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By S K. Michelic, N Preisser

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

Aug 21, 2024

By Penny T. G

BHP Diamonds and their joint-venture participants DiaMet Minerals, Chuck Fipke and Stewart Blusson are currently developing Canada's first commercial diamond mine in the arctic barren lands of the Northwest Territories (NWT) of Canada. The paper reviews the early history of the project leading up to the discovery of the first kimberlite pipe in September 1991, diamond exploration techniques and the subsequent advanced exploration and development work carried out at the site. In many aspects, this exploration work represented a development project in itself. Coinciding with the advanced exploration work, the project team prepared an Environmental Impact Statement (EIS) and went through federal review of the project at the highest level. External affairs strategies regarding the federal review and aboriginal land claim issues were crucial components to the approval process. Upon approval in principle by the

Jan 1, 1997

Results are presented of the investigation of gas dynamics of the blast furnace process obtained on laboratory models and operating furnaces. Gas residence times were measured using a helium tracer technique developed for the purpose. Residence times were determined in furnaces of 1007 m3 and 1719 m3 and results used in the calculation of the burden parameters and to estimate the distribution of the gas flow along the furnace radius. The effect of tuyere injection of coal dust on gas distribution was also investigated and the advantage of continuous injection compared with intermittent injection is noted. The unevenness of gas distribution across the furnace area is found to correlate well with differences in the size analysis of the iron-bearing component of the burden. The mixing of the gas streams between the neighbouring raceways was studied. It is shown that in the central region of the furnace gases from every tuyere are mixed together, whilst in the peripheral regions mixing is more localised and includes only the sections consisting of five adjacent tuyeres. A solution is proposed to the problem of a theoretical evaluation of the critical gas velocity. A simple relationship between the Reynolds and the Archimedes numbers was obtained from which, after substitution of the burden size data and the gas parameters, it is -possible to evaluate the critical gas velocity. Conclusions include information relating to the optimisation of the gas distribution and views on reducing gas injection at elevated furnace levels.

Jan 1, 1975

By Leung L, Downey M

This paper presents an overview of a technology package developed by BHP for locating discontinuities in coal seams using an in-seam seismic (ISS) exploration technique. The technology package includes instrumentation, data processing software, field procedures, numerical modelling and interpretation know-how. The technology developed has proved to be highly successful; features such as faults and dykes, not detected by other methods, have been delineated. Using equipment specifically designed for underground use, surveys are carried out quickly and at low cost. More than 30 ISS surveys have been conducted by BHP in Australia. Substantial savings in production revenue have been realised in situations where ISS has identified mining conditions which would have impeded longwall operations. Case studies of several ISS surveys are described in the Paper.

Jan 1, 1987

By G Chitombo, M Ruest

In surface mining, studies of the kinematics of blasted rocks using high speed film/video image analysis have allowed the estimation of the starting time, direction and magnitude of visible movement of fixed sections of the free face. Horizontal displacement versus time plots from discrete targets at the face generally report changes in slope over very small time intervals. These changes indicate step increases in velocity due to the action of explosive gases. In practice, the onset of rock mass movement, different to localised spalling, has been associated with a response time which exceeds the combined times of detonation, propagation and reflection of stress waves. This time is referred to as minimum response or burden movement time. As an engineering index, burden movement time has been used to provide guidelines for the selection of inter-hole and inter-row delay sequences in production blasting. With respect to improving breakage and fragmentation, it has been demonstrated that the delay interval between adjacent explosive charges should be less than the expected burden movement time. Similarly to reduce confinement between rows, delay intervals should exceed the expected burden movement time. The Hybrid Stress Blasting Model (HSBM) is a modelling framework that dynamically links an ideal and non-ideal explosives detonation code to a geomechanical rock model. This blast simulation tool is aimed at analysing the role played by different explosive formulations in fragmenting and/or damaging various rock types under different degrees of confinement. In the current framework, the rock behaviour under extremely high pressures and loading rates is calibrated from shock tests and the role of the explosive in fracture growth is accounted for and assumes a compressible fluid flowing through the explicit fracture network. The model is being developed as part of an international collaborative research project funded by a consortium of companies comprised of explosive and equipment suppliers and major mining houses. As part of the development and validation of the HSBM project, data from literature addressing the kinematics of the rock mass (ie burden displacement, face velocities and response times) has been collated and used to evaluate the current version of the code. A series of numerical experiments have been conducted with the view to: evaluate the response of the rock mass to changes in burden distance given by the impact of both stress waves and radial gas flow pressure;compare the modelling outcomes in terms of displacement, response time and face velocities to documented field observations; andcompare stress induced and stress/gas induced modes in terms of burden displacement outcomes. Results from these experiments have shown that in its current form the model is able to capture the trends observed and measured in practice. This is with respect to the simulation of burden displacement, response time and average face velocities for different geometries and charging conditions. The experiments have served as consistency checks which form part of an ongoing and comprehensive evaluation and validation of the HSBM code also aimed at addressing some of its current limitations.

