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By G Balog, T Ormerod, D Cox

This paper discusses the methods utilised by the technical team to identify and quantify the SLC risk factors, the modifications to mine design and scheduling, and the changes to the planned risk management practices. The paper also describes the future work currently planned by the OZ Minerals technical team to quantify the various risk factors in terms of space, time and magnitude. This may better inform the future mining practices within not only the Carrapateena province but also the wider Gawler Craton.

Mar 15, 2021

By P M. Hetherington, M P. Murphy, K E. Crook, F Pym

Resource characterisation is critical for informed decisions in both strategic and operational space. The sources of information for resource characterisation are limited by: direct measurement of resource attributes, such as grades, rock-types, mineralogy, and are available only from sparse locations, ie drill holes; or indirect geophysical measurements such as seismic, gravity or electro[1]magnetic survey. Data collection tools, methods, and processing technologies are constantly improving providing a broad spectrum of options for data collection strategies. The cost of each data survey varies from thousands to millions of dollars with the value of each additional data having diminishing return for a particular business decision. The value of information analysis provides the optimal decision on data collection strategy within a limited available budget. This work presents an example of value of information analysis for new Blast Hole Assay Tool (BHAT) and Reverse Circulation Grade Control (RCGC) data used in addition to the wider spaced exploration data. The value of information is quantified in terms of reduction of grade uncertainty, ore loss and dilution by comparing different combinations of data collection methods. Four different strategies were considered: exploration samples in addition to 50 per cent of blastholes surveyed with BHAT, exploration samples in addition to 33 per cent of blastholes surveyed with BHAT, exploration with wide-spaced RCGC data, and exploration without additional grade control. For each strategy the observed values have been simulated using advanced multivariate geostatistical simulations and compared with simulated ground truth models. The calculated uncertainty, ore loss and dilution informed the optimal data collection strategy. Opportunity to reduce sample density from the nominal 50 per cent of drill holes was evaluated.

Mar 22, 2022

By R G. Reddy

The complexity in treating environmentally harmful impurities such as As, Sb, Bi from the base metal matte or metal in the smelting stage are responsible for the high cost of the refining process. The impurity capacities (such as arsenic, antimony and bismuth) of slags were calculated a priori using Reddy-Blander (RB) model. The capacity predictions were for a wide range of matte and slag compositions in copper smelting conditions. The calculated impurities capacities and impurity distribution ratios results are in good agreement with the available experimental and industrial slags data. The a priori knowledge of impurities is useful for reduction of energy consumption and enhanced environmental control in the current and future non-ferrous metal processes.

Aug 21, 2024

By S Gezgin, F Beckstein, M Müller, D Rapp, D Sergeev, J Qi, A Lichtinger

Salts and their mixtures play an important role for industrial and energy sectors, eg metallurgy, biomass gasification and combustion, nuclear and solar powerplants and electrochemical processes. Depending on the composition of salts (eg Li+, Na+, K+, Mg2+, Ca2+ // NO3-, F-, Cl-, CO32-, SO42-, etc), the temperature range for different applications can vary starting from room temperature and going up to 1500°C. For the proper design and modelling of heat exchangers and other equipment, it is necessary to have reliable and validated data sets of thermophysical properties. The 50 mol per cent NaNO3 – 50 mol per cent KNO3 salt mixture as a well-studied composition was selected for validation of relevant thermophysical properties (heat capacity, enthalpy of phase transitions, thermal expansion, viscosity and thermal conductivity). To study these properties of the liquid phase, special crucibles and approaches should be implemented. Verification of these crucibles for different methods (differential scanning calorimetry (DSC), thermomechanical analysis (TMA), laser flash analysis (LFA) and rheometers) has been performed. The low thermal conductivity of salts is one of the main problems in implementing latent heat storage. In this project, the authors intend to develop a fundamental solution to this problem using chemically bonded metals with salts. These are known as metal-salt solutions. To fit the main parameters of new phase change materials to the requirements of thermal energy storage, a wide variety of possible combinations should be considered. CALPHAD modelling is used together with thermal analysis for the development of a consistent thermodynamic database including chloride salts (Li, Na, K, Mg, Ca // Cl) and corresponding metals (Li, Na, K, Mg, Ca). The results of the study of quasibinary and multicomponent metal-salt (eg Mg-KCl and Ca-KCl) systems as well as the selection of suitable crucible materials and challenges by studying of these systems will be discussed.

