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By D. A. J. Swinkels

The problem of determining oxygen levels in liquid steel to aid in deoxidation control has received general attention for a number of years. Work in this direction started at the B.H.P. Central Research Laboratories early in 1967 with an evaluation of sampling techniques followed by vacuum fusion analysis to determine the oxygen content of the samples (1). It was found that these techniques had a number of drawbacks if they were to be used for deoxidation control. The method of analysis was rather too slow to allow effective control and measured total oxygen level rather than dissolved oxygen. Furthermore, the results were found to be very variable due to slag entrainment in the samples. Attention therefore turned to the galvanic cell method using a solid oxygen ion conductive electrolyte such as cubic stabilised zirconia. The ionic conductivity properties of electrolytes such as (ZrO2) 85 (CaO).15 had been studied by a number of investigators and had already been applied to the measurement of oxygen activity in gases, in lower melting metals such as copper, lead, tin, silver, alkali metals and indeed the first studies in steel had been made (2,3). Since then the results of a number of studies in the development of an expendable oxygen probe for steel have been reported (4-9).

Jan 1, 1972

By Armstrong AB

It has been identified that particulate matter in the form of suspended solids and bed load has the ability to adsorb heavy metals. Each year Ranger Uranium Mines Pty Ltd (RUM) identifies potential danger areas which could become major sediment sources during the wet season. Methods of suppressing sediment uptake such as hydromulching and coating areas with Poly Vinyl Acetate (PVA) glue are used. Other methods of reducing the sediment load after uptake such as diversion bunds, filters across drains, stone filters, minor sumps and settling ponds are also used. The 1983/84 wet season saw drain sediment loads reduced to acceptable levels before the water reached the outside environment. Studies to qualify and quantify flows from minor drains are still underway.

Jan 1, 1984

By C. S. Barrett

IT has been observed that deformation in iron takes place by slip on {110} + {112} + {123} planes1,2 but in silicon ferrite with low deforma-tion temperatures or high silicon contents (exceeding 4 per cent) the authors have found that slip is confined wholly to {110} planes, at least with small amounts of deformation. The purpose of the present inves-tigation was to determine the effect of this alteration of slip mechanism on preferred orientations in cold-rolled and recrystallized strips. Inci-dental observations on the effect of the recrystallization temperature were also made. The numerous determinations of the texture of cold-rolled iron and steel have been in satisfactory agreement as to the principal features of the texture. (with the exception of a few conclusions that apparently have been based on insufficient data). The texture is chiefly one in which [110] directions of the grains lie along tile direction of rolling, with a deviation of a few degrees, and in which the (100) planes lie in the plane of the rolled sheet, with a deviation from this position chiefly about the rolling direc-tion as all axis 3-9. This deviation about the rolling direction as an axis has been measured by different observers and lies between about 45° and 50° or 60° for iron5,6,9 and is usually in the neighborhood of 50° for mild steel6,7,8. The range of this deviation is a function of the percentage of total reduction 8, 10. Post' reported that it decreases with increasing percentage reduction, but apparently he .studied only the surface material, which Gensamer and Mehl7 found to be somewhat differently oriented from the material in the inside of the sheet. McLachlan and Davey10 found that the deviation also decreases with increasing percentage of total reduction for the material in the interior of the sheet and is independent of the percentage of reduction per pass.

