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By Xiyun Yang

Magnetite was prepared by hydrogen reduction method. For a conversion to cobalt-modified magnetite, magnetite particles were suspended into a solution containing Co2+ and Fe2+ to precipitate a cobalt ferrite layer on the surface. pH value influences the particle composition directly, the desirable CoFe2O4 is obtained when pH value is 12. The coercivity increases with the increase of cobalt content, cobalt efficiency reaches a maximum value at cobalt content of 2.71wt%. With cobalt modification, magnetite particles have similar lattice constant and squareness ratio to that without cobalt modification. TEM and XPS analyses indicate that acicular morphology is retained during the coating process, the epitaxial growth layer consists of CoFe2O4and 0.3Co2O3CoFe2O4 at cobalt content of 2.71wt% and 5.03wt%, respectively.

Jan 1, 2006

By Bruce Hebblewhite

This paper recognises the 25th year of the Morgantown International Ground Control in Mining Conference, by offering a twenty five year review of ground control in the Australian mining industry ? primarily in underground coal. The paper provides an overview of the developments in ground control design methodologies, practices and products. It not only summarises what has been done, but attempts to highlight at least some of the major issues, significant developments, controversies and areas of contention, plus some of the continuing gaps in our understanding or capabilities as we go forward into the next 25 years. Some of the issues included are in relation to: the development of the high strength bolt and cable reinforcement practices widely adopted today and the contrast between stiff and soft systems; a focus on local detail, at the expense of understanding regional stability concerns; dramatic improvements in the use of, and systems available for underground geotechnical instrumentation and monitoring; some of the ground control management trends, including occupational health and safety concerns, availability of suitably trained staff and legislative requirements; the opposing approaches of the empiricists versus the numerical modellers ? is there some middle ground?

Jan 1, 2006

By A. P. Schissler

Mining has several characteristics, uncommon in other business sectors, which pose additional challenges to the implementation or design of IT and management systems that use the information. Understanding these characteristics would improve the chances of successfully importing new information technology and management techniques to mineral producers. The most important characteristics that should be understood are workplace issues, the industry’s dual nature of being a continuous construction project using cyclical factory processes, labour challenges, workplace culture, information availability, integrative data elements, and the current technical education of mining engineers. These characteristics were taken into account in two applications of information technology and systems design at operating companies. The research and consulting projects focused on the development of an IT-enabled performance management system at several underground metal mines in Canada and an integrated data warehouse for surface mines spread throughout the United States and Latin America.

Jan 1, 2006

By David Davison

Metafex®* is an inert material that is more energetic than explosives when activated. Because Metafex is inert until activated (a moment before use), it can profoundly change the logistics of systems and processes that require energetic materials. We have obtained positive test results for a Metafex configuration (called a flat pack) that operates at the practical voltage of ~20 kV. We describe the outcome of the testing and potential uses of the material.

Jan 1, 2006

By Florian Kongoli

While calcium ferrite slags have been successfully used in continuous copper converting for the last 30 years, ferrous calcium silicate slag was proposed about 8 years ago as an additional alternative for copper smelting. Although both slags are normal extensions of each other their phase relations have not been completely clarified. In this paper the liquidus relations of both slags have been quantified at various areas that cover both of them. The existing experimental data have been first reviewed and discussed in relation to the solidification procedure. An original physical model is then used to predict various diagrams of the liquidus surface of both slags. It is shown that the ternary liquidus diagrams normally used for FeOx-SiO2-CaO system are not suitable for industrial slags. The new model diagrams of Fe/CaO versus SiO2 and Fe/SiO2 versus CaO as well as Fe/CaO versus Temperature and Fe/SiO2 versus temperature are proven to be much more convenient for ferrite and ferrous calcium silicate slags. Based on these diagrams the effect of SiO2 and CaO on the melting temperature is quantified. The effect of Cu2O is also quantified through the model. Some Fe/CaO versus Cu2O and Fe/SiO2versus CaO at various copper contents are predicted and the results show good agreement with the experimental data. It is also shown that in the presence of liquid copper, Cu2O is dissolved in the slag depending on the oxidation degree of the system and might lower the liquidus temperature. Some discussions are also presented taking into account plant observations and important conclusions are drawn for copper smelting and converting