Aug 21, 2024

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 R A. Pakhomov, L V. Krupnov, P V. Malakhov, I M. Dymov

The article presents results of thermodynamic calculations and laboratory studies, focusing on the cobalt behaviour during oxidative smelting of copper-nickel mattes. The compositions of the studied solutions are related to the products formed during the second stage of the converting process of copper-nickel matte at the Nadezhdinsky Metallurgical Plant (NMP) of MMC Norilsk Nickel company. These sulfide products typically contain from 1.5 to 12 wt per cent of iron. The obtained experimental results and thermodynamic calculations indicate that adjusting the CaO ratio to increase the proportion of CaO or complete replacement of SiO2 with fluxes containing CaO leads to a significant increase in cobalt recovery rates in the matte phase (with an iron concentration of 2.5 wt per cent) raising them from 30 per cent to 45 per cent. Meanwhile, the recovery rates of copper and nickel remain constant.

Aug 21, 2024

By A Mooney, G Balog, P Burns, R Brooks

This paper outlines the rationale for the location of the crusher, geotechnical analysis and basis of ground support design, design and scheduling of the chamber and supporting excavations as well as the operational outcomes and lessons learned. Contributions from mining operations, planning, geotechnical and infrastructure teams enabled the Crusher Station One excavation to be completed on schedule, with opportunities taken for underground mining and infrastructure to work safely in parallel to deliver crusher station infrastructure on schedule. Installation of crusher infrastructure was ongoing at the time of writing.

Mar 15, 2021

By S Wan, F Zhang, J You, K Tang, X Tang, C Bessada, A Canizarès, Q Zhang, L Lu

Microstructure of CaO-SiO2-based glassy samples with various Al2O3 contents were examined quantitatively by Raman spectroscopy and 27Al MAS NMR (magic-angle spinning nuclear magnetic resonance). Sequence of multiple cluster models of aluminosilicate system modified with Ca2+ and Na+ cations have been designed, and Raman spectra simulation were carried out after geometric optimisation by quantum chemistry (QC) ab initio calculation. The functional relationship between Raman scattering cross-section (RSCS) and stress index of silicon-oxygen tetrahedron (SIT) for aluminosilicates was established, which was applied to the calibration of experimental Raman spectra. Some five-fold coordinated aluminium (AlV, around 5 per cent) and less than 2 per cent sixfold coordinated aluminium (AlVI) were detected by 27Al MAS NMR, while most of aluminium remained in tetrahedral sites (AlIV). The hyperfine quantitative results of Raman spectroscopy and NMR showed a gradually production of AlIV with addition of Al2O3, along with the significant adjustment of Qi species distribution, in which Q1, Q2 reduced and fully polymerised Q4 increased while Q3 showed a non-monotonic variation and obtained the maximum at Al2O3 = 18 mol per cent. Furthermore, the effects of aluminium to bridging oxygen bond types (T-Ob, T = Si, Al) and the degree of polymerisation were also discussed in detail. The evolution of microstructure and its correlation with the viscosity of CaO-SiO2 based melts, incorporating various Al2O3 additives, have been investigated by employing in situ high temperature Raman spectroscopy at 1823 K and viscosity model. These structural features related to composition are essential theoretic foundation to understand their properties. The average Qi evolution culminates in an overall enhancement of the degree of polymerisation. Viscosity was determined utilising a rigorously selected viscosity model, elucidating a consistent upward trajectory as Al2O3 content is incrementally added. Furthermore, a quantitative analysis of the relationship between viscosity and structure was conducted based on the average number of non-bridging oxygen per network-forming tetrahedron (NBO/T). It provides valuable insights for examining and predicting viscosity behaviour of aluminosilicate systems.

