Search Documents

By R. Dippenaar

The emergence of new steel grades is largely driven by the need to produce high quality steel at a competitive price. The principal aims are to attain ultra-high purity, (especially low interstitial elements) and ultra-cleanliness (by the control of the inclusion content and size). Whereas the steel used to build the Titanic contained 650 ppm sulphur, resulting in MnS stringer-inclusions 25 mm in length, modern quality requirements for arctic pipelines would only allow 10 ppm of sulphur and inclusions in ball-bearing steels must be smaller than 5µm. Most developments are aimed at hot-metal treatment before refining and ladle treatment after decarburisation. Because ferroalloys are added during or after the refining step, it is the secondary (ladle) refining production technologies that are of specific interest to the ferroalloy producer. Through ladle treatment, hydrogen and nitrogen contents are reduced, ultra-low levels of solute impurities are attained and the shapes as well as the composition of inclusions are modified. Steelmakers are concerned about the cost effectiveness of the use of ferroalloys such as consistent product analysis and delivery, improved financing arrangements and technical support. Minimal variation in product sizing is vital because it impacts on handling problems and because particle size determines the rate of particle dissolution. The required ferroalloy product quality depends on the specific use but in general sulphur, phosphorous and nitrogen contents are of concern. Apart from the presence of trace and impurity elements, ferroalloys also contain inclusions. For example, ferromanganese may contain MnO-MnS-SiO2 inclusions while high-carbon ferro-chrome may contain different kinds of Cr-Mn-spinels. The presence of these impurities and inclusions has a significant impact on steel production techniques and cost and hence, on the selection and use of ferroalloys. The interrelationship between ferroalloy quality and steel production technology is plant and product specific and hence, effective communication between ferroalloy suppliers and steel producers is essential.

Jan 1, 2004

By Maurizio Siepi

The realisation of most of the civil engineering works is subordinate to the execution of consolidation works, in order to improve the soil physical-mechanics characteristics. The works classifiable with the term "Soil Improvement" can be realised using several technologies, among which the Deep Mixing Method is distinguished for his remarkable flexibility and productivity characteristics. The Deep Mixing Method is a process whereby a rotary drilling machine mechanically drills a constant diameter hole while cement slurry is injected into the soil at high pressure. The process combines state of the art construction techniques merging mechanical and hydraulic mixing energies at the tool bit. The result is a soil-cement column of engineered strength, consistency and dimension. Whereby the soil cement column formation process is controlled by a computerised device, the result is a speedy installation, thorough mixing, and a high degree of control, repeatability and documentation.

Jan 1, 2002

This paper presents a virtual prototype for the stress analysis of cable shovel components based on combination of flexible and rigid body approach. The general mechanical system of the cable shovel is modeled as a multi-body system with rigid and flexible bodies. The relevant theories applied for the dynamic model are described in terms of Lagrangian multi-body dynamics and finite element method. A virtual prototype of the cable shovel is built in the Automatic Dynamic Analysis Mechanical System (ADAMS) environment, which allows visualizing the motion of general mechanical system and analyzing the dynamic stress of structural components of the cable shovel. An example is given to perform dynamic stress of durability analysis for the boom and handle. Attention of this study is devoted to the mechanisms of damage of the cable shovel and also the critical high stress areas. Keywords: Cable shovel, Von Mises stress, Virtual prototype simulation, Stress virtualization.

Jan 1, 2009

By D. J. Adams, W. K. Rymon-Lipinski

Rock engineering plays a crucial role in contributing to sustainable development in South African mining. A framework for this has been created through legislation and structures to encourage the mining industry to have a long and prosperous future. However, rock engineering input is an essential element to achieving success. The most accessible deposits have been mined in South Africa and although large reserves still remain, many of these are difficult to access and will require excellent rock engineering knowledge and skill in the future. This is borne out by the fact that more than 50 % of fatal accidents are related to rock engineering issues. Many of these may be addressed with rock engineering solutions which are not beyond current rock engineering technology. A reduction in fatalities and injuries contributes to a sustainable mining industry.