Jan 1, 2007

By Spottiswood DJ, Kelly EG, Bull WR

An empirical model of a 254mm water-only cyclone treating minus 17001im coal has been developed. The model includes the prediction of by-passing, SG50 corrected, water split and the use of a single equation forthe reduced performance curve of particles in the range 1700-106pm. Particles finer than 106pm did not separate according to specific gravity. Simulations using the model showed the water-only cyclone performance to be dependent more upon feed size distribution than washability when the feed contains high-ash fines, but that, with a deslimed feed, the yield and ash content of the over-flow should be controllable by altering feed rate or feed pulp density.

Jan 1, 1985

By M Roper, M Lovitt

WMC Resources Olympic Dam Operation located in South Australia, is a poly metallic underground sublevel open stoping (SLOS) mining operation with a current annual production rate in excess of 9.0 Mt. Stope size, geometries, geotechnical considerations, drilling and blasting are critical components in stope performance. These factors are further influenced by stringent ventilation requirements due to the presence of airborne radioactive contaminants from uranium mineralisation. Stope planning is complex and mass blasting methodologies have been trialled at Olympic Dam with the view to reducing the frequency of stope blasts, improving stope stability, productivity and ultimately improving overall stope performance. A key aspect in the ability to undertake underground mass blasts of this scale is the application of i-konTM electronic initiation technology by Orica. In the past two years in excess of three million tonnes has been initiated utilising this electronic technology, with an average blast of 250 000 t ranging to the largest to date being 580 000 t. By providing flexibility in blast designs, the use of electronic detonators has allowed mass firings over multiple sublevels. This has resulted in a significant reduction in stope extraction steps compared to conventional pyrotechnic firings. The benefits of this reduction in the number of stope blasts are wide ranging from improved stability of interim stope voids between blasts, reduced blasthole damage, improved blast vibration management and reduction of complex changes to ventilation systems for blasting.

Jan 1, 2004

By Zhang S

A probabilistic approach is proposed for updating open pit slope sta- bility based on successful performance. The suggested approach is developed within the framework of Bayesian probability theory. In seeking solutions to geomechanics problems consideration must be given to inher- ent variability of shear strength parameters and to the errors in the esti- mation of these parameters. The latter can be significant and may lead to consistent overestimation or underestimation of the values derived from site investigation and testing. Conventional deterministic methods of slope stability analysis do not allow systematic modelling of uncertainties in applied loads or in shear strength parameters. Within a probabilistic framework indicators of stability may be calculated, e.g., the reliability index and the probability of failure. Based on observation of slope per- formance at any given stage of a project, the mean or the standard devi- ation (or both) of a shear strength parameter may be updated. Consequently the indicators of stability can also be updated. The appli- cation of such an approach is demonstrated by an illustrative example.

Jan 1, 1989

This paper examines the latest advances in mine drive and motor systems. In the last decade, the drive technology employed for large mine winders has migrated from the traditional dc technology to ac motors with cyclo convertor drives. Recent advances in pulse width modulation (PWM) drives have resulted in these being applied to large winder drives. While having many advantages for the winder system, the PWM drive must be carefully designed to ensure long-term reliable operation. When combined with induction motor technology, the PWM drive presents the ideal solution for winder drives. This paper examines the factors in choosing a suitable PWM drive for a winder installation. Factors under consideration include: winder duty cycle, drive rating restrictions, choice of power semiconductor device, cooling, and low speed operation.The cage induction motor is the motor of choice for large winder drives and has a number of advantages over the synchronous motor. The induction motor is ideally suited to integrated winder applications where the motor is built inside the friction drum, as installed at WMCÆs Olympic Dam site. The challenges of integrating the induction motor into the friction drum will be detailed, including: assembly, ventilation, air gap adjustment, and position sensors.

