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The world is getting flatter through internet, mobile phone technology, relatively low cost travel, massive outsourcing of manufacturing to China and the transfer of company backroom operations to India. In the iron and steel industry, however, things will remain relatively the same with slow gradual improvements in technology; only the geographic location of plants may change over time. Or will it? The blast furnace smelting process has remained largely unchanged since 1828 when James Neilson came up with the idea of preheated air being delivered to the tuyeres. Likewise, oxygen steelmaking that takes molten iron from such blast furnaces has remained conceptually unchanged since Sir Henry Bessemer invented an air-based system in 1856. These two processes are the core of integrated steel mills that we know today. Typically such mills consist of coke ovens, sinter plant, blast furnace, oxygen steelmaking, continuous caster, rolling mills and metal coating lines. In the intervening 150 years the only real disruptive technology to the integrated steel mill has been the minimill. Based on the use of the electric arc furnace (EAF), in conjunction with a continuous caster and rolling mill, the term minimill is used because steel products are produced at down to one-tenth the scale required for economic operation of an integrated mill, with the EAF producing molten steel using largely scrap steel as its feed, as against transforming coal to coke (coke ovens), iron ore, coke and limestone into molten iron (blast furnace) and molten iron to steel (oxygen steelmaking). There are, however, a number of technologies in development that may cause a paradigm shift in the way steel products are produced and perhaps push the evolution of the minimill as a disruptive technology. Two examples are direct iron smelting, where iron is produced in a matter of seconds by injection of ironmaking feed materials into a molten bath, and thin strip casting, where molten steel is cast into 2 mm strip or less, in similar time. Both have Australian connections. A leading iron smelting technology is the HIsmelt« process, which has its first commercial application at Kwinana, Western Australia, where a joint venture of international parties, consisting of Rio Tinto and the Nucor, Mitsubishi and Shougang corporations, are in the stage of ramping up commercial production. The leading strip casting technology is the Castrip« process that arose from development work done by then BHP Steel, with IHI of Japan, at Port Kembla, New South Wales in the 1990s. Nucor followed this work up, building the first commercial plant for the technology at its Crawfordsville site in Indiana in 2001 and has recently announced an intention to build a second plant in the USA. While both technologies are only into the early stages of commercialisation they are likely to change the face of iron and steelmaking as we know it over the next 20 years. This paper elaborates on the technology of the two processes, why they could change the face of the iron and steel industry forever, what might drive the rapid change and what the changes may look like.

Jan 1, 2006

The history and milestones in the evolution of support systems utilised in the mass-mined chrysotile mines of Shabanie and King are discussed in detail. The use of block caving, false footwall or sublevel caving mining methods brings with it some major support problems, which are exacerbated, in our low rock strength mining environments. The paper discusses the various support elements and systems that have been used successfully or otherwise in these operations. Some predictions for the future of rock reinforcing in our ground conditions are highlighted, in relation to geomechanics, levels of mechanisation and production risk analysis.

Jan 1, 2000

By R Hall

The magmatic arcs of SE Asia and SW Pacific contain some of the worldÆs major magmatic-hydrothermal gold deposits. Most gold deposits in SE Asian and SW Pacific arcs formed during periods of plate reorganisation rather than during periods of normal or steady state subduction. These plate reorganisations were caused initially by the collisions of the Australian Craton with the Philippines-Halmahera Arc and the Ontong Java Plateau with the Melanesian Arc at ~25 Ma. A second Mid-Miocene period of mineralisation accompanied plate reorganisation following maximum rotation or extrusion of Indochina and cessation of spreading in the South China Sea at ~17 Ma. However, the vast majority of deposits from New Zealand to Taiwan formed since 7 Ma during an important period of tectonic reorganisation that accompanied and followed changes in the relative motion between the Indian-Australian and Pacific plates between ~8 and 3.5 Ma. Magmatism in unusual tectonic settings produced the most abundant and largest deposits with many deposits associated with high-K calc-alkaline, shoshonite, adakite and alkaline magmatism. In particular peak mineralisation appears related to melting of sub-arc lithosphere that has been previously modified by subduction. During large-scale plate reorganisation this can occur towards or at the end of a period of normal subduction, following arc collision or accompanying subduction reversal at approximately the same time in different parts of a complex system of arcs such as in SE Asia and the SW Pacific.

