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By James P. Bennett

EAF slag chemistry and its control have been recognized as important in producing quality steel at a low price for a number of decades_ EAF steel producers make lime and dolomite additions to furnaces, controlling the CIS ratios and sulfur pickup from the steel. Existing phase diagram data at 1600°C for CaO, MgO, FeO, SiO2, and Al2O3 was used to write a computer model optimizing slag chemistry for slag foaming and reduced refractory wear. The model, its development, and its use in an industrial steelmaking environment will be discussed along with how the model can improve energy efficiency. The importance of EAF mass balance to account for critical materials like Si in scrap and refractory wear using the model will also be emphasized_

Jan 1, 2003

By Toru H. Okabe

As part of a systematic study on the thermodynamic properties of complex nitrides, phase equilibria of the system Li-M-N (M Mg, AI, Ga) at 900 K were investigated. An attempt to determine the thermodynamic properties of complex nitrides was made by using the galvanic cell method, which utilizes LiMgN as an electrolyte under nitrogen atmosphere. The electromotive force (Emf) of the cell at temperatures between 800 and 1100 K was measured. While the Emf of the cell at 900 K was measured to be 0.137 V, data discrepancies of ±0.03 V were found. It was difficult to determine temperature dependence of the Emf. The Gibbs energy change for the reaction, 113 Li3N (s) + 1/3 Mg3N2 (s) = LiMgN (s), at 900 K was determined to be !'J.Go, (LiMgN) = -13.2 (±2.9) kJ/mol. Using thermodynamic information on the binary nitride from literature, the standard Gibbs energy of LiMgN was derived to be !'J.Go f (LiMgN)= - 121 kJ at 900 K. The thermodynamic stability range of nitride was discussed by constructing isothermal chemical potential diagrams that provide a better understanding of the stability region of the LiMgN phase. The diagram was found to be in good agreement with the isothermal phase diagram determined by the alloy equilibration method. Although the obtained data includes large uncertainties, the results provide a better understanding of the thermodynamic stability of nitrides. The potential application of this complex nitride to nitrogen chemical sensors or a medium for controlling nitrogen potential is also shown.

Jan 1, 2003

By Alex Mezei

Experimental rheology data are needed to produce design criteria for mass and energy transfer processes. Large throughput plants operate under continuous flow mode. The capital cost is determined by the accuracy of the rheology data used for design. The operating cost is dictated by the energy required to sustain the flowing conditions of various process slurries. Typically, rheology investigations are carried out during the final stages of metallurgical testwork, which is too late to set the design criteria for the pilot plant. This leads to increased testwork cost, and sometimes lowers confidence in the quality of the data produced. In addition, the engineering and feasibility studies are often delayed because of the lack of pertinent rheology data. One of the objectives of this paper is to emphasize the importance of timely planning and execution of the rheology study, which is shown to be a critical component of the overall testwork program. Various applications are discussed, including elaboration of process and equipment design criteria. In this paper, the emphasis is placed on gold and nickel laterite hydrometallurgy applications.

Jan 1, 2003

By Daniel Tempelis, Tom Freeman, Eric Fordham, John Shamma, Steven Duke

The Arrowhead Tunnels in southern California are being completed by MWD under stringent groundwater in?ow limits established by the U.S. Forest Service. Pre-excavation grouting, new TBMs and a bolted, gasketed, pre-cast concrete segment initial lining are employed to control water in?ows. The effectiveness of prescribed water control measures was analyzed using conservative assumptions with the analytical techniques described by Goodman (1964), Heuer (1995), and numerical modeling. Analyses results suggest groundwater in?ows to the tunnels can be maintained well below the limits with aggressive pre-excavation grouting balanced against a reasonable rate of advance and quality erection of the initial lining system.

