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By F. J. Guevara

A two-dimensional mathematical model for fluid flow and heat transfer in a sixin- line electric smelting furnace was developed to study the effects of temperature on slag viscosity in both the liquid and mushy zones. The model focused on the fluid dynamics of the molten slag and the effects on the formation of a slag freeze layer on the hot face of the furnace wall. Previous experimental and mathematical work, carried out under Ra number of 109 and using a fluid with Pr number of 65, showed that it is possible to mathematically describe the freeze layer formation over a vertical wall using a fixed-grid model. The chemical composition of the slag was taken into account through its effect on the viscous activation energy as well the solidus and liquidus temperatures. The results show that the flow pattern is strongly modified in areas of high viscosity, in front of the cooling system and at the slag-matte and slag-calcine interfaces. The results are discussed in terms of heat flux over the refractories and their effects on cooling system design.

Jan 1, 2007

By V. ?. Chanturiya, I. Zh. Bunin, M. V. Ryazantseva

"Surface changes in naturally occurring metal sulfides (pyrite, arsenopyrite, sphalerite, chalcopyrite, galena, and molybdenite) due to treatments from high-power electromagnetic pulses (HPEMP) at varying times were studied using X-ray photoelectron spectroscopy. Analysis of the obtained results revealed common patterns and differences in surface transformations. The transformations were found to include two main stages. The first stage was observed at low treatment intensities (up to n ~103 pulses). At this stage, formation and accumulation in the surface layer of the nonstoichiometric sulfide phase, oxides and hydroxides, as well as elemental (polysulfide) sulfur and/or metastable sulfur species (thiosulfate, sulfite) was observed. The second stage (N = 3·103 pulses) is characterized by thermal removal of sulfur species and renewal of the mineral surface (sulfidization).It was found that the chemical changes of the sulfur on the surface layer of pyrite, arsenopyrite, chalcopyrite included accumulation/formation of S0 (Sn 2-) at the first stage of the transformation, followed by its removal. An increase in the surface concentration of elemental sulfur for pyrite and chalcopyrite was 10–12% while arsenopyrite was approximately 5%. A more complicated chemical change was observed for sphalerite and galena, that included formation/accumulation of metastable sulfur species (thiosulfate, sulfate) at the initial stage (up to 103 pulses) and during longer treatment times, the sulphur is reduced back to its initial state (sulfide or disulfide). The increased concentration of S0 sulfur, compared to the original sample, was only 3% in galena and sphalerite.The application of HPEMP treatment to improve flotation selectivity is supported by singlemineral flotation tests. Changes in flotability as a result of HPEMP treatment are principally explained by surface phase changes that resulted in higher adsorption activity."

Jan 1, 2016

By A. Ghirian

Once cemented paste backfill (CPB) is transferred and placed into a mine stope, various coupled mechanisms will take place in the CPB material or structure. It will be subjected to strong coupled thermal (T), hydraulic (H), mechanical (M), and chemical (C) processes. Field studies have shown that the in-situ properties and performance of CPB differ from those obtained in the laboratory. This is mainly due to effects of the aforementioned coupled THMC mechanisms or processes. For a reliable and cost-effective design of a CPB structure and barricade, it is crucial to have a proper understanding of the THMC behaviour and evolution of CPB. Also, it is important to consider the effect of coupled THMC factors (e.g., self-weight pressure, drained/undrained and thermal conditions, pore pressure) while curing the CPB specimens. For this purpose, a laboratory setup is developed to investigate the properties of CPB materials. The setup is capable of curing CPB specimens (10 cm in diameter and 20 cm in height) under controlled vertical pressure (curing under stress) and various coupled THMC conditions, while continuously monitoring the evolution of total stress, pore pressure, suction, temperature, water drainage, chemical composition of the pore water and vertical deformation. Once the required curing time is achieved, the specimen can be extracted and then subjected to experimental tests of interest, such as those that determine the Unconfined Compressive Strength (UCS), shear strength parameters, saturated hydraulic conductivity and thermal properties. In this paper, we describe the developed experimental setup and present some results of the THMC behaviour of CPB under various curing stresses and rates of backfilling. The obtained results show that the THMC properties of CPB are strongly coupled due to several mechanisms, such as self-weight pressure, heat of hydration and suction development as a result of self-desiccation. The findings can assist researchers and practitioners to better understand THMC behaviour and thus design more cost-effective CPB structures.