Jan 1, 2003

By D. B. Sikka, R. B. Bhappu

Porphyry-type copper-molybdenum (Cu-Mo) deposits typically occur in the Phanerozoic rocks and have been well-documented. During the past two decades, a number of porphyry-type Cu-Mo deposits that range in age from 1055 Ma to 2970 Ma have been identified in the Precambrian rocks of Australia, Canada, China, Finland, India. Namibia and Zambia. The Malanjkhand porphyry copper deposit M.P., India is estimated to contain 789 Mt (870 million st) averaging 0.83% copper (mill headgrade); 0.004% molybdenum; 0.2 g/t (0.006 oz/st) gold; 6 g/t (0.175 oz/st) silver and a cap of 7.5 Mt (8.2 million st) of oxide ore averaging 0.8% copper. The economic potential of the expanded copper mining milling, smelting and refining complex is expected to yield cathode copper 118.6 kt (130,700 st); molybdic oxide 830 t (914 st); gold 1.9 t (61,732 oz); silver 46.6 t (1.5 million oz); sulfuric acid 240 kt (264,500 st), copper from leach dumps 11.5 kt (12,600 st); nickel 24 t (26,400 st); cobalt 84 t (92,600 st); bismuth 16 t (17.6 st); selenium 48 t (53 st), tellurium 4.8 t (5.3 st).

Jan 1, 1995

By H. Walqui, C. Noriega

Southern Copper Corporation (SCC) is one of the world’s largest copper companies and is finishing the modernization of the Ilo copper smelter. A single ISASMELTTM furnace will start smelting 1,200,000 tons per year of concentrate at the end of 2006. Three existing Peirce Smith converters are being upgraded plus a new one for converting the matte to blister copper is being installed. Two new anode furnaces and a twin anode casting wheel have being operating since January 2006. This represents one of the main changes in the process because the final product of the smelter is now anode copper instead of blister copper. A new oxygen plant, acid plant, and others facilities are in the ramp-up stage. This environmental project will ensure that the new smelter will comply with the environmental regulations of Peru by the end of January 2007. This paper summarizes the background to the modernization project, describes the different stages of the project including engineering, procurement and construction, describes the main areas of the new copper smelter and also the pre-operational testing, commissioning and start-up of them. This is a brown field project with a target of reducing as much as possible the production losses of the existing operation. This paper presents the details of the development of the Ilo Smelter Modernization Project and explains the main aspects of the new facilities, the products to be obtained and the associated facilities for their commercialization, including a Marine Trestle for bulk acid exportation.

Jan 1, 2007

By P. M. Johnson

A design for a laser-powered optical interferometer, using a specimen whose thermal expansion is to be measured as part of the optical system, was conceived and applied in a prototype dilatometer. The object of thin work was the development of an absolute dilatometer capable of use at elevated temperature, particularly above 1,000° C. The prototype has been operated at temperatures exceeding 1,510° C. Results obtained with this device agree within 2.5 percent with the published data for the coefficient of expansion of columbium.

Jan 1, 1968

By M. Nete

Qualitative analysis of three mineral samples from northern Mozambique was accomplished by X-ray diffraction (XRD), microscopy, scintillation, and magnetic determination. Chemical characterization was accomplished using ICP-OES and pressed powder XRF after dissolution using microwave-assisted digestion and flux fusion. The samples consisted of a mixture of minerals with tantalite as the major component, with minor amounts of microlite, quartz, mica, accessory garnet, and tourmaline. Incomplete dissolution was obtained using microwave digestion, with maximum recoveries of 90.25 ± 0.06% and 88.90 ± 0.04% for Nb2O5 and Ta2O5 respectively. Complete dissolution using Li2B4O7 resulted in recoveries of 98.5 ±0.2% Nb2O5 and 100.4 ± 0.3% Ta2O5.

Jan 1, 2012

By G. Bierie

The conveying of bulk materials is prone to problems. These problems can reduce the capacity and efficiency of the plant, and even threaten the health and safety of the workforce. This presentation will look at new conveyor technologies systems, and how, used separately or in combination, they can improve material handling.

