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The accurate determination of trace level gold in ores, metallurgical samples and process solutions is required because of the value of gold, the efficiency of the cyanide leach process and because of the high gold recovery from these cyanide solutions. It is thus necessary to routinely analyse geological and metallurgical samples with gold concentrations of 3 g tonne (ug g- 1ppm) and process solutions with a gold concentration of 0.01 mgL 1 (ppm) preferably with sufficient accuracy to quote at least two significant figures. Several techniques have been reviewed for their suitability for the routine gold analysis of these samples which also contain signif- icant concentrations of other ions. The classic fire assay technique has achieved the respect and confidence of mining personnel because of the results achieved by very experienced assayers. Other extraction and concentration techniques have now been shown to be equally effective. The use of instrumental analytical techniques particularly atomic absorption spectrometry have shown that cheaper procedures, which are as reliable, are now available to gold producers for the routine analysis required to maintain an efficient gold recovery process.

Jan 1, 1982

If an orebody has been drilled to achieve some level of regulatory compliance, then a number of associated geological databases will exist, representing 10 000 to 100 000 m plus of core intervals. The databases usually contain data about assays, lithology, mineralisation and geophysical attributes. They will also include location information such as collar positions and downhole surveys. Obviously this data is collected by geologists for, predominantly, geologists and mining engineers. However, from a process design viewpoint process engineers usually ignore the geology where possible and rely on a small number of metallurgical test samples. Typically these test samples are sourced from convenient and available cores or from a small number of specially drilled metallurgical holes. One of the worst instances known to the author was the design of a SAG mill using only two SAG specific test results (one for each of the major ore types) while, geologically, the orebody was defined by more than 30 000 m of drilling. This paper sets out a philosophy to maximise the use of the geological data, both for process design and in preparation for the commissioning phase of projects. Geological data is used in the identification of preferred locations for metallurgical test samples, for checking the metallurgical validity of the geological ore-type definitions, where necessary developing new ore-type definitions (geometallurgical domains) and developing mathematical relationships for the estimation of important metallurgical factors across the geological database. If the estimation of factors (for example ore competence) is considered reliable enough then there is also the possibility of feeding calculated data back into the block modelling process to allow the generation of metallurgically relevant outputs in the mine plans.

Jan 1, 2007

By Govett G. J S, Currie D. A, Cohen D. R

Analysis of mechanical size fractions of soils around the Paddington deposit (W.A.) and the Charters Towers Goldfields (Queensland) shows a bimodal gold distribution, with enrichment in the coarsest and finest fractions; this is probably a common feature of soils in arid terrains. To establish the true distribution of Au within the soil fractions, the effect of bulk Au content and percent weight variations in size fractions can be reduced by a normali- zing procedure. The greatest extent of lateral dispersion of Au recorded in the -125 ¦m fraction at Paddington and the -63 ¦m in the Charters Towers area as compared to the coarser fractions, and increas- ed levels of sample representivity in the finer fractions, favours their use in exploration. If orientation studies indicate the preferen- tial use of coarse or intermediate fractions, only wet sieving can quantitatively dis- aggregate the clays and remove finer contamina- ting material. The collection of extremely fine fractions such as the -63 ¦m is also accelerated by wet sieving. The additional costs of wet sieving may be offset by better interpretation of results through increased analytical sample representivity, anomaly contrast and continuity.

