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By S Wright, W Bruckard

The current status of battery collection and recycling schemes in Australia are explored in light of current developments in product stewardship and increasing pressure to decrease materials going to landfill by originating equipment manufacturers. Used consumer batteries, both single cycle and rechargeable contain a mixture of valuable metals and potentially toxic materials that may become a resource/revenue stream to offset the cost of disposal/recycling. Although the volume of batteries discarded in Australia is modest compared to other global population centres, the expected increase in battery use with increasing equipment portability and future developments in the automotive industry, provide an opportunity to recycle. The requirements for a battery recycling facility in Australia and the most promising processing platforms that may exploit the resource with enough flexibility to cope with battery developments and market trends, are explored.

Jan 1, 2006

The Marvel Loch Operations (MLO) plant was treating ores from up to six MLO sources and in addition needed to blend externally sourced ores with its own ores. This presented a metallurgical accounting dilemma, which was subsequently addressed by the design, implementation and testing of an automatic sampling system. The MLO automatic sampler was well designed and has been the subject of previous internal and external reviews. The sampling action is fully automated and the unit is essentially self cleaning particularly when sampling primary ores. The purpose of this paper is to document the rationale behind the design, the specific details of the sampling station, its use for ore purchase purposes and an assessment of the sampling system to meet the needs of the operator.

Mar 1, 2010

By K Watanabe

A relational database in which its complex contents can be navigated through a map interface (ie spatially enabling) is relatively a new concept yet attractive for geoscience fields. This concept is made possible using the new breed of geographic information system (GIS) that utilises component object model and relational database management system. Such sophisticated yet open and highly interoperable platform makes possible the integration of data management, analysis, and modeling processes into single workflow. Taking benefit of this technology trend, several initiatives emerge in geoscience to establish digital data models, such as the petroleum industry, the North America digital geologic map data model, and the ESRI geology data model. The mining industry unfortunately has not followed same paths due to the lack of data model and standards in its history. This paper presents an effort on establishing a digital data model for mining-related geoscience databases. The aim is to promote several standards by proposing a preliminary data model and demonstrating that the model is working for the mining business datasets. The case study is the island of Java, the western part of the Sunda island arc of Indonesia. Many types of datasets, such as geologic maps, topography, mineral deposits, structures, geochemical and geophysical data were dealt with and were transformed relational geologic databases of Java using the new Geodatabase geographic data model. Intelligent GIS tools were investigated for geologic applications, ranging from generic to specific purposes. Subtypes and domain were used to set up constraints, while topology rules and relationship classes were used to create links among data layers. The linear referencing system was used to model drillhole data. The current results show that the generic GIS and relational database can handle typical tasks related with mining business datasets. A preliminary data model is finally suggested.

Jan 1, 2004

By W Roy

When it comes to plan implementation and securing success in organisations in the 21st century, if there was such a thing as the secret to success it would be effective communication. Commoditisation brings financial, operational and cultural advantages to organisations that use effective communication. Effective communication tools turn æpeople problemsÆ into system control solutions, removing personality clashes that hide procedural malfunctions. By introducing communications frameworks available in the market place today, and case studies of their use, this paper provides insights into the successes available to organisations courageous enough to redefine their communications for the 21st century.

