<<

and Mineral Processing

What does a metallurgist do? WHAT DOES A Mineral Process DO? Within the minerals industry, metallurgists work at mine sites in Minerals process transform the ores found in nature concentrators and metal recovery operations, in smelters, metal to value-added products. These ores can be high-grade refineries, foundries, and research and development laboratories. materials taken directly into metal extraction, such as iron ore into They use their knowledge of chemistry and physics, mineralogy, production of iron and steel. For most other metals (and for some underlying process fundamentals and process to iron ores) it is necessary to upgrade or concentrate the ore into an control and improve the processes that separate, concentrate intermediate product that is then subject to extractive processes and recover minerals and their valuable metals from the natural for metal recovery. Further refining of the metal may be necessary. ores. Depending on the mineral and metal, the process stages Ores typically contain many waste and undesirable elements, can include mineral processing that upgrades or concentrates and their treatment can involve surprisingly complex and difficult the mined ore, and extraction of a metal or intermediate process technology. The continuing variation in feed requires a product. This extractive or primary metallurgy can include wet high level of metallurgical process understanding or hydrometallurgical process stages, high-temperature or and control. pyrometallurgical process stages, and electro-metallurgical A mineral process engineer may perform the following tasks: process stages. Sometimes, crude metals can go through complex refining processes. The metal products can be subject • and development; to further processing, termed secondary metallurgy or physical metallurgy, that includes process such as alloying, casting in • process control and management; foundries, rolling, and extrusion. • application of chemical, metallurgical and process engineering Some of the many roles that a metallurgist can take are: fundamentals to production processes; management of process data collection and analysis; • application of physical and chemical methods to concentrate • valuable minerals from their ores; processes can involve • metallurgical problem solving with application of modified methods such as magnetic, electrostatic, gravity, and or addition unit processes; flotation processes; • application of economic analysis of production processes • application of a combination of processes involving to effect optimal performance; hydrometallurgy, electrometallurgy and pyrometallurgy to produce crude or refined product metal for market; • planning of production, budgets, operational and management reporting; • management of the technical aspects metallurgical operations using tools such as on-line process monitoring, • human resource management of both professional and sampling, chemical analysis, data analysis and operational staff. process modelling; Metallurgist - Extractive/General • management and supervision of production staff in metallurgical operations; Extractive Metallurgists study and apply metallurgical techniques for extracting and refining metallic materials from their ores or • design of mineral processing and extractive metallurgical plant; concentrates. They research, develop, control and provide advice • study and application of the fundamentals of metallurgical on processes used in extracting metals from their ores and the processes to both aid control and improve their physical washing, crushing and grading of ore or refining metals. They and economic operation; coordinate the analysis of samples taken from metallurgical process streams to ensure safe and economic operation and • undertake or manage research and development studies to they advise operations personnel on process changes required improve existing processes, or to apply existing or possible to obtain desired products, processes and quality control. processes to new ores or concentrates; Mineral Processing Engineer • improve environmental performance of metallurgical operations and ensure all environmental standards are met; Minerals process engineers transform low value impure minerals, recycled materials and by-products of other processing operations • prepare reports on metallurgical operations and projects; into commercially valuable products. The main sources of these raw materials are low grade minerals, by-products of other • liaise with a wide variety of people on the job such as operators, maintenance and engineering staff, geologists, processing operations and recycled materials. Minerals process mining engineers, and supporting specialists in process engineers are employed in all stages of raw materials processing control, computing, technology provision and research.