Jan 1, 1988

By S Ellis, J McMullen, M Habner

A new leaching regime was implemented at Kalgoorlie Consolidated Gold MinesÆ (KCGM) Gidji plant on a cyanide leach of ultra-fine ground sulfide concentrate. High lime concentration and lead nitrate were used to overcome the refractoriness of the fine sulfides (high reactivity of fine sulfides with the presence of gold tellurides). The leach pretreatment stage was shown to be detrimental and was shut down. Lime titration was introduced as part of the process control. It was shown that the leach could be performed at low dissolved oxygen, (ie 3 - 5 ppm) to avoid sulfide oxidation and the associated high cyanide and lime consumption. Plant results showed reduced cyanide consumption (40 per cent) and an accelerated leaching rate, whereby most of the gold was dissolved in 24 hours compared to 72 hours used previously. Similar work was performed at KCGMÆs Fimiston plant, which leached a combined ultra-fine ground sulfide concentrate along with the slimes fraction from hydrocycloning the bulk flotation concentrate. The use of lead nitrate, high lime and carbon-in-leach generated a faster leaching rate and minimised adsorption of gold on fine pyrite particles. The grind, previously controlled with a P80, was replaced by a P98 to give a better operational indication of top size hydrocyclone performance. Before the implementation of the changes, average leach residues for slimes and UFG were respectively 4.0 g/t and 5.5 g/t. With the modifications to the leaching regime, average leach residues were lower by 1.5 - 2.0 g/t. Whilst significant improvements have been demonstrated, further work is progressing at KCGM to further reduce ultra-fine concentrate leach tail grades, and also to improve the understanding of concentrate refractoriness and the factors responsible for differences between laboratory and plant leach results. Estimated profits since the implementation of the new approach are in the range of $A3.5 million per year.

Jan 1, 2005

The earliest caveman, very much a minority group, in the face of great adversity and person- al peril, had to take his livelihood by stealth or force of arms - aided by some degree of reas- on and ingenuity. He was pretty much a law unto himself. As time went on, his type became more numerous; and, after bumping heads with the- tough bloke who lived in the cave across the valley, he decided that perhaps he ought to try to get along with him. Perhaps he could trade some over-ripe emu meat for that `roo skin that he had tried to take. Then too, next time he wants a woman, he had better use a lighter club and just stun her a little - that last one was pretty badly bashed. Perhaps he should keep her around the cave and train her to keep the fire going, gather some roots, and skin the game. Those joeys of hers are kind of cute too. Of course they eat, and it would necessitate bringing in more food. So man gained increasing responsib- ilities to his family and neighbours. He domesticated animals, learned that he could cultivate certain plants that were palat- able and would supplement the meat diet, and found that he could modify earth materials to make tools - he became a grazier, a farmer, a miner and a manufacturer. He ceased to be nom- adic and community life came into being. This complicated life and made more rules essential.

Jan 1, 1974

North Broken Hill Limited came into prominence as a producing mine at· the commencement of the present century, when a great many of the disabilities experienced in earlier mining operations th:rough lack of adequate stope filling had been overcome.The northern or narrower ore-body was first mined in the upper levels and, in the early stages, no great difficulty in mining was experienced. In depth, under the influence of its northerly pitch,. the wide southern ore-body entered the North mine between the 400 and 500-ft. levels. Owing to its flat dip and the relatively weak nature of the hanging wall and footwall, the value of close filling was recognized and this policy has been followed throughout the life of the mine. This feature undoubtedly contributed to the freedomfrom "creep" action to which some of the older mines had been subjected.The Broken Hill lead-zinc-silver ore-bodies occur as well defined replacements of favou:rable horizons, in intensely folded Pre-Cambrian sedimentaries. In the North mine two main replacement zones occur, the Gre being found where the beds are involved in a certain set of minor folds. The resulting ore-bodies are roughly elliptical in cross-section, the long axis of one being north-east of, and somewhat offset from the long axis of the other. The ore-bodies pitch eastwards at 40° and dip northwards at 60° in a fairly regularmanner. The southern Ore-body has an average length of 700 feet and an average width of 90 feet with a maximum width of 230 feet, whilst the nonhern ore-body on the lower levels averages 500 feet long and 40 feet wide.