Jan 1, 2005

An Environmental Impact Statement (EIS) for a major mining development typically has to address various aspects of surface water management, including some which generally tend to be the more contentious: the diversion of rivers and creeks from areas disturbed by mining, and their rehabilitation; the effective management of disturbed area run-off via the collection, containment and treatment of contaminated water on site in sedimentation dams; the collection, containment and treatment of mine pit water; the decommissioning of surface water storages; final void water quality; and water discharge criteria. Environmental Impact Assessment processes for proposed mining developments in Australia at the state and commonwealth level usually involve a form of Initial Advice Statement (or Notice of Intent), Terms of Reference, an EIS, and a Supplementary Report (or similar) which responds to agency and public comment on the EIS. The EIS is used by approval agencies to decide the acceptability of the Project, and to set the conditions of approval. The conditions are often in the form of a state-issued æOperational LicenceÆ or similar. With mining, the initial approval at the EIS stage is often just a pre-cursor to various other planning related approvals, including obtaining a mining lease. Afterwards, mine plans and plans of operations must be submitted to government at various stages of the mineÆs life, ostensibly to provide the detailed mine planning over periods of one û five years. Despite all this additional planning and documentation beyond the submission of the EIS, government approval agencies are increasingly not satisfied with conceptual water management designs and commitments to an outcome (such as meeting a specified water quality standard) in the EIS. Agencies are also requiring sufficient water management design information to be convinced that the outcomes are achievable. To assist proponents of major mining developments, the Queensland Government has published Technical Guidelines for water management, and Environment Australia has published a æBest Practice Environmental Management in MiningÆ booklet on water management. In addition, the Australian and New Zealand Environment and Conservation Council (ANZECC. 2000) has published Water Quality Guidelines which provide an approach to water management, and provide receiving water investigation trigger criteria. So, what are the water management issues that are likely to be the subject of comment, debate and negotiation prior to the EIS being approved? and what commitments may a mining proponent have to make in order to convince the approval agencies that sufficient investigation and design has been provided? This paper provides some answers to this question, by reference to recent major mining proposals which the author has managed through state and commonwealth Environmental Impact Assessment processes.

Jan 1, 2003

By MJ SMITH

For the past 150 years, drilling and blasting has been an integral part of the underground mining industry in Australia. Ever since Busby's Bore was developed using black powder to supply Sydney with water, miners have been drilling holes, filling them with explosives and blasting the rock into a manageable size. The drilling was fairly straight forward but the explosives were always a mysterious commodity. It worked, but how and why? The explosives industry is now working much closer to the mining industry to dispel these mysteries and also to aid the advancement of explosive technology. This paper looks at the results of these advances in the form of explosives, accessories and blasting systems.

Jan 1, 1992

The paper describes the progress made in the last decade with the introduction of comprehensive monitoring of the mine atmosphere into U.K. collieries. Brief descriptions are given of the various portable and fixed point instruments which have been developed for this purpose and the methods available for transmission of information to the surface are also discussed. The paper also outlines some of the research work being carried out both in the laboratory and underground on the development of alternative methods of fire detection. Some of the results from this work are illustrated and discussed.

