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By L Barrere, J P. Sykes, A Trench, R S. Davies

Western Australia (WA), alongside Brazil, has remained at the forefront of the global seaborne traded iron ore market for over 40 years. Despite this apparent stability and strong market position, WA continues to face strong external international supply-side competition, mainly from Brazil, but also periodically from often marginal, non-traditional sources of iron ore. Additionally, WA iron ore supply has undergone significant decadal change internally, both of an evolutionary (brownfields expansion) and revolutionary nature (major new greenfields projects). Since 2006, a new generation of WA-focused iron ore explorers, developers and producers have emerged.The majors, BHP Billiton and Rio Tinto, have expanded mine production to record levels and the Roy Hill project is now approaching nameplate capacity. Fortescue Metals Group (FMG) is, however, the largest new market entrant of the last decade, delivering upon their vision of becoming the ‘new force in iron ore’. Unlike most of the other new WA market entrants, FMG’s operations are substantive. Most of the other smaller, new WA iron ore miners have struggled during the period of falling prices, though it is worth noting that collectively they have made a material supply-side impact during the price boom – typical of marginal supply. Finally there have been some contributions from new magnetite projects, however, the delivery and economics of these projects have not met expectations.In this paper, we touch briefly upon the key global market changes of the last decade, namely China-driven demand growth and the changes to the pricing mechanisms for iron ores – before reviewing the rise in WA iron ore supply in response to these markets. We finish by focusing on the most significant WA-focused supply-side development of the last decade, the rise of FMG as a major new supplier and the strategic situation that facilitated its rise. The unprecedented China-led rise in iron ore prices felled many traditional barriers to market entry into an oligopolistic industry, allowing many new market entrants (in WA and around the world). However, the downturn in iron ore prices resurrected these barriers to entry, with only FMG (thus far) breaking the entry barrier with significant scale. Difficult corporate decisions have been forced upon the smaller WA iron ore miners who, in some cases, will now struggle to further expand, or indeed continue to operate in the longer run.The changes that have taken place over the last decade of WA iron ore production hold insights for other emergent mineral commodity exports from the state. Successful market entry, even when industry barriers are high, does not always require an immediate low-cost production assumption alongside a strong balance sheet. FMG could see a new market, within an established commodity market, target an appropriate and new product at it, overcome temporarily-felled barriers to entry in infrastructure and finance, then innovate and aggressively cut costs ensuring it was behind the barriers to entry when they rose again after the price boom.CITATION:Barrere, L, Trench, A, Sykes, J P and Davies, R S, 2017. New generation Western Australian iron ore – strategic insights far beyond the Pilbara?, in Proceedings Iron Ore 2017, pp 375–386 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By H. Walqui

This paper describes operating gains resulting from standardizing operating and maintenance practices to improve the performance of the pebble crushing circuit at he Empire Concentrator. Past efforts have led to improved operating time but no additional throughput gains. New Operating standards and checklists were developed and introduced. The content and frequency of the review process indicators was then changed to take advantage of the new practices resulting in an increased feed rate and availability through the pebble crushing circuit.

Feb 27, 2013

By B. Larsen, S. Z. Nascimento, K. Fidje, J. P. M. Amaro, H. Gran

Safe and good operation of Søderberg electrodes is dependent upon high quality electrode paste coupled with correct electrode operating procedures. Good electrode performance depends further on proper melting and densification of the electrode paste. The melted paste should form a dense and viscous layer that prevents gasses from the baking process to move upwards. Both paste cylinders/blocks and briquettes can be used, but the procedures may differ between the various types of paste products. For briquette columns the formation of the important viscous layer is obtained through melting and densification of the briquettes. By basic rheological studies of electrode paste and by laboratory tests of briquette beds at isothermal conditions we have achieved a better understanding of the melting process. The effects of temperature gradients, pressure and friction between the briquettes and the electrode casing have also been evaluated qualitatively in pilot scale experiment and in industrial scale tests. The paper shows that melting and densification starts at a considerable lower temperature than the pitch softening temperature. It is concluded that the formation of a briquette electrode column depends on parameters as temperature, briquette column pressure and the friction. Operating conditions influencing the above parameters should be defined and established for each specific furnace operation. Such factors are e.g., charging and slipping procedures, column heating and electrical conditions.

