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By M D. Melville, B C. T Macdonald, J Dixon

The acidic and metal rich waters that are generated from acid sulfate soil (ASS) drainage can have damaging impacts upon ecosystems. The most obvious impact has been the discolouration of water and occasional fish kills. ASSÆs produce these acidic and metal rich waters when pyrite in soil is oxidised. Land management techniques are an essential long-term requirement to minimise the amount of pyrite oxidation. Acidic water that cannot be prevented through land management can be neutralised by other techniques. Powdered lime is the most common material in agriculture that is applied directly to soils and waters. Powdered lime can be expensive and if applied dry it may aggregate. Since the aggregated particles of lime are larger they could sink rapidly in the water column and not react. In waters with high concentrations of dissolved iron and aluminium the lime particles may become coated with a metal oxy-hydroxide precipitate, which will decrease its reactivity. A unique lime-dispensing machine, the Waterways Lime Spreader, has been developed to neutralise acidic waterways. The Waterways Lime Spreader can produce a solution rich in fine lime from larger limestone fragments. The current size of the machine means only 3.5 grams per second of limestone can be emitted. This output will neutralise low acidity waters, however, for high acidity waters the time for neutralisation can be long. More reactive chemicals such as hydrated lime or increasing the size of the machine will reduce this neutralisation time. The Waterways Lime Spreader is also capable of producing slurry mixtures if powdered materials are required. Trials with the Waterways Lime Spreader were undertaken in part of the Clothiers Creek catchment located in northeast NSW, Australia. A small drain with a water volume of 4 m3 was neutralised with crushed limestone to pH 6.9 from an initial pH of 2.6 and an acidity of 902 mg/L CaCO3 in 160 minutes. In comparison a drain with a slightly larger volume of 6 m3 that had an initial pH of 3.2 and an acidity of 753 mg/L CaCO3 was neutralised with hydrated lime to pH 11.8 in five minutes. The Waterways Lime Spreader has been used successfully to neutralise water from acid sulfate soils. It is expected that future applications of the machine may be for the neutralisation of acid rock drainage or acidified lakes.

Jan 1, 2003

By J Robinson, L D’Uva

"The Gold Fields group and Gekko Systems have successfully worked together on multiple projects, including at the St Ives, Agnew and Granny Smith operations in Western Australia, and the Damang operations in Ghana, with gravity recovery design, technology installation and optimisation the key driver on each occasion.In 2014, Gold Fields Australia identified an opportunity to challenge the historical thinking at Granny Smith and reassessed the benefit of upfront gravity gold recovery. The historical approach had been to employ gravity on the tailings stream of the carbon-in-pulp (CIP) circuit, recovering sulfide minerals into a concentrate from spiral concentrators for further liberation of gold via a regrind circuit.Gekko was engaged to assess the implementation of a gravity circuit within the grinding area, and to perform a comprehensive gravity recoverable gold test program. Test data was fed into the AMIRA P420 BCC Gravity Model to confirm the gravity recovery potential of the ore, and for process design basis generation. Height, space and capital limitations proved to be a design challenge. However, collaborative learnings throughout the project ensured the design and operation of a reliable and economic gravity gold circuit. Ultimately, the Granny Smith gravity circuit was a success, satisfying all the project objectives and yielding consistent, measurable benefits. On average, the gravity circuit recovers 33 per cent of total gold, resulting in an increase to overall gold recovery by 0.7 per cent.This paper highlights the key project drivers for Gold Fields, and the development of the Granny Smith free gold gravity circuit. It details application of test work and modelling, and the challenges and learnings encountered during the design, installation and commissioning stages. This paper seeks to demonstrate that continuous improvement in a long standing operation can be beneficial to overall circuit flexibility and increased ounce production.Citation:D'Uva, L, Robinson, J and Bell, T, 2016. Defying Gravity - Brownfield Continuous Improvement, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 135–144 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By S Hapugoda, J R. Manuel, M J. Peterson, A Poliakov, E Donskoi

