Search Documents

By Dolf Gielen

This paper discusses the results of a Western European energy and materials systems engineering study that analyses the impact of greenhouse gas (GHG) emission reduction on the future of the steel and aluminum industry. he technology selection will be significantly affected by future CO2 policies. The avail- ability of C02 removal and storage technology and the social acceptance of this strategy for GHG emission reduction is of key importance for the strategy selection. The use of coal based smelting reduction technologies is optimal in case of weak C02 policies or in case of strong C02 policies and low CO2 removal and storage costs. The selection of CCF or Corex technology depends on the penalty regime. However, if C02 removal proves to be problematic, CCF development fails and strong C02 policies are introduced, the gas based DRI production processes will become more attractive. In both cases, the energy efficiency of the iron and steel industry will further increase in the next decades. The impact of GHG emission reduction on aluminum prices and aluminum use can be significant. However contrary to common notions the aluminum production will be positively affected by GHG emission reduction, notwithstanding the currently high emissions in aluminum production. A combination of emission mitigation in production and significant GHG emission reduction effects further down the product chain cause this effect. A significant potential exists for improved materials efficiency. This potential is generally neglected in energy efficiency and CO2 reduction studies. However improved steel qualities are of similar importance for C02 emission reduction as increased energy efficiency. It remains to see if this potential will be used to its full extent in the next decades. Model calculations indicate that the impact of C02 policies on the competition with other materials will be limited. Greenhouse gas emission mitigation will have much more impact on materials production and waste handling than on materials consumption.

Jan 1, 1999

By Anton Sroka

The German hard coal production predominantly derives from underground multiseam mining activities. Beside common surface damages, ?inner mine damages? on underground infrastructures (i.e. main roads, cross cuts and shafts) due to mining excavations occur to an increasing extent. As these "inner mine damages" dramatically increased because of the development towards high performance longwall mining technologies, this matter raised to be a severe problem concerning mining economics. To protect durable and long lasting underground infrastructures, precautionary measures such as suitable mine layouts, adapted planning of mining operations and moderate face advances have to be considered. Some examples of "inner mine damages" recorded by means of mine surveying methods are given in this paper. An empirical-mathematical model based on the principles of mining subsidence engineering methods will be introduced. This model allows to minimize ?inner mine damages? and helps to support and optimize mining processes.

Jan 1, 1999

By P To, A Sharp-Paul, S Jones, C Monahan

A key environmental management issue associated with mining projects is tailing disposal. In high rainfall environments this is particularly challenging and generally requires the discharge of excess water from a tailing dam to adjacent streams or coastal waters. Such discharges can potentially have adverse impacts on downstream water quality and the environmental values associated with these waters, such as providing a drinking water supply for local villagers, maintaining a fisheries resource or protecting a fish species of high conservation significance. An alternative to the construction and operation of a conventional tailing dam is Deep Sea Tailing Placement (DSTP). The key features of such a system are:Discharge of the tailing slurry at considerable depth (approximately 120 - 150 m) below the oceanÆs surface. This requires a pipeline to be laid from the process plant to a mix tank, where the tailing is mixed with seawater and entrained air released. The pipeline then continues down the ocean floor to the required discharge depth, which is below the surface mixed layer and the euphotic zone. After discharge, formation of a density current which continues to descend along the ocean floor as long as the slope is sufficiently steep. Final deposition of the tailing in an area where the slope of the ocean floor is insufficient to maintain the density current. This typically occurs at depths of more than 800 m. Water quality issues associated with DSTP include: Impacts on the oceanic water column due to the formation of subsurface plumes which break away from the descending density current. The occurrence of elevated concentrations of contaminants in the interstitial waters of the deposited tailing solids. Fluxes of contaminants from the tailing deposits into the overlying oceanic water column. This paper discusses the water quality aspects of DSTP with particular reference to a case study in Papua New Guinea. The evaluations undertaken as part of the DSTP impact assessment included consideration of both the short- and long-term chemical behaviour of contaminants and bioassays, within the appropriate water quality assessment framework.