Jan 1, 1937

By R. S. Hooper

In attempting to describe recent mining developments at the Bunker Hill mine, it may be well to recall first the old days of hand mining when holes were laboriously drilled by hand to a maximum depth of three feet, and were shot one or two at a time, in order that the miner could take advantage of every slip, crack or bedding plane, and so save as much drilling as possible. Broken muck, of course, was loaded by hand shoveling into wheelbarrows or small cars, and heading advances or stope tonnages were governed by the number of men that could find room to work in any given place. The first big improvement over these old methods was the introduction of the reciprocating type of air-powered rock drill. This innovation, crude as it was, enabled the miners to set up a machine and drill a complete round of holes in one shift; but broken muck was still loaded by hand, and the size and rate of advance in headings were limited by time required to remove the broken rock. The next improvement of consequence was the appearance of the hammer-type rock drill, which greatly increased drilling speed over the reciprocating type, and made possible the completion of a full cycle in one shift, by the use of crossbars in headings, and permitted drilling and mucking to be carried on at the same time. Rock drills continued to improve as time passed, and finally the smaller and more efficient mucking machines appeared on the scene, and it became possible to muck out a round of broken rock and have a clean setup for one or more drill columns and machines. A complete cycle of mucking, drilling, and blasting was completed in one shift with an average advance of five feet. These conditions prevailed for several years, but as the mine grew deeper, the distances to transport the workers grew longer, and this fact together with the shortening of the working day, soon presented the problem of attempting to complete a cycle of operations in a shift of only six hours at the working faces. Anticipating this condition, the operating heads at the Bunker Hill had started an intensive study of more and better mechanization, and over a period of comparatively few years have adopted and placed in service methods and machines that make it possible for a three-man crew to consistently advance headings seven by nine feet in cross section, at the rate of eight feet, and more, per shift, doing all the mucking, switching, drilling and loading. These improvements consist of the following major items: I. The development of a light, flexible, easily transported jumbo equipped with pneumatic columns (Fig I), that has decreased the "setting up" and "tearing down" time an average of 11/2 hr per shift, Or 25 PCt of the available working time. These jumbos were developed at the Bunker Hill mine by members of the staff and consist of two pneumatic columns attached to a suitable carriage. They fold

Jan 1, 1949

By V. Nudo, R. del Villar, A. R. Laplante

"Fine iron ore recovery from the tails of Les Mines Quebec Cartier was investigated using Reichert trays and spirals. The effect of feed rate, density and splitter setting on the performance of rougher, cleaner and recleaner stages of a 2DS tray assembly was determined using 2- and 3- factorial experimental designs. The tray concentrate, assaying 27% Fe, was further upgraded by spiral to yield a concentrate assaying 55% Fe. Further laboratory scale testing showed this material to be easily upgraded to 65-66% Fe with high Fe recoveries.This paper presents the metallurgical results of the three tray stages. The model used to predict the performance of a full recovery circuit is then described. Simulation results are presented and their reliability assessed. Finally, an economic evaluation of the proposed scavenging circuit is summarized.INTRODUCTIONThe Mount Wright plant (UWP), located near Fermont, Quebec, processes daily 130,000-150,000 tonnes of iron ore assaying between 27 and 33% Fe, to upgrade it with three stages of 44.5 cm pitch GEC spirals to 66% Fe, while rejecting approximately 80,000 tonnes assaying between 6 and 11% Fe (1-3). Heavy liquid separation (at 3. 3 g/mL) of the plus 37 µm fraction (+400 mesh) of the tails reveals that a significant fraction of the iron is in the sink product, below 150 pm (100 mesh), as shown in Table 1. Also shown is the iron grade of the sink and float fractions. The high grade of the fine sink indicates that hematite ls well liberated below 105 µm (150 mesh), as previous studies have shown (4,5). The iron grade of the floats is very low in the fine size range, but increases with increasing size above 105 pm, because of incomplete liberation. Overall, two thirds of the plus 37 µm iron ls in the sink product, which constitutes less than 10% of the total tail."

Jan 1, 1987

By Golab K, Partridge AC, Fletcher CAJ, Holtham P

Spiral concentrators are used globally in the fine coal processing industry to segregate particles, by gravitation, on the basis of density and size. Consisting of an open trough that twists vertically downwards about a central axis, a slurry mix of particles and water is fed to the top of the concentrator. Particles are then separated radially as they gravitate downward. Since their introduction to Australia in the 1940's, the generic design has evolved largely by laboratory trial-and-error investigations of different prototypes. However, this approach has proven expensive and optimal designs have not been necessarily developed. Accordingly, Computational Fluid Dynamics (CFD) analysis has been used recently as an alternative method of investigation, to assume as is envisaged, a role in the design process. To date, CFD models have progressed to simulations of turbulent fluid flow on current production spiral designs, and are continuing to be adapted for inclusion of particles at realistic feed concentrations. To be able to use the models confidently however, laboratory experiments must also be performed to validate the predictions during the development stage. This paper reports the current findings of an ongoing CFD and experimental program applied to one spiral unit. Satisfactory quantitative agreement has been achieved for the fluid and particulate flow characteristics, and although further validations are appropriate, the model already possesses significant potential for use as a reliable predictive design tool.