The occurrence and deportment of manganese in a number of ferromanganese and Mn-bearing iron ore samples from supergene-upgraded deposits, as well as from magnetite banded iron formation (BIF) and magnetite skarn deposits, was characterised in order to provide a basis for improved understanding of the processing characteristics of different ore types and investigate the potential for development of a robust geometallurgical classification for Mn-oxide ores. An understanding of the Mn mineralogy in mixed Fe-Mn deposits is necessary to inform any attempt to separate the Fe and Mn during beneficiation and to understand and predict the behaviour of lump and fine ore products during processing.A suite of analytical techniques was utilised, including hand sorting of lump ore particles, optical microscopy, X-ray fluorescence (XRF)/inductively-coupled plasma mass spectrometry (ICP-MS) chemistry, X-ray diffraction (XRD), scanning electron microscopy (SEM)/electron probe microanalysis (EPMA) and gas and solid phase pycnometry, in order to elucidate manganese mineralogy, mineral chemistry and mineral textures. Manganomelane group minerals (eg cryptomelane, hollandite), pyrolusite and lithiophorite were the most common manganese oxides in the samples examined. From the microprobe work, there was evidence of probable substitution of Mn, as well as Al and Si, into the structures of goethite and hematite. Manganomelane minerals were often intimately associated with goethite, in particular, and a clarification of this association and the associated Si and Al impurities is fundamental for improved understanding of beneficiation and sintering behaviour of Mn-oxide ores. Due to the poor or very fine crystallinity of some supergene manganese deposits and of some Mn oxide minerals, in particular the extent of overlapping peaks and their variable mineral chemistry, XRD was a problematic technique to equivocally determine Mn mineralogy.For lower-grade, earthy, poorly microcrystalline ores the mineralogical and textural association between mixed Mn, Fe and Al (¦ Si) phases was also critical. The deportment and potential separation of these elements in these deposits, especially Al, was complex, as they were characterised by forms of æhydrousÆ cryptomelane with higher levels of Fe-Al-Si substitution, as well as intimate intergrowths of ochreous-earthy goethite (probably aluminous in part) with cryptomelane, lithiophorite and/or kaolinite.Trace amounts of alkali elements in ferromanganese deposits were considered likely to be preferentially structurally associated with Mn oxides, while lateritic deposits with significant amounts of lithiophorite could contain elevated levels of deleterious impurities; Co and Ni in particular.A combination of solid and gas phase pycnometry proved to be a useful technique for broadly discriminating hematitic, goethitic and mixed Mn oxide-goethite lump particles based upon differences in their envelope and apparent densities. Based upon these preliminary results and ongoing Raman spectroscopy work on manganese deposits sensu stricto, Raman spectroscopy is a technique considered to have promise during targeted research to better link the optical and compositional properties of ferromanganese ore particles. CT-scan (computed tomography scan) analysis could also be combined with Raman spectroscopy and pycnometry to link mineral composition, mineral texture, ore particle textures and particle porosity/permeability to the high-temperature processing behaviour of lump and fines products.CITATION:Peterson, M J, Hapugoda, S, Manuel, J R, Donskoi, E and Poliakov, A, 2013. Textural characterisation of manganese minerals to improve the geometallurgical characterisation of ferromanganese and iron ores, in Proceedings Iron Ore 2013 , pp 281-300 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By Koh P. T L, Varnas S. R

Fluid flow, heat transfer and combustion in a nickel flash smelter have been investigated by numerical modelling and flow visualisation. The three-dimensional numerical model incorporates turbulent two-phase fluid dynamics, radiative heat transfer and combustion. The main features include the use of the k-E turbulence model, the Lagrangian tracking of particles, radiative heat transfer based on the spherical harmonics method, and chemical reactions. The predicted flow fields are in good agreement with data obtained from a series of flow visualisation experiments on a cold water model. The interaction mechanism between the fluid flow and the solid particles is examined for a range of particle sizes both with and without injected oil in a series of simulations. The heat transfer in the shaft is dominated by combustion and radiation, whereas the ignition of particles is influenced by the particle size and the added oil. Flow and temperature fields for both gas and solid particles are presented as well as the fraction of sulphur removed from the particles.

