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By I. A. Minaev

The conditions of a stability of metallurgical films on a surface of solid on the basis of classical regularities of a thermodynamics are considered. For specific conditions of metallurgical processes the basic equations relevant to non-metallic inclusions (product of steel killing) migration and transfer through the interface boundary of metal-slag are obtained. The basic criteria equations of conditions of stability of metallurgical dispersed systems are developed in view of films formation. The probable thermodynamics reason of wetting due to formation of stable films are discussed. The experimental measurement of thin and thick films elastic resistance for metallurgical systems are carried out and the results are discussed. The presence of a wetting thick film increases stability of dispersed systems (facilitates an inverse implication of non-metallic inclusion in a melt) due to a barrier effect of wetting films. The quantitative evaluations of non-metal inclusion stability for steel in contact with any metallurgical slag are carried out. The results are in accordance with technological experience. Keywords: Inclusion removal, Film thermodynamic, Slag-metal dispers system

Jan 1, 2004

By P. Gonzalez, C. Ariyo, L. Holappa

Oxidation state of titanium was determined in CaO-SiO2-TiOxslags in the composition range25–53 per cent CaO, 27–46 per cent SiO2, 10–55 per cent TiOxat 1873K using gas equilibration method. In the experiments, slags with different titanium oxide contents were equilibrated with a known carbon monoxide and carbon dioxide ratio. The results were used to determine the Ti3+and Ti4+contents as well as the activity coefficient ratio of corresponding oxides in the slag. The dependency of the activity coefficient ratio as a function of oxygen partial pressure was determined. Keywords: titanium, titanium oxide, activity, activity coefficient, slag iron, carbon monoxide,carbon doixide, gas, equilibrium.

Jan 1, 2004

The modelling of lithological domains is a critical step in mineral resource and reserve evaluation. Deterministic models rely on an interpretation of the available drill hole data and expert knowledge, but do not account for the uncertainty in the spatial extent of the lithological domains. Instead, probabilistic models based on conditional simulation can be used to map the probabilities of occurrence of the domains within the deposit, which reflect the uncertainty in their presence or absence at unsampled locations. The mineral grade model is then obtained by weighting the predicted grades associated with each lithological domain by the probability of occurrence of this domain. Such an approach accounts for the continuity of the grades proper to each lithological domain and for the uncertainty in the spatial extent of these domains within the deposit. An application to a porphyry copper deposit is presented. Keywords: spatial uncertainty; plurigaussian simulation; geological control; kriging; geostatistics.

Jan 1, 2007

Despite the wealth of information available on phase equilibria of oxide systems there remainmany gaps and inconsistencies in our knowledge base. From an industry perspective there is anongoing need to adequately describe the phase chemistry of slag systems in order to optimizeprocess performance and improve productivity. Since this chemical behaviour cannot be predictedfrom first principles it follows there is also an ongoing need for accurate experimental data. The advances made in recent years in the capabilities of sophisticated analytical and measurement equipment have made it possible to develop new experimental techniques for the direct determination of phase equilibria in low order and complex multi-component slag systems. In addition the development of powerful computer modelling tools makes it possible to provide more comprehensive descriptions of the phase chemistry, to present the information in a range of perspectives, and to critically analyse the various types of related thermodynamic and structural information available. This review provides an overview of the types of information that can be used to determine phase equilibria in slags systems, analyses the influence of uncertainty and the relative importance of these types of data, and describes the advantages and limitations of the various experimental techniques that can be employed to obtain this information. Examples of recent studies are provided that demonstrate how an integrated approach to the determination of phase equilibria in complex systems, involving the use of targeted experimental studies and systematic thermodynamic model development, can lead to a better utilization of our current research capabilities and resources and more accurate descriptions of these systems. Keywords: slags, phase equilibria, experimental techniques

Jan 1, 2004

By A. F. Lee

A pick-up apparatus capable of yielding quantitative results has been described. Studies of some collector-mineral systems have been presented to illustrate the versatility of the apparatus and prove the validity of results.