Jan 1, 2007

By William Reisz

Over the years as surface mining operations have become more sophisticated, angle drilling has become a more popular blast design technique, especially in areas where overburden and stripping ratios have increased. Another method of blast design is the staggered pattern, which greatly improves explosives distribution within the blast. While both methods present some engineering challenges, this paper will discuss how the two methods can be combined to enhance fragmentation, improve cast percentage, drill production ratios and highwall control. A practical engineering approach will be presented as well as a discussion on the discipline required to maintain a quality blasting plan.

Jan 1, 2002

By Aly M. Mohammad

The Delaware River Tramway will link civic and retail developments in Philadelphia, Pennsylvania and Camden, New Jersey. Twin 300-foot towers will anchor the cables at either side of the river. Four high capacity drilled shafts designed by the Geotechnical Department of DMJM+HARRIS support each of the towers. At the Philadelphia tower, each 6-foot diameter shaft extends 130 feet deep and terminates with a 30-foot rock socket. The shafts are situated within the footprint of an existing relieving platform, which complicates the typical construction sequence. Also, the subsurface conditions at the site provide a unique challenge in both the design and construction of the drilled shafts. During the construction of the four-drilled shafts for the Philadelphia tower, a 6000-ton Osterberg load test was performed on the first shaft to verify design assumption and confirm the shaft capacity. The results of the test were utilized to establish load transfer characteristics and develop foundation design parameters suitable for the site conditions. By doing so the Design Engineer was able to reduce the length of the rock sockets on the remaining production shafts by approximately 5 feet per shaft. As a result, the test provided a significant cost saving to the Owner by eliminating 15 feet of rock drilling from the construction costs. This paper presents a description of the unique design and construction methods adopted for the foundations, also on the Osterberg load test including equipment used, number and locations of strain gages, and interpretation of results. The results and findings presented in this paper could benefit both the design and construction industries because it provides a comparison between geotechnical design assumption and actual field measurements; which has always been a challenge particularly for rock formation.

Jan 1, 2002

By F. Mendaña

The characteristics of the igneous and metamorphic bedrock, extra-hard and abrasive, of the Guadarrama Tunnels, a bi-tube project of length 28.4 km without any intermediate attack, are first commented upon. Next, a detailed discussion is given of the most relevant aspects of the performance of the four double shield type TBMs. The experience of this leads to various recommendations to be borne in mind in future designs of TBM having to work in rock of similar characteristics.

Jan 1, 2007

By K. Woo

The increasing move to block cave mining methods (including sublevel and panel caving) to access deeper and lower grade ore deposits as near surface sources become exhausted raises questions as to the extent and magnitudes of caving-induced subsidence as it may affect strain-sensitive infrastructure on surface. Predicting these surface deformations is difficult as they tend to be discontinuous and asymmetric due to large movements around the cave controlled by geologic structures, rock mass heterogeneity and topographic effects. Of further impediment is the sparse number of case histories available, in which actual subsidence measurements are reported to provide guidance and empirical constraints for subsidence calculations. This study reports the development of an exhaustive and comprehensive database of available (i.e. public domain) subsidence data from block cave mining operations from around the world.

