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By S van der Sluijs, M van Ende, Y Tang, A Emami

This paper presents a phenomena-based model for investigating the possibility of scrap melting in an Open Slag Bath Furnace (OSBF) for green ironmaking. The goal of this study is to enhance the circularity of the steelmaking process by utilising scrap as a green source of iron in OSBFs. The model takes into account the fundamental differences between OSBFs and traditional processes such as Electric Arc Furnaces (EAFs) and Basic Oxygen Furnaces (BOFs). The model considers three primary regions where scrap heating and melting occur: the solid feed pile, slag and hot metal. It accounts for factors such as the furnace geometry, scrap charging mechanism and specific heat and mass transfer properties of the reactor. The model was validated using literature data and was used to investigate the heating and melting behaviour of individual scrap particles under various process parameters. The study finds that the scrap melting process in OSBFs involves three stages: shell formation, shell remelting and subsequent melting of the parent scrap. The carbon content of the scrap and the liquid hot metal plays a critical role in determining the melting behaviour. Depending on the carbon concentration and temperature, the melting process can be heat transfer controlled or mass transfer controlled. The paper also examines the scrap feeding methods in OSBFs, including direct charging into the slag or charging through a feed pile. The model provides insights into the melting rate of scrap compared to Direct Reduced Iron (DRI) in OSBFs and highlights the role of carbon in this process. Overall, this phenomena-based model contributes to the understanding of scrap melting behaviour in OSBFs and provides valuable insights for optimising the circularity and efficiency of green ironmaking processes. The findings of this study can inform the design and operation of OSBFs, paving the way for increased utilisation of scrap as a sustainable feedstock in the steel industry.

Jun 19, 2024

By S K. Michelic, N Preisser

For certain applications, steels have to feature a very distinct and well-defined level of cleanness in terms of the number and composition of non-metallic inclusions. Therefore, one crucial aspect of steelmaking is removing and controlling said non-metallic inclusions during the process. Particle removal during ladle refining comprises three stages, namely: 1. Flotation 2. Transport through the steel/slag interface 3. Dissolution of the particle in the slag. Only if all three stages are completed the particle can be considered as fully removed from the steel melt which, in turn, leads to the slag being one of the most influential parameters for inclusion removal and control. Depending on the composition of the particles and the slag, the dissolution can be controlled by different mechanisms. This study focuses on the diffusion-controlled dissolution of solid oxidic particles in slags. For this, a model of particle dissolution has been developed. For modelling diffusion, either the differential equation following Fick’s second law can be solved, or an analytical solution to this equation valid for stationary interfaces can be used. Both approaches allow for calculations of concentration profiles of the dissolving species in surrounding slag. From this, the mass flux can be derived, which finally leads to calculating the boundary layer velocity due to considerations of mass balance. In this work, both methods as well as results of dissolution experiments using High Temperature Confocal Scanning Laser Microscopy are compared. This research aims to provide a framework for diffusion-based dissolution modelling in further expanding the understanding of particle dissolution in secondary metallurgy.

Aug 21, 2024

By T van Niel, M Trefry, B Baker, I Rea, A Hawdon, D McJannet, D Boadle, R Fandrich, A Littleboy

Many open cut mines extend to depths well below the natural water table level with constant dewatering required to maintain operations. When mining activities cease the groundwater starts to fill the void and pit lakes form. The resultant pit lake is directly connected to the surrounding water table and understanding the hydrological and chemical evolution of these lakes is important for minimising environmental impacts. In Western Australia alone there are currently 1800 mine voids and more than 150 mines operating below the water table (Johnson and Wright, 2003). In conjunction with BHP Billiton Iron Ore, CSIRO has been undertaking research to measure and model rates of evaporation from pit lakes in the Pilbara region of Western Australia. Extreme high temperatures and low humidity ensures that this region experiences the highest evaporation rates in Australia.CITATION:McJannet, D, Hawdon, A, Boadle, D, Baker, B, van Neil, T, Littleboy, A, Trefry, M, Rea, I and Fandrich, R, 2016. Measurements and modelling of evaporation from abandoned mine pit lakes, in Proceedings Life-of-Mine 2016 Conference, pp 106–109 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 28, 2016