Jan 1, 1981

By Hll J. K, Zhang Y. G

The wear mechanisms of impregnated diamond drill bit matrices are complex and believed to be the key point in solving drill bit self-sharpening problems. A method has been developed to find the change in c,, the wear rate of matrices having different fracture toughness K_ at the increment of drill pressure P. The worn surfaces of specimens were placed under a scanning electron microscope to examine the wear patterns and wear mechanisms at different pressures, and were compared with the worn surface of a practical drill bit. A model is proposed that within a wide range of pressures there exist two different wear mechanisms and three wear regions for cemented car- bide matrix materials. In region one (linear region), at low pressure, the major wear mechanism is plastic deformation in which the preferential wear of the binder phase of the matrix results in the loss of WC, tung- sten carbide particles. Wear rate is controlled by hardness, H as Archard's formula predicts. Wear enters region two and three (non-linear region) simultaneously as pressure is being increased. Consequently, wear transfers to fracture mechanism in which micro-fracture occurs at the root of wear grooves and the material is removed mainly in piece and mass. It has been shown fracture toughness K,, plays a more important role than hard- ness H. It is concluded that for a specific drilling condition, the pressure on the matrix should be carefully controlled and a balance between hard- ness and toughness of the material is essential for a steady drilling Condition.

Jan 1, 1989

Kalgoorlie Consolidated Gold Mines Pty Ltd is currently developing the 'Super Pit' gold mine in the mining area known as the Golden Mile adjacent to the city of KalgoorlieBoulder, Western Australia. The presence of numerous abandoned mine workings and complex structural geology has required considerable geotechnical input into the determination of the optimum pit slope geometries for both interim and ultimate pit slopes. Slope design is based on detailed site investigation and stability analysis which is balanced with historical operational experience. This paper discusses the process of determining the optimum pit slope angles for each of the stages of the west wall of the 'Super Pit'. The risks associated with slope instability are discussed for each stage.

Jan 1, 1994

By Rowe J

The case study is based on the largest ore deposit at Mt. Lyell; the Prince Lyell deposit, comprising a regular lensoid mass of dissemina- ted and vein pyrite-chalcopyrite mineralisation. Reserve estimation employs conventional techniques, based on diamond drill hole and relevant development sampling data. Probable ore reserves are estimated using the contouring (isoline) method an longitudinal projections for ore thickness and accumulation (m %Cu) at a '0.8% Cu' cutoff. Final stope and pillar res- erve estimates (proved ore) are derived from designed ring tonnages and contoured accumula- tion for individual mining units, following more intensive sampling. Systematic grade control procedures have been adopted and individual stopes and pillars reconciled against mill production. The proved ore estimates have been found to com- pare favourably with the reconciled production.

Jan 1, 1979

Plant growth is likely to prove the most suitable and satisfactory material to stabilise and cover quarry faces and worked-out surface mining sites. The careful selection of plant species is of paramount importance to the success of any attempts to re- vegetate these sites. Various tech- niques are recommended and attention is drawn to different factors,which will adversely affect plant growth.

Jan 1, 1976

A mathematical model for spontaneous combustion of coal with moisture included is presented in this paper. The one-dimensional unsteady state model consists of conservation equations for oxygen, water vapour and inherent moisture of coal and energy for both gaseous and solid phases. A first order Arrhenius reaction rate for oxidation under both pore diffusion and chemically controlled reaction regime is considered. The rate of evaporation or condensation is also considered as a function of temperature of coal, water content of coal and gas streams. The equation of the model is solved numerically by the finite difference technique. Influences of different parameters on the process of spontaneous combustion can be examined by using this model. Also the model can be used to simulate full-scale storage conditions.

Jan 1, 2005

The comminution process indicates that the most energy-efficient comminution system would be one where the particles leave the breakage field as soon as they reach product size. Contrary to the free falling gravitational (vertical) flow in crushers, the grinding millÆs energy efficiency essentially depends on ore characteristics and the discharge rate of broken particles, which in turn depends on how efficiently the discharge pump (grate and pulp lifters) operates. The essential function of a pulp lifter is to transport the broken material and slurry from the discharge grate out of the mill. Hence, the design optimisation of pulp lifters affects not only the energy efficiency and throughput of autogenous grinding/semi-autogenous (AG/SAG) grinding mills, but also contributes other process benefits such as improved wear life and operator-friendly steady and smooth mill operation. Following its introduction in 2006, OutotecÆs patented Turbo Pulp Lifter (TPLÖ) design has been retrofitted at existing sites and also installed in some new ones around the world. This paper will provide operational experience and data on how the TPLÖ design has allowed AG and SAG mills to operate efficiently.