Jan 1, 2005

By S Bhandari

A model for predicting dust plume dispersion from blasting operations using the Eulerian mathematical algorithm has been developed. This model considers atmospheric stability, and wind velocity and direction for computing dust concentrations at different distances from the blast. Software has been developed which simulates the movement of a dust plume at a given horizontal distance from the blast location and time elapsed after the blast. The concentration of dust is also given in vertical planes. It takes into account ground profile and atmospheric conditions such as temperature, pressure, humidity, wind velocity, wind direction and shear. Experiments were carried out in two limestone mines to calibrate the accuracy of the predictions made by such model. High volume dust samplers were used to collect dust samples. Difficulties encountered in satisfactory dust sampling and quantification of results have been described.

Nov 8, 2011

BECAUSE of the attention given in recent years to the flotation process, there is an extensive range of equipment available to any staff detailed for: the design of a flotation mill. This statement applies not only to the flotation machines, but also to equipment for crushing and grinding, elevating the pulp, dehydrating of concentrates, and the methods of driving the various equipment.Distributed through the Proceedings and Transactions of various metallurgical societies and journals there are many excellent descriptions of flotation mills, their equipment and performance.Whilst these articles describe-in many cases in detail-the equipment in the mills to which they refer, the reasons which govern the choice of each particular equipment are not usually given.

Jan 1, 1929

By S Paciornik, G Schinazi, M H. de Pinho Maur-cio, M B. Vieira, O da Fonseca Martins Gomes, D T. Wagner

Vale (previously CVRD û Companhia Vale do Rio Doce) evaluates the microstructure of sinters in order to understand their characteristics and behaviour in the agglomeration process, and the correlation with conventional quality parameters. Efforts on image analysis development are in progress between Vale and PUC-Rio in order to improve both the qualitative and quantitative evaluation of a representative portion of material. In the present work, digital microscopy techniques were developed allowing this kind of assessment. Employing a motorised and computer controlled optical microscope, low magnification mosaic images covering complete sinter samples were automatically obtained. The mosaics provide a powerful qualitative overview of the whole sample while allowing low resolution quantitative evaluation of the major phases. In addition, quantitative results for phase fractions were compared for the same sample regions at three magnifications (5x, 10x and 20x objective lenses). A single field (1 x 1) at the lowest magnification corresponds to mosaics of 2 x 2 and 4 x 4 images at the higher magnifications. The automated system allows perfect registration between the mosaics and the single image. Changes in phase discrimination were evaluated as a function of optical resolution, and phase fractions obtained by interactive segmentation of the image histograms were compared. While finer dark phases, eg silicates, were only visible with the best optical resolution, coarser phases such as haematite and pores were measured at all resolutions. For haematite, magnetite, ferrite and pores, the largest relative error in area fraction, between the images obtained with the 5x and 20x lenses, was 12 per cent. The results for silicate were less accurate with a relative error of 44 per cent. The results indicate that digital microscopy provides a flexible method for qualitative and quantitative evaluation of these materials.

Jan 1, 2008

By Artmont G. J, Palmer K

Alluvial gold is an ideal exploration tracer to bedrock source and indicator of bedrock mineralisation style because (i) gold occurs in a wide range of deposit types, (ii) primary composition is sensitive to style of mineralisation, and (iii) it is a heavy resistate mineral that is readily preserved and easily sampled. In regional exploration of the Central Ranges of Irian Jaya, alluvial gold mineralogy has been applied to maximise the information return from panned concentrate sampling and to focus exploration effort. Primary gold is a solid solution of Au+Ag¦Cu¦Hg, ¦ trace Pd, Te, and Sb. In general Ag¦Hg increase and Cu decreases with inferred decreasing temperature of formation, and gold from particular mineralisation styles has signature compositions that can be used as indicators of bedrock mineralisation type. Furthermore, the abundance of alluvial gold is an indicator of the economic potential of a catchment. The convergent continental-oceanic plate geology of the Central Ranges is conducive to a wide range of mineralisation styles. Mineralogy of gold in ophiolite, skarn, porphyry, mesothermal vein and possible VHMS environments is characterised from alluvial and bedrock samples, and the use of gold mineralogy in prospecting at regional scale through prospect definition to drilling is demonstrated.