Aug 21, 2024

By K S. Park, J K. Kim, J H. Park, Y Su

The present study investigates the possibility of the direct removal of oxygen from the Ti-30Ni (wt per cent) alloy melt through the thermodynamic equilibrium reactions at 1623 K in the vertical tube furnace. The deoxidation efficiency of Ti-Ni alloy melt by adding different contents of metallic calcium (Ca) as a deoxidant was evaluated with the binary CaF2-MgCl2 flux. The thermodynamic equilibrium experiments showed that the total oxygen content in the alloy decreased from about 650 ppm to 350 ppm when 3.5 wt per cent Ca was added to the Ti-30Ni (wt per cent) alloy. Alternatively, the effect of flux composition in the CaF2-MgCl2 flux on the oxygen content was also investigated at 1623 K. Therefore, the effect of binary flux systems on the deoxidation ability was compared at 1623 K. According to the results, the flux system with 80 per centCaF2– 20 per centMgCl2 exhibited the best deoxidation capability, ie total oxygen content in the alloy reduced from 1450 to 550 ppm.

Aug 21, 2024

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

By D Bruce, D Cox

The main access decline at Carrapateena mine was excavated through two different underground aquifers. In these areas of decline, pressurised water finds the path of least resistance through the rock and into the excavation. In some locations the ground water would upwell underneath the roadway resulting in rapid deterioration of the running surface. The deterioration of the road was so rapid that the two areas of decline required significant roadworks every single shift or it would become impassable by mine traffic. With a full fleet of underground trucks hauling to the surface, managing these sections of roadway was impractical and unproductive. The site team resolved this issue by installing Roller Compacted Concrete (RCC) to the affected sections of decline. RCC is a specialist concrete product that is delivered to the site near dry and is installed using a grader and roller similar to road base. This product can be installed quickly and be trafficked within hours of installation, making it ideal for mines with single access declines and unfavourable road conditions. RCC roadways were successfully installed at Carrapateena mine in conjunction with under-road drainage. These roadways have proved to be a very effective solution which requires minimal maintenance and are resistant to water ingress from the aquifer. This paper discusses the technical aspects of the RCC, as well as the practical implementation of the solution as a whole.

Mar 15, 2021

By W Y. Kim, Y B. Kang, Y J. Park

The phase equilibria in the Al2O3–TiOx system were investigated in wide ranges of temperature and oxygen partial pressure: 1300~1600°C and 10-16.6~10-8 atm, respectively. The equilibrium phases and their compositions were identified using X-ray diffraction (XRD) and electron probe microanalysis (EPMA), respectively. Most noticeably, a wide range of pseudobrookite solid solution was found in equilibrium with almost pure alumina. At each temperature, the cationic ratio expressed as RTi = nTi/(nAl + nTi)) of the pseudobrookite solid solution showed a noteworthy dependency on the oxygen partial pressure. This resulted in the formation of a broad range of pseudobrookite solid solutions, ranging from Al2TiO5 (RTi = 1/3) to Ti3O5 (RTi = 1.0). Complete miscibility within the pseudobrookite solid solution was observed at 1600°C, with only a minor miscibility gap becoming evident below 1500°C. Based on the results obtained in the present study, the behaviours of Al2TiO5 pseudobrookite have implications in two key domains: (1) understanding changes in the physical properties of the materials, and (2) elucidating the evolution of Al–Ti complex oxide inclusions in liquid steel which can deteriorate the steel cleanliness.

Aug 21, 2024

By A Boucher, M Baudin, P Androszczuk, I Minniakhmetov, A Rigby, P Machado, M Wright, B Van Dijken

