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By I T. Cameron

The commercial production of copper metal involves a sequence of purification stages. One step of this process eliminates bulk quantities of iron and sulphur from matte Cu2S(FeS to produce blister containing 95.5 per cent copper. This task is traditionally performed in the Pierce-Smith converter, a cylindrical vessel in widespread use throughout the copper industry. Typically, multiple Pierce-Smith converters are arranged along an aisle, simplifying material transfer from vessel to vessel. Materials are moved through the aisle in pots and boats, using overhead cranes. In terms of the overall process, the converter aisle represents a critical processing unitùit contributes significantly to the value added nature of the metal. The aisle is subject to significant process disturbances. Thus, improvements in the operationÆs modes and conditions have a direct impact on process profitability. As with any commercial operation, improvements are always sought to increase process performance. The general approach involves process modelling, followed by an application of control and optimisation theory to this model. The results of such a study are then applied to the real process, leading to improved performance.

Jan 1, 1998

By C Tapia Cortez, A G. Dempster, R Fradet, S Saydam, T de Roche, R Shishko, J Coulton

Human ventures into space are entering a new phase in which missions formerly driven by government agencies are now being replaced by those led by commercial enterprises – in launch, satellite deployment, resupply of the International Space Station and space tourism. In the not-too-distant future, commercial opportunities will also include the mining of asteroids, comets, the Moon and Mars. This research examines the role of off-Earth mining in a growing space economy. In this investigation, the term ‘mining’ is taken to embrace minerals, ice/water and other in situ resources. As the off-Earth mining initiative could be the engine that drives the space economy, it would be useful to understand what off-Earth mining market conditions and technology requirements are needed for that economy to prosper. These specific elements are studied in the wider context of creating an economy that could ultimately support a sustainable Mars colony. The methodology for developing the model focuses on the extraction of ice from the surface of Mars to produce propellant and water for life support for a possible colony.CITATION:Saydam, S, Shishko, R, Tapia Cortez, C, de Roche, T, Fradet, R, Coulton, J and Dempster, A G, 2015. An integrated economics model for in situ resource utilisation in support of a Mars colony, in Proceedings Third International Future Mining Conference, pp 305–312 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By Sano S, Ishikawa T, Nagaoka H, Hayashi Y, Hasegawa M

The stirred mill is regarded as one of the most efficient devices for micronising materials and has come to be actively used for preparation of fine particles. Recently, the demand for ultrafine particles was increased in many kinds of industries. In this paper, autogenous grinding to get submicron particles based on mutual friction feed material has been carried out using a stirred mill. The mill used was made of stainless steel and its volume was about 5.5 litres, and has 12 impeller blades. Sample used was limestone. In the present work, two operating parameters such as stirring speed and feed size of limestone were considered. The ground products were sieved in the size range from feed size to 325 mesh (45 lun), and from 45 to 0.17 pm the size distributions were measured by a laser diffraction and scattering method. The progress of grinding was evaluated by the increasing amount of submicron particles in products. As a result, the rotational speed of impeller with the minimum energy consumption to produce submicron particles was observed. It was found that the autogenous grinding with a stirred mill is an effective method for producing submicronized limestone.

