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Nickel WestÆs Kalgoorlie Nickel Smelter operates three Peirce-Smith converters, each processing 110 tonnes of matte per charge. The vessels are lined with chrome-magnesia refractory with a mouth traditionally constructed from steel liner plates, protected with cast refractory. Mouth refractory is damaged by molten material and the action of cleaning solid buildup off the mouth. Once damage has accumulated, the mouth must be frequently maintained with hot refractory gunning or a mouth leak may occur. Such a leak requires a 32 hour repair period. A converter mouth redesign program was undertaken with the aim of reducing the rate of mouth damage during operation, eliminating mouth leaks and shortening mouth replacement times during vessel rebuild periods. An overview of the redesign process and operational performance is contained herein.

Jan 1, 2005

By Premur V

In industry and power production and distribution large quantities of fine wastes are produced. These are above all fly ash and phosphogypsum. Attempts are made to use them as secondary raw materials in industry and construction. Since they contain dangerous and harmful components or are nonhomogeneous their direct application is limited so that they are treated as waste. This paper reports on tests conducted with the aim of agglomerating the mentioned fine industrial wastes by pelletisation. The aim of this resarch was to obtain agglomerated product suitable for handling, transport and dumping. At the same time efforts were made to incapsulate harmful components by producing pellets with protective shells. Next, pellets without binders and with different binders were produced. Strength, resistance to freezing and solubility of pellets were tested. All the fine industrial wastes under survey were found to be suitable for pelletisation. The utilisation of appropriate binders ensures pellet strength required for safe handling and ecologically sound deposition of pelleted Material.

Jan 1, 1993

Modern mining and coal cleaning techniques lead to the generation of large quantities of fines which give rise to problems in their storage, handling, transportation and further processing. Pelletisation, a method of particle agglomeration, can alleviate such problems. This paper provides a brief overview of the principles of pelletisation and a survey of the coal pelletisation literature. Then it reports results from an experimental investigation of the effect of surface active reagents on coal pelletisation. Finally the paper is concluded with a few remarks on applying the results from the experimental study to practical coal agglomeration.

Jan 1, 2000

By B H. Yin, S Mendoza, M Nusheh' C W Bumby, A Zhang

Hydrogen-direct-reduction of iron ore in a vertical shaft furnace is a potential process that could significantly reduce CO2 emissions from the steel industry. This approach requires the pelletisation of iron ore fines, which then undergo high temperature induration to strengthen the pellets before they can be fed into the shaft furnace. Here we report on investigations into the disc-pelletisation behaviour of New Zealand titanomagnetite ironsand, and its subsequent induration and hydrogenreduction behaviour. Initial studies focused on the effect on pellet strength of varying ironsand particle size and induration conditions using bentonite and a commercially sourced carboxymethylcellulose binder. Green pellets formed with ironsand of average particle size of 65 μm exhibited optimal strength. The compressive strength of these pellets after induration at 1200°C for 2 hrs in air was measured to be 976 N. Interparticle bonding within the indurated pellets occurs due to a combination of titanohematite recrystallisation (from oxidation of titanomagnetite), and the formation of a liquid bonding phase due to interdiffusion with the bentonite and subsequent melting. Further investigation with various binders showed that a combination of both organic and inorganic binders was essential to achieve optimal pellet strength. Carboxymethyl-cellulose binders provides green strength, whilst inorganic binders such as bentonite promoted high indurated pellet strength. Hydrogen reduction tests in a thermogravimetric furnace showed that all the pellets could achieve a maximum reduction degree of 97 per cent at 1100°C, indicating that the different pellet preparation procedures had no significant effect on reducibility. Pellet recipes developed in this work are now being used to investigate vertical shaft hydrogen-DRI processing of NZ ironsand in a kg-scale laboratory reactor.

