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By H Hy÷tyniemi

In this paper multivariate data analysis performed on a new multi-camera system implemented to zinc flotation circuit of PyhSsalmi mine is presented. Image-analysis-based system was developed to take advantage of the commonly known fact that the changes in the flotation process are reflected to the visual appearance of the froth surface. Most often the changes are seen first in the froth and later in other process measurements. The image variables are already utilised in closed loop control and considerable savings are achieved with the current setting, but the results coming from the separate cells are used individually. This is clearly not the optimal way to take advantage of the many measurements coming from different locations of the process. A better approach would be for example to use the measurements coming from the early stages of the process to predict the behaviour (or improve the quality of measurements) in the later stages. The methods described in this paper are aimed to improving the situation in this sense.

Jan 1, 2005

By T Suwa, S Ishida, J Xue, S Fuchida, H Shimada, Y Aoki, C Tokoro

Pyrite depression with prolonged pre-conditioning treatment in high salinity water has attracted much of researchers’ interest in recent years considering the increased utilisation of multiple stage flotation, closed water circuits, clay minerals, and sea water in flotation plants. In this study, the role of calcium (Ca)/magnesium (Mg) precipitates in stabilising the dissociative ferric hydroxy-xanthate (FHX), and its effect on modifying the balance of hydrophobic/hydrophilic species on the pyrite surface were primarily investigated. The total amount of extractable Fe-bearing species on pyrite concentrates and tailings after floatability test was quantitively determined using ethylenediaminetetraacetic acid (EDTA) extraction tests combined with inductively coupled plasma optical emission spectroscopy (ICP-OES). A more evident accumulation of extracted-Fe in pyrite concentrates rather than it in pyrite tailings was observed at both pH 9 and 10.5 when pyrite was pre-conditioned in Ca/Mg-bearing solutions for 360 min. Fourier transform infrared (FTIR) spectroscopy showed the main xanthate derivatives changed from di-xanthogen (1155 cm-1 ) to FHX (1167 cm-1 ) on the oxidised pyrite samples that were preconditioned in Ca/Mg-bearing solutions. Scanning electron microscopy-energy dispersive spectrometry (SEM-EDS) suggested the preferential accumulation of FHX upon secondary Ca/Mg-bearing precipitates as reflected by the higher Fe/S ratio together with the decrease of O element herein after xanthate conditioning. Although the hydrophilic secondary Ca/Mg/Fe-bearing minerals on the pyrite surface generally deteriorate pyrite’s floatability, the upper section of these secondary hydrophilic aggregates is partially covered by FHX alongside with further multilayer-adsorbed di-xanthogen. The precipitated Ca/Mg-bearing precipitates promotes the immobilisation of dissociated FHX derived from the reaction among iron oxyhydroxides and xanthate anions upon the localised secondary Ca/Mg/Fe-bearing minerals via acid–base complexation. Therefore, this phenomenon alleviates the hydrophilic modification of secondary Ca/Mg/Fe-bearing minerals to pyrite considering the immobilised FHX upon localised precipitates shows a slight hydrophobicity, and meanwhile, the upper FHX benefits the multilayer adsorption of di-xanthogen via the interaction among their inner hydrophobic alkyl chains.

Aug 24, 2022

The adoption of new technologies is accompanied by risks that the stakeholders will wish to understand and minimise. The process of developing a dynamic simulation and the plant it will be used in provides a discipline and attention to detail that highlights and provides an opportunity to mitigate risks that will exist in a production environment. The simulations will enable investigation of what the outcome of process failures will be and the impact maintenance. Enumerating this information will enable designs to be optimised and operating and control strategies to be tested.The success of new technology is dependent on the operators and their understanding of it and the machines that use it. In this context dynamic simulations can provide training and experience without risk to personnel, equipment or production. This experience will include situations that would not be induced in a production plant for training purposes. This paper outlines a generic template for a dynamic simulation that can be used to evaluate the introduction of an emerging technology into an operating environment. It includes process flows and surge capacity, breakdown and maintenance, operator interactions and availability, push and pull production scheduling and system control.

