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By J McQuie

The concentrator at WMCÆs Leinster Nickel Operation has operated with flash flotation in the grinding circuit since the early 1990s. There has always been a positive correlation between flash flotation Ni recovery and overall Ni recovery û however this relationship could be explained by differences in the ore, rather than by the action of the Flash flotation cell in reducing overgrinding of Ni. In July 2003, refurbishment within the plant made it necessary to operate the concentrator for a period with the flash flotation cells off. The resulting data set provided evidence that flash flotation in the grinding circuit changes the size distribution of Ni to reduce the amount of slow-floating fine (-7 ¦m) Ni produced. Ni recoveries in the finer size fractions were similar with flash flotation on or off û but because less fine Ni is produced when the flash flotation cells are operated, overall Ni recovery improved.

Jan 1, 2005

The geologists at the Zinc Mine in Broken Hill have developed a method of logging core using portable MS-DOS computers and LOTUS 123. The computer based logging system has almost halved both the time and cost to produce a completed log. The system is fast, flexible, easy and pleasant to use.

Jan 1, 1990

The ER&S Company operates a copper sinter plant, blast furnace and converter smelting complex at Port Kembla. Eighty percent of the smelter feed is dirty copper concentrates that contain some lead and zinc. The remaining twenty percent of the smelter feed is copper bearing secondary materials, some of which contain lead, zinc and tin. A predominately lead/zinc fume is produced during the smelting and converting of this feed mix. The composition and tonnage of fume produced at Port Kembla has varied over the years as the smelter feed sources have changed. The economic processing of the fume has always been dependent on the value of the metals contained in the fume and on the fume composition. Both pyrometallurgical and hydrometallurgical methods have been used to treat the fume for the recovery of some or all of the following metals - lead, zinc, tin, copper, cadmium, silver and bismuth. A detailed description of the treatment methods that have been investigated and used to process ER&S fume is given.

Jan 1, 1984

Alluvial gold exploration is aimed at recognizing areas of anomalous gold content as evidenced by the nature of the drainage system, its age, geomorphic history and other features of the geological environment including the provenances. Subsequent studies to quantify the findings are governed by the need for accurate data based upon precise measurements. Computerization allows the use of more complicated mathematical procedures than are feasible manually, thus promoting the development of more advanced technological aids. Data banks provide the means of storing vast quantities of information for instant recall.Sample representivity is a major problem and a clear understanding of both sampling and analytical requirements is essential for dealing with problems arising from variations in sample size and particle size distribution. Field samples must always be large enough to ensure adequate representivity or the sampling has failed in its purpose.

Jan 1, 1984

By H Peiming, W Sakurai, Y Matsuhisa, H Shimazaki, Y Fukahori

Oxygen and carbon isotope mapping of hydrothermally altered wall rocks was applied to the blind ore prospecting of skarn Pb-Zn deposits in the Kamioka mining district, centralJapan, where the wall rocks consist of heterogeneous rock units. The results (d18OSMOW of -1.1 to +17.3ë and d13CPDB of -5.0 to +4.8ë for limestones, and d18OSMOW of -0.8 to +12.5ë for silicate rocks) show isotope zonations of the wall rocks with depletions in heavy isotopes (18O and 13C) toward the centre of mineralization. The isotope zonations likely formed by interaction of migrating thermal waters with the wall rocks during the mineralisation. The heavy-isotope depleted zone, which indicates higher temperature or higher water-to-rock ratio of the system, occurs in the footwall of a fault, indicating that the fault played the role of main conduit of the ore-forming fluids. A heavy-isotope depleted zone was also found in an area, where significant mineralisation had yet to be identified. Recent drilling in this area has intercepted a zone with a grade of 16.0% Zn, 0.8% Pb, and 35g Ag per metric tonne at a depth of about 360 m.

Jan 1, 1995

Lihir Gold Mine is situated in a dormant volcanic caldera on a small island off PNG. Not æextinctÆ but dormant. Current ground temperatures are up to 150 degrees Celsius with active geysers in the workings of the mine, pools of boiling ground water adjacent to low-grade dumps and hydrogen sulphide gas emissions. It is a unique mining environment by world standards. This paper will deal with the following issues encountered and managed by the operation:blasting in hot and reactive ground; management of sulphide gas emissions; disposal at sea of all mining waste rock; one dear to all Australian minerÆs hearts û dealing with landowner groups; and unusual human resource issues.

