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By S K. Michelic, N Preisser

For certain applications, steels have to feature a very distinct and well-defined level of cleanness in terms of the number and composition of non-metallic inclusions. Therefore, one crucial aspect of steelmaking is removing and controlling said non-metallic inclusions during the process. Particle removal during ladle refining comprises three stages, namely: 1. Flotation 2. Transport through the steel/slag interface 3. Dissolution of the particle in the slag. Only if all three stages are completed the particle can be considered as fully removed from the steel melt which, in turn, leads to the slag being one of the most influential parameters for inclusion removal and control. Depending on the composition of the particles and the slag, the dissolution can be controlled by different mechanisms. This study focuses on the diffusion-controlled dissolution of solid oxidic particles in slags. For this, a model of particle dissolution has been developed. For modelling diffusion, either the differential equation following Fick’s second law can be solved, or an analytical solution to this equation valid for stationary interfaces can be used. Both approaches allow for calculations of concentration profiles of the dissolving species in surrounding slag. From this, the mass flux can be derived, which finally leads to calculating the boundary layer velocity due to considerations of mass balance. In this work, both methods as well as results of dissolution experiments using High Temperature Confocal Scanning Laser Microscopy are compared. This research aims to provide a framework for diffusion-based dissolution modelling in further expanding the understanding of particle dissolution in secondary metallurgy.

Aug 21, 2024

By E Villaescusa, C Drover

The stability of access tunnels is one of the main engineering challenges in deep underground mine construction. Many underground hard rock mining operations are now reaching depths where the induced stresses are such that sudden and violent failure of the excavations can occur very soon after construction. The loading conditions on the installed ground support schemes are often underestimated by conventional engineering design methods. Therefore, the actual loading conditions often exceed the installed ground support capacity. This can result in failure of the excavations and, in extreme cases, potentially closure of mining operations amounting to hundreds of millions of dollars in lost production. More frequently, violent excavation instability at great depth causes operational delays, costly and unplanned rehabilitation, as well as risks to worker safety. In order to address this challenge, this paper briefly summarises a modern, innovative approach to the design and construction of mine development at great depth. The process follows seven main steps. The first step is to characterise the rock mass strength, structure and stress. The second step is a stability assessment, which identifies the plausible modes of excavation failure, based on the rock mass characterisation. The third step is the definition of an excavation geometry which is harmonic to the high stress conditions. The fourth step is to prepare a site-specific face destressing drill and blast design which will reduce the potential for rock mass instability during the development construction cycle. The fifth step is to accurately quantify the expected loading conditions on the installed ground support. The method of doing so is uniquely analytical and probabilistic. It is based on the natural mechanical relationships between rock strength, structure, induced stress and the physical characteristics of the instability, including its mass and ejection velocity. The sixth step of the design process is to specify a ground support scheme arrangement with sufficient strength and displacement capacity to exceed the rock mass demand by a safe margin. The final stage is to install the complete ground support scheme using mechanised technologies which minimise the exposure of the equipment operators to unsupported ground at the tunnel face.

Nov 29, 2022

By V Malysiak, N J. Shackleton

In the flotation of platinum group minerals pyroxene is a major gangue mineral. This study shows using zeta potential and ToF-SIMS analyses that when pyroxene is exposed to copper, nickel and/or calcium ions in solution at alkaline pHs a surface reaction occurs between the hydroxy species, in the case of copper and nickel, or divalent calcium ions and the pyroxene surface which influences the floatability of the pyroxene. Following exposure to copper and nickel ions at pH 9 addition of SIBX resulted in the pyroxene floating readily. It is also shown, in the case of copper, that the activating effect of the adsorbed copper hydroxy species can be reduced by the addition of complexing amines prior to SIBX. Proposals are made to explain these observations.