Jan 1, 1940

COAL constitutes such a gigantic item in modern industry, either for direct heating, production of coke for smelting, or for the generation of power, that its quality and price play a very significant part in economic industrial progress. Australia is still a very young country industrially, and is groaning under many disabilities compared with competitors overseas, not the least of which is the quality of coal. Linked with the word "quality" should be that of "utility," for high-ash content prevents efficient utilization of the fuel.The marketing of good quality coal is a very important matter indeed, and if industry in Australia is to progress in the way that it should, this matter must receive keen attention.New South Wales, above all the other Australian States, has been blessed by nature with vast coal-fields, from which fuel is shipped to every State, and provides the base for power for most of our railroads and industries.Experts frequently refer to the fact that in some districts only partial extraction of thick seam coal is being made, without a care or thought for the future. Ranking next in importance to this is the fact that much of the coal is being carelessly marketed.Very few collieries in Australia are equipped with coal-washing plants for dealing more particularly with small coal grading which most industries require, and to which coal producers as a whole pay the least attention. In England each year nearly20,000,000 tons of coal is being water-washed before sale, and is marketed as a fuel of far greater utility once it has been freed from extraneous ash.Investigation proves that a great many pits in New South Wales are marketing coal (more particularly small coal) containing a considerable quantity of extraneous ash, due to the admixture...

Jan 1, 1926

Distal air-fall ashes are widespread deposits that may record volcanism many hundreds of kilometres from their source. They are characteristically thin, fine-grained and have a low preservation potential usually being either eroded, or reworked and incorporated in overlying sediments following deposition. The most likely sites of accumulation are deep sea, lake and swamp environments where low energy conditions favour preservation. Post-depositional alteration of predominantly glassy volcanic ash is commonly extensive hampering identification of such layers in the geological record. As a result air-fall tuffs are poorly represented in the rock record and furthermore are commonly misinterpreted. Southeast Queensland during the late Triassic hosted active silicic volcanism and a number of fault-controlled basins in which coal-bearing sediments were accumulating. Silicic volcanics of late Triassic age are represented by the Brisbane Tuff in the Brisbane city area, the Chillingham Volcanics to the south of Brisbane and extending into New South Wales, the North Arm and Mount Byron Volcanics to the north of Brisbane, the Aranbanga Beds exposed around Gayndah and the Agnes Waters and Muncon Volcanics which occur northwest of Bundaberg. Stephens (1986) interprets these Volcanics as the remnants of a major silicic igneous 'province which he likens to modern continental orogenic margins. The Ipswich, Tarong and Callide Basins of southeast Queensland all contain coal measure sequences of late Triassic age that accumulated in alluvial plain environments. A Dicroidium flora is common to all and palynol.ogical evidence indicates a late Triassic (Carnian) age (de Jersey, 1975; Stevens, 1981). The coal seams of the three basins are characterised by their thickness (up to 25 m) and the presence of abundant thin, laterally persistent, kaolinite claystones (tonsteins) that show a marked similarity of morphology, texture and mineralogy. Detailed studies of the Ipswich Coal Measures (Falkner, 1986) suggest a volcanic air-fall origin for the tonsteins of the Ipswich Basin. Similar.tonsteins from the Tarong and Callide Basins provide evidence for widespread silicic volcanism during the late Triassic in southeast Queensland.

Jan 1, 1987

Application of Agitated Leaching for Iron Removal from Silica Using Sulfuric and Hydrochloric Acid In this research, iron removal from silica used in glass industry was investigated using agitated leaching method. Silica sample was provided from silica concentrate originating from Chalchoog Silica Mine located in Abhar, Iran. The sample contained silica, iron oxides and clay minerals. For characterization of samples XRD and XRF analysis and atomic absorption method were applied. Silica and iron oxide (Fe2O3) grade of head sample was 98.41 per cent and 0.067 per cent respectively. Two inorganic acids (sulfuric and hydrochloric acid) were used in agitated leaching tests. Two series of L9 orthogonal array of Taguchi design with replication were used to determine the effect of parameters including acid dosage, leaching duration, ambient temperature and solid content on iron removal. The statistical calculations and analysis of variance (ANOVA) were carried out by means of DX7.0, Minitab14.0 and Winrobust1.02 softwares and also statistical calculations were checked manually using Excel software. Also multivariate regression was applied in order to forecast Fe2O3 conent of final product. The optimum conditions for leaching tests which sulfuric acid was employed are as follows: 40 minutes leaching time, temperature of 85¦C, 40 g/L acid concentration and solid content of 20 per cent. Under this condition the amount of iron oxide in silica was decreased to 0.042 per cent. The optimum conditions for leaching tests which hydrochloric acid was employed are as follows: 80 minutes leaching time, temperature of 75¦C, 30 g/L acid concentration and solid content of 20 per cent. Under this condition the amount of iron oxide in silica was decreased to 0.035 per cent.