Aug 1, 2013

By D. G. Sediako

Chemical composition and the casting/rolling production routes determine the cost and properties of the wrought material. For example, the coarse-grained structure frequently associated with DC casting requires complex rolling schedules to refine the grain size. Hot forming (rolling/forging/extrusion) results in a strong crystallographic texture, which is responsible for the tension-compression strength asymmetry frequently exhibited by magnesium alloys. Understanding the influence of alloy composition on texture evolution during forming provides useful practical information to optimize industrial hot-forming technologies for magnesium alloys. In this study, a series of Mg-based alloys containing varying combinations of Al, Rare Earths, Zn, Ca, and Sr were subjected to identical casting and extrusion processes in order to isolate the effects of alloy composition on texture evolution. Textures were measured by neutron diffraction at the NRC Canadian Neutron Beam Centre. The ability of neutrons to penetrate deeply into materials allowed information to be retrieved from all regions of the bulk specimens without destructive and time-consuming sectioning operations, thereby providing true bulk texture data. {1010} , (0002), {1011}, and {1012} pole figures were generated for all of the as-processed alloys, from which Orientation Density Functions were obtained. The were then used to reconstruct the pole figures and to extract semi-quantitative texture data showing how the (0002) and {1010} planes align themselves with respect to the extrusion axis. It was found that varying the concentration of aluminum (3-4 wt%) and Rare Earths (2-3 wt%) in AE alloys had a weak effect on texture development. All of the alloys showed similar magnesium extrusion textures, in which the (0002) poles align themselves preferentially with the extrusion axis. The substitution of Sr for Rare Earths also did not have a significant impact on texture development. On the other hand, while the presence of small amounts of Zn and Rare Earths did not have a strong effect on texture development, alloys with higher concentrations of these alloying additions (in combination) showed an enhanced tendency for the {1010} poles to align themselves with the extrusion axis. The addition of Ca also enhanced the alignment of the {1010} poles with the extrusion axis. These textures can complicate further processing and introduce a significant anisotropy that could influence creep properties.

Jan 1, 2007

By S. Amira

The corrosion behavior of high pressure die-cast and thixocast AXJ530 magnesium alloys has been investigated in 0.05M NaC1 solution at pH 6.0 using potentiodynamic polarization tests, electrochemical noise (EN) technique, electro-chemical impedance spectroscopy (EIS) and scanning reference electrode technique (SRET). The behavior of die-cast and thixocast specimens were compared using each of these techniques and the results discussed. Further tests have been carried out with die-cast AZ91D alloy to better compare and interpret the results. Experiments indicate that the thixocast specimens of AXJ530 alloy have a better corrosion resistance than those of die cast alloy in neutral solution.

Jan 1, 2006

By A. D. Pittuck

Refractory minerals .containing uranium and columbium have been successfully treated at Queen's University, Kingston, to produce high-grade concentrates. Recoveries of over 90 per cent of the uranium and columbium have been obtained when treating concentrates containing euxenite, fergusonite, betafite, and pyrochlore. The processes ?consisted -of leaching the columbium with hydrofluoric acid, and the uranium with nitric acid, sulphuric acid, or sodium carbonate solutions. The leach liquors were extracted with organic solvents from which the values were stripped and precipitated, producing final products assaying 45 to 55 per cent Ob2O5 and 60 to 70 per cent U3Os.

Jan 1, 1958

By Gaston Giuliani, Jérome Massot, Didier Bourlès, Lionel Siame

"Abstract - We present a new approach for the evaluation of the potential of emerald reserves in gem projects using beryllium (Be) mobility. The distribution of Be in the different phases of hydrothermally altered (albitized) black shale hosting Colombian emerald deposits indicates that Be mobility is associated with the breakdown of Fe-Mn oxyhydroxide phases. The amount of Be that can be mobilized (~0.7 x 10-6 g/g; i.e., 0.7 ppm) may represent up to 18 wt% of the total Be contained in the black shale. A mass balance calculation applied to a well-constrained alteration zone of the Chivor mines, and based on the quantification of Be that can be mobilized under hydrothermal conditions, gives an estimate of the total gem reserves of these mines. Resumé - Une nouvelle approche, basée sur la mobilité du béryllium (Be) pour l’évaluation des réserves d’émeraude dans des projets d’exploitation de gemmes est présentée. La distribution du Be dans les différentes phases minérales de schistes noirs hydrothermalisés (albitisés) qui contiennent les gisements d’émeraude colombiens, indique que le Be mobilisable se trouve dans les oxyhydroxydes de fer et de manganèse. La quantité de Be potentiellement mobilisable (~0,7 x 10-6 g/g; soit 0,7 ppm) constitue jusqu’à 18% poids du Be global contenu dans le schiste noir. Un bilan de masse appliqué à la zone d’altération hydrothermale des mines de Chivor et basé sur la quantification du Be mobilisable, donne une première estimation des réserves à émeraude de ces mines. rieur."