Jan 1, 2006

Project Sustainability Assessment - Matching Method to Enterprise Size Sustainable development requires managing natural resources, including minerals, in a way that is conducive to long-term wealth creation and the maintenance of capital (natural, social, human, economic and physical). One aspect of the minerals sustainability discussion focuses on replacing depleted mineral capital with other forms of capital so as to ensure that the contribution of a mineral project is net positive over its life. Another, equally important, aspect focuses on selection of projects and technologies that contribute to the achievement of a variety of sustainability objectives, such as environmental protection, efficient use of resources, water and energy, worker health and safety, and the equitable distribution of risks and benefits within and across generations. Technical feasibility and relative economic performance remain necessary decision criteria for mineral investment decisions, but they are no longer sufficient. Enterprises, regardless of size, are now confronted with the challenge of comparing investment alternatives based on a new, broader set of criteria. The field of integrated sustainability assessment (ISA) emerged in response to this changed social and business environment. ISA is a structured process for examining the economic, social and environmental impacts of a project or technology. The purpose of an assessment can be broad, a strategic review of corporate behavior for example, or quite narrow, input to a specific decision process such as the selection of a piece of equipment. There are numerous methods and analytical tools available to conduct ISAs and selection of the most appropriate for a given situation will depend upon temporal focus (retrospective to prospective), decision context (strategic, tactical or operational), and phase of the assessment process (problem structuring, analysis, resolution, ex post review), among others. Selection also depends upon enterprise size and the attendant availability of financial and human resources. Large multi-national firms often undertake complex, data intensive sustainability assessments, in part because the projects they are involved in are multi-faceted, long term, and require significant financial investments. Small and medium sized enterprises are seldom able to commit the same level of resources to an ISA, and if the projects they undertake are less complicated, a time consuming and detailed assessment may be unnecessary. Regardless of enterprise size, the tangible and reputational benefits of conducting as ISA must exceed the actual monetary cost of doing so. This presentation will provide an overview of available ISA tools, categorising them in terms of their data requirements, methodology, outputs and applicability in various decisions contexts. Distinction will be drawn between situations where reasonable approximations of project impacts can be expected to provide an adequate amount of information and those for which more detailed analysis is essential. Finally, ISA strategies that have been successful and cost effective at different scales of business enterprise will be identified. This is an abstract only. No full paper was prepared for this presentation.

Sep 13, 2010

It should be stating the æbleeding obviousÆ to say that the most efficient method of recovery must be used during the testing and evaluation phases of an orebody. Furthermore, the company will be literally throwing away money by not using the most efficient recovery plant during mining. This is especially true in the case of a low concentration/high value commodity such as diamonds. Unfortunately, this economic recovery criterion is not always the driving force. Some inexperienced companies think that they can preserve capital by using cheaper, and generally less efficient, recovery plants to mine their product. This philosophy is invariably a fallacy. Furthermore, it is also important to use the correct sized plant for the proposed task. It is no use trying to use a small testing plant to treat large quantities of ore, as this may result in loss of recovery efficiency. The converse is equally true.

Jan 1, 2004

Future climate variability and change will impact on mining operations and their attendant communities. To minimise this impact, early and informed risk management is warranted. However, research into the risks posed by climate to the Australian mining industry has so far been limited. We are conducting a systematic study of the mining life-cycle to identify the main areas of vulnerability and adaptive capacity of operations and communities. This project aims to assess what adaptation activities are currently being undertaken within the mining industry and its communities across Australia and to develop a risk management approach that will aid the adaptation of practices in and around the industry, better assuring the security of people, jobs, revenue and the environment under changed or extreme climate conditions. The Canadian mining industry was recently assessed through a similar study, which found that many mining companies perceive a real risk to mining from climate change in the future, despite few companies being actively involved in managing such risk. At a workshop held by CSIRO involving mining specialists, the most vulnerable stage in the mining process in the Australian context was assessed to be production. In particular, impacts on water and energy supplies and also transport and infrastructure were of high concern. Additionally, heat stress on workers and equipment, changes in groundwater flow and increases in geohazards were also identified as important factors in the short and long term if problematic climate events become more extreme or more frequent. Risks in the planning and post-mine stages were also identified. Based on literature reviews and preliminary discussions with mining experts, here we present an initial assessment of the climate adaptation issues relating to mining and its associated communities and describe our future work plans in this area.

Jun 1, 2010

India is on fast economic growth. Even in the turbulent years of global crisis, it could achieve a growth of over eight per cent. In recent past, Indian Government has been contemplating a faster growth in all the sectors of economy so as to make the nation an economic power in the world.Steel is a versatile material. It has its role in most of the major industrial activities, such as infrastructure, automobiles, urbanisation, consumer durables and other. In other words, steel is a part and parcel of industrial expansion, urban and rural development. It is rightly admitted that steel acts as pillar of any development model. Volume of steel consumption is the barometer which measures economic progress and/or industrial status of any country.India and China are the two countries in Asia which have the significant impact on the global steel industry. Of course, China is much ahead of India in consumption level of steel.

