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By K Nesbitt

Draw control at Premier Mine is considered important to avoid conditions of isolated draw, which results in early waste ingress, compaction of the kimberlite ore and loss of ore reserves. The Premier Mine kimberlite pipe is unique in that the pipe is cut at a depth of 400 metres below surface by a 75 metre thick gabbro sill. All cave mining at Premier is below the sill and failure to exercise good draw control could cause early ingress of gabbro waste. Gabbro causes problems in the diamond recovery plant and the amount of gabbro sent to the plant needs to be closely monitored. Fortunately coarse gabbro fragments are easy to recognise in drawpoints. It was anticipated that only 85 per cent of available ore would be drawn from the blocks immediately overlain by the gabbro sill before excessive gabbro waste forced the closure of drawpoints. Data on tons drawn per drawpoint and loaded per LHD as well as the tons tipped per pass is gathered by the vehicle monitoring and control (VMAC) system and information recorded by the load-haul-dump (LHD) drivers. Draw control staff monitor drawpoints on a shift basis and record the occurrence, type and height of hang-ups. Information pertaining to the status of the drawpoint in terms of support, waste and availability is also recorded. A database has been compiled that has been used to analyse the overall pattern of draw control, the frequency of occurrence of different types of hang-ups, secondary blasting efficiencies and drawpoint and LHD productivity. The gabbro sill has provided a unique marker horizon that has allowed the arrival of rock from a level 100 metres above the production level to be recognised. Data shows that ore migrates extensively towards groups of drawpoints that are heavily drawn with many drawpoints more than 100 per cent drawn before gabbro waste was recognised. This indicates that an accurate mixing algorithm is essential for good draw control. Data on tons drawn, drawpoint availability, productivity and the occurrence of various types of hang-ups has allowed better control of the mining operation and provided data for planning future caves. In the BA5 mining block a drawpoint spacing of 22 metres, horizontally across the major apex, has still allowed drawpoints to be pulled to waste with no loss of ore. In the BB1E mining block the drawpoint spacing has been increased to 23 metres and no problems have been experienced to-date. Future initiatives centre on improving the data gathering integrity of the vehicle monitoring and control system and a linear programme that will optimise draw control and productivity.

Jan 1, 2000

By E Beltran, S Ngunz, F Orrante, F van Zyl, M Westcott

"The primary control objective of the project is to achieve milling optimisation by ensuring that the energy available for rock breakage is used as efficiently as possible. This is achieved by increasing the level of mill filing until a process constraint is reached. Stable operation against this limiting constraint is then maintained to ensure long-term optimised operation.Semi-autogenous grinding (SAG) mill control optimisation presents a number of challenges. SAG mills have multiple inputs that are used to control multiple outputs (MIMO process). Secondly, the SAG mill loading process is a ‘high inertia’ process that can be approximated as an integrating process. This means that it is open-loop unstable. The hybrid control strategy presented implements an advanced ‘load stabiliser’, which transforms this integrator process into a more manageable first order process, which can be steered stably against the constraints. This SGS hybrid Expert control strategy implemented on both SAG mills at the Porgera concentrator therefore consists of two integrated parts responsible for:stabilising the mill load to a targetdriving the mill load target to the maximum determined by the process constraints (eg maximum power draw) to maximise efficiency and throughput. A comparative study is done between the operation of the plant for a period of a month before and a month after the implementation of this strategy. The results indicated a significant improvement in the SAG mills’ stability and operation as well as a reduction of overload situations leading to a loss of throughput.Citation:Ngunz, S, van Zyl, F, Orrante, F, Beltran, E, Westcott, M and Wilson, S, 2016. Simplified Hybrid Semi-autogenous Grinding Mill Control - Explanation and Practical Results at the Porgera Concentrator, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 313–320 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By J Boshoff, D Reid