Jan 1, 1999

By Du Xinfeng

The resource quantity of the low rank coalbed methane (CBM) accounts for 47% of the total resource quantity of CBM in China. Compared with the exploration and development of the high rank CBM in Qinshui Basin, China and the low rank CBM in Powder River Basin, USA and Albert Basin, Canada, the exploration and development of the low rank CBM are still in the initial test stage. In this paper, on the basis of analyzing the mining geological conditions such as that the Huanglong Jurassic Coalfield is largely situated in the hills and gullies zones, and the coal reservoir has the features such as the low metamorphic degree, large coal seam thickness, simple coal matrix texture, high permeability and small CBM content and so on, it discusses the key technologies such as the development pattern of CBM, well location arrangement, drilling and well completion technology and fracturing technology and so on. It indicates that the underbalanced drilling and the cavity well completion based on the reservoir protection will be the development directions of the CBM development technology in this area.

Aug 1, 2013

By Asbjørn Solheim

The service life for aluminium reduction cells is often limited by the cathode carbon, due to preferential wear along the periphery of the cell leading to the so-called "W" wear pattern. The reason for this preferential wear is not well understood. Two mechanisms are suggested in the present paper; 1) non-stationary dissolution of aluminium carbide into a layer of sludge that periodically forms and disappears, and 2) electrochemical formation and dissolution of aluminium carbide within an aluminium carbide layer containing bath-filled pores. The latter mechanism may be related to the high local current density at the periphery of the cathode.

Jan 1, 2011

By P. Su

Friction stir spot welding of a range of Mg-alloys is investigated (AZ91, AZ31, AM50 and AM60). The peak temperatures during friction stir spot welding of all Mg-alloys are close to their solidus temperatures. Also, the apparent material viscosity of Mg-alloy sheet is lower than that when Al-alloy sheet material is spot welded. This is important since it means that the widths of the stir zones forming during spot welding of Mg-alloy sheet are smaller than those when Al-alloy sheet is welded (when identical welding parameter settings are applied). These lower apparent viscosity values must be taken into account during numerical modeling of the Mg-alloy spot welding process. The efficiency of energy utilization is very low when Mg-alloy sheet is spot welded and is of the same order as that when fabricating Al-alloy sheet. The energy generation contributions of the rotating pin and the tool shoulder are investigated. When the spot welding operation is carried out without the application of a dwell period, the contribution made by the rotating pin vis-à-vis energy generation is around 66%. The contribution made by the tool shoulder increases to about 65% when a dwell period of four seconds is incorporated during the spot welding operation. This increase results from a longer contact time between the tool shoulder and material within the stir zone, The failure load during overlap shear testing increases when the bonded area and the energy input increase during spot welding. Sample failure initiates from unbonded regions and from discontinuities at the edge of the stir zone. The formation tendency of discontinuities is increased when Mg-Alloy sheet is spot welded because of the limited deformation characteristics of the base material at lower temperatures.

Jan 1, 2006

By O. Bouaziz, O. Magnea, P. Cugy, E. F. Rauch

The experimental difficulty to perform Equal Channel Angular Extrusion (ECAE) of a bulk sample of hard material such as steel was overcome. The original method proposed in this paper consists in replacing the bulk sample by a stack of alternated hard metal (steel) and soft metal (aluminium) sheets. By applying this procedure to an Interstitial Free steel (IF steel), 2.7µm grain sized material was obtained after recrystallisation. Its mechanical properties (hardness, formability in shear, hardenability and faigue limit) were investigated and compared with the properties of the same IF steel with conventional grain sizes (12m and 25µm).