Jan 1, 1993

By K L. Avarmaa, M A. Rhamdhani, A D. P Putera, H T. B M Petrus, G A. Brooks

Multistage slag treatment was carried out to investigate boron removal from metallurgical grade silicon. Boron is known to be one of the most difficult elements to remove from silicon. Depending on boron initial concentration, boron can be removed from silicon into certain level; most previous studies have attained final 50–100 ppmw (parts per million weight) boron in the silicon using slag treatment. The term ‘multistage’ refers to a process where the resulting silicon from the initial slag treatment is further refined multiple times using a new slag. In this study, an initial slag composition of 45CaO-45SiO2-10Al2O3 (wt per cent) was utilised. Using this technique, boron level in the silicon was expected to be gradually lowered because the new slag will always have more capacity to reach the equilibrium distribution coefficient (LB = (ppmwB)slag/(ppmwB)Si). The current study was carried out through combined thermodynamic calculations (using FactSage™ ver 8.2, by Thermfact Ltd, thermochemical package) and high-temperature experimentation. The thermodynamic calculations were carried out for reactions at 1500, 1550, and 1600°C for three different scenarios: 1. Single stage refining with varied slag to Si ratio. 2. Multistage refining with slag to Si ratio of 1:1. 3. Multistage refining with slag to Si ratio of 2:1. The multistage experimental work was carried out at 1550°C under inert gas atmosphere each time for 2 hrs, with slag to Si ratio of 2:1. The simulation results indicate that the boron distribution coefficient stay essentially constant with varying slag to Si ratio and temperature, around 1.8 to 2, and the experimental results measured LB in the same range, between 1.5 and 2.5. By harnessing this feature, the simulation showed that boron can be removed by approximately 78 per cent in each stage. The experimental result confirmed that the boron concentration in the silicon was reduced by a total of 97.8 per cent from its initial value using four stages of slag treatment, from initial 270 ppmw down to 6 ppmw.

Aug 21, 2024

THE plant is one of the usual type of Mond plants, and contains no new features worthy of comment. A brief description of the process, however, with a few remarks on the working of the plant, may prove of interest.Producer gas is made by passing a mixture of air and steam through incandescent carbon contained in a furnace called a producer, which, in the Mond type, is a cylindrical casing of steel plate, lined with firebrick, and fitted at the lower end with sloping fire-bars'. Coal crushed to an even size (about 2-in. gauge) is elevated to bunkers over the producers, from which it is fed into a measuring hopper on each producer.The hopper is a cast-iron cylinder fitted with a swing cover at the top and a bell valve at the bottom, worked by a lever and balance weight. When a charge of coal is run from the bunker into the hopper, the cover is closed, and the bell valve is lowered, allowing the coal contents to drop into the producer. Thus no gas can escape from, or air be admitted to, the producer during the process of charging. The hopper discharges its coal through a steel pipe-shaped container called the bell, which projects about 9 in. through the roof of the producer. The function of the bell is to spread the coal evenly over the fire, and supply coal to any portion of the fire as it settles.

Jan 1, 1918

The Kunwarara magnesite deposit is the largest known magnesite (MgCO3) deposit in Australia. It is located under black soil plains to the north of Rockhampton in Queensland. The deposit consists of magnesite nodules set in a fine-grained sandstone, siltstone and mudstone matrix. The magnesite is derived from weathering of serpentinite in adjacent hills and transport of magnesium in solution to a Tertiary/Quaternary river system. The magnesium has come out of solution in the active river system, and combined with atmospheric and biogenic CO2 to form magnesite nodules. The magnesite can be very pure with certain varieties up to 98 per cent MgO (LOI free). The deposit has been mined since 1991 and processed into magnesia (MgO) which is sold into refractory, agricultural and other markets. The geologist is an integral part of the small mine technical team. The role of the geologist includes characterisation of the ore through drilling and bulk sampling, supervision of geological aspects of mining and assistance in the optimisation of ore processing.

Jan 1, 2000

AT Broken Hill, N.S.W., where flotation is tbe final stage in concentration, the gangue minerals are discharged as an aqueous pulp, and water recovery from the pulp being essential, provision must be made for the clisposal of the solids and for the return of the clear water to the cemcentrating mill circuit. This water also contains an appreciable quantity of flotation reagents, and is more effective for flotation than supply water.In the development of a scheme for the disposal of large quantities of residues, several of the more important factors for consideration are:(a) Tonnage to be handled.(b) Grain size of residues and pulp density.(c) Dewatering of residues and return of clear water to mill circuit.(d) Possible uses of residues.-A varying proportion of sand residues is used for underground filling, and to a limited extent for yoncrete making and other engineering work.(e) Choice of a suitable dumping area. - Before deciding upon this area consideration will be given to possible future operations so that the dump will not be likely to interfere with any development which may be necessary. Again, residues dumped at the present time as worthless or...

