A geometallurgical model is the combination of a spatial model representing an ore deposit and a process model representing the comminution and concentration steps in beneficiation. The process model itself usually consists of several unit models. Each of these unit models operates at a given level of detail in material characterization - from bulk chemical elements, elements by size, bulk minerals and minerals by size to the liberation level that introduces particles as the basic entity for simulation (Paper 1). In current state-of-the-art process simulation, few unit models are defined at the particle level because these models are complex to design at a more fundamental level of detail, liberation data is hard to measure accurately and large computational power is required to process the many particles in a flow sheet. Computational cost is a consequence of the intrinsic complexity of the unit models. Mineral liberation data depends on the quality of the sampling and the polishing, the settings and stability of the instrument and the processing of the data. This study introduces new tools to simulate a population of mineral particles based on intrinsic characteristics of the feed ore. Features are extracted at the meso-textural level (drill cores) (Paper 2), put in relation to their micro-textures before breakage and after breakage (Paper 3). The result is a population of mineral particles stored in a file format compatible to import into process simulation software. The results show that the approach is relevant and can be generalized towards new characterization methods. The theory of image representation, analysis and ore texture simulation is briefly introduced and linked to 1-point, 2-point, and multiple-point methods from spatial statistics. A breakage mechanism is presented as a cellular automaton. Experimental data and examples are taken from a copper-gold deposit with a chalcopyrite flotation circuit, an iron ore deposit with a magnetic separation process. This study is covering a part of a larger research program, PREP (Primary resource efficiency by enhanced prediction). / PREP

The demands for efficient utilization of ore bodies and proper risk management in the mining industry have resulted in a new cross-disciplinary subject called geometallurgy. Geometallurgy connects geological, mineral processing and subsequent downstream processing information together to provide a comprehensive model to be used in production planning and management. A geometallurgical program is an industrial application of geometallurgy. Various approaches that are employed in geometallurgical programs include the traditional way, which uses chemical elements, the proxy method, which applies small-scale tests, and the mineralogical approach using mineralogy or the combination of those. The mineralogical approach provides the most comprehensive and versatile way to treat geometallurgical data. Therefore it was selected as a basis for this study. For the mineralogical approach, quantitative mineralogical information is needed both for the deposit and the process. The geological model must describe the minerals present, give their chemical composition, report their mass proportions (modal composition) in the ore body and describe the ore texture. The process model must be capable of using mineralogical information provided by the geological model to forecast the metallurgical performance of different geological volumes and periods. A literature survey showed that areas, where more development is needed for using the mineralogical approach, are: 1) quick and inexpensive techniques for reliable modal analysis of the ore samples; 2) ore textural characterization of the ore to forecast the liberation distribution of the ore when crushed and ground; 3) unit operation models based on particle properties (at mineral liberation level) and 4) a system capable of handling all this information and transferring it to production model. This study focuses on developing tools in these areas. A number of methods for obtaining mineral grades were evaluated with a focus on geometallurgical applicability, precision, and trueness. A new technique developed called combined method uses both quantitative X-ray powder diffraction with Rietveld refinement and the Element-to-Mineral Conversion method. The method not only delivers the required turnover for geometallurgy but also overcomes the shortcomings if X-ray powder diffraction or Element-to-Mineral Conversion were used alone. Characterization of ore texture before and after breakage provides valuable insights about the fracture pattern in comminution, the population of particles for specific ore texture and their relation to parent ore texture. In the context of the mineralogical approach to geometallurgy, predicting the particle population from ore texture is a critical step to establish an interface between geology and mineral processing. A new method called Association Indicator Matrix developed to assess breakage pattern of ore texture and analyze mineral association. The results of ore texture and particle analysis were used to generate particle population from ore texture by applying particle size distribution and breakage frequencies. The outcome matches well with experimental data specifically for magnetite ore texture. In geometallurgy, process models can be classified based on in which level the ore, i.e. the feed stream to the processing plant and each unit operation, is defined and what information subsequent streams carry. The most comprehensive level of mineral processing models is the particle-based one which includes practically all necessary information on streams for modeling unit operations. Within this study, a particle-based unit operation model was built for wet low-intensity magnetic separation, and existing size classification and grinding models were evaluated to be used in particle level. A property-based model of magnetic beneficiation plant was created based on one of the LKAB operating plants in mineral and particle level and the results were compared. Two different feeds to the plant were used. The results revealed that in the particle level, the process model is more sensitive to changes in feed property than any other levels. Particle level is more capable for process optimization for different geometallurgical domains.