IGO Ltd’s (IGO’s) Nova Operation (Nova), which is 160 km east-north-east of the town of Norseman in Western Australia (WA), mines and processes nickel-copper-cobalt (Ni-Cu-Co) sulfide ore from the magmatic Nova-Bollinger Deposit (Nova-Bollinger), which is hosted by the Mesoproterozoic age high-grade metamorphic rocks of the Albany Fraser Orogen. Over its 56-month life-of-mine (LOM) operations to 31 December 2020, Nova has processed 5.63 Mt of ore grading 2.04 per cent Ni, 0.86 per cent Cu and 0.07 per cent Co from its underground mine. At the end of 2020, both the Nova-Bollinger JORC Code reportable Mineral Resource estimate (MRE) and Ore Reserve estimate (ORE) were >90 per cent classified in the highest JORC Code confidence categories of Measured Mineral Resource and Proved Ore Reserve respectively. The high JORC Code classification confidences assigned to the Nova-Bollinger MRE and ORE results from the 386 km of surface and underground diamond drill testing of the deposit to a nominal 12.5 by 12.5 m pierce point spacing in mineralisation. The close spaced high-quality drilling and bulk mining method employed at Nova has effectively removed the need for any grade control modelling outside of the MRE process. Importantly, having only the one fully drilled out deposit being mined and only the one process plant, Nova’s reconciliation process is in the fortunate situation of not being confounded by issues such as external ore sources and constant updates as new grade control information becomes available. IGO’s Nova reconciliation processes are focused on reconciliation ratios that quantify operational period differences between the MRE and ORE head grade and tonnage forecasts and the process plant head actuals. These metrics have been used to identify key reconciliation issues and have initiated several studies into the causes for specific reconciliation results, which are discussed in the paper. In late 2020, a period of sustained poor reconciliation results led to the recognition that increasing the understanding of risk between the MRE and ORE should be investigated. To assist with modelling stope level risk within the mine plan and subsequent reconciliation, an attempt was made to develop a formula to quantify ‘stope risk’ from MRE metrics such as sample spacing, kriging efficiency and so on

Mar 22, 2022

By G M. Tranell, M Tangstad

The CO2 footprints in the production of Mn-ferroalloys and silicon/ferrosilicon are correlated with the fossil carbon consumption. The CO2 emissions may be reduced in the Mn-ferroalloy process by increasing the degree of prereduction and reduction of carbonate materials, while the silicon/ferrosilicon process is optimised based on silicon yield. By changing the fossil reductant into biogenic reductants, the global warming potential will be decreased even more. Even if the reductants are biogenic reductants, there will still be a global warming potential (GWP) in eg the electrode consumption and the CH4 emissions in the charcoal production. To reduce the use of fossil reductants there are also more disruptive technologies like the use of H2 that at least for the silicon production is on a very low technology readiness level (TRL). Using metallothermic processes will reduce the use of carbon but requires carbon neutral metal reductants. Electrowinning can have low CO2 emissions, and the electrowinning of pure Mn is a technology of high TRL. Salt and oxide electrolysis is under investigation for both Mn and Si production however the research is still on a low TRL. The use of CCS/CCU (carbon capture storage/utilisation) is a part of obtaining carbon neutral processes. Last, the energy mix used for these energy demanding processes is discussed.

Aug 21, 2024

By S L. Martin, M Wimberger

The binary indicator coding of assay and lithological data according to a single criterion or multiple criteria is a powerful technique for representing mineralised shapes through the modelling of probabilities. This can be as simple as using a single indicator to model the probability of occurrence of a condition, usually a grade threshold or a lithology, but it can also be used with a number of categories. Case studies are presented to show the power of this approach, where the geological controls on mineralisation or on the distribution of a rocktype or alteration, often coupled with mineralisation, are unclear. The categorical approach is often used as a de facto grade filter in disseminated or stockwork mineralisation. The ultimate expression of the indicator formalism is in multiple indicator kriging (MIK), where a conditional distribution of probabilities is generated for each estimation panel. This has applications in recoverable resource estimation, as the input for continuous or categorical simulation, where the distribution of sample grades is multimodal, or when there are superimposed mineralisation events with different orientations. However, in some cases, MIK is being used as an excuse for ignoring a quality geological interpretation. Examples from the public domain show the abuse of the categorical and MIK approaches to modelling probabilities, together with a plea for greater consideration of the geology.