Jan 1, 1998

By R. H. Hopkins, R. W. Kraft

X-ray and metallographic analysis reveal that the preferred cryslallograPhic relationships in direc-tionally solid~fied Pb-Sn eutectic specimens can be stated: interface growth direction, Experiments in which tin single-crystal seeds were used to nucleate the eutectic demonstrate that the normal lamellar structure observed at steady state can be forced to break down initially to a semide-generate structure when the crystallograPhic direction of the tin seed does not lie within the preferred eutectic interface plane. A normal structure eventually develops by preferred grain growth. X-ray topo-graphs and rocking curves substantiate that the perfection of eutectic samples increases as growth proceeds until steady-state conditions prevail. RECENT years have seen substantial progress made in the understanding of eutectic solidification through both intensive theoretical1'' and experimental investigations (see Ref. 7 for a review and extensive bibliography of both aspects). Several important observations concerning the nucleation and growth aspects of binary eutectic solidification have been brought to light. Briefly some of these include the nonrecipro-cal nucleation of one phase upon another,'j9 the tendency for a specific low-index direction of one or both phases of the eutectic to be aligned in the growth direction during unidirectional solidification,'0711 and the production of lamellar microstructures having a preferred interface plane between "11-13 phases. Questions quite naturally arise as to the mechanism by which preferred grain growth evolves during eutectic solidification and what relationships (if any) connect the initial nucleation of one phase upon another with the preferred growth directions and interface planes observed after a few centimeters of growth in many systems. This study was initiated in an attempt to answer these questions. An experiment was devised in which both the nucleation and growth steps in the crystallization of a binary eutectic, Pb-Sn, could be correlated with subsequently developed eutectic morphology and crystallography. This was accomplished by nucleating the eutectic upon a tin single crystal seed and then causing the eutectic to grow from the seed by directional freezing. The morphology of the structures produced in this manner was then monitored metallographically and the orientation relationships and substructural perfection determined by X-ray analysis. The information thus ob- tained was correlated to the growth history of the samples. EXPERIMENTAL DETAILS The eutectic of composition 38.1 wt pct Pb and 61.9 wt pct sn14 was prepared by accurately weighing lead and tin of 99.999+ (from ASARCO and Lytess Metals and Chemicals, respectively), melting in a clean Pyrex beaker under an argon blanket, and casting into the proper crucible for resolidification as described below. Tin seeds were grown by the method of ~halmers," saw-cut, oriented by the Laue method, and soldered to the pull rod of the Czochralski puller. All seeds were given a final electropolishing (to assure the removal of any deformed material from the cutting operation) and acetone degreasing immediately prior to the nucleation experiment in which they were to be used. Eutectic samples were unidirectionally solidified in a horizontal graphite boat1' or by pulling from the melt16 with tin (or graphite) seeds. A flowing argon atmosphere was employed in all experiments and growth rates and temperature gradients, constant for a given run, varied from 2 to 4 cm per hr and 8" to 15°C per cm over the course of all the experi-

Jan 1, 1969

The fast rate of development in the micro technology industry is enabling computer based systems to be used in ways never considered before. Micro technology can be used to great advantage in the mining industry to improve both safety and productivity. The planned use of electronic 'IN/OUT' boards at The Zinc Corporation, Limited and New Broken Hill Consolidated Limited (ZC/NBHC) mines will provide a much improved system for checking that the mines are clear before firing. The provision of remote ocaputerised core logging facilities made possible by small remote data entry terminals will greatly improve the productivity of the personnel involved in all stages of core Logging.