This thesis primarily addresses the problem of automatic measurement of ore textures by image analysis in a way that is relevant to mineral processing. Specifically, it addresses the following major hypotheses: • Automatic logging of drill core by image analysis provides a feasible alternative to manual logging by geologists. • Image analysis can quantify process mineralogy by physically meaningful parameters. • Multi-scale image analysis, over a wide range of size scales, provides potential benefits to process mineralogy that are additional to those available from small-scale analysis alone, and also better retains the information content of manual logging. • Image analysis can provide physically meaningful, ore-texture-related, additive regionalised variables that can be input to geostatistical models and the definition of domains. The central focus of the thesis is the development of an automatic, multi-scale method to identify and measure objects in an image, using a specially-developed skeleton termed the morphological CWT skeleton. This skeleton is a multi-scale extension of the morphological skeleton commonly used in image analysis, and is derived from the continuous wavelet transform (CWT). Objects take the form of hierarchical segments from image segmentation based on the CWT. Only the Mexican hat, also known as the Laplacian-of-Gaussian, wavelet is used, although other wavelet shapes are possible. The natural scale of each object is defined to be the size scale at which its CWT signal (the contrast between the interior and exterior of the object) is strongest. In addition to the natural scale, the analysis automatically records the mineral composition of both the interior and exterior of each object, and shape descriptors of the object. The measurements of natural scale, mineral composition and shape are designed to relate to: • The size to which ore must be broken in order to liberate objects. • Minerals that need to be separated by physical or chemical means once objects have been liberated. • Capability to distinguish qualitatively different ore-texture types that may have different geological origins and for which different processing regimes may provide an economic benefit. Measurements are taken over size scales from three pixels to hundreds of pixels. For the major case study the pixel size is about 50 µm, but the methodology is equally applicable to photomicrographs in which the pixel size is about 4 µm. The methodology for identifying objects in images contributes to the field of scale-space image segmentation, and has advantages in performing the following actions automatically: • Finding optimal size scales in hierarchical image segmentation (natural scale). • Merging segments that are similar and spatially close together (although not necessarily touching), using the structure of the morphological CWT skeleton, thus aiding recognition of complex structures in an image. • Defining the contrast between each segment and its surrounding segments appropriately for the size scale of the segment, in a way that extends well beyond the segment boundary. For process mineralogy this contrast quantifies mineral associations at different size scales. The notion of natural scale defined in this thesis may have applications to other fields of image processing, such as mammography and cell measurements in biological microscopy. The objects identified in images are input to cluster analysis, using a finite mixture model to group the objects into object populations according to their size, composition and shape descriptors. Each image is then characterised by the abundances of different object populations that occur in it. These abundances form additive, regionalised variables that can be input into geostatistical block models. The images are themselves input to higher-level cluster analysis based on a hidden Markov model. A collection of images is divided into different ore texture types, based on differences in the abundances of the textural object populations. The ore texture types help to define geostatistical domains in an ore body. Input images for the methodology take the form of mineral maps, in which a particular mineral has been assigned to each pixel in the image prior to analysis. A method of analysing unmapped, raw colour images of ore is also outlined, as is a new model for fracture of ore. The major case study in the thesis is an analysis of approximately 1000 metres of continuously-imaged drill core from four drill holes in the Ernest Henry iron-oxide-copper-gold ore deposit (Queensland, Australia). Thirty-one texture-related variables are used to summarise the individual half-metres of drill core, and ten major ore texture types are identified. Good agreement is obtained between locations of major changes in ore type found by automatic image analysis, and those identified from manual core logging carried out by geologists. The texture-related variables are found to explain a significant amount of the variation in comminution hardness of ore within the deposit, over and above that explained by changes in abundances of the component minerals. The thesis also contributes new algorithms with wide applicability in image processing: • A fast algorithm for computing the continuous wavelet transform of a signal or image: The new algorithm is simpler in form and several times faster than the best previously-published algorithms. It consists of a single finite impulse response (FIR) filter. • A fast algorithm for computing Euclidean geodesic distance. This algorithm runs in O(1) arithmetic operations per pixel processed, which has not been achieved by any previously published algorithm. Geodesic distance is widely used in image processing, for segmentation and shape characterisation.

