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By Edmonds G. A

The power station went into operation in 1931, when the installed capacity was 12,500 kVA. with a loading of 4,000 kVA. In 1936 the loading increased to 6,750 kVA. which necessitated the addition of a third set which went into operation in 1937, the installed capacity at that date being 18,750 kvA. with a loading of 7,000 kVA. This remained fairly constant until 1945, when a gradual increase was noticed, the loading in 1952 being 10,598 kVA.With the addition of the copper plant, additional generating capacity was required and it was decided to raise the installed capacity by the addition of a fourth set to 34,375 kVA. with an expected loading, when producing copper, of 20,000 kViA.MAIN POWER PLANTThis consists of three GiE.e. alternators of 6,250 kVA. or 5,000 kW. at 0.8 P.F. rating and one G.E.C. alternator of 15,625 kVA. or 12,500 kW. at 0.8 P.F. rating, making a total generating capacity of 34,375 kVA.Each alternator is driven by Fraser and Chalmers turbines at 3,000 r.p.m.SYSTEMThe main 3 phase 3 wire 3,300 volt distribution system has the neutral point of alternators earthed through by one or two earthing resistors designed to limit earth fault current to 3,000 amp. for 20 seconds, in the case of the large machine, and to 1,100 amp. for 10 seconds, in the case of the smaller machines, or full load of either size machine at rated voltage.

Jan 1, 1953

By M Spleit

A long-term production schedule for the LabMag iron ore deposit in northern Quebec, Canada is derived using stochastic integer programming. The optimisation formulation maximises the schedule’s net present value while simultaneously managing the risk of deviations in production tonnages and qualities by considering stochastic simulations of the orebody instead of a single deterministic model. The formulation also smooths and minimises haul truck requirements and ensures that as mining progresses, space is created within the mined out pit for the return of waste material.CITATION:Spleit, M, 2014. Production schedule optimisation – meeting targets by hedging against geological risk while addressing environmental and equipment concerns, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 397–404 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

The Marvel Loch Operations (MLO) plant was treating ores from up to six MLO sources and in addition needed to blend externally sourced ores with its own ores. This presented a metallurgical accounting dilemma, which was subsequently addressed by the design, implementation and testing of an automatic sampling system. The MLO automatic sampler was well designed and has been the subject of previous internal and external reviews. The sampling action is fully automated and the unit is essentially self cleaning particularly when sampling primary ores. The purpose of this paper is to document the rationale behind the design, the specific details of the sampling station, its use for ore purchase purposes and an assessment of the sampling system to meet the needs of the operator.

Mar 1, 2010

By S Coward, J Vann, R Wolff, S Jackson, S Moayer, A Bye

Uncertainty about the future and orebody should significantly impact evaluation of mining projects. Scenario planning, widely used in other industries, for example in the petroleum industry, can provide organisations with an opportunity to explore the consequences of uncertainty on their future plans. By developing plausible scenarios, scenario planning assists decision makers by allowing them to make systematic and possibly effective decisions for the future. This paper reviews existing mine project evaluation in the context of a new framework called scenario-based project evaluation (SBPE) (Vann et al , 2012) that addresses many shortcomings of existing approaches. SBPE uses conditional simulations (CS) models as inputs which are evaluated against future alternative project pathways (æalternativesÆ). These alternatives are evaluated using multiple plausible images of the deposit (CS realisations) which capture realistic variability and as an ensemble, map uncertainty of various orebody attributes at fine scale. The alternatives can involve different mining, stockpiling, blending and processing strategies. The ultimate output is a (stochastic) set of cash flows for each alternative from which financial measures, such as NPV, can be derived. Alternatives can then be explored in the presence of against external scenarios such as changes in prices, costs, and taxation. The obvious problem with such data rich results is knowing which scenarios or group of scenarios are optimal.An innovative approach to robust stochastic optimisation (RSO) suited to the SBPE framework is presented here for the first time. This approach to RSO aims to deal with the large number of alternatives generated from SPBE. The goal of applying the RSO approach to SBPE is to identify robust strategic alternatives (project configurations) which have the flexibility to deal with variability and uncertainty of geological and processing inputs such as density, grade and process performance. By applying the proposed RSO method, it is possible to deal with uncertainty and identify the best project configuration in the face of a large number of envisaged scenarios. A case study is provided, in which we have tested the application of the proposed method and compared the result with conventional methods. An important conclusion from this research is that selecting the value of the penalty coefficients in the RSO approach proposed is (as is all optimisation) an exercise of trade-offs; a higher net present value (NPV) is generally associated with a higher risk and a lower risk is associated with a lower NPV. Indeed, this is a strong argument for considering the RSO approach outlined here over more conventional approaches.CITATION:Moayer, S, Vann, J, Coward, S, Jackson, S, Bye, A and Wolff, R, 2012. An innovative approach to robust optimisation for scenario-based mineral project evaluation, in Proceedings Project Evaluation 2012 , pp 141-148 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 24, 2012