Jan 1, 1983

By D. W. Wu, M. T. Haque

A novel impedance probe was commissioned specifically for capturing fast dynamic information about filtration processes. It provides an attractive alternative to more complex measurement techniques in situations where the slurry system is primarily one-dimensional. The probe can monitor mudline, slurry densification and drainage. Dynamic variations in cake permeability are obtained by combining dynamic mudline information obtained with the probe and filtrate rate data derived from a leaf test apparatus. The measurements are reviewed in relation to micro structural measurements obtained on iron ore filter cakes. The practical significance of these measurements for optimization of the filtration process is discussed.

Jan 1, 2002

Jan 1, 1904

By J. Lui

The 15m high Inco flash furnace uptake was designed as a reaction chamber with the objective of destroying the H2S contained in the furnace off-gas by combustion with oxygen at about 1300?C. Until recently, the oxygen required for this purpose was injected through afterburners located at the bottom of the uptake. An undesirable side effect of this practice was the formation of build up accretions on the inside walls of the uptake. This buildup had a negative impact on both the furnace on line time and the control of the flash smelting process. In late 200 I, the afterburners were relocated to the roof of the uptake. As a result, about 80% of the uptake accretion buildup disappeared with obvious beneficial effects for the operation of the furnace. This paper discusses key flash smelting aspects that affect the operation of the flash furnace uptake such as the dusting rate, the formation of H2S in the freeboard of the furnace, and the impact of using coke to supply some of the heat required by the process. The mechanism of buildup formation and its dependence on uptake afterburners location are also examined. Prof. Yazawa's sulfide smelting thermodynamic relationships proved instrumental in understanding the conditions that influence the formation and the elimination ofH2S and uptake buildup.

Jan 1, 2003

By Schon RW, Stephens CJ

The Whitsunday Volcanics occupy most of the offshore islands from the Whitsunday Group, southeastwards through the Cumberland and Northumberland Groups, possibly extending to the mainland adjacent to Shoalwater Bay, a distance of 370 km. Some of the islands of this group are granitic, but preliminary Rb-Sr data indicate these to represent Permo-Triassic basement. Cretaceous volcanism is interpreted to have occurred during initial rifting prior to the continental breakup of northeastern Australia and subsequent development of the Tasman Basin.The volcanics comprise mainly lithic ignimbrites, with local development of inter-bedded surge and bedded tuff, accretionary lapilli tuffs, lithic concentration zones, and lag deposits. Isolated fluidual rhyolite and dacite domes occur. The deposits are considered subaerially emplaced. A Rb-Sr isochron age for volcanism of 110 Ma is determined from new data. The total thickness of the volcanics is unknown, but a minimum thickness of 4-5 km on Whitsunday Is. is suggested. Eruptive centres are inferred to be distributed throughout the volcanic zone. The volcanics are cut by numerous, dominantly near N-S, dykes ranging from dolerite through to rhyolite in composition.Chemically, the volcanics and dykes exhibit a continuous range of compositions from basaltic andesite, through andesite, dacite, to rhyolite, with minor more alkalic compositions. Phenocryst mineralogy in the silicic rocks is mainly plagioclase, augite, and Fe-Ti oxides, with less frequent quartz and hornblende occurrence. Sr and Nd isoptic compositions for volcanics and dykes are close to mantle values. These data are tentatively interpreted in terms of a lower crustal magma arc source separated from the mantle only a geologically short time prior to Cretaceous magmatism.