Jan 1, 2005

By S Hapugoda, J Manuel, N Ware, A Dehghan-Manshadi

The effect of titania (TiO2 ) addition on the sintering performance of hematite iron ore has been studied by doping pure TiO2 into a sinter blend. The results of laboratory-scale compact sintering tests confirmed the considerable effect of TiO2 addition on sinter strength and mineralogy. The tumble index measurements confirmed an improvement in the strength of the sinter in response to TiO2 addition. The melting point of the sinter was also affected by increasing the TiO2 content, indicating a possible relationship between coke breeze consumption and TiO2 on industrial-scale sintering of Ti-bearing ores. Analysis of the sintered structures using optical and scanning electron microscopes confirmed a general improvement in the overall pore structure and sinter melt characteristics with the addition of TiO2 to the sinter blend. An important feature of the sinter structure was the formation of a perovskite phase (CaTiO3 ) and an increase in the proportion of this phase in the structure as TiO2 levels increase.CITATION:Dehghan-Manshadi, A, Manuel, J, Hapugoda, S, Ware, N and Donskoi, E, 2015. Effect of titania on the sintering performance of hematite iron ores, in Proceedings Iron Ore 2015, pp 29–34 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Pitkajarvi J

Waste rock dilution causes mill feed grade to be lower than mineral resource grade. In nickel mines relative grade decrease (dilution) may be tens of per cent because of irregular ore boundaries and weak wall rocks. Five per cent dilution costs millions of dollars annually in medium size underground mine. In Outokumpu Group selective bench and fill stoping, cable bolting/shotcrete-skin support and fast ore boundary definition (OMS-logg in-hole logging or sludge sampling) are the key tools in dilution control. Commitment of the whole organisation to keep dilution low is also needed. Dilution sources and effects are discussed with examples of the dilution control methods applied in Outokumpu mines.

Jan 1, 1996

By Riley S. J

Ranger Uranium Mine is located within the Alligator Rivers Region of the Northern Territory of Australia and surrounded by the World Heritage listed Kakadu National Park (Figure 1). The mining operation is currently producing about 1500 tonnes of uranium oxide annually, as well as considerable volumes of waste rock, low grade ore and tailings. The rehabilitation of the project should ensure that the radioactive mill tailings and other contaminants remain contained for at least 200 years, as required by the existing guidelines (Commonwealth of Australia, 1987). The present uranium mining operation is regulated by the Northern Territory Department of Mines and Energy who must refer to the Environmental Requirements when considering regulatory options. These Environmental Requirements were agreed by the

Jan 1, 1994

By Kam KM, Tran B

Statistical techniques of Box and Jenkins (1976) have been used to assess the existing control schemes and determine the dynamics of flash smelting furnace at the Kalgoorlie Nickel Smelter. Pertinent process variables, such as, oxygen flow, flux flow, matte grade and iron to silica ratio in slag, were considered in the analysis using routine operating data collected over two periods of operation. Results indicate inadequate control of some of the important variables. Dynamic characteristic parameters (dead time and response time) between a set of input and output variables were identified to improve optimisation of the existing thermodynamic model used for flash furnace control.

Jan 1, 1996

By D Stow, M Edmondson

Lemington coal mine is operating in an environmentally sensitive area in the Hunter Valley, NSW, Australia. Late in 1999 the southern pit was developed using a series of box cut blasts. After the initial development the area would have been free dug due to the soft, well-jointed nature of the deposit. However, it was decided to trial drill and blast to determine if shovel productivity could be improved to enable an overall mining cost reduction. The initial trial blast results were less than satisfactory with both environmental issues occurring and the desired shovel productivity not being achieved. An audit of the blasts indicated that wet ground and the presence of soft clay inter-bedded with harder rock caused the poor blast results. Also, water-affected explosive product combined with explosive energy loss into soft ground led to flat spots and tight digging in the hard band areas, resulting in the lower dig rates. Lemington Mine and Orica Explosives developed a plan to match the rock with the appropriate explosive type and energy. This resulted in a number of blasts over a six-month period using a new non fuming explosive product, æNovaliteÆ. The results have been excellent with the environmental issues being totally resolved and dig rates improved, enabling reductions in mining costs. This has allowed the mine to continue with their exemplary record of environmental management whilst achieving operational efficiencies.

Jan 1, 2001

By Woodhouse M, Drew GJ, Andrews DL

The Honeymoon nickel sulphide deposits are located 45 km south of Wiluna in the 2.7 Ga old Agnew-Wiluna greenstone belt in the NE of the Yilgarn Craton (Figure 1). Both disseminated and massive nickel sulphide deposits are present within the deformed and metamorphosed Honeymoon Well ultramafic complex and are hosted by distinctly different komatiitic lithologies (Gole et al, 1996). The deposit styles and host rock lithologies reflect formation in markedly different volcanic settings. Metasomatism has affected parts of the ultramafic complex, including sections of the sulphide deposits, and has had a marked impact on mineralogy and bulk sulphide compositions. The present indicated resource is 158 Mt at 0.71 per cent Ni in four deposits (0.4 per cent Ni cut-off, resources above 300 m depth, December 1995). This includes a massive sulphide resource of 2.5 Mt at 3.36 per cent Ni.