Jan 1, 1927

The economically significant seams in the Bowen Basin fall into four age groups, two in the Lower Permian and two in the Upper Permian. Coal deposition in the Galilee Basin did not commence until late in the Lower Per- mi-an and persisted into the Upper Permian. The Lower Permian and early Upper Permian coalfields of the Reids Dome Beds, the Collinsville Coal Measures and the Fair Hill-German Creek Formation are restricted to the west flank of the Bowen Basin. The uppermost Permian Rangal-Elphinstone-Baralaba Coal Measures have widespread distribution across the northern half and on both flanks of the Basin. Coal Measures in the subsidiary basins at BlairAtho/ and Ca/en were probably deposited at the same time as the Collinsville Coal Measures. The structure of the north west flank of the Bowen and the east flank of the Galilee Basin is essentially simple, but in the remainder of the basin doming and faulting complicate the structure. Also, bordering a large sec- tion of the east flank, is the Dawson Tectonic Zone, where the beds are tightly folded and faulting is intense. Cok- ing of seams is common in the northern sector of the Basin associated with igneous intrusion. With the exception of the Duaringa Basin on the east flank of the Bowen Basin, Tertiary sediments and basalt flows are more common at the western basin margin. Thick deposits of Tertiary sediments also occur in the south of the Galilee Basin. Con- sequently, coal subcrop, especially in the older, more westerly situated, coal measures is often at depths in excess of 100 m. East of this, the depth of weathering can be as shallow as 13 m and most of the coal subcrop is acces- sible to mining by open cut techniques. Coals deposited in the early Upper Permian are commonly more vitrain rich than those above and below. In the Bowen Basin, coal rank decreases from the north west to the south east, that is, from the semi-anthracites associated with the Dawson Tectonic Zone to the sub-bituminous coals of the southern Galilee Basin.

Jan 1, 1975

By J Zhou, D M. Hunter, S M. Iveson, K P. Galvin

The recovery and concentration of ultra-fine iron ore can provide significant economic benefits. Presently, there are limited options available given the low settling rates achieved by conventional gravity separation and the relatively poor performance of reverse flotation. The Reflux Classifier is a new water-based gravity separation technology that consists of a set of parallel inclined channels positioned above a vertical fluidised section. This arrangement promotes a powerful throughput advantage compared to conventional fluidisation and a highly selective hydrodynamic basis for achieving sharp separations. A high shear rate develops within the inclined channels, which generates sufficient hydrodynamic lift to convey the lower-density particles (even if they are relatively coarse) to overflow while retaining the high-density particles (even those that are ultra-fine) for discharge to the underflow. The technology has previously been used around the world on particle sizes in excess of 0.1 mm. The present work, however, is concerned with density-based separations down to much finer particle sizes approaching 0.01 mm.A major advantage of the Reflux Classifier technology is the achievement of simultaneous gravity separation and desliming via a single-stage separation. A series of continuous experiments was conducted using an iron ore feed with head grade of 35 wt per cent FeT and nominal top size of 0.106 mm, with 59 wt per cent being below 0.038 mm in size. At a low throughput of 1.5 t/(m2 h), the Reflux Classifier produced high-grade products at a high recovery. For the entire feed, grades of 66.1 wt per cent FeT with Fe recoveries of 80 per cent were achieved in a single-stage separation. Within the 0.020–0.038 mm size fraction, grades of 68.8 per cent were achieved with iron recoveries of 94.7 per cent. Excellent recoveries of up to 57.0 per cent were achieved for the -0.020 mm size fraction. The ability of the inclined channels to retain the fine dense material further enhances the effectiveness of the Reflux Classifier by creating an autogenous dense medium effect within the vertical section. This helps to elevate large gangue particles up into the overflow.CITATION:Hunter, D M, Zhou, J, Iveson, S M and Galvin, K P, 2015. Gravity separation of ultra-fine iron ore in the reflux classifier, in Proceedings Iron Ore 2015, pp 143–148 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