By Y. Wang, S. Sridhar, B. Coletti, G. N. Shannon, S. Vantilt

The final removal of inclusions in the ladle, tundish, and mold in a continuous casting process involves the kinetic steps of liquid film drainage, interface rupture, and absorption of the inclusion into the overlaying molten slag. During this process, oxide inclusions can undergo chemical reactions with the slag. This paper presents recent results on imaging the slag/steel interface and elucidates the evolution of Al2O3and Al2O3-CaO inclusions during their separation from the steel and on their incorporation into the slag. Experimental results, obtained through a Confocal Scanning Laser Microscope, are compared with thermodynamic predictions.

Jan 1, 2004

By J. Cygankiewicz

Efficient prevention of mine fires is impossible without predicting the self heating processes in the given geological and mining conditions. The respective forecasting method is presented in this paper based on the following assumptions: - factor deciding on fire hazard in the underground workings is the process of heating of coal from the primary rock temperature to the critical temperature when the heating rate growth rapidly - another important factor is the fire incubation time defined as time needed to achieve the critical temperature. This time is determined by balance of heat and mass in the heated coal - contact of crushed coal with oxygen in air cause some exothermic processes as : physical and chemical sorption of oxygen , oxidation reaction and evaporation of humidity Heated coal transfers its thermal energy to the environment by conductivity to the rocks and by convection to the flowing gases. The heating is possible if thermal energy generated from coal is greater then the share transferred to the environment. The paper presents the laboratory method of measurement of heat generation in adiabatic conditions. Also the mathematical model with examples of computation enabling to forecast the self heating process of crushed coal is presented.

Jan 1, 2003

By M Lipalile, A B. Tunono, A W. Naismith

Konkola No 3 shaft experienced severe mining induced stress and time related deterioration in ground conditions in an area where an over-cut and bench (OCB) mining method was used to extract a shallow dipping wide orebody. This caused an unacceptable risk for safe mining operations to sustain the required levels of production. After a review of the conditions it was decided to change the mining method to CASCADE to recover ore in the affected area and modify the OCB method and use a modified over-cut and bench method (MOCB) for new mining sections. This paper describes the geotechnical criteria included to derive the mining standards for the MOCB. The geotechnical risks are identified and taken into account to develop stope design parameters, stoping sequences and support requirements. A monitoring programme to assess conditions as mining progresses is also discussed.

Jan 1, 2005

By A. B. Fox, R. P. Thackray, K. C. Mills

The role of mould fluxes in continuous casting is reviewed. The main functions of the flux are described and the importance of the flux in providing lubrication and the right level of heat transfer between the shell and the mould is described. The major problems of longitudinal, transverse and star cracking, gas and slag entrapment and deep oscillation marks in the steel product and ?sticker breakouts? are analysed. The important physical properties of the flux in combating these various problems are identified. Physical property data for the fluxes are given.

Jan 1, 2004

By J. Ekengård, H. Srinath, M. Andersson, P. Jönsson, D. S. Sarma

The present paper deals with mixing between the metal and slag phase during the ladle refining process, including vacuum degassing. Dispersion of metal drops in ladle slags has been studied. The results show a larger quantity of metal droplets in ladle slag during the alloying and stirring phase than during the subsequent vacuum degassing phase. The thermodynamic and kinetic aspects of the interaction between metal drops and the slag matrix have been considered and probable reasons for the observed distribution discussed.

Jan 1, 2004

By A. Hiltunen, R. Hiltunen

The utilization of blast furnace and BOF slags has long traditions and well-known applications in the building and road construction industries and in soil conditioning. The starting point for product development has been the basic physico-chemical properties of slags. This development has led to the almost 100% utilization of blast furnace slags and also considerable amounts of steel slags. While new methods and applications are continuously being looked for and developed in order to recycle and utilize all types of slag, there is at the same time an increasing debate over the exact nature of the slags, whether they are products or waste material, and whether they should be considered substances or preparations. These questions have emerged as a consequence of the environmental effects of the slags and current environmental legislation. The environmental effects of slags can be seen to be both beneficial and less beneficial. There is no doubt about their benefits in the road construction industry, as they allow significant savings in terms of natural materials and in transportation. It is also a known fact that using slags as fertilizers and in the cement industry leads to reduction in CO2emissions. The less favourable effects are the possible harmful emissions into the soil and groundwater. In this paper we describe the properties of slag products and their environmental effects according to investigations carried out in Finland. Keywords: utilization, blast furnace slag, steel slag, properties, solubility, environment