Sep 18, 2023

By Xu Z, Hu C

An attempt has been made to investigate the performance of green pellet formation of the Daye magnetite concentrate from the weak-magnetic separation plant. The optimum conditions for the commercial production of green pellets was found through experimental research. The satisfactory size range for balling is 75 ¦ 3 per cent -200 mesh. The suitable moisture content is between 8.7 and 9.1 per cent and the optimum amount of bentonite added is between 1.5 and 2.5 per cent. The emphasis is on the size of the feed materials since the grinding fineness, which can be obtained at the plant, at most is 78 per cent -200 mesh. If the optimum fineness for the pellet formation is above this value, this means that the concentrate must be re-ground before balling. The results from experiments showed that a good quality green pellet can be attained by using materials below 78 per cent -200 mesh, which provides a strong foundation for the commercial production of green pellets.

Jan 1, 1999

A programme began in 1970 to eliminate the charging of fine materials into the copper blast furnace of The Electrolytic Refining and Smelting Company of Australia Ltd. at Port Kembla, N.S.W. A disc pelletiser and drying plant has been installed as part of this programme. Feed material for the plant is a blended mixture of copper concentrates, fine copper-bearing residues, and blast furnace cyclone dust. The operating parameters for the disc have been calculated by comparing the perform- ance of three other discs on the plant. Re- search work on choice of binder, feed moisture and drying conditions has led to the production of reasonably high strength pellets. A description of the pellet plant and modifications necessary to overcome the initial performance problems is given.

Jan 1, 1974

By X Hu, C-C Yang, J Pan

In this work, preheating and roasting tests of pellets made from blends of Western Australia ultra-fine (WAU) magnetite concentrate and Chinese domestic magnetite concentrate or Brazilian hematite concentrate were carried out. The results showed that pellets made from 100 per cent WAU magnetite concentrate possesses inferior preheating and roasting performance when preheating at 1050°C for 20 minutes and roasting at 1300°C for 40 minutes, the compressive strength of preheated and fired pellets is 502 N/pellet and 2313 N/pellet, respectively. When 40 per cent Chinese domestic magnetite concentrate or 20 per cent Brazilian hematite concentrate was blended with 60 per cent or 80 per cent WAU magnetite concentrate, the appropriate preheating temperature of the pellets are reduced from 1050°C to 950°C and 975°C, and also the firing temperature of two types pellets are decreased from 1300°C to 1250°C and 1280°C respectively. Moreover, the compressive strength of fired pellets is obviously improved up to 2746 N/pellet and 2630 N/pellet respectively. Microstructure analysis of the fired pellets made from 100 per cent WAU shows its poor growth of Fe2O3 grains, low interlinkage degree of hematite grains, small size of crystallised grains and high porosity of pellet; however, the fired pellets that blended with domestic magnetite concentrate or with Brazilian hematite concentrate have fully growth of Fe2O3 grains, closer interlinkage of hematite grains, lower porosity and stronger consolidation. The preheating and roasting performance of WAU magnetite concentrate pellets can be improved by optimising ore matching.CITATION:Pan, J, Hu, X, Zhu, D-Q and Yang, C-C, 2017. Pelletising performance of Western Australian ultra-fine magnetite concentrate and strengthening technique by optimising ore matching, in Proceedings Iron Ore 2017, pp 97–104 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By Parsons A. E

The application of known pelletizing tech- nology was successful in the agglomeration of zinc concentrate into pellets of minus 6mm siz- ing using fine zinc calcine and sulphuric acid as binder. Subsequent roasting trials conducted in a 0.3 m diameter fluid bed reactor, showed that the pellets satisfactorily withstood hot physical abrasion during fluidization. Fines generation was low and the pellet calcine was hard, possessing excellent handling properties. Results of laboratory scale static pellet sinter- ing tests showed conclusively that the deterior- ation in sinter physical quality experienced with fine calcine was not apparent when the calcine was added to the mix in pellet form. Based on the results of small scale exper- imental work, a one tonne per hour pilot plant was constructed and operated. Several thousand tonne of pellets were produced-for fluid bed roasting in Badische Analin and Soda Fabrik (B.A.S.F.) turbulent layer (T.L.) roasters previously designed for roasting iron pyrite concentrate. Continuity of the T.L. fluid bed roasting operations was achieved when the waste heat boilers were replaced with atmospheric coolers and thus eliminated the problems of gas flow restrictions. Sinter plant trials were conducted over a period of two weeks with the addition of pellet calcine to the sinter feed. Results showed a marked improvement in sinter plant performance, and as a result of better bed permeability, increased sinter production was achieved, with- out significant deterioration in sinter quality.