Jan 1, 1995

The production of synthetic crude oil requires a suitable coal or a coal extract modified by hydrogenation for pyrolysis. Existing classifications are broadly based on historical and current needs. One, Seyler's, is based on a visual display which can be used to present petrographic bounds. The analysis of the coal extracts from solvent hydrogen-donor testing allows an experimental limit to be described and a plant limit to be indicated. Australian black coals are discussed within these petrographic and plant bounds and their limitations as a feed for the production of synthetic crude presented. Potential uses for the aromatic liquid products are suggested. The application of the diagram as a screening procedure for sub-hydrous coals is described.

Jan 1, 1975

The aquifer at Phosphate Hill, north-west Queensland, presents special management challenges. The site contains a phosphate rock mine, fertilizer plant and camp. All of the site water is provided by the Duchess Embayment Aquifer, located within the Burke River Outlier of the Georgina Basin. The Duchess Embayment is a triangular shaped, Cambrian marine sedimentary basin consisting of siliceous and calcareous phosphorites, shales, siltstones and sandstones. It is fault-bounded on all sides and has a regional dip of 5¦E. The aquifer is largely confined to the siliceous facies of the Beetle Creek Formation. It has a very flat potentiometric surface and an average thickness of 45 m with confining beds above and below. The siliceous facies derives from weathering of the calcareous phase and is highly transmissive while the calcareous zone itself contains less water and is dependent upon interconnecting fractures for its permeability. Recharge appears to occur where the siliceous facies crops out around the edges of, and within, the Embayment. Aquifer management issues revolve around two points: successful dewatering of the orebody for mining; and efficient management to maintain water quality and ensure supply over the predicted 30-year life of the project. Current operations are extracting water at levels much below that originally estimated. This is having a detrimental effect on mine dewatering with the SWL lowering at a rate slower than anticipated. As a result, ore parcels are now beginning to intersect the water table, providing a major constraint to the mining plan. The aquifer drawdown cone is extensive and very flat so to keep the water table at an appropriate level for mining the management plan will include more aggressive dewatering to lower the level of the entire aquifer. The additional water will either be disposed of downstream or stored in a holding dam or via the use of artificial storage and recharge. Water resource management will also need to maintain the current quality. About 37 per cent of the water currently extracted forms the low chloride supply required by the ammonia plant and the power station. This ratio is expected to remain applicable under any future operating conditions but the low chloride resource is restricted so will require prudent management to enable the supply to continue. At current usage rates aquifer recharge versus use will need careful monitoring to ensure that the resource remains viable in the long-term.

Jan 1, 2003

By M Sandy, P Bamford

The Challenger Gold deposit was discovered in 1995 by Dominion Mining Ltd in a remote western area of the Gawler Craton in South Australia. Mine development commenced in 2002 with initial production from an open pit supplemented by ore from a very small adjacent auxiliary pit. Development of the underground mine commenced in 2004. The orebody plunge of just less than 30 degrees requires careful attention to mine design. Production from the M1 orebody, with less than 800 ounces per vertical metre (ovm) and very limited æsurgeÆ capacity, requires careful scheduling and implementation to ensure continuity of ore feed for milling. Initial production results from underground stopes included more dilution than anticipated. The narrow, high-grade zones proved to have much more complex geometry than early interpretations had indicated. Greatly improved understanding of the mineralisation controls resulted in important changes being made to the underground mine design and method. Coupled with careful control of development and drilling and blasting practices, this resulted in an immediate reduction in dilution and high recoveries of the resource. The benefits of these changes flowed through in the 2005/06 financial year, resulting in a 150 per cent increase in gold production to 108 080 oz and a sharp reduction in cash operating costs to A$280/oz. This was followed in 2006/07 with production of 108 91 oz of gold at an operating cost of $309/oz and in 2007/08 with 109 326 oz of gold at $367/oz. Production to June 2008 has been mainly from the M1 orebody, with the lowest stoping to date on the 580 m Level (615 m below surface) above development mining on the 520 Level. The rate of vertical advance of mining this orebody has averaged 150 vertical metres per year. The increased current combined JORC compliant resource and reserve position of over one million ounces, now includes the M2 and M3 orebodies with a current total average gold inventory up to 1400 - 1500 ovm. Exploration has intersected other shoots and all shoots are open at depth. The adjacent M2 and M3 orebodies are being developed for stoping. The narrow width of these zones from 1 m up to 4 m will require continued focus on ore zone definition, accurate development and careful drill and blast practice. In addition, to minimise cost increases in the current period of rapidly escalating labour, equipment, consumables and energy costs, high productivities will need to be maintained to allow the established rapid mining advance to continue at low unit costs.