The south-east Missouri cobalt-copper-lead-zinc district is the worldÆs largest lead producer and a significant producer of by-product zinc, copper, cobalt, silver and cadmium. Current production in the district comes from six or seven mines in the Viburnum Trend. Most ores in the Viburnum Trend are characterised by a small number of minerals with simple compositions. Portions of some orebodies contain ores that exhibit greater variations in mineralogy, and these include shale-hosted lead- copper ores, bornite ores and nickel-arsenic sulfide ores. Ore textures include both replacement and open space filling textures, and the paragenetic sequence for the ores is characterised by repetitive periods of deposition of all of the ore and gangue minerals. Ore microscopy is an effective tool for not only the identification of the minerals and textures shown by the ores, but also to determine the mineralogy and textures responsible for beneficiation problems. An interesting variety of sedimentary and structural ore controls have determined the locations of individual orebodies in the district. Based upon the positions of orebodies with respect to Precambrian ridges and knobs, together with areal patterns of mineral/metal zoning, it is interpreted that the ore fluids came from diverse directions to form the deposits in the district. It is concluded that the Old Lead Belt subdistrict was mineralised by fluids that flowed from the north-east and north-west, the Fredericktown area by fluids from the north-east, the Indian Creek subdistrict by fluids from the north-west and the Viburnum Trend by fluids from the north-west and west.

Jan 1, 2008

By R Talebi

A research project to better understand the rock mass behaviour and the seismic response has been conducted during the design and construction of the 9215 level at the E-Block sector of the Northern Star Kanowna Belle Mine. The research program was undertaken at a tunnel located 1100 m below the surface with the results applicable to feasibility studies on underground mining projects in highstress conditions, where failure can occur very soon after tunnel construction. Semi-circular excavation shapes coupled with the use of de-stress blasting techniques were designed to monitor the excavation in conditions of very high stress. The ground support was designed considering high energy dissipation ground support schemes (HED) as described by Arcaro et al (2021). The results indicate a decreased rock mass demand due to the change of excavation shape. Also, localised reduction in rock mass stiffness was achieved due to the implementation of de-stress blasting. Finally, increased ground support capacity was gained by the implementation of the high energy dissipation ground support schemes. The Kanowna Belle Mine has significant ore reserves at depths exceeding 1000 m below the surface. The results of this research will be used to optimise the extraction of the remaining E Stoping Block at depths exceeding 1350 m.

Mar 29, 2023

By Moylan T, Stewart D

A case study examining the procedures and financial benefits of introducing dump leaching to augment the Mt Gibson Gold Project CIP operations is discussed. Metallurgical testwork, followed by pilot dump leach operations, confirmed that gold recoveries of greater than 60 per cent could be achieved by dump leaching Mt Gibson laterite ore. Capital and operating costs were determined. Pit optimisation using the Whittle FOUR-D optimisation program calculated an optimum cutover grade between CIP and dump leaching for one orebody. The resultant recalculation of reserves based on CIP and dump leach operating costs showed that reserves for that orebody could be increased from 329 000 tonnes at 1.9 g/t An, to 1 488 000 tonnes at 1.2 gh An. NPV for the CIP only option of $1.4 m, was increased to $4.0 m for the combined CIP/dump leach option. This technique can be applied to existing gold projects and to new Developments.

Jan 1, 1992

The Emmaville district is located in the northern part of the New England region of New South Wales some 400 miles north of Sypney. Better known for its substantial production of tin and tungsten ores, the Emmaville district has also been the centre of a small and somewhat sporadic production of copper, arsenic, silver, lead and zinc. This production has come principally from three mines-Webb's Silver Mine, Webb's Consols and, to a lesser extent, Pye's Creek Silver Mine.The ores from these mixed sulphide deposits are texturally and mineralogically complex and the problems of beneficiation are rather formidable.GENERAL GEOLOGYThe main rock type of the Emmanville district is a dark, brown to blackish massive siltstone of Permian age which overlies acid volcanics possibly also of Permian age. In places the siltstone gives way to conglomerates and standstones with discontinuous lenses of calcareous sediments (David, 1887).The whole series is folded but because of the massive character of the more expansive siltstone, detailed structure is difficult to delineate.Toward the close of Permian time the area was intruded by a series of intermediate to acid plutonic and hypabyssal rocks. Mineralization within the region is ascribed to the more acid of these intrusives-granodiorite, granite, and quartz-felspar porphyry (Lawrence, 1957, 1960).No intrusive rocks outcrop in the immediate neighbourhood of Webb's Silver Mine though granite occurs two miles...