Jan 1, 2004

By Douglas Milne

Most empirical and numerical approaches to design in rock mechanics incorporate rock mass classification. Numerical design methods generally use classification values to calculate input parameters for stress-based failure criteria. Empirical methods use classification to allow comparisons between similar rock mass conditions, generally based on a graphical design technique that differentiates stable and failed opening geometries. Classification systems are the best tool available for assessing rock mass properties; however, there are problems with classification systems that should be high-lighted. Rock mass performance can only be realistically estimated by coupling a unique description of the rock mass with known loading conditions. Current classification systems cannot provide a unique classification value. The weightings applied to quantify rock mass properties for classification can result in significantly different rock masses having the same classification values. These weightings have been proven effective for tunnel design and support, but classification systems are now used for many more applications. Rock classification systems evolved from a quick and easy field tool for estimating tunnel stability and support requirements. The need for a rapid field tool means that rock mass classification is relatively insensitive to improved methods of measuring rock mass properties. Problems with classification systems and their application are highlighted in this paper. These problems must be recognized and documented before improvements can be made. An understanding of the evolution of classification systems and their application for both numerical and empirical design approaches is invaluable in highlighting current shortcomings.

Jan 5, 2007

By I. Westermann, K. Marthinsen, M. S. Remøe

"Al-Mg-Si alloys often add small additions of e.g. Mn or Cr, to form dispersoids, which may act as nucleation sites for Mg2Si particles after homogenization. The purpose is to ensure a high density of uniformly distributed small ?’-particles, which can be dissolved during further processing prior to the final age hardening step. However, their density and spatial distribution are critically dependent on the homogenization procedure. It is therefore important to have a robust and reliable method for assessing their spatial distribution. In the present work an existing methodology for assessing spatial uniformity, the Global Shannon Entropy (GSE), has been implemented and evaluated for different dispersoid structures characterized by scanning electron microscopy. This metric is highly dependent on the parameters used, but by careful selection of adequate parameters, it can be effective in detecting non-uniformity. An important weakness with the GSE was identified, and a modification to improve on the ability to differentiate degrees of non-uniformity is suggested. To evaluate the proposed methodology, the effect of heating rate on dispersoid precipitation behaviour during homogenisation of four Al-Mg-Si alloys with different Mn/Cr-content has been investigated. The metric with the new term has demonstrated promising results, and improved the ability to differentiate degrees of spatial uniformity.INTRODUCTION Al-Mg-Si series alloys are the most common aluminium extrusion alloys and are attractive for applications in a range of sectors (e.g. construction, automotive and recently also in consumer electronics), due to their generally good combination of strength, ductility and corrosion resistance. However, their extrudability and end properties depend critically on the alloy chemistry as well as prior processing conditions. Coarse ß-AlFeSi or Mg2Si-particles typically have a detrimental effect on extrudability, while small dispersoid particles may affect recrystallization, grain growth and precipitation of Mg and Si. The strengthening potential in the final age hardening step depends strongly on the amount of Mg and Si in solid solution after extrusion. The manner in which these particles are spatially distributed will decide whether the final product will exhibit uniform properties, and the number density and sizes will determine the extent of the effect. As such, these are important characteristics."

Jan 1, 2018

By Scott Orenstein

Construction blasting has allegedly been the cause of property damage in the following situations: (1) When the detonation of the shot hurls rock and debris into the air that causes property damage upon impact; and (2) When property owners notice cracks in their walls and foundations after they experience the momentary vibrations that coincide with the detonation of the shot. The current state of the law for both these situations is firmly established. Blasting is classified as an abnormally dangerous activity, for which the blaster is held strictly liable, whether the damage is the result of flying debris or vibrations and concussions generated by the blast. It is when the alleged blasting damage is supposedly from concussions and vibrations, however, that the courts usually reach the wrong result. The typical scenario involves property owners that thoroughly investigate their property after feeling blast generated vibrations, and find cracks that they believe did not exist beforehand. Most often the truth is that the property owners have never noticed these cracks before because they have never looked that closely before. Any structure has a certain number of cracks due to a variety of causes, such as settlement overtime and temperature and humidity changes.

Jan 1, 2004

By I Ross, C deWolfe

Block caving has been the favoured mining method for large underground hard rock mines for the last few decades. The orebody must be of a size large enough to cave and generally amenable to a caving method. Typically, these mines ranged from 15 000 to 50 000 tonnes per day (50 kt/d) and have been some of the largest and most productive underground mines in the world.Now mining companies, in the quest for improved shareholder return, are looking for higher production rates from new underground mines. Whether a ‘Greenfields’ development, or a replacement for ageing large open pit mines, minimising capital and maximising production has been a focus of project teams. These new block cave mines are what have become known as ‘super caves’. These caves range from 80 kt/d to over 150 kt/d and are being planned or constructed by several major mining companies including Codelco, Freeport-McMoRan, Newcrest and Rio Tinto.Issues facing these super caves include high initial capital costs, very long development periods and significant technical challenges. These issues tend to make it difficult to present an attractive business case for such a project.This paper will discuss some of the potential benefits as well as the technical challenges and risks of operating a mine with the block or panel caving method at these very high tonnage rates. Considerations including geotechnical conditions, development rates, panel widths and ore column heights are discussed. The risks associated with these technical challenges and potential benefits for successful approaches will also be discussed.CITATION:deWolfe, C and Ross, I, 2016. Super caves – benefits, considerations and risks, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 51–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Svetlana Nikitina