Dec 6, 2010

The mining industry continues to faces significant challenges due to increasing resource constraints (quality of ore bodies, water, energy, human resources) and increasing license to operate requirements (safety, health, environment, location) from society, employees and shareholders. Technology advancements and hence research are necessary to ensure that the industry remains viable in this changing environment. Collaborative research is an important part of a company's research portfolio and offers the opportunity for the industry to work on generic issues that it is facing. Obvious benefits include the reduced cost to individual companies by sharing the costs, the opportunity to leverage government funding and the opportunity to conduct longer term projects resulting in skills development (PhD and MSc). Limitations of collaborative research include the reduced focus on company specific issues and the loss of competitive advantage from owning the outcomes of the research. The challenge for researchers and research managers is for them to demonstrate the value derived from longer term, pre-competitive collaborative research. The competitive advantage is not necessarily derived only from the outcomes of the research but rather from the company's ability to direct the research, translate the generic research outcomes to address company specific issues and to implement improvements at its operations. Implementation remains the greatest challenge. In this paper, case studies of selected collaborative research projects are presented to demonstrate key success factors required for implementation of research outcomes. This is an ABSTRACT ONLY. A full-length paper was not prepared for this presentation.

Sep 13, 2010

By E Nik, A Manzoori, H Namavari, P Witt

The smelter building at Sarcheshmeh Copper Complex, Iran, houses two reverberatory furnaces and five Pierce-Smith converters. Under normal operating conditions SO2 emissions fill the building, posing a major health problem for all workers in the building, and reducing their ability to maintain the plant. The converter fume extraction system was analysed using plant measurements, engineering modelling of the entire system and CFD modelling of the extraction hoods. By applying fundamental engineering concepts, a user-interactive computer program was developed that enabled plant engineers and operators to gain a detailed understanding of the system. In conjunction with plant measurements, the model quantified the amount of inleakage throughout the system, identifying it as a significant contributor to the poor extraction performance. Furthermore, it enabled investigation of the effects of hood gates, converters on line, hood dampers, flue insulation, electrostatic precipitator (ESP) operation, and inclusion of an acid plant. The model gave unprecedented insight into the operation of a counterintuitive buoyancy-driven extraction system.

Jan 1, 2004

By B N. Noller, J C. Ng, S L. Bruce

Mining activities can result in the transfer of harmful elements, including arsenic and lead, into the environment. In Australia, one of the potential future uses of rehabilitated mine land is to stock grazing animals. Elemental uptake is dependent on bioavailable fraction for adsorption upon exposure. Bioavailability data are generally lacking in order to provide realistic health risk assessments relating to harmful elements from mine tailings in Australian conditions. Another key component of risk assessment is the ability to estimate a realistic exposure, or dose rate, of the tailings to the grazing cattle over a set period of time. Hence, we aimed to conduct grazing trials directly on rehabilitated tailings facilities in order to provide valuable in situ information on heavy metal dose rates and associated accumulation. For the laboratory-based evaluation of comparative bioavailability, groups of cattle were fed five days a week on a normal diet spiked with mine tailings or soluble pure salts of target elements (eg sodium arsenate, sodium arsenite and lead acetate) for about eight months. For the field validation, cattle were allowed to graze directly on rehabilitated tailings facilities over a similar length of time. Blood and a biopsy of the muscle and liver were periodically collected to monitor arsenic accumulation. At necropsy, blood, muscle, liver, kidney and other saleable tissues were measured for arsenic concentrations. Although this study was focused on arsenic, lead and other metals were also measured. Predictive models for arsenic and other metals have been established to calculate the maximum grazing duration without the risk of exceeding specific food safety guidelines. The outcome of this study is a predictive model for maximum beneficial use of certain rehabilitated tailings for cattle grazing where grazing activities do not impact on the integrity of the tailings dams.CITATION:Ng, J C, Noller, B N and Bruce, S L, 2014. A predictive model for beneficial use of rehabilitated mine tailings for grazing cattle after mine closure, in Proceedings Life-of-Mine 2014 , pp 563–572 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By M Dalm