By P Navarra, R Kuhne

Dynamic simulation (discrete event simulation) is the preferred methodology to evaluate the impact of dynamic aspects of processing plants on the overall plant capacity. This tool can be used to: identify bottlenecks in the plant,justify upgrade and expansion projects by evaluating their impact, oroptimise maintenance and operating practices without disrupting the operation. Iron Ore Company of Canada's (IOC) pelletising plant is a complex operation because of multiple products, varying equipment capacity and shifting bottlenecks. Furthermore, with extensive capital requirements for projects and long lead times, a high level of confidence in project outcome is required. Therefore, a model of IOC's pelletising plant in Labrador City was constructed in 2007 by a joint IOC and Hatch team. The model includes both operational and metallurgical aspects in order to better capture the complexity of IOC operation. In this paper, the justification, boundaries, and functionality of the model are described. A comparison of simulation results to historical plant operation is given. It is observed that projects have interactions and that the benefits of combined projects are not equal to the combined benefits of the individual projects. Projects can have synergies that result in greater benefits when combined or can have overlapping benefits that result in lower benefits when combined. The power of the proposed modeling exercise lies in the ability to assess the impact of projects on overall performance.

Jan 1, 2009

By D Craw

The Macraes gold deposit is located in a low angle NE dipping (~15¦) shear zone, the Hyde Macraes Shear Zone (HMSZ) cutting greenschist facies metasediments of the Otago Schist. The shear zone is host to large volumes of mineralised schist and relatively sparse quartz veins. Early in the development of this through going shear the schist experienced an episode of hydro fracturing and fluid redistribution. As a result, presently exposed schists within the Intrashear sequence are pervaded by localised swarms of quartz filled pure extension and extensional shear fractures hosting goldscheelite mineralization. The swarms comprise networks or æstockworksÆ of veins that strike NE, are subvertical and form subperpendicular to the shear zone fabric. Vein frequency across strike is typically ~1 m-1, with most veins five to ten centimetres thick and vertically continuous for up to ~20 m. Many of the veins show delicately banded internal textures that are parallel to the vein margins. These bands/lamina indicate incremental growth and are defined by a variation in grain size or alternatively by thin slivers of wallrock schist, though typically uncommon. The majority of veins are overprinted by a weak plastic deformation, although primary structures are largely preserved. This deformation has produced subgrain structures, migration of grain boundaries with sutured margins and undulose extinction of grains. These microstructural observations possibly indicate that temperatures were around 300¦C during stockwork vein formation. In general, the mode of brittle failure that developed the stockwork veins can be directly related to lithological variation. The geometry of stockwork veins indicate that local vertical shortening and extension occurred in the Intrashear sequence of the HMSZ synkinematically with thrusting. Localised extension was mainly parallel to the structural trend; that is, it took place perpendicular to the direction of inferred thrusting. The development of lateral ramps most likely gave rise to extension in parts of the shear zone during continuous shortening to form swarms of stockwork veins.

Jan 1, 2004

By D Bradshaw, R Dunne, S Farrokhpay

It is well known that clays affect the flotation performance, and many of the refractory gold ores around the world contain clay minerals. Therefore, an ore sample from the Carlin Trend was selected for this study as these ores contain large quantities of clays. The presence of clay minerals in an ore makes it susceptible to a range of variables, such as the solution chemistry determined by pH and the chemistry of the rheology modifiers. The viscosity of the ore slurry was measured as a function of solid concentration and particle size distribution, in addition to using different rheology modifiers and pH regulators. The results were correlated with the ore flotation performance. It was found that various reagents known commonly as dispersants or rheology modifiers have different effects on the ore slurry viscosity. This study revealed that the gold flotation recovery can be improved by changing the pulp rheology.CITATION:Farrokhpay, S, Bradshaw, D and Dunne, R, 2013. Rheological investigation of the flotation performance of a high clay containing gold ore from Carlin Trend, in Proceedings World Gold 2013, pp 333-340 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By A Rantala, C Cruickshank, I Muzinda, O Haavisto, J Timperi