This paper discusses some topical issues on the mining administration and legislation fields including:  1. Licensing û Administration and associated specialist functions including:Processing and volumes of mining privilege applicationsFuture organisation and possible decentralisationSpecialist staffFacilitiesGuide to the Mining Act 1971 2. Mining Amendment Act 1981 Transitional procedures 3. Planning Tribunal First hearing of objectionsPoints of principle resulted there from 4. Quarries and Tunnels Bill Currently before Parliament û implications for metallurgical mining

Jan 1, 1982

The Hishikari gold deposit, discovered by the Metal Mining Agency of Japan, has become a giant class epithermal gold deposit with the highest grade of gold yet recorded in the world through detailed exploration and development by the Sumitomo Metal Mining Co., Ltd. The exploration strategy involved a regional approach combining geological and gravity surveys over a 900 km2 area which had historically produced over 120 t of gold. These surveys were carried out to grasp the common geologic features of epithermal gold deposits in the survey area. A genetic model for epithermal gold deposits in the area under regional survey was also considered based on detailed research of the Kushikino epithermal gold deposit which was in operation at that time. This model was applied to the targeted areas, and important relationships between mineralization, host lithology, intensive propylitic alteration and gravity highs became apparent. The Hishikari block was selected in this way and bonanza gold was discovered during drilling. Since the development of the Hishikari mine, information useful for further exploration for the same type of deposit has been accumulated.

Jan 1, 1995

By Y Peng, D Wannas

In the fine particle flotation technologies being developed today the fine hydrophilic (gangue) particles are usually well dispersed. These highly dispersed fine particles can be recovered into the flotation froth product by mechanical entrainment. Flocculation of hydrophilic particles caused by polymer depressants could potentially reduce the mechanical entrainment of these particles. This paper reports testwork completed on fine particles of several solids, iron oxide, hydroxylapatite, galena and sphalerite, as well as on a relatively coarse quartz sample (-75+38 ¦m). Dodecylamine was used as a collector for the quartz, and several dispersants and polymer depressants, including sodium silicate, sodium metaphosphate, zinc sulfate, potassium dichromate, corn starch, corn dextrin and carboxymethyl celluloses (with molecular weights of both 700 000 and 80 000) were used as flotation modifiers. The major part of the testwork involved flotation tests in a 200 ml flotation column. Both water and solid recoveries were recorded. The degree of flocculation and dispersion was determined by settling tests in 250 ml graduated cylinders. It was observed that flocculation of the fine hydrophilic particles significantly reduced their mechanical entrainment, while dispersion severely aggravated it. Thus, in the flotation separation of artificial mixtures of the -75+38 ¦m quartz and fine iron oxide or hydroxylapatite, polymer depressants that caused flocculation were found to perform better than the ones that did not cause flocculation.

Jan 1, 2005

By R Ayothiraman

Tunnel excavation may induce adverse effects on nearby existing structures/foundations in urban areas. Accurate prediction of tunnelling effects on pile foundations of nearby structures in the urban environment poses a major challenge during design. Several studies have been undertaken to understand the mechanisms of the soil-tunnel-pile interaction, which focused only on influence of tunnelling on nearby existing building and foundations. However, effect of pile loading on existing tunnels did not receive enough research attention so far. So it is essential to measure the response of existing tunnel-lining due to loading on newly constructed pile to assess to the safety against the additional forces/moment caused by pile loading and to evaluate the critical distance for the proposed construction of any structures from the tunnel location. This paper presents result of three-dimensional (3D) finite element analysis carried out in ABAQUS to investigate the effects of pile loading on existing tunnels embedded in cohesive soil. It is found that the effects on tunnel lining depend on horizontal separation distance between pile and tunnel as well as location/elevation of pile tip with respect to tunnel location.

