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By R E. Gerald II, B Zhang, T Sander, J D. Smith, J Huang, R J. O’Malley, H Tekle

In the steelmaking process, mold fluxes are essential for ensuring thermal insulation, refining, and the efficiency of continuous casting. Real-time understanding of the in-service composition of slags and fluxes are crucial for optimising the steel production process and improving the quality of the final product. An in situ fibre-optic Raman probe that enables the study of the structure, composition, and viscosity of molten slags and fluxes at steelmaking temperatures has been developed and demonstrated both in the lab and in foundry scale experiments. The focus of this study is on the structural, compositional, and property analysis of molten fluxes in a laboratory setting, with the aim of applying this technology for in situ monitoring during industrial production. Raman spectra were successfully collected at various temperatures from 1000°C to 1400°C in real-time and analysed using a deconvolution algorithm to isolate and quantify peaks in the spectra associated with the specific structures of molecular components in molten and solidifying flux. The research successfully combines in situ Raman spectroscopy with high-temperature viscosity data, specifically targeting CaO-CaF-SiO2-Al2O3 based mould flux systems. Specified ratios of the deconvoluted Raman peaks, such as Al-O-Al/Si-O-Si ratio, shows good correlation with the flux chemistry, while the Q3/Q0 peak ratio shows good correlation with viscosity. A ruggedised Raman probe system was also developed and demonstrated in an 80 kg induction furnace. Ultimately, the goal of this work is to demonstrate in situ slag and mould flux analysis in industrial processes, such as in the continuous caster or electric arc furnace (EAF).

Aug 21, 2024

North Flinders Mines Limited (N.F.M.) is an Australian-owned mineral exploration and mining company based in South Australia. In the 1970's it researched the prospectiveness of the Tanami (central western region of the N.T.) for the identification of possible economic gold deposits. Having outlined the potential for such a deposit at The Granites (550 km. N.W. of Alice Springs), it marked out and in 1975 applied for the grant of eleven gold mining leases (G.M.L.'s) under the provisions of the then Mining Ordinance. This application was deferred by the Commonwealth Government during the time of the Aboriginal Land Rights Commission (Woodward), subsequent enactment of legislation and land claims. In 1980, the Walpiri and Kartangarurra-Kurintji land claim encompassing the G.M.L.'s, became Aboriginal land. It therefore became necessary for N.F.M. to negotiate a mining agreement with the Central Land Council (C.L.C.) represent- ing the Traditional Owners, before the G.M.L.'s could be granted. In August 1983, the C.L.C. and N.F.M. concluded an agreement to enable the grant of mining interests necessary for the devel- opment of The Granites Gold Project. In several ways this agreement is unique in That:

Jan 1, 1984

Transformations of minerals to processed mineral products fundamentally involve wholesale chemical change, and therefore have a high potential for the release of chemicals and wastes. In this regard minerals processing contrasts with downstream production operations, which involve mainly physical changes. The contrast with mining, which must take place where the minerals are found, is that mineral processing allows choices as to location, processes, fuels and reductants. These choices provide a foundation for dealing with issues of resource stewardship. This paper locates the mineral processing industry in the global perspective by quantifying the masses of major material inputs and outputs, based on current processing choices. Estimates for recycling have also been collated, revealing figures that differ surprisingly from commonly held impressions. The paper draws on a variety of current sources, mainly those available through the Internet, to rank the major transformed virgin mineral products by production, price and value. The figures demonstrate the dominance of Portland cement and steel in the global environmental impacts of mineral processing. Aluminium comes a distant third in the list, and the metals particularly associated with localised environmental impacts have relatively small global effects compared with those of the staple materials of our built environment. This global macro input/output perspective, with materials flows expressed per unit of virgin product, provides a benchmark for grasping sustainability challenges within specific operating businesses. Because of the global scope and pervasive impact of the minerals processing industry, the issue of resource stewardship is rising as a matter for public concern. There appears to be a developing view that the mining and mineral processing sector should take responsibility for these products throughout their various life cycles. However, in a future of stabilising consumption, dematerialisation and intensive recycling, the mining industry would only need to provide the top-up to a stock of recirculating materials. The question of responsibility for stewardship over SocietyÆs stock of materials remains open.