It has been recognised worldwide that the liquefaction risk of unconstrained tailings stacks or cyclone underflow embankments requires careful consideration. The stability of a tailings deposit where the perimeter embankments are made up of hydraulic fill is often governed by post-liquefaction stability.Cyclones are frequently used around the world to classify tailings into a coarse underflow for building a tailings impoundment wall and a finer fraction that is disposed of into the basin. The shear strength of the tailings that form the outer embankment of a tailings storage facility (TSF) and the location of the phreatic surface are the two most significant factors influencing the structural integrity of the facility. The coarse underflow is placed in such a way as to contain the overflow, which is finer, has low strength and is often poorly consolidated.A cyclone field trial was undertaken at a gold mine in Western Australia to assess the feasibility of using the cyclone deposition method to optimise and increase the capacity of an existing tailings cell. The aim of the cyclone trial was to collect information to demonstrate to the client and the regulators that cyclone deposition was a feasible option for raising TSF embankments. The cyclone trial provided an opportunity to assess the cyclone under field conditions and the quantity and quality of the underflow fraction produced on-site. A variety of methods were used to assess the flow liquefaction susceptibility of the tailings underflow sample produced during the cyclone field trial.The field trial, laboratory testing and analysis will be discussed in this paper.CITATION:Boshoff, J and Reid, D, 2015. The resistance of cyclone underflow material to flow liquefaction, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 151–156 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

Results are presented of the investigation of gas dynamics of the blast furnace process obtained on laboratory models and operating furnaces. Gas residence times were measured using a helium tracer technique developed for the purpose. Residence times were determined in furnaces of 1007 m3 and 1719 m3 and results used in the calculation of the burden parameters and to estimate the distribution of the gas flow along the furnace radius. The effect of tuyere injection of coal dust on gas distribution was also investigated and the advantage of continuous injection compared with intermittent injection is noted. The unevenness of gas distribution across the furnace area is found to correlate well with differences in the size analysis of the iron-bearing component of the burden. The mixing of the gas streams between the neighbouring raceways was studied. It is shown that in the central region of the furnace gases from every tuyere are mixed together, whilst in the peripheral regions mixing is more localised and includes only the sections consisting of five adjacent tuyeres. A solution is proposed to the problem of a theoretical evaluation of the critical gas velocity. A simple relationship between the Reynolds and the Archimedes numbers was obtained from which, after substitution of the burden size data and the gas parameters, it is -possible to evaluate the critical gas velocity. Conclusions include information relating to the optimisation of the gas distribution and views on reducing gas injection at elevated furnace levels.

Jan 1, 1975

By Ormsby W. R, Nicholson P. M

Woodcutters is a polymetallic vein-style deposit hosted by sediments of the Palacoproterozoic Whites Formation which forms part of the sedimentary sequence in the central Pine Creek Geosyncline. Past production and identified resources total over eight million tonnes at 5.5 per cent lead, 12.1 per cent zinc and 110 gA silver. The local geology is influenced by Archaean basement highs; the Rum Jungle and Waterhouse Complexes. Unconformably overlying basement are interbedded clastic and crystalline carbonate units (Batchelor Group) representing cyclic changes in the depositional environment. These exhibit onlapping features with the underlying rocks. Sediments of the overlying Frances Creek Group suggest a quiet period during subsidence and subsequent increase in water depth (the carbonaceous dolomitic shales and the interbedded dololutites of the Whites Formation) followed by proximal uplift resulting in the inundation of turbiditic flows (Acacia Gap Quartzite). All of the Palaeoproterozoic rocks show evidence of being affected by penecontemporaneous, basement circling faults with steep dips. The stress regime during the deposition of the Frances Creek Group was characterised by alternating episodes of thrusting and transpression. Periods of relaxation also occurred. The compression resulted in major NS strike-slip (transpressional) faulting, en-echelon NNE trending folds and NW-SE tensional cross faults. Thrusting produced N-S striking, steep dipping reverse faults and a possible decollement immediately above the Batchelor Group. Relaxation is evidenced by the intrusion of lamprophyre dykes and dolerite sills (Zamu Dolerite). Mineralisation at Woodcutters occurred in faults within the Whites Formation, probably synchronous with deformation and the deposition of the upper parts of the Frances Creek Group. Greenschist facies metamorphism occurred as the rocks were further buried. Several massive sulphide bodies occur at Woodcutters. A number of features influence the location and shape of these bodies. They are: ò the N-S transpressional faults and in particular associated dilation zones; ò intersection of the N-S transpressional faults with the axial plane of the NNE trending Woodcutters Anticline; ò intersection of the N-S transpressional faults with the NW-SE cross-faults; ò intersection of dololutite rich units with the NS transpressional faults where local replacement takes place; ò thickening of the lithological units in the vicinity of the anticlinal axis; and ò the anticline doubly plunging to both the north and south. The mineralisation exhibits vein-like features as well as epigenetic textures. Its boundaries are sharp, its thickness varies rapidly down dip and along strike, and no alteration halo exists though stringer veins of quartz-carbonate-pyrite ¦ sphalerite/galena occur in close proximity. A number of sulphide mineral assemblages have been recognised, each separated by periods of deformation and partially replacing the earlier assemblages. Vertically continuous zonation patterns highlight the presence of rich galena-sphalerite-silver in zones of maximum dilation and pyrite-arsenopyrite-gold concentrated at the along strike peripheries. The genetic model proposed has the mineralisation occurring whilst the transpressional regime was active. It was deposited from the same fluid that elsewhere in the Geosyncline formed the stratiform deposits higher in the sedimentary pile. Hydrocarbons sourced from the organic-rich Whites

