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By D Stepanenko, G Stovpchenko, L Lisova, D Togobitskaya, L Medovar

Classical electroslag remelting of consumable electrodes is a drop-by-drop melt feeding through a slag layer into a renewing molten metal bath, slowly solidifying into a homogeneous, dense, defectfree ingot in a copper water-cooled mould. The new look at the additive nature of the electroslag remelting (ESR) process in a protective atmosphere allowed us to formulate the principles of a comprehensive thermodynamic-based model that can predict dynamic changes in slag and metal composition at certain ingot remelting. The model considers drastically different slag-to-metal mass ratios at the beginning and end of remelting and predicts gas, slag and metal composition in a chain of thermodynamic subsystems. Despite consisting of calcium fluoride and stable oxides, the ESR slag can oxidise main and active elements from steel and alloys (primarily aluminium, titanium and silicon) due to chemical reactions between slag and metal. ESR is not an electrochemical process in its nature. However, slags are ionic melts and deviation in their composition causes a change in their properties, affecting both operation mode and ingot quality. Another important understanding derived from the modern metallurgy technological route is that the ability to refine metal from impurities is not a priority for the ESR because consumable electrode has already passed all stages of refining and deep degassing at ladle treatment that changes ESR slags engineering principles. The critical importance became slag’s ability to generate process heat and keep the melting composition in the metal bath unchanged (except for non-metallic inclusions assimilation). Slag engineering for ESR required a compromise between chemical inertness to a metal composition and desired physical properties deriving from technological reasons. The Directed Chemical Bonds Concept (DCBC) in a multicomponent oxide system was used to build predictive models of electric conductivity and the melting temperature of fluoride-oxide slag based on their chemical composition. Both models help to design a customised composition of effective slags for steel and alloy groups or individual grades, and they are significant steps in the development of a comprehensive model of electroslag remelting.

Aug 21, 2024

By Reilly L, Worner H. K

The EnvIRONment process has been developed to treat steel works dust and organic wastes simultaneously. A pelletised feed is fed into a special DC electric furnace, the pellets becoming immersed in a molten slag above a carbon saturated bath. The iron oxide in the pellets is reduced and carburised whilst the organics are broken down to carbon monoxide, carbon dioxide, hydrogen and water vapour. Volatile metals are vapourised and collected in the baghouse. Over two years of trials in a 100 kg DC electric are furnace has brought the process to the stage where it is ready for commercialisation.

Jan 1, 1995

The Bradford Process, Australian Patent No. 11253, has had considerable application in the treatment plants of Broken Hill mining companies, and is at present being used by the North Broken Hill Limited for the treatment of weathered slime accumulations.The "Mining and Scientific Press," of 28th September, 1918, describes the Bradford Process at Broken Hill, specially featuring its application to slime material at the Proprietary mine-the home of the process.The points then stressed for galena flotation were acidulated slime pulp (0.025 to 0.030% H2S04) at temperature 85° to 90° F. and suitable time contact, with 1.5 to 2 lb. of sodium hyposulphite (per ton on slime) to permit the released S02 to "wet" or depressthe blende mineral. Also 1.0 to 1.3 lb. of crude sulphur (per ton on slime) was burnt, to supply S02 for keeping the lead concentrate clean during flotation. Pulp density varied from 23 to 26% solids. Since 1918 the process has been simplified in its application.Acidity of circuit, temperature, and sodium hyposulphite have been dispensed with, and now the S02 is practically all obtained by burning crude sulphur. I The plant units now employed for control and absorption of S02 gas constitute the main advance made in process, and these, with other details, are fully explained in this paper.APPLICATION AT BROKEN HILL NORTHThe existing North Broken Hill Limited gravity mill commenced operations on 9th September, 1909.

Jan 1, 1929

By Hinrichsen H. D, Rathburn D. R, Stieger W

The present situation in the field of iron ore pelletizing is briefly described with particular view of the Lurgi/Dravo travelling grate process. To meet todays pellet quality requirements with regard to physical and metal- lurgical properties it is often necessary to add basic fluxing materials. It has been de- monstrated that for certain ores, basic addi- tives provide a considerable improvement in fired pellet quality. The production of self- fluxing pellets is becoming increasingly attractive. One Lurgi/Dravo plant is now in operation and another is under construction which were designed for the production of self- fluxing pellets. Self-fluxing pellets may be considered as the primary or exclusive blast furnace burden and the installation of a sinter plant is not necessary if the pellet plant-can handle all in-plant fines. Reference is made to the first pellet plant utilizing iron ore concentrate, in-plant fines and basic flux. The use of solid fuel for pellet indura- tion is discussed because of the increasing prices and possible shortages of heavy oil and natural gas. Since there is a strong tendency to increasing plant capacities, the design fea- tures of travelling grate pelletizing plants for productions up to 6 million tonnes are Discussed.