Jan 1, 1999

Aitik, a Boliden owned and operated open pit mine located in northern Sweden, will expand production from 18 Mt per year today to 36 Mt per year copper ore during 2010. The challenge for the mine operation is to double production with a planned increase of the shovel and truck fleet of only 50 per cent. This will be achieved through improved shovel and truck utilisation and productivity. In early 2005 Aitik started projects to enhance the utilisation of truck engine hours and to reduce fuel consumption. Both projects were successful, within a year efficient2 utilisation of engine hours increased from 60 per cent to 75 per cent and fuel consumption was reduced by six to eight per cent. The truck utilisation project focused on minimising idle truck hours by for example four operators on three trucks thus reducing idle engine hours to minimise lost time for breaks and shift changes. Other measures included focusing on improved dispatch usage, parking trucks when overtrucked, etc. Eco-driving was a project together with Swedish Road Administration with the objective to combine economical and environmental savings. To keep the focus on eco-driving a reward was set up for the shift team with the lowest fuel rate over rolling 15 weeks periods. Both activities included a comprehensive training program for mine foremen, dispatchers and truck operators focusing on efficient use of trucks from economic driving to optimised truck dispatching and minimising idle engine hours. Online monitoring of trucks activities and fuel consumption combined with continuous reporting gave shift foremen and management a tool to discuss and follow trends and individual shift team performance. The combination of close monitoring of mainly organisational practices and operator training resulted in significant productivity increase and lower operating costs without any capital investments.

Jan 1, 2007

Investigation on Comprehensive Utilisation of Nickel Slag from JNMC

Sep 13, 2010

By S Natsui, Y Goto, S Kawanishi, J Takahashi, H Nogami

The demand for copper increases yearly, and further improvements in copper smelting efficiency using flash furnaces are required. This study was conducted to understand and promote the interfacial reaction associated with the collision of silica flux and iron oxide particles, ie the formation reaction of fayalite slag, in the reaction shaft of the flash furnace. High-temperature microscopy was used to observe the reaction behaviour of a 2 mm granular SiO2 reagent in contact with micrometreorder- sized FeO reagents in situ. When the amount of FeO was lower than the stoichiometric amount with SiO2, the molten slag formed at the interface between FeO and SiO2 diffused into the SiO2 particle before dissolving the remaining FeO particles. It did not contribute to the subsequent reaction, and despite having the lowest amount of FeO among the samples in this study, many unreacted FeO particles remained on the surface of the samples after testing. On the other hand, under conditions with high FeO content and close to the eutectic composition of the FeO-SiO2 system, a liquid phase formed from low temperatures, gradually increasing in volume and eventually completely dissolving the 2 mm SiO2 grain. These results indicate that the early-stage slag is essential in increasing the interfacial area between FeO and SiO2 and facilitating the supply of FeO to SiO2. In other words, the FeO/SiO2 determines the amount of liquid phase and significantly influences the subsequent interfacial reaction rate between FeO and SiO2. Therefore, the local FeO/SiO2 of the particles falling down the reaction shaft should also be optimised to ensure early slag formation. Meanwhile, the time required for 2 mm SiO2 to complete the reaction for the temperature history employed in this study was significantly longer than the particle residence time in the reaction shaft. Further detailed investigation of the effects of silica flux particle size, composition, and reaction temperature on the reaction time will help find the conditions under which the reaction of silica flux can be completed in the reaction shaft. These kinetic approaches could contribute to future innovations in the copper smelting process using flash furnaces.

Jun 19, 2024

It is no longer adequate in running mines and quarries to simply select the best equipment. Today's competitive international commodity markets demand superior efficiency. This requires efficient production and commercial processes together with systematic involvement of people in continuous improvement of processes. True Total Quality of Management (True TQM) principles provide an operating philosophy for maximising productivity and minimising unit costs of output. Unfortunately, even though these principles are proven in all industry sectors worldwide, they have not always been used correctly. This paper describes basic methodology for correct use of these principles to successfully improve the productivity of rock breakage production processes.

Jan 1, 1995

By L Hussey, H Thanasekaran, J Kohmuench

Conventional flotation technology has historically failed to achieve high recoveries when treating <15 µm particles (Lynch et al, 1981). The new StackCell™ flotation technology was developed to specifically target this particle size range, and was tested at pilot plant scale at Mt Keith Nickel Concentrator. The streams tested, Slimes Rougher Tailings and Fines/Slimes Cleaner Tailings, represent 21% and 11% of the total nickel lost to tailings in the plant. Laboratory scale test work indicated that an economically significant fraction of these losses was consistently available to be recovered by additional flotation. The pilot plant experimental scope included over 50 tests. A grade recovery curve for each stream was developed, as well as information on the effect of ore type, feed rate, wash water, air flow, collector and frother on the performance of the cell. The single StackCell was able to achieve nickel recoveries of 16.8% and 16.5% on the Rougher Tailings and Cleaner Tailings, respectively, at grades consistent with these blocks. Additional test work of the StackCell in a cleaner scalper duty yielded final quality concentrate with a maximum nickel recovery of 59.5% for the single stage StackCell. Laboratory scale simulation of the downstream impacts of the StackCell operating as a cleaner scalper indicated a net recovery benefit of up to 2.0% for this cleaner block.Tests were completed to compare residence time requirements of the StackCell, as compared to conventional flotation. In 55 seconds, the pilot plant StackCell achieved 50% of the recovery of a 960 second laboratory scale conventional flotation on the same feed material. The apparent improvement in flotation kinetics is attributed to the novel high intensity aeration system, which provides efficient bubble-particle contact thereby shortening the residence time required to achieve high recoveries. The smaller footprint and lower energy costs of such a cell are also benefits of this technology, which is being considered for industrial scale installation as a result of this test work. Given the industry’s historical poor performance treating slimes with conventional flotation, it is clearly best practice to challenge the status quo through innovative new technology, such as the StackCell.CITATION:Hussey, L, Thanasekaran, H and Kohmuench, J, 2017. The application of high intensity flotation technology at Mt Keith nickel concentrator, in Proceedings MetPlant 2017, pp 259–278 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