Jan 1, 2003

By R S. Suglo, G-K Er

Mineral processing is an essential component of a mine production chain and it accounts for significant proportion of the production cost. Over the past decade, significant research progress has been made in processing plant efficiency using theoretical, experimental and simulation modelling techniques. However, these studies are limited to process plant system as stand-alone units with no interactions with the mining units. In order to maximise the total mining system efficiency and more accurately simulate the system, the processing plant must be modelled as part of an integrated mining system. This becomes increasingly important in continuous surface mining systems, with limited ore processing capacity. In addition, plant efficiency is roughly estimated with known parameters or with simplistic statistical data, without regards to the stochastic processes governing these parameters, such as processing plant feed introduction. In this paper, a comprehensive model of the ore processing plant system is given and the object-oriented design (OOD) of the system is briefly introduced. The joint operation of ore processing plant system and haulage system is analysed. Numerical modelling is used to analyse the ore processing plant system under different conditions. Analysis of the results show that the optimum plant capacity is 0.7 tons/sec (2520 tons/hour). The results also show that the plant system resources cannot be fully utilised because the production rate is always less than the plant capacity. When plant capacity reaches an optimum value 0.7 tons/sec, the production rate is about 0.64 tons/sec. The underlying stochastic processes associated with plant and mine capacities cause this variability. In order to reduce this variability, there is the need to tightly set tolerances for the function variables.

Jan 1, 2003

By Carlos Antonio da Silva

Steel refining reactors based on chemical heating are being used as an alternative to ladle furnaces. They show a high degree of flexibility in respect to heating rate in addition to carrying out refining reactions such as de-S, inclusion removal, alloying etc. IR-UT and CAS-DB are examples of such reactors. Their performance is dependent upon geometrical characteristics as well as operational conditions which determine the flow field inside the vessel. A physical model of the IR-UT process of the Companhia Siderurgica de Tubarao, steel plant located in Serra, Espirito Santo, Brazil, was developed to assess the features of the flow field and its influence on the metallurgical behavior. Results of the physical model were used to optimize the process parameters in the industrial unit.

Jan 1, 2003

By Toshiyuki Kozuka

CdTe metal composite semi-conducting material has high potential in good performance of energy conversion efficiency for solar cell and there is much room for improvement of the performance by developing a process of making a thin CdTe film. In this paper, the imposition of intense magnetic field on CdTe electro-depositing surface is proposed, which is one of the possibilities for improving the energy conversion efficiency. In the experiment, cryogen-free super-conducting magnet up to 5T was used and CdTe film was deposited electrically in -o.nv vs. SHE The electrolyte was Cd and Te ammonia alkali solution with controlled temperature in the acrylic cell of 70mm diameter. Electro-deposition behavior of CdTe has affected by the imposition of the intense magnetic field due to microscopic convection in the vicinity of the depositing surface. Electro-deposited surface of CdTe becomes smooth due to microscopic convection around the surface, and the crystallization behavior is also affected, where crystallization temperature and the grain size is changed by the imposition of intense magnetic field.

Jan 1, 2003

By V. Velicka, J. Ptacek, R. Snuparek, P. Konecny, G. Takla

Coal mining in Ostrava-Karvina coalfield is being accompanied by rockbursts. 82 rockbursts occurred within the period between 1990 and 2002. Natural and technological factors from these rockbursts were collected and analysed. They confirmed that rockbursts are complex geomechanical events and that the relations between co-acting technological and natural factors are very complicated. Der Abbau in dem Ostrava-Karvina Steinkohlenrevier wurde von Anfang an durch Gebirgsschläge begleitet. 82 Gebirgsschläge in dem Zeitabshnitt von 1990 bis 2002 erfolgten. Die Angaben über natürliche und technische Faktoren der Gebirgsschläge wurden gesammelt und analysiert. Es wurde bestätigt, dass die Gebirgsschläge komplexe geomechanische Phänomene sind und dass die Beziehungen zwischen den zusammenwirkenden Faktoren sehr kompliziert sind. L´abattage d´houille dans le Bassin houiller d´Ostrava-Karvina est accompagnée par les coups de terrains. 82 coups de terrains s´étaient produit dans la période entre 1990-2002. Les données sur les facteurs naturels et techniques ont été ramassées et analysées. Les résultats ont corroboré que les coups de terrains sont des phénomènes géoméchaniques complexes. Les relations entre les facteurs techniques et naturels coopérants sont très compliqués.