Mar 22, 2022

By M Suzuki

Although several models for the surface tension of molten oxide slag have been proposed, suitably accurate predictions of this property are not yet possible. The surface tension, or surface excess free energy, of molten oxides is largely determined by the ionic coordination induced by surface relaxation. However, the associated mechanism of surface structural relaxation for molten oxide mixtures such as slag is complex and not yet fully understood. To allow a better evaluation of surface relaxation characteristics, the present work analysed the ionic coordination associated with the surface-relaxed states of several oxide mixtures. This work especially focused on calcium aluminate slags because these materials exhibit complex relationships between composition and surface tension. The effects of incorporating low concentrations of SiO2 as a surface active component on the surface ionic coordination were also examined. X-ray absorption techniques were used to assess oxygen and cationic elements in glassy samples after surface relaxation treatments, and molecular dynamics simulations based on a polarisable ion model of molten slag with vacuum/melt interfaces were also performed. The X-ray absorption techniques provided data related to electron yields (which are primarily associated with surface features) and fluorescence yields (which evaluate the bulk material). Thus, the ionic coordination characteristics of both regions were investigated. The results of molecular dynamics calculations allowed statistical analysis of the distributions of Al- or Sicentred polymorphs as well as the bond angles between cations and oxygen anions in the vacuumexposed and bulk regions in the equilibrated melt. The results indicated that bridging oxygen ions were preferentially distributed in the relaxed surface region rather than non-bridging oxygens. These bridging oxygen ions represented vertex connections between AlO4 or SiO4 tetrahedra. In the case of the calcium aluminate slags, the addition of one Ca2+ ion as charge compensation for two Al3+ ions was found to be necessary to form two AlO4 tetrahedra. This specific feature of surface ionic coordination could be responsible for the complex trends observed in surface tension data. The incorporation of low concentrations of SiO2 reduced the proportion of tetrahedrally-coordinated Al ions such that higher coordination states become dominant in the bulk of the material, whereas AlO4 tetrahedra were preferentially distributed in the surface region. SiO4 tetrahedra were the preferred Si-centred polymorph and were likely connected to one another to form bridging oxygen ions at the surface. On the basis of these results, a model to predict slag surface tension was proposed, and the energy of the formation of the ionic clusters resulting from surface relaxation was taken into account.

Aug 21, 2024

By K Smith

This paper presents an assessment of the Robertson (2010a) method within the CPTu inversion parameter framework of Been et al. (1987), using CPTu calibration chamber data presented by Jefferies and Been (2015) and in other literature to assess the validity of the method, with particular focus on applicability of the method to TSFs (i.e. its applicability to loose silts and silty sands). The assessment demonstrates that although the method estimates values of k consistent with calibration chamber data, the method estimates values of m that are generally 1.5 to 2 times greater than calibration chamber data. As a result of this, the method generally overestimates Ψ for values of Ψ less than 0, and underestimates Ψ for values of Ψ greater than 0. This may result in both overly conservative assessment of materials as potentially liquefiable and unconservative predictions of material behaviour for loose materials.

Jul 1, 2021

By D Pateman, F de Fredrick

The Bentley underground mine, which is located 60km north of Leonora, Western Australia, is owned and operated by Round Oak Minerals Pty Limited. A high-grade Zn-Cu Volcanogenic Massive Sulphide (VMS) orebody, Bentley was discovered in 2008 with production commencing in 2012. Long-hole open stoping is employed to mine the steeply dipping ore body, and in recent years the Avoca method has been adopted. This requires all development in a particular area of the mine to be completed prior to stoping commencing in a bottom up sequence. Voids are commonly backfilled with loose Run-of-Mine (ROM) waste loose rockfill (LRF); or alternatively cemented rockfill (CRF) can be used. Stopes in the 3860 AOS and 3900 AOS panels were located below previously extracted Avoca zones, with LRF situated immediately above them. These high-grade stopes were originally designed with rib and sill pillars to maintain control of the existing backfill during extraction. Due to changing factors over time, including mining economics, alternative options to achieve full extraction of the stopes were reviewed, including: • Mining small successive full height stopes which would involve drawing a blanket of LRF down with the extracted ore (stoping under waste); • Stabilisation of the existing LRF above the stopes and implementing a primary/secondary stoping sequence, with the primary stopes backfilled using a cement fill. An assessment of these options was undertaken which determined that the second full extraction method was the most beneficial to the operation, and could be achieved using a cement grout (Minova’s FB200 grout) to stabilise the LRF in conjunction with implementing a sequence where the primary stopes would be backfilled with cemented aggregate fill (CAF). Footwall drives were developed adjacent to the rockfilled stopes, allowing for the installation of horizontal grouting conduits, as well as providing access to the top of the planned 3860 and 3900 level stopes for the placement of CAF. An interval at the base of the previously rockfilled stopes was grouted at multiple horizons to achieve the required thickness, with a comprehensive quality assurance/quality control (QA/QC) process undertaken. Primary stopes were CAF backfilled via an arrangement of downhole winzes, linking the top of primary stopes to cross-cuts developed off the associated footwall drives. CAF was delivered underground through an open reticulation network that was extended to the specific levels. Overall the successful implementation of the revised mining method effectively increased ore recovery while maintaining control of overbreak and dilution, providing significant financial upside. This was achieved while maintaining effective controls in light of the changes to the risk profile. Stabilisation of the existing rockfill has allowed the extraction of stopes to full height, including the originally designed sill pillars, representing an average 23% increase in ore tonnes on the initial design, with dilution from the stope crowns averaging less than 1%. The use of CAF in association with primary/secondary stoping, eliminating the need for rib pillars, has yielded an average 47% increase in ore tonnes compared to the base case mine design.