Jan 1, 1992

By G Baird, M Seto

A low-cost methodology that allows the determination of in situ stresses using oriented core specimens has been investigated. The technique can be used to determine the stresses during the early stages of a project, even in undeveloped areas of a mine. The research aim was to compare the experimental results estimated by the Acoustic Emission and Deformation Rate Analysis methods with those estimated by conventional Hollow Inclusion cell measurements. The studies have been focused on full stress tensor determination from a single oriented rock core. In all cases the rock core specimens recollected the in situ stresses reasonably well compared with the standard overcoring method.

Jan 1, 2000

By V Liebezeit

Data management is a significant, but perhaps unrecognised, consideration for any organisation embarking on a geometallurgy program. While resource geologists are accustomed to dealing with thousands or millions of samples and their associated assays, metallurgists and mineralogists have traditionally carried out only a few expensive and complicated tests and consequently tend to manage the resultant data in spreadsheets. The emerging discipline of geometallurgy arrives with significant challenges as a result of the sheer volume of data generated. As an example, the Olympic Dam geometallurgy program has generated more than:60 000 physical subsamples analysed for up to 30 analytes; 25 000 spreadsheet-based laboratory test results; 30 000 sized fractions analysed via QXRD, MLA and/or QEMSCAN;multiple external providers of data, and more than seven terabytes of data. Considerations for any geometallurgy data management system include storage space, data integrity, accessibility, traceability (sample provenance), maintenance and ease of use, integration with data providers and the ability to modify the system to adapt to changing requirements. Further, aspects of a geometallurgy program, such as conducting a range of tests on one sample, producing subsamples such as concentrates and tailings, compositing and routine QA/QC may not be well handled by existing software and providers geared to standard geochemistry, mineralogy or metallurgical test programs. The development of a geometallurgy database using existing software (AcQuire), and the associated file management system will be described for a large geometallurgy program at Olympic Dam. As with many aspects of geometallurgy there is no approach that meets the needs of every site or program. Recognition of data management as an issue, a structured approach in the program planning phase and commitment to executing the strategy will increase the chances of successfully mining the geometallurgical data.

Sep 5, 2011

By I Gray

While in some cases it is vitally important to measure the virgin stress in rock prior to tunnelling there are a number of cases where such stress measurement is really not required. The concept of having to have a number to put in a numerical model representing a continuum is often quite inappropriate. This paper discusses the cases when virgin stress measurement is required and the most appropriate means to measure it. The techniques discussed cover all of the overcoring systems, hydrofracture and borehole breakout measurements. It also covers the use of rock surface stress measurement, which is easy to perform and should be used to check for changing stress conditions. Unfortunately this technique has been ignored in recent times because engineers are addicted to numerical models requiring far field stresses rather than measuring the real values that exist where they matter – at the tunnel wall. A case is presented in which the measurement of surface stress in a tunnel boring machine tunnel enabled the far field stress to be determined in what must be the world’s largest overcore.CITATION:Gray, I, 2014. The measurement of rock stress for tunnelling, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 153–160 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

By G Davison, C Rossimel, M Bouazza

Expanding rock bolts anchor within a rock mass more efficiently than non-expanding varieties. This is of great importance in weak ground conditions, where grouted friction bolts perform less efficiently than in good ground conditions. Filling a Split Set with demolition concrete has been shown to double the load-carrying capacity when compared to conventional use of Split Sets. This report details verification of these results by installing and pull-testing 14 Split Sets of varying grout conditions within in a fault zone. These Expanding Split Sets achieved loads double and triple that of ungrouted and normally grouted conventional Split Sets. A literature review and chemical analysis were conducted to understand the expansion process better. It was found that 20 per cent more calcium is included in expanding cement, which is responsible for its growth. Factors most affecting the expansion process were identified. Furthermore, the expansion rate of a bolt outside a borehole was measured and 6 mm of expansion across its diameter was found. The compressive properties of the cement were compared with other types, due to expanding cement becoming uncohesive after the expansion process is complete. When confined within a Split Set, compression testing demonstrated that this grout is just as strong and rigid as normal grout. Finally, the bolts were tested by shear and it was found that the Expanding Split Set (ESS) has a similar shear capacity to grouted Split Sets, which is 70 per cent higher than that of ungrouted Split Sets. These results enabled the mechanism for improved performance in weak ground conditions to be verified. Expanding grout will expand the Split Set into its borehole of varying diameter and lock it into place, creating increased friction and resistance to pull-out. This paper shows that ESSs can be a useful reinforcement technique in weak ground conditions.CITATION:Rossimel, C, Davison, G and Bouazza, M, 2014. An investigation of expanding split sets in weak ground, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 159–170 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By B Hayes