Jan 1, 1999

By John Frostiak, Lloyd Buckingham, Kenneth G. Thomas, Luis Wilson

"The El Indio roasting facility associated with El Indio Mine in Central Chile has operated since 1981. It is a facility developed to remove arsenic and antimony from gold bearing enargite/pyrite flotation concentrates.The three installed roasters are Nichols Herreschoff units each with 14 hearths and measuring 4.85 metres diameter. Hearths are rabbled by central shaft driven rabble arms. Product is progressively heated to 750°C under neutral to reducing atmospheric conditions to drive off labile sulphur, arsenic and antimony.Ancillary equipment includes skip hoist feed arrangements, water cooled screw conveyors for transporting and cooling calcine, gas cyclones, post combustion chambers, heat exchangers, electrostatic precipitators, bag houses, gas scrubbers and packaging facilities .Operating practices, history, mineralogy and results are reviewed. The improvements to arsenic and antimony extraction, ambiental conditions and environmental achievements are discussed.INTRODUCTIONHistoryThe El Indio property lies in the El Indio belt, a copper, gold and silver area approximately 175 km long by 10 km wide. The property is located in the Andes Mountains of the central part of Chile at latitude 30"" South and 160 km from the sea-side city of La Serena. Plant location is at 3850 meters above sea level.The property currently consists of two underground mines feeding the El Indio plant and an open pit feeding the newer Tambo leach plant. The property has been controlled by a succession of owners (St. Joe Minerals, Fluor, Bond Gold International and Lac Minerals Ltd.) before acquisition by Barrick Gold Corporation in 1994."

Jan 1, 1999

By Weber P, Sneyd S

The total world steel production in 1998 amounted to approximately 780 000 000 t. The share of electric steelmaking was in the range of 35 per cent and is expected to increase further to over 40 per cent of the world's production within the next ten years. As electric steelmaking is primarily based on the use of scrap and as it is progressing more and more into higher steel grades the need for low-residual metallics will become increasingly important. Consequently, the demand for scrap substitute material will increase, reflected in the world wide spate of interest for DRI (Direct Reduced Iron) and HBI (Hot Briquetted Iron). The increased significance of DRI/HBI as a substitute for steel scrap has obviously emanated also from its comparatively lower and more predictable costs per ton and definable chemistry. In 1998 already 37 million tons of DRI/HBI were globally produced.

Jan 1, 1999

By M. H. Rogers

Coal has been at the forefront of mankind?s drive to improve his quality of life and also for sustainable development, from the Industrial Revolution onwards. The international coal industry today is large, with some 3,7 billion tons being produced and consumed in 1997. South Africa is an important participant in the coal industry, selling some 220 million tons in 1997 of which 64 million tons were exported. It is the second-largest thermal coal exporting country in the world. Despite the size of the world coal industry, it is not immune to change. The address examines growth projections for the industry and the change drivers that will impact on it in the future. Environmental pressures, the most important of which being the climate change debate, the Kyoto Protocol arising from this debate and the development of clean coal technologies, to reduce the impact of coal production and usage on the environment are considered. Other major change drivers considered are competition from other sources of energy and that between coal producers, the deregulation of the electric power industry, corporate restructuring and for the South African producer, legislative reform. The declining (real term) coal price, the consequent squeeze on margins and the need for producers to actively contain costs is covered. Technology has, in the past, been the driver behind the growth and change of the South African coal industry and its future role in ensuring that coal is the fuel of choice for continued improvement in standards of living and economic development is addressed.

Jan 1, 1999

It has been proven theoretically and experimentally that the use of 10 - 30 per cent DRI in blast furnace along with iron ore or sinter results in lower coke rate and higher productivity. However, to-date this remains unpractised on a regular basis mainly because of economic reasons. The DRI produced by several methods are expensive and difficult to store/handle in large quantities because of its reactive nature and thus DRI in blast furnace remains unacceptable.

Jan 1, 1999

By Tracy Lucas, Ian Hamill

"Issues of importance in the area of continuous casting centre around product quality. This can be affected by particle inclusions transported into the mould from upstream processes and by draw-down of particles from the meniscus. Turbulence of the meniscus can increase the latter and is also detrimental to product surface quality.Suitably validated Computational Fluid Dynamics (CFD) modelling can provide the operator with an efficient tool with which to investigate the effects of changes to the design and operation of the caster and associated plant.In this paper, examples are presented of the use of the CFD software, CFX, to simulate:•,free-surface shape and turbulence in the mould using deforming meshes•,solidification in the mould using a fixed-grid, source-based method•,argon gas injection through a submerged entry nozzle using a full multiphase model•,inclusion motion and removal in tundishes using an algebraic slip model.The CFD simulations of the free surface shape are complemented by detailed Particle Image Velocimetry measurements performed on a full-size water model of a thin-slab mould and upper strand. Close agreement is demonstrated between the predictions and experiments."