Jan 1, 2003

By V S. T Ciminelli

This work aimed at evaluating the acid rock drainage (ARD) potential of five samples of a Brazilian gold sulfide mine in a decommissioning process. Three of the most traditional ARD prediction techniques, Standard Acid Base Accounting (Std ABA), Modified Acid Base Accounting (Modified ABA), as static methods, and humidity cells as a kinetic method were tested. Both the Std ABA and the Modified ABA results indicated an acid generation potential for some of the studied samples. In the other cases the results were inconclusive. The five samples were then submitted to humidity cell tests during 27 to 30 weeks. At the end of the period, the leachate pH was stabilised in a range from 3.4 - 4.1 (four samples) to 5 (one sample). The presence of relatively high levels of sulfate and dissolved metals was detected throughout the operation, specifically, Ni and Zn, and less frequently, As. These findings are discussed with the help of the samples mineralogy and Eh-pH diagrams. The results obtained in this investigation indicated potential environmental risks of this mining area. In this particular case, the kinetic tests were shown to be essential to the identification of the samples ARD potential.

Jan 1, 2003

By M Simanjuntak, A M. Supomo

PT Freeport IndonesiaÆs copper/gold operation disposes of approximately 222 000 dry metric tonnes of tailings per day via two thickeners. Reduction of the flocculant dosage rates in each of the tailing thickeners has been achieved with the installation of Clarometers«, modifications to the existing operating DCS control strategy and a change in plant flocculant. This has reduced the flocculant consumption rate in the last twelve months by approximately 20 per cent. It has also highlighted the disparity in the settling rates of the two thickeners. Collaborative efforts between Cytec technical site engineers and Freeport operational personnel have made possible the overall gains achieved in the tailings thickener optimisation.

Jan 1, 2003

By R. Matikainen

Since the Brundtland Commission in 1987, the use of natural resources has been an issue of global concern. Minerals are among the most important Earth resources and will definitely be essential for the development of societies also in future. Increasing scientific effort is needed not only to discover new deposits, but also to promote resource management in ecologically and socially sound way. Sustainable resource management is essentially a multidisciplinary challenge of developing life-cycle analysis and recycling of non-renewable resources from local to global scale. It offers great opportunities for geological surveys not only in EU, but all over the world to contribute positively to the welfare and sustainability of societies.

Jan 1, 2003

By Shulin Xu, Moreno Pescara, Nicola Avagnina, Piergiorgio Grasso

The Roreto Tunnel is a shallow, twin-bore, road tunnel on the connection between the A6 and the A21 motorway in NW Italy. The challenges faced the design and construction of this tunnel derive from 1) the presence of groundwater, both phreatic and artesian; 2) excavation in loose and/or little cohesive materials; 3) excavation in cohesive materials containing water-saturated, sand lenses; and 4) surface constraints due to the urban environment. In this paper, these problems are examined and the rationale led to the optimum design choices and construction solutions explained. The experience should be useful to others when tunneling in similar situations.

Jan 1, 2003

The objective of this international conference was to assist the mining and minerals industries in their global transition to sustainable development. The main theme of the meeting, therefore, was the development, monitoring and assessment of sustainable development criteria for mineral operations. Emerging technologies that can assist in the development of criteria and performance measurements were also presented at the meeting. A goal of the conference was also to conclude with a consensus plan and a process, representing a variety of stakeholders, which can provide guidance to the global minerals community on the path to sustainable development. A number of papers were not submitted in time to be included in the printed proceedings. Hence this addendum was compiled and includes last minute paper submissions. The pages of this addendum are numbered consecutively to the main volume of proceedings, so that when a reference is made to a paper, a proper page number may be quoted.

Jan 1, 2003

By Francesco Vegliò, Luigi Toro, Francesca Pagnanelli

Different hydro-metallurgical processes have been studied in order to recover manganese(II) from oxidised minerals such as MnO2. An innovative acid reductive leaching carried out in mild experimental conditions was here considered using agricultural and industrial wastes containing carbohydrates as reducing agents. The leaching process was investigated from a kinetic and equilibrium point of view in order to optimise the experimental conditions, develop a kinetic model and obtain high purity concentrated MnSO4 solutions. To study the leaching kinetic a Shrinking Core Model (SCM) was modified by a variable activation energy term to take into account both the variable reagent concentrations and the reaction rate change with respect to the manganese dioxide conversion. The influence of the particle size in the kinetic model is discussed with the support of SEM analysis before and after leaching. Manganese extraction yield was maximised (170-190 g/L) using appropriate carbohydrates and acid excesses, while impurity concentrations were kept low (Fe<10ppm and Ca<300ppm) pre-treating the ores, using hydro-alcoholic leaching medium and different combinations of down-stream processes. In particular precipitation, solvent extraction and adsorption onto active carbon were tested to eliminate Fe and Ca from MnSO4 solutions.