Jan 1, 2002

By Mutmansky J. M, Organiscak J, Qin J, Bhaskar R

The results of a two-year research study into the relationship between quartz dust levels in host material and in respirable dust in continuous mining sections are presented in this paper. The experimental design and sampling procedures for underground data collection are outlined. The sample analysis procedures for quartz determination, the analysis results and conclusions of the study are discussed.

Jan 1, 1988

By H Zahiri

Utilisation of the InSAR technique for monitoring of subsidence in mining areas, employing open pit and underground mining methods, has large potential due to sensitivity and safety issues associated with usage of the classical surveying techniques. InSAR can also be very competitive concerning the cost of provided results. However, there are a few issues that may significantly limit InSAR applicability for subsidence monitoring in mining areas. The altered terrain topography, involving steep slopes and deep pits, may lead to the layover of radar signal for specific satellite and pit geometry. Also, the highly dynamic character of subsidence induced by mining, especially using mass mining methods, may lead to issues such as apparent heave and ambiguous results. In this paper the authors analyse the above-mentioned issues and demonstrate how InSAR technology was applied, as a supporting system, to monitor large scale and highly dynamic subsidence for a real case study in Western Australia.

Jan 1, 2008

By L E. Krause

This paper discusses the considerations for optimum maintenance of critical ore handling infrastructure in order to minimise the cost to the business of maintenance periods. As maintenance periods are a direct interruption to production, time is of the essence and careful management of shutdown periods is essential. The ore pass systems currently in use at Xstrata Copper û Mount Isa Copper Operations are up to 30 years old and have had significant wear over the years. The maintenance of these passes and their brows and chutes in a production situation is a challenge as it can potentially expose personnel to high risk situations in addition to the production interruptions. Some alternatives for mitigating the risk of working in ore passes including plugging and ballooning are described. Criteria are included for selecting a method for the safe entry into a given ore pass. Experience in adapting the method of ore pass plugs and some lessons learnt in the process are also discussed.

Jan 1, 2005

By Evans A, Jones O

Surface subsidence resulting from "total extraction" of coal in the Collie Basin first occured in 1987 when Western Collieries Ltd trialled the Wongawilli mining method. Because very little quantitative subsidence data existed for the weak, Permian sediments, a research program was set up prior to the extraction of the first panel. The objective of the study was to be able to predict subsidence characteristics and effects prior to mining future total extraction panels. Attempts at predicting subsidence began using existing subsidence models from other coal mining regions, however, as more site information became available, it became clear that it was necessary to develop a separate, she specific predictive model for the Collie Coal Basin. Analysis of extensive field monitoring data for both surface and subsurface subsidence has produced a series of empirical models which can predict the shape of surface subsidence troughs and corresponding tilts, and strains for rectangular panels and describe the sequences of ground movement from the mine roof through to the ground surface.

Jan 1, 1992

Utah's Blackwater mine began operations in 1967. The four CQCA mines controlled by Utah followed over the period 1971 to 1979. Project feasibility studies for all these were based on open cut mining to overburden depths of 60 metres, with typical project lives of 12 to 16 years, depending on reserves Further studies, initiated after the mines had started, showed that continuation of open cut mining beyond the 60 metre highwall was viable. In 1973, the Deep Stripping Project (DSP) was launched to define the scope for stripping deeper, to determine what the additional equipment needs might be, and to pu forward proposals for a full scale trial system. The project commenced at grass roots with a literature survey, proceeded through a sequence of equipment evaluation, specification, design and manufacture to the commissioning of the Goonyella BWE system. Studies are continuing to assess the future deep stripping requirements for all Utah's Bowen Basin mines.