Sep 26, 2011

By M-A Van Ende, N Kumar, I-H Jung

In order to utilise the powerful thermodynamic databases for process simulations, a concept called Effective Equilibrium Reaction Zone (EERZ) was introduced to couple thermodynamic database calculations and reaction kinetics. Using the EERZ concept, many process simulation models for steelmaking processes have been developed within the FactSage steelmaking consortium. After validation of the simulation results by comparing with plant data, the simulation models have been applied to improve plant operations. Several success stories of the improvement of real steelmaking operations are shared. A new user-friendly FactProSim software developed for building process simulations is introduced.

Aug 21, 2024

By T Roberts

The transition of mechanical cooling refrigerants from their inception in the 1800s through to the current day has been driven by several factors. Original refrigerants such as sulfur and carbon dioxide, chloromethane and ammonia, whilst effective came with toxicity and/or flammability issues. In 1930 DuPont trademarked a new synthetic refrigerant known as Freon® 12, this development was the introduction of ‘chlorofluorocarbons’ (CFCs).Throughout the 1930s and 1940s additional synthetic refrigerants were developed, namely Freon® 11 and Freon® 22. Due to their non-toxic and non-flammable characteristics, synthetic refrigerants were extensively used for domestic, commercial and industrial applications for the next 60 years.In 1985, one of the first scientific papers suggested a potential mechanism linking CFCs and areduction in the density of the ozone layer. In 1987 the Montreal protocol is ratified; it is the first UN treaty to be ratified by every country on earth. Due to CFC’s ozone depletion potential (ODP), the treaty required the consumption of CFC’s to be reduced by 50 per cent over the next ten years. By 1996 the phase out of CFC’s (Freon® 12) is completed, the phase out of HCFC (Freon® 22) refrigerants comes into effect.On 1 January 2018 the phase down of HFC’s begins. Whilst having zero impact on the ozone layer HFC refrigerants have high global warming potential (GWP). As we transition through the HFC phase down (2018–2035) we are beginning to see the emergence of what some consider to be the fourth synthetic wave, hydrofluoro-olefins (HFO’s). HFO’s and their blends have zero ODP and low GWP’s, ranging from 150 to less than 1. The reduction in GWP with HFO’s typically comes at the expense of flammability, which is not ideal. Each refrigerant has its optimal application, therefor when considering refrigerant choices for mining systems, a complete assessment of the environmental, health and safety, efficiency and commercial impacts should be considered now more than ever.

Oct 12, 2022

Mining is a global industry. The conference is a good example of this, as itÆs jointly organised by professional associations from Canada, Australia and South Africa, and has attracted speakers and delegates from around the world. I commend the organisers for their initiative. I am pleased to be asked to participate in this panel û although I would hasten to add I see myself as perhaps an informed observer rather than an expert. It wonÆt be news to most in this room that AustraliaÆs mining sector is booming. As one of the most productive and diversified mineral regions in the world, this activity is also something that has not escaped the attention of CanadaÆs largest mining companies! This means that I follow what is happening in the industry and more specifically what might be occurring here. Two-way investment between Canada and Australia stood at $9.8 billion in 2005 with Canada as the seventh largest overall investor in Australia with $8.22 billion in investments. The majority of this investment is by Canadian minerals and metals companies. In recognition of the importance of Canadian investment in this sector in Australia, I maintain close contact with our companies. By way of example, in the past two months I spent a week in Western Australia visiting Perth and meeting with companies for example, like Teck Cominco and LionOre as well as seeing various Barrick Gold operations in Kalgoorlie. I attended the opening of AlcanÆs new Asia Pacific Headquarters in Brisbane in August and just two weeks ago was in Cowal, NSW for the opening of BarrickÆs new mine there. Having met with BHP Billiton in Vancouver, IÆm equally aware of active Australian mining interests in Canada. This is not designed to indicate how active I am but rather to demonstrate the dynamism in the mining industry and the diversity of Canadian mining interests in this country and Australian interests in Canada.