The production at First Quantum Minerals’ (FQM) Kevitsa Mine, located in northern Finland, commenced during the second quarter of 2012. Presently, the mine processes approximately five and half million tonnes of ore annually, producing nickel, copper and platinum group metal (PGM) concentrates. In order to support fast production ramp-up and optimise the performance of flotation thereafter, an extensive advanced flotation control solution was implemented by Outotec in collaboration with FQM Kevitsa.In addition to basic process instrumentation and process control, each of the 14 Outotec 300 m3 and another 26 cells, ranging from 20–160 m3, have been equipped with state-of-the-art systems providing froth image analysis and automatic froth speed control. Also, the flotation cell levels are stabilised with advanced feed-forward level control.The online analyser provides key feedback information of the process performance for the advanced process control (APC) system. Based on this information, APC system defines grades and recoveries according to rules defined by Kevitsa process metallurgists. This system executes the control strategies for optimising the production of concentrates.Throughout the implementation and support phases, specific and intensive attention was paid to ensure plant personnel gained full understanding of interacting with the system and how to incorporate their process experience and skills to optimise the APC strategy. This level of expertise is also a valuable asset in understanding the APC system’s contribution to the overall performance of the plant as well as providing the ability and confidence to define key performance indicators used for continuous assessment. The experiences and results from site achieved so far are discussed in this paper.CITATION:Rantala, A, Muzinda, I, Timperi, J, Cruickshank, C and Haavisto, O, 2014. Implementation of advanced flotation control at First Quantum Minerals’ Kevitsa mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 369–378 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By M W. A Asad, E Topal, D S. S Sandanayake

Underground mine planning requires an optimal stope layout as a prerequisite for the definition of an optimal production schedule. The procedure to generate an optimal stope layout considers an orebody model and economic parameters as inputs. It evaluates all possible combinations of mining blocks and creates a set of stopes by satisfying the physical mining and geotechnical constraints. Thus, the procedure is computationally complex, and generating a solution to the problem is a challenge. This paper presents an implementation of a new heuristic algorithm that solves the stope layout problem. In two case studies, the algorithm achieves 11.2 per cent and 22.5 per cent superior solutions to the industrially available maximum value neighbourhood approach.CITATION:Sandanayake, D S S, Topal, E and Asad, M W A, 2014. Implementing a new heuristic approach to the underground mine stope layout problem, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014 , pp 243–248 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 24, 2014

By S Bluhm, L van den Berg

In planning mine ventilation systems, heat issues are normally associated with deep-level mines where auto-compression and virgin rock temperatures play a major role. However, a number of mines suffer from high ambient temperatures and humidity, very steep virgin rock temperature gradients and an influx of hot groundwater. Mines in Australia and, particularly, South-East Asia have to deal with these environmental conditions, both in the operational and planning phases. These operations normally have to take heat into consideration during the planning stages at much shallower depths. In high rainfall regions, the water table is saturated and groundwater flow rates are particularly high, which add significant water heat load potential to the mine ventilation system.This paper considers the ventilation challenges associated with hot groundwater conditions in mechanised mines. The paper is based on specific project experience gained from a number of projects in the United States, Australia and South-East Asia and draws on data from mines that experience hot groundwater conditions. For one site, actual decline temperature survey measurements, modelling techniques, management strategies and design considerations are presented.CITATION:Van den Berg, L and Bluhm, S, 2015. Ventilation planning considerations when dealing with hot groundwater, in Proceedings The Australian Mine Ventilation Conference, pp 211–218 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By R Schmitt, Y Ghorbani, I McElroy, N J. Bolin, M Parian