Similarities and Dissimilarities in Florida Phosphate Ore Types - Surface and Bulk Property Analysis of the Flotation Feed, Concentrate and Tails

Sep 13, 2010

By Sengstock G. W, Spathis A. T

Benchmarks of mine equipment involved in the excavation process of coal mines would suggest that such equipment is not always operating at an optimum level. Dragline operations and truck/shovel operations rely on efficient use of their plant in order to maintain high mine throughput. The first process which affects the material to be excavated is the drilling and blasting process. Drilling and blasting delivers a fragmented material with a given disposition ready for excavation by mine equipment. As mine operators demand more productivity from their major excavating equipment, many sites are considering the use of productivity monitors to measure their outputs. Some of these productivity improvements will be directly related to the drilling and blasting process, so that as the monitoring systems improve, the opportunities to evaluate all drilling and blasting variables will also improve. This paper reviews current and newer methods for monitoring equipment productivity in mines. These include simple time and motion studies obtained by either manual timing of processes or by automated data collection equipment being adopted by the industry. Case studies for truck/shovel operations are discussed and the productivity improvements are compared with typical industry standards. These improvements relate specifically to parts of the load, haul and dump cycle and the potential for significant improvements are identified. Particular opportunities for drilling and blasting improvements are also presented.

Jan 1, 1995

By Gray N. B

The need to improve existing metallurgical processes and to develop new processes to meet the economic challenges that lie ahead requires the application of the tools of process analysis viz. mathematical models, physical models, pilot plants, laboratory measurements and plant tests. Examples of the application of these techniques to processes are described in this paper. Several of these techniques, combined with basic knowledge, are necessary to make improvements and for existing processes this always involves plant measurements. Also because metallurgical processes include extraction, refining, alloying, casting, mechanical working and heat treatment, an interdisciplinary approach to research and development is essential. This paper argues that metallurgical engineering is a discipline that is uniquely able to encompass the broad spectrum of chemical- and physical-metallurgy processes and is therefore essential to the health of the metallurgical industry.Regrettably many metallurgical engineering departments are not offering courses on process analysis, control, optimization, etc so necessary to meet modern industrial challenges.

Jan 1, 1985

By B Murphy, A Uliana, P STrgio de Oliveira, G Ara·jo de Souza Franco, T Miettinen

Outotec has performed numerous research and development projects and various surveys in the study of reverse iron ore flotation. Over the past four years their TankCell-70 and TankCell-160 flotation cells at the Germano concentrator of Samarco in Brazil were extensively surveyed. These surveys have revealed some extreme operating conditions in reverse iron ore flotation and are the subject of this paper. Some of the findings include large variations in the content of solids in the various flotation stages. At the bottom of the cleaner cells, the content of solids by weight reached over 60 per cent, whereas at the bottom of the scavenger cell this was less than 50 per cent. Froth carry rates were also significantly different in the various flotation stages. In the case of coarse material, the scavenger cells operated at a froth carry rate of over 40 t/h.m2. With fine material, however, froth carry rates of less than 10 t/h.m2 were measured. High froth carry rates caused significant changes in the residence times at Samarco. In the rougher cells, the fifth cell had more than double the residence time of the first cell. This was even more pronounced with the scavenger cells, where the second cell had more than triple the residence time of the first cell. High froth carry rates also caused losses in iron recovery. As a consequence of such findings, it appears that different rules apply in the sizing of reverse flotation circuits compared to direct flotation circuits. Different operating parameters (mixing intensities and air flow rates) must also be used in the rougher, cleaner and scavenger cells in order to optimise the metallurgical performance. Outotec has also been working on a number of new technologies aimed at improving the metallurgical performance of iron ore reverse flotation circuits by increasing froth carry rate and decreasing fine iron entrainment.CITATION:Miettinen, T, Uliana, A, Ara·jo de Souza Franco, G, STrgio de Oliveira, P and Murphy, B, 2013. TankCell flotation at SamarcoÆs Germano concentrators, in Proceedings Iron Ore 2013 , pp 441-444 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

