Abstract: A method of sorting mined material to separate the mined material into at least two categories is disclosed. The method comprises exposing particles of the mined material to microwave energy and heating the particles depending on the susceptibility of the material in the particles. The method also comprises thermally analysing the particles using the temperatures of the particles as a basis for the analysis to indicate composition differences between particles and then sorting the particles on the basis of the results of the thermal analysis. The method also comprises compensating for temperature variations in the mined material that is supplied to the method.

Abstract: A method of sorting mined material to separate the mined material is disclosed. The method comprises exposing particles of the mined material to microwave energy and heating the particles depending on the susceptibility of the material in the particles. The method also comprises thermally analysing the particles using the temperatures of the particles as a basis for the analysis to indicate composition differences between particles. The thermal analysis step includes thermally assessing particles against a background surface. The thermal analysis step also includes heating the background surface to a temperature that is different to the temperature of the particles to provide a thermal contrast between the particles and the background surface. The method also comprises sorting the particles on the basis of the results of the thermal analysis.

Abstract: A method of mining ore in a mine pit (3) and a mine are disclosed. The method comprises drilling and blasting ore in a bench (19) of ore within the mine pit and collecting ore blasted from the bench from a floor (5) of the mine pit using at least one mobile excavation machine (11). The method also comprises delivering ore that has been collected by the mobile excavation machine to at least one mobile-in-pit crusher (41), and transporting crushed ore to outside the pit on at least one ladder conveyor (23) that extends up the wall of the pit.

Abstract: A direct smelting process for producing molten metal from a metalliferous feed material in a direct smelting vessel is disclosed. The process includes using a stream of off-gas from the vessel as a fuel gas in (i) stoves for generating a hot blast of air or oxygen-enriched air for the process and (ii) a waste heat recovery apparatus for generating steam for the process. The process also includes controlling pressure in the vessel by controlling pressure in the off-gas stream while the process is producing molten metal.

Abstract: Metallurgical processing installation comprising a metallurgical vessel lined internally with water cooled panels. A vessel access tower (61) fits around vessel (11) and supports a coolant flow system (62) to provide for flow of cooling water to and from the cooling panels within the vessel through water inlet and outlet connections (42,43) distributed around the exterior of the vessel. Coolant flow system (62) includes large diameter water supply and return pipes (66,67) mounted on an upper part of the tower (61) to extend around the upper end of vessel (11), a first series of vertical dropper pipes (68) of relatively small diameter connected to the main water supply pipe 66 and extending downwardly to connections with the water inlet connectors for respecting cooling panels of the vessel and a second series of smaller diameter vertical pipes (69) connected at their upper ends to the main return pipe (67) and at their lower ends to undivided outlet connectors for the cooling panels in the vessel.

Abstract: A process for leaching an ore containing sulphidic copper-containing minerals is disclosed. The process includes carrying out an aerated oxidising leach of a part of the ore and causing reactions with a source of iron such as pyrite in the ore and producing an acidic leach liquor containing ferrous ions, ferric ions, and copper ions in solution. The process also includes carrying out a leach of another part of the ore using the leach liquor produced in step (a) under conditions that minimise reactions with a source of iron such as pyrite in the ore and producing a leach liquor containing copper ions in solution.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: A steelmaking process is disclosed. The process includes producing molten steel and molten steelmaking slag in a steelmaking process, the steelmaking slag including iron units and flux units, and thereafter producing molten iron in a molten bath based direct smelting process using a substantial portion of the steelmaking slag as part of the feed material requirements for the direct smelting process. A direct smelting process is also disclosed. The process includes pre-treating ferrous material including steelmaking slag and thereafter direct smelting molten iron using the pretreated ferrous material as part of the feed material for the process.

Abstract: A method of cold starting a molten bath-based direct smelting process for producing molten iron in a vessel (3) is disclosed. The method includes a step of preheating the vessel before supplying solid feed materials into the vessel. The method also includes a subsequent step of supplying an oxygen-containing gas and solid feed materials including material for forming slag, iron-containing feed material, and carbonaceous material into the vessel and generating heat and forming a bath of molten material that includes molten iron and molten slag in the vessel. This step includes supplying feed materials to promote formation of molten slag over molten iron in an early stage of developing the molten bath.

Abstract: Method of building a direct smelting plant comprising a metal smelting vessel (11) and ancillary plant components such as the components of a hot air supply station (24), an offgas treatment station (32), a solids feed station (41), a hot metal desulphurization station (47) and hot metal and slag launders extending from the smelting vessel (11). The ring track (53) of a ringer crane (51) is installed in front of location at which vessel (11) is to be installed. Crane boom (54) is laid out along elongate stretch of the building site which becomes a corridor (60) between major ancillary components when plant is fully erected. Boom (54) is connected to crane carriage (52) and hoisted to provide high lift capacity over a ground area embracing proposed site of vessel (11) and ancillary components. Prefabricated components are then lifted by crane (51) into appropriate position for final installation.