Jan 1, 1974

By X Yang

White phosphorus (P4) is a critical element in industry, but its current production from phosphate rock using the carbothermal reduction method raises significant environmental and health concerns. This pressing issue necessitates the development of new technologies that facilitate the sustainable production of P4. In response, my team is actively developing an innovative, coke-free approach for white phosphorus production. This method involves the dissolution of phosphate rock in molten CaCl2, followed by the extraction of P4 through electrochemistry at relatively low temperatures. Moreover, this approach has the potential to utilise phosphate-bearing solid wastes as raw materials, further enhancing its environmental benefits. By employing this cutting-edge technique, we aim to revolutionise the phosphorus chemical industry towards greener and more sustainable practices. This paper provides evidence of the feasibility and effectiveness of our proposed approach.

Aug 21, 2024

By C Reed

Titaniferous magnetite deposits are a significant source of vanadium for use in high strength steel alloying and other chemical applications. The mineralogy of the deposits varies markedly and the ore characteristics strongly influence the process route selected and the metallurgical outcomes. Characterisation of the ores reveals the presence of magnetite, ilmenite and other minerals such as spinel hematite and goethite with variable degrees of weathering along with weathered products of host rock. The standard processing route is to crush, grind and magnetically recover a concentrate for salt roasting to produce a soluble vanadate. Ore beneficiation is practised to generate an iron based mineral concentrate containing much of the vanadium with low silica levels of two per cent. Typical processing problems encountered are fine liberation size, over grinding of the magnetite and variable response to magnetic separation resulting from the weathering profile. Beneficiation options are restricted, and generally focused on producing a combined iron and titanium rich concentrate containing vanadium due to the fact that ilmenite and magnetite and their products of weathering are magnetic and have similar specific gravities making their separation difficult. The ilmenite usually contains low levels of vanadium making its separation highly desirable from the iron mineralisation containing higher levels of vanadium. Salt roasting of vanadium ores followed by water leaching has been the standard processing route for many years. The cost of suitable sodium salts, availability of capital and increasing energy costs and energy availability are critical factors in determining the viability of aspiring vanadium producers. To date, only Windimurra has acquired full capital funding, secured energy and sodium salt supplies at suitable cost that enable the construction of the project. Low overall recoveries of vanadium to concentrate roasting at up to 1200¦C are critical cost issues. In this paper, factors influencing the recovery of vanadium are reviewed and emerging processing trends explored. The important features of the processing of titaniferous magnetites have been condensed from the literature, published works, company websites, our own work and personal communication.

Jan 1, 2008

By Davis RA, Wasp EJ, Cowper NT

The transportation of solids by pipeline is not new. In 1891 a United States patent broadly covering a method of pumping coal with water was granted to W. C. Andrews. His pilot plant was constructed on what is now the site of the New- York Public Library in Manhattan. His process was applied to pumping coal mine waste back into the worked out portion of coal mines. On October 26, 1967, the world's first long distance iron ore slurry line was put into service by Savage River Mines. The commissioning of this 5.0 million dollar installation climaxed three years of development, testing, and construction and proved the Company's faith in pioneering' this unique transportation method for iron ore. This paper will discuss some of the more pertinent items in connection with that three-year period. Also to be discussed will be the operation of this line during the past eleven months.