Aitik is a large copper porphyry type deposit located in northern Sweden, currently exploited at an annual rate of approximately 45 Mt. The ore’s exceptionally low head grade of 0.25 per cent Cu and varying degrees of hardness across the entire deposit pose challenges to the two fully autogenous grinding lines, each of which comprises a primary autogenous mill in series with a pebble mill. The variability in ore grindability frequently leads to fluctuations in mill throughput. Within the framework of a geometallurgical approach, the present study investigated the relationships between ore grindability and modal mineralogy. For this purpose, drill core samples from different lithologies were subjected to Boliden AB’s in-house grindability tests. This fully autogenous laboratory-scale test generates a grindability index mainly related to abrasion breakage, which is a significant breakage mechanism within autogenous mills. The test results suggested divergent degrees of grindability within and across the selected rock types. A combination of scanning electron microscopy, X-ray powder diffraction, and X-ray fluorescence analyses was performed for the grinding products and bulk mineral samples. The resulting mineralogical and elemental properties were subsequently correlated to the parameters from the grindability tests. It was shown that the main mineral phases, such as plagioclase, quartz, and micas, correlate well with the grindability indices. Similar correlations were found regarding the sample’s chemical composition, attributable to the main mineral phases. A further inverse correlation was established between the sample’s calculated average Mohs hardness and the grindability indices. Moreover, mineral liberation information provided by scanning electron microscopy was associated with the parameters mentioned earlier. The identified relationships between grindability, modal mineralogy, and element grades may help Boliden develop a predictive throughput model for Aitik based on the mine’s block model.

Aug 24, 2022

By D P. Blair

There are two major aspects to wall control blasting – the potential for any blasthole to cause wall damage and the potential for a delayed sequence of blastholes to cause damage. The damage potential of individual blastholes is governed by standoff distance and charge weight. However, for locations sufficiently close to a highwall, dynamic finite element models and field measurements show that there is also a critical nature to those blastholes very close to the wall, over and above standoff distance. At many mine sites, the charge weight/standoff-distance is set by trial and error. Thus, a significant aspect of the present work is the determination of dynamic stress radiating from a blasthole. Unfortunately, the modelling and measurement of this dynamic stress is still faced with many difficulties. Typical models have questionable aspects, which casts serious doubt over their predictions, and it is shown that the Hustrulid Bar experimental technique does not correctly account for stress wave attenuation in extended media. In an attempt to solve the dynamic stress problem, the present work describes a model based on an exact solution under the assumption of viscoelastic material. The model takes full account of the rock mass elastic/viscoelastic properties, the explosive type, geometry and primer location and predicts a dynamic stress for direct comparison with the unconfined compressive strength of the local rock mass. This model predicts the standoff distance required to avoid damage due to a single blasthole. The behaviour of a delayed sequence of blastholes is analysed using an upgraded waveform superposition model, covering a range of initiation delay combinations, which predicts the peak particle motion (PPM) induced in the wall for each combination. This approach shows that there is no need to fire dedicated trim shots close to walls; all that is required is a carefully modified production shot. The mechanism of vibration screening is discussed, and its use in a superposition model highlights the potential of reverse firing (shield blasting) to reduce wall PPM. A conceptual model is also introduced to give a further insight to vibration screening and damage (via ground heave). This model predicts that a centre-lift blast will have a central heave profile and that a reverse-fired shot will produce a smaller power trough than that produced by a standard shot. It is demonstrated that the mechanism of presplit formation is not well understood; nevertheless, experimental evidence shows that presplits can be an effective method for reducing wall vibrations.CITATION:Blair, D P, 2015. Wall control blasting, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 13–26 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By J Cronin

For the last decade, we have read about the great technical innovation that is coming to the mining industry that will increase safety and productivity. There is consensus that it will be a technical innovation that will produce a step change in mining costs and outputs (as opposed to bigger machines or less people); however, this innovation (while freely available) has not taken hold in the industry. While there are a few mines that have embraced technology, the majority of underground mines simply do not have the expertise or technical capability to implement innovation and automation.With unexploited mineral deposits becoming deeper and more remote, and thus more hazardous to mine, telepresence offers the ability to remotely execute production tasks while separating personnel from hazards. As the technologies required to deliver telepresence mature, the potential for there to be no personnel underground during production activities is becoming a reality (the ‘dark factory’). So significant is the capacity of telepresence to mitigate risk, it is proposed that it be included as a separate entry in the hierarchy of hazard mitigation controls.Technical innovation such as the optimised short-term interval control of the production process and the automation of underground mobile fleets offer significant increases in production along with lower operating costs. This paper explores the most critical components for the successful implementation of technology in underground mining; redundant, robust and high-bandwidth communications networks to carry data from distributed networks of smart sensors and to convey teleoperation commands; and high-definition video to provide operators with detailed, real-time data. The days of analogue ‘leaky feeder’ as a base case for communications are over. The human resources required to support the expected wave of innovation are significant and will be difficult to maintain in remote areas as the same skills and expertise are in demand in other industries.The paper highlights barriers to innovation in the mining industry, and a lack of technical and scientific expertise within the industry to be able to identify, implement and manage technologies that can increase safety and productivity. As well, an over-reliance on basic net present value (NPV) financial analysis that is used in the industry punishes investment in technology (capital expenditure; CAPEX) and accepts higher operating expenditure (OPEX) due to the discounting of future savings in operating costs.CITATION:Cronin, J, 2017. Telepresence – the application of remote control and automation technologies for increased safety and productivity, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 213–224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By P Vix

