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By Swapan Ghosh, Amitava Sengupta, Proloy Das

Ferro-alloys are very important ingredients used for making of quality steel with desired composition. In view of high demand in various types of ferro-alloys, it has become necessary to produce the same efficiently, safely and cost-effectively with consistent quality maintaining the anti-pollution norms. To achieve this goal, it is necessary to adopt latest process/equipment with the state-of-the-art instrumentation and automation system. A Programmable Logic Controller (PLC) based automation system with suitable Human Machine Interface(HMI) terminals along with intelligent field mounted sensing/control devices allows to monitor and control the complete plant effectively with optimum deployment of man-power. In association with this, use of process optimization controllers enables to achieve specialised functionalities of the submerged arc furnaces like material management, lining management, electrode management, power management, overall production management etc.

Jan 1, 2007

Historically the insurance industryÆs involvement in any project has been relatively late in the process. Often it was a case of the last item to be ticked off the checklist has been to ensure that the insurance is in place. However, in more recent times insurers have imposed more restrictions on the cover they are prepared to provide, which has in some cases necessitated a change in the contracting structure to accommodate the insurance policy(ies). In addition, changing contractual practices have changed the allocation of risk between the various parties involved. This calls for a more proactive approach to the design and implementation of an insurance program for both the construction and operational phases of any resource project. This paper explores how a risk managed approach to the design and implementation of an insurance program for a resource project can align itself with current management approaches to project development. From the authorsÆ experience, this approach is best adopted early on in the project (often in conjunction with the bankable feasibility study) and follows AZ/NZS4360 to objectively examine and compare a wide range of risk exposures of the project in a time-effective manner across the following areas: personnel; environment; general management; compliance û legislation, systems, protocols; asset management; change management; financial impacts to the organisation; products/services; service delivery; and technology. Having identified and then analysed the risk exposures according to common consequence and likelihood ratings the next step is to develop a risk map of all considered exposures. The true value of this approach lies in the development and implementation of a risk treatment plan for identified exposures where the exposure is unacceptable. The plans will lead to the optimal solution to the appropriate risk prevention, risk mitigation and risk transfer options available. This paper also examines other benefits to the project that may arise from adopting a risk managed approach in addition to the ability to design an insurance program which recognises the exposures and the ability of the organisation (and other project parties) to retain risk.

Jan 1, 2007

By David Leidel

A major characteristic that distinguishes modern society from its predecessors is the understanding that events are not driven by the whims of the gods, pre-ordained fate or nature, but are controlled to a greater or lesser extent by the actions, (or inactions), of people. The study of risk assessment is the basis for determining risk or the likelihood of an event occurring combined with the consequences of that event if it does occur. This study is indubitably linked to the mathematics of probability and statistics which permits the quantification of risk. As the Industrial Revolution significantly increased the exposure of persons to new types of energy sources, materials, equipment, and means of more rapid transportation of goods and people, quantitative risk assessment became a vital tool in protecting workers and the general public exposed to these new technologies.

Jan 1, 2007

A series of flotation experiments were carried out in a 2.25-dm3 laboratory-scale Rushton turbine cell using hydrophobic quartz particles. Flotation was performed at a constant mean bubble diameter over a range of superficial gas velocities and impeller rotational speeds. The overall flotation rate constant increased linearly with increasing superficial gas velocity (and hence bubble surface area flux). The rate constant also increased linearly with increasing energy dissipation, until a maximum value was reached. A further increase in energy dissipation had little effect on the rate constant. The dependency of the rate constant on energy dissipation is a reflection of the size range and hydrophobicity of the particles used in this study. The flotation rate constant increased with increasing particle size, except at the highest energy dissipation value examined, for which the flotation rate of the larger particles reached a plateau and, in some cases, decreased. Good agreement was obtained between the experimental results and those predicted by a fundamental flotation model using experimentally measured values for mean energy dissipation and the Sauter mean bubble diameter. The bubble velocity was adjusted to obtain the best fit to the experimental data. The inferred bubble velocity, based on the flotation model, was found to increase with increasing superficial gas velocity (and bubble surface area flux) and was found to decrease with increasing impeller rotational speed. While the inferred bubble velocities were significantly lower than experimentally measured bubble velocities, and, except at low superficial gas velocity values, significantly higher than the bubble swarm velocity calculated from gas holdup measurements, similar trends with impeller rotational speed and superficial gas velocity were observed in all cases.