Jan 1, 1990

By Thomas D. Kaufmann, Robert C. Drury

Few factors are as important as fluctuations in aggregate economic activity and exchange rates in determining the profitability of mineral investments. Macroeconamic theory explains how the two factors are interconnected in today's world and in tomorrow's. We can use macro¬economic theory to lessen some of the risks in mineral investments. And in the current state of the world the risks are high. The above paragraph summarizes our argument. Our goal in this paper is to examine the nature of contemporary business cycles so as to explain their implications for the metal industries, particularly the implications for capacity. Thus, our first section examines the workings, causes, and history of the recent economic fluc¬tuations. In doing so we must understand how current world economy is interconnected, that is, how economic events in one country are trans¬mitted to the rest of the world. Our view is that governments and central banks are key actors in the creating of economic fluctuations. Then, in section two, we work out the implications of section one for the metal industries focussing on comparative advantage, trade, and capacity decisions. Over the last fifteen years the world economic system has had slow overall economic growth and has had strangely unpleasant recessions. While future business cycle will not repeat the de¬tailed pattern we have seen, there will be similarities. The similarities need to be under¬stood before investment occurs. The slow growth in the world economy since the early 1970s has aggravated the problems from business cycles, created its own problems, and has partially hidden the effects of other events. Major realignments of currencies are likely to take place over a business cycle. The nature of the causes of the cycle will determine the direc¬tion of change in the exchange rates. For example, whether a USA recession will be accompanied by a weaker or a stronger dollar will be determined by the cause of the recession. The realignment of currencies over a business cycle leads to a realignment of comparative advantage in the metal industries. Thus, not only will world metal consumption vary over the business cycle but the impact on various countries' metals industries will differ consi¬derably. Competitiveness often depends more on the value of the dollar than it does on inherent efficiency and wage rates. Capacity decisions are inherently riskier due to the country specific nature of exchange rate risk. A realignment of currencies changes the pattern of trade if and only if the country with the cheaper currency also has idle capacity. The importance of our topic is indicated by Table 1 which shows the impact of cyclical and exchange rate shocks on the USA metal industry. In the cyclical downturn, from the peak of 1979 to the trough of 1982, consumption dropped by a fifth to a third. Metal price moved in the same

Jan 1, 1989

Elastomeric compression gaskets for segmental tunnel liners are capable of fulfilling all sealing requirements for one pass constructed tunnels.Once the segments are mounted and the gaskets are compressed the watertightness of the tunnel is guaranteed at once and for the whole technical life time.The only prerequisite for effective sealing is that tolerances in the tunnel segments be kept within reasonable limits.

Jan 1, 1993

By T. Gerritsen, T. Plikas, K. Ochoa, M. Loveless, R. MacRosty, J. Reichart, R. Pula

Sidewall accretion in a smelting furnace plays an important role in furnace integrity as it provides protection to the sidewall cooling elements and thereby extends the furnace campaign life. The extreme thermal and mechanical stresses in the furnace and changes in the slag chemistry can cause the sidewall accretion to melt or break away decreasing the lining protecting the cooling elements. Thin accretion is highly undesirable as it increases the risk of exposing the cooling elements to the molten bath and in the worst case may lead to a failure. Therefore, monitoring the sidewall accretion on an operating furnace is extremely important to manage furnace integrity and to support safe furnace operation. Operators often generate estimates for sidewall accretion and refractory thickness using either copper cooler temperatures or heat load into the cooling water circuits. Multivariate statistical models, on the other hand, have the capability to consider all the process measurements simultaneously to provide a more reliable estimate. This paper describes the application of multivariate statistical models for sidewall integrity monitoring on a Flash Converting Furnace (FCF) and also discusses the online implementation of these models as the Sidewall Accretion Monitoring System. INTRODUCTION Rio Tinto’s Kennecott Utah Copper (KUC) smelter located near Salt Lake city, Utah operates a Flash Smelting Furnace (FSF) and a Flash Converting Furnace (FCF) to produce high-grade matte and blister copper respectively. Since the commissioning of smelter in 1995, several improvements were made to these furnaces to increase their efficiency and operational safety. At present, Kennecott smelter is known to be among the lowest-emission and highest energy recovery copper smelters in the world. Since the smelter start-up, Kennecott has invested in several advanced furnace monitoring practices to evaluate the integrity of the furnaces and improve their campaign life. An example is their temperature monitoring system installed for the smelting and converting furnaces, which continuously monitors the furnace sidewall temperatures and notifies the operators during temperature excursions. During an investigation on the converting furnace, it was revealed that there were frequent temperature excursions in the settler sidewall area towards the reaction shaft end of the furnace that caused significant furnace downtime. The reason for the sidewall temperature excursions was not clearly known.