Jan 1, 1994

By G B. French

Post a serious heating event underground, and at the direction of the State Mining Safety Authority, a mining company needed to demonstrate the use of cutting-edge technology to mitigate future events. Yokogawa were contracted to provide a turnkey solution to help the mine achieve this objective. The solution was to use a fibre optic-based Heat Detector that will allow entry into and around the mine considering the potential volatility of the environment, also the need to redeploy as mining activities moved underground and more boreholes are added. Industrial strength fibre optic cable and a robust connector system was chosen to achieve this goal and give the customer the ability to send cable down boreholes of up to +1 km and continuously monitor the temperature ofunderground roadways. Being able to re-deploy the cables into different boreholes and link borehole temperature measurements gave insight into all areas on the mine. The machines deployed on-site were the Yokogawa DTSX1 heat detector incorporating the Ramen Backscatter principle. Being of a robust construction and a low power consumption device, it was easily included into the portable monitoring trailers designed by the customer and built locally.

Oct 12, 2022

By T Kang, V Sahajwalla, L Lu

During devolatilisation, physical behaviour of coals was investigated in horizontal electrically heated furnace with an inert gas atmosphere, and gasification rates of four coal chars and coke were measured thermogravimetrically in a carbon dioxide atmosphere at temperatures in the range 1100oC - 1500oC. The volume change of chars was also measured in horizontal electrically heated furnace at various temperatures. Both reactivity and the activation energy for the gasification of coal chars were found to be strongly influenced by pore structure and the carbonisation conditions employed during preparation. CO2 reactivity of chars increases with increasing reaction temperature, and particularly increases more rapidly over 1300¦C. CO2 reactivity of coke is lower than that of non-coking coal chars in the range of 1100¦C to 1500¦C. CO2 reactivity of chars with smaller pore area and bigger pore diameter is less than that of chars with bigger pore area and smaller pore diameter. During gasification, the volume of chars did not change significantly at the lower temperatures of 1100¦C and 1200¦C, but at the high temperatures, 1300¦C to 1500¦C, the volume of chars quickly decreased due to ash softening and melting. The CO2 reactivities of the chars are controlled by the mixed control of chemical reaction and pore diffusion in the temperature range 1100¦C to 1300¦C, and by bulk diffusion in the temperature range 1400¦C to 1500¦C.

Jan 1, 2000

By T Sasaoka, H Shimada

Mined-out limestone/aggregate quarries in Japan contain many high and enormous pit walls. Many precious resources are abandoned in these final pit walls. In addition, there are many mines which are located in or near populated areas in Japan. Utilisationof the potentially useful under- ground space at mined-out sites is a topic relevant to the practice of surface mining. This paper describes and discusses the concept of underground space utilisation and tunnelling systems, referring specifically to geotechnical/ tunnelling parameters.