May 1, 2009

By Christopher Mark

Colombia is 11th largest coal producing nation in the world, and the world?s fifth largest coal exporter. But while most of Colombia?s coal is mined at large modern surface mines located near the Caribbean coast, there are also underground mines that produce high-grade metallurgical coal. These mines employ traditional hand-loading techniques in a variety of geologic environments, and they have some of the highest accident rates of any Colombian industry. The National Institute for Occupational Safety and Health (NIOSH) has been collaborating with POSITIVA, the primary provider of worker?s compensation insurance to the Colombian underground coal industry, to reduce the economic and social cost of rock falls in these mines. The specific goals of the collaboration are to 1) document practices and conditions in Colombian underground coal mines, 2) identify relevant international best practices, and 3) provide recommendations for developing a national campaign to reduce fatalities and injuries associated with roof falls. NIOSH conducted a survey of seven underground coal mines in four separate coalfields. Five of the mines were characterized by steep dips and weak roof and floor rock. The coal was loaded by hand at all seven mines, though two employed partially mechanized longwall techniques. Wood posts were by far the most common ground support. Roof bolts were not observed in use at any of the mines, and they are unlikely to replace timbers any time soon. While long-term entries generally appeared to be adequately supported, the survey found that less attention was paid to the temporary support that is installed right after the coal is removed. This temporary support is critical for protecting the workers from rock falls, however, because with hand-loading mining methods most of the activity takes place between the permanent supports and face. The study concluded that improving the temporary support in the working faces would be the most effective way to reduce the number of rock fall injuries. The key principle should be that every worker is protected by planned roof support at all times. Ground Support Management Plans, consisting of specific rules about when, where, and what roof support is to be installed, should be the focus of the campaign. Each Plan should be tailored to a specific mine based on the geologic conditions and mining methods in use. The Plan provides miners with clear, simple rules that can be easily understood, while management can easily check to see if it is being followed. Ground Support Management Plans will also provide the campaign with a concrete focus for the necessary cultural change.

Jan 1, 2014

By Bruce W. Woolpert

During the SME Board of Directors’ midyear meeting in Monterey, CA Aug. 25, I discussed trends in the construction aggregates industry. Many construction-material suppliers may not have yet fully internalized the changes that are taking place. But the changes are significant. And they have shifted the focus in the aggregates industry from “assets” to “people and innovation.” Construction-material suppliers serve many customers. A typical quarrying operation at Graniterock would have more than 1,000 customers, mostly civil engineering contractors. Along with the push toward people and innovation, there is increased emphasis on vertical integration from aggregates to ready-mix concrete and hot mix asphalt, to final construction. If a company is not vertically integrated, it will at least have strong partnerships with other firms, to deliver a high-quality finished project on time.

Jan 1, 2002

By Jilai Xue

Fe-Ni alloys can be used as raw material in making stainless steel. Laterite nickel ore is one of mineral resources for producing nickel alloys. In this work, the laterite ore after dehydration at 800 °C and the anthracite as reducing agent were mixed for pre-reduction at 900 °C, and then reduced to form Fe-Ni alloys at 1550-1620 °C through carbon-thermal reduction process. A high Ni-content alloy component in the metallurgical mixture can be formed through pre-reduction. Better separation of the resulting metals from the slag is found with lower Ni-content alloys produced or higher temperatures during reduction. An effective processing of Fe-Ni alloys needs further understanding of the process fundamentals and optimizing of the process parameters.

Jan 1, 2010

By A G. Thompson, E Villaescusa, A De Zoysa, J R Player

Ground support performance is critical to the safe and economical extraction of ore. This is particularly important for mass mining extractions at great depth, which are currently being considered by a large number of mining companies worldwide. As the in situ stresses concentrate around critical excavations, failure occurs at the excavation boundaries and ground support is required for the excavations to remain safe and accessible for their intended lifespan. Ground support consists of reinforcing elements that are installed within the rock mass to modify its internal behaviour (generally to within one excavation radius) and surface support elements that are installed at the exposed boundaries to retain the failed pieces of rock. For surface support to be effective, the loadings need to be transferred to the reinforcing elements; however, the combined performance of rock bolts and mesh is poorly understood in terms of the energy dissipation capacity available for a typical ground support scheme implemented at most mass mining operations.Over the last 15 years or so, a large number of large-scale laboratory experiments have been completed at the Western Australian School of Mines (WASM) Dynamic Test Facility for reinforcement systems and surface support systems loaded separately. The objective of more recent testing has been to establish the combined energy dissipation capacity of typical and enhanced reinforcement systems combined with mesh surface support. Total energy dissipation has been separated into energy dissipation attributable to the reinforcement and to the mesh. The results of the tests are presented and compared with the existing WASM design demand and capacity guidelines.CITATION:Villaescusa, E, De Zoysa, A, Player, J R and Thompson, A G, 2016. Dynamic testing of combined rock bolt and mesh schemes, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 789–798 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By J. Bakken, M. Th. Jonsson, G. Sævarsdottir