Jan 1, 2004

By W. C. Joughin

Problems with the stability and performance of rockpasses in deep-level mines are common. This paper presents the results of an investigation into the recorded performance of rockpasses in deep-level gold mines. Records relevant to the geological environment in which the passes are excavated, their excavation details, and their historical performance are not at all well documented on mines. In general, the quality of data available from mines is poor. The investigation showed that very large spans frequently developed in passes during use, and that rock mass quality, the orientation of the pass with respect to the dip of the strata, and the magnitude of the stress acting normal to the axis of the pass were the main factors of influence. From the historical information obtained, the risks of instability in rockpasses are identified.

Jan 1, 2005

By A. Rejeb, A. Millard

ABSTRACT: An evaluation of the importance of the thermo-hydro-mechanical couplings (THM) on the performance assessment of a deep underground storage design has been made as part of the international DECOVALEX III project. It is a numerical study that simulates a generic repository configuration in the near field in a granite medium. The thermo-hydro-mechanical evolution of the whole configuration is simulated over a period of 100 years. The model used to represent the unsaturated behaviour of the various porous media makes allowance for moisture transfers through the effect of thermal and water gradients. The paper presents a comparison of the temperature, water pressure and stress fields obtained by TM, TH, HM and THM coupled calculations. The results demonstrate that temperature is hardly affected by the couplings. In contrast the influence of the couplings on the mechanical stresses is considerable. This is attributed to the key role that water has on bentonite swelling or shrinkage effects that are dependent on its saturation level variations. KEY WORDS: Modelling, thermo-hydro-mechanical couplings, temperature, pressure, stress. ZUSAMMENFASSUNG : Im Rahmen des internationalen Projekts DECOVALEX III wurde untersucht, wie groß der Einfluss thermisch-hydraulisch-mechanischer Kopplungen (THM) auf die Leistungsfähigkeit eines Konzeptes zur Lagerung hoch radioaktiver Abfälle zu bewerten ist. Bei dieser numerischen Behandlung wird eine generelle Lagerungskonfiguration in granitartigem Milieu simuliert. Die thermisch-hydraulisch-mechanischen Prozesse werden für eine Dauer von 100 Jahren simuliert. Bei dem Modell, mit dem das Verhalten der verschiedenen, unterschiedlich porösen Milieus in ungesättigtem Zustand dargestellt werden soll, werden die Feuchtigkeitstransporte infolge thermischer und hydraulischer Vorgänge berücksichtigt. Verglichen werden in diesem Artikel verschiedene Temperatur-, Wasserdruck- und Beanspruchungsfelder, die sich aus TM-, TH-, HM- und THM gekoppelten Berechnungen ergaben. Dabei stellte sich heraus, dass die Temperatur nur gering von den Kopplungen berührt wird. Die Einflüsse der Kopplungen auf die Mechanik sind hingegen bedeutend; ausschlaggebend dafür ist der Faktor Wasser, der den Bentonit je nach Sättigungsgrad quellen oder trocknen lässt. SCHLÜSSELWÖRTER: Modellbildung, thermisch-hydraulisch-mechanische Kopplungen, Temperatur, Druck, Beanspruchung. RESUME : Dans le cadre du projet international DECOVALEX III, une évaluation de l’importance des couplages thermo-hydro-mécaniques (THM) sur les performances d’un concept de stockage de déchets fortement radioactifs a été menée. Il s’agit d’une étude numérique simulant une configuration générique de stockage en champ proche dans un milieu granitique. L’évolution thermo-hydro-mécanique de l’ensemble est simulée sur une période de 100 ans. Le modèle utilisé pour représenter le comportement non saturé des différents milieux poreux prend en compte les transferts d’humidité sous l’effet de gradients thermiques et hydriques. L'article présente une comparaison des champs de température, de pression d’eau et de contraintes obtenues par des calculs couplés TM, TH, HM et THM. Les résultats montrent que la température est peu affectée par les couplages. En revanche, l’incidence des couplages sur la mécanique est importante; ce qui est attribué au rôle majeur joué par l’eau à travers les effets de gonflement ou de retrait de la bentonite selon la variation de son degré de saturation. MOTS-CLEFS : modélisation, couplages thermo-hydro-mécanique, température, pression, contrainte.