The Ambuklao and Binga Rehabilitation Project is a 175 MW hydro power project currently under construction across dual sites in the north region of Luzon Island, Philippines. When it was built in 1956, the Ambuklao Dam harnessed the second largest hydro-electric reservoir in Asia. However, due to landslide erosion and prolonged silt infiltration caused by an earthquake in 1990, the power plant has been rendered inoperable since 1999.To bring the power generating facility back to life, the project scope entails the rehabilitation and construction of civil structures, shafts and tunnels. A major component of these works is the decommissioning of a section of the seven metre diameter headrace tunnel by installing a concrete plug. The headrace tunnel is part of a closed waterway system that connects the dam via a shaft, exhibiting a hydrostatic pressure of 13 bar (1300 kPa) at the location of the new tunnel plug. In addition, the power station ball valves have seized ajar and the damaged intake riser is unsafe toaccess thereby requiring the plugging operation to be carried out under live flowing conditions.Working under hydrostatic pressure and live conditions, the headrace plug will be an underwater tremie pour operation that includes drilling and concrete injection through blow out preventer caissons installed in the floor of an underground chamber above the tunnel. The purpose of this paper is to describe the key engineering and planning components involved in this operation including pre- and post-grouting, chamber crane, sonar, local water compensation, jet flushing, drilling, caisson installation, and concrete design, production, delivery and placement. The success of this task rests on the strategic preparation and operational management of risk and safety in a challenging rural environment.

Mar 8, 2011

By S Maritsa, E K. Chiwandika, S M. Masuka

The iron and steel industry is experiencing an increase in the use of iron and steel commodities within societies, decarbonisation pressures, depletion of high iron ore grades and high energy consumption. This necessitates scrap metal recycling, low-grade ore utilisation using the induction or electric arc furnace to achieve the global target of net zero CO2 emission. The available highquality scrap metal cannot sustain the steel industry but the world has unused hematite-goethite ores. It is the aim of this research that this resource be utilised using the induction furnace to sustain the steel industry in an environmentally friendly manner. Indurated pellets prepared from the hematite-goethite ore, 5 wt per cent limestone and 5 wt per cent coal addition were smelted in the induction furnace at 1350 ± 50°C with 25 mins holding time. The effects of basicity and carbon content were also investigated to optimise the smelting parameters. The results showed that the careful control of the basicity, and iron-to-carbon ratio maximised total metal recovery. The optimal basicity ratio was determined to be 1.3 and a carbon to iron ratio of 1.4 achieved a total metal recovery of 73 per cent. The metal recovery was closely related to the estimated slag melting temperature. The basicity ratio of 1.3 achieved the lowest slag melting temperature estimated to be around 1380°C based on the CaO-SiO2-Al2O3 phase diagram. The recovered metal had a comparable chemical composition and microstructure to that products from an ITmk3 furnace.