Jan 1, 1999

By M Malec, J Szczerbinski

Hazards in underground mines are concomitant with the mining of mineral deposits and have their source in a minerÆs work environment. The authors of the paper have undertaken a trial classification of these hazards into three groups, depending on the sphere of their occurrence:lithosphere, ie rock mass, atmosphere, ie air in mine workings, and technosphere, ie machines, equipment and facilities in mine workings. The lithosphere creates such hazards as bumps, rock outbursts, the atmosphere is a factor causing fires, methane explosions and climatic hazards, whereas accidents concomitant with an operation of machines and equipment occur in the technosphere. Assuming that the number of accidents in the mining industry, concomitant with hazards, reflects the degree of safety, it has been shown, that in Poland they are under control to a large extent.

Jan 1, 1999

By Y. V. Swamy, B. Bhoi, H. S. Ray

Low-grade manganese ores with low Mn/Fe ratios can he enriched through selective carbon reduction of iron oxide to magnetite followed by magnetic separation o f the magnetite. Thermogravimetric analysis (TGA) was used to assess the preferential isothermal reduction of pure M1702 and Fe2O3 using solid carbon. This was followed by reduction of a synthetic analogue of composition comparable to an actual low-grade ore (i.e., Sandur manganese ore, Sandur, India). The carbothermic reduction of the manganese ore converts the hematite and goethite minerals to magnetite (Fe3O4), with the magnetite then going into the magnetic, fraction. The resultant nonmagnetic ,fraction becomes depleted of iron with an enhanced manganese content. These results show that it is possible to reduce the iron from 22% to 5.85%, thus increasing the Mn/Fe ratio from 1.52 to 6.2 with a manganese recovery of about 50%. The recovery was, further improved by grinding the magnetic fraction to -75 µm.

Jan 1, 1999

By Jorj O. Osterberg

The Osterberg (O-Cell) Method makes it possible to separate the side shear resistance (skin friction) from end bearing. The O-Cell is placed on or near the bottom of a drilled shaft and after the concrete is poured and cured, an equal upward and downward pressure is applied. From the test, the load-upward deflection curve in side shear and the load-downward deflection curve in end bearing are drawn. Typical curves are shown where the ultimate load in side-shear is reached and where the ultimate load in end bearing is reached. Several examples of tests in which the test load reached ultimate loads far in excess of what was expected are shown. The side shear in rock sockets is shown to be much larger than generally estimated. Examples are given of where side shear is smaller than expected and the reasons discussed. Disturbance of the sides of drilled holes due to poor construction techniques and ways to avoid these conditions are considered. Examples of bottom hole disturbance are given and ways to prevent the disturbance are discussed. A graph showing the actual measured capacity of drilled shafts compared to the estimated capacity as a function of the hardness and strength of the soil or rock is presented.

Jan 1, 1999

By K Akiro

Volcanogenic massive basemetal sulphide and gold mineralisation of predominantly low sulphidation style has been located within Lower Tertiary basaltic and felsic volcanic and sedimentary sequences at Ufuo, in the Left April River area, northwest Papua New Guinea. The four discrete massive sulphide bodies, which have been so far identified, occur within a 3 +5 km area situated within a north west trending structural corridor. The sulphide bodies are all localised on the margins of the corridor where the bounding major through going faults are transected by regional faults. Mineralisation is characterised by massive pyrite-bornite-sphalerite-barite-quartz-anhydrite deposition with later galena-tennantite-chalcopyrite. Minor phases include enargite, goldfieldite and bismuth sulfosalts. Jasperoidal silica lenses and bioturbated sediments are closely associated with the massive sulphides. Basemetal sulphide mineralisation is also closely associated with phyllic-style quartz-sericite- altered host rocks underlying the massive sulphide lenses. This mineralised phyllic alteration is localised to fractures, veins and breccias that cross-cut propylitic style alteration characterised by quartz, epidote, chlorite, adularia and zeolite. The mineralised system possesses several hydrothermal features consistent with a copper-rich submarine exhalative volcanic hosted massive sulphide (VHMS) system, ie discrete massive sulphide bodies with abundant barite, associated jasperoidal silica and bioturbated sediments. However, exploratory drilling of the alteration zone underlying each of the massive sulphide bodies has not identified a well-defined zoned alteration pipe that is characteristic of such systems. The alteration is also similar to that of a porphyry-related low sulphidation system in which phyllic alteration has overprinted a regional propylitic style assemblage. The presence of sporadic enargite (and ?tennantite/tetrahedrite) suggest there were intermittent pulses of acid fluids in the system probably derived from exsolved magmatic SO2 which flowed directly to the surface along reactivated faults. The occurrence of tellurium and bismuth minerals is also consistent with a magmatic contribution to the metalliferous hydrothermal fluids. It is proposed that the VHMS orebodies are the products of submarine exhalative deposition generated by a crystallising magma emplaced within crust of on-going tectonism. Ufuo mineralisation is similar to many VHMS deposits elsewhere in that it is unclear whether the metals are derived from the magma directly, or via seawater leaching of the wallrock. Additional studies such as oxygen isotope analysis may assist in resolving this issue. If the metals are shown to be of direct magmatic origin then there may be good prospects for discovering economic-grade porphyry-related mineralisation at depth below the massive sulphide deposits.