In comminution machines, the product properties (particle size distribution, mineral liberation characteristics) and process consumables (energy for size reduction, wear) are affected by various parameters. On the one hand, understanding and optimizing these parameters can provide an energy efficient process and a specified product. On the other hand, a fundamental understanding of the breakage process can even be used for designing new or improved comminution machines. In this thesis, breakage fundamentals are analyzed and set against the principles of various comminution machines. The study of the breakage fundamentals is crucial for a better understanding of the effect of different comminution environments on ore types and their textures in order to achieve a desired product size and liberation. This work defines three main areas of breakage processes with breakage fundamentals, namely “loading mechanism”, “breakage mechanism” and “breakage mode”. The “loading mechanism” is defined as the physical action that is applied to a particle or several particles in order to introduce mechanical stress. The resulting pattern of the particle failure is named “breakage mechanism”. Finally, the “breakage mode” defines the particle breakage in terms of being random or non‐random. Non‐random breakage depends on the ore texture, which can be categorized as preferential breakage and phase boundary breakage. Promoting the breakage mode to the phase boundary breakage could help to increase the liberation degree. Various studies have assessed the effect of ore texture and operational parameters on mineral liberation. While ore texture is related to the particle inherent characteristics, operational conditions such as loading mechanism are related to the comminution environment. In all these investigations, little attempt has been made to explore the combined effects of loading mechanism and quantitative ore texture features on breakage mode and mineral liberation. In addition, a lack of fundamental understanding of the breakage process and mineral liberation can be seen. Accordingly, a more fundamental study of the causes behind the effects of loading mechanism and texture is required in order to optimize the comminution process in terms of mineral liberation. The objective of this work is, therefore, to investigate the effects of different loading mechanisms on particle breakage and breakage mode. In order to achieve this goal, work has started with using two methods including three‐dimensional deformation and two‐dimensional crack quantification. The former method involved X‐ray computed micro‐tomography (XCT) imaging and Digital Volume Correlation (DVC) measurements which determiners the breakage mode in terms of being random or non-random. Whereas the latter was done using an image processing code in MATLAB to quantify cracks in terms of random and non-random breakage (preferential or phase boundary) from Scanning Electron Microscopy (SEM) images. In addition, XCT 3D imaging was used in order to track the propagated cracks in the third dimension. Moreover, phase boundary breakage in magnetite grains was studied qualitatively based on optical microscopy images in order to identify and characterize the propagated cracks.

This thesis study employs textural classification techniques applied to four different data groups: (1) visible light photography, (2) high-resolution drill core line scan imaging (3) scanning electron microscopy backscattered electron (SEM-BSE) images, and (4) 3D data from X-ray microtomography (μXCT). Eleven textural classes from Aitik ores were identified and characterized. The distinguishing characteristics of each class were determined such as modal mineralogy, sulphide occurrence and Bond work indices (BWI). The textural classes served as a basis for machine learning classification using Random Forest classifier and different feature extraction schemes. Trainable Weka Segmentation was utilized to produce mineral maps for the different image datasets. Quantified textural information for each mineral phase such as modal mineralogy, mineral association index and grain size was extracted from each mineral map.  Efficient line local binary patterns provide the best discriminating features for textural classification of mineral texture images in terms of classification accuracy. Gray Level Co-occurrence Matrix (GLCM) statistics from discrete approximation of Meyer wavelets decomposition with basic image statistical features[PK1]  (e.g. mean, standard deviation, entropy and histogram derived values) give the best classification result in terms of accuracy and feature extraction time. Differences in the extracted modal mineralogy were observed between the drill core photographs and SEM images which can be attributed to different sample size[PK2] . Comparison of SEM images and 2D μXCT image slice shows minimal difference giving confidence to the segmentation process. However, chalcopyrite is highly underestimated in 2D μXCT image slice, with the volume percentage amounting to only half of the calculated value for the whole 3D sample. This is accounted as stereological error. Textural classification and mineral map production from basic drill core photographs has a huge potential to be used as an inexpensive ore characterization tool. However, it should be noted that this technique requires experienced operators to generate an accurate training data especially for mineral identification and thus, detailed mineralogical studies beforehand is required. / Primary Resource Efficiency by Enhanced Prediction (PREP) / Center for Advanced Mining and Metallurgy (CAMM)