Jan 1, 1974

Commercial pelletizing commenced in 1955 to agglomerate very fine concen- trates which could not be fed directly to the blast furnace. Extensive develop- ment has taken place and is continuing. There are now three main heat hardening processes in use. Plants are operating, or under construction, throughout the world capable of producing in excess of 125 million tons per year of pellets from concentrates or direct mined orefines. The Whyalla Pellet Plant, which commenced production in May 1968, is examined in detail to illustrate the general principles of pelletizing. This plant converts high grade iron ore fines into high quality pellets at a rate in excess of 2 million tons per year.

Jan 1, 1971

By Bhattacharyya A. K>

The Pemali Open Pit Mine is situated in a small island called Bangka in Indonesia. It produces approximately 165,000 m3/year of tin ore with an average grade of 3.67 kg/m' of tin from a primary deposit. The deposit occurs at the rim of a granitoid intrusion within sedimentary beds. The rock formations, all extremely weathered, and the overlying alluvium, are exposed to a rainfall exceeding 3m/year. Serious slope stability problems are experienced at the mine, despite using overall pit slopes of 20¦-29¦, the latter resulting in a stripping ratio of 4:1. This paper outlines a computer based back analysis of a major slope failure involving some 250,000 m' of material which occurred on the west wall of the pit in February, 1984. The findings from the analysis, together with other information, are used to examine the stability of the east wall of the pit, where tension cracks developed later. The results indicate that the large influx of water was the most significant cause of such slope stability problems and a more intensified water management programme would be beneficial.

Jan 1, 1989

By S Hapugoda, H Han, L Lu

Sinter quality depends heavily on the mineral phases, textures and physical structure of the sinter, which are formed upon solidification of the sinter melt. The interaction of sinter initial melt with its surrounding materials will impact the properties of the sinter melt and consequently the solidified structure and quality of resultant sinter. Spreading and penetration are two important phenomena dictating the interaction of the initial melt with its surrounding materials, such as nuclei and adhering fines. In the present study, the penetration behaviour of an initial melt into various natural iron ore substrates of different ore types during sintering was studied using a laboratory scale penetration testing procedure. The penetration depth and width were found to increase with temperature and vary with the type of iron ore due to their unique pore structure and mineralogical texture.

Nov 8, 2021

From time to time efforts have been made to classify rocks according to their hardness, toughness and abrasiveness, and to use these classifications to provide an indication of the ease or difficulty with which they may be drilled. However, rocks classified as of similar type on this basis may vary considerably in their .resistance to the penetration of a rock drill bit due to differences in their physical state.For instance, fine grained rocks of granular texture are more difficult to drill than equivalent' rocks of coarser structure, altered rocks drill more readily than unaltered ones, and silicified rocks usually exceedingly hard and tough may be so shattered by movement as to be drilled at a rate comparable to quite soft rocks. Therefore, considerable latitude has existed in this method of defining their drillability, and no values generally acceptable have materiaJised; so that, when the drilling properties of rocks are discussed, it is common practice to refer to their hardness or toughness in a greater or lesser degree depending to some extent on the emotional state of the drill runner.REFERENCES AND STANDARDSThe 'introduction of tungsten-carbide tipped rock-drill bits for use with percussion rock-drills has thrown increasing emphasis on the need for defining a rock's resistance to penetration in a more concise and generally acceptable...