12 Professional Careers in the Minerals Industry

Hydrometallurgist Metallurgy/Mineral Processing - Research Hydrometallurgists are involved in the treatment of ores through Academic and Research metallurgists/mineral processors low temperature refining and wet processes such as leaching. often work in universities or CRC’s (cooperative research centres). Hydrometallurgists study the nature and properties of different Rather than looking primarily at the economic issues of how to metals and materials and remove insoluble and toxic materials extract metals and minerals from ore, they investigate why and from metal using water-based solutions to find a more pure form how things behave the way they do or are the way they are. of ore. They may use electrolytic refining and processes. Pyrometallurgist Chemical Engineers design, develop and operate processes for Pyrometallurgists design and develop high temperature heat- converting and refining raw materials into products. A chemical based processes and equipment to concentrate, extract, refine engineer may improve/develop new processes and materials; and process metals and other materials. They extract and obtain design/ improve methods and equipment for extraction, filtration, pure metals and ore through various extractive processes such distillation; prepare reports and detailed costing of changes/ as refining, welding, fusing and smelting metals. They control improvements; design/operate pilot plants; design plants and temperature adjustments, change mixtures and other variables specify equipment/processes and layout; test the quality of the in operations such as blast-furnaces and steel-melting furnaces process/product; find faults in plant equipment and take corrective to obtain materials such as pig iron and steel of specified action to ensure safe operation. metallurgical characteristics and qualities. Materials Engineer Metallurgy/Mineral Processing - Consulting Materials engineers investigate the properties of metals, ceramics, Consulting Metallurgists and Mineral Processing Engineers often polymers and other materials and develop and assess their work on a variety of processes, plants and ores. They will typically commercial and engineering applications. Materials engineers may be based in coastal cities and fly out to projects as necessary. study the structure and properties of metals and other materials, investigate methods for shaping and fabricating materials, and Consultants can and do specialise in certain processes or metals/ study methods for joining materials, improving existing materials minerals and therefore act to provide certain specific technical and evaluating new ones. They participate in the design of information to companies and operations. products using advanced materials, investigate material failures and study ways to extend the life of materials. PR

OFI Mathew Revell challenges if you put your hand up. The What formal qualifications do I have? BEng(Minerals Processing, Hons), industry also offers you the chance to travel. I initially completed a double degree in Arts and L

ES Postgraduate Diploma Finance and Lastly there is also a great variety of characters Engineering at Monash University, deferring Investment, MAusIMM Senior Paste Engineer, you meet. It is also a very small industry and along the way to complete an honours year in Revell Resources you tend to keep in touch with a large range Arts – my major was Japanese language. In of people. 2001 I graduated from WASM with a Masters What formal qualifications do I have? degree in Mineral Economics – I completed I completed a 4 year Minerals Processing For someone considering a career in this degree via intensive coursework sessions Engineering degree at the University of your profession are there any words of over two years while working full time for WMC Queensland. I graduated in 1997. I also wisdom to pass on to them? Resources Ltd. completed a Postgraduate Diploma in Finance I must say that vacation work was a huge and Investment by correspondence through bonus for me. I really didn’t have any clear Why did I choose my particular the Securities Institute. I completed the idea of what I wanted to do. By doing vacation career(s)? diploma in 2003. work you get a clear idea of the industry, the I did well at school and particularly liked culture and the type of work you will be doing. Chemistry and Japanese. Not wanting to Why did I choose my particular I also found having mentors in my early years abandon either field of study, I investigated career(s)? was very important. For my job at Cannington, combined degrees. Initially I was heading In the first year at University of Queensland it one of the driving factors for accepting the towards an Arts/Science degree, but a is a general engineering course. At the end of job was the strong metallurgical team and the friend’s boyfriend who was studying first year first year I heard about vacation jobs, that paid experience I could gain from them. Lastly the engineering at the time convinced me that, good money, were available in the coal mines. I mining industry is a small industry, so always for an extra year of study, I would be more worked for three months at a Bowen Basin coal put in 100% and you may be surprised by the employable with an engineering degree than a mine and really enjoyed it. As a result I decided opportunities that arise down the track. science degree upon graduation. So I settled to choose Minerals Processing Engineering. on Engineering/Arts. During Year 11 at school What have I enjoyed most about my I participated in what was then known as the profession(s)? Miriam Lyons-Stanborough CRA National Science Summer School in More than anything I have enjoyed the variety BE (Chem, Hons) BA (Hons) MSc (Mineral Canberra. of challenges that the mining industry offers. Economics) MAusIMM MIEAust At most mine sites there is always something Clarification Area Supervisor, Pinjarra going on, and there are more than enough Refinery, Alcoa of Australia

13 PR

OFI It was a fantastic experience, and after I always enjoyed and excelled in Maths and experience - I believe that to truly understand returning the following year as a staff member, I Science at high school, and when I had to the process, (esp. as a young engineer) you L