Abstract: A forehearth (5) for containing a volume of molten material and a direct smelting vessel (3) that includes the forehearth are disclosed. The forehearth includes a forehearth connection (15) for connecting the foreheath with a smelting chamber (4) of a smelting vessel (8) so that molten material can flow from the smelting chamber into the forehearth. The forehearth connection is formed so that there is an unrestricted line of sight through the forehearth connection from a location that is external to the forehearth. This makes it possible to unblock the forehearth connection by a mechanical drill or other equipment extending into the forehearth connection and operated externally of the forehearth.

Abstract: A direct smelting vessel (3) for operating a molten bath-based direct smelting process under pressure conditions in the vessel is disclosed. The vessel includes a forehearth (67) for tapping molten metal continuously from the vessel. The forehearth includes an open connection (97) that extends through a side wall of the vessel into the interior of the vessel. The open connection is formed to dampen the impact of sudden changes in pressure in the vessel on molten metal flow in the forehearth that could result in an undesirable surge of molten metal from the forehearth. The open connection is also formed so that molten metal does not freeze in the connection for at least 6 hours when molten metal is not being discharged from the vessel into the forehearth via the open connection.

Abstract: A method of sorting mined material for subsequent processing to recover valuable material, such as valuable metals, from the mined material is disclosed. The method includes a combination of selective breakage of mined material (for example, by using microwaves and/or high pressure grinding rolls), subsequent size separation, and then particle sorting of a coarse fraction of the separated material based on differential heating and thermal imaging.

Abstract: A gravity gradiometer is disclosed which has a sensor in the form of bars (41 and 42) which are supported on a mounting (5) which has a first mount section (10) and a second mount section (20). A first flexure web (33) pivotally couples the first and second mount sections about a first axis. The second mount has a first part (25), a second part (26) and a third part (27). The parts (25 and 26) are connected by a second flexure web (37) and the parts (26 and 27) are connected by a third flexure web (35). The bars (41 and 42) are located in housings (45 and 47) and form a monolithic structure with the housings (45 and 47) respectively. The housings (45 and 47) are connected to opposite sides of the second mount section 20. The bars (41 and 42) are connected to their respective housings by flexure webs (59). Transducers (71) are located in proximity to the bars for detecting movement of the bars to in turn enable the gravitational gradient tensor to be measured.

Abstract: A method and an assembly for treating minerals using microwave energy are disclosed. The method includes exposing a moving bed, preferably a mixed moving bed, of mineral particles to pulsed high energy microwave energy so that at least substantially all particles receive at least some exposure to microwave energy.

Abstract: A smelting apparatus includes a vessel and a solids injection lance extending through an opening in the wall of a vessel barrel into the interior space of the vessel. The lance includes a central core tube through which to pass solid particulate material into the vessel and an annular cooling jacket surrounding the central core tube throughout a substantial part of its length. The lance has a mounting structure including a tubular part extended about the cooling jacket and about twice the diameter of the cooling jacket. The tubular part fits within a tubular lance mounting bracket welded to the shell of the vessel barrel to extend outwardly from the vessel. The lance is held within the mounting bracket by clamping bolts acting between flanges on the tubular part and the tubular bracket.

Abstract: The present invention relates to an apparatus for injecting gas into a vessel. The apparatus may include a gas flow duct and a central body within a forward end region of the duct. The central body and the gas flow duct form an annular nozzle for the discharge of gas from the duct. A plurality of flow directing vanes are disposed about the central body to impart swirl to a gas flow through the nozzle. The flow directing vanes have substantially straight leading end portions radiating outwardly from the central body and extending along the duct. The vanes also have substantially helical trailing end portions extending helically about the central body toward the front end of the duct and transition portions joining the leading end portions to the trailing end portions. The transition portions are shaped so as to merge smoothly with both the leading end portions and the trailing end portions and to smoothly and progressively change shape between them.

Abstract: A process for producing desulphurised iron in a solid form. The process includes (a) direct smelting an iron-containing metalliferous feed material and producing molten iron; (b) desulphurising molten iron produced in the direct smelting (a); and (c) casting desulphurised molten iron from the desulphurisation (b) into a solid form, such as pigs.

Abstract: An apparatus for injecting particulate and/or gaseous material into a metallurgical vessel for performing a metallurgical process is disclosed. The apparatus comprises a duct and an annular duct tip at a forward end of the duct. The apparatus also comprises inner and outer cooling water flow passages configured such that out flowing water passing from the duct tip to a rear end of the duct must travel through a longer flow path than inflowing water passing from the rear end of the duct to the duct tip.

Abstract: A process for recovering copper from chalcopyrite is disclosed. The process includes oxidising sulphur in chalcopyrite with a solution under predetermined contact conditions and thereby releasing at least part of the copper in the chalcopyrite into the solution as copper ions. The process includes a subsequent step of reducing sulphur in a solid product from step (a) to a minus two, ie. sulphide, valence state with a solution under predetermined contact conditions. The process further includes a subsequent step of oxidising sulphur in a solid product from step (b) with a solution under predetermined contact conditions and thereby releasing at least part of the remaining copper in the solid product into the solution as copper ions. The process further includes recovering copper from one or more of the solutions from steps (a) and (c).