Jan 1, 2003

By Markus A. Reuter, Joep Verwoerd, Marc J. A. Pijnenborg, Yongxiang Yang

"Incineration is a proven disposal technology for all waste materials with heat release potentials, and provides high degree of toxic destruction and control for a broad range of hazardous materials. In the Netherlands, all the hazardous wastes are processed at AVR-Chemie located at the Rotterdam harbour, through rotary kiln incinerators. The newly enforced regulations from the European Union with stricter emission levels require a better understanding of the incineration process and improved process control. However, the transport phenomena and combustion processes within the kiln system are very complex and not well understood. In order to get better understanding of the incineration process, research has been carried out to study the fluid flow and combustion behaviour of the incineration system. Computational Fluid-dynamics (CFD) was used to simulate the gas flow and waste combustion process, and temperature measurements of the operating rotary kiln incinerator were conducted to validate the CFD model. This paper will present the latest results from the current research project for simulating gas flow and combustion heat transfer for a wide range of hazardous waste streams.The simulation of the waste incineration process was carried out using a general-purpose CFD code Phoenics. The rotary kiln and the secondary combustion chamber (SCC), with a waste processing capacity of 50,000 ton/y and an energy input of 30 – 40 MW, is translated into a CFD model. The model includes a k-e turbulence model and a global gas-phase combustion model (3-gas or 7-gas combustion model). The 3- gas model (Simple Chemically-Reacting System, SCRS) predicts only the thermal effect of the fuel combustion, and only one global fuel is used, therefore, real chemical species are not taken into account. In the 7-gas combustion model, (an Extended SCRS, ESCRS), different forms of waste fed into the incinerator have been modelled into a mixture of a general hydrocarbon fuel C3H4 and other components such as CO, CO2 and H2O. Thus, all the incoming fuel streams with different compositions and calorific values can be properly converted into separate inlets. The combustion of the waste is assumed to take place only in gas phase in two steps: (1) primary combustion of the main fuel component C3H4 to form CO and H2, (2) secondary combustion of CO and H2O to form CO2 and H2O. The rate of each combustion reaction is assumed to be controlled by turbulent mixing of fuel and oxidant (air or oxygen), i.e. the Eddy-Break-up (EBU) model. The resulted temperature field was validated with temperature measurement data, and the simulated temperature distribution from both 3-gas and 7-gas model have reasonable agreement with the measured data."

Jan 1, 2003

By I. R. Muirhead, S. Frimpong

"The mechanization of mining operations in underground coal mines has led to faster cutting rates of coalfaces with increased levels of emission of gaseous and particulate contaminants in the workings. Consequently, the fresh air streams from the main ventilation systems reaching distant workings are often insufficient, ineffective or inadequate and have to be supplemented by auxiliary ventilation systems to create and maintain the required working environments underground. The efficiencies of auxiliary ventilation systems are largely affected by drivers of the system such as the type and capacity of the fan; the type, length, diameter and condition of the ventilation ducting and the distance from the discharge end of the intake ducting to the face. Traditionally, single point measurements of methane gas concentrations using either flame safety lamps or hand-held measuring instruments have been used to assess how safe underground coal workings were. Unfortunately, such occasional measurements of methane gas concentrations do not give an accurate picture of the real gas concentration in the working as they are often taken from the easily accessible locations in working. Continuous monitoring of the methane gas concentration in development headings enables a better assessment of the environmental conditions prevailing there. All variations in the methane concentrations are more easily captured on a continuous monitoring basis than by instantaneous single point measurements. The approach adopted in this work was to continuously monitor the concentration of methane very close to the face and about 60 m outbye in development headings, observe the types of auxiliary ventilation equipment and their sizes being used in the working as well as noting the lengths from the discharge ends of the forcing and exhaust ductings to the face.In this paper, empirical methods are used to calculate the mean efficiencies of the auxiliary ventilation systems in selected development headings in coal mines in North America. This enables the assessment of the effectiveness of the auxiliary ventilation systems and the identification of the system drivers in them. The results show that the efficiencies of the forcing systems ranged from 17.02% to 96.81% while the efficiencies of the overall systems varied from 6.04% to 54.16%. The distance from the discharge end of the intake ducting to the face appeared to be the strongest driver in the performance of the auxiliary ventilation systems studied. It was also noted that when the discharge end of the intake ducting to the face does not exceed 7 m, there were faster purging rates of methane at the face and the efficiencies of the overall auxiliary ventilation system were greater than 50%. These findings are very important in underground coal mining in North America as they will assist to avert calamities, such as the Westray coal mine disaster in 1992 which resulted from the explosion of methane gas, by identifying which components of the ventilation system need special attention to create safe working conditions underground."