A thermodynamic model of the copper Peirce-Smith (P-S) converter has been developed to predict the behaviour of magnetite in the converter slag, the amounts of slag and matte, the compositions of slag and matte, the volume of the bath, the bath temperature and the SEMTECH OPC signals. The predictions of bath temperature, slag and matte compositions and magnetite content in the slag have been validated by the industrial data. The effects of fluxing strategy, returns and skim charges, oxygen enrichment and temperature on the magnetite formation in the slag have been predicted and discussed. Some industrial applications of this model have been presented.

Jan 1, 2005

By E de Necker, F D. I Hodg, L-M Cruywagen

The acid mine drainage (AMD) situation at three opencast collieries in the Witbank Coalfield, South Africa, was evaluated from different perspectives. Twenty-seven test pits were dug into the spoils of these collieries to characterise the in situ conditions of spoils of varying age. Detailed static testing was done on surrounding drill holes and additional samples were taken from the test pits. Selected samples were tested using different techniques, namely ABA, mineralogy and kinetic tests. Groundwater monitoring boreholes from the areas surrounding these spoils were also used for characterisation. The ABA results compared favourably with the in situ determinations; acidic test pits proved to be potentially acid-generating from ABA, even when the samples had neutral paste pH. Kinetic test results showed these samples to yield low pH leachate over the test period. In several of these results, the theoretical depletion of neutralising potential and the onset of acidity were well matched. NAG pH-values and final observed water chemistry corresponded for the cells predicted by ABA to acidify, but compared poorly in cells that did not acidify. Results from the non-acidic spoils were consistent with the in situ observations. Alternative kinetic test methodologies were also employed. Duplicate samples were tested in humidity cells and in aerated trays that were manually wetted on a regular basis. Results from these tests showed an excellent correlation. Detailed mineralogical determinations using XRD and XRF were used for comparison to the ABA and, in some cases, humidity cell results. These comparisons show that the ABA results are consistent with the results expected from the mineralogy. The conclusion from these assessments is that ABA, in most cases, provides information that can be correlated to the field, mineralogy and to humidity cells. The use of multiple techniques leads to a higher degree of confidence in the use of the data.

Jan 1, 2003

By Atalla YM

Steel rolling mill product finishing pro cesses gradually become or often already are unsuited for current production and marketing conditions. Indications are made as to what has been done to (i) rectify situations of this kind and, (ii) to reduce both product finishing time and costs. The principal features of two separate case studies are reviewed, these being (a) the finishing-end of B.H.P.'s Newcastle o.2 Merchant Mill and, (b) a mixed functions finishing yard and warehouses group (known as he Merchant Mills Loading Yard) which has been perating for a number of years. The areas in ach case are identified as a system while the arious functions, principal product streams nd processing equipment are respectively iden- ified as sub-systems and system elements. etails are given of the models used in each Sub-system dependency on the system as a le is traced by means of an information and ision analysis or by time studies and the sonableness of the system elements is deter- ed by computer programming or by simple com- ison methods. The-accumulated data is used derive improved mill finishing-end or Load Yard,functioning concepts according to pro- rules whilst at the same time considering

Jan 1, 1975

By C McCracken, R Landers, B Hesse

Minnovare identified the potential to improve production drilling outcomes in underground long-hole stopes through the adaptation of new technology which was under ongoing development. An approach to Evolution Mining resulted in the companies agreeing to a collaborative agreement to further develop the technology for use on underground long-hole drilling equipment. During a period of six months in FY2018, a series of trials were conducted to compare drilling accuracy using two different methodologies and the subsequent impact this had on ore dilution. Testing was conducted at Cracow underground gold mine in Queensland, Australia. The drill rig’s existing setup/alignment process was compared to the new technology system with the following observations: • Using the existing process only 20% of holes surveyed recorded toe points within the +/ 300mm (11.8in) tolerance blast-hole deviation. • The new technology was proven to limit rig setup/alignment error, reducing average blasthole deviation and increasing the number of holes drilled within tolerance by 160%. The increased accuracy reduced stope dilution by reducing over-break of subgrade ore: • Stopes drilled using the new technology recorded 62.6% less average dilution. • This contributed to an overall reduction in dilution for the full year (FY18) of 5 percentage points compared to FY17 - from 22% to 17% (a net decrease of 22.7%). • With the system implemented as standard practice following results of the FY18 trial and continued success, overall dilution for full year FY19 showed continued reduction to 12% Evolution has continued use of the new technology at Cracow, where the improved accuracy has allowed the extraction of narrower stopes where drilling accuracy is critical. Evolution has also deployed the technology at the Mungari operation and has stipulated that the contractor use the technology at the Mt Carlton operation, which is currently under development. Future implementation of the Development Optimiser system should be verified by commencing additional trials to include a larger data base for validating the initial trial results.