ES kept up contact with CRA which eventually led pick what I wanted to do at Uni; Engineering have to get right into it and the best way to me getting vacation work with one of their seemed like a natural choice. Despite growing to do this is be involved in the operations subsidiaries, Argyle Diamonds, at the end of up in Mount Isa I didn’t know much (if anything) team. After Uni I was offered a position in the first year at uni. And that’s when I realised that about careers in the mining industry apart WMC Graduate Program at its Phosphate Hill the mining industry was for me. from apprenticeships, but I did know Chemical Operation. I spent 6 months moving around the Engineering could lead into a variety of fields, different plants interacting and being a part of What do I enjoy about my role? including mining. As part of preparation for production crews. I also did The opportunity to work in both technical a scholarship interview, I organised to visit 6 weeks in Mt Isa at the WMC Acid Plant and line-management roles. All the roles I a Chemical Engineer working at the Copper working on optimising their sampling regime. have performed have required a high level Concentrator in Mt Isa and learnt a little about Phosphate Hill was more a chemical plant of communication skills. I love working with what she did, and what options were generally than a traditional base metals concentrator, people, rather than in isolation. available for Chemical Engineers. Once at Uni, but the plant I started working in as a Process For someone considering a career in while completing the generic first year of Eng, Engineer was basic Minerals Processing with your profession are there any words of I attended all the information sessions held by crushing and screening. I was involved in a wisdom to pass on to them? the different Eng departments to learn a bit screen optimisation study and also developing Find out as much as you can about the more about each field. During these sessions, some Metallurgical Accounting systems. As profession and industry while you’re still I became aware of a program to give 1st year part of the Graduate Program I was offered studying – vacation work in particular is so Eng students Vacation Work in metallurgical the opportunity to move to WA and work at valuable. Start your career planning early – I roles. After spending summer at Osborne WMC’s Mt Keith Operations, which is a more stalled for a few years, waiting for someone to in NW Qld, learning about the plant, doing complicated Nickel concentrator. I spent time offer me opportunities, until I realised that I had surveys and experiencing the FIFO lifestyle, on shift learning the day to day operations to get out there and tell people where I wanted I decided to take the plunge and chose the of the plant, then acted in the Production to go and what I could do. specialised option of Minerals Processing Planning Metallurgist role, then spent 12 Engineering (rather than general Chem Eng) months as a Plant Metallurgist.

What have you done? Do you have any regrets about how your Megan Kropp I was very fortunate to have three sets of career has developed? BEng (Minerals Process) GAusIMM vacation work while at Uni - Osborne, Mt My career is still developing; only four years Process Engineer, BHP Billiton Mitsubishi Gordon and Ernest Henry. The first two out of Uni and at this stage, everything I Alliance Central Qld. Office were spent working in a metallurgical role, do whether right or wrong gets chalked What formal qualifications do you have? conducting plant surveys at Osborne, and up to experience, and you soon learn not Minerals Processing Engineering at the developing lab tests to model the process to repeat stupid mistakes. I am still aiming University of Queensland, after high school in at Mt Gordon. My vac work working as an towards a career more in the production, day Mt Isa. operator at Ernest Henry was very interesting, to day running of the plant, and getting my mainly looking after the thickeners and hands dirty, but will keep an open mind as Why did you choose your particular concentrate area. This was an awesome opportunities arise. career(s)?

14 Professional Careers in the Minerals Industry Minerals the in Careers Professional desktop studies. I’ve travelled extensively interstate and worked overseas in a number of and roles. commodities different perspective of the industry and different career career perspective of the industry and different options. Rio Tinto then supported my final paid my expenses and project year research the (including a trip to Perth to present findings). In my final year I successfully applied to Rio Tinto for a graduate position and was supervisor project interviewed by my research Having over 12 months industry and manager. experience and my work being known to them undoubtedly helped my application. Day one of my full time employment saw me mine, ore in the Pilbara working at an iron I stayed for 5 months; followed by a where spending my 2 month stint in Perth before first day at my desk back in Melbourne (7 months after starting). Since then I’ve worked Uranium), a number of Coal at ERA (Ranger, operations in Queensland and NSW and nearly South Africa, Bay, a year overseas in Richards know of any don’t another story...I but that’s other graduates in any industry that have had these kind of opportunities! What have you enjoyed most about your profession? enjoy the diversity of the work I do I really In the past year Engineer. as a Metallurgical I’ve been involved in pilot plant construction, equipment decommissioning, mine site energy molten metal test high temperature reviews, plant and laboratory trials, work, numerous advanced computer modelling and technical Living at college is an excellent experience Living at college is an excellent close it’s place to meet friends; and a great of care taken are to campus and most things on studying for you so you can concentrate justify the costs I and socialising. If you can it to everybody. recommend far in your What have you done so career? At completion of first year university I landed at Cadia my first vacation job with Newcrest I was quite (Copper/Gold flotation) in NSW. I commenced shift work as a when ‘green’ but gained a plant operator that summer, of knowledge that helped me at deal great university and earned enough money to pay a good portion of my expenses for the following I completed Each year afterwards year. company vacation work with a different commodity (MIM, Mount Isa in a different (Lead/Zinc flotation); AngloGold, Pine Creek (Gold CIL); Rio Tinto, Bundoora (Iron/Titanium R&D) which gave me a good Pyrometallurgy 15