Jan 1, 1996

By M D. Goodz, Wright R. F

This paper highlights the importance of accurate observational technical reports compiled by Mining Geologists and Engineers. Before uncovering the original reports in July 1992, all previous investigations discounted returning to old mining areas on the belief that all operations were suspended because they were 'unpayable'. However, the detail of the original reports removed any doubt of the economic value of retrieving remnant ore.The important feature was that the description of 'unpayable' by GMA could be equated to 11.6 - 35 g/t over the history of the mine. On the basis of these reports the Morning Star mine has been re-opened.

Jan 1, 1993

Thank you chairman, good afternoon ladies and gentlemen. In my talk this afternoon I intend to cover a brief history, some of the recent experiences and an overview of the McArthur River project.If we consider the themes of this forum, Obstacles and Opportunities, I can confidently say that in attempting to develop the McArthur River deposit Mount Isa Mines Limited (MIM) must have encountered almost every obstacle that can be imagined. However the large size and the high grade of the deposit has ensured an opportunity, from which it is very difficult to walk away from.The McArthur River Here's Your Chance (HYC) Deposit is located in the Northern Territory of Australia. It was discovered by Mount Isa Mines Limited geologists in 1955 and is one of the largest known sedimentary stratiform zinc-lead-silver deposits. The deposit has been the subject of numerous investigations and considerable expenditure culminating in a major feasibility study in 1979. There were a number of factors which prevented development, these being the size of the project, the fine grained mineralization, geographical location, market, social and capital cost. The latter had been estimated in the 1979 study to be $800 million at that time.

Jan 1, 1993

The tankhouse of the electrolytic zinc plant at Nordenham is operating with a very high operating efficiency of 99 per cent. This has been achieved not only by strict control of the quality of the zinc sulphate cell feed solution but also by all the improvements in housekeeping in the tankhouse developed during the past years: aluminium cathode specification, cathode stripping cycle, edge strips, copper contacts, anode isolators, cell cleaning, fittings and washing devices. During 1987 to 1992 the casting department was completely remodelled in order to improve the quality of the zinc products, the safety of the operations and the flexibility. The remodelling includes the enlargement of the area for the casting shop, the storage buildings and the five casting lines on the same ground level. New lines for alloying products and for SHG25 kg zinc ingots have been constructed. The line for galvanising products has new equipment in some parts and the other lines have been modified.

Jan 1, 1993

By Nicol SK, Engel MD

Ion flotation involves the adsorption of ionic species, in association with surfactant molecules, at the surface of rising gas bubbles, for the purpose of recovering and concentrating those ions. The objective of this study was to optimise the ion flotation process using a heap-leach liquor, containing gold cyanide, and the surfactant cetyl trimethyl ammonium bromide (CTAB). The aim was to minimise the surfactant reagent dose, maximise the throughput of feed liquor in the process, and satisfy the dual constraints of a high gold recovery and a high volume reduction factor. Development of a first order model of the ion flotation process formed the theoretical basis for the test program procedure and the interpretation of the results. Batch tests were used in order to determine the ultimate recovery curve for the heap leach liquor-CTAB surfactant system. The results indicated that a surfactant dose of about 0.083 g/l would be necessary in order to achieve a satisfactory gold recovery. Continuous tests were then performed on a small-scale pilot plant at the Newcastle Laboratories. The optimum result achieved was a gold recovery of 85 per cent, a volume reduction factor of ten, and a feed throughput of 2.3 m3/m2-h. Recent work also indicates that very much higher volume reductions can be achieved using a larger diameter vessel. The improvement may be a consequence of a reduction in wall effects and hence an improvement in foam drainage.

Jan 1, 1993

By Sauer P

The paper deals with the method of operat- ion, types of construction and sizing of screening machines as well as the selection of suitable screen decks. The application of novel screening mac- hines in hard coal preparation plants is explained in detail by way of examples.