Jan 1, 1969

By P J. Cullen, B P. Banerjee, S Raval

Continuous monitoring of mining impacts on the surrounding environment is a necessary sustainability criterion. Traditional monitoring approaches such as in situ sampling and airborne and satellite-based remote sensing have several limitations. Over the past few decades, unmanned aerial vehicles (UAVs) have evolved into popular platforms for remote sensing. UAV-based remote sensing has been successfully applied in different sectors, including agriculture, forestry, urban environments and disaster management. However, the potential of UAVs for mine environmental monitoring has not yet been fully established. This paper envisages the use of UAVs and sensor systems to monitor the environment of future mines.CITATION:Banerjee, B P, Raval, S and Cullen, P J, 2015. Unmanned aerial vehicles for mine environment monitoring, in Proceedings Third International Future Mining Conference, pp 137–144 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 4, 2015

By R Lastra, Y Choi, C Hamilton, P Kondos

Hydroseparation (http://www.cnt-mc.com) was used to concentrate sized fractions (from <38 ¦m to 150 ¦m) of various ore products ahead of carbon-in-pulp (CIP)-treatment. The resulting size-by-size concentrates were mounted as monolayer polished sections and subjected to automated unattended precious metal searches by image analysis (see Lastra, Wilson and Cabri, 1999). Systematic variations in Au-deportment permit quantification of Au reporting as discrete grains from fresh-feed through to pressure oxidation (POX)- and CIP-feed. Application of hydroseparation, image analysis and assays to characterising tailings (from <10 ¦m to 106 ¦m) from four mine sites is also described. Results are encouraging enough to predict that the combination of hydroseparation (HS) and automated image analysis could become a standard methodology for study of precious metal ores and metallurgical products.

Jan 1, 2008

By M Creech

During the 1990s, wider and more productive longwall panels were being introduced into the Newcastle Coalfield. The strata of the Newcastle Coalfield incorporate numerous massive sandstones and conglomerates, some of which formed the immediate roof of the coal seams being mined. The unexpected implications of introducing wider panels into this geological environment included more variable and increased subsidence, severe periodic weighting (with associated mid-face falls) as well as windblast.Subsidence prediction at the time was based on empirically derived data essentially relating subsidence to the width/depth ratio of the panel without accounting for actual widths, nor the impacts of variable geology. This approach required modification as locally derived data was gathered and reinterpreted.The interaction of massive strata located close to the roof of the mined seam resulted in dramatic implications for some of the operations. When associated with longwall goaf geomechanics severe periodic weighting events and crippling mid-face roof falls were the consequence. When associated with narrower panels and shortwall goaf geomechanics, mines in the region experienced aggressive windblast events. The relationships between the overlying massive strata, longwall panel geometry and the various risks encountered during this period is in the author’s opinion, the most concise still documented.As the extensive coalfields of Queensland turn to underground mining operations the relevance of these experiences cannot be underestimated. This paper will discuss recent developments as well as incorporating diverse subjects such as microseismic monitoring, low frequency radio emissions and ‘electrophonics’ as they relate also to the topic.Like Moriarty, massive strata can be disguised and can offend when you least expect. This paper documents a trail of crimes committed by conglomerate in the Newcastle Coalfield that were inflicted on the general public, miners and mining equipment. Although this paper concentrates on the criminal behaviour of conglomerate, this story is also relevant to other massive units such as coarse sandstones that may be more difficult to identify and apprehend. Currently Moriarty remains at large and able to reoffend at any time, once again taking advantage of the unwary.CITATION:Creech, M, 2014. Moriarty was a conglomerate – experiences and implications of coal mining under massive strata in the Newcastle Coalfield, in Proceedings Ninth International Mining Geology Conference 2014 , pp 47–54 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By G Steward

Gravity Leaching of high-grade gravity gold concentrates, such as Knelson Concentrates, with the ACACIA Reactor represents a new generation of concentrate treatment methods. The ACACIA Reactor is a complete packaged plant for the maximising of gold recoveries from gravity gold concentrates. This paper will introduce the process technology and provide process results from the Porgera ACACIA Reactor installation. The advantages of the ACACIA Reactor are many, and justification for installation has been varied. The typical advantages of the process include: increased recovery of gold from the Knelson Concentrate; no return of high-grade table tails, often grading several thousand g/t, into the mill circuit; reduction in tails grades of slow leaching gold; reduction in the requirement for operating staff by the removal of the manual tabling process and replacing with a fully automated treatment system; improved security by removing the tabling step where operating staff come into direct contact with visible gold; improved health and safety, by the removal of the treatment steps for the table concentrate, which often include operators handling corrosive chemicals and the production of sulphur and arsenic compound fumes; and improved metallurgical accounting, by allowing daily head grade calculations. The ACACIA Reactor was developed by Anglogold for Union ReefÆs Gold Plant and has been in production for over two years, and has proven to be a low cost, high recovery, mechanically reliable method for the processing of gold concentrates. Such has been the success of the plant, there are now four full installations of the processing plant, including Anglogold Union ReefÆs, Anglogold Sunrise Dam, PACMIN Carosue Dam and Porgera Joint Venture.