Mar 15, 2021

By J Zhang, O Ostrovski, C Zhang D Cai, Q Wang

The conventional CaO-SiO2-based mould fluxes are not suitable for high-Al steel casting because of the strong reaction between silica in the flux and aluminium in the steel strand. In the process of casting of high-Al steel, flux composition changes; with the decrease of the silica concentration and increase of alumina. Knowledge and understanding of the effect of the Al2O3/SiO2 ratio on flux structure and properties are useful for flux design for the high Al-steel continuous casting. This paper investigated the effect of the Al2O3/SiO2 ratio on structure, viscosity, phase composition of fluxes quenched at different temperatures and heat transfer of CaO-Al2O3-SiO2-B2O3-Na2O-Li2OMgO- F fluxes. It was found that flux melting temperature increased with the increase in Al2O3/SiO2 ratio. Viscosity of the flux melts increased significantly with the increase of the Al2O3/SiO2 ratio from 0.7 to 1.2, reaching the maximum value, and then decreased with further increase of the Al2O3/SiO2 ratio. Raman spectroscopy analysis revealed that the change of the Al2O3/SiO2 ratio led to the change of aluminate and silicate structural units. The turning point for viscosity was attributed to the change in the degree of flux polymerisation. X-ray diffraction (XRD) analysis showed that increasing Al2O3/SiO2 ratio increased crystallisation tendency of the fluxes. Heat transfer measurement by infrared emitter technique (IET) revealed that increasing Al2O3/SiO2 ratio led to the decrease in heat flux which is correlated well with the increased crystallinity of the flux. The results suggested that the flux with Al2O3/SiO2 ratio 4.3 is the best candidate among the studied CaO-Al2O3-based mould fluxes for casting of high-Al steel.

Aug 21, 2024

By E Jak, M Shevchenko, E Nekhoroshev, D Shishin

In the field of pyrometallurgy, the presence of multiple molten phases with distinct chemical compositions, such as slags, mattes, speiss liquids, metals and molten salts, is a well-known phenomenon. These phases exhibit strongly non-ideal solution behaviour and are mutually miscible to varying degrees. To describe these complex molten liquids, the Modified Quasichemical Model (MQM) has proven effective and has been applied to numerous binary, ternary and several higher-order multicomponent systems related to pyrometallurgy. In recent decades, the complexity of high-temperature processes has escalated due to increased impurity concentrations in primary ores, the incorporation of recycled consumer products and the integration of metallurgical plants through by-product and waste exchanges. To address these issues, PYROSEARCH laboratory has been developing large 20-component thermodynamic database using a generalised CALPHAD (CALculation of PHAse Diagrams) methodology integrated with experimental investigations. Over the past decade, strategic decisions were made balancing the ability to generate experimental data, prediction power, accuracy, stability of calculations, as well as computational time, which are discussed in the paper. Examples provided for issues of >3 liquid immiscibility, non-ionic behaviour and exaggerated ‘sharp’ enthalpies of mixing in silicate slags, dealing with multiple oxidation states, as well as comparative analysis of pair and quadruplet approximation in MQM.

Aug 21, 2024