Jan 1, 2003

By Jeff Peterson, Alastair Grogan

During the winter of 2001/2002, a number of seismic exploration projects were carried out in the Mackenzie River Delta area of the Northwest Territories, in Canada. The purpose of the seismic projects was to identify potential drilling targets for subsequent drilling programs, using explosives as a seismic source. Recent changes to fisheries regulations meant that blasting under lakes, the Mackenzie River and offshore from the delta, was not allowed to induce water overpressures in excess of 100 kPa in these water bodies, and that a water overpressure monitoring program had to be conducted to confirm that this requirement was being met. This paper describes the water overpressure monitoring program on one of the exploration projects, presents the results of the monitoring, and discusses the challenges of carrying out this work in the middle of an arctic winter.

Jan 1, 2003

By Doug Halbe

?Many are called, but few are chosen.? The biblical adage applies not only to life, but also to hydrometallurgical processes. There have been, in the past, many outstanding successes with new processes ? and also some dismal failures. What are the odds of success for a new process? When there have been problems, why? What can you do to make sure these problems don?t occur with your process? What effect will a slow startup have on project economics? How do financial institutions ? the people who loan your company money for the project ? feel about new processes and why? Is it possible to predict or estimate the time required to reach design parameters?and if so, how do you sell this estimate to management ? and financial institutions? Probably most important ? when do you start thinking about the answers to these questions?

Jan 1, 2003

By K. G. Lomberg

The integration of various highly sophisticated IT applications has been implemented at Bafokeng Rasimone Platinum Mine, a new platinum mine in the Anglo Platinum Group. This system is required to assist with compiling the necessary geological and grade information together with safety, environmental, ventilation, rock engineering and logistical constraints, to allow the design of the appropriate mining layout, to schedule this design, provide the necessary output for technical review and costing as well as budgeting to allow medium- and long-term business planning. In addition the production management and short-term planning needs must be met. This includes the plotting of all underground and surface infrastructure and excavations, giving the necessary mining and best cut instructions, daily production management, ore reserve and grade management as well as assisting with budgetary management. In addition all safety, health, environment and risk assessment requirements and legal requirements have to be met. The system at Bafokeng Rasimone Platinum Mine has met these criteria. Keywords: Platinum, Bushveld Complex, Mine Planning, Production Management

Jan 1, 2003

TasmaniaÆs mineral endowment has resulted in 600 abandoned mines. Commonly occurring sulfide minerals such as pyrite and pyrrhotite can generate acid drainage and also mobilise heavy metals. Due to the StateÆs steep topography and high rainfall the risk to water quality in the receiving environments is significant. Surface waters impacted by abandoned mine sites typically showed high sulfate and metal distribution at pH range of 2.0 to 5.0. The impacted waters generally showed metal distribution in the high acid/extreme metal to low acid/low metal range. A similar trend was shown by sulfate distribution. Elevated levels of metals and sulfate downstream from several abandoned mine sites indicated that active sulfide oxidation is occurring and these sites may be potential point sources of metal pollution in the receiving environment. High correlation between metal and sulfate distribution suggests that sulfate distribution in surface waters may be used as a cost-effective investigation tool for preliminary assessment of acid drainage.

Jan 1, 2003