A typical three-phase submerged-arc furnace for production of silicon metal and ferrosilicon has arc currents ~100 kA, phase voltages ~100 V and total furnace power ~10 - 60 MW. The arcs burn in gas filled cavities or "craters", where the main atomic components of the plasma mixture are silicon, oxygen and carbon. Two quite different simulation models for high-current AC arcs have been developed: the simple Channel Arc Model (CAM), and the more sophisticated Magneto-Fluid-Dynamic Model (MFD). These models have been described extensively and results reported at INFACON-8 and INFACON-9, respectively. The coupling between the arcs and the AC power source is described by a complete three-phase Electric Circuit Model. Recent numerical modelling studies of industrial AC arcs show that the boundary conditions at the cathode and anode are critical for the simulation results. A novel Cathode/Anode Sub-Model for high-current AC arcs that treats both cathode and anode indicates a completely different cathode behaviour than previously assumed. A cathode spot which serves a high-current electric arc is shown to be dominated by the energy impact from the arc. This leads to lower cathode fall voltage than obtained from previously developed models. The anode fall voltage is negative, as the main function of the potential barrier is to repel plasma electrons. The cathode spot is diffuse in the sense that the arc in fact contracts away from the cathode. Simulation results are compared to measurements on both industrial furnaces and smaller scale pilot furnaces. An important conclusion, supported by our arc studies, is that the arc length in silicon metal and ferrosilicon furnaces does not exceed 15 cm and the arc may burn anywhere on the electrode, not necessarily beneath the electrode tip.

Jan 1, 2004

By Guillermo Turner-Saad

"Best practice in the economic evaluation of mining projects and operations is based on the integration of geological, mining, metallurgical, environmental, marketing, economic and corporate information and strategies. Fundamentally, the economic evaluation takes into account mining, blending, stockpiling, processing, smelting, refining and marketing ore resources with grades estimated by geostatistical methodologies.Nevertheless, a realistic economic evaluation consists of a concurrent and integrated optimization process that maximizes the concentrates or products of liberated and selected ore minerals from mineral deposits. The optimum solution is obtained through a trade-off among mining, blending, stockpiling and processing ore reserves with distinct mineralogy and texture characteristics. The concurrent optimization determines both the practical mining sequence of ore reserves and the dynamic and robust mineral processing flowsheet design over the expected life of mining projects and operations.A combined risk-adverse and concurrent optimization process takes into account the spatial uncertainty of the mineralogy and texture characteristics of ore reserves. Additionally, a variety of mineral processing linear, non-linear, additive and non-additive parameters modeled spatially. The spatial uncertainty of these ore reserves characteristics and parameters has a direct impact in the expected mining sequence, mineral processing flowsheet design, concentrates or products quantity and quality, and economic value of mining projects and operations.Geometallurgical domain constrained stochastic geostatistical methodologies and multivariate mathematical models are applied for spatial uncertainty modeling of ore reserves characteristics and parameters. These mathematical models correlate the mineral processing liberation and selectivity responses of the mineralogy and textures within each geometallurgical domain. These models, in turn, are defined based on results of mineral processing and environmental testwork of unbiased and representative samples chosen for their variability. These samples are selected within mutually exclusive spatial geometallurgical uncertainty domains with similar mineralogical and textural characteristics in mineral deposits.Geometallurgical domains are defined by applying and combining multivariate statistical analysis and implicit modeling methodologies. These involve determining and constraining mineral processing liberation and selectivity properties explicitly contained in the extensive and integrated exploration drillhole database."

Jan 1, 2010

By J. J. Carlson

Studies were carried out to determine whether filtration rate changes observed in an iron ore concentrator were due to variations in particle shape. It was confirmed that ores mined from different locations differed in filtration rates by as much as 60%. However, when image analysis was used to quantify the shapes of the individual particles in the filtration feed, it was found that the particle shapes showed almost no variation, and the shapes did not correlate with the filtration rate. It was also determined that the filtration rate variations were not caused by changes in particle size distribution. These results suggest that the differences in filtration rate are due to factors other than size and shape, such as surface chemistry.

Jan 1, 2008