Jan 1, 2002

By M Gwynne

McArthur River Mine is located approximately 50 km south-east of the NT township of Borroloola and approximately 120 km from the Gulf of Carpentaria. The mine hosts a series of layered shallow dipping tabular orebodies, with current reserves of approximately 22 Mt, grading 13.6 per cent zinc, 6.3 per cent lead and 65 g/t silver. Owing to economic considerations, the lower most orebody (No 2 orebody) has been selected for initial mine production. Following the completion of the No 2 orebody, mining will transfer to the lower grade and metallurgically more complex No 4 orebody. The mine employs a total of 235 people throughout the underground and surface areas. The majority of the workforce work a fly-in/fly-out, seven-day- on/seven- day- off roster with 12-hour shifts. Presently, a further 18 contractors are involved in trial mining areas. An apparent dip room and pillar technique has been selected as the primary mining method. Officially opened in September 1995, the current production rate of 1.2 Mt per annum will eventually escalate to 1.5 Mt per annum. Though most production is achieved through the use of conventional loaders, trucks and jumbos, the recent development of methods utilising scrapers, hand held machines and modified jumbos has produced encouraging results in steeper dipping areas of the mine. Initial production has been hindered by several factors including extensive and largely unpredictable faulting, worse than expected ground conditions and difficulties with some mining equipment. Compounded by the relatively thin 3 m ore seam, initial mining resulted in high dilution and poor production. This paper describes the development of unique planning and production systems that were evolved in order to overcome these problems and achieve the targeted production rates and head grade.

Jan 1, 1998

By Y Gu

Based on the mode of occurrence, gold is classified into three categories: microscopic gold, submicroscopic gold and surface-bound gold. Microscopic gold, or visible gold, refers to gold minerals in which Au occurs in a substantial amount, such as native gold and electrum. Submicroscopic gold, ie invisible gold, refers to gold contained in the structure of other minerals (mainly sulfides) in minor to trace amounts. Surface gold is the gold that was adsorbed onto the surface of other minerals during mineralisation and subsequent oxidation or metallurgical processing. Gold mineralogy has a significant impact on its extractive metallurgy. Gold process mineralogy helps address problems related to gold ore processing. It is widely used as a predictive and troubleshooting tool in gold ore processing, and provides useful information on process selection, flow sheet development, recovery improvement and reagent consumption optimisation. This paper will begin with the classification of gold ores, and will focus on gold mineralogy and how it impacts extractive metallurgy through case studies.

Jan 1, 2008

Development of a global failure criterion for rocks has been a desired goal in rock mechanics. Due to variations in factors affecting rock specifications and their mechanical properties, proposing a single failure criterion suitable for all rock types has proven to be unachievable. The theoretical failure criteria do not fit the real data correctly. Amongst empirical criteria, the Bieniawski criterion has demonstrated an acceptable agreement with laboratory generated data. It has been experienced that the ability to estimate rock strength via the modified form of this criterion is significantly improved. Based on the modified Bieniawski criterion and using VB.net, an associated Microsoft Windows program named 'RAMOCE' has been developed. The inputs of RAMOCE can be triaxial compressive strength data, Bieniawski parameters of a specific rock or the type of given rock. Based on input data, potential outputs of the program are Bieniawski's rock parameters, sensitivity analysis of the effective parameters, rock failure prediction and defining the type of given rock.

Nov 25, 2010

Consideration of the questions: (i) is it feasible to study groups of processes in a generalised way? (ii) to what extent does purpose affect the form of a process model? (iii) are there any significant, novel investig- ations which can be made by computer simulation? (iv) what long-term developments are desirable in extractive metallurgy? has led to some new broad objectives for research in hydrometallurgical process engineering. Propositions for grouping processes, developing models for different specific purposes, using a systems engineering approach and developing high technology processes are discussed, and the role of computer simulation indicated by reference to particular projects.