Sep 13, 2010

By V Narayanaswamy

SustainabilityÆs imperative of economic development in tandem with social advancement and environmental protection is widely accepted, but much debate remains about the practical implications for the minerals processing technologies and practices for the future. Experience in other industry sectors however suggests that sustainability can be a value-adding framework for innovation in processing technologies, business models and management systems. This position paper explores how sustainability can drive innovation in minerals processing, by reviewing pertinent ideas and experiences gained in non-minerals sectors. Sustainable innovations can generally be broadly ranked from incremental to transformative, with each category having its own typical improvement potential, timescale and technological and operational challenges. This leads to a æmud mapÆ for sustainable innovation in minerals processing with three distinct tracks: eco-efficient operations; sustainable plant design and sustainable processing. Competing models for the sustainable innovation process through either forecasting or back-casting, have in common the strong reliance on vision, perspective and competency, which in turn highlights the importance of sustainability frameworks. Such sustainability frameworks provide normative goals and option elicitation prompts to assist with the analysis of current processes and scoping of more sustainable alternatives. A comparative analysis of five prominent environmental sustainability frameworks revealed three cross cutting sustainability themes that challenge current resource processing technologies and practices. These are: fate of materials (zero dissipation of materials); compatibility of materials and processes; and materials intensity of industrial products and processes. Although the sustainability concepts presented in this paper have not been extensively road tested in the minerals processing industry, there is ample evidence that recent initiatives in the Australian resource sector illustrate the applicability of the proposed framework. It is therefore argued that more in-depth assessment of sustainable innovation concepts would be a valuable contribution to the sustainable resource processing theory and practice.

Jan 1, 2004

By F Baars, M Zu, C A. RosiFre, L Lobato

A genetic model for the genesis of high-grade (>65 wt per cent Fe) Proterozoic, banded iron formation (BIF)-related iron deposits such as the Tom Price, Mount Whaleback deposits in the Hamersley Province (Australia), the N4E, N4W, N5 deposits at Carajßs (Brazil), the Aguas Claras, Conceitpo, and Casa de Pedra deposits in the Iron Quadrangle (Brazil), the Donkerpoort West, Kwagas East deposit in the Thabazimbi iron ore district (South Africa), or the Saksagan ore field at Krivoy Rog (Ukraine), needs to take into account the: timing of regional metamorphism with respect to the upgrade of BIF to high-grade iron ore; significance and relationship of the proto-ore to the hydrothermal alteration minerals and zonation and the process of iron enrichment; source and oxidation state of the hydrothermal fluids that caused the iron enrichment; types of geochemical processes that caused the hydrothermal alteration and iron enrichment; and significance of the widespread carbonatisation of the host rocks as a prerequisite for high-grade BIF-related iron mineralisation.We argue that a unifying model for high-grade BIF-related iron deposits cannot, presently, adequately explain the geological and geochemical characteristics observed in these deposits and, therefore, provide two end-member models that take into account the diversity of geological and geochemical ore deposit features. Our discrete model for the genesis of high-grade, BIF-related iron deposits is based on the interpreted tectonic setting, distinct hydrothermal fluid source of, and processes observed in, major BIF-related iron deposits. We divide two end-members: Proterozoic deep fault-magmatic (Carajßs) type, and Proterozoic rift-basin (Hamersley) type.Both end-members experienced varying degrees of deep weathering episodes that effected the hypogene enrichment and, ultimately, yielded the high-grade iron ore mined in many places today.