Jan 1, 1999

By Fogarty J. G H

Ausmelt Technology has a unique capability of removing the impurities, phosphorus and sulphur, from the feed materials to the process. Sulphur is removed to the gas phase almost completely because of the interactions of ore and coal in the reaction region at the top surface of the slag bath. Phosphorus is removed to the slag phase, with both basic and higher, controlled iron oxide levels in slag being achieved in the process. The significance of these features of the process relate to the production of pig iron with very low levels of these impurities for the further processing to steel, and to the treatment of high phosphorus and high sulphur raw materials. The marketability of pig iron and the raw materials are discussed in relation to this feature of Auslron.

Jan 1, 1999

By K. Pathak

Loaders and dump trucks are the most commonly used surface-mining equipment. Negligence of the safety-engineering aspects of dump trucks may result in serious accidents in a mine. A reduction in the risk of an accident due to the deployment of trucks can he achieved by engineering analysis, risks assessment, improved safety features, active safety devices, condition-based maintenance, in-built protection systems, etc. This paper presents some cases of accidents in Indian surface coal mines and advocates a systems approach to safety.

Jan 1, 1999

By J. Nielen van der Merwe

During the process of pillar extraction at the Welgedacht Colliery, an unexpected pillar collapse resulted in the entrapment of equipment. The area was visited soon after the event to evaluate the stability of the area for the purposes of extracting the equipment. It was found that the area had stabilised sufficiently to allow work without undue risk to the safety of workers. The equipment was reclaimed successfully. A subsequent investigation into the reasons for the collapse was conducted. It entailed detailed underground and surface subsidence observations and numerical modeling. It was found that none of the perceived negative factors that were present at the time could result in pillar loads that were sufficient to cause the collapse. It was concluded that the local pillar strengths were less than the nationally used value and that they were possibly further reduced by aging.

Jan 1, 1999

Direct reduced iron (DRI), produced by the reaction between iron ore and reducing gasses, is used as a source of low-residual iron, in addition to ferrous scrap and pig iron, in the production of steel mainly through the electric arc furnace (EAF) route of steelmaking. The main DRI technologies in use are those of Midrex and Hyl, but in recent years a myriad of newer processes emerged based on variations in feedstock, reducing agent and fuel sources. Since the beginning of the nineties, DRI has increasingly emerged as a cheaper, low-residual iron feedstock for EAFs, which have traditionally relied almost entirely on ferrous scrap feed. The main stimulus behind the interest in DRI has been the increasing popularity of the EAF and the ?mini-mill? set-up as the favoured steelmaking option compared to the traditional and much less flexible blast furnace/ basic oxygen converter. This, however, has been creating a problem with regard to availability of low-residual scrap, resulting in upward pressure on high quality scrap prices and leaving DRI, traditionally the ?expensive alternative?, as a much more competitive consideration. The second main determinant has been the increasing production efficiency of existing steel plants which, in the light of improvements such as continuous casting and near net shape casting, has been constraining the supply of low-residual domestic scrap, traditionally the prime source of EAF feed. The explosion of current and proposed DRI projects has been accentuating the mounting interest of global role-players in assuring the availability of reliable sources of low-residual iron units for the future, especially in cases where definitive competitive advantages exist with regard to proximity to primary sources of iron ore and fuel (gas or coal).