Jan 1, 1983

By Wang Y. J

This paper describes a more generalised or generic approach for the mine ventilation network problem. More specifically, it defines the network variables in a manner that establishes the network problem in a nonlinear programming format. Assigned to each branch are three variables: air quantity, regulator pressure loss and fan pressure. Each variable is imposed with lower and upper bounds. Based on these, the generalised network problem for a mine ventilation network with B branches is presented as a system of B independent network equations in 3B unknowns (variables) with variable bound restrictions, and it is classified as a nonlinear optimisation. A nonlinear programming model has been developed for this generalised network optimisation problem. The model is formulated and transformed into a standard equality-constrained nonlinear programming form with given variable bounds. Then, MINaS (Modular In-core for Nonlinear Optimisation System) is used to obtain solutions. Examples are given to illustrate this nonlinear programming approach to the mine ventilation optimisation problem.

Jan 1, 1993

By R Dimitrakopoulos

Optimisation and mathematical formulations for open pit design and long-term production scheduling have been available since the 1960s. There are two main concerns in the application of existing mixed integer programming (MIP) models in open pit mines: a. the feasibility of generating both optimal solutions and practically mineable scheduling patterns and b. the inability to deal with in situ variability in orebodies and account for uncertainty. In dealing with these issues, a general open pit production scheduling method for multi-element deposits is presented and subsequently used to optimise the long-term production schedule in a nickel laterite deposit. The application shows the weaknesses of MIP formulations in terms of generating optimal solutions as well as practically feasible mining patterns. The application of the same formulation in the presence of in situ orebody variability and uncertainty uncovers a major reason for deviations of scheduled production from actual production, and outlines additional limits of traditional optimisation formulations as well as future needs.

Jan 1, 2003

By E Rubio, N Morales

Currently, mine plans are optimised by using several criteria as objective functions, like profit, life-of-mine, concentration of some pollutants, mining costs, confidence level or ore resources, with consideration of constraints related to production rates, plant capacities and grades. Whilst this approach is successful in terms of producing high value production schedules, it uses a static opening sequence of the drawpoints and therefore the optimisation is made within the level of freedom left by the original opening schedule, and as a result it is far from the true optimal value of the project. This paper presents a model to optimise the sequence of drawpoint opening over a given time horizon. The emphasis is in the precedence constraints that are required to produce meaningful operational sequences considering the exploitation method (panel or block caving), physics considerations and logical rules. Further on, while it applies the standard approach of maximising net present value (NPV), it considers other targets for optimisation, like the robustness and constructability of the plans. Finally, it applies the model to real data to obtain feasible plans by means of this model. The first tests were done varying the production capacity of the mine.

Sep 26, 2011

By W J. Rankin

A study of refined metallic copper and nickel production was carried out using Life Cycle Assessment methodology to estimate the life cycle emissions of greenhouse and acid rain gases for these metals using data derived from the literature. Various processing routes were investigated which included a pyrometallurgical and a hydrometallurgical route for each metal. The effect of a number of process variables, namely ore grade, fuel type for electricity generation and efficiency of generation were also examined in the study. The results of the study, expressed in terms of total (or full cycle) energy consumption, Global Warming Potential (GWP) and Acidification Potential (AP), showed that the hydrometallurgical processes involving solvent extraction and electrowinning had higher energy consumptions and GWPs than the pyrometallurgical processes for both metals. Nickel metal production was shown to be several-fold more energy intensive than copper metal production. The significant effect that falling ore grades have on attempts to meet greenhouse emission targets was also highlighted in the study.

Jan 1, 2000

The Tregoora Gold Project is centred around the old Mitchell River Antimony Field located 100 kilometres west-northwest of Cairns, North Queensland. The project is currently the subject of a joint venture between Strategic Minerals Corporation N.L. and Hawk Investments Limited.Historical BackgroundThe Tregoora area was first prospected for antimony and gold around 1890. During the periods 1905 to 1914 and 1937 and 1944 approximately 100 tonnes of antimony and an unknown quantity of gold were won from a number of small mines the principal one being the "Retina". A strong increase in the demand for antimony in the early 1970's resulted in renewed exploration activity in the region and the re-development of the Retina Mine. Despite the intermittent interest in the region for antimony it was not until 1984 that the potential of the area for hosting gold resources was realised with the delineation by Strategic Minerals Corporation N.L. of a significant gold deposit now referred to as the Black Knight.