While many question "sustainability" as an intellectual field on the grounds that it is too broad and "undisciplined," we are able to achieve a good balance between breadth of coverage and depth of inquiry in our team-taught seminar "The Grand Challenges: Sustainable Development for the 21st Century" offered to first year students at Worcester Polytechnic Institute. We strike this balance between breadth and depth by a) problematizing key sustainability issues in class discussions; b) by explicitly exploring the lenses of different disciplines (the historical context, the scientific facts, the engineering interventions and the philosophical foundations of unsustainable behaviors); and c) by offering our students opportunities to pursue a targeted project on specific sustainability issues (vertical gardening, metals recycling on college campus) through which they gain depth of understanding as well as practical exposure to all components of the problem, which puts them on the path of seeking effective solutions.

Jan 1, 2010

By C. E. Van Orstrand

An intrusive body is a mass of igneous rock that has migrated upward, presumably from great depths. Great variations in form, composition and depth of burial occur. It is not proposed in this paper to go into all of the details of the problem. Instead, it mill be assumed here that the intrusive has the form and characteristics represented in Fig. I. According to W. 11. Emmons minerals are not deposited in appreciable quantities below the "dead line." Important amounts of ores of virtually all metals may be found around summit cupolas, but only gold, copper and zinc (in limited quantities) are usually associated with trough cupolas. Most students of ore deposits agree that temperature changes are largely instrumental in precipitating many ores in the "hood" and that the difference in temperature between the intrusive and that of the country rock may be the chief factor in determining the mineralogy of a deposit. A problem then of some interest is to correlate the principal physical features of the intrusive with the phenomena of heat conduction as evidenced by the cooling curves and the isothermal surfaces. Mathematical Theory In order to show the possible application of heat conduction to the interpretation of the processes of metalliferous deposition associated with intrusives, it will be as- sumed that the intrusive is a large par-allelopiped of dimensions, 2l, 2m, 2n. The equation that represents the flow of heat from the parallelopiped into country rock (v = o, 1 = o), which has the same thermal properties as the intrusive, is2,3 l-x v I FT 2 [2 2 — l-x m — y — m — y n — z In this equation, the origin, x = o, y = o, z = o, is at the center of the parallelopiped. v = temperature at point x, y, z, time 1. v, = initial temperature throughout the intrusive, 1 = o. k = coefficient of thermal diffusivity. a, ß, y are variables of integration. Put n = m in Eq. I, and we have v I [2/5 [2I-x 2 — l-x m — y 2 2 2 kt 2 20xt e-a2da ebrdß

Jan 1, 1946

By C. E. Van Orstrand

An intrusive body is a mass of igneous rock that has migrated upward, presumably from great depths. Great variations in form, composition and depth of burial occur. It is not proposed in this paper to go into all of the details of the problem. Instead, it mill be assumed here that the intrusive has the form and characteristics represented in Fig. I. According to W. 11. Emmons minerals are not deposited in appreciable quantities below the "dead line." Important amounts of ores of virtually all metals may be found around summit cupolas, but only gold, copper and zinc (in limited quantities) are usually associated with trough cupolas. Most students of ore deposits agree that temperature changes are largely instrumental in precipitating many ores in the "hood" and that the difference in temperature between the intrusive and that of the country rock may be the chief factor in determining the mineralogy of a deposit. A problem then of some interest is to correlate the principal physical features of the intrusive with the phenomena of heat conduction as evidenced by the cooling curves and the isothermal surfaces. Mathematical Theory In order to show the possible application of heat conduction to the interpretation of the processes of metalliferous deposition associated with intrusives, it will be as- sumed that the intrusive is a large par-allelopiped of dimensions, 2l, 2m, 2n. The equation that represents the flow of heat from the parallelopiped into country rock (v = o, 1 = o), which has the same thermal properties as the intrusive, is2,3 l-x v I FT 2 [2 2 — l-x m — y — m — y n — z In this equation, the origin, x = o, y = o, z = o, is at the center of the parallelopiped. v = temperature at point x, y, z, time 1. v, = initial temperature throughout the intrusive, 1 = o. k = coefficient of thermal diffusivity. a, ß, y are variables of integration. Put n = m in Eq. I, and we have v I [2/5 [2I-x 2 — l-x m — y 2 2 2 kt 2 20xt e-a2da ebrdß