More and more mining companies are becoming aware of the potential benefits of sensor-based ore sorting and process optimisation. This is reflected by a growing number of analysers that are available for drill hole logging, conveyor belt scanning, ore sorting, slurry analysis, etc. These tools all rely on a specific sensor technology that can be used to detect a material property such as colour, density, mineralogy, or chemical elements. However, all sensors have restrictions on the minerals and/or elements that can be detected or inferred. This is caused by the physical mechanisms behind the technology and depends on mineral concentration and compositional heterogeneity of the ore. Since nearly every ore deposit is unique in composition and characterised by different geological features that drive heterogeneity, no one-size-fits-all sensor solution is available. This makes it difficult for mining professionals to find suitable sensing technologies that can help them solve problems and improve processes for their specific ore types.

Sep 1, 2024

The use of scrapers in mining and earthmoving operations is not new, in fact they are one of the earliest methods of bulk earthmoving. A single machine which can load, haul, and dump material with a minimum of ancilliary support is a highly productive and cost-efficient method of earthmoving. In recent times scrapers have been unpopular due to perceived problems and operational limitations, but the last couple of years have seen a resurgence in the use of scrapers in the Bowen Basin as a primary prestripping tool. The main operational limitation of scrapers is the economic operating range. maximum productivity and lowest cost per bcm is achieved on short leads, as the lead distance increases the cost per bcm quickly reaches and then overtakes that of an truck-excavator fleet. The geometry of a ætraditionalÆ coal mine does not readily allow short leads for prestrip fleets due to the nature of dragline stripping operations. The strip arrangement means that material has to be taken around the end of the pit, meaning a longer haul distance than the actual point-to-point distance between load and dump. This can be alleviated by using pit bridges, however these can cause spoil problems for draglines if not properly planned and have been avoided by many mines. Due to the economic haul distance limitation of scrapers, truck-excavator fleets have become the normal method utilised. Currently more geologically complex mines are opening up, which do not allow traditional down-dip strip mining to occur. Cross-dip mining methods allow for short leads between prestrip loading and dumping areas, hence scrapers and bulk doze are realistic alternatives to a truck-excavator fleet in the prestrip environment. Keeping the lead distance to a minimum a fleet of 657Æs can move material at a very low cost. The other main operational limitation of scrapers is the type of material that can be economically excavated. Hard material can lead to damage to the bowl, free-flowing sand will not readily stay in the bowl leading to reduced load factors. Ripping the material with a dozer prior to excavating can lead to improved loading time, and greatly reduced GET consumption. When considering scrapers for prestrip operations a number of things must be considered: is the lead distance within the economic haul distance? should twin power (push-pull) or single power (dozer pushed) scrapers be used? do I need to rip, what should I rip with? what ancilliary support is required? is there another system already available on-site which is currently under utilised? This paper considers the parameters under which large twin power scrapers are the most effective way of undertaking prestrip operations.

Jan 1, 2003

By P Walker, I Crnkovic, D Bennett

The Phu Kham deposit represents a copper-gold porphyry system, with mineralisation present in skarn, stockwork and disseminated styles. Significant folding and alteration events have created a complex heterogeneous mineralogy horizon. Weathering and water table contact have created a leached zone, overlying transition zones with supergene chalcocite- dominant secondary copper mineralisation and clay-rich gangue. Primary ore copper mineralisation is mainly chalcopyrite with minor bornite. The major challenges to the copper-gold flotation process are a wide size distribution of chalcopyrite mineralisation and poor primary grind liberation, a high pyrite content in skarn ore requiring aggressive pyrite depression conditions, clay-rich gangue and non-sulfide copper mineralisation in weathered zones, and a significant association of gold with pyrite.The Phu Kham concentrator has been developed as a conventional semi-autogenous grinding (SAG) and ball milling circuit followed by selective rougher flotation, regrinding and cleaner flotation to produce a copper concentrate containing payable gold and silver values. The concentrator flow sheet design offered a capital efficient compromise between high copper recovery bulk sulfide flotation with large cleaning capacity, and lower recovery copper selective rougher flotation to ensure concentrate specification of 24 per cent copper grade could be achieved. This paper will examine and discuss concentrator flow sheet development, including projects implemented since commissioning to improve copper recovery, and future projects designed to maintain and enhance copper in concentrate production with decreasing copper grade and increasing pyrite content of ore feed, and increasing hardness of primary ore.CITATION:Bennett, D, Crnkovic, I and Walker, P, 2012. Recent process developments at the Phu Kham Copper-Gold Concentrator, Laos, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 257-272 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By R Razanatsimba, A Galli