Mar 8, 2011

By M A. Jardine, J A. Miller, M Becker, M Harris

"Although the role of texture has been increasingly recognised as a geometallurgical indicator of ore characteristics and their variability, the ability to appropriately quantify and correlate it with metallurgical performance remains an ongoing challenge. In this study, we propose the 3D characterisation and quantification of ore textures from drill core using X-ray computed tomography (XCT) with an appropriate image analysis methodology (grey level co-occurrence matrices, GLCM). This methodology has been specially customised for application of 3D XCT grey-scale volumes. This approach has potential as an online mine site analysis tool providing detailed 3D information on both quantitative texture and simple mineralogy.The approach is illustrated in this paper using drill core samples that were manually extracted from various rock types and textures representing the Nkomati Main Mineralized Zone (MMZ) sulfide nickel ore deposit. A preliminary classification of the samples was performed based on their particle size distribution after laboratory scale rod milling. Accompanying QEMSCAN analyses were also used to guide the interpretation of the grey-scale mineralogy and texture in the 3D XCT volumes. The resultant GLCM produced from quantitative 3D image analysis of the XCT volumes indicated sensitivity to ore variability and was able to capture a simple mineralogy and grain size distribution. The approach holds many possibilities for geometallurgy, of which the potential for automation is promising.CITATION:Becker, M, Jardine, M A, Miller, J A and Harris, M, 2016. X-ray Computed Tomography – a Geometallurgical Tool for 3D Textural Analysis of Drill Core?, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 231–240 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By R F. Cota, C Freeman, A Heberle

"The Lamego mine is an underground gold mine in the Iron Ore Quadrangle in Minas Gerais state, Brazil. The mine produces 48 to 50 koz per annum, as part of the larger Cuiabá-Lamego Complex. This combined unit is AngloGold Ashanti’s largest gold producer in the Americas, contributing with 310 to 320 koz per annum.The mine started production in 2009, utilising cut-and-fill mining methods.A mining method change was trialled in 2014, introducing open stope methods. The key benefits proposed from this change are considered to be: improved safety by eliminating re-entry mining methods reduced mining costs/increased productivity from utilising bulk-mining operations.The results from the trial were encouraging, and open stoping participation expanded beyond a trial.Production from open stope areas reached 180 000 t (40 per cent of total run-of-mine; ROM) in 2015. While the change in mining method resulted in higher production rates, it also introduced a critical issue in terms of stope recovery rate.Average underbreak (unplanned loss of ore) in the larger open stopes reached 21 per cent in 2015. To manage this ore loss, a project targeting higher recovery was structured with three primary components: analyse current performance to define contributing factors (design process gaps, operating practices) investigate corrective actions apply corrective actions and maximise team engagement to ensure changes become standard practice.Within six months of commencement, a range of contributing factors had been identified, and the majority of the associated corrective actions implemented, including increased team engagement to ensure changes were not ‘once off’ actions.The outcomes show a clear reduction in underbreak (average ~12 per cent for 2016), with further improvement opportunities identified. The challenging target is now to achieve a further reduction to 10 per cent underbreak as the average for 2017. The results contributed 1400 oz and additional US$ 0.5 million to the cash generation profile for 2016.CITATION:Heberle, A, Freeman, C and Cota, R F, 2017. Increasing stope recovery in an underground gold mine by using effective analysis, corrective action and employee engagement processes, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 117–122 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 16, 2017

The Illawarra Branch of the Australasian Institute of Mining and Metallurgy over recent years has established an enviable reputation for organising and conducting conferences, colloquia and symposia. And this Symposium must surely enhance that reputation. The subject of the Symposium, Seam Gas Drainage has become a matter of great import- ance to the Australian Coal Industry in a comparatively short time. Our short experience being due to our operations, until recent times anyway, not being unduly affected by gas. The Australian Industry, by virtue of its mines getting deeper and higher rates of extraction being required is now encountering the difficulties with gas which have for so long been part of the coal mining scene in many other countries. Because these gas emissions affect our working conditions by way of creating hazards and affect our production by way of bringing about cessation of operations from time to time this Symposium must be regarded as being very timely out here. I must congratulate the Branch Committee on the general set,yp :o.f the programme of papers. The classification of papers into four groups and the sequence in which the papers were presented provided an excellent flow through from introduction to finality. It is not my intention to further discuss individual papers - already they have been well discussed in this forum and as I understand it outside in the early hours of the morning,