Jan 1, 2007

By Xinxian Zhai

Jining No. 3 Coal Mine, a subsidiary of Yanzhou Coal Company Limited. China, is a super-large modern mine. The coal mine is not only the first one constructed with five-million tons of designed production capacity in China, but also a modern underground coal mine with coal transportation systems by trains and ships, and with a power plant. Based on the hard roof conditions of the sublevel caving coal face in the fault-affected zone, the authors designed rebar and cable bolts for supporting the tailgate that is separated from the gob by a narrow pillar. With extensometers and borescope, strata behavior was systematically studied during tailgate development: (1). Roof convergence is much smaller as well as roof strata separation between inside and outside the anchored zone. (2). The affected zone during tailgate development is approximately 50 m. (3). Because of serious floor heave and obvious rib convergence, the tailgate finally turned into a reversed-trapezoid from the original rectangular shape. (4). There being many joints and fractures in the pillar, coal is crushed from the elastic bedded structure into loose blocky materials. But the tailgate met the service requirements during longwall retreat mining, and demonstrated that the method of roof support was a success. Since then, roof bolting has been widely used for the tailgate of longwall panels at Jining No. 3 Coal Mine. Keywords: coal mine; bolt supporting; tailgate; convergence of surrounding rock; ground control; strata behaviors.

Jan 1, 2007

By J. Tuominen

Outokumpu Direct-to-Blister Flash Smelting is currently in operation in two smelters, a third one is under construction and a fourth one is in the design phase. The two smelters in operation are the Glogow 2 smelter of KGHM Polska Miedz S.A. in Poland and the Olympic Dam smelter of BHP Billiton in Australia. The Outokumpu Direct-to-Blister smelter of Konkola Copper Mines Plc. in Zambia is under construction and the new smelter of Glogow 1 is under design and waiting for final go-ahead decision. Additionally, the Garfield smelter of Kennecott Utah Copper Corp. makes blister copper out of matte in a Flash Converting furnace. A similar operation is under construction for Y anggu Xiangguang Copper Co. in China. The slag cleaning process, which is needed to clean the slag of the Direct-to-Blister Flash Smelting Furnace, has different requirements depending on the feed to the flash furnace. These differences are discussed in the paper. The differences between the processes and slag produced are discussed as well as the metallurgical requirements for slag cleaning. The Direct-to-Blister process, where the blister copper is produced directly from concentrate in one step, requires at least a partial treatment of the slag in an electric slag cleaning furnace. The existing impurities determine the specific requirements of the actual cleaning process. The different processes are discussed in the paper. The newest developments of Outokumpu Technology Oy for electric slag cleaning furnace design are presented as well as the characteristics which the furnace shape gives to the process.

Jan 1, 2007

By James McNally, Adam Stremcha, John MacGregor

With 13.7km of TBM tunneling in Atlanta’s hard gneiss well under way, drill and shoot work continues on several sites throughout the city. In order for the City of Atlanta to meet the consent decree imposed by the federal government, an aggressive construction schedule was a necessity. Construction consists of two deep, large diameter tunnels, four construction shafts, a pumping station, one overflow shaft, three large intake structures, and two connecting tunnels. Due to the multitude of blasting insensitive urban environments, a high standard of seismic and air-overpressure criteria, coupled with time restrictions, was adopted for the project. At any given time, drill and blast operations were under way at four of the seven sites requiring a certain amount of coordination between the TBM excavation, surface work, and the forces of Mother Nature. This paper addresses the challenges faced and the techniques used to safely and successfully complete the rock excavation of the West Area CSO Tunnel and Pumping Station project.