Building the Unified Comminution Model The Unified Comminution Model (UCM) was formulated with the vision of bringing all comminution models onto a common base. The structure of the model relies on knowledge of the mechanical environment in the comminution devices to predict the modes and rates of collision in a device. A detailed understanding of the breakage modes and an ability to correctly test these modes for the ores in question is then required to feed into the UCM. A model structure has been developed that has the capability of dealing with multiple modes of breakage, such as low energy impact surface damage, chipping, sliding abrasion, cumulative impact body breakage and the transition of rock between modes. A critical review is presented on the shortcomings and limitations of utilising the discrete element method (DEM) to provide the mechanical environments. The assumptions and applicability of utilising DEM in milling models are presented and proposed routes to building a realistic mechanistic model are proposed. Based on this more realistic measures of collision energy have been derived from the DEM simulations, which better mimic the real breakage tests. Generic forms of the collision energy distributions have been observed and developed into functional forms for use in the simulation environment. The method of application of this model to a pilot SAG mill is presented.

Sep 13, 2010

With the progress of modern mining engineering, one of the features of which is the mining from greater depths and the hoisting of greatly increased loads, it becomes a matter of increasing importance that the engineer should be able to determinewith some degree of precision the character of the strains on the hauling rope. But a wire rope is a complex structure; it is made up of spirally-twisted strands, which in turn are composed of spirally-twisted wires, and it is not particularly easy to say exactly what happens when this "doubly-twisted structure is wound round a drum or over a pulley.. The difficulty has been generally evaded in ordinary practice by the simple device of adopting a large factor of safety for the rope-usually from 8 to 10-a factor which experience has shown is sufficiently large to cover the bending strains set "up when the rope is passed over pulleys of the sizes commonly considered appropriate.When, however, we add the stress due to the bending of the rope to the stress produced by" the direct pull, we find that the actual factor of safety is usually more nearly 4 than 10, and frequently the bending stresses in the rope are so large compared with the simple tensile stresses that their neglect may easily lead to disastrous results when dealing with problems a little out of the common run. Common Empirical Rules.-It is always "recognized that the bending of a wire rope round too small a pulley is likely to do the rope serious injury, but as it is desirable in ordinary winding operations to reduce the inertia of the moving parts to a minimum...

Jan 1, 1907

WINDING engines are one of the most important units in the equipment of a mine. Upon the winding machinery depends not only the output of the mine, but it supplies in most cases the only means by which workmen enter and return from the mine, and consequently the utmost care and attention is desirable in its design. The efficiency of a direct acting winding engine, as a machine is very low. In other words, the proportion between the useful work performed and the actual work the engine is capable of performing (under the most favourable conditions) is very small. The reasons for this are:-1. The intermittent nature of the work; the engine is stopped from 20 to 25 %(or even more) of the time which would constitute a useful day's work.2. The large amount of power that is absorbed applying the brakes to bring the load to rest.3. That the net useful load raised is small in comparison with dead load to be lifted, and the parts to be set in motion.4. That, owing to the frequent stops, initial condensation in the cylinders is always greater than in a continuously running engine, whilst radiation from steam pipes, valve chests, &c., goes on whether the engine is running or...

Jan 1, 1911

By J Mar·n, R Anderson, S Strohma, R Harvey

Xstrata is the operator of both Minera Alumbrera Ltd (50 per cent Xstrata, 50 per cent Wheaton River) and Ernest Henry Mining Pty Ltd, (99.99 per cent Xstrata), both copper-gold deposits, using conventional SAG/ball milling at current capacities of 36 Mt/yr and 10.3 Mt/yr respectively. Alumbrera is located in Catamarca Province, in the north west of Argentina. Ernest Henry is located in Cloncurry, north west Queensland, Australia. Both operations started in late 1997, with commercial production achieved in early 1998. Different designs and equipment are in use for both operations, however the evolution of SAG milling performance, although logically related to their specific features, reflect similar trends of consistent increases in throughput. This paper will discuss the main changes to the SAG mill liners in both operations and the results achieved to date. A summary of the operating strategies will be included.

Jan 1, 2003

Construction work on one of the world's largest landslide stabilisation projects is drawing to a close in Central Otago. Begun in mid 1990, major stabilisation work has been carried out on seven large rockslides which will be partially inundated when the Clyde dam reservoir (Lake Dunstan) is filled. The work has required the construction of 14.5 kilometres of tunnel, 60 kilometres of surface drilling, 78 kilometres of drilled drainage holes and five million cubic metres of earthworks. The stabilisation programme has been carried out by the Electricity Corporation of New Zealand as part of the Clyde Power Project, a hydroelectric development on the Clutha River.

Jan 1, 1992