Jan 1, 1984

By P D. Erskine, A Hine

The current Queensland Government’s rehabilitation guidelines for post-mining landforms present a hierarchy of preferred outcomes for different areas within the mine site (see Figure 1). Within all areas, restoration of a ‘natural’ ecosystem is clearly prioritised as the preferred end land use, although it is not a mandatory practice. Beyond the official guidelines, there is also an implied preference for renaturalisation echoed in most environmental impact assessments and closure plans (Lamb, Erskine and Fletcher, 2015). In practice, however, ecosystem restoration does not extend to construction of a realistic topographic form, largely rejecting the ‘natural’ aesthetic implied by ecosystem restoration in favour of adopting a functional aesthetic in deference to standard engineering criteria.This presentation argues that the established disconnection between actual and implied landform aesthetics is indicative of a wider problem around end landform planning. It contends that such disconnects are the result of the impact of competing ‘ways of seeing’ (Bradley and Kearney, 2007) the same landscape, and reflect the struggle between, and inclusion of, these differing perspectives within the planning process itself. We propose that recognition of the complexity of landscape perceptions is key to improving post-mining landscape outcomes, and the misalignment between land use values and landscape aesthetics can be addressed by establishing an overarching framework for landscape preferences. As such, we outline the reality of stakeholder landscape preferences, and present a critical response to current planning practices within the life-of-mine (LOM).CITATION:Hine, A and Erskine, P, 2016. Recognising and integrating stakeholder landform expectations into life-of-mine planning, in Proceedings Life-of-Mine 2016 Conference, pp 154–157 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

By J B. Collier, R M. Fraser, O Dahl, I M. Platten

Grade control is a process of maximising value and reducing risk, through the delivery of quality tonnes to the mill via the accurate definition of ore and waste. It essentially comprises data collection, integration and interpretation; local resource estimation; stope design; supervision of mining and stockpile management. The foundation of all grade control programs should be that of geological understanding led by high-quality mapping and sampling to drive appropriate estimation strategies and mining. Gold veins show various complex features relating to erratic grade distribution (nugget effect), variable geometry and internal architecture. These include variations in dip, strike and width, late-stage faulting/shearing effects and geometallurgy. Such variations generally require close geological understanding to ensure optimum grade, minimal dilution and maximum mining recovery. A well designed grade control program will prove to management and stakeholders that by applying geological knowledge, the mining process can be more efficient and cost effective. This paper reviews the issues of grade control in underground gold mines and focuses on integrated mapping and sampling through three case studies.

Jan 1, 2009

Delivery of effective plant shutdowns is primary to the business success of mining and processing plant operations. This paper sets out a methodology that starts with understanding the business objectives of the shutdown and promotes rigorous detailed planning, effective communication, appropriate governance and effective participation of plant operations personnel. The result is delivery of business effective outcomes.

Jan 1, 2004

By Kuganathan K, Potvin Y

Enterprise Mine at Mount Isa is to expand ore production from the current 1.4 to 3.5 mtpa by mining the 3500 Orebody, from which production is scheduled to start in February 1998 making this the deepest underground mine in Australia with its lowest mining horizon at nearly 1.6 km below surface. The following fill requirements were defined for the 3500 Orebody during the feasibility study: 1. a minimum filling rate of 250 ma/h, 2. a curing time of 28 days, and 3. minimum free fill water. This paper mainly describes the investigation of high density and paste fills for the 3500 Orebody. The investigation covered all the key issues relating to fill option selection, including design criteria, material supply and demand assessment, drainage modelling, tailing dewatering method, mix design and a pump loop test. Results of the investigation indicate that both high density fill and paste fill are technically feasible. The investigation has led to the selection of a blended tailing paste for the 3500 Orebody as the paste option has significant advantages over high density fill in stope filling rates and fill reticulation. The blended tailing for paste fill is finer than Isa deslimed tailing but coarser than full plant tailing. The paste fill selected has minimum binder and tailing dewatering requirements while a relatively high filling rate is achieved.

Jan 1, 1998

The underground storage of LPG and other hydrocarbons is in current commercial use in Northern Hemisphere countries in Europe, Asia and the USA.Elgas Pty Ltd, a 50 per cent joint venture between AGL and BOC, embarked on a worldwide feasibility investigation in 1989 to establish the viability of constructing an underground LPG storage facility in Sydney, Australia, the first of its kind in the country. Elgas recognised that with the limited 19 000 tonnes of storage capacity at Port Botany and the limitations imposed by use of small coastal ships (up to 10 000 tonnes capacity), a larger storage facility was required to utilise higher capacity ships from more remote sources such as the North West shelf and overseas. This would achieve security of supply in high demand periods and economies of scale. The underground option also provides improvements to safety and environmental standards.

Jan 1, 1999