Jan 1, 2005

By Sorokin M. L, Komkov A. A

Flash smelting of nickel sulphide concentrate has been practiced at WMC's Kalgoorlie Nickel Smelter for 20 years. The mineralogy of the concentrate from the original mines was particularly suited to this process. However, taking a strategic view, potential new processing routes should be fully evaluated as possible replacements for the current technology. The Vanyukov process has been under development in Russia for the past 40 years and has been successfully applied on a large scale to the smelting of copper concentrates, at two locations - Norilsk and Balkhash. The potential for the application of the Vanyukov process to the smelting of nickel concentrates offers a number of processing advantages, including smaller reactor and decreased dependence on fuel oil. This paper reports on preliminary investigations into the application of the Vanyukov process to the smelting of nickel concentrates. At this stage the investigations are limited to semi-quantitative comparisons and modelling studies.

Jan 1, 1992

Mine planning is difficult. Even for small operations, it involves reasoning with complex variables and the practical difficulties of mining. It is also about predicting and planning the future in an unpredictable physical and economic environment. Yet we rely on a handful of individuals and their spreadsheets to tell us how to do it û planning the business and activities of mining to hopefully produce results that will please stakeholders. Does it work? Not as well as it could. Planning affects everyone in the organisation. Company executives are demanding more reliability and stability in cost and revenue forecasts from their operations. Management want to explore ways of being more cost effective. Miners and contractors want more useful plans and realistic targets. And the planners have to describe the method that will translate business objectives into implementable plans. Even with the use of computer technology a lot of effort is expended to produce plans that are largely qualified by the level of knowledge and experience of individuals. Better use of information and the application of Intelligent Technologies can improve the quality and reliability of mine plans and schedules. By capturing the knowledge within the organisation and speeding up the planning process, Intelligent Technologies allow more options to be considered more rigorously. But it is not just about technology. It is about how technology is implemented and embodied in the way the business is managed for performance. When this happens, the real benefits of better planning start to flow.

Jan 1, 2003

By Li G, Dean-Jones G. L, She T

Highwall mining is a specialised and largely automated mining method developed in the United States for the extraction of coal left under a shallow overburden cover after cessation of economical open cut mining operations. As the name indicates, coal is extracted from the seam exposed along a highwall by a remotely controlled continuous miner operating in a single unsupported opening and brought to the surface by a string of conveyor segments. The single entries are separated by coal .pillars and driven normal to the highwall, over areas where the thickness of cover and volume of recoverable coal is insufficient to allow or justify conventional underground mining. An additional highwall mining method is augering. The success of high wall mining operations depends significantly on geological features, notably the stability of the working roof, determined by the type and mechanical properties of the immediate roof strata. Stability of the ribs, absence of floor heave, faults and dykes are further important prerequisites for profitable highwall mining. The geometric relationship between the spatial attitudes of existing joint systems, the direction (azimuth) of the single entry opening and its vertical profile determine the unimpeded depth of penetration into the coal and thus its economic success. The mechanical implications of the lithological transition zone from a coal seam to either primary or original roof strata, compared to an interface between the coal seam and overlying strata, characterised by a sharp erosional boundary between coal and a secondary immediate roof stratum, are very significant. The compatibility between the response to mining by the geological system (floor-seam-roof) and the capability of the mining equipment to prevent the development of instability are essential requirements from a mechanical viewpoint. The minimisation of vibrations, very good horizon control, an ability to vary the profile of the opening, and the maintenance of consistently high advance and retreat rates, are also important aspects of profitable highwall mining.

Jan 1, 1995

The process of mine planning at AnacondaÆs nickel and cobalt laterite operation located at Murrin-Murrin in the Northern Goldfields of Western Australia is carried out in a number of stages in an endeavour to determine the optimum mining sequence in order to maintain supply to the 4 Mtpa plant subject to operational constraints. The 296 Mt @ 0.99 per cent Ni and 0.064 per cent Co ore reserve (based on a cut-off grade of 0.8 per cent Nickel) is spread geographically widely over three regions comprising Murrin North (15 km + 15 km), Murrin South (7 km + 16 km) and Murrin East (5 km + 13 km) (refer Figure 2). The nickel mineralisation has been broken up further within each region into 18 separate manageable block models representing the 32 different deposits. The models are based initially on the 50 m + 50 m resource drilling for long term planning and updated with 12.5 m + 12.5 m grade control drilling prior to mining. Each of the individual block models are optimised using Whittle 4X software to provide the shells used as the basis for each of the 126 pit designs. The pits are generally nested with starter pits targeting the higher value shells with subsequent pits incrementally cutting back ultimately to the life of mine shells. A series of steps including: the coding of the individual pits into the block model; data export; TCL scripting (to calculate additional economic and tracking information); importing; and re-blocking; completes the transfer of the data into a MineMax (mixed integer linear programming schedule optimising software) model. Using MineMax and the application of operational and production constraints allows the optimisation, assessment and economic evaluation of alternative scenarios in order to determine the optimum life of mine plan and schedule.