Jan 1, 1999

By Toshia Ishii, Jun Kubota, Noriko Kubo

"For steel continuous castings, it is essential to control molten steel velocity at the meniscus, since the velocity is closely related to surface defects on the resultant products. Argon gas is supplied with molten steel into the mold through the submerged entry nozzle to prevent nozzle clogging. In this study, to investigate the influence of argon gas on molten steel flow, a numerical simulation was carried out by a two-phase model. Simulation results indicate that as argon gas bubbles ascend near the nozzle by their buoyancy, they induce the molten steel flow with them and resulted a meniscus molten steel flow from the nozzle to the narrow face of the mold. This flow direction is opposite to the case without argon gas. The calculated data are compared with the experimental data. The comparison shows generally good agreement between the measured and the calculated data. IntroductionIn a steelmaking process, molten steel carried by a ladle is first fed into a buffer vessel called tundish. From the tundish, it is then fed into a continuous casting mold. Molten steel solidifies gradually in the mold (the primary cooling zone) forming a solidified shell. As the solidified shell is just thick enough to support the molten steel at the mold exit, it is withdrawn through the mold by pinch rolls. It is progressively thicken as it is further cooled with water sprays in the secondary cooling zone. At the end of guide roll zone, completely solidified steel is cut into desirable lengths. Schematic view of a typical continuous casting is shown in Figure 1."

Jan 1, 1999

By A J. Burchell

The introduction reviews the tunnelling carried out in Singapore since the early 1980s. Between 1983 and 1990, Phases 1 and 2 of the mass rapid transit system were constructed. These included some 20 km of bored and cut and cover tunnels together with 18 underground stations. Some particular points of interest in this massive project are briefly commented upon. Reference is also made to other underground or underwater schemes undertaken during this period such as the proposed large caverns project and the submerged tunnel to Pulau Seraya. A description of the subsurface works, now under construction in Singapore, follows. This includes an all underground North-East railway line 20 km long with 16 stations. At a budget of US$ 3 billion, this is a major civil engineering undertaking. Another project is the extension of the railway to Changi Airport which involves 3.5 km of twin tube tunnelling together with a major underground station which is fully integrated into the airport terminals. An on-going program of further major railway extensions over the next 10 to 15 years is in place and an outline is given of some of the most important underground sectors. Other proposed projects such as the underground roads system and the deep level sewers are briefly described. Together they demonstrate the very significant volume of underground construction scheduled for the next century in Singapore.

Jan 1, 1999

By W Valery, S Morrell

In the mining industry blasts are usually designed to fracture the in situ rock mass and prepare it for excavation and subsequent transport. The run of mine (ROM) fragmentation is considered good when it is fine enough and loose enough to ensure efficient digging and loading operations. Mining optimisation strategy is hence usually focussed on minimising total mining costs and maintaining these ROM fragmentation characteristics. Although this approach ensures an efficient mining operation it ignores the potential impact on crushing and grinding. Investigations by several researchers have shown that designing blasts to produce ROM fragmentation to optimise crushing and grinding performance enhances the overall efficiency and profitability (Eloranta, 1995; Kojovic et al, 1995; Bulow et al, 1998; Kanchibotla et al, 1998; Scott et al, 1998; Simkus and Dance, 1998). Field experimentation in this area is often found to be difficult because of high implementation costs and insufficient understanding about the effect of fragmentation at different stages in a comminution circuit. Modelling and simulation of blasting and comminution processes provide a more economic alternative to explore the impact of blast design changes on the down stream operations (Kanchibotla et al, 1998; Kojovic et al, 1998; Adam and Siddall, 1998; Bulow et al, 1998). However, the reliability of such simulations depends on:the ability of the models to reproduce the physical processes that take place; characterisation of rock mass in terms of its blastability and comminution characteristics; and in the case of blast modelling the ability to predict fines (-10 mm) has been found to be particularly important as this fraction has a significant effect on mill throughput.

Jan 1, 1999

By Joseph P. Sobanski, Michael P. Bruen

The North Branch tunnel segment of the Tunnel and Reservoir Plan Mainstream System consists of 14,075 m (45,885 ft) of 9.2 m (30.2 ft) finished diameter and985 m (3,232 ft) of 2.5 m (8.25 ft) finished diameter concrete lined rock tunnels. The TBM mining and concrete lining methods used in completing this $166million project differed from “typical” TARP construction methods in that a two-stage concrete lining was placed and the lining was initially placed concurrently with TBM mining as a two pass system in the same tunnel segment. For the main tunnel (9.85 m diameter), TBM mining averaged 24 m/day (79 ft/day), excluding downtime associated with two main bearing changes, and the concrete lining placement, averaged 117 m/day (380 ft/day) and 53 m/day (174 ft/day) for the invert and arch segments, respectively.

Jan 1, 1999