Mar 15, 2021

By J Li

Cannington Mine has been developing through paste backfilled stopes since the year 2000. These paste drives have been used as either production drill accesses or long-term bypasses. Prior to this study, the ground support requirements for each paste development cut were: an initial 50 mm layer of fibrecrete, weld mesh bolted with 2.4 m split sets, followed by a second coat of 50 mm fibrecrete. Both layers of fibrecrete and the layer of mesh were to be installed before the next cut could be bored and fired. This support regime proved successful at Cannington, however, the total cycle time for each cut was lengthy due to the installation and curing times associated with each layer of surface support. In an effort to reduce the cycle time a study was carried out, with the aid of RocScience’s Phase2 numerical modelling software. The modelling reviewed all of the parameters controlling the stability of a newly excavated development cut. The parameters studied included the early strength of fibrecrete, the ground support load capacity, and the strength of the paste fill masses which varies depending on the cement content. As a result of the study, the ground support standard was revised. The revision has significantly decreased the cycle time as well as fibrecrete consumption, all the while maintaining the safety of personnel and equipment.

Mar 21, 2011

By V Novoselov, R Sabirov

Flotation processing technology of water-soluble minerals has made it possible to realise, since the 1960s, the wide scale industrial processing of potash and potassium-magnesium ores (about 200 million tonnes per year) as well as to create the multi-tonnage worldwide production of sylvite (KCl) for industrial and agricultural application. In this paper the particularities of the effect of reagents (blinders, collectors and frothers) during cation flotation in saturated saline solutions are outlined. New reagent modes for activating the effects of alkylamines during the flotation of KCl and the perfecting of technological flow sheets for processing potassium ore have been developed. The results of research on the reverse flotation of carnallite ore, with the help of alkylmorpholine û a new developing technology for benefication carnallite as raw material for the production of metal magnesium and fertilisers are listed. Examples are given of the industrial applications of processed reagent modes at potash flotation factories in Russia.

Jan 1, 2005

By J Pan, C M. Tang, D Q. Zhu, C C. Yang, S W. Li, Z Q. Guo

The short process of electric furnace steelmaking with direct reduction iron (DRI) as raw material is an important process for smelting high-quality and special steels. In order to prepare high-quality DRI, the pellets with basicity of natural basicity and 0.4 were prepared from magnetite concentrate (MR=0.09, MR=0.4) and hematite concentrate (HR=0.02, HR=0.4). Based on the HYL method, the gas-based direct reduction experiments were conducted under the condition of rich hydrogen (H2/CO = 2.6). The reduction index (RI), reduction swelling (RSI), cold compressive strength (CCS), and phase changes of the pellets were systematically studied. The results show that the RI of four kinds of pellets is greater than four in the temperature range of 800~950°C. For the magnetite pellets, at a fixed reduction temperature, the RSI increases and then gradually decreases, reaching a peak between 50 per cent and 80 per cent. Moreover, the RSI enhances with the increase of the reduction temperature. In general, the RI, RSI, and reduced CCS of the MR=0.09 pellets are better than those of the MR=0.4 pellets. For the hematite pellets, the maximum RSI decreases from 23 per cent to 17 per cent during hydrogen-rich reduction, while the compressive strength increases from 500 to 1070 Nꞏpellet-1. The main reason is that the glass phase generated by the increase of basicity adheres to the surface of hematite grains, hindering the contact between reducing gas and particles. As a result, the apparent activation energy is reduced, which is not conducive to the reduction process. In addition, the glassy phase attached to the hematite reduces the migration rate of Fe2+/Fe3+, resulting in a difference in the reduction expansion rate of hematite in the inner and outer layers of the pellet. Thus, concentric cracks are formed inside the pellets, the RSI increases and reduced CCS decreases.

Sep 18, 2023