Jan 1, 2019

Falconbridge Nickel, the one-time subsidiary that grew up to swallow its own parent, Ventures Limited, in 1962, is not about to be left behind by rising nickel consumption. At a cost of several hundred million dollars, this Canadian firm has undertaken a series of new projects that will not only ensure its present share of the market, but also lead it into new areas of the nickel business. Although Falconbridge Nickel Mines Ltd. was not formed until 1928, it actually had its start in 1917- 18 with the discovery of a large, good grade nickel- copper deposit in Falconbridge, near Sudbury, Ontario. However, due to several factors, financing could not be obtained and the orebody lay fallow. It was not until 1928, when the Thayer Lindsley interests bought the property from the original owner, that it was developed.

Jan 10, 1968

By D. Thibault, A. Akhiate, M. Brochu, E. Braud

Cast martensitic stainless steels, 13%Cr-4%Ni, having carbon contents between 0.018 wt% and 0.067 wt% were normalized, air quenched, and tempered at two different temperatures (550°C and 610°C). Their microstructures were characterized by optical microscopy and X-ray diffraction (XRD). Macro and microhardness, tensile strengths, and impact resistance were quantified for each material and condition. Results show that the prior-austenite grain size is constant through the materials but the percentage of reformed austenite, contained in the martensitic matrix, depends strongly on the material chemistry and on the tempering temperature and on its duration. It is observed that, independently of tempering conditions, an increase in carbon content increases the material hardness and tensile strengths, whereas the elongation remains constant. In contrast, the results of Charpy type impact toughness tests show a different trend. The material containing the average carbon content (0.034 wt%) is significantly tougher than the two other alloys. Surprisingly, the toughness of the steel containing 0.034 wt% carbon was found independent of the reformed austenite content. It is thus concluded that carbon and reformed austenite contents are not the only parameters affecting the toughness of these steels.

Jan 1, 2014

The operation of quarries for the production of crushed stone and aggregates, depends heavily on rock blasting efficiency, which usually represents a major share of total production costs. After investigating the causes of this situation, a series of technical aspects have been detected, and they are described for the purpose of contributing to the minimization of costs, which also reduces the effects of blasting on the environment. Utilization of empirical design methods, of inadequate explosive types, and of erroneous drilling pauems with respect to rock properties, are the main factors to be corrected, as a consequence of poor engineering criteria, with scarce use of computational methods and field instrumentation. Several concepts of blasting optimization are pointed out, and their application to industrial operations in a Portuguese limestone quarry indicated clear trends for the reduction of production costs, as well as some of the deleterious consequences of blasting on the environment.

Jan 1, 1990

By Lawson F

A rotating disc geometry has been used to provide a uniformly accessible surface for a kinetic study of the cementation of the metals cadmium, lead and silver from dilute aqueous solutions. This work is an extension of studies carried out on the Cu/Zn and Cu/Fe systems for which the rection rate was found to be completely solution-phase mass-transfer controlled. When the amount of material deposited was greater than 0.2 to 0.4 mg/cm2 there was an apparent enhancement in e which is attributed to the formation of a roughened deposit. This same phenomeon was obseived in the Cu/Zn Cu/Fe systems. Again, the rate of reaction of each system investigated was found to be solution-phase mass ,..~sfer controlled.

Jan 1, 1970

Both safety and productivity in underground gassy coal mines can be improved substantially if an appropriate gas management system is introduced. A strong direct relationship exists between the gas emission rate, roof and floor strata relaxation zones characteristic, mining activities and gas drainage practices. Detailed knowledge of geological factors, gas and coal-rock properties, as well as mining systems are necessary for the methodology used in predicting overall underground gassiness, and planning gas capture and ventilation systems. Early gas emission calculations for various mining activities, particularly for the longwall mining system are essential. A reasonably accurate prediction of gas make as well as the design of ventilation, gas recovery (drainage holes) techniques can be made using 'Floorgas' and 'Roofgas' computer simulations, provided sufficient geological, mining, and gas data are made available.

Jan 1, 1998