Jan 1, 2008

By H Ishikawa, H Zhou, M Spagnolo, R Halomoan, S Palaniandy

The Karara Mine concentrator commenced operation in November 2012 to produce high-grade magnetite concentrate. The circuit consists of three stages of comminution plus magnetic separation at each stage for early gangue rejection. High-Pressure Grinding Rolls (HPGRs) are used for fine crushing, followed by ball mills and TowerMills in secondary and fine grinding duties respectively. In recent times, the plant throughput rate has had to exceed design by 18% to maintain the targeted concentrate productivity. Meanwhile, the ore hardness has increased by 25% to 15 kWh/t, leading to changes in the circuit operation and design. These changes led to coarser and harder feed to the TowerMill circuit that affects the subsequent separation processes. Nippon Eirich (the TowerMill manufacturer) has partnered with Karara Mining Limited (Karara) to optimise the TowerMill circuit operation to achieve a circuit product with an 80% passing (P80) of 35 µm. Several activities, including a TowerMill circuit audit and performance evaluation, multi-component analysis, modelling and simulation, were carried out as part of the optimisation exercise. The circuit audit results revealed that the TowerMill circuit feed size F80 had increased and ranged from 67–75 µm. The circuit product P80 ranged between 42–55 µm. The average circuit specific energy was 3.4 kWh/t. Moreover, the differences in density between magnetite and gangue minerals had affected the hydrocyclone performance where the efficiency curve exhibits coarse end deflection indicating that low-density coarse material was bypassing to the overflow stream. A multi-component analysis was carried out to further investigate the coarse end deflection of the hydrocyclone efficiency curve. The analysis showed that the magnetite and gangue minerals had different cut sizes of 32 and 64 µm respectively. Furthermore, 33% of the magnetite (below 35 µm) was being recycled back to the mill due to the density effect. Based on these findings, several recommendations for process improvement were identified and implemented including:• converting to a bottom feeding configuration to improve the grinding efficiency in the mill• additional grinding power in the fine grinding duty to compensate for the increase in plant throughput and ore hardness• improved classification efficiency by converting to smaller size hydrocyclones. Simulation studies carried out to evaluate the impact of these implementations had indicated that a P80 close to 35 µm with a steeper size distribution could be achieved by using the bottom feed configuration with additional grinding power. The TowerMill circuit was converted to bottom feed configuration and the performance was evaluated. The operating work index, size specific energy and circulating load were 30% lower than the top feed configuration, indicating that the bottom feed configuration had a higher grinding efficiency. This paper discusses the outcome of the circuit audit, multicomponent analysis, circuit simulations, improvement strategies and quantification of the improvements. CITATION:Palaniandy, S, Spagnolo, M, Halomoan, R, Zhou, H and Ishikawa, H, 2017. Fine grinding circuit process improvement at the Karara mine concentrator, in Proceedings MetPlant 2017, pp 101–120 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By W Wu

The prospect of discrete element modelling (DEM) being used as an everyday design tool for transfer chutes in the iron ore mining industry is becoming more and more probable. However, much care needs to be taken to ensure accurate results are obtained. Whilst there are many publications in industry portraying the potential of DEM, there is little evidence of where it has been validated against a real set of experimental results. The purpose of this investigation was to gauge whether the incorporation of the physical properties of a specific bulk material at the DEM pre-processing stage can yield visually and numerically accurate simulations for a simple flow case. Effects such as irregular particle shapes, varying frictional properties and coefficients of restitution, all found through experimentation were investigated. Video analysis was used to compare simulations to real flow cases. It was found the most critical attributes in determining the accuracy of the simulations were particle shape and wall friction. Keeping the particle-to-wall friction factor constant was not sufficient to describe the flow accurately. But by introducing the varying effects of wall friction with consolidation stress, the correct results were simulated.

Jan 1, 2007

Prior to 1972, Peko Mines Limited at Tennant Creek used a central mill at Peko, which consisted of a gravity circuit, flotation and cyanidation of tailings, to treat their gold ore from surrounding mines. The Warrego concentrator, 60km to the west, was built to handle the Warrego and Gecko copper orebodies, which were being developed concurrently with the concentrator construction The Warrego concentrator consisted of a flotation circuit, using autogenous grinding at 100 - 120 tph, compared to the more elaborate Peko circuit employing rod mill - ball mill grinding capable of treating only 18 - 26 tph. During development of the Warrego copper mine a gold rich ore pod was located, because of which the mining plans were adjusted to allow simultaneous, separate extraction of the copper and gold ores. However, the plans for the concentrator were not affected as the gold ore could be carted 60km to the Peko central mill for processing.

Jan 1, 1978

By J C. de Vries

When times are tough in the mineral industry û as they have been for some time û typical responses by mining companies are to cut costs and/ or increase production. The latter is seen to spread fixed costs, thereby also reducing unit costs per tonne mined. However, most mineral deposits respond to increased production rates by lowering ore grades, so the reduction in cost per tonne of ore does not necessarily result in a reduced cost per unit of metal produced. The authorsÆ experience is that this process often leads to a mine plan that is a long way from optimal. Producing to the point where marginal cost equals marginal revenue may work well in a manufacturing operation, but it is not necessarily the best strategy for a mining company with a depleting resource. Variations in tonnage and grade with depth, ore reserve optimism and a variety of other factors conspire to produce variations in production rates and grade that often result in suboptimal outcomes and potential mine failure. Added to this is the focus of industry analysts and senior corporate management on such measures as unit costs and ounces in reserves. This is perceived to have the perverse effect of driving the share price down when strategies are adopted that actually improve the value of the mining operation, and vice versa! Many mine failures can be prevented by a close examination of the tonnage grade curve and an understanding of how margins, net cash flows and resulting business risk change with cut-off grades and rates of production. A few relatively simple analyses early in the evaluation of a project can demonstrate the tradeoffs between the main decision parameters, leading to right-sizing of the operation. Once major commitments to major capital items have been made, and reserves have been publicly reported, optimisation of the operation becomes much more difficult than if it had been done earlier. Such investigations can also identify the upside potential and downside risks associated with factors outside the companyÆs control. Many strategies that may enhance value in the good times significantly increase the downside risk in the bad times. What is often called risk analysis typically looks at superficial issues, and does not evaluate the major factors leading to the potential for financial disaster. This paper illustrates some of these major risks, and demonstrates how they may be fully evaluated so that corporate decision makers can make fully informed decisions that take account of the real risks.

