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By L Manca, P B. Hills, D Tyler, N Pollington

This paper describes a collaborative project undertaken by Newcrest Mining Limited (Newcrest) and pitt&sherry to identify, develop and then implement global best practices to manage the exposure to inrush (dry and mud) hazards in underground mining operations. An extensive literature review was undertaken to identify past experience globally and the current state of knowledge and practice in managing inrush hazard. A key requirement of the literature review was the development of a list of guiding questions which would form a framework for approaching operators to discuss the topic, capture recent learnings and understand current operating practices to allow the development of a best practice solution. An initial cohort of 14 mines across four continents chose to contribute and detailed interviews were carried out by the project team. The outcome from the literature review, interviews with participating mines and various internal discussions was a comprehensive summary document detailing Basic versus Best Practice management of the inrush hazard. This document is being used as a gap analysis tool by Newcrest to assess and guide the management of inrush hazard at their existing and future operations. The summary document has also been provided to the participating mines for their consideration. The project is iterative and will continue to evolve as new experiences, knowledge and practices come to light.

Mar 15, 2021

By B E. De Gee, N Viviers, A Naidoo

In 2013 the Mopani Copper Mine Mufulira plant in Zambia embarked on a project that was aimed at improving concentrator recoveries. The project commenced with the automation of the milling and flotation circuits. This involved the installation of new instrumentation, namely measurement devices and actuators, and the connection of these to new programmable logic controllers (PLCs).The infrastructure changes were followed by the implementation of basic proportional-integral-derivative (PID) controllers on the PLCs. Supervisory control and data acquisition (SCADA) interfaces were also implemented to allow for switching between controller modes, inputting of setpoint variables and to provide a visual display for process monitoring. The final phase of the project involved the installation and commissioning of advanced process control (APC) solutions on the milling and flotation circuits. This work was carried out by Mintek over 21 on-site days. The APC solutions included the MillStar and FloatStar suites of advanced controllers.The MillStar control suite focused on stabilising the mill feed and mill discharge on the two primary mills as well as the flotation circuit feed. Mintek’s CyLas instruments, which provide a measurement of the hydrocyclone underflow angle, were also installed. The measurements were incorporated into the discharge stabilisation control on both milling circuits. The FloatStar level stabiliser controller provided flotation cell pulp level control on fourteen cells, including two columns.Performance tests showed that the Mintek APC system stabilised the mill feed and mill discharge while ensuring the process remained within operational constraints. The MillStar control system utilised the CyLas instrument to prevent roping on the hydrocyclone underflow. This was not always achieved under normal operation. Additionally, the flotation section was stabilised as a result of improved level control by the FloatStar control system.Performance comparisons showed that the Mintek control system improved the operation of the milling and flotation circuits resulting in a greater copper recovery.CITATION:Naidoo, A, De Gee, B E and Viviers, N, 2014. Implementation of an advanced milling and flotation control system at Mopani Mufulira copper mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 363–368 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By J P. Evert

Didipio gold-copper mine operation is situated in the island of Luzon, approximately 270 km north of Manila in the Philippines, in an area of high seasonal rainfall. The hydrogeological water flow model implied that there would be high connectivity between regional structures and underground operations. This model predicted that underground mine groundwater inflows were expected to quickly rise as the decline progressed to a peak of 510 L/s. Designing a capital pump station to deal with 510 L/s has its own challenges, however developing the decline down to the required level, always dealing with 300 L/s of water and constructing the pump station is extremely challenging and required a robust water management plan and mine design. When dealing with expected high volumes of water, underground mine design and scheduling plays a key role in protecting electrical infrastructure, equipment, secondary pumps, and the decline from flooding. A good drainage system and controlled dewatering plan is essential for safety and progress. This paper details the dewatering techniques and mine designs required to accomplish decline development with high water inflows as used in the Didipio project. It will describe the learnings and outcomes that are achievable with a flexible design, as new structures are mapped, and water intersections are increased. It also highlights the potential for adaptability in mine planning to provide evolving improvements or to evade problems that are expected from the constant reconciliation of data recorded during development.