Jan 1, 2006

By B Crowdey, J Wall

The particular underground operation relating to this paper is a gold producer and has an orebody predominately consisting of rhyolite and marcasites pyrite. The ore has been identified as being reactive to nitrates.Operations currently utilise two twin boom Tamrock™ Super-Drill Jumbos for development mining. Capital (waste) headings have a nominal size of 7 m wide × 6 m high, while ore headings are designed at 5 m wide × 5 m high, with the lower reaches of the mine narrowing down to a 4.5 m × 5 m design. Production drilling is currently undertaken with an Atlas-Copco L6 Solo. Due to the reactivity of the ore, inhibited emulsion phase bulk explosives are used for all blasting activities, with electronic detonators utilised in the production sequence.Sublevel shrinkage stoping is utilised when the orebody is stronger than the host rock. After blasting the ore, and during extraction, the surrounding host rock cannot maintain integrity and it ‘collapses’ on top of the ore. Gravity forces this collapsing rock to follow the blasted ore through the drawpoints.The highest risk involved with sublevel shrinkage stoping is the necessity for charge crews to work upon ‘rills’ at the drawpoints, which are occasionally unstable, to charge the next blast ring to be fired. To overcome this issue a loading technique called ‘precharging’ is used whereby two to three rings are charged, but only the first ring is fired. This technique can minimise risks by taking the charge crew away from the rill and brow.As this mine contains hot and reactive ground, strict guidelines from the Australian Explosives Industry and Safety Group Inc (AEISG) are adhered to. These guidelines relate to the sleep time for the precharged rings.This paper describes the issues faced with precharging in hot and reactive ground, the monitoring required and the systems and procedures that were put in place to enable a successful outcome.CITATION:Crowdey, B and Wall, J, 2014. Precharging sublevel shrinkage production rings in hot and reactive ground with electronic blasting systems, in Proceedings 12th AusIMM Underground Operators’ Conference 2014 , pp 283–288 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Mar 24, 2014

By G F. Johansen

The erratic and localised occurrence of economic gold grades is a common feature of high-nugget effect gold veins. The nugget effect is a consequence of small-scale geologically controlled enrichment, and the inclusion or exclusion of sparse gold particles because of the sampling process. Such deposits do not always contain visible or coarse gold, and can be characterised by fine gold particles. Economic grade accumulations are generally contained within discrete oreshoots, which are surrounded by barren to low-grade material. Problems are often encountered where small sample types (eg drill core or channel samples) often vastly understate in situ grade, due to their general inability to intersect rare gold particles. As a result, the definition of grade and its distribution is often challenging, and leads to substantial resource uncertainty. Proxies, or indicators for grade, can help the geologist gain a better understanding of grade distribution and grade potential. These are based upon geological (eg mineralogical, textural, etc) and/or geochemical (eg specific elemental ratios, fluid inclusion compositions, elemental correlations, etc) criteria. The paper discusses the use and application of such proxies through three case studies.

Jan 1, 2004

Gold has been known and mined in Australia for over 150 years. It occurs and is mined in all States and the Northern Territory. In the past 30 years approximately 8300 t of gold has been mined and gold exports have contributed over $106 billion to the Australian economy. In the first three quarters of the Australian financial year 2006 - 07 (ending 30 June 2007) gold exports were valued at $7.3 billion, which was 13 per cent of the value of all minerals exported and five per cent of AustraliaÆs total goods and services exports over the period. Clearly gold has been and remains a very important component of the Australian economy.

Jan 1, 2007

By Eren H

For a hydrocyclone of fIXed geometry, DC, Di, DO and ? are constants, the variable parameters affecting the performance are Qi, Fi, Du and H. (See Appendix 2 for definition of symbols).The relationship between d50c, Qi, Fi, Du and H gives models which can effectively be used for performance predictions. Such models have already been established by Lynch et al and by Plitt.These models have been tried in a limited manner under continuous operating conditions for on-line cowol. For on-line control effective and accurate instrumentation is required for which a new set up is proposed. Using this set up, a new model was established. A feature in this model is that deviations from the norm of operational parameters affecting d50c were considered. It is shown that these deviations generated by the disturbance of one or more of variations in the parameters, can be monitored by a computer and suitable signals generated to control servo mechanisms for restoring the required d50c value.The logic followed in developing the computer software is described and the application of the model is indicated.