Jan 1, 1946

By E. Carvajal I

Large diesel engines provide the mining industry the substantial power and torque needed to move large amounts of material efficiently. But the stresses generated by such power and torque necessitate complex maintenance programs to ensure the utmost operating capabilities are not compromised. Of all its available sensors, the Exhaust Temperature differential between the right and left banks can provide the most valuable indicator of the overall operating condition and potential degradation of a large diesel engine. BHP Billiton Escondida Mining has implemented real-time remote monitoring, diagnostics, reporting, and tracking of Exhaust Temperature differential using Modular® technology. As a result of the processes and procedures put into place surrounding their MineCare maintenance management system, Escondida has proactively replaced over 300 injectors, resulting in an increase of 4% in Engine availability.

Jan 1, 2011

By Mario E. Rossi

The full economic evaluation of a mining project requires a block model that provides an estimate of the tons and grades of available resources. The model must be representative of the mineralization to be found at the time of mining for specified extraction periods and within acceptable error margins. In an operating mine, there may be a reasonable understanding and estimates of actual dilution and ore loss. This paper discusses the issue from the perspective of a project at a feasibility or preproduction level of development. Three types of dilution are discussed. Internal dilution (or change of support) is function of the spatial distribution of the mineralization and its relation to the operation?s selectivity. Geologic contact dilution is the unavoidable mixture at contacts or boundaries of material with different geologic characteristics, grades, or metallurgical performance. Operational planned and unplanned dilution should also be considered, sometimes incorporated by factoring the resource model, but more accurately by mimicking the grade control process. The resource estimation process always carries uncertainty, which is sometimes significant, and usually caused by several factors. These include quantity and quality of drill hole information; quantity and quality of geologic data; grade estimation methodology; dilution and mining recovery factors applied; etc. A key decision is to whether estimate as accurately as possible the in-situ geologic resource or to estimate the tons and grade of the material to be fed to the processing plant. The geologic modeling and grade estimation methods used are conditioned by this decision.

May 1, 2009

Fine Gravity Separation in the Reflux Classifier, Exploiting a High Shear Rate, Laminar Flow Mechanism The Reflux Classifier is used in the gravity separation of particles over a broad range of particle sizes. The device consists of a fluidised bed zone, with a system of parallel inclined channels above. The inclined channels provide a significant hydraulic advantage over conventional fluidised beds via the so-called Boycott Effect (Boycott, 1920). This paper describes a new advance in fine gravity separation based on the high shear rate and laminar flow profile that arises when closely spaced inclined channels are deployed. As reported recently (Galvin et al, 2009a), a powerful density based separation mechanism develops from this arrangement, suppressing the effects of particle size. In this paper we focus on two areas, firstly the application of the separator in the laboratory for batch fractionation of particles of varying size and density to determine the grade recovery curve and hence the liberation, and secondly the step change in separation performance achieved on a continuous steady state basis when closely spaced inclined channels are used. The variation in the separation density with particle size decreases significantly, and the Ecarte Probable Error (Ep) remains at low levels over a broad size range.

Sep 13, 2010

By M. Mikhaylenko

Rhenium, molybdenum and tungsten are the elements demanded by high-end technologies. These metals are found in process solutions in forms of their oxyanions: ReO4-, MoO42- and WO42-. The later two can exist in forms of iso- and/or heteropolyanions. Basically all three metals demonstrate very similar chemical behavior in aqueous solutions. Unfortunately, in their mineral sources these elements commonly accompany each other, like pairs of rhenium-molybdenum or molybdenum-tungsten. Their economical separation is a challenging task.

Jan 1, 2012

By S Smit, P J. J Strobo

ZINIFEX Century Mine is a zinc, lead and silver concentrate producer. Flotation is the primary method of minerals separation in this circuit. The flotation circuit is quite large with 79 flotation cells. The levels in each of these interconnected cells are controlled at more than 45 level control stations. Due to the multivariable interaction throughout the circuit, good level control was found to be difficult to achieve by just using normal Proportional-Integral-Derivative (PID) control. As a first step in advanced process control, the FloatStar Level Stabiliser, a multivariable controller developed specifically for flotation circuits, has been commissioned at Century mine to solve the level control problems. The first section of this paper therefore discusses and shows the results and improvements obtained by using the FloatStar level stabiliser. The results and benefits of the FloatStar Flow Optimiser are discussed in the second section of this paper.