Jan 1, 2007

By D La Rosa, W Valery, A Jankovic, S Ese

Metso Minerals Process Technology Asia-Pacific (MMPT-AP) has been working with many mining companies worldwide performing æMine to MillÆ or Process Integration and Optimisation (PIO) studies. MMPT-AP has developed a proven methodology to improve the efficiency of the mine-mill interface and gain maximum benefit. The PIO methodology involves rock characterisation, mathematical modelling and simulation to generate a list of operational and control changes for both the mine and concentrator. Following the methodology, the list of recommendations is developed relatively easily; the more challenging part depends on the company. Success of a PIO project relies on the ability of an organisation to implement change û both operationally and culturally: the human element. When a PIO project is started, there is initial interest and commitment from the company. But how can this be maintained? How does an operation know if the benefit continues? MMPT-AP is now developing long-term relationships with clients to ensure that the increased production and improved efficiency continues. Direct and indirect measurements are used to determine the key factors involved and to understand the cause/effect relationships. Simulation tools also can be used to compare current with recommended practices û so when material properties vary over time, the benefits can still be quantified. PIO is about empowerment: by measuring and understanding what parameters affect concentrator performance, the site personnel now have the knowledge to make a difference. Rather than simply reporting variable or poor concentrator performance, operations can predict when production will be affected and put controls in place to prevent it from happening. This requires support and commitment from the company or æbuy inÆ. Ensuring this buy in continues is the challenge facing every company involved in PIO work û but the benefits are well worth it. This paper will review MMPT-APÆs experiences in implementing PIO projects in the long term: from both the consulting and operational viewpoints. MMPT-APÆs involvement with a number of companies will be discussed as examples of what works and what does not.

Jan 1, 2007

By François Robichaud

"The Laronde mill has been in operation since 1988. Actual milling rate ranges from 7,000 to 8,500 mtpd. Laronde uses SAG/ball mill grinding followed by copper and zinc flotation circuits. A cyanidation/Merrill-Crowe process recovers the remaining gold and silver in the flotation tails.In 1999, the carbon in pulp circuit was replaced by a Merrill-Crowe circuit in order to cope with a much higher ratio of silver/gold associated with the discovery of the Penna shaft. Marine type diatomaceous earth was used as filter aid in both clarifier pressure leaf filters and recessed pressure filter presses from 1999 to 2005. In 2005, this filter aid was gradually replaced by alpha-cellulose after several laboratory and plant filtration trials. The selected cellulose is considered to be much less sensitive to parameters such as pH and reagent concentration and have increased clarifier and filter press filtration performance. Also, since cellulose is exothermic, replacing diatomaceous earth with cellulose as filter aid in the filter presses has increased calcining and oxidation rates in the calcining ovens since cellulose is exothermic. Finally, better calcining conditions have resulted in energy and reagent savings at the arc furnaces.This paper describes how the filter aid replacement has contributed to increasing productivity and Net Smelter Return of the refinery while reducing worker’s hazards and operating cost.INTRODUCTIONAll Merrill-Crowe circuits in the world are operated with filter aids. For years, the market for precoat filter aid has been dominated by mineral filter aids such as diatomite and perlite. Flowsheet and equipment selection at the Laronde refinery were performed in the late nineties. At that time, some key parameters of the design criteria had clearly identified marine type diatomaceous earth (DE) as the most successful filter aid. Parameters such as reagent cost and availability, clarity of the filtrate solution and good historical filtration performance in other concentrators had designated DE as the best suited filter aid. Pregnant solution processed in the refinery from its start-up through 2001 was fairly stable in flow rate and reasonable in terms of impurity content (cationic and anionic compounds)."

Jan 1, 2007

By Harry R. Price, Behrooz Tahmasbi, Charles J. Roarty

The 2,408 meter (7,900-foot) long Middle Rouge Parkway Interceptor Extension varies in size from 1.52-meter (5-foot) to 2.36 meter (7-foot 9-inch) inside diameter. Most of the sewer was constructed in tunnel through fine sands and silts. Piping of these soils through the concrete liner eventually resulted in a loss of soil support, settlement and/or severe distress of the sewer, and the formation of several sinkholes. The repair and restoration was generally performed in the sewer and included cast-in-place concrete, shotcrete, cured in place pipe, soil stabilization, cement grouting, dewatering, and chemical grouting. As a part of the work, temporary pump stations and flow diversions were required to perform the work while minimizing discharges to the adjacent Rouge River.