Jan 1, 1990

At the outset, I guess we should define what we mean by "com- modities". In the 20 minutes or so which I have for this paper, it is impossible to tackle all commodities -one would need to con- sider not only the base metals but also the ferrous iron and steel products as well as energy commodities such as coal, oil and even uranium. For the purpose of this address however, I would prefer to refer to the principal non-ferrous commodities: copper, lead, zinc, aluminium and nickel and, I would like to consider some of the changes which have taken place in the industry over the past 20 years-and the likely reasons for these changes. I would also like to dwell a little on the future and some of the key issues which-may influence the future path and direction of the metals industry.

Jan 1, 1988

By S Versace, D Arnott, D Bojcevs, A Shaw

The George Fisher deposit is a significant sediment hosted silver-leadzinc resource located 2 km north of the Hilton Mine in NW Queensland. The George Fisher feasibility project involved the completion of underground and surface drilling programs to delineate Measured and Indicated Resource which could be converted to an Ore Reserve through mining and commercial studies. The geological information which was collected and used for the feasibility study included a major program of diamond drilling, predominantly from underground sites, but with some drilling also completed from surface. All drillcore was geologically and geotechnically logged, sampled and assayed. Data was also collected from underground cross-cut and drive development which was mapped for rocktype, ore distribution, structure and geotechnical condition. This new geological data, generated during the Pre-Feasibility and Feasibility stages, was combined with results of all previous drilling campaigns in the George Fisher area to produce a comprehensive database on which geological modelling and Resource estimation could be based. To allow fast and accurate collection and utilisation of data from the drilling program, digital collection processes were used where possible. This resulted in rapid data entry into the project database, significantly enhanced data quality, 100 per cent data ownership within the project team and increased productivity levels. Processes used during the project data collection program are described, lessons learned are related and suggestions for ænext timeÆ are listed using the benefit of hindsight.

Jan 1, 1998

By S Hanrahan, S McLaughlin

A case study is presented that details the safety journey at a North American project involving two major contracts: a 1000 m shaft recovery and rehabilitation, and the development of a drainage gallery in a large open pit operation. In the early stages of the contracts, there were a number of incidents that created tension between the owner and contractor, which resulted in the contractor being placed on a final warning with almost imminent potential termination. As a result of this, it was agreed to initiate a focused safety recovery plan as a ‘last chance’.Over a period of two years, the engagement and consequent performance of the contractor was turned around, steadily working to set it up for success such that in one of the contract work areas, a record of ‘one year LTI (lost time injury) free’ was achieved. The journey involved the owner and the contractor teams working cohesively to educate all parties in the safety requirements and, most importantly, providing the context and understanding for certain requirements being put in place. Early on in the process, it was recognised that the owner team unknowingly was an impediment in that they did not fully understand the safety requirements and so was not able to lead the way for the contractor effectively. The journey to rectify the situation was supported and followed up by focused engagement with the project team, which generated a progressive improvement in a very challenging environment.In particular, the contractor turnaround was significant and of enough value for the contractor to ultimately export some of the safety systems from this site to other contract sites. This demonstrated the ultimate benefit of the contractor understanding and buying into a safety culture and system.CITATION:Hanrahan, S and McLaughlin, S, 2016. Winning the safety battle, in Proceedings International Mine Management Conference, pp 181-186 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By P Barrette