Jan 1, 2006

By Pinakin C. Chaubal

Today?s steel industry is in a vibrant and resurgent mode. This transformation has been in the making for some time now. Over the last few decades, the industry was steadily transforming itself into becoming a high tech industry. New technology was adopted, efficiencies were enhanced, lean manufacturing concepts were brought in and a strong customer focus was developed. Today?s mills employ sophisticated instrumentation, computerized monitoring, on-line smart systems etc. driving processes that are producing at rates of many tons/minute. All this is not possible without judiciously using the latest available technologies in various fields and developing a more sophisticated work force. Prof. Sohn has been a pioneer in driving the concept of process engineering in process metallurgy. In this paper the focus is on some aspects of process engineering ? primarily process modeling - as applied to iron and steelmaking processes. Examples are shown to demonstrate how problems have been addressed. Some thoughts on future directions are presented.

Jan 1, 2006

By B. Daniels, A. Tieu, W. Yan, B. Ren, M. Vijay

"Plasma or thermal sprayed coatings are becoming more widely used in a wide range of industrial applications. The preference to use thermal sprayed coatings is mainly attributed to its superior wear, and corrosion resistant properties akin to hard chrome but without the harmful health implications of chrome in the coating process. Specifically, High Velocity Oxygen Fuel (HVOF) plasma sprayed Tungsten Carbide & Cobalt (WC/Co) coatings are presently being tested on aircraft landing gear. This coating can be efficiently applied and is highly resistant to corrosion and wear. However, HVOF coating's durability also makes it difficult to be stripped for inspection and overhaul. Current coating removal methods usually involve a multi-step process whereby the coating must undergo diamond wheel grinding, chemical dipping, grit blasting, ultrahigh pressure (UHP) 380 MPa (55 Kpsi) water blasting, and subsequent chemical dipping, depending on the type and thickness of the coating. As explained by Yan, et al [l]"" a unique method has been developed for removing HVOF coatings with the use of only water. The method consists of modulating a stream of water at a pressure of only 69 MPa (10 Kpsi) with ultrasonic waves to generate a forced pulsed waterjet. The resulting cyclic loading of the hard coating due to the impact of the water pulses easily causes it to flake off the substrate. This paper will briefly describe the fundamentals of the forced pulsed waterjet technique with an emphasis on insitu applications of the removal of various plasma and HVOF coatings."

Jan 1, 2006

By Daryl W. Wurster

The Liberty Bridge in Greenville, South Carolina is a curved, cable-stayed, pedestrian bridge with primary support provided by two towers. The bridge is part of the Falls Park redevelopment. The bridge was originally designed to be supported on drilled piers. Alternately, the bridge was supported on a combination of micropiles and anchor piles because of difficult access and subsurface conditions. The use of micropiles and anchor piles led to improved construction scheduling and reduced costs. Micropiles were used to resist compressive loads. Anchor piles were used to resist tensile forces and to eliminate excessive settlement of pile caps into underlying fill during pre-stressing. This paper describes the site history, bridge construction, site and subsurface conditions encountered, and the decisions that led to support of the bridge using micropiles and anchor piles and foundation construction.

Jan 1, 2006

By José Carlos D?Abreu

The Tecnored process is a new ironmaking technology, developed on a unique approach that combined empirical and theoretical knowledge backed by extensive tests carried out in a dedicated pilot-plant and with close support of universities and research centers. Campaigns in the pilot-plant focused on operate different reactors of different sizes, including a full size slice of the industrial furnace. This approach provided actual conditions to develop the main features of the process such as the internal dimensions, raceway pattern, thermal and gaseous profiles, etc, besides provide reliable data to feed and calibrate a specific mathematical process modeling. This paper presents the first computer model used by the Tecnored technical staff, focusing the behavior of a self reducing agglomerate in the upper shaft of the furnace (zone of solid state reduction). Some results of this model are given and discussed.

