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By P Pieterse

Kumba Iron Ore Ltd is currently commissioning the Sishen Expansion Project (SEP) û a brownfields project on the Sishen Iron Ore Mine located in the Northern Cape Province, South Africa. SEP is designed to produce 13 Mtpa of product from 21.7 Mtpa of ROM feed. The beneficiation section of SEP employs jigs to process narrow size fractions in the 25 x 0.8 mm size range. The -0.8 mm fraction is screened out ahead of the jig plant and rejected as waste without any prior beneficiation. The processing of this fraction was not included in the early stages of SEP development because no suitable beneficiation or dewatering technologies could be identified within the time-frame required to implement SEP. This paper presents the SEP 1B project, ie the metallurgical and process engineering study that was done to evaluate the techno-economic viability of processing the -0.8 mm material of SEP. To support this evaluation, metallurgical bench scale testwork was done on selected samples characterising the material types used in the SEP for gravity concentration beneficiation. Subsequently, pilot testwork on a 300-ton bulk sample demonstrated that an integrated teeter-bed/spiral circuit could be used to successfully beneficiate the -0.8 mm fraction. The study has established the viability of the proposed process and has concluded that approximately 390 000 tpa could be produced and added to the SEP fine ore product without violating the applicable product specifications. The proposed process has been designed to be implemented in modular units in order to facilitate implementation and ensure future expandability. Based on the recommendations of the study, approval has been granted for the detail design feasibility study. Production is scheduled to commence in the first quarter of 2010.

Jan 1, 2008

By Kikuta K

ISP (Imperial Smelting Process) produces zinc and lead simultaneously from zinc and lead sulphide concentrates and recovers copper and precious metals into a lead bullion. The strength of sinter is important to keep permeability in the shaft of the Imperial Smleting Furnace. The residual sulphur content of the sinter is also important as it causes metal losses into slag. The paper describes an investigation into the sintering operations to improve sulphur elimination and sinter strength. The micro structure of the sinter and the effect of the blast rate, sintering temperature etc have been studied.

Jan 1, 1993

By Skinner W, Netting A. K O

Surface analysis of ore samples collected from corresponding concentrate and tailings process streams is now a widely used tool in many Australian base metal sulphide concentrators, particularly those involved in AMIRA projects. The use of tec

Jan 1, 1997

By Purvis A. H, Greenwood-Smith R, Sowerby B. D

A nuclear technique for the determination of copper and nickel in bulk samples and drill core has been developed at Lucas Heights andfield-tested at Mount Isa. The technique, which is highly specific to the element being measured, utilises the gamma-ray resonance scallering process.A bulk mineral analyser was installed in mid-1976 for the routine assay of copper in bulk samples and drill cores, and remained in operation until late 1981. The operation of the analyser over this five-year period is reviewed with particular emphasis on reliability, accuracy and principal usage.The main application of this analyser was in stope planning and design whereby several thousand drill-core and Wall-chip samples were analysed. It was also used as an aid to underground grade control of stopes where ore dilution by supporting barren backfill was a problem.

Jan 1, 1984

By Mckenzie CK, Scott A

The injection of coal as an auxiliary fuel in ironmaking blast furnaces has been introduced on many furnaces worldwide. This paper examines the present practice of coal injection and discusses future directions for the technology. This has been undertaken through the use of a heat and mass balance model which predicts the replacement rates of coke by coal and the effect of coal injection on blast furnace productivity. The results indicate that future pulverised coal injection could replace substantial quantities of metallurgical coke, but that the energy balance economics of individual steel plants will have a dominating influence on the future of the technology.

Jan 1, 1987

By M Wortley, J McKay, D La Rosa, O Guyo

It has been a generally held concept that crushing operations were, by their nature, too simple to benefit from the implementation of advanced process control. The commissioning of an OCS¬ expert control system and image-based oversize detection system, VisioRock, at the Pilbara Iron Tom Price facility are dispelling these notions. A constraint-based OCS¬ expert control system has been designed and commissioned on the high-grade crushing and screening plant along with a vision-based oversize detection system functioning on six product conveyor belts. To date, the expert control has demonstrated the ability to increase production by maximising dynamic constraint utilisation. Dynamic constraint utilisation is a concept developed by Rio Tinto Technical Services for effectively evaluating constraint-based control logic performance. The VisioRock system has been installed and configured and has been operating for a period of several months. Currently, Tom Price and Metso personnel are working to define correct oversize detection thresholds. Details of the plant implementation are discussed.