Jan 1, 2004

By Rolf Andreas Lauten, Adam Pratomo, Dani Ramdani, Helminton Sitanggang

A universal challenge for the mineral processing industry is the diminishment of high grade ores. Instead, low grade ores, sometimes also containing problematic gangue minerals is the reality. With lower head grades the industry has to put more effort into processing to maintain the output and achieve suitable recoveries. In an effort to reduce the impact of declining head grade, a biopolymer was evaluated as an additive in the gold leaching operation at Antam Pongkor in Indonesia. Laboratory testing revealed that biopolymer usage lead to an increased gold recovery without apparent negative impact on the other parts of the process. Further plant trials revealed both a recovery increase around 1.3% and higher throughput (9%) in the presence of the biopolymer. Some scenarios that can explain these findings will be discussed.

Jan 1, 2014

By Cesar H. Oboni

The development of specific risk-based methodologies to guide and prioritize clearing decisions in countries contaminated by Unexploded Ordnance and Land Mines (generically defined as Explosive Remnants of War: ERW) either at country-wide scale or road-network-scale was used in an unexpected way when a large mining company asked Riskope (www.riskope.com) to develop a multi-modal transportation network risk assessment plan, which included ocean going vessels, ports, wharves, railroad, trucking and other modes of transportation. What had been a first-in-the-world attempt in the humanitarian landmine clearing industry turned out to be extremely useful and equally innovative in the extractive corporate world. Instead of a country contaminated by man-made hazards such as Explosive Remnants of War (ERW) we were now dealing with a very complex multi-modal transportation system afflicted by all sorts of potential hazards from quakes to climate change, sabotage to labour strikes, and vulnerable infrastructures to potential energy crises. Interestingly enough the method developed to deal with ERW risk based clearing was also capable of solving the transportation risk evaluation problem, after necessary customization. This paper shows how ?out of the box? thinking and industry cross dissemination can bring significant evolution and a competitive edge even to unexpected areas of the world-wide mining industry. The results of the logistic system risk assessment shed new light on the management of the system, changed the way insurance coverage was purchased, and led to significant potential cost reductions in a period of global recession.

May 1, 2010

By Jean-Jacques Bouillon, Michel Jébrak, Stephane Faure

"Le gisement polymétallique (Cu-Zn-Au-Ag) des Mines Selbaie est forme par un réseau de filons encaisses dans une séquence de pyroclastites felsiques du sill on Harricana-Turgeon. Les minéralisations sont encaissées dans le tuf de Selbaie, situe sous une épaisse séquence d'ignimbrites Iitées. Ce gisement se distingue des autres gites archéens par une chronologie atypique des minéralisations: les veines de chalcopyrite, de sphalérite et de galène recoupent un amas exhalatifpyriteux stérile. Un vaste halo d'altération hydrothermale a chlorite et mica blanc est associe à cette minéralisation.La mise en place des veines minéralisées est associée à une phase d'extension NNW-SSE. Le complexe volcanique subit, par la suite, trois phases de déformation. Une compression, orienté N-S, développe une schistosité à peine pénétrative et un réseau de fentes de tension. Une réorientation des contraintes locales selon une direction WNW-ESE conduit au chevauchement de I' écaille d'andésite et de tonalite de Brouillan. Un réseau conjugue de failles normales cassantes est associe au relâchement des contraintes."

