. The district hosts mineralised and barren, outcropping and hidden porphyry and equigranular intrusions. There are at least six major (100+ m wide) porphyry intrusions identified from surface and underground mapping and drill cores. These are the Grasberg Igneous Complex (GIC), Karume porphyry, Lembah Tembaga porphyry, Ertsberg Stockwork Zone porphyry, Kay intrusion and the Wanagon intrusion. Recent deep drilling adjacent to the GIC identified a new hidden porphyry at depth, the Gajah Tidur (Sleeping Elephant), which extends south-west beneath the Kucing Liar skarn. Other named small porphyry dykes and plugs in the district include the West Grasberg, North Grasberg, Idenberg, South East and Zaagkam intrusions. The largest equigranular intrusion is the multiphase Ertsberg diorite.Igneous activities occurred in a relatively short span (<1 million years) from about 3.4 Ma to 2.7 Ma ago, based on U-Pb zircon dating. The various intrusions in the district related to ore mineralisation are high K and appear to have been derived from the same parental chamber, based on similar whole rock rare earth element patterns. Radiogenic Nd- and Sr-isotopic variations indicate that there were multiple recharge events into the parental chamber.The larger intrusions and all economic mineralisation occur in a 4 km wide zone that parallels the N60W-trending axis of the Yellow Valley Syncline (YVS), one of the large folds generated during collisional tectonism. Intrusion pathways at ~3 Ma were localised into dilatational areas in a late and/or post-collisional NW-trending, left-lateral strike-slip zone with Riedel shear offsets between the major fault zones. An early phase of lower K magmatism produced small intrusions in the south-west limb of the YVS.CITATION:de Jong, G, Sunyoto, W and Cloos, M, 2015. Composition, lithochemistry and radiogenic isotopes of porphyritic and equigranular intrusions in the Ertsberg mining district, Papua, Indonesia, in Proceedings PACRIM 2015 Congress, pp 347–356 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By T J. Howard

At BHP Billiton Iron Ore operations, run of mine ore from the several Newman Joint Venture (NJV) mines is railed in 12 kt rakes to Port Hedland. Rakes are processed sequentially, with the lump and fines components from each rake sampled after crushing and screening. The grade of ore from the individual mines varies around consistently different means. Although a discrete sample is attributed to each rake, the sample contains some material from the following and/or the preceding rakes due to dilution by ore from the neighbouring rakes during the dumping, screening and crushing processes. Individual rake grades at the port are therefore biased according to the mine sources of adjacently processed rakes. Dilution does not affect the grade of the overall NJV product or the accuracy of port stockpile grades; however, it does limit the ability to use port rake grades to review the quality performance of individual mines and provide meaningful lump-fines algorithms and port to mine biases for individual mines, information that is useful when scheduling ore for mining. A non-linear regression model has been used to estimate the average dilution from the preceding and following rakes. It has been shown that the lump and fines samples for 12 kt rakes are each diluted within the Port process with about 8.3 per cent of the sample coming from the preceding rake and about 3.6 per cent from the following rake. This can bias the reported rake grade by up to one per cent iron. The results of this analysis have been incorporated into the daily grade scheduling system to provide more accurate individual mine grade data and consequently better decision making.

Jan 1, 2007

By D C. S M, J Skudder, R F. Sandenbergh

Metallic sulfide minerals present in most gold ores, Morila gold ore included, often decompose under typical gold leaching conditions. The reactions and their products consume oxygen and sodium cyanide, consequently competing for oxygen and cyanide used in gold dissolution. The resultant effect is to reduce both the kinetics of gold dissolution and overall extraction efficiencies. The present paper discusses results obtained from plant data analysis and laboratory work investigating the problem of higher than expected consumption of sodium cyanide at Morila Mine Gold Plant. Cyanide consumption at the Morila Mine Gold Plant had been consistently running at 46 per cent higher than the expected value without any corresponding increase in gold recovery. In fact, plant data analysis showed an inverse relationship between cyanide consumption and grind, as well as cyanide consumption and gold recovery. Experimental and plant data analysis indicated that better control of the [CN-]/[O2] ratio is necessary for the efficient use of reagents and achievement of higher gold recoveries. Careful control of this ratio at a minimum of eight enabled the reduction of sodium cyanide consumption by 200 g/t, that is, from 650 g/t to 450 g/t. Coupling these experimental conditions with the addition of lead nitrate at 100 g/t improved the overall gold recovery to 93 per cent compared to the average plant recovery of 90.2 per cent over a six-month period. This improvement was also reflected in the leaching kinetics where 70 per cent gold extraction was achieved after four hours, as compared to 59 per cent in the absence of lead nitrate addition. Also of great importance is the fact that the combination of hydrogen peroxide and oxygen gave inferior performance relative to either of the two reagents used separately. This scenario presents an opportunity for excluding hydrogen peroxide, an expensive reagent, and focusing on improving the oxygen addition system to boost dissolved oxygen concentration in the plant.