The manual gravimetric drying moisture determination methods currently employed by most mineral processing plants fail to provide timely and accurate information required for automatic control. The costs associated with transporting and handling concentrates represent a major portion of the overall treatment price. When considering the cash flow of a mining operation that is governed by both the smelter contract, with moisture penalties and the quantity and quality of the concentrates shipped, any tool that provides real-time feedback on the process is vital (Edwards, RP 1994). The introduction of an on-line moisture sensor would become a welcome addition to the process control field instrumentation package now applied. A novel on-line determination system for ore concentrate moisture content would replace the tedious manual procedure. Since the introduction of microelectronic-based control systems, operators have strived to reduce the treatment costs to the minimum. Therefore a representative and timely determination of on-line moisture content becomes vital for control set points and timely feedback. Reliable sensors have long been on the æwish listÆ of mineral processors since the problem has always been that you can only control what you can measure, (Konigsmann, 1990). Today, the task of moisture determination is still done by the classical technique of loss in weight utilising uncontrolled procedures. These same methods were introduced in the earliest base metal concentrators. Generally, it is acceptable to have ore concentrate moisture content vary within a range of seven to nine percent, but controlling the moisture content below eight percent is a difficult task with a manually controlled system. Many times, delays in manually achieving reliable feedback of the moisture content results in the moisture varying from five to twelve percent before corrective actions can be made. This paper first reviews the traditional and widely available methods for determining moisture content in granular materials by applying physical principals and properties to measure moisture content. All methods are in some form affected when employed on mineral ore concentrates. This paper introduces and describes a unique and promising novel on-line moisture sensor employed for mineral processing de-watering applications, which not only automates the tedious tasks but also results in reliable moisture feedback that can be used in the optimisation of the de-watering process equipment such as pressure or vacuum filters and fuel-fired driers. Finally, two measurement applications will be presented to indicate the usefulness and to summarise the measurement requirements for the proposed method of employing drag force and mechanical properties of the material itself to determine the moisture content. The commercial model of the equipment is described with the features and benefits to the users summarised.

Jan 1, 2003

Many types of micro-organisms inhabit iron ore deposits contributing to biogenic formation and conversion of iron oxides and associated minerals. Bacteria such as Paenibacillus polymyxa are capable of significantly altering the surface chemical behaviour of iron ore minerals such as haematite, alumina, calcite and silica. Differing mineral surface affinities of bacterial cells and metabolic products such as proteins and polysaccharides can be utilised to induce their flotation or flocculation. Mineral-specific bioreagents such as proteins are generated when bacteria are grown in the presence of haematite, alumina, calcite and silica. Alumina-grown bacterial cells and proteins separated from such cells were found to be capable of separating alumina from haematite. Biodegradation of iron ore flotation collectors such as amines and oleates can be effectively utilised to achieve environmental control in iron ore processing mills.

Jan 1, 2009

By H Turrer, M Badawi, R Belissont, Y Foucaud, E Kleiderer, L Southavy, J Mesquita, Y Basselin

The Mont Reed iron ore deposit, owned by ArcelorMittal, is situated approximately 140 km southwest of the Mont-Wright mine in the southern region of the Labrador Trough, Canada. Acquired by Québec Cartier Mining (QCM) in the 1960s, the Mont Reed mining property has remained unexploited due to the complex nature of the ore in the area. However, during the last years ArcelorMittal’s R&D team has been dedicated to developing a process to beneficiate the Mont Reed ore and produce high-quality pellet feed suitable for direct reduction furnaces. Extensive research revealed that achieving a good liberation degree of particles required grinding the material below 75 μm (P80 of 53 μm). To find the most effective technology for this task, a detailed comparison between ball mill and vertical stirred mill grinding was conducted. Both grinding technologies underwent detailed testing in bench-scale experiments. The ground products were comprehensively characterised, including size distribution analysis and chemical analysis per size fraction. Additionally, liberation analysis was performed using an automated scanning electron microscope (SEM). To determine the grinding specific energy, a method previously developed at Samarco (Brazil) for fine grinding of iron ores was employed. Furthermore, magnetic separation and flotation tests were conducted on the ground products. After a thorough evaluation of all the results, it was observed that both ball mill and vertical stirred mill grinding produced samples with similar physical characteristics. However, the vertical mill demonstrated higher efficiency in grinding the material. To conclude the study, an economic evaluation was conducted for both options considering various factors. Overall, ArcelorMittal’s R&D team’s dedicated efforts have brought them closer to unlocking the potential of the Mont Reed ore deposit and paving the way for its future utilisation to the production of high-quality pellet feed.

Sep 18, 2023

The Jurassic Walloon Coal Measures crop out over much of the Moreton Basin and contain numerous thin, banded coal seams which have been mined at various locations since the 1870s. Historically most mining has been by underground methods. Increased exploration during the 1970s and 1980s has led to the delineation of significant open cut coal resources and to the development of the Oakleigh, Jeebropillly and Ebenezer open cut coal mines in the Rosewood-Walloon area. Over 2 170 million tonnes in-situ of shallow, high volatile bituminous coal with a mean maximum vitrinite reflectance of between 0.5 and 0.6 have been proven in the Basin.