Jan 1, 1990

By Wei Huang, Anh V. Nguyen

"Potash flotation is an industrially proven success of flotation of soluble salts, but its collector adsorption mechanism remains elusive. In this paper, specific ion effects in NaCl-KCl flotation with carboxylate collectors were investigated. Flotation recovery and contact angle were determined as a function of brine composition of NaCl and KCl. The experimental results have shown that wettability of KCl and flotation of the soluble salts with laurate collectors were dependent on brine ion composition. Specifically, adding Na+ to brines decreased hydrophobicity of KCl crystals and their flotation recovery. Both KCl and NaCl could be floated with laurate collectors. However, flotation of NaCl was greatly enhanced by adding K+ to brine whereas flotation of KCl was significantly suppressed by the presence of Na ions. The decrease in KCl recovery upon adding Na+ is attributed to the counter-ion binding in the pulp. The flotation recovery enhancement of NaCl in the presence of K+ is explained by two effects: 1) increasing K+ concentration leads to a better dispersion of collector colloids in the pulp and 2) K+ enhances the collector adsorption at NaCl crystal surfaces. The water affinity matching rule can explain the specific ion binding behaviors and supported by the SFG spectroscopic results.INTRODUCTIONPotassium is an important fertilizer. Its primary source comes from potash ores, which are a mixture of sylvite (KCl), halite (NaCl) and many other complex double salts such as carnallite (KCl·MgCl·6H2O), alkali nitrates such as KNO3 and NaNO3, and sulfates-langbeinite (2MgSO4·K2SO4) with water-insoluble minerals such as clay and carbonate minerals. Previously, these salts were recovered with a lengthy hot leaching method, with further crystallization of potassium salts from saturated saline solutions. Selective flotation has been preferred since 1940s. Various collector adsorption mechanisms have been proposed soon after the industrial introduction of potash flotation. These include the formation of the insoluble compound model (Halbich, 1933; Singewald, 1961), an ion exchange model (Fuerstenau and Fuerstenau, 1956), a heat of solution model (Rogers, 1957), the surface hydration model (Schubert, 1988), the surface charge model (Roman, 1966; Miller et al., 1992), the interfacial water structure model (Hancer and Miller, 2000) and the colloid adsorption model (Leja, 1983; Burdukova and Laskowski, 2009). Most of the early exercises attempting to propose a unified rule on collector adsorption mechanisms can be seen as heroic endeavors due to the consideration of a vast number of salts in the pulp including alkali halides, nitrates, and sulfates, even the practically insoluble heavy earth metals. Additionally, several types of surfactants with different polarization features and alkyl chain length have been employed. As for the recent models, due probably to the preferential application of long chain amines as collectors in industrial potash flotation, most researchers are only devoted to collectors with low polarization features like amines and sulfonates (Hancer and Miller, 2000; Du et al., 2014). Collector adsorption mechanisms are therefore proposed based largely on a neglect of carboxylates as collectors. However, carboxylates remain an important collector type in soluble salt flotation systems where both salt minerals can be floated using anionic collectors and cationic collectors. Fatty acid type collectors are still one of the widely used collectors for soluble salt flotation and also one of the first to be applied on an industrial scale for the separation of potash ore (Hernáinz et al., 2003; Titkov, 2004). Here we examine some recent models that are relevant to our study to reveal a long neglected specific ion binding effects in potash flotation."

Jan 1, 2016

By M. Tanaka, H. Narita, T. Fuchikami, K. Morisaku, K. Nagao, T. Yoshida, K. Kuroda

The effect of various N-substituents on the performance of amide-containing tertiary amine compounds in the extraction of Rh(III) from HCl solutions was investigated to optimize the structure of these compounds for industrial use. It was found that N-2-ethylhexyl-bis(N-di-2-ethylhexyl-ethylamide)amine and tris(N-di-2-ethylhexyl-ethylamide)amine, which have long, branched alkyl chains, were suitable for Rh extraction, because they were soluble in a practical diluent (80 vol% n-dodecane?20 vol% 2-ethylhexanol) and stable against highly concentrated HCl/Rh solutions, and showed high selectivity for Rh(III) over Pd(II) and Pt(IV).

Jan 1, 2014

By H. Higuchi

The Sumitomo Metal Mining Company Ltd. (SMM) started to produce electrolytic nickel at the Niihama Nickel Refinery in 1939. In 1992, the conventional matte electrorefining process was converted to the matte chlorine leach electrowinning (MCLE) process, which is currently in practice. SMM has mainly used two kinds of nickel matte as the raw material for the MCLE process. Treatment of new raw materials, which have different impurity contents from the original nickel matte, has become mandatory because of changes in the market. Therefore, the MCLE process has been required to increase its flexibility to treat the different impurity contents in the new raw materials. An increase in the capacity for iron removal is included in such requirements. A new iron removal circuit in the MCLE process, based on a process development study, was recently installed. The iron removal circuit is in operation, and efforts are currently underway to optimize the performance of the circuit by changing the present operating parameters. In addition to the removal of the iron, the application is also expected to improve the nickel recovery. The outline of the new circuit and the current iron balance in the MCLE process are described in this paper, together with the effect of the circuit on iron treatment capacity.