Jan 1, 1986

By Meloy TP

Several important, fundamental aspects of the grinding behaviour of mineral systems are addressed. The Levenberg-Marquardt algorithm for systems of constrained non-linear equations was used to solve the steady-state and dynamic population balance model (PBM) grinding equations to obtain the mill matrices and grinding selection and breakage rate functions, respectively. The fact that the PBM model equation Inverse Problem is degenerate or underspecified is demonstrated. Multiple solutions to the same PBM equations are provided. It is shown that there is no unique solution to the Inverse Problem unless additional constraints are provided or assumptions are made such as the Arbiter-Bhrany normalisation assumption. The severity of the non-uniqueness problem for steady state grinding is demonstrated in several examples using typical feed distributions and mill matrices. In addition, it is also demonstrated that when higher than single powers are used in steady-state mill matrix expressions during simulation or calculation (or iterative procedures are used during numerical simulation) and four or more size intervals are used considerable amount of error is propagated throughout any calculation. Each solution to a PBM, while giving the same prediction during a single mill pass, gives different solutions or predictions for mill composition upon subsequent passes. In addition, it is shown that there is a problem with building up a grinding mill knowledge base with PBMs. A similar analysis was done for the dynamic or kinetic PBM equations. The fact that the dynamic PBM Problem is degenerate or underspecified is also demonstrated. Multiple solutions to the same dynamic PBM equations are provided. Again, it is shown that there is no unique solution to the Inverse Problem unless additional constraints are provided or assumptions are made such as the normalisation assumption. Each solution to a dynamic PBM, while giving the same prediction for a given grinding time interval, gives different solutions or predictions for mill composition for other grinding times. Actual experimental grinding data was assessed to determine the functionality of mill selection and breakage functions. The functionalities obtained through constraints were compared with those obtained with the normalisation assumption of Arbiter-Bhrany which relates breakage functions to particle size distribution. The capability of the population balance model to predict grinding behavior over time in various mineral grinding systems was assessed. The required functionality of selection and breakage functions for effective prediction of grinding behavior in mineral systems is discussed.

Jan 1, 1993

The mathematical modelling of rock fragmentation by blasting is one of the most difficult and challenging problems of applied mathematics. Not only is complex mathematics required but there is incomplete understanding of the basic physics and chemistry involved. The possibility of getting the physical basis of a model correct by simple mathematical and experimental procedures is demonstrated for the novel process of fragmenting rock by high-pressure arc discharges. While the importance of obtaining the correct physical basis for a model is emphasised, high-pressure arc induced fragmentation of rock is shown to be a powerful laboratory tool for the study of blasting.

Jan 1, 1990

By D J. Williams, G W. Wilson, S, A B. Tran

A comprehensive field program was implemented to evaluate the internal structure and hydrology of two full-scale waste rock piles. The excavation of waste rock dumps for in-pit disposal at the two mine sites provided an opportunity to characterise the in situ properties of the dumps given contrasting geologic and climatic settings. The internal structure and materials within the dumps were observed and sampled as the waste rock piles were being excavated and placed in the open pits for permanent closure. The field program was designed to fully characterise the structure and material properties of the waste rock. The alteration of the material by physical and chemical weathering was also observed. Samples were analysed for paste pH, water content, grain size distribution and geochemistry. In situ density and matric suction were also measured. Soil water characteristic curves and saturated hydraulic conductivity were measured for representative materials. These properties were used to predict seepage pathways through the waste rock and the resulting outflow geochemistry using the finite element model SEEP/W. The materials in the dump at Site 1 were predominantly fine-grained in texture and highly weathered. The presence of dipping beds with alternating coarse and fine materials was evident throughout the profile of the dump. The structure of the waste rock appears to have an impact on the hydrologic pathways within the waste rock pile. The material in the dump at Site 2 was found to be competent and resistant to particle size breakdown. The particles range in size from clay size to large boulders with the median particle size being approximately 125 mm in diameter. The coarse-grained texture of the waste rock resulted in a loosely packed arrangement of coarse particles with little matrix material infilling the pore spaces between the coarse-grained particles. Seepage modelling for Site 1 was completed to predict seepage paths based on observed structure and hydraulic properties measured in the laboratory. The modelling showed that materials with a fine grain size distribution become the dominant pathways for flow through the waste rock pile. The modelling also showed that layers with high silt and sand contents are subject to the highest flow rates. Finer grained clay rich layers have a low hydraulic conductivity and do not convey large volumes of water. Alternately, coarse gravel and cobble materials are unsaturated under values of matric suction that approach the residual water content of the material and do not transmit liquid water. The seepage modelling together with the results of the geochemical analysis show that the dominant particle size that receives the most fluid flow and flushing ranges from fine sand to silt, corresponding to materials with air entry values ranging between 5 kPa to 50 kPa.