A mining company has entered into contractual commitments to supply certain quantities of its product to clients in each time period. Failure to fulfil its obligations would damage its reputation as a reliable supplier. The planned production would normally be sufficient unless major problems such as highwall failures, roof falls, natural disaster, or strikes that interrupt production or delays in obtaining environmental permits, occur. To overcome these difficulties, the company may be able to obtain more of the commodity: from its strategic stockpile (if there is sufficient there); by buying it on the spot market; or for some commodities such as gold and uranium, by leasing it. Two sources of uncertainty, the spot price of the commodity and the occurrence of serious incidents that interrupt production, are considered. For simplicity it is assumed that the commodity price follows a geometric Brownian motion, that productions incidents have a binomial distribution, that they are independent from one time period to another and that they do not affect prices. A branching tree structure is used to model the joint evolution of prices and production incidents. The aim of this research project was to evaluate the companyÆs options for fulfilling its contractual commitments. When evaluating these options, multi-stage stochastic programming with recourse was used to solve this problem because in addition to providing the dollar value of the project, it gives decision-makers the æroadmapÆ to reach the optimal value. That is, how much material should be bought/sold on the spot market, how much to add to/subtract from the stockpile, how much to lease and in the worst case what the shortfall would be, for each time period as a function of the current spot price and breakdown status. A case-study over a five-year period is used to illustrate the proposed procedure. In this study the production would be sufficient to cover the companyÆs contractual commitments unless production incidents occur. Focus is on evaluating the impact of the quantity initially in the stockpile on the value of the project when the commodity market is tight, that is, when only small quantities can be bought on the spot market or by leasing.

Sep 26, 2011

The energy supply in the 21st century is still secured by coal. According to estimates of the International Energy Agency (IEA), coal will have the same importance as oil for the world-wide supply of energy until 2030. Coal is also an important element of EU policy, its future use is closely linked to effectively addressing the environmental challenges it poses. Hard and brown coal represent approximately 80 per cent of European Union (EU) reserves of fossil fuels and coal utilisation can co-exist with the development of power generation based on renewables. Europe is the world's third largest consumer of coal behind China and the United States.The Czech Republic is poor in energy resources except for coal. Brown coal is relatively abundant (mineable reserves estimated at 1800 Mt, output 48 Mt/a) and significant quantities of hard coal (mineable reserves 900 Mt, 13 Mt/a), much of it suitable for coke production, are also present.Severoceske Doly (SD Company), the biggest Czech coal mining company (22 Mt/a, 48.6 per cent Czech market share) and one of the biggest in Europe, reinforces despite the last deep crisis in the Czech and European economies its long-standing stable and strong market and financial position. From 2009, the SD Company co-owns, with partners, a brown-coal mining company MIBRAG (21 Mt/a). SD Company invests in large mining equipment (eg new giant spreaders and bucket-wheel excavators, extension of overland belt conveyors), rebuilds and upgrades mining and processing installations, auxiliary and other machinery. We should see the investment we make today in tomorrow's mining and reclamation as an opportunity and not as a burden. They enable to make our position more resistant in the longer term. Projects focused on the environment and operational safety went hand in hand with these efforts.R&D activities relate to technical innovations, improvements of mining equipment, research and evaluation of conditions for extracting coal seam and/or overburden and mitigation of environmental impacts, utilisation of coal in new products. The company spends considerable amounts on reclaiming affected land and creating a new post-mining landscape.Our dialogue with influential stakeholders in the region where we operate contributes to the long-term improvement in the quality of life of local residents. Such dialogue with communities in the last ten years has been instrumental for confidence building. SD Company helps to develop many projects of towns and villages in its vicinity. The stable and transparent relations with our neighbours are in accordance with our basic principles of corporate social responsibility.