Jan 1, 2006

By C. Pelley, S. Kelebek, T. Katsabanis, B. Nanthakumar

"As part of a larger investigation on generation of fines from mining activities and their effect on downstream operations, ore samples from Onaping area stockpiles of Falconbridge Ltd were studied. Batch flotation tests were conducted on the stockpile samples and fresh ore samples to explore the effect of stockpiling on grade-recovery performance. Head grade and particle size distribution of the samples from stockpiles were adjusted so that the samples compared are similar to each other. In additional tests, fresh ore samples were blended with stockpile samples at various percentages, representing 27.4, 50.2 and 81.5% of stockpile samples.The samples from stockpiles produced inferior nickel grade-recovery curves compared to fresh ore. The poorer grade-recovery performance was attributable to two factors. First, a significant dilution effect was observed due to the nearly complete flotation of pyrrhotite. Secondly, while pyrrhotite from stockpiled ore became highly floatable, the same stockpiling conditions caused nickel losses that were attributable to non-floatability of some pentlandite.In the case of blending, there was generally insignificant difference in the nickel grade-recovery between fresh and blended samples when the blending cases involved 27.4 and 50.2% stockpile samples. However, an increase in pyrrhotite recovery was observed for both blending cases. At 81.5% blending case, degraded grade-recovery was significant primarily due to the nearly complete flotation of pyrrhotite. There was a small, but noticeable amount of nickel loss for this case. However, for lower ratios of blending this loss was negligible.The increase in pyrrhotite recovery was partly attributed to its activation by Cu and Ni ions. Formation of a significant amount of elemental sulphur was also apparent from analysis of stockpiled samples. It can be concluded that pyrrhotite is mildly oxidized under stockpiling conditions while part of the pentlandite undergoes a more severe oxidation."

Jan 1, 2006

By S. Akhlaghi

In many electronic/optoelectronic devices, interaction between the metal stack and solder is undesirable. If a reaction happens, a nonuniform joint containing spikes and voids is likely to form and as a result the heat dissipation deteriorates significantly, which in turn, leads to the degradation of the bond. In the present work the interaction between Ti/Mo/ Au metallization system, which was sputter deposited on AlN substrates, and Pb-Sn solder was studied by using scanning electron microscopy (SEM). Also, an EDX system was used to trace the changes in chemical composition of the layers after solder tests. The microstructural examinations show that the Ti and Mo layer from the Ti/Mo/ Au metallization system are not impermeable enough and thus Ca from the surface of the substrate moves all the way up to the interface of Au/Mo and forms an intermetallic at the interface, which grows over time.

Jan 1, 2006

By Richard Campbell

Effective strata control, utilising fully encapsulated resin grouted roof bolts is dependent on the installed quality of the reinforcement elements. Resin based grouts are the main form of rock bolt anchorage in the underground coal industry in Australia and New Zealand. To be effective the system requires the mixing of the catalyst and mastic components of the resin as well as shredding of the cartridge that contains the resin. Over the past six years Solid Energy New Zealand Ltd (SENZ) has pioneered an extensive work programme quantifying the effects and extent of poor installation quality due to gloving, poor mixing and loss of encapsulation (Pastars 2003, Campbell et al 2003, Mould et al 2004, Campbell et al 2005 and Pastars & MacGregor, 2005). The One-Step Bolt (OSB), an innovative bolting solution designed and manufactured by Hilti Pty Ltd offers a self drilling, single pass bolting method that eliminates gloving, guarantees mixing quality and encapsulation performance of the installed product while not jeopardising the mechanical performance of the bolt. This paper details recent work undertaken by SENZ designed to understand and quantify the system performance of the Hilti OSB in New Zealand?s thick coal seam mining environments.