Jan 1, 2003

Conventional blasthole sampling for grade control has acquired an extremely bad reputation for the last 50 years. The introduction of many sources of bias is a structural reality. Delimitation biases are devastating. Extraction biases are of great concern as well. Weighting biases aggravate an already bad situation. Furthermore, preparation biases are many. Some of these biases are due to the type of drilling machine that is used and are nearly unsolvable. Some of these biases are due to the sampling tools that are used and often unsatisfactory. Attempts to automate blasthole sampling at the drilling site have failed, not because it cannot be done, but mainly because it interferes with drilling productivity. As a result the miner most often rejects the idea after a few weeks of practice. Manual sampling of blasthole piles is a disaster for many reasons; some are related to the methodology, some to the selected sampling protocol, some to the training of operators, some to limited manpower available, and some to limited supervision. Furthermore, with blasthole sampling a time logistic problem is unsolvable as the miner wants the ore grade control geologist to make up his mind within two or three days at most; as a result not enough time is allowed for samplers, preparation facilities, laboratory, and resources department to perform a good job as everyone is working under unreasonable pressure. The economic impact of poor blasthole sampling for grade control has been vastly underestimated by mining companies. The resulting ore grade misclassification is responsible for severe reconciliation problems and massive financial losses every year. This paper suggests areas along this grim scenario where things can be greatly improved; however it is clear that too many problems are unsolvable. An alternative using reverse circulation drilling for grade control is suggested. A thorough analysis of the respective advantages and disadvantages for blasthole and reverse circulation drilling for grade control is presented in this paper.

Jan 1, 2008

Australian wheat belt agriculture is causing a decline of its natural resource base. The major problem, salinity, arises from a small reduction in water consumption by agricultural crops compared to what prevailed under the prior native vegetation. This causes groundwater accumulation which, in the low relief landscapes of the wheat belt, is leading to extensive surface saturation in low landscape positions and dramatic, destructive change in the hydrological behaviour and habitat of streams and rivers. The ability of agriculture to invest in salinity control is severely limited by its long-term decline in its terms of trade. Extensive planting of perennial vegetation has the potential to increase water use and arrest the salinisation process. If these perennials were also commercially attractive, the cost of salinity treatment could be minimised. Given the difficult commercial position of food commodities, it is logical to develop ænon-foodÆ perennial crops, in particular woody crops suitable for industrial products. This paper looks at the example of Sweden, where there has been a generation of investment in developing forest harvest residue recovery, and short cycle woody crops for bioenergy, but with only limited success. In contrast, secondary residues (processing wastes) from forestry industry are readily saleable for low value uses like bioenergy. This suggests that the model woody crop must have a higher value fraction to facilitate delivery and commercial use of its lower value fractions. This model is being emulated in the development of native mallee eucalypts as short cycle woody crops in Western Australia. Some $50 million has been expended on mallee development in the past decade and this has culminated in an engineering demonstration of integrated processing. The putative high value products are activated carbon and eucalyptus oil and the residue (plus waste heat) will be converted to electricity. The potential scale on which crops of this type would be required to achieve salinity control means that many more high value and residue products will have to be developed. Metallurgical charcoal appears to be a promising product option.