Jun 19, 2024

By G Swayn, J Harpley

Spent Pot Lining (SPL) is an unavoidable waste product of the electrolytic process in the smelting of aluminium. SPL is considered to be a hazardous waste in various countries because it contains significant quantities of absorbed fluoride along with traces of cyanide. The disposal of SPL has been primarily in landfill because of difficulties in the development of a successful techno-economic SPL treatment process. Increasing concern about SPL landfilling practices is resulting in regulations in some countries to ban this form of disposal. As a consequence stock piling of SPL is occurring in an increasing number of countries pending the development of a successful treatment process. In 1992 Portland Aluminium investigated a SPL treatment process based on pyrometallurgical technology and approached a company called Ausmelt in Dandenong, Victoria, Australia, to ascertain if their submerged lance technology furnace process would be suitable to treat SPL. This approach resulted in Portland Aluminium, Alcoa and Ausmelt personnel working together on trials during 1992 - 1994 in Ausmelt's demonstration furnace to produce a slag and off gases containing hydrogen and sodium fluoride. The trials also evaluated the effect of oxygen enrichment to increase the concentration of hydrogen fluoride and the ability to recycle sodium fluoride particulate produced as the furnace off gases cooled. Other separate developmental work by Portland Aluminium, using CSIRO, resulted in the production of aluminium fluoride from the offgases from the pyrometallurgical process. The results of these projects influenced Portland Aluminium and Alcoa to authorise up to $A26 400 000 in December 1995 to construct a Research and Development processing facility to treat SPL at Portland. The Portland Aluminium unique gas treatment process converts hydrogen fluoride in the furnace offgases to aluminium fluoride in a multistage fluidised bed reactor, designed by Portland Aluminium. The aluminium fluoride produced in the reactor has been trialed successfully in Alcoa's aluminium smelting process as a replacement for imported aluminium fluoride. The installation in mid-2001 of a slag granulation system has enabled the production of a granulated vitreous slag having leachability qualities that conform to Victorian EPA criteria for the unrestricted use of the granulated vitreous slag from 'The Alcoa Portland SPL Process'. The unrestricted use of the granulated slag successfully completes 'The Alcoa Portland SPL Process' which treats the hazardous waste material SPL and converts it into non hazardous useful products.

Jan 1, 2002

By S J. Loach

F-Series reconciliations are formal comparisons of estimates and measurements of ore quantity and quality made at pre-determined points along the mining value chain. F1 is the ratio of ‘Depleted Grade Control Ore/Depleted Long-term Model Ore’ and validates the models upon which Resource and Reserve statements are based. F2 is the ratio of ‘Produced Tonnes and Grade/Depleted Grade Control Ore (-) Changes in Pre-Crusher Stockpiles’ and validates that the ore tonnes and grade delineated in the pit are being accurately extracted and correctly delivered to the processing plant. These factors provide important corporate assurance for a mining company by providing quantitative feedback on model-predicted tonnes and block grade estimates. Since 2009, BHPs Western Australian Iron Ore F-Series reconciliations have been calculated in a single, centralised sequel-server database. This software routinely collates data regarding mineral resource block model depletions, grade control model depletions, pre-crusher stockpile inventories and production tonnes and grade measurements and then calculates F-Series factors for both tonnes and product quality. This paper will present case studies where reconciliation factors were used to identify improvement opportunities leading to projects that improved our models and subsequent forecasts of production tonnes and quality. In addition, it will show how reconciliation factors are tools that monitor control during periods of rapid change and provide feedback on the effectiveness of improvement projects.

Sep 18, 2023

By R K. A Taylor

The growth in production of beneficiated ilmenite products has been one of the most significant trends in the titanium feedstock industry over the past 30 years. In this period, the production of titanium slag and synthetic rutile has grown five-fold to the point where these products represented 56 per cent of total feedstock production in 2000. Additional production capacity is being proposed as the core component of new feedstock supply projects presently under consideration. A high proportion of these products is based on technologies for which the inherent quality of the is an essential factor. Location specific factors also play a large part in determining the cost of production. As the demand for such products grows, and the availability of favourably located sources of ilmenite of suitable quality declines, it can be expected that existing beneficiation technologies will become increasingly constrained. Existing beneficiation technologies, and those which have been developed, but are not yet commercially applied, are reviewed. Future issues which are likely to impact on the cost effectiveness of these technologies, or the quality of final products, are identified. These factors suggest directions for development of ilmenite beneficiation technologies to achieve economic production of the quality of feedstocks which will be demanded by the TiO2 pigment industry in the future.

Jan 1, 2001

Quay Magnesium Limited (QMG) listed on the Australian Stock Exchange in late September 2004 having raised approximately A$30 million with the object of designing, constructing, commissioning and operating a 15 000 tpa magnesium alloy production facility in Nanjing, China. Site construction commenced in February 2005, with installation of all major components completed by the end of October 2005. Hot commissioning was simultaneously commenced with the final stages of installation, leading to the first stage of continuous ingot casting by mid November 2005. Since that time, ramp-up to the name plate capacity has been undertaken. This presentation highlights some of the more significant technical and logistical hurdles that have had to be overcome in order to meet the high quality product specifications required by a range of QMG customers.