Jan 1, 2008

By Hammond J. R, Ward T. A

The Tom Price orebody, in the Hamersley Ranges of North West of Western Australia, is mined by Hamersley Iron Pty. Limited. The orebody is a folded sequence of hematite and shale bands capped with goethite, with a con- sequential variable iron content. The overall grade is below that required to yield spec- ification product, necessitating selective mining, 'Zone Plans' based on geological structure have been developed to yield forward information on material types and grades. Short and medium term mine plans - the initial stage of quality control - are based upon these 'zone plans'. Blasts are laid out to break to the grade boundaries, thus minimising dilution, and the samples taken from the blasthole cuttings provide blast grades. Blending of shovel out- put from different blasts forms the operational basis of grade control. Shales, being more friable than hematite, produce fines that are lower in iron grade than lump. Quality control in the mine centres around maintaining the target fines grade, compensation being applied in the mine if the fines grade lies outside the target range.

Jan 1, 1973

By Stille H

The choice between drill and blast and mechanical boring methods is often not obvious. There are several factors which may have a de- cisive influence on this choice, such as the geometry and length of the tunnel, site con- ditions and borability of the rock. Both the un- confined compression strength and the joint dis- tance have a considerable influence on the net penetration rate. Site conditions, rock quality and water conditions influence the utilization of the tunnel boring machine. The drill and blast method is normally less sensitive to devi- ations from assumed ground conditions.

Jan 1, 1987

The Jundee gold mining operation is located in the Western Australian Yandal Greenstone belt. Jundee is a mature operation encompassing multiple and complex underground ore resources, dwindling open pit reserves, large surface stockpiles, small satellite resources and two near-mine but stand alone process plants. The imminent completion of continuous open pit mining and the associated drop-off in total mill feed precipitated a review of the strategic mine plan and development of options that would optimise the exploitation of the remaining mineral resources and the utilisation of the existing plant and infrastructure.An initial review of the strategic decisions to be made, available options as well as the quantity, complexity and co-dependency of the strategic variables quickly led to the conclusion that an Operations Research style modelling approach would be appropriate. An 'off-the-shelf' program engine by the name of WHATSBEST! (LINDO Systems Inc.) was chosen on the basis of price, reputation and ease of use. The model was formulated with the unknown variables (being the ore mining rates) expressed as a proportion of the maximum achievable ore mining rate from each source. Costs were defined as variable or fixed, with this definition being a key aspect of the modelling process. The critical application of the model was in determining the optimal extraction rate of ore, the destination (ie Jundee or Nimary mill) and the sequence of extraction of each ore source that maximized the cash flow of the operation. The program was designed to be able to quickly derive an optimal result from the many variables, replacing the previous laborious iterative process of arriving at an acceptable answer by means of several large and static spreadsheet models. This paper presents the process of selection, formulation, application and scope of operation of the turn-key linear and non-linear program strategic model now used as part of the Jundee Operation strategic decision making process.

Jan 1, 2002

By R H. Boffey

The Osborne copper-gold deposit was discovered in North-West Queensland in 1989. Underground production activities commenced at Osborne deposit in April 1996. This paper will examine technical and operational aspects of the underground mine during its development to a 1.2 Mtpa operation . Technical aspects discussed include geology, mine design and mining methods, equipment fleet selection and capital infrastructure. Operational aspects discussed include the evolution and performance of the integrated work teams that are utilised at Osborne to perform all mining and maintenance activities.

Jan 1, 1998