Jan 1, 2005

By Wasp E. J

A review is given of recent commercial long distance slurry pipeline systems in- stalled worldwide. The technological advan- ces in slurry engineering and system opera- tion are discussed, together with a brief re- view of the economics of slurry transportation and future trends in the industry.

Jan 1, 1973

The first stage in process design for coal preparation is a study of the coal seam and its associated features followed by an examination of the mining method to.be employed and the coal market requirements. Normally benefication is based upon the differences in relative densities of the coal constituents and asso- ciated ash forming components. Since initial liberation is obtained at a relatively large particle size, the size to which coal is crushed is more subject to the market requirements than to liberation studies. It is possible to estimate energy requirements for comminution and recoveries and product grades can be cal- culated following the interpretation of standard laboratory tests. Numerous units are available for the separation and concentration of the components of run of mine coal in- cluding jigging, dense media separators, and for the finer particle size fractions, flowing film separators, dense media cyclones and froth flotation.

Jan 1, 1975

Prior to 1975, most geochemical drainage surveys for gold were based on analyses for pathfinder elements, such as As and Cu, rather than direct analysis for gold, for two reasons. Firstly, analytical methods lacked the required sensitivity and precision to determine gold abundance at background levels in stream sediments (usually in the range 1 - 10 ppb). Direct analysis was also inhibited by concern about the potential for gross sampling error, brought about by the dispersion of gold as rare discrete particles of the extremely dense native metal. This sampling error, commonly termed the 'nugget effect' has two components: erratic distribution of the element within the stream environment, related to hydraulic factors, and the difficulty in taking representative samples, both in the field and later in sub-sampling for analysis. In more recent years the collection of very large samples was commonly advocated to overcome the sampling problem (Hams, 1982; Nichol, 1986).Two methods have been widely used to evaluate the gold content of bulk samples (Elliott and Towsey, 1989). The preparation and analysis of heavy mineral concentrates has in recent years been largely superseded by the leaching of gold contained in bulk samples by cyanide, commonly termed the BLEG (Bulk Leach Extractable Gold) or BCL (Bulk Cyanide Leach) methods. The terms BLEG and BCL are essentially interchangeable and the latter will be adopted for the remainder of this paper. The strengths and weaknesses of these two techniques were compared with conventional total gold analysis on fine fraction (

Jan 1, 1976

The orebodies at Kambalda are complexly faulted, folded and intruded. It is realized that the ore reserve calculations will be wrong and steps are taken to minimise the errors. The calculations are a combination of computer data handling and manual input. Initially Geological Ore Reserves are calculated and then production data and experience are used to produce a Planned Mining Reserve. At all stages maximum professional judgement is incorporated. The basis of the calculation is the polygonal method of area estimation, and production reconciliations together with the style of data available indicate that it is a most suitable technique. It is also a tech- nique that is easily communicated to all levels from operators to management.

Jan 1, 1979

By Laffin N. W

Invariably when a new plant is cammissioned operations personnel on takeover look at ways and means of reducing certain restrictions and improving process conditions. These improvements are generally of a mechanical/engineering nature with minor metallurgical alterations to fine tune and maximise recovery. Most operations are continually reviewing and updating existing equipment and equipment spares to gain the maximum performance hereby reducing operating costs. Design of current carbon-in-pulp/carbon- in-leach (CIP/CIL) plants has evolved to such a high degree that many of the medium sized plants can have a "blue printed" design from one to the next if the same engineering designer is used.