Jan 1, 2003

By Grinbaum B, Stevens G. W, Dalton R. F

Many hydrometallurgical processes produce large amounts of acid waste. This is illustrated by the copper S/X-E/W process which produces a bleed from the electrolysis tank house in the form of a concentrated sulphuric acid stream. Currently, the bleed stream is necessary to remove impurities such as iron that decreases the efficiency of the electrowinning process. However, this comes at a high financial cost owing to large quantities of make-up sulphuric acid required. A process has thus been developed with Zeneca Specialties (UK), ICI Australia and Gunpowder Copper Co at the University of Melbourne for the recovery of sulphuric acid from copper tank house bleed liquor. The recovery process uses the method of solvent extraction. Solvent extraction has the advantage of being a well-established technology in the mining industry and will reduce the environmental impact of the S/X-E/W process, as all additional chemicals can be completely recycled. A simplified diagram of the process is shown in Figure 1. Tank House

Jan 1, 1997

By G W. Wilson

Net solar radiation is one of the key factors affecting evaporation from soil covers on waste rock dumps. While net solar radiation is normally taken as a uniform parameter over a site for modelling purposes, there can be significant variation in the radiation actually received on various portions of the dump. These variations are a function of the difference in the cover slope and direction of exposure. A predictive model has been developed to calculate the actual radiation received on the dump surfaces, based on the net radiation data measured at a weather station on a horizontal surface. The model has been designed for application at any mine site in the world, and can be used in conjunction with evaporative flux models to help estimate the effect of three-dimensional variations in the cover surface exposure. The waste rock dump at Equity Silver site (located in British Columbia, Canada) has a barrier-type soil cover system to limit oxygen entry and water infiltration. This cover has been monitored for the past nine years. The new net solar radiation model has been applied to this site and the predicted net radiation was compared to the values of actual net radiation measured on the site. The predicted variations in net radiation over the three-dimensional surface of the waste rock dump have been applied to calculate spatial variations in potential and actual evaporation (or evapotranspiration) from the site. Preliminary analyses indicate actual evaporation from a site at this latitude could vary by a factor of two for exposed versus shaded slopes. The implications of these variations for the site are considered.

Jan 1, 2003

Mechanical and electrical (M&E) systems in road tunnels are constrained by the traffic envelope and the construction profile. Whilst these spatial constraints are often ælocked inÆ early in the design process, the detailed M&E design continues for some considerable time after key civil engineering issues have been resolved. Ventilation design criteria for both normal and emergency operation often involves considerable negotiation with a wide range of stakeholders. Final system performance and spatial requirements are only finally resolved when suppliers are selected following the tender process. Lighting design is dependent upon a wide range of factors including tunnel lining materials and associated colours as well as agreed maintenance regimes. Cabling systems can only be developed when the general arrangement for power distribution is agreed and a system of substation, switchrooms and equipment rooms is in place. Many other systems such as fire protection and communications facilities fill the available space beyond the traffic envelope, where physical, structural and æsight lineÆ requirements must all be accommodated. The more co-ordinated civil engineering and M&E design is and the earlier the process starts the better the outcomes for all parties.