allowed me to obtain two degrees within five allowed me to obtain two degrees years rather than seven (4 year Engineering, 3 years Business Administration). Doing a has certainly made me more double degree that it was a and I am quite sure rounded contributing factor to securing both strong vacation work every year and my graduate position. a I was lucky enough to also be offered place at Ridley College, which was residential place to live after moving out of home a great and down to Melbourne. Services Why did you choose your particular career? Whilst completing high school I was interested in Chemistry and Physics and wanted a career that would combine these disciplines and be “hands on”. In addition to ‘the sciences’ I’d in business management also had an interest (topping my class), so when applying to university I decided to aim for a dual As nothing like Engineering/Business degree. to look to this was available locally I was forced a place at RMIT to Melbourne, and was offered Engineering and Business study Metallurgical as a double Administration concurrently difficult to get is more A double degree degree. workload, but it into and means an increased career has developed? has career had fun and achieved No, I have worked hard, beyond what my early goals were. What have you enjoyed most about your profession(s)? I have enjoyed the variety of challenges that along with the the mining industry offers a small industry which chance to travel. It’s attracts like minded people. Along the way I have made many close enduring friendships. Adam Lonergan BE (Metallurgical Engineering) (Hons) BBus (Business Administration), MAusIMM Rio Tinto Technical Metallurgical Engineer, technical Due Diligence teams which has technical Due Diligence teams cobalt/ base metal, investigated numerous nickel, gold and coal projects/prospects. I have been intimately my career Through and establishment involved in the development Isa Process, of new technologies including Jameson Cells, heap Bioleaching/aeration as well as being and SX coalescing systems involved in a number of innovative design/ engineering developments. PS and had a lot of fun along the way about how your Do you have any regrets

Creek Copper Project, and Maroochydore and Maroochydore Copper Project, Creek I have also headed up Straits Copper project. well as corporate and operational technical David has also headed the management role. development teams for a number of Feasibility Whim Copper Project, studies including Tritton optimisation of several significant successful including Girilambone Copper projects Operation, Nifty Copper Operation, Browns Gold Operation and Sebuku Coal Mine. Creek as I took on site based management roles headed the Process/Metallurgical/Engineering headed the Process/Metallurgical/Engineering team within Straits, a small Australian resource companies, for the past 7 years. During this time I have overseen the development and 1987 I was the inaugural winner of the AusIMM G.B O’Malley Medal and was also part of the the 1999 AusIMM team that was awarded I Award. Mineral Industry Operating Technique I have developed an international in reputation, result as a my chosen field of hydrometallurgy, of industrial and consulting experience and extensive publication of technical papers. In number of the Australian Copper Leach SX-EW and operations and have also had projects extensive overseas experience in the Americas, South East Asia. and Europe design, commissioning, optimisation, operation and management of numerous specialising in base projects metallurgical and biohydrometallurgy, metal hydrometallurgy coal and gold. I have been involved with a as well as roles with Mount Isa Mines Limited, as well as roles Pasminco Metals and the South Australian I have been involved Institute of Technology. flowsheet development, in test work, process Technical Services Manager with Cobre with Cobre Services Manager Technical Straits Las Cruces (on secondment from Business Development Manager Resources), Engineer with CMPS&F and Senior Process years experience in the Mining and Minerals employed in a variety of professional Industry, Manager Processing Group including roles and Engineering with Straits Resources, better chance of gaining entry. better chance of gaining entry. What have you done? Metallurgical Professional I am Chartered 15 CPMet) with over Engineer (FAusIMM attended a University Careers day and liked day attended a University Careers I also found out that what I saw in Metallurgy. less competitive than the entry criteria were so felt I had a other engineering based degrees Minara Resources Ltd Minara Resources particular Why did you choose your career(s)? sciences. I the I was always inclined towards d Readett Davi BEng(Metallurgical Engineering) Development - Manager Project Group

PROFILES