Jan 1, 2007

It is difficult to evaluate exploration properties in a manner that is transparent, repeatable and easily re-calculated to cater for different geological interpretations, but the risk-based assessment methodology, the Geological Risk Method, developed and described by Lord et al (2001) attempts to satisfy all these criteria. This paper examines a case study example based on valuations of exploration projects conducted by SRK Consulting using this methodology, and describes some of the advantages and limitations of the method.

Jan 1, 2007

By H Dehghan Jan Abadi, K Shahriar

The iron ore district of Gol-e-Gohar (GEG) is located 60 km south-west of the city of Sirjan, in the Kerman Province of the Islamic Republic of Iran. Six exploration targets have been identified and iron ore has been mined from one area with dry and wet concentrate products sold. Prior to mining commencing in 1999, the proven reserves were estimated at 265 million tonnes (Mt) in 2004 and 40 Mt of 100 Mt overburden has since been mined. Of the six exploration targets, the largest anomaly in the GEG district is Deposit No 3. This paper discusses economic considerations focusing on mine extraction and construction of a concentration and pelletising plant to process ore from Deposit No 3 of GEG. Planned capacity of 10 Mt product (concentrate and pellet) per year is targeted to commence in 2011, and nominal capacity by 2014. The economical evaluation and analysis is one of the most important stages in the feasibility study of mine development. Financial calculations including the provision of financial resources, operation period revenue, loss and profit statement, cash flow, net cash flow, internal rate of return and net present value have been undertaken as part of the feasibility study. The feasibility study operating plan assumes a large open pit mine containing proven reserves of approximately 250 Mt. The feasibility study assumed an economic return of $80 per tonne iron pellet. The economic study determined that Deposit No 3 of GEG can be economically developed by open pit mining followed by magnetite separation and flotation to generate iron concentrate and pellets.

Jan 1, 2007

By A. M. Engelbrecht

Paper written on project work carried out in partial fulfilment of B Eng. (Chemical) Membrane processes are vital to a diverse range of technical and biological systems, which also feature in mineral processing applications such as the treatment of mine effluent and extraction of metals. In this study, the use of cellular automata to model a semi-permeable membrane that separates two compartments is considered. Cellular automata are simple models that enable the analyst to represent well-understood local effects, such as the chemical or steric interaction between molecules themselves and between molecules or particles and their environment, which can lead to very complex behaviour on a macroscopic scale. Various physical phenomena, including reverse osmosis, were simulated. Initial results for the effect of temperature, membrane structure and chemical properties of the solutes on the performance of the membrane appear promising. Keywords: cellular automata, dynamic modelling, filtration, membrane fouling, osmosis.

Jan 1, 2007

By A. Warczokand

The cleaning of copper smelting slag requires magnetite and cuprous oxide reduction. The slag reduction with coke, injected coal powder or bunker oil is strongly endothermic and requires heat generation by fuel combustion or the use of electric energy. The reduction of fayalitic slag with calcium carbide is slightly exothermic and the formed calcium silicate modifies the slag. Thus, the additional energy is required only for covering furnace heat losses. Results of crucible scale tests showed the rate of slag reduction approximately five times higher in comparison of the slag reduction with coke under the same conditions. It seems that the effect of exothermic reaction and slag modification with CaO at the reaction interface results in very high rate of slag reduction. Industrial scale tests carried out in the Anglo-American Chagres Smelter demonstrated the possibilities of effective reduction and cleaning of the slags from a flash smelter and Peirce-Smith converters in a Teniente Slag Cleaning Furnace. The slag reduction was carried out without any reductant or stirring gas injection, simply by calcium carbide charging through a furnace mouth, and was very fast.

Jan 1, 2007

The rate of liquid copper deoxidation during top blowing of reducing flames has been investigated using a high capacity thermogravimetric unit at 1200 °C. For 1 kg copper samples, it was observed that the rate of deoxidation was proportional to the flow rate of the reducing reagent (H2 or CO). Under similar experimental conditions, it was found that H2 is more effective than CO even though both have similar thermodynamic potential to deoxidize liquid copper. The rate of deoxidation of liquid copper with reducing 0 2/CH4 flames was measured for 0 2/CH4 molar ratios of 1.5 to 2. The deoxidation rate depends on the 0 2/CH4 ratio and decreases as it approaches the stoichiometric ratio (02/CH4 = 2). Estimation of the rate of deoxidation of liquid copper with top blowing flames based on the thermodynamic composition ofH2 and CO in the product gases, agrees well with measured values.