Jan 1, 2006

By A. O. Orumwense

Mill circumferential speed, the number of passes of pulp through the grinding chamber, media type, size and filling ratio were investigated in an attempt to determine how to effectively grind copper concentrates in a stirred mill. The stirred mill product fineness was enhanced to some extent by decreasing media size, high media filling, and an increased number of passes of the pulp through the grinding chamber. Shape also plays a major role in grinding media effectiveness, with spherically shaped media producing a finer size. The fineness of the product increases with increasing power consumption but the method of energy transfer is very important in energy utilization. The effect of the mill parameters on copper flotation was evaluated. Copper recovery was influenced by grinding media size, mill speed and the number of pulp passes through the grinding chamber.

Jan 1, 2006

By M. K. Elmouttie, G. V. Poropat

Mapping of exposed rock walls provides data on geological features such as joints, bedding planes, faults etc critical to the economics and the safety of mine operations. Traditional, manual methods of mapping can be time consuming, error prone and limited in their coverage. New methods have been developed to map exposed faces remotely and safely however the benefits of these methods are only fully realised when exposed structures can be quickly and easily mapped using automated methods. This paper describes the application of an automated method of analysis of 3D images that provides users with the capacity to map exposed structures automatically. The method is based on the use of vector classification methods used in some neural network systems and provides rapid and reliable identification of exposed planes. CSIRO Exploration and Mining is applying these methods to 3D images for a range of applications from pit mapping to machine automation.

Jan 1, 2006

By Y. L. Mehta

The working experience of the Zinc Smelter, Debari, Udaipur with process modifications and iron control practices is described in detail in this paper. Most of the modifications were made at different times as part of capacity enhancement campaigns that led to distinct advantages, thereby increasing both zinc production and recoveries. This smelter came into existence in 1968 with a humble beginning of producing 18,000 metric tonnes (MT) of zinc per annum, using the conventional batch hydrometallurgical roast-leach-electrowinning technology. Zinc production capacity was increased stepwise to 45,000 MT, 49,000 MT and 59,000 MT, by making suitable process modifications and adopting new technologies, particularly in the leaching section. During these modifications, the process of iron separation as Moore cake was also changed to jarosite cake production. At present, jarosite is being disposed in a secured landfill at the Zinc Smelter, Debari (ZSD) and as Jarofix at the Chanderiya Lead Zinc Smelter (CLZS). As a result of subsequent in-house performance improvement and debottlenecking campaigns, this smelter could achieve further increases in production. Zinc production for the financial year 2005-06 was 81,000 MT.

Jan 1, 2006

By T. Bernard, P. Dozolme

Electronic initiation devices appeared on the market more than 15 years ago and have definitely changed the rules of blasting. It becomes clear that this technology represents a powerful alternative to the traditional accessories. Electronic Delay Detonators (EDD) have attained solutions that were difficult and even impossible to achieve with the previous technology, thanks to the accuracy, usually inferior to one millisecond, and flexibility of the programmability range offering thousands of timing possibilities. Technological progress is long awaited to represent a step ahead compared with the last generation of products. In the case of electronic initiation, some limits nevertheless rapidly appeared, leading to the paradox of loosing operative and safety benefits, compared with the traditional technology it was supposed to outclass.

Jan 1, 2006

By M. England

Keywords: Bi-directional tests, Osterberg cell, O-cell®, static load tests, Timeset® Static load testing, where loads are applied vertically to the top of the pile and often referred to as 'top down testing', has been used for many years and has become a 'standard' test for the world of foundation engineering. The method, although well developed, cannot be used under certain circumstances, magnitude of load being a particular issue. There is a finite limit to the load capacity that can be applied with either kentledge, the use of reaction piles or anchors, and as the loads increase, the costs escalate dramatically. A novel test method seeks to overcome all the associated problems of large scale and restrictive area "top down testing", utilising static load testing techniques. The method requires the foundation element to be divided into two or more sections and these can be loaded axially as required using a portion of the foundation element as a reaction. This paper presents some recent applications and developments in the use and application of the bi-directional testing technique using the Osterberg Cell or O-cell® and outlines some of the many advantages of the system. Recent bi-directional test loads applied to bored piles have mobilised capacities of 279 MN and with flight auger piles up to 25 MN.