Jan 1, 1991

By D Carroll

Mining of the zinc, lead and silver deposit at the Broken Hill Southern Operations site has been occurring for over 100 years. As a result of this, a significant amount of high-grade ore is now taken from narrow remnant pillars left between old stopes and zones of previously mined ground. Stopes have been filled with either hydraulic fill (also known as ‘sandfill’), cemented hydraulic fill (cemented sandfill), waste rock backfill or a mixture of these fill types.In the last ten years, there has been considerable success mining through narrow pillars where sandfill is exposed in the development face and/or walls using a ‘shell’ support regime, wherein a layer of bolted mesh is sandwiched between two layers of sprayed fibrecrete (25 mm fibrecrete, then mesh and bolt, followed by a final 50 mm layer of fibrecrete). Shell support is also used in very poor, broken, relaxed ground conditions and in areas filled with cemented fill (sandfill with a minimum four per cent cement content).The next stage of innovation has been to develop a technique for mining through old stope voids filled with uncemented sandfill, known locally as ‘contours’ (old cut-and-fill working), an activity where unconsolidated sandfill can run at the face and from the backs. The challenge is to prevent exposed sandfill in the face and the backs from failing before it can be supported.To achieve this, the Southern Operations mine has implemented a technique in which 6 m long spiling bars are used to strengthen and stabilise the sandfill in front of the face. The hollow steel bars are driven in around the heading perimeter in a closely spaced pattern then pumped full of grout. The bars and the grout stabilise the sandfill in front of the face, preventing it from failing into the drive during excavation and prior to further support being installed.A final support system consisting of shotcrete, mesh, bolts and steel girders is installed as excavation progresses. Both the initial and final support systems are essentially passive support systems designed for a low-stress environment (as the stress originates mostly from the mass of unconsolidated sandfill).This process is slow and labour intensive. Fifteen separate cycles of people/machinery are needed to progress one equivalent heading cut (compared to six for a standard fibrecrete- and bolt pattern-supported rock face heading). This slow pace introduces scheduling challenges, but the process opens up parts of the orebody that were previously uneconomical to mine.CITATION:Carroll, D, 2014. Mining through sandfill using spiling bars, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 95–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

By J MacDiarmid

Atlas Copco is a leading provider of industrial productivity solutions (Atlas Copco, 2007) and one of the worldÆs largest suppliers of rock drilling equipment. The business division of Atlas Copco Construction and Mining Technique is based in +rebro, Sweden with the majority of their equipment produced in a number of facilities within the area. As part of the 2006 AusIMM/Atlas Copco Scholarship I was fortunate enough to visit these facilities to experience first hand this truly unique global company. Through numerous presentations on the various divisions and products manufactured by the company, I saw the broad range of products and services offered by the company and came to realise it is much more than just selling drills. Other highlights included a brief love affair, a tour of EuropeÆs largest underground mine (or factory depending who you ask), a drink at the ice bar at the ice hotel in JukkasjSrvi, and a number of dinners of reindeer. Overall this it was a truly amazing experience with all involved with the program going out of their way to ensure I got the most out of the trip. More importantly, through no effort at all, everyone naturally conveyed their passion for the industry and the company which is a great credit to the æAtlas Copco WayÆ thereby creating a company æcommitted to your superior productivity through interaction and innovationÆ.

Jan 1, 2007

Laboratory tests were conducted to study the effects of thrust or pull-down force and rotary speed on the vibration signatures of a particular drill in a known rock type, and to determine how the vibration signatures could be used to assess bit wear. The vibration signatures were analysed using a Wavelet Transform analysis technique, which decomposes the signals in multi-bands of frequency and presents the results simultaneously in time and frequency domain. Results show that as the bit wears, large fluctuations in amplitudes in the high frequency ranges occur, and prominent peaks in the low frequency ranges were observed for a worn bit. The Wavelet Transform technique provides an appropriate and effective metrics for monitoring and evaluating the state of wear as drilling progresses through the post-processing of wavelet coefficients. This study provides a basis for the development of an on-line detection technique of bit wear in rock drilling through Wavelet Transform technique or time-frequency analysis that can be used in real time.

Jan 1, 2000