Jan 1, 2009

By Middlebrook PD

The problems of education and research in the extractive metallurgy area are being tackled by the University of Melbourne through activities centring on the Department of Chemical Engineering. The establishment of the G.K. Williams Laboratory and the enhance- ment of the teaching of material relevant to extractive metallurgy in the Chemical Engineering course aim-at providing graduates and experienced researchers for the industry and at providing a strong research group carrying out industrially significant research in the area of pyrometallurgy.

Jan 1, 1986

By Nikaido M, Kanda Y

A rotary type separator has been developed which separates particles on the basis of their shape. This separator was applied to a particle size range of about 50 - 120 ¦m, and to our present knowledge may be the smallest size range ever to be separated. A theory of the separation is given based on the difference of an adhesive force of the particles: the adhesive force between spherical particles and plate is more powerful than that of irregular shaped particles for the same particle size. These facts have been ascertained by the measurement of an adhesive force by a centrifugal method. US and Japanese patents have been obtained on this separator, which consists of a borosilicate glass cylinder of 150 mm outside diameter, 120 mm in width, and an AC electromagnet. The samples used in this study were mixtures of spherical glass particles and non-spherical shaped glass particles. The results are summarised as follows. In the case of mixtures of spherical particles and irregular shaped particles in the weight ratio of 1:1, the spherical content of the spherical product became 70 per cent - 75 per cent, and in the case of 3:1, the content became 87 per cent - 90 per cent, as the result of one separating operation. However, for a mixture of somewhat rounded particles and irregular shaped particles of weight ratio 1:1, the rounded content varied between 58 per cent - 73 per cent. The feed rate of the particles mixtures was about 0.3 g/min. Newton's Efficiency was 20 per cent - 60 per cent. The separator may find application in shape separation of ceramic powder, metal powder or industrial diamond powder.

Jan 1, 1993

By J J. Plumb, P D. Franzmann

A study was conducted to describe the microbiology of the MICCL Monywa chalcocite heap bioleaching operation. Microorganisms were detected in the heap using culture-based techniques and cultureindependent PCR-DGGE analysis of the 16S rRNA gene. The metabolic requirements, temperature and pH optima were determined for selected strains isolated from the heap material. Six strains (BH1-BH6) were enriched and isolated from heap solids and leachate samples. Phylogenetic analysis of the 16S rRNA genes showed that strains BH3 and BH4 were closely related to the acidophilic bacterium Acidithiobacillus caldus and strains BH5 and BH6 were closely related to Leptospirillum ferriphilum. The optimum growth temperature for L. ferriphilum was 41.3¦C and the optimum pH range was 1.1 to 1.5. A new species of Archaea was isolated from the heap samples. Cells of the proposed species, Ferroplasma cyprexacervatum (æcyprusÆ L.n. meaning copper; æexacervoÆ L.v. meaning æto heap upÆ), are non-motile pleomorphic cocci, capable of chemomixotrophic growth with ferrous sulfate and yeast extract. Cells grow anaerobically on ferric iron in the presence of potassium tetrathionate and yeast extract as electron donors. Growth occurs from 14¦C to 63¦C, with an optimum temperature of 55.2¦C. The optimal pH for growth was 1.0 - 1.2. The species was phylogenetically most closely related to Ferroplasma acidiphilum with a 16S rRNA gene sequence similarity of 95 per cent. Molecular analysis of mine samples (16S rRNA PCR-DGGE) detected the above-mentioned cultured strains of microorganisms as well as species of Sulfobacillus and other unknown Proteobacteria. The microbial community of the Myanmar bioleach heaps contained similar levels of diversity to a dump bioleach operation in Chile, but contained greater amounts of biomass than another heap bioleach operation in Australia. The operating parameters of the Myanmar heaps (low pH and moderate temperature) have selected for the growth of moderately thermophilic microorganisms that are more commonly found in extremely low pH acidic mine drainage sites than in heap systems. The novel species of Ferroplasma is thought to be involved in the aerobic and anaerobic cycling of iron within the heap bioleaching environment.