Mar 29, 2023

By T Kojovic

"The index A*b, determined from the Julius Kruttschnitt Mineral Research Centre (JKMRC) drop weight tester (DWT) results, has become well-known in the mining industry as a reliable measure of ore hardness in impact or crushing, having the inferred units of t/kWh. This index evolved from a long history of comminution studies at the JKMRC, including the development of the now superseded JKTech twin-pendulum, the industry standard JK Drop Weight Tester (JKDWT) and the faster alterative JKMRC rotary breakage tester (JKRBT). A reduced version of the DWT, the semi-autogenous grinding mill comminution test (SMC test®), also provides estimates of the A*b though the testing of only one particle size at five specific energies. Experimental determination of A*b using the above devices/tests requires samples, with sufficient mass, to be sent to designated laboratories, registered to conduct such tests. This protocol is fine for bankable and commercial testing, where material characterisation data is used in conjunction with machine specific data in modelling and simulation, and power based calculations. However, for comparative testing, where results are required at the time of sampling (eg for plant troubleshooting or spot-surveys), or for rapid ranking of geometallurgical samples, these existing tests simply do not provide a timely, viable and cost-effective solution. In order to address this critical void in the realm of comparative testing, a new device has been developed, exploiting a central feature of single particle impact testing – that the A*b can be reliably estimated using one precise low energy test. This device, for which a patent is currently pending, called the HIT (Hardness Index Tester), has been precision engineered to allow users to break narrowly sized fragments at a set specific energy, in a safe and easy manner. The manufacturing materials have been chosen carefully to ensure compatibility with the intended use and portability to any site, whilst minimising cost. The device is supplied with a novel quality assurance / quality control (QA/QC) feature, to ensure that the targeted potential energy is consistently delivered. The product from the HIT breakage test can be quickly sized using a single screen to determine the mass per cent undersize, from which the A*b index is calculated directly at site – eliminating the need to send the raw data off-site for analysis. On presized fragments, a single test using 20 fragments takes less than five minutes to complete, and the results are immediately available. The HIT is currently being tested at a major mining laboratory in the US and the results to date have proved it can deliver on all fronts. This paper describes the new prototype device, which offers users a low cost in-house mechanism for estimating the A*b at any mine site, with potential applications on fragments up to 25 mm from drill core, blast chip rejects or the grinding circuit feed. It also outlines the results of field tests carried out by an objective third party mining group and compares the results with those from current industry standard tests conducted on the same material.Citation:Kojovic, T, 2016. HIT - a Portable Field Device for Rapid Testing at Site, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 9–16 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

Carbon sequestration in planted forests provides an immediately available, low cost option to address the greenhouse impacts of coal mining and coal utilisation in a carbon constrained world. In addition, planted forests also offer the opportunity to address other environmental issues, particularly salinity and loss of biodiversity. Given salinity is characteristically associated with agriculture in the 500 to 700 mm rainfall belt, then where such forests can also produce commercial timber products, they offer the additional opportunity to establish new, diversified rural employment in both timber growing and processing. In the majority of Australian catchments affected by salinity, where rainfall is generally less than the 700 mm limit to conventional forestry, and where groundwater reserves are often saline, the objective of achieving economically viable forestry production presents a significant challenge. In 1996, Saltgrow commenced a collaborative breeding program to combine the salt and stress tolerance of E camaldulensis, with the growth rate, stem form and wood properties of the commercial species, E grandis and E globules. This program aimed to produce trees with the potential for commercial rehabilitation of saline landscapes. Results covering a range of site conditions from SaltgrowÆs network of over 100 trials around Australia are presented. The opportunity for commercial plantations integrated with agriculture in low to medium rainfall areas to address salinity and sustainability will be discussed. In addition, the significant potential for partnerships between land-rich, cash-poor farmers, catchment management authorities seeking to invest in public good projects that enhance environmental sustainability, and major carbon producing industries with either mandated or voluntary requirements to curtail net emissions will also be discussed.

Jan 1, 2005

By K L. Brown

Sampling and analyses of deep waters from Wairakei and Rotokawa geothermal systems indicate a wide range of precious metal concentrations (<0.1 to 23 ppb Au; 6 to 2400 ppb Ag), suggesting that eastern ôandesiticö TVZ geothermal systems (eg Rotokawa) have higher aqueous gold and silver than western ôbasalticö geothermal systems (eg Wairakei); this interpretation is consistent with known occurrences of high grade precipitates in wells from eastern systems. The fact that the deep waters are undersaturated in gold further suggests that the aqueous gold concentrations of deep waters are limited by metal availability. The flux of gold for the two systems ranges from ~1 to 50 kg Au/yr, and the flux of silver ranges from 65 to 6900 kg Ag/yr. At Rotokawa, it only takes ~600 years to flux one million oz of Au and >100 million oz of Ag. The supply of hydrothermal gold and silver is obviously important during genesis of an epithermal deposit, but ore formation also depends on the existence of a suitable ôtrapö that efficiently extracts metal from solution in a small volume of rock. Such traps seem to have been poorly developed until geothermal drilling in the TVZ.