Jan 1, 2006

By L. Dubourg, H. Habibi, D. Rasmussen

The combination of laser welding with Gas Metal Arc Welding (GMA W) forms the hybrid laser-OMA W welding. This process is an attractive tool with a high potential in welding lightweight structures, especially for aluminum alloys. For five years, this technology has increasingly attracted interest in both, industry (aeronautics, automobile, metal industries producing large structures) and academia (universities and research centers). Hybrid laser-OMA W welding process is generally accepted for its robustness, efficiency and flexibility. Coupling of a deep-penetrating laser beam with the heat and molten metal feeding of GMA W significantly expands the original welding application range of lasers. Its main advantages compared to the two individual components are deep and stable weld penetration, gap-bridging ability improvement, low distortion and easy filler metal addition. Hybrid welding allows a much wider groove tolerance compared to laser welding, especially for aluminum welding. Moreover, the reduction in distortion decreases the post-welding rectification needed and makes the assembly easier. In addition, if metallurgical factors are critical, the weld composition can be balanced with filler metal, decreasing the hot cracking susceptibility of some aluminum alloys. The combination of these two welding processes can also improve the weld bead shape quality (including the elimination of undercut), possibly reduce the porosity and increase the welding speed. This article reviews the recent works about the laser-OMA W hybrid welding of aluminum alloys. After a brief presentation on the interaction mechanisms between a laser beam and an electric arc, the paper depicts the typical welding parameters and experimental methods along with their characteristics.

Jan 1, 2006

By Tsunehisa Nishimura

Stable operation of the blast furnace needs adequate control of the lower part. To clarify the behavior of the lower part of the blast furnace with accurate consideration of the property of slag and its flow characteristic, a new mathematical model has been developed. Using this model, the effects of the change of operational conditions on the behavior of the lower part of the blast furnace were studied. Further, means to control of the lower part of the blast furnace, especially effective means to maintain adequate temperature, were discussed. And desirable slag property and composition, especially the method to control FeO concentration dripping from the bottom of the cohesive zone to avoid a decrease in temperature of the lower part of the blast furnace was estimated.

Jan 1, 2006

By Dirk Verhulst

The Altair Hydrochloride Pigment Process is a new ?third route?, besides the established high-temperature chloride process and the older sulfate process, to manufacture TiO2 pigment from ilmenite ore. It has been tested at a scale of 5 t/day feed. The ore concentrate is digested in high-acid, high total chloride solution (+/- 39% Cl). Titanium and iron both go into solution. Iron is separated as FeCl2 crystals after reduction and cooling. Titanium is transferred by solvent extraction into a purified, high-Ti stream. It is spray-hydrolyzed to produce a TiO2 hydrate and further calcined with additives into high-quality pigment. HCl solutions generated by pyrohydrolysis and spray hydrolysis are treated by pressure-swing distillation to regenerate HCl gas for re-injection into the digestion reactor. All chloride streams are recycled. Recent work has concentrated on optimization, particularly in 3 areas: - Solvent extraction: a new organic mixture, including a new diluent, makes it possible to work at room temperature, to avoid TiO2 hydrolysis problems and to improve phase disengagement and impurity separation. - Pigment finishing: a systematic study of the parameters involved, followed by long runs in the best conditions confirm pigment quality. - Flow sheet optimization: innovative modifications of the conditions of spray hydrolysis and pyrohydrolysis, combined with re-routing of streams achieve significant energy savings. A 100 t/year pilot plant including these features as well as other process improvements is under construction.

Jan 1, 2006