Jan 1, 2003

A physical modelling study has been carried out to simulate the slag-metal dispersion induced by a high-strength bottom gas injection. Water and kerosene were utilized to simulate metal and slag respectively. A water model of CLU (Creusot-Loire Uddeholm) vessel was used with three different nozzle orientations, namely, off-centre, triangular off-centre and centre. The gas flow rates changed from 0.00599m3/sec to 0.01081m3/sec. Height of heavy and light phases was kept fixed at 0.23 m and 0.02 m respectively. The dispersed phase holdup was determined at various axial and radial distances, gas flow rates, and tuyere configurations. The observations revealed that at a fixed gas injection rate, as the vertical distance increased in the centerline, straight off-centre orientation resulted in greater dispersed phase hold up values than those of the centre configuration and the triangular off-centre orientation. The dispersed phase holdup was found to increase with gas injection rate and decreased with axial distance. The variation of the dispersed phase hold up with the dimensionless axial distance and the gas injection rate was correlated by using the Modified Froude Number. The experimental values of the dispersed phase holdup were found to be in good agreement with the correlated values obtained from the modelling equations. The findings of the present study may be utilized in the ferroalloy refining vessels in terms of designing tuyere locations for optimum processing conditions.

Jan 1, 2004

By P. Dennis, T. Pieters, A. De Kievit, S. Ganguly

TEMCO has been producing manganese ferroalloys in submerged arc electric furnaces for over 40 years. The furnace linings all along have been of conventional insulation type until 2001 when a freeze lining of UCAR concept was installed for a 20 MW Furnace. Continuous improvement of furnace lining performance has been a key component in improving the business competitiveness of TEMCO. The expected minimum campaign life of the freeze lining is fifteen years as compared to the ten years of the conventional linings. The success of the freeze lining is very critical to the quanta and direction of heat flow through the lining that control the freeze protection. Under freeze protection can lead to reduced lining life and over freeze protection, on the other hand, can lead to operating difficulties and loss of smelting efficiency. It was, therefore, necessary to develop a computer based system to monitor and control the freeze protection. The computer based monitoring and control system uses the basic principles of heat transfer, activeX object and heat flux from dual thermocouples and that is reviewed.

Jan 1, 2004

By S. -H. Chang, C. -I. Lee, Y. -K. Lee

Based on results from triaxial compressive tests, an experimental damage model to simulate post-peak behaviours as well as nonlinear behaviours before peak strength was developed. In order to consider pre-peak behaviours, variations of elastic constants at each damage level were regressed by functions of confining pressure. In addition, post-peak behaviours were simulated successfully by using Hoek-Brown constants. As results, the experimental model could predict nonlinear behaviours, peak strengths and stiffness changes observed in experiments. Basé sur des résultats des essais compressifs à trois axes, un modèle expérimental de dommages pour simuler des comportements de poteau-crête aussi bien que des comportements non-linéaires avant la force maximale a été développé. Afin de considérer des comportements de pré-crête, des variations des constantes élastiques à chaque niveau de dommages ont été régressées par des fonctions de pression d'emprisonnement. En outre, des comportements de poteau-crête ont été simulés avec succès en employant des constantes de Hoek-Brunes. Comme résultat, le modèle expérimental a pu prévoir des comportements non-linéaires, des forces maximales et des changements de riidité observés dans les expériences. Auf Basis der Ergebnisse des dreiaxialen Drucktests wurde das experimentelle Schadensmodell, das sowohl das nicht-lineare Verhalten vor der maximalen Stärke als auch das Verhalten nach der maximalen Stärke simulieren kann, entwickelt. Um das Verhalten vor der maximalen Stärke zu berücksichtigen, wurden die Veränderungen der elastischen Konstante bei dem jeweiligen Schadensniveau durch die Funktionen des begrenzten Drucks zurückgegangen. Außerdem wurde das Verhalten nach der maximalen Stärke unter Benutzung von Hoek-Brown Konstanten erfolgreich simuliert. Schließlich konnte das experimentelle Modell das nicht-lineare Verhalten, die maximale Stärke und die Veränderungen bezüglich der Steifigkeit während der Experimente voraussehen.