Jan 1, 2006

By C Delwig

ThyssenKrupp specialises in the manufacture of high-grade steel-sheet products. Its main customers include the automotive, construction, household appliance, energy and packaging industries.At its works in Duisburg, Germany, ThyssenKrupp Steel Europe produces 12 Mt of crude steel annually, making Duisburg one of the world’s largest steel hubs.ThyssenKrupp have installed an online elemental analyser and limestone dosing control System on one of three Sinter strands at Duisburg in an attempt to control the sinter raw mix with better precision. Traditionally, set point changes to the raw mixture were made after sampling and laboratory analysis of the sinter product. The analyser chosen uses prompt gamma neutron activation analysis to determine the elemental content of moving material on a conveyor each minute and was supplied by Thermo Fisher Scientific. The project goal was to control the CaO/SiO2 ratio (basicity) and reduce its variability in the sinter feed.Evaluation of the system has shown that the addition of the online analyser reduces the time lag related to the former method, therefore upset conditions can be reacted more quickly by the control system, and this has resulted in a more stable sintering process. As a result, the sinter feed variability in case of the basicity has been reduced by half. While CaO/SiO2 control was the initial aim of the project, a number of other benefi ts have been realised, such as a reduction in return fi nes and a financial benefi t of 0.11 €/ton of sinter attributed to the reduction of coke breeze and limestone. ThyssenKrupp Steel Europe has identifi ed that additional information available from the analyser could be used to optimise the complete sinter process.The project was carried out with a financial grant of the research program of the ‘Research Fund for Coal and Steel’.

Jul 11, 2011

By Y Xie, L O’Connor, S C. Dominy

"Sheeted vein gold deposits are characterised by multiple subparallel veins and free milling gold. In situ heterogeneity of mineralisation results in grade and process parameter variability, which will increase project risk. Measured variability is often enhanced by poorly designed sampling and test work protocols. Protocols that are optimised within the framework of the theory of sampling to suit the ore type, together with quality assurance/quality control systems, will reduce variability and provide fit-for-purpose results. The geometallurgical approach requires spatially distributed samples within a deposit to support variability modelling. Diverse attributes from core logging, mineralogical/textural determination and small-scale tests are used to measure variability. This contribution emphasises early stage geometallurgical intervention during project development. It presents a discussion of representative sampling in the context of the theory of sampling. A case study presents a protocol that exemplifies how data can be gained from a well-designed and planned program to support a resource estimate and prefeasibility study.CITATION:Dominy, S C, O’Connor, L and Xie, Y, 2016. Sampling and Test Work Protocol Development for Geometallurgical Characterisation of a Sheeted Vein Gold Deposit, in Proceedings The Third AusIMM International Geometallurgy Conference (GeoMet) 2016, pp 97–112 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jun 15, 2016

By D Roughsedge, J van der Sandt, L van den Berg

Axial flow fans are commonly used as auxiliary fans in underground mines to supply air to development headings. As diesel dilution requirements increase the fans used in conjunction with ventilation bags are becoming larger in diameter to move greater quantities of air over greater development distances. It is not uncommon for mining operations to sometimes use a number of these larger auxiliary fans with high airflow capacity in parallel as primary fans for the operations. These primary fan stations are often considered temporary installations and the fan selection and fan station design is rarely optimised. These temporary installations may become permanent resulting in an inefficient or unreliable primary ventilation system. A recent study looked at the likely causes of multiple primary fan failures at one operation with axial fans installed as primary units where the fan selection and fan station aerodynamic design was far from optimal. This paper explores some of the typical mechanisms of failure such as high pressure stall, unbalanced airflow, and fan tip speed as well as fabrication material. The paper proposes a number of good practise principles that should be considered during the design of a fan station. A second topic covered is the advantages and disadvantages of using different types of fans such as axial, mixed flow and centrifugal units. Here the concept of fan specific speed and its relevance to fan selection is discussed. Finally the paper quantifies the effect of using a high pressure auxiliary fan as a primary fan in a low pressure circuit, which may increase the mineÆs operation cost.CITATION:van der Sandt, J, van den Berg, L and Roughsedge, D, 2013. Practical considerations when using auxiliary axial flow fans as a primary mine fan, in Proceedings The Australian Mine Ventilation Conference , pp 63-70 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 1, 2013

India is on fast economic growth. Even in the turbulent years of global crisis, it could achieve a growth of over eight per cent. In recent past, Indian Government has been contemplating a faster growth in all the sectors of economy so as to make the nation an economic power in the world.Steel is a versatile material. It has its role in most of the major industrial activities, such as infrastructure, automobiles, urbanisation, consumer durables and other. In other words, steel is a part and parcel of industrial expansion, urban and rural development. It is rightly admitted that steel acts as pillar of any development model. Volume of steel consumption is the barometer which measures economic progress and/or industrial status of any country.India and China are the two countries in Asia which have the significant impact on the global steel industry. Of course, China is much ahead of India in consumption level of steel.