Jan 1, 2004

By R Chinamatira

Several technical and economic factors have to be taken into consideration in developing an optimal mining method. This paper describes some of the important factors learnt during the evolution of the sublevel cave mining method at Trojan Nickel Mine, part of the Bindura Nickel Corporation (BNC) in Zimbabwe. Sublevel caving (SLC) has been successfully implemented at Trojan mine since its introduction in 1994. The method has evolved over the past six years into a system that has brought about improvements in efficiencies and productivity. Although the original design parameters used were sound and provided a solid foundation for the system, they needed to be optimised to get the best out of the mining method. Improvements and changes have been made in areas such as the drilling process, charging and blasting techniques, ring pattern design, development size and shape, and the draw control system. This has enabled the mine to develop an SLC operation that is efficient and innovative. Experience gained, together with the theory available has given us a much better understanding of the system. This knowledge will be used in the future to enhance the system further. Given the low grades of the BNC Mines, management recognises that only through technical excellence and efficient mining can the mines reduce mining costs and maintain profitability and competitiveness on the world market. In the Zimbabwe mining industry reaction to technological change, mechanisation and advancement have been relatively slow, due to isolation and economic constraints, compared to the rest of the world. Economic difficulties prevail, with high inflation levels, a poor exchange rate, lack of foreign currency and other associated problems. Despite these constraints, the bold steps taken have transformed Trojan mine into a more efficient and competitive operation, presenting itself as the leading mine in the BNC group. Appendices give data to illustrate the benefits obtained.

Jan 1, 2000

By J A. Shonhardt, I Porter

All types of coal are liable to spontaneous combustion to a variable degree according to the inherent characteristics of the coal and also extrinsic factors. In order to successfully extract coal from highly capital-intensive longwall mining operations it is necessary to evaluate and manage any risks that may be present due to spontaneous combustion. A spontaneous combustion risk management plan for longwall mining is described in this paper. This risk management system comprises identification of conditions promoting spontaneous combustion risk, a laboratory or empirical risk classification system, determination of gas ladder, adoption of adequate ventilation plans and gas monitoring systems that will lead to the development of the spontaneous combustion action plan. The risk management system was applied to a greenfield site in NSW in 1992 when prediction of a high-risk category for the coal seam was made. After commencement of production a spontaneous heating problem emerged as predicted. Description of the case history of spontaneous combustion risk management for a longwall operation in this coal seam is included in this paper.

Jan 1, 2003

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

Jan 1, 2003

Between, 1980 and 1984, the demand for non- ferrous metals in the free world grew annually by 1.5 per cent for copper, 0.4 per cent for lead, 1.4 per cent for zinc, and 2.5 per cent for nickel. The growth rate decreased substantially compared to the rate experienced before 1980, and was far lower than the GNP growth during the corresponding period. The main reasons for this are considered to be 1. resource-saving efforts by industrialized countries resulting from the first and the second oil crises, 2. saturated demand for durable consumer goods, and 3. substitution of non-ferrous metals by new materials such as optical fibers.

Jan 1, 1986

By Moritz P

Thiourea has been recognised for a long time as an acid-stable complexant for gold. Generally, the use of thiourea has been shown to exhibit enhanced leaching kinetics compared to cyanide but suffers the disadvantage of excessive reagent consumption. Thiourea leaching is particularly com- patible with the extraction of gold from refractory ores. This is due to the need for an oxidative pretreatment to liberate the gold. Such pretreatments typically result in the production of an acidic residue. The application of novel thiourea leaching technologies to the extraction of gold from a bioleached pyrite concentrate was investigated. The interac- tion of leach variables with thiourea consumption and gold extraction was established. An economic assessment of thiourea leaching was compared with conventional cyanidation. The results indicated that gold leaching of the bioleached residue using thiourea compared very favourably with cyanidation.

Jan 1, 1991