Jan 1, 2003

By P.J. Terbrugge

Open pit slope design has conventionally been effected as a bottom-up function utilizing available geotechnical information. This results in a decision criterion based on probability of failure and factor of Safety with a risk assessment being carried out on the proposed design slopes. The design approach recommended reverses the process using fault event tree decision methodology. The consequences of this approach are that acceptable risk criteria have to be determined by mine owners. Slopes are then designed by the technical staff to achieve these corporate goals. Benefits that arise from the process are that the owners take a proactive decision on the risk-benefit relationship allowing the technical staff to optimize the geotechnical exploration programme and design.

Jan 1, 2006

By M. D. Lionnet

The Bafokeng Rasimone Platinum Mine (BRPM) is a joint venture between Rustenburg Platinum Mines Limited and Royal Bafokeng Resources (Pty) Ltd (Bafokeng). The mining lease has been granted over Boschkoppie 104JQ and is located approximately 10 km south of the Pilanesberg Alkaline Complex. The Merensky Reef, which constitutes the principal orebody, is geologically complex. A relationship between its geological variability and the associated mineralization has been established by defining a number of facies types. The Merensky Reef has been subdivided into seven distinct facies types: the pegmatoidal facies, contact facies, FW1 potholefacies, FW3 pothole facies, FW6 pothole facies, and FW7 pothole facies. The Merensky Reef, which does not form part of the potholed reef, has a large component of footwall mineralization. The pothole facies, in contrast, has mineralization located in the hangingwall. Statistical analysis of the facies types indicates that they are unique populations and hence need to be evaluated independently. The mining lease has distinct structural domains that have added additional complications to evaluation of the Merensky Reef. The Merensky facies on BRPM exhibit unique geological and statistical characteristics within well-defined structural blocks. Due to the extreme variability of the Merensky Reef on BRPM a unique approach has been developed, within Anglo Platinum, to evaluate the deposit. Mining cuts are defined and composited for the individual facies types, and then modelled individually by applying known geological controls. The resultant grade models are weighted based on statistical and local geological knowledge. The object of weighting the facies is to replicate the variability observed in the orebody. The introduction of stringent geological controls to the evaluation process has resulted in increased confidence in the in situ grades estimated as an input to the mine planning process.

Jan 1, 2007

By A. V. Pavlov, A. V. Dubachev, K. L. Kossyrev

The purpose of the given research was to investigate the possibility of high-carbon ferrochromium refining to remove harmful impurities as a result of metal treatment by slag mixtures on the basis of the CaO-MgO-SiO2system. The final conclusions were drawn from experimental results. It was shown that the treatment of high-carbon ferrochromium by SiO2-MgO-CaO slag mixtures with additions of chromium sinter or iron-ore concentrate removes carbon, sulphur and phosphorus from the metal. A mechanism of phosphorus removal from a melt to a gas phase is proposed.

Jan 1, 2004

By D. van Heerden

In the mining industry abrasion caused by both sliding and impact have over the years resulted in costly damage to installations such as ore passes and silos. Good geotechnical practices combined with the use of a high quality abrasion resistant concrete can prolong the life of such an installation and minimize problems associated with abrasion. In order to maximize the life of an abrasion resistant concrete, the choice and combination of the correct raw materials (cement, aggregate and fibre) and overall mix design needed to make up such a concrete are important. This paper presents technical data and practical experience showing that concrete formulated with calcium aluminate cement resists severe abrasion conditions better than similar OPC-based concretes.

Jan 1, 2005