Jan 1, 1961

By Laros T, Schoenbrunn F

Deep paste thickeners have been proven capable of consistently producing medium to low slump material for disposal without the need for filters. However, proper design of the entire system is critical for a paste project to he successful. Some of the factors that must be carefully considered in design of a paste system include thickener sizing, tailings inipoundineni design, underflow pumping, and control system.

Jan 1, 1998

Maintaining and improving the economics of open pit mining in the future requires understanding of the characteristics of open pit mining that are different to other mining or business activities, designing mines in the first place to be less susceptible to changes in these important characteristics, and adopting strategies which yield reliable returns despite unforeseen change. Planning and production personnel require guidelines and performance standards that are based on sound economics not solely on production criteria. The guidelines adopted for long-term implementation must assume a declining price for mineral products along with declining real costs, with research efforts directed at development of both evolutionary and revolutionary ideas aimed at implementation. Decision-making must focus on risk and probability criteria rather than just simple return-on-investment criteria, and the approach for management of personnel must support the higher level of communication essential for fast decision-making in the new environment of continual change.

Jan 1, 1992

By K Williams, T Donohue, W Chen, T Roessler, A Katterfeld

Wet sticky iron ore poses particular difficulties in every aspect of the material handling process. Material hang-ups in bins, pipes and chutes; carry-back and spillage due to insufficient belt cleaning; clogging of screens; malfunctioning of crushers as well as rat holing of gravity reclaimed stockpiles are all predominantly due to the inherent cohesion and adhesion characteristics of the wet, sticky ore (Roberts, 1993). Limited understanding and quantitative measures on the stickiness of such a material significantly lower the mining operation efficiency.This research aims to investigate the cohesion and adhesion characteristics of the wet, sticky ore on physical modelling, experimental techniques and numerical implementation. Initially, the suitable bridging mechanism that contributes to the cohesive and adhesive forces within the iron ore material was identified (Hering, Martin and Stohrer, 1989; Rumpf, 1958). A cohesion/adhesion energy density factor based contact model was then introduced to describe the stickiness of the material. Secondly, an experimental system was proposed to directly test the stickiness of the material. Such a system is able to obtain both the cohesive/adhesive shear force and tensile force of the material at a specific moisture content. Lastly, the implementation of the proposed cohesion/adhesion model into the discrete element modelling (DEM) software was also discussed. A cohesion/adhesion calibration for modelling wet sticky iron ore in DEM was then conducted to ensure the material modelled in the simulation is reflective of the reality.From the study, understanding of the cohesion/adhesion characteristics of the wet iron ore material is significantly enhanced. Experimental and numerical outcomes can be directly applied for better designing or optimising the material handling processes that involve wet sticky iron ore. Consequently, the mining operating costs can be greatly reduced.CITATION:Chen, W, Donohue, T, Williams, K, Katterfeld, A and Roessler, T, 2015. Modelling cohesion and adhesion of wet, sticky iron ores in discrete element modelling for material handling processes, in Proceedings Iron Ore 2015, pp 387–392 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By C Mason, A Littleboy

This paper presents the results of a large scale survey of The Australasian Institute for Mining and Metallurgy (AusIMM) membership. This survey aimed to understand and define the key issues and drivers that AusIMM members perceived would shape the development of the Australian minerals industry over the next 20 - 30 years. Nine hundred and fifty-nine participants rated the importance of 11 issues and six drivers (generated from interviews with AusIMM members), and 236 of these participants also provided qualitative descriptions of the future. Issues were defined as problems or opportunities for the minerals industry that may be controlled or influenced by the industry, while drivers were defined as those factors that will influence the direction of the industry that are not within the control of the industry. The quantitative data revealed that the top four issues, in order of their perceived importance to the Australian minerals industry, were: investment in exploration, workforce, health and safety, and innovation. The top three drivers in order of their perceived importance, were: economics of mining, global context and Australian society. While the top four issues were largely consistent across professional groups examined, metallurgy and mineral processing professionals rated water inputs and energy inputs significantly higher than the other professional groups. For the list of drivers, there was strong agreement regarding their ranked order of importance across the professional groups examined. Within the qualitative data, however, a single issue (technology) and a single driver (economics of mining) dominated participantsÆ descriptions of the future. These findings provide important input into a broader program of scenario development for the Australian minerals industry being undertaken by CSIRO and its partners. The results of this study demonstrate the importance of using a mixed methodology in generating these inputs to understand more fully how important stakeholders view the future and the factors that will shape it. The results of this study are also discussed with respect to the role that CSIRO may play in facilitating the exploration of uncertainty around the future of the Australian minerals industry.