Dec 6, 2010

By P Ridley

EnergyAustralia’s Sydney Central Business District (CBD) cable tunnel network will form a loop 6.2 km in length. The 3.2 km long, 3.5 m, diameter city east cable tunnel (CECT) currently in design, will complete the loop in 2014. This paper discusses the ventilation design of the CECT, considering operation for four functions:1. normal (unmanned),2. access (manned),3. purge, and4. emergency fire modes.The dominant design criterion which determines the required ventilation capacity for CECT is the specification of an upper air temperature limits of 35°C (dry bulb) and 24°C (wet bulb) for manned access, during all ambient weather conditions and cable heating loads. Simplistic static heat transfer analyses do not yield a sufficiently accurate calculation of tunnel air temperature and humidity to provide a safe and yet economical design. The primary refinement in the analysis discussed in this paper is associated with modelling of the system’s dynamic behaviour.Our means of analysis is through a thermo-fluid-dynamic simulation of the interactions between the diurnally and seasonally varying loads (cable heat generation, ambient air conditions and groundwater inflow), tunnel airflow and the resulting tunnel air temperature and humidity. These simulations are validated using experimental data from the existing city south and city west cable tunnels.Fire life safety scenarios are also analysed and discussed in association with the ventilation design. Ventilation strategies are developed for dealing with such emergency fire situations.The understanding and insight provided by the work offers the ability to optimise ventilation plant provisions in future cable tunnels, particularly long and high energy density tunnels.

Mar 8, 2011

The modern resource extraction enterprise is a complex capital intensive business operating in a world of constantly evolving social, environmental and economic scrutiny. Investors, government, media and special interest groups expect to see business environmental and social performance respond and deliver increasing corporate responsibility and sustainability.   Thorough interrogation of business performance using a multi-disciplinary due diligence approach presents a more sophisticated review and benefits beyond the traditional compliance/conformance 'audit' style assessment.   Using a due diligence approach allows assessment through a comprehensive lens which examines potential short- and long-term risks including sometimes less tangible environmental and social liabilities, and informs management, investors and regulators of broader business performance. This approach provides information in a form that business can measure performance in a repeatable and enterprise wide sense.   This paper provides an outline of the due diligence process applied in this way, drawing from lessons learnt and industry based experiences in the due diligence process and the benefits and tools that can  be applied in an environmental and social due diligence business performance assessment

Jun 1, 2010

By R Moreby

This paper is a demonstration of the techniques developed during an Australian Coal Association Research Program (ACARP) funded research project aimed to develop aids, principally computer based, to assist mine personnel to more efficiently manage significant incidents in coal mines. These aids include software to aid in the location of the incident, electronic information storage and retrieval, online site emergency response manuals and software to aid in decision-making.

Jan 1, 2005

Safety remains a critical priority for the Australian mineral resource industry and will receive increased focus in the future. This is particularly evident in underground coal mines where reserves are becoming deeper and more hazardous to extract. The CSIRO, through its Exploration and Mining Division, have recently delivered on two projects aimed at providing step-change capabilities in real-time risk management and hazard control. This paper describes the key outcomes of these projects.

Jan 1, 2005

By C Smith, R I. Maczkowiack, P D. Erskine

Open cut coal-mining has been conducted in the Bowen Basin region of central Queensland for almost five decades, and has disturbed an estimated area of 140 000 ha of agricultural land until 2011. Approximately one-third of the area disturbed by mining has been rehabilitated to pastures or bushland. However, none of the rehabilitated land has yet been assigned a specific end-use. This research project develops an approach for assessing end-use risks for the regionÆs mined land, and develops risk assessment models for selected end-uses. First, a web-based survey of stakeholders was used to identify risks to be assessed. The risks identified were surface erosion, subsurface erosion, bushfires, weeds and feral animals. The survey also identified possible end-uses of bushland and grazing. Second, conceptual risk models were developed based on the risk assessment concepts of likelihood and consequence specified in the Australian and New Zealand risk assessment standards. Likelihood was modelled using site characteristics and management factors that influence the occurrence probability of risks (eg surface erosion), while consequence was modelled using a set of site condition indicators and condition thresholds (changes in root-zone water-holding capacity, soil erodibility, vegetation ground cover and soil organic matter and transition probability to a non-preferred ecosystem type).The factors influencing likelihood and consequence for each risk have been integrated using Bayesian networks. The next step in model development is to parameterise the Bayesian networks using existing equations, empirical datasets, or expert opinion where data are not available. The parameterised models will be used to assess grazing and bushland end-uses against erosion, bushfire, weed and feral animal risks for rehabilitated mined land sites, with the purpose of identifying the relative risks associated with each end-use, and the landform design specifications and land management practices under which end-use risks are minimised.CITATION:Maczkowiack, R I, Smith, C and Erskine, P D, 2012. Risk assessment models for post-mining land