Jan 1, 1982

Reconciliation involves the collection of tonnage, grade (quality) and contained metal (product) data from disparate and hopefully independent sources. Examples are exploration data, production sampling data from blastholes or drawpoints, and process plant data. These data may be compared by means of ratios (factors). The F1 factor usually relates short-term (ore control) model tonnages, grades and metal content to ore reserves depleted. The F2 factor usually relates received-at-mill tonnages, grades and metal content to delivered-to-mill = production tonnages, grade and metal content. The F3 factor is F1 × F2 and enables a comparison of a mineÆs ability to recover the tonnage, grade and metal content estimated in ore reserves. The F1 factor measures the accuracy of orebody knowledge in the ore reserves to the demarcation of ore and waste by ore control (short-term model). The F1 factor may be used to check and calibrate the selectivity of mineral resource models and/or planned dilution assumed in transfer from mineral resources to ore reserves. The F2 factor enables a check on unplanned dilution entering the ore stream between ore control and the mill. Using the factors it is possible to calculate a monetary value on improvements in the accuracy of orebody knowledge, selectivity and the effects of dilution and ore loss. Reconciliation should be an implicit part of the mining process, and reconciliation targets should be a key performance indicator for well-run mines.

Sep 26, 2011

By Y A. Stepanyants, J Crawford

A practical field method for determining the maximum value of the intrinsic oxidation rate, Smax , of sulfidic materials in waste rock dumps is proposed. Knowledge of the intrinsic oxidation rate of sulfidic materials distributed in a dump is necessary for predictive modelling of oxidation and pollutant generation over time. The suggested method uses the fact that drilling waste rock dumps to install probes for monitoring temperature and oxygen concentration causes large volumes of air to be injected into a dump by the drill rig. By measuring the rate of decrease of oxygen concentration along the length of a borehole immediately after installation, it is proposed that Smax can be calculated at different depths. The aims of this work were: to derive a simple, practical formula for the estimation of Smax from the oxygen concentrations measured over time, based on some simplifying assumptions; to use a two-dimensional numerical model that incorporates all the necessary physical processes to model the behaviour of an aerated dump over time for a reasonable range of dump and material parameters; and to compare the results of the two approaches to assess the validity of the simple formula as a method for estimating Smax. It has been found that the technique can provide reliable estimates of Smax when the value is of the order of 10-7 kg(O2) m-3 s-1 or greater. At the lower end of the range however the radius of the zone aerated during drilling becomes an important parameter and further work has been recommended to investigate this aspect of the method.

Jan 1, 2003

By J Rutter, J du Plessis, er, M Scott, D Alex

It is generally acknowledged that bulk ore sorting is an attractive prospect for the mining industry. However, uncertainties relating to the operational performance of sensor technologies, the grade heterogeneity present in analysed material and the physical separation performance of the coupled system complicate the evaluation and deployment of bulk ore sorting strategies at operations. To assist in the quantification of these uncertainties, the Cooperative Research Centre for Optimising Resource Extraction (CRC ORE) and Anglo American have implemented a systematic methodology to evaluate the deployment of sensor technologies for bulk ore sorting. This methodology was implemented at a bulk ore sorting demonstration plant using penetrative prompt gamma neutron activation analysis (PGNAA) and surface x-ray fluorescence (XRF) measurements of base metals, as a proxy for precious metals, at Mogalakwena PGE Mine. The methodology comprises of three phases. The initial phase involves the preliminary investigation of sensor technologies and analysis to reduce identified risks prior to commissioning of the bulk ore sorting plant. The second phase executes a series of experiments to prove the sensing technologies in the operational environment and provide confidence the sensors can drive separation. The final phase demonstrates the production scale bulk ore sorting performance of the plant and validates its performance by campaign of the sorted products at the processing plant. Throughout the operational deployment and evaluation of bulk ore sorting at Mogalakwena, several key lessons were learned. These learnings relate to the calibration requirements of the sensor technologies, the application of surface vs penetrative sensor techniques and the preservation of grade heterogeneity delivered to the sensors. This paper presents the methodology used, and lessons learned, in the operational deployment and evaluation of PGNAA and XRF sensors for bulk ore sorting at Mogalakwena PGE Mine.