Jan 1, 1999

By J A. van Niekerk, J G. Jardine, J W. Olivier

The Runruno Gold Project is located on the island of Luzon, approximately 200 miles north of Manilla in the Philippines. The mine is an open cut operation and uses the proven BIOX® and carbon-in-leach (CIL) processes to recover gold, and the ASTER™ process for detoxification of the CIL residue prior to discharge to the Residue Storage Impoundment (RSI). Work to date has defined a mineral resource of 1.39 million ounces (Moz) of gold, and the operation will produce 96 700 oz of gold per annum over a mine life of 10.4 years. The BIOX circuit is designed to treat 140 000 t/y of concentrate with a design capacity of 404 t/d of concentrate at a design sulfide sulfur grade of 17% S2-.The Runruno BIOX Plant is the first application of the Outotec BIOX Generation III design principles, focussing on ease of operation and maintainability. During development and implementation, the project team focussed on identifying opportunities to optimise the capital efficiency while not compromising on the operability or overall efficiency of the process or the equipment. The BIOX plant also incorporates the latest developments in the design of the BIOX agitators for more efficient mixing and gas dispersion. This paper will discuss some of the critical aspects and decisions taken during the development and implementation of the BIOX Process at the Runruno Gold Project. The paper will highlight some of the factors affecting the commissioning process as well as the improvements seen through the introduction of the Generation III BIOX design principles. CITATION:van Niekerk, J A, Olivier, J W and Jardine, J G, 2017. Implementation of the BIOX® process at the Runruno Gold project, in Proceedings MetPlant 2017, pp 218–228 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

For some time fine coal (-0.5 mm) flot ation has been considered as a bulk flotation problem. Combinations of hydrocarbon oils and frothers have been used as surface active agents in coal flotation. The selectivity of the flotation process has always been poor in such cases. With the increase in fine coal production due to mining methods and coal handling systems, optimisation of fine coal treatment.has become important. Petrographic and mineralogical composit- ions of coal particles have been reported to influence their flotability. The problem becomes more complex due to surface oxidation of coal and the presence of slime forming clay minerals in the run of mine coal. In this paper, the flotation problem is examined on the basis of various constituents of coal and their associated gangue minerals. The selection of reagents has been suggested on the basis of their surface chemical properties. Factors such as surface modific- ation of coal and gangue materials, flotation kinetics and hydrocarbon oil - coal inter- action have been critically evaluated to improve fine coal flotation recovery.

Jan 1, 1978

By J Langhans, Y Choi, Q Wang, J Y. Baron, P Kondos

Barrick has successfully developed the thiosulfate leaching process to treat sulfidic high preg-robbing ores. The process was developed through rigorous bench test programs and proved in pilot campaigns and demo plant operations. The process uses calcium thiosulfate as a leaching reagent, resin for gold recovery with sulfite/trithionate elution and reverse osmosis as a mean of reagent recovery. The thiosulfate leaching plant is under construction as a brownfield project and the start-up is planned in 2014 at Goldstrike, Nevada, USA, one of BarrickÆs operations.CITATION:Choi, Y, Baron, J Y, Wang, Q, Langhans, J and Kondos, P, 2013. Thiosulfate processing - from lab curiosity to commercial application, in Proceedings World Gold 2013 , pp 45-50 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

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 B Kretschmer, G Bartel, B de Villiers, W Watt

"The Nyrstar Port Pirie Smelter, located on the eastern shore of the Upper Spencer Gulf in South Australia 230km north of Adelaide, began operation in 1889 to process lead concentrate from the Broken Hill lead and silver mines. The site still operates an updraft sinter machine, commissioned in 1955, with the product fed into a blast furnace. While sinter plant technology has changed and improved since 1955, development has reached the stage where further enhancements are not possible or economic. High purity lead concentrates command lower margins and for the smelter to remain economically viable a wider range of higher value materials must be treated. The current flowsheet cannot meet this demand. Additionally, community blood lead levels particularly in children below four years of age, are a critical indicator used to measure the site’s environmental performance. The smelter’s environmental licence to operate is dependent on meeting future community and regulatory expectations. To achieve this a major step change in the emission performance of the smelter is required. Since 2008 pre-feasibility work has been undertaken to develop a new flowsheet and business model to allow Port Pirie to operate sustainably into the future. The main requirements were for the smelter to reduce lead and sulfur dioxide emissions that impact on the local environment and community to meet current and future environmental expectations, as well as dramatically reducing current feed constraints and change the business case from a marginal business to a sustainable profitable business. After reviewing all practical options a decision was made to replace the sinter plant with an Outotec Top Submerged Lance (TSL) furnace. This paper describes how the new furnace technology was selected and how it will be integrated into the present flowsheet; the unique funding arrangements that are in place to deliver the redeveloped site; and future opportunities that are associated with the implementation of the new flowsheet. CITATION: De Villiers, B, Bartel, G, Watt, W and Kretschmer, B, 2015. Nyrstar Port Pirie redevelopment, in Proceedings MetPlant 2015, pp 325–337 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 7, 2015