Jan 1, 2004

By Steve Kral

The timing was right for SME to celebrate its 50th anniversary in February as a member society of AIME. The mining industry is in the midst of a commodities boom that appears to have legs. Not only is the demand for metals, construction materials and the like increasing in developing nations, but developed nations have also seen the demand for those materials increase at impressive rates. So, in addition to networking and seeing old friends, attendees at the SME Annual Meeting and Exhibit in Denver, CO. Feb. 25-28, had several reasons to enjoy the week — a healthy industry and their society’s landmark anniversary. This annual meeting was held jointly with the Colorado Mining Association’s (CMA) 109th National Western Mining Conference.

Jan 1, 2007

By L. S. Jeffrey

Estimates for South Africa?s coal recoverable reserves made in 1999range from nine to 59 billion tons; latest estimates by the Minerals Bureau suggest that 33 billion tons is a more likely figure. As much as 70% of that coal is located in the Waterberg, Witbank, and Highveld coalfields, as well as lesser amounts in the Ermelo, Free State and Springbok Flats coalfields. However, the Witbank and Highveld coalfields are approaching exhaustion (estimated 9 billion tons of recoverable coal remaining in each), while the coal quality or mining conditions in the Waterberg, Free State and Springbok Flats coalfields are significant barriers to immediate, conventional exploitation. New extraction technologies, technologies exploiting the energy content of the coal in situ, as well as suitable uses and markets for low-grade, high-ash coal are required before the country can utilize its admittedly vast coal resources. Major challenges for exploiting some Limpopo province coalfields are severe water shortages, insufficiently developed infrastructure, fragile environments and poor roof conditions due to the depth and complex geology. In the Central Basin (Witbank, Highveld and Ermelo coalfields) technical innovations for thin seam extraction, economic mining of both pillar coal and intrusion-fragmented resource blocks and the utilization of lower-grade coals are required. The success of the fluidized bed combustion technology is necessary to utilize the low-grade coals of the Free State and Molteno coalfields, while environmental exemption for past problems, together with strategies for mining small, disjointed thin-seam resource blocks, is required in KwaZulu-Natal. Clean coal technologies, coal cost and quality, environmental considerations, sustainable development, the growth of the South African economy and Government?s regulation of the electricity industry are the main challenges to the continued use of coal as South Africa?s primary energy source.

Jan 1, 2005

By W. Stumpf

Mill log analyses and complementary hot deformation studies were carried out on the as-cast structure and on a hot rolled structure of the same low carbon steel (SAE 1006) that had been processed according to the direct or hot charge route in a compact strip plant. The main softening mechanisms during hot rolling were found to be complete dynamic recrystallization during each pass above about 1000°C for the as-cast structure with an austenite grain size of 277µm and, secondly, incomplete static recrystallization after each pass with a finer austenite grain size of about 26 µm and tested below 1000°C. A two-stage hot working mechanism has also been found by others on a similar steel also processed by the hot charge route and this may appear to be a characteristic of this type of material. Constitutive constants determined from hot working studies were combined with other constants from the literature and incorporated into a grain size development model that correctly predicts the final ferrite grain size in the hot rolled strip steel. The predicted incomplete static recrystallization during the last three finishing passes in the plant appears to result in some retained strain in the hot rolled austenite as it transforms to ferrite on the run-out table. Analyses with the model predict relatively little sensitivity of the final ferrite grain size to process and product variables such as temperature and strain per pass for the last three passes and also the starting austenite grain size in the slab. Keywords: Low carbon steel, hot rolling of strip steel, rolling mill log analyses, austenite grain size, ferrite grain size, grain size modelling.

Jan 1, 2003

Thermal method of diagnostic as a nondestructive monitoring is based on data logging of infrared radiation from heated surface or from the associated thermal field. Monitoring of gearcases and motors hidden faults, such as, bearing degradation (deep-seated wears and tears, fretting wear, spalling and jamming solids of revolution) is closely related to high variations in temperature. The use of portable thermal imaging devices provides considerable advantages due to: easy remote access to the unit under test even when it is operating; minimum time required to obtain information and an opportunity for a real-time diagnosis of the tested subject's condition.

Dec 6, 2010

Comparison of Industrial Cyanide Destruction Processes

Sep 13, 2010