Jan 1, 1989

By A J. Morrison, M Yahyaei, J S. Siong, J Wang, K Runge

The flotation cells used to upgrade ultrafine metallurgical coal (-250 µm) are usually poorly controlled leading to unnecessary loss of combustibles from the flotation system. This is mainly because coal flotation cells are typically controlled for process stability rather than optimisation of flotation performance. This is especially true for a flotation device commonly used in coal applications in Australia – the Jameson Cell. This then provides an opportunity to improve the flotation performance by shifting from a stabilising control strategy to a proactive optimising control strategy. For an optimising control strategy, the control system will require a means of relating and then measuring in real-time, the effect of changing operating conditions on the coal flotation performance. Hence, the major aim of this work is to propose a possible model-informed process control strategy that could be used for real-time performance optimisation. In this study, industrial site work was conducted on an industrial-scaled Jameson Cell at a Coal Handling and Preparation Plant (CHPP) in Central Queensland, Australia where superficial gas velocity was controlled to six different levels. At the same time, other process variables such as froth depth and flotation feed properties were measured. The empirical models developed from this study suggested that combustible recovery is a function of superficial gas velocity, froth depth, feed solid content and feed ash content and that a peak in combustible recovery existed as a function of superficial gas velocity. This led to the development of a model-informed control strategy that aimed to maximise the combustible recovery by determining and then operating the cell at the superficial gas velocity at which the peak occurs. This peak superficial gas velocity was found to be only a function of feed solid content. Based on these findings it would seem possible to operate a Jameson cell at peak performance by online measurement of feed solid content, prediction of the optimum superficial gas velocity and stabilising control to maintain operation at that superficial gas velocity set point. The development of this modelinformed control strategy can serve as a basis for the development of a more sophisticated modelpredictive control (MPC) system. However, more work will need to be done to improve the predictivity of the combustible recovery model by measuring and modelling performance over a wider range of operating conditions.

Aug 24, 2022

By Dunn J, Nguyen G, Graham J

A pyritic gold concentrate from the Golden Mile, Kalgoorlie, was roasted over a range of temperatures in a pilot scale fluid bed reactor. The calcines were subsequently cyanide leached. Mineralogical studies of the con- centrate, calcines and leached residues were also undertaken. Calcines produced at 500'C gave the poorest gold extractions and high cyanide consumptions. Gold recoveries of approximately 90 per cent were obtained from calcines produced at 550-600'C but higher roasting tempera- tures resulted in an increase in the residual gold content of the leached calcine. There is some evidence of flash smelting of the pyrite at the higher roasting temperatures and encapsulation of gold particles. Mineralogical examination of the calcines shows that the mechanism of oxidation is temperature dependent. At 500'C pyrite is directly oxidized to hematite with a concentric layered texture which appears to inhibit lixiviant access to enclosed gold particles. At higher temperatures the conversion sequence pyrite-pyrrhotite-hematite produces a spongy calcine which al- lows easier penetration by the leaching medium.

Jan 1, 1991

By Royston, Woods R

ANI Bradken Vortex Pulp Lifters and Grates, both as original equipment and retrofitted to existing SAG mills, are now in field operation. The development of the Vortex leading curve pulp lifter was based on an analysis of traditional radia

Jan 1, 1997

Rockbursts, as they occur in South African deep level gold mines, have a lot in common with natural earthquakes. Both violently release seismic energy and cause damage to underground and surface structures. Rockbursts are the main cause of fatalities in deep gold mines and the problem may increase in severity with future mining at greater depths. Although the emphasis in Rock mechanics is on the prevention of rockbursts, prediction would provide a partial solution to the rockburst problem. A research project was initiated in 1981 on Western Deep Levels to investigate the possibility of detecting and identifying precursive microseismic activity. This project has succeeded in locating potential sources of seismic events with reasonable confidence. The timing of these events may be estimated with less confidence, and an important parameter, namely the potential size of the rockburst, still cannot be determined. An example of a large seismic event and its associated precursive activity are discussed. Practical prediction systems will, at least for some time, involve subjective decision making which will place a new responsibility on the mine manager as well as the rockburst specialist. The moral pressure on the manager as the final decision maker will probably be greater than the fear of leqal prosecution.