Jan 1, 2006

By S La Brooy, C Fountain

Throughout its history the mining industry has focused on the highest-grade deposits sited in the most convenient locations. The burgeoning global population and higher standards of living not only increase the demand for mineral products but also make it harder to mine and process them. The future will include the development of lower-grade, more complex orebodies, and orebodies in difficult locations. The industry will be expected to provide for humanityÆs needs while reducing its environmental footprint and maintaining profitability. This paper reviews some of the likely adaptations in mineral processing that will occur over the next 20 years. The challenges inherent in adapting to lower grade and more complex materials might be exacerbated by such factors as the availability of water and low-cost energy. In underground mining, higher energy costs are likely to foster further developments in underground preconcentration, especially for ores that can be upgraded at relatively coarse sizes. The adoption of underground crushing could also render material amenable to semi-dry preconcentration options such as might be achieved by the rotary classifier developed by CSIRO and being commercialised by RCR Tomlinson, or more modern versions of the hand-sorting of ore that use sensors based on colour or other suitable rock properties. The cement industry and some gold roasters have used the alternative of dry grinding and classification, which might also have a part to play in dry processing. There is also likely to be increased interest in options such as in situ leaching that further minimise the surface disturbance. Underground operations will have to balance the energy savings from reducing the amount of material brought to the surface and reduced surface disturbance against the practical limitations of installing and maintaining processing equipment underground. On the other hand, surface disturbance and energy issues in open cut operations will be balanced by potentially lower mining costs and higher overall recovery from the deposit.

Jan 1, 2008

By O Pasca, B Hogg

Consistent slag blow end point detection remains one of the challenges in the Peirce-Smith converters at Mount Isa MinesÆ Copper Smelter. Under blowing results in foaming on copper blow and carry forward of oxide skims to the anode furnace. Over blowing results in high copper losses to the slag. Both present safety issues and contribute to lower copper production. The end points of the slag making phases are assessed by inspection of a bar sample. A bar sample is a thin accretion layer that adheres to a steel bar when it is inserted into the tuyere while the converter is blowing. This method is biased and subjective, so there is heavy reliance on operator experience. The Semtech Optical Process Control (OPC) system was installed in early 2002 for converter slag blow end point detection. Initial plant trials did not improve all aspects of converter operations, and uptake by operators was poor, so the system was not used. In early 2005, the Semtech OPC system was re-visited and another short trial was conducted to evaluate the permanent use of the system for slag and copper blow end point detection. During this trial, the Semtech OPC method was found to be superior to bar sampling for slag blow end point detection. The implementation and refurbishment of the Semtech OPC system has resulted in plant improvements and given a better insight into converter operation during blowing. Oxide skim generation carried forward to the anode furnace has been shown to decrease with increasing compliance with Semtech OPC. Some of the expected improvements to converter operation were not found to be significant. Semtech OPC is now well received and utilised by converter operators. Individual paper available only. Not included in book or CD ROM Proceedings.

Jan 1, 2005

By J Tuma

Technical measurements are an integral part of research and development of new technical devices. Now they are also an integral part of production too, especially as a part of quality control systems. More new problems started with they applications up, like storing and following preservation of big data files. Many problems are also with processing of the measurement results, especially to be up to standards of ISO 9000 normative. It includes basic data about the measurement (structured data) and measurement outputs (huge data streams). Using database systems looks as good idea, because of structured measurement data and they processing. They were developed more concepts of database measurement system support during the research project MSM 272300012. It was decided to develop specialised measurement systems, on the base of experiments and experiences with they use in operating conditions. It proved to be wrong to develop general system, because of compound operating and long response of the system. And it is not possible to use these systems for mass production systems. The problem of data storing is not as easy to be answered, because of dependence on used technical devices. During realisation the measurement system for gearbox noise measurement are data stored to the database, because used analyser system PULSE (Brnel and Kjµr Co) is open structure and can cooperate with other software systems. Anyhow the data streams are not longer (after compression) than the Memo data type, in practical use increases the data file too fast (about hundreds MB daily). Therefore we must include a special supervisory system for administration and creating data files to the system. Nevertheless the used system MS-Access supports data files up to 1 GB, for practical application is better if the file size do not exceed the capacity of CD-ROM disc.

Jan 1, 2003