Jan 1, 2006

By A J. Gunson

The Norman B Keevil Institute of Mining Engineering, or the Department of Mining Engineering (the Department), at CanadaÆs University of British Columbia (UBC) is addressing the integration of sustainable development concepts into mining education and research on behalf of industry and society. Over the past decade, the DepartmentÆs education and research model has been evolving to incorporate collaborative and multidisciplinary strategies, where sustainability initiatives are taught in classes, supported in research and discussed in a voluntary collective of mostly graduate students û the Sustainability Working Group (SWG). The SWG has brought together a diverse array of disciplines from academia, industry, government, non-governmental organisations (NGOs) and mining communities. The operational mechanisms and structure of the SWG have enabled momentum to be gained through several multidisciplinary educational and research networking initiatives. It acts to attract new students with diverse backgrounds, foster innovative research, develop relationships and networks, and create the space to discuss progressive ideas and projects. The original cohort of SWG graduate students laid the foundation for sustainable research initiatives within the Department at UBC. Novel research has incorporated topics such as: community resilience, artisanal small-scale mining, sustainability indicators and corporate social responsibility, environmental assessment and impact benefit agreements and the recycling of waste. Propelled by the support of the Department and inspired by the works completed, a host of new graduate students have embarked on their research quests to integrate sustainability principles into their projects. Such projects include: social impacts and benefits of mining, artisanal small-scale mining, community health, the production and transport of mine pollutants, mine waste management, mineral process plant design and the evolution of community education and mine policy. This paper reports on the departmentÆs continuing research and development towards an understanding and evaluations of the ongoing contributions of mining to sustainable development.

Jan 1, 2009

By B Dold

Western Europe is a dynamic region, with an emerging co-operation between the individual nations both politically, economically, technically and scientifically. The European Union, today with 15 member States and with a range of central European States applying for membership, is a catalyst for this Cupertino, using a combination of EU funds, for financing research initiatives, and legislation to enhance development of technology and environmental performance. Europe is a major net importer of metals but with a large potential for own production, in particular in the accession countries. The metals and mining sector is furthermore identified as having a large potential to generate wealth both in todayÆs EU and in the future, widened Union. This paper provides a chart of examples on the many research initiatives presently underway in Europe, addressing environmental issues related to mining. The list of programmes and projects does not claim to be complete; it is rather an illustration on the wideness of the approach, describing various ways for transboundary Cupertino. The approach taken by many of the programmes goes beyond the strict ARD scientific area and therefore only a limited number of the many programmes can be identified as ARD research programmes. Also national programmes, without EU funding, are operating, eg in Sweden, Germany, and UK. The picture is continuously changing with new programmes being commissioned and old ones being completed.

Jan 1, 2003

By E Villaescusa, A Kusui, R Talebi, R Hassell, C Arcaro

Northern Star Resources (NSR) operates several seismically active mines as part of its Kalgoorlie Operations. In order to successfully continue mining at depth in increasing stress conditions, strategies need to be developed to reduce, control and manage the impact of seismicity causing damage to the rock mass. Consequently, a research partnership was developed with the WA School of Mines (WASM) through Mining3. The main aim of the project was to develop appropriate ground support standards that could withstand the expected dynamic response with minimal to no rehabilitation required for the life of that excavation. The project utilised a design methodology for determining the required energy demand based on detailed geotechnical mapping, probabilistic analysis of wedge formation and an estimate of rock ejection velocity based on uniaxial compressive strength of the intact rock (Villaescusa et al. 2016). The ground support scheme consists of high tensile chain link mesh, resin encapsulated de-coupled posimix bolts and plain strand cable bolts, in one, or multiple passes together with plain shotcrete. Implementation of the design posed several challenges including how to install the chain link mesh, maintaining the required productivity, ensuring quality control, and understanding the interaction of the several ground support components within the scheme. The implementation of the system within a trial area was successful from development mining to open stope extraction. The most significant field verification of the system occurred with near field M+1.9 seismic occurring in proximity to an operating long-hole drill. Despite large displacements exceeding 0.5m in places, there was no significant ejection of rock or failure of the ground support system. Following the successful trial, the ground support design methodology and standards have been implemented across several NSR sites. The system forms the basis for the successful extraction of resources in future high seismic risk areas.