Nov 10, 2020

By B Dold

"Mining has still today high potential for improvement in the exploitation efficiency. Especially low-grade ores have very low recoveries. In Cu bioleaching operations from porphyry copper deposits extraction of only five and 15 per cent with maximum of 40 per cent are reached. This means that 60–95 per cent of the resource is not exploited. Consequently, any metal not extracted will end up in the waste material, therefore increasing the risk of environmental pollution. This inefficiency is mainly due to the use of element concentrations for decision-making on the daily basis of a mining operation (eg cut-off ore grade, acid-base accounting – ABA). If, instead, quantitative mineralogical and geochemical data together with information on the bioleaching behaviour of the ore assemblage (the biogeometallurgical approach), is used for decision-making right from the beginning of the exploitation, higher recoveries and less environmental impact can be achieved, ie an increase in sustainability can be reached.CITATION:Dold, D, 2016. The Biogeometallurgical Approach – the Information We Need to Increase the Sustainability of Mining, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 169–172 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By M G. Shaw, M A. Rhamdhani, S P. Singh, A R. Duffy, B Eisenbart, A K. Shukla, G A. Brooks

The field of astrometallurgy is a growing area of study. Metal production on the Moon is likely to begin in less than a decade as major space agencies such as NASA (National Aeronautics and Space Administration) and CNSA (China National Space Administration) are preparing to construct permanent lunar bases. The utilisation of regolith to generate oxygen and metals is expected to be important in the development of a sustainable lunar habitat. This paper provides an overview of potential metallurgical processing methods for lunar conditions, emphasising the impact of lunar factors on slag chemistry. The interaction between regolith and the extracted metals, as well as their impact on slag composition and refractory performance, are critical considerations in metal production on the lunar surface. The initial research on lunar metallurgical technologies is focused on oxygen extraction and Fe-Si alloys are reported as the by-products of these processes. This paper delves into the fundamental thermodynamics associated with the carbothermic reduction of lunar regolith. Thermodynamic analysis using the FactSage™ ver 8.2 software package indicates that the Fe-Si alloy can be produced as a metallic product from the lunar regolith at temperatures ranging from 1400°C to 1600°C under terrestrial conditions. However, under ultra-high vacuum conditions (3 × 10-15 bar) on the Moon, the required operating temperature for producing ferrosilicon would be significantly reduced. Thermodynamic modelling results indicate that under lunar vacuum conditions, Fe-Si alloys only exist as solid phases at lower temperatures below 650°C. At higher temperatures, both Fe and Si are expected to be present in the gas phase. In this work, the carbothermic reduction of the Lunar Mare Simulant (LMS-1) is conducted under terrestrial conditions. The findings indicate that the process can readily yield Fe-Si alloys with 7–10 wt per cent Si at 1600°C. Additionally, energy dispersive spectroscopy (EDS) analysis of the resulting Fe-Si alloy indicates the presence of phosphorus up to 1 wt per cent.

Aug 21, 2024

By S Grimsey, E Janetzki, J Emery

Floor failure on the longwall face is a complex problem due to the dynamic interaction between the surrounding strata and powered roof supports involving multiple variables. It can also be highly problematic and costly when not well understood as there are significantly less remedies available post event. This was the early experience at the case study mine where significant lost time was incurred due to unplanned delays in the first two panels. To detect and prevent such occurrences is clearly the best approach, hence a tool to predict both floor failure occurrence and magnitude prior to mining was developed. Several parameters were determined as the key drivers for the failure events that had been experienced at this site. These parameters were, in list of influence from highest to lowest, material strength, retreat rate and the presence of water. The parameters were evaluated using a semi quantitative risk rating system ‘Heave Risk’ and given a weighting per their apparent influence. This ‘expert system’ methodology was selected as the use of risk rating systems in underground coal mining is well established. The heave risk model was first applied to previously mined panels. It accurately identified all areas of known major floor heave, with clearly defined areas of low and high risk apparent. The heave risk model was then used prior to mining and evaluated post mining based on observed conditions. It was found to also be highly accurate for prediction. The variability of each parameter and its influence on the overall risk rating is illustrated and discussed.