Jan 1, 1984

In taking the chair at this meeting of the Australasian Institute of Mining Engineers, I feel it my duty to thank you for the honour you have conferred upon me by electing me President for the current year, especially as Bwken Hill is the birth place of the Institute and myself one of its foundation members. I will now endeavour to entertain you for a short time with a few reminiscences of Broken Hill from its inception. Beyond the fact that the mines on the Broken Hill lode have paid to their shareholders in dividends and bonuses no less a sum than £896,500, created and maintained a city of 25,000 inhabitants. supplied a large proportion of the revenue on the railways of a sister state, and made their influence felt throughout the 'commercial centres of the world, very little, I regret to say, is known by the general public as to the form, extent, or vastness of the ore bodies, or the mode of occurrence of the various classes of ore which have been found to exist in them. It has occurred to me that a short paper by the senior mining manager on the line of lode might prove interesting. There has been great difficulty in getting some of the figures relating to the field, the total output of metals from the Broken Hill mines not being obtainable from the Mining Department in Sydney j but an inscription on the foundation stone of the Technical College recently opened in this City, sets forth that the Broken Hill Mines started in 1880...

Jan 1, 1903

The Great lady gold deposit presented the challenge of providing a new grade control system for an usual type of orebody in the Eastern Goldfields. Mineralisation occurs as secondary enrichment about a quartz sand - granite saprolite contact 30m below surface. The ore horizon, which averaged 2.5m thickness, was near-horizontally disposed in contrast to the typical steeply dipping, shear hosted deposits of the region. A trial mining operation was undertaken on the richest, most continuous portion of the deposit to test the economic viability of this type of orebody. Controlling and minimising vertical ore dilution was considered crucial to the profitability of the operation.An understanding of the grade distribution combined with the practicalities of mining produced a grade control system which allowed for the mining of 1/2rn composited grades on level lm benches. Ore mining was combined with strict monitoring of levels, truck destinations and ore boundaries. Ore reconciliation results showed this system to be effective.

Jan 1, 1990

By Clements R. J, Davey J. M

Development of the process from the pilot stage to the current operation of the Capel, W.A. plant is briefly described. The design criteria for a larger sized plant are discussed together with factors that relate suitable feedstocks and coal types to the capital cost, capacity and product grade of future plants at locations other than Capel. The application of the process to the direct reduction of iron ores is briefly discussed including its commercial application at Rockwood, Tennessee.

Jan 1, 1979

By Shoobridge PH

Operating difficulties during 1977 with the Imperial Smelting Furnace operated by Sulphide Corporation Pty. Limited at their Cockle Creek zinc-lead smelter were found to be caused by premature softening of sinter in the upper shaft of the furnace. This soft- ening was shown to be a consequence of raw materials and operating policies which led to unusually high levels of both lead and silica in a sinter of low basicity. A programme of softening tests and micro-examination of a range of sinters established that premature softening occurred when lead and silica increased to the point where a lead-calcium silicate with a low lime content became the major continuous phase in the sinter. This information was used to define a range of compositions which kept the softening temperature acceptably high for furnace operations.

Jan 1, 1978

A 1991 survey of 48 mining companies, employing more than 24 000 employees, showed that disabling injury and disease rates continue to be the most common measurements of safety management effectivness in the Australian mining industry.Of the companies surveyed, 22 claimed to be making regular safety audits. Of these only two listed the improvement of audit scores among their goals for 1991.Influenced by loss control management thinking, some managers have expanded the scope of their safety programs to include all accidental operational losses adversely affecting mine profitability.Learning from their new experience with total quality management some managers are now recognising that successful safety management outcomes depend on the effective management of program inputs. They are thus turning away from measurements of accident consequences - the failures of the management system - to measurements of management control.The new focus of safety management attention is now on corrective actions before accidents happen.

Jan 1, 1992

By Grant JR, McKavanagh BM, Dear SJ

A geophysical technique of rock mass assessment for engineering purposes is being investigated and shows positive correlation with direct structural logging and mapping techniques for the detection of major geological features. The technique is cross-hole acoustic surveying incorporating high speed signal averaging, with a maximum hole separation in excess of 30 metres in hard unfractured rock masses. The bulk of the field test work was carried out in open stopes in the copper ore bodies of Mount Isa Mines Limited. The investigation forms part of an integrated study of blasting in mining, aiming for fragmentation control through blast design modification. The rock quality factor, Q, is presented as a blasting index and can be determined for a significant portion of a production stope.

Jan 1, 1981