Jan 1, 2006

By M. Mbonimpa

Field experimental cells were constructed in 2007 to assess the performance of different cover scenarios for the reclamation of the Parc 1 tailings disposal facility at the Westwood-Doyon Mine site (Abitibi, Quebec). Three configurations of cover with capillary barrier effects (CCBEs) with different thicknesses and material types for the moisture retention layer (MRL) were studied. MRL with 80 cm till, 40 cm till, and 40 cm clayey silt were used for cell nos. 2, 3, and 5, respectively. The capillary barrier layer (CBL) and drainage and protection layer (DPL) of the CCBE consisted of 30 cm gravel. A reference cell without cover was also constructed to compare the geochemical performance of the CCBEs. Due to an unexpected flooding in the leachate exit area of the cells in spring 2008, the cell instrumentation for hydrogeotechnical monitoring was postponed to spring 2009. Changes with time in volumetric water content, suction, soil oxygen concentration, and temperature were measured at different depths. This paper presents and discusses preliminary results obtained from spring 2009 to autumn 2010. In all cases, the degree of saturation Sr is lower in the CBL than in the MRL, indicating the presence of capillary barrier effects at the interface of these layers. Cell nos. 2 and 5 showed hydrogeotechnical behavior typical of an effective CCBE, with Sr maintained above 85% in the MRL and lower than 30?50% in the DPL and CBL. Based on the obtained results, and as expected, MRL thickness and the type of construction material used appear to affect the hydrogeotechnical behavior of the CCBE. Oxygen concentration profiles through the CCBEs were used to estimate the oxygen flux, and results indicate that cell nos. 2 and 3 performed better than cell no. 3. CCBE performance is currently being investigated using the geochemical monitoring data.

Aug 1, 2013

By D. F. Malan

"This document highlights some of the topical problems associated with the design and support of deep tabular excavations in hard rock. The displacement discontinuity boundary element method has been used for at least five decades to analyse stress and displacement distributions around narrow width excavations with complex plan outlines. The assumption is made in most cases that the rock mass surrounding the excavation is perfectly elastic. Although this approach works well to minimise stress concentrations in practice, it has limitations as important parameters, such as the effect of mining rate, cannot be investigated. Recently, a limit equilibrium model has been studied as a means to enhance standard layout design exercises by including an interactive on-reef damage model. This approach can include explicit energy release dissipation computations. A second problem faced by engineers in the mining industry is the evaluation of pillar and remnant stress. The paper highlights two aspects namely the effect of element size in displacement discontinuity modeling on pillar stress and the difficulty to estimate the effect of total closure on the regeneration of stress in old mining areas. Regarding the support of the tabular excavations, current efforts are focussed on providing improved aerial coverage using hangingwall bolting and temporary nets. An unresolved issue is the installation of permanent mesh in low stoping width areas. INTRODUCTIONSince 1886, more than 50 000 tons of gold has been mined in the Witwatersrand Basin of South Africa (Hartnady, 2009). The nearby platinum mines also saw significant growth in recent years and more than 80% of the world’s platinum group metal reserves are contained in the Bushveld Complex of South Africa (Nell, 2004). Apart from the economic aspects, the mines served as an outstanding rock engineering “laboratory” for many decades owing to the deep, tabular nature of the excavations. The period from 1960 to 1980 was especially lucrative in terms of research and world-renowned researchers investigated the support and rockburst problems (e.g. see Cook et al., 1966; Salamon, 1968; Bienawski, 1973; Wagner, 1984). Many of the rock-related problems nevertheless persist up to the present day and this paper explores some of these problems and recent progress. The production of gold declined substantially in recent years (Hartnady, 2009) and well-directed rock engineering research can play a meaningful role to slow this trend. The objective of the document is to highlight critical areas requiring additional research and not to discuss the topics in detail. The reader is referred to the many references for additional information. The paper only focuses on three areas namely numerical modelling, pillar stress estimation and aerial support. Although these are diverse topics, it is included in one paper to illustrate the many unsolved and practical problems associated with deep tabular excavations."

Jan 1, 2015

By W. Basuki, B. Setyotomo, L. Hakim, R. Hendrajaya

Due to high crack sensitivity of slab product of gas and oil line pipe application, its steel making process and alloy composition were evaluated and then improved to overcome its critical solidification process and reduced surface defects. The study was conducted at Slab Steel Plant Krakatau Steel. The purpose was to improve slab surface quality by reducing surface defects so that the slab surface doesn't need to be totally repaired. The method applied was by performing plant trial process, which the secondary process parameters such as alloying method and the casting parameters such as casting powder selection, metallurgical cooling, mould level control, and superheat were continuously monitored and then adjusted to the surface quality of the product. Based on the calculation of Ferrite potential of the steel, the chemical composition was designed to achieve optimum casting parameters in order to avoid high shrinkage during solidification. The results of the study are decreased surface defect quantity, and smooth casting process. The quantity of crack decreased by almost 90%. The slab surface repairing was significantly reduced from 85. % to less than 10%. These new casting parameters and developed alloy composition are then used and standardized for the mass production of the steel.

Jan 1, 2005