Jan 1, 1950

There is growing acknowledgement that successful organisations, including mining companies, achieve their competitive advantage by better managing their employees, customers and other stakeholders. The fact that I have been asked to address this conference is perhaps evidence of the recognition of the importance of ensuring the improved management capabilities of the personnel within Australian mining companies. As many of you will be aware, prior to my appointment to the role of President of Minera Alumbrera Limited (MAA), the operator of the Bajo de la Alumbrera project, my career had been more generally focussed on industrial relations and human resources management. My appointment was met by surprise in some quarters, as it is unusual for a person without the technical background of a mining discipline to manage a world-class mining operation. However, it was recognised early in the life of the Alumbrera project that the operation did not lack technical expertise or a committed workforce; rather what was required was innovative management of the project and its operational resources, particularly given that we were operating with totally ægreenÆ workforce in a country without a large-scale mining culture. It is my experience that a particular shortcoming of mining companies is that they have tended to ægrowÆ managers based on their technical expertise rather than people management skills. Historically, many companies have assumed, or at least hoped, that their better technical people would develop the requisite skills to take on the challenges of management. Such philosophy has not always met with success. Whilst the topic for my presentation was originally published as People in the Mining Industry, within the context of the overall theme for this plenary session, People: Education for the Future, it is a subject with an extraordinary breadth of possibilities for discussion. Therefore, I have chosen to redefine my presentation to People Management Issues in Offshore Mining Projects,an issue which I consider to be an important area within the overall topic and one which has particular currency given the increased tendency by Australian miners towards offshore exploration. It is also relevant from the perspective of continued rationalisation of our industry, the recognition that there will be more large-scale, global corporate mining entities and that significantly more mining professionals will become æcitizens of the worldÆ. We therefore need to prepare our future leaders for these challenges. The topic also allows me to highlight the importance of an holistic management approach as the establishment of a new project in a foreign environment puts into stark relief the need for the application of the full range of competencies, rather than the narrow ætechnicalÆ approach to doing business. I hasten to add, however, that the mining industry is not alone in this regard and I was interested to read an article in the Weekend Australian of 22/23 January 2000, which reported on the first key speech of former Westpac CEO, Bob Joss, as Dean of the Stanford University Graduate School of Business. He said: à We know that when our students go out into the world, if they have to struggle, it will not be because theyÆre not smart enough, or they donÆt have enough good ideas. It will be because they struggle over managing themselves and their relationships to other people. The article then went on to say that Bob Joss foreshadowed an initiative to build alliances between the Business School and other Humanities departments within Stanford University to draw on their learning. Other business schools have also recognised this need, albeit somewhat late in the day, as have the most enlightened of modern corporations; in summary, successful businesses have recognised that in an age where competitive advantage through, for example, technological breakthroughs is very short-lived, it is the quality of management that will provide the leading edge. By using the Alumbrera project as a case study, I will identify certain of the challenges with which companies and individuals may be confronted in the establishment of a greenfields project outside Australia. However, many of the issues raised will have direct application in the context of the development of an Australian operation. My objective is to provide an indication of areas which should be considered at the formative stages of a projectÆs development, with particular focus on the issues of people management. I would expect that such a study would be of benefit to companies, education institutions and individuals in preparing themselves for similar experiences.

Jan 1, 2000

The determinants of human behaviour are numerous and complex. Many scientific disci- plines focus on various processes which play some part in shaping the actions of individ- uals and groups. Behavioural science attempts to synthesise data produced by these investigations in an attempt to formulate principles by which people's thoughts, feelings and actions may be described, diagnosed, predicted and changed. While no comprehensive account of people and their reactions can be attempted in a brief paper a review of six principles does provide a framework within which managers can establish reliable knowledge applicable to all their subordinates and to themselves. This information may be used to arrange organizational environments and management practices which enable people to discover, release and increase their best intellectual, emotional and motivational capacities.

Jan 1, 1982

Rather like the mythical "Economic Man" "an employer" in this context must necessarily be an abstraction, and the views possessed by such an abstraction, a composite of many views known to have been expressed. Not even the complex Conciliation and Arbitration legislation in this country provides any helpful specifications, except in one peculiar particular. The Australian Conciliation and Arbitration Act provides an almost totally tautological definition, except in that one oddity referred to above. It is this : "An employer means any employer in any industry, and includes any person who is usually an employer in an industry, and also includes a Club." No doubt there is some perfectly justifiable reason for such specific and unique particularity in an otherwise meaning- less definition. That need not trouble us in this exercise.