Jan 1, 2007

By C. Tsiouvaras

Restoration of bauxite mining areas constitutes a difficult issue to address due to the destruction of the vegetation and soil decay of the excavated area. In this study woody species growth, in relation to altitude, heavy metal concentrations and mechanical texture of the underlying mining waste, were investigated. The research was implemented on restored sites of a bauxite mine in the Fokida Prefecture of Greece. These sites were located in three different elevations and the restoration took place in two phases, in 2001 and 1996. Heavy metals measurements showed some correlation among the different metals, whereas their concentration was also associated with plant growth parameters.

Jan 1, 2007

In the future, Illawarra Coal, the primary metallurgical coal producer in the southern coal fields of New South Wales, will face many unique challenges not found in other coal or minerals production areas. To manage these challenges and determine the best strategy for the business, Illawarra Coal has adopted a systematic strategic planning process, which starts from the broadest possible options analysis and culminates in a ægo-forwardÆ operating case that individual mine sites use as the basis for short-term planning. This paper will discuss two major topics. Firstly an overview of the Illawarra Coal and BHP Billiton strategic planning processes. This will demonstrate the range of variables and inputs that are required for the planning process, and the system which is followed to evaluate different alternatives for the extraction of the resource. Secondly, having discussed the primary external and internal factors that must be accounted for in the planning process, and the main issues affecting the viability and likelihood of each alternative, the paper will discuss the particular challenges that Illawarra Coal will face in the coming decades. These challenges include: market and price uncertainty; managing impact on surface features, infrastructure and environment; community interaction; transport and logistics constraints; unknown mining environments; lack of geological knowledge; limited surface access for new mining domains; changing attitudes to longwall mining in the Illawarra; ageing workforce; and cost and overhead management. The paper intends to discuss how these issues impact the business currently and how they are incorporated into Life of Asset plans and overall corporate strategy for Illawarra Coal.

Jan 1, 2007

By H. Jeram

The ilmenite, rutile and zircon processes of the mineral separation plant generate tailing streams, which still contain valuable mineral. This is due to a combination of factors, which include separator equipment efficiency, particle size effects and inefficient operating practices (equipment overloading, blockage, etc.). Recent developments by metallurgical equipment suppliers have led to increased mineral separator performance enabling recovery of previously lost valuable mineral. Mineralogical studies were conducted using QEM*SEM and MLA techniques to identify and quantify gangue mineral species and determine mineral association. Laboratory and pilot-scale test work was then conducted to develop suitable process flowsheets for the recovery of ilmenite, rutile and zircon from current and stockpiled tailings.

Jan 1, 2007

By C. Bucknam, M. McComb

Mercury and silver polythiocarbonate sludge that was generated from the pilot testing of optimized mercury removal from cyanidation pregnant eluate solutions prior to Merrill-Crowe recovery of gold and silver were tested for long term stability at Newmont Metallurgical Services. Sludge samples were mixed with heap leach residue to simulate disposal of the sludge in spent or active areas of the heaps and leached for twenty weeks with water and cyanide leaching solution, respectively. Leach testing results are presented as well as analysis of the sludge using scanning electron microscope techniques down to the <1000 nanometer scale.

Jan 1, 2007

By L. Voisin, K. Yamaguchi, D. G. Mendoza, K. Ltagaki

The behavior of arsenic and antimony in the Cu-0 system was thermodynamically investigated to understand their elimination during a blister-making stage in copper smelting. Firstly, the phase relations in a miscibility gap composed of the liquid slag and copper phases in the Cu-0-As and Cu-0-Sb systems at 1523 K were established by a quenching technique. It was found that arsenic and antimony distributed preferentially into the slag phase in the miscibility gap. Secondly, the activities of arsenic and antimony in the miscibility gap of these systems were determined at 1523 K by using a double Knudsen cell - mass spectrometer method. It was clarified that the activity of arsenic in the copper and slag phases showed the negative deviation from ideality while that of antimony in the copper phase a slightly positive deviation. These data obtained in this study suggest a possibility to eliminate arsenic and antimony by means of over-blowing in a converter after discharging the slag.

Jan 1, 2007