Nov 29, 2022

By Filmer AO

In contrast to the '50s and '60s, the period of the '80s and '90s seems likely to have low growth in demand but much greater levels of technological change. In such a climate there will be pressure on costs, productivity will continue to rise and competitiveness will be closely associated with maintenance of the most effective technology. The penalties for inappropriate investments, whether short sighted or mistakenly based on a particular view of the future, will be greatly enhanced. Accordingly, there will be a need for significantly improved anticipation of technical change and thus for better planning. Study of the funding and direction of the world's R&D effort can provide a useful input to the planning processes within industries and individual firms. Such a study also suggests some insights into the characteristics of those countries which have achieved substantial growth and high standards of living over the past two decades. These characteristics may offer significant reminders for our own development. The particular implications for the Australian minerals industry include the need for direction that is sensitive to changing market requirements and customer practice. This is not simply "more of the same." In particular it appears essential for both basic and applied R&D to provide a sound basis for the purchase and ongoing development of the new technology required to achieve international Competitiveness.

Jan 1, 1986

Autogenous and Semi-Autogenous grinding has become an accepted method of reducing primary crusher product to micron sizes in a single or a two-stage grinding circuit. The elimination of secondary and tertiary crusher circuits and sometimes rod mills helps to lower overall operating costs and, in many instances, can make uneconomical projects viable. Selecting AG/SAG Mills have been rather a "hit and miss" affair over the years, but now with the many different types of tests available, accurate mill size predictions can be made, provided the test data is evaluated correctly. This paper endeavours to simplify the process of evaluating test data and sets down some guidelines for designers to follow when selecting AG/SAG Mills.

Jan 1, 1991

Large GDP increases in the Pacific Rim countries have been accompanied by similarly large increases in demand for oil products. In the case of residual fuels, this demand has been tempered by the substitution of other energy products such as coal or gas.In the region's developing and newly industrialised nations, it has not been possible to make the very large investements in infrastructure which allow other energy sources to be used for transportation. As a result, GDP growth has been mirrored in the demand growth for automotive fuels. Other non-sustitutable products such as lubricants have also benefitted by the region's GDP growth.The combination of a number of years of sustained growth, coupled with increasing quality requirements is now stretching the upgrading capacity of the region's refineries. If, as seems likely, the region continues to enjoy a high GDP growth rate, then this will be accompanied by increasing reliance on finished products coming out of the Middle East. The owners of the most simple form of refinery in which crude is simply distilled and the naphtha reformed into petrol will face major capital investments. If they decide not to bear this cost, they will face increasing problems in selling their surplus residual fuel oil at an economic price. Quality will become an increasingly important issue. Not only in the well publicised areas such as unleaded petrol, but also for products such as lubricants which play a major role in the efficiency of modem equipment. Quality of service such as hours of opening, ease of access, and service station facilities will also become increasingly important as the oil companies use these to attract customers and gain brand differentiation.

Jan 1, 1990

By P Clark

This paper discusses the challenges, solutions and lessons learnt as tunnelling work continues on the Melbourne Main Sewer Replacement (MMSR) project.The MMSR project is a $220 million dollar project for the Melbourne Water Corporation. It involves the construction of approximately 4.2 km of new sewer from the southern fringe of the CBD through the inner metropolitan suburbs of Port Melbourne and South Melbourne.Of the 4.2 km of sewer currently in construction approximately 2.2 km will be constructed using a 2.95 m diameter Lovat EPB tunnel boring machine (TBM) with approximately 1.9 km of small diameter (300 to 600 mm) reticulation sewers constructed using trenchless techniques.These sewers are being constructed in a dense urban environment, which means that the tunnels and shafts are often in close proximity to buildings and structures. The underground constructionof the sewer is further complicated by the variable geology of the ancient Yarra River delta which includes weathered basalts, the infamous Coode island silt formation and fine loose sands.Some of the key challenges and lessons learnt so far during construction include:· steering and alignment control of the TBM through very soft silt with little residual strength,· development and refinement of a monitoring and alarm system for leaving the machine dormant on a day works only project,· control and measurement of tunnel lining defl ection during ring build and grouting,· prediction and monitoring of surface settlements during tunnel excavation,· improved understanding of the geology and hydrogeology at this previously unchartered area of Melbourne,· consolidation settlement due to dewatering at shafts required careful construction controls, and· ground support and excavation in close proximity to the existing 110 year old sewer which requiredvery detailed risk control measures.

Mar 8, 2011