Jan 1, 1986

A combination of highly structured, fissile stope hangingwalls and high ground stresses have caused difficult mining conditions in the Main Lode Deeps at Lancefield Gold Mine. Cyclic reviews of ground support and stoping techniques, coupled with geotechnical investigations, and the application of numerical modelling has led to the successful management of stoping operations.

Jan 1, 1995

The Blackwater Coal Mine is a modern open cut operation using large draglines for over- :)urden removal and shovels, loaders and trucks to mine and haul coal to the crushing and coal ?reparation plant. Operations at the mine are described in sequence following through overburden removal to the railing of product coal from the mine site. The close operating connection between the mine and washery, which results from the blending of raw coal into clean product via the qashplant bypass system, is stressed. Some features of special interest at Blackwater Mine, such as land reclamation and slope stability,are outlined.

Jan 1, 1974

THE millng methods employed in the Mount Lyell Mining and Railway Company's mines are, perhaps, less known to the milling world than those of other important districts, due to the geographical remoteness and isolation of the Mount Lyell field,but they present many features which are unusual, and should be of interest to the mining engineer. Typical mining is carried out on an open-stope system, details of which are the result of local experience and evolution, and of which the outstanding feature is that the ground is so worked as to be largely self-supporting by virtue of domical form given to the stope roofs. It is locally termed "rill" stoping,' but differs widely from what is generally understood by that designation, chiefly in that the "rill" or slope is developed in every direction from a central focus, and not merely in directions followllig the strike of a lode or ore-body whose longitudinal dimensions are very much greater than its width. Such terms as "donie stoping" or "arched-back stoping" would be more appropriate and descriptive.The company's active operations' at the present time extend to the Mount Lyell and North Lyell mines, and, though the fundamental principles of stoping methods are the same in each, the dissimilarity of the ore-bodies, both in nature and mode ofoccurrence, necessitates considerable variation as to details to meet the respective conditions. The Mount Lyell pyritic body lends itself to the adoption of the .system in its simplest and almost ideal form, and a description of stoping in this mine willserve best to illustrate it, while later reference to details of practice in the North Lyell mine will indicate how it may be varied to meet more difficult circumstances.

Jan 1, 1915

By Aspinall T. O, Just G. D

Computer software systems have been developed to assist in a wide range of specific mine planning and scheduling applications. In selecting appropriate systems for any mining operation it is apparent that certain features have particular advantages for each mine site. The ideal solution to this problem is to select a range of systems which best relate to sections of each mining operation. This approach raises potential data linking difficulties where output from one system is incompatible with input requirements for other systems. A study at the University of Queensland investigated the problems related to the integration of a number of mine planning and scheduling software systems. The project used data from large scale coal strip mining operations in Central Queensland. Two major computer packages used extensively in the study were the SURPAC mine planning and XPAC mine scheduling systems. Dragline and truck and shovel operations were analysed in the project. Results of the work have been directly applied at the mine site to assist current strip design by effectively automating the design procedure. This enabled sensitivity studies to determine the effects of changing dragline working levels and varying pit dimensions. Coal blending studies and procedures to optimise operations have been investigated using linear programming within a spreadsheet software application. Output from the SURPAC and XPAC programs was directly linked to the linear program for this analysis. The simulation program GPSS/PC was also used in a similar manner to assess optimisation parameters.

Jan 1, 1992

Selective open pit mining for gold has been in progress at Harbour Lights since the onset of mining in March 1985. Selective mining techniques used are similar to those in other recently opened gold mines in Western Australia. However certain practices have been introduced to accommodate the irregular distribution of mineralisation and comparatively high mill tonnage throughput. These include selective mining with large bucket excavators, sequential waste stripping - ore mining normal to the strike of the orebody and sample line preparation and ripping on bench floors. Application of these selective mining practices at Harbour Lights enables the operation to maintain delivery of approximately forty by 50-tonne truck loads of ore to the mill crusher everyday, with limited rehandling of material through ore stockpiles.

Jan 1, 1986