Jan 1, 2007

This paper describes techniques that have been used at RixÆs Creek Colliery to control blast vibration from throwblasts that face a residential area 4 km in front of the face. The paper describes blast design, face control including laser profiling, selective loading of blastholes after borehole camera surveys, and techniques used to assess the effect of burden variation, the cumulative effect of drilling and delay sequence, and the effects of meteorology.

Jan 1, 2001

It is generally known that Charters Towers was discovered by Mosman, Clarke and Fraser in 1871. However, the time was ripe, and these three were barely in front of others. There is one account that prospectors from Ravenswood visited the area months before but decided it was too far from water, and that one of them had told Mosman and party of the find. There is another account that Joe Larkins found the discoverers before they had registered any ground - this may explain Mosman's quick departure for Ravenswood.When the news spread, the rush was rapid, and there was soon a sizeable population: probably too many, as within twelve months the infant settlement was under considerable stress. First, the presiding Gold Commissioners had adopted "unusual and arbitary" interpretations of the Regulations, and many of the miners were aggrieved; Charters, the senior Commissioner, was accused of favouring moneyed interests, and of retiring ill whenever a brawl or confrontation occured. As a result, the law of the field soon became "the survival of the strong". Second, the settlers were, divided on where the main town should be: Millchester, near the water, or Charters Towers near the mines. Third, the discovery of gold at the Millchester Deep Lead in August, 1872 was followed by highly exaggerated accoants in_' the southern papers, apparently fabricated by local business speculators. The resulting rush resulted in hundreds of unlucky prospectors having to return or seek other fields. In that period two men were killed in squabbles over ground. To make matters worse, by October 1872 a drought had set in, water cost three pence a bucket, fodder was scarce, cartage expensive, and the price of crushing ore rose to thirty shillings per ton.

Jan 1, 1986

By A S. Derrington

In some parts of Australia, mine air cooling may not be needed until a depth of 1300 m below surface is reached. In other locations, it may be essential at a depth of only 300 m below surface. The reasons for these differences are multifaceted. This paper discusses the main factors and describes a simple method to assess whether or not mine air cooling will be required. The method uses a graphical relationship that considers depth below surface, geothermal gradient, surface climatic conditions and directness of the mine intake routes. This relationship has been developed, tested and refined over a period of more than ten years using data collected from most of Australia’s deeper metalliferous mines. The method provides a ‘first-pass’ indication of whether more detailed cooling studies may be needed. Perhaps more importantly, the method’s underpinning by benchmarking against other mines improves confidence in the assessment results. Like any empirical method, the context must be understood and this aspect is also discussedCITATION:Derrington, A S, 2014. Will your mine require cooling?, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 181–186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

The lignite mines in the Latrobe Valley of Victoria/Australia have been using continuously operating mining systems for more than 50 years. The relatively small bucket chain dredgers of the early years have been progressively displaced by bucket wheel dredgers with increasing size, increasing capacity and increasing service weight. The large machines for the new open pit Loy Yang have a bucket wheel outreach of 46m, an effective capacity of 3350 bm' coal/h respective 2500 bm' overburden/h and a serv- ice weight of approx. 4500 t. The time between signing of con- tract and starting of operation for these machines is at least four years. The high service weight, the resulting high capital invest- ment and the long period for design, design review, manufac- turing, erection and commissioning of these machines directed the SECV to investigate a possible application of compact dredgers for the Latrobe Valley.

Jan 1, 1989

By P Dean, M Elmouttie

Radar monitors are now widely used in surface mining for monitoring slope deformations and predicting failure events. Their introduction has facilitated better management of risk associated with slope failure during mining and therefore protection of personnel and equipment. However, a wellrecognised problem is that radar monitors only measure deformation directed towards the detector (line-of-sight bias). This bias can lead to misinterpretation of deformation size, rate and failure mechanism, and therefore miscalculation of failure volume, which can significantly impact safety and productivity. This paper presents recently completed research and field trials into the feasibility of using low cost vision systems to mitigate this issue. It has been demonstrated that by integrating a computer vision system with an existing slope monitor, high precision tracking of features in the field of view can be performed. Combined with assumptions on the deformation characteristics, the true 3D deformation vector can be estimated. The applicability of using this technique for monitoring iron ore mine slopes is discussed.

Nov 8, 2021