Jan 1, 2009

By A Jyoti, J R. Black, R R. Haese, E O. Ansah

Copper (Cu) is a critical metal in the transition to a low-carbon power supply. Presently, low-grade copper sulfide ores account for almost 80 per cent of the global reserves. Large amounts of water are required to process these low-grade copper ores. The mining industry utilises lixiviants from recycled water from different sources to conserve water, whilst enhancing Cu recovery. Some utilise intermediate to pregnant leach solutions, sea water, and processed water from electrowinning circuits with highly variable concentrations of ions. Previous studies have highlighted the formation of precipitates that passivate the surfaces of minerals in these low-grade copper ores and/or block flow paths for lixiviant during heap leaching. In this study, we utilised concepts of phase replacement to devise an innovative means of controlling precipitation and increasing copper recovery using industrial brine as opposed to freshwater. We propose the formation of Al-rich phases (such as AlSO4 + or alunite) to replace iron sulfate and iron hydroxysulfates (such as jarosite) during the chalcopyrite dissolution-precipitation mechanism. The rationale is to have available Fe3+ throughout the chalcopyrite leaching process. We tested this method by carrying out various batch experiments using CaCl2, AlCl3, and NaCl industrial brine types compared to freshwater and explored the capacity to leach Cu from chalcopyrite. There is higher Cu recovery during oxidative leaching of chalcopyrite in industrial brine with 91 per cent recovery using AlCl3-rich brine, 84 per cent with NaCl-rich brine, and 56 per cent with CaCl2-rich brine as compared to 35 per cent recovery using freshwater. In the absence of Al3+, various forms of iron sulfates, and jarosite are formed, reducing the availability of Fe3+ for chalcopyrite dissolution. The introduction of Al3+ leads to the formation of AlSO4 + species, thus lowering sulfate activity and the tendency for K-jarosite formation.

Aug 24, 2022

By Hare S. M, Lumsdaine I, O&apos

Converter slag assaying 3.7 per cent Cu is produced by Mount Isa copper smelter at a rate of up to 180 000 tonnes per annum.Priority is given to the processing of ore, however concentrator capacity periodically exceeds that of the mine and the opportunity is taken to treat converter slag. It is processed in batch campaigns, typically through the Copper Concentrator, but the Hilton Concentrator has also been used. Slag and ore are kept as separate as possible, since each has an adverse effect on the flotation performance of the other.

Jan 1, 1993

By M Dean, M Nehring, P Knights, M S. Kizil

Integrated continuous mining techniques such as fully mobile in-pit crusher and conveyor (FMIPCC) systems offer inherent labour, energy and environmental benefits to deep pit metalliferous mines. However, before such systems become commonplace, a number of barriers must be overcome.This paper outlines a number of commonly perceived barriers to FMIPCC application, together with a number of suggested solutions. The paper advances a design approach for specifying FMIPCC systems for deep pit metalliferous applications. A novel FMIPCC configuration is advanced using a hydraulic excavator in backhoe configuration. Because of the requirement to minimise belt extensions, a mine planning approach is presented based on a series of parallel and radial belt conveyor moves.The FMIPCC system does not fully replace truck-shovel systems. In the proposed mine plan, sinking is undertaken with truck-shovel systems using a series of box cuts, whereas pit ‘widening’ activities are accomplished via the FMIPCC system. Because of inherent differences in mine sequencing, the net present value derived from the FMIPCC mine will differ markedly from that derived from traditional, nested-pit, truck-shovel mining approaches. Therefore, any comparison of the FMIPCC and truck-shovel approaches must take into account radically different mine planning approaches.CITATION:Dean, M, Knights, P, Kizil, M S and Nehring, M, 2015. Selection and planning of fully mobile in-pit crusher and conveyor systems for deep open pit metalliferous applications, in Proceedings Third International Future Mining Conference, pp 219–226 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015