Jan 1, 1982

Trade unions are people. As organisations they exist to represent the needs and interests of their members; that is the workforce. Thus one of the underlying objectives of the trade union movement has been and will continue to be: achieving from management recog- nition that the labour input to the production process - whether that be in the factory, office or service context - is made up of individual people who can not be treated as just another factor of production. The essential difference between labour input and other factors of production such as capital and raw material is the "humanness" of the individual entities which make up a firm, company or industry's labour supply. Recognition of the "people" input to the production process has essentially two aspects: humanisation of the workplace and the treatment of labour as human beings who have a role to play both within the workplace and within broader society.

Jan 1, 1982

Immigration has influenced Australia's development more than any other factor. As well as being critical to our economic growth and development, it has made a major contrib- ution to our population growth, to the richness and diversity of our society and to our inter- national relations. Migration from the United Kingdom has been the mainstay of our settler intake for many years, but its relative importance has declined in recent decades. Non-British European migration formed an important part of our post-war intake and, in the past few years, migration from Asia has reached significant levels - particularly through our resettlement of Indo-Chinese refugees. In planning our future immigration, it is important to look beyond short term direct economic consequences. Australia has looked to its resources for progress, but Japan, Korea, Taiwan and Singapore have achieved dramatic economic progress without resources, based on the will and dynamism of their societies. Immigration can contribute greatly to the development of a dynamic, outward looking Australian society able to make the most of our great resource potential.

Jan 1, 1982

By Cole RT

The cultural ages of man have been defined in terms of smelting and hence as a prerequisite, mining for example the iron age and the bronze age. There could be no separation of the man from his role as the technologist (miner/ smelter) for his early metal working efforts were to enhance survival. In the millenniums since, the artisan specialist developed and the technologist emerged. The process is a sort of technical natural selection. From the generalist hunter, gatherer, miner, metalworker we advanced over the centuries with great 'steps for mankind' to the series of specialists each largely intent on securing his/her technical functions from the curious assaults of other tribal members. The relevance of all this to the theme, 'Past, present and future of the Victorian mining and metallurgical industries', is simply that people have always, and will always, be the moving force in our industries. It is the effectiveness of people now and in the future that this paper addresses.

Jan 1, 1982

Total quality control in tandem with Japanese style management largely accounts for the high product quality and international competitiveness of growing manufactured exports from Japan. Japanese management is often identified with life-time employment, promotion by seniority, company-based unionism, the process of obtaining the sanction of executives to a plan by circulating the draft prepared by a person in charge of a particular matter, internal consultation, consen- sus-based decision-making, etc., all of which are just formal manifestat- ions of the underlying current of the spirit of cooperation that translates itself into "management through labor- management cooperation".

Jan 1, 1982

By K Orth

The volcanic successions that host massive sulphide deposits are diverse in composition, facies types and facies relationships. They also show a variety of spatial and temporal relationships to mineralisation. In many examples, such as the Koongie Park Formation in Western Australia, the host succession includes more or less conformable syn-volcanic sills with peperitic contacts. Such sills can be an important source of heat for fluid circulation, influencing patterns of hydrothermal alteration and the location of co-eval and later mineralisation. The impact of syn-volcanic sills on the host succession depends in part on the initial porosity and permeability of the enclosing facies. The special properties of glassy pumice û being highly porous, permeable, and reactive û allow pumice-rich facies to preferentially focus hydrothermal fluid flow. However, the same properties promote early alteration and porosity reduction. Hence, the diagenetic and compaction history of pumiceous facies strongly influences their potential to host massive sulphide mineralisation. In contrast to pumice, dense glass has relatively low porosity, at least initially, and does not compact. Non-vesicular glass is a major component of submarine lavas, syn-volcanic intrusions and some volcaniclastic facies. However, especially in submarine settings, dense glass is commonly intensely perlitically fractured soon after eruption. The fractures greatly increase the porosity and permeability, locally accelerating diagenetic and hydrothermal alteration. In addition to false pyroclastic textures, altered perlite may exhibit false porphyritic textures. Silica- or feldspar-altered perlite kernels surrounded by intensely altered phyllosilicate domains can resemble phenocrysts in a fine grained groundmass.

Jan 1, 1999