Jan 1, 2003

Carbonation of reinforced concrete is a potential durability issue for vehicular tunnels. This is particularly the case where elevated carbon dioxide concentrations exist and when the design life is 100 years or more. The process of carbonation can result in loss of passive protection to embedded steel reinforcement and initiation of corrosion. Therefore, tunnel design needs to consider the potential for carbonation on internal surfaces and how design life can be achieved in severe environments. This paper examines methods for predicting carbonation and how deterioration can be mitigated through appropriate concrete mix design and construction practices.

Jan 1, 2008

One of the responsibilities of the Melbourne and Metropolitan Board of Works is to provide a sewerage system for the metropolis of Melbourne which now contains over 2.5 million people. In providing this sewerage system it was necessary for the Board to embark on a large tunnelling programme some 20 years ago. As a result of this extensive tunnel construction programme, tunnel boring machines and shaft sinking methods have been developed to cope with the soft ground and soft to medium rock found in the southern and eastern areas of Melbourne where the majority of the recent tunnelling has been carried out. While in the last few years radical changes in construction methods have not been made, development has continued and improvements have been made, which have enabled the Board to extend the limits of the ground conditions in which it can efficiently construct shafts and also tunnels with boring Machines.

Jan 1, 1976

The Transportable Moisture Limits, as ,measured by the procedures laid down in The IMCO Code of Safe Practices for Bulk Cargoes, determine the target moisture contents for the concentrates produced at the West Coast Mines of Electrolytic Zinc Company of Australasia Limited at Rosebery. Filtration of these concentrates gives moisture contents considered to be low in comparison with those achieved for similar sulphide concentrates, but which are very close to these Transportable Moisture Limits. The filtering techniques used are outlined and the problems associated with-maintaining concentrate moistures below the required limits, together with the methods used to solve these problems are discussed.

Jan 1, 1978

By S K. Michelic, M Schickbichler, A Kharicha, E Karimi-Sibaki

The requirements for the controllability of metallurgical processes are increasingly becoming the focus of both industry and research. Advances in this field of research not only impact the stability of processes but often also influence the quality of the final product. One important way to examine processes in-depth, and thus show potential for improvement, is to describe them using physicsdriven models. In metallurgy, thermodynamic and kinetic descriptions of interactions between individual components of a system are often used to describe and analyse important metallurgical phenomena across the entire process. However, for the creation of physics-based models, boundary conditions and process variables must be implemented to enable a description that is as realistic as possible. The collection and generalisation of boundary conditions and process variables is, therefore, an important step towards functional models. The focus of this study is the determination of mass transfer coefficients between all components in a steel/slag/refractory system. For this purpose, experimental and theoretical methods are applied. Laboratory scale experiments are carried out in an induction furnace, and the mass transfer coefficients of the defined steel/slag/refractory system are calculated from changes in the chemical composition of the various components. Additionally, a calculation of the mass transfer coefficients based on dimensionless quantities is carried out. By comparing the values of the mass transfer coefficients determined theoretically and those determined experimentally in the trials, the suitability of the calculation is examined. The collection of mass transfer coefficients provides essential findings for future kinetic descriptions of inclusion modification based on the effective equilibrium reaction zone (EERZ) approach.

Aug 21, 2024