Mar 15, 2021

By G J. Harbort, K Lam, C Sola

The relationship between the geology of porphyry copper deposits and their processing performance is an area of interest. Being able to predict comminution properties of the ore from physical characteristics and geological descriptions would allow an increase in the precision of capital cost estimates, operating cost estimates and throughput rates. This geometallurgical approach would reduce the requirements for expensive comminution tests.As the comminution circuit is the highest capital cost item in the plant and a possible throughput bottleneck, understanding the variability in hardness within the orebody is critical. A geometallurgical model allows calculation of ore hardness values in mining blocks from ore characterisation data. This model subsequently uses a combination of simulation and power-based approaches to relate ore hardness and flotation feed size to grinding circuit throughput.This paper reviews the geometallurgical models developed for seven porphyry copper deposits and discusses the strengths and shortfalls of the methodology and similarities and differences between the different deposits.CITATION:Harbort, G J, Lam, K and Sola, C, 2013. The use of geometallurgy to estimate comminution parameters within porphyry copper deposits, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 217-230 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By S Lehane, S Pearce

The characterisation and assessment of waste rock has been the subject of considerable research, and many guidance documents have been published both internationally and within Australia. While these documents provide detailed information on how to characterise waste rock, there is not a great amount of detail on how to determine the optimal waste management options from an operational viewpoint. For example, typical questions that a mine operator would seek answers to include: What placement method should be used (eg end tipping versus paddock dumping)? What is an optimal tip head height for waste placement in a storage facility? How should sulfide grade control be carried out?Defining the contributing factors to waste management and waste material placement and assessing the contribution of each variable directs these assessments towards a semi-qualitative and quantitative methodology. Quantitative methodologies show an increase in the confidence of these assessments by providing logical, measureable assessments.As part of a strategic assessment for waste management at an active mine site, a detailed risk-based investigation of the influence of variables common to waste placement was completed. These variables included placement method, placement height, sulfur grade and material conditioning (eg compaction) on the associated risks of waste material storage. The assessed risks include temperature assessments (potential for thermal take-off as a result of spontaneous combustion), toxic gas production and flow and acid production potential. Applying a numerical modelling approach to the assessment of the different waste material placement strategies allows for the variation in risk to be graphically presented and communicated through risk matrices and histograms.CITATION:Pearce, S and Lehane, S, 2015. Quantitative risk assessment tools to assist with waste management and placement guidelines, in Proceedings Tailings and Mine Waste Management for the 21st Century, pp 353–364 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By S Basu, S L. A Gowravaram

CaF2 has been a common constituent in a wide variety of welding fluxes, including those used for submerged arc welding (SAW). The widespread use of CaF2 stems from its role in lowering the liquidus temperature as well as the viscosity of the molten slag that covers the weld pool. However, the harmful effect of fluoride evaporation from molten flux, on the environment as well as the health of the users is becoming increasingly evident over the years. This has led to increasing attention towards reducing the CaF2 concentration in the fluxes. The fluoride-free formulations face the challenging requirement to maintain the thermo-physical properties (viscosity, liquidus temperature etc) like those observed in fluoride-containing fluxes. In the present work, three fluxes with compositions in the CaO-MnO-SiO2-Al2O3 system have been identified as promising alternatives to the CaF2-rich fluxes. However, the thermo-physical properties of any such flux need to be comparable to CaF2-based commercial SAW fluxes before it can be adopted for regular use. The single hot thermocouple technique (SHTT) has been used by several researchers in the past as a tool for observing the melting and solidification characteristics of fluxes. This device has been developed in the present work and is used to characterise the melting behaviour of the fluxes. The measured solidus and liquidus temperatures from SHTT were compared with the results from differential thermal analysis (DTA) and simulations using the FactSage™ software for a comprehensive understanding. In spite of having a slight deviation in the measured values from the multiple techniques, the results obtained from these multiple methods show that the selected compositions could be potential CaF2 free alternative welding fluxes.

Jun 19, 2024