Dec 6, 2010

This paper describes a mine truck hauling process called "Truck Jigging" which is currently the subject of a process patent application.The investigation explores the production and cost advantages of using the potential energy available in a descending haul truck to assist in elevating an ascending vehicle. Applications are studied for both strip cut mines and open pit operations. Various mechanical connections between the two vehicles are considered, based on a pulley mounted rope system. Fifteen year operating cost estimates show savings of up to 26.5 percent over conventional mine truck operations.

Jan 1, 1989

By D Rattray, D Macfarlane, I Robb, N Halpin, G T. Dale

Mining faces many environmental, social and regulatory liabilities of which water management is just one. Others include site rehabilitation, carbon emissions, biodiversity offsets, strategic cropping land, subsidence, and noise and dust generation. Management of these liabilities is commonly seen as a cost of doing business and each is often independently addressed, bypassing the opportunity to reduce costs through integrated approaches. Furthermore, approaches to dealing with these liabilities tend to be constrained by a prevailing culture of engineered solutions and lack of appreciation of risk associated with alternative and hybrid alternative-engineered solutions. Suboptimal outcomes can also be reinforced by rigid regulatory constraints. While the cost of addressing operational liabilities may be a small proportion of overall mine management costs, failure to do so effectively may influence social licence to operate and, as recently demonstrated by the decision of the NSW Land and Environment Court to block expansion of the Warkworth Mine near Singleton, absolute licence to operate.Integration of environmental, social and regulatory liabilities with value-creating and risk-reduction opportunities such as beneficial water use, carbon bio-sequestration, habitat connectivity, keyline farming, improved grazing design and management systems, windbreaks and visual screens, presents opportunities to reduce risk and create value. This potential may achieve overall improved outcomes in both economic and non-economic mine performance criteria.Two case studies in beneficial use of waste water from the mining and coal seam gas (CSG) sectors (which operate under different legislation) will be used to illustrate the potential to address mine development, operational and closure liabilities by understanding opportunities to reduce risk and create value through a holistic water management framework. The technical requirements and alternative approaches to beneficial use of mine water are addressed, along with the direct economic benefits for mine operational costs and opportunities to positively engage communities and build resilience into social licence to operate. Regulatory barriers to achieving improved outcomes will be discussed.CITATION:Dale, G T, Robb, I, Halpin, N, Macfarlane, D and Rattray, D, 2013. Opportunities for integrated mine management to minimise risk and create value, in Proceedings Water in Mining 2013 , pp 227-234 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

A key issue in maintaining the mining industryÆs social contract to access community-owned resources, is the need to be able to demonstrate professional management of resource extraction and the risk associated with mining hazards. Significant failures such as disease relating to coal dust and asbestos and mine disasters such as Moura, Appin and Gretley have resulted in judicial and legislative interventions that respond to the community outcry but do not necessarily effectively manage the longer term risk in a sector driven by new technology. With the implementation of recent amendments to the Queensland Professional Engineers Act, senior engineers in all industries including the mining industry are required to be registered and to demonstrate that they have æmaintained competency in the practice of engineering in the area of engineering for which the (engineer) is ... registeredÆ. This may be facilitated through a report produced by an æAssessing EntityÆ. These entities are approved by the Minister on advice from the Board of Professional Engineers, Queensland. Engineers Australia and The Australasian Institute of Mining and Metallurgy (The AusIMM) are the two professional bodies approved as æassessing entitiesÆ charged with facilitating successful implementation of the process established by the legislation. The scope of the legislation covers engineering enterprises in Queensland and engineering activities elsewhere that may have been designed in Queensland. There is currently a challenge to determine what the necessary health and safety competencies for the mining industry are and how the maintenance of these competencies will be assessed. The different approaches taken by the two assessing entities are compared and contrasted. At the legislative level, establishing an obligation to assess professional competency is simple, but at the level of the profession, it is new ground that warrants a substantial research and development input. The challenge is to develop criteria by which the quality of such system can be assessed. The comparison is made by considering such issues as equity, effectiveness, efficiency, objectiveness and transparency. These five indicators are considered in terms of how they are applied in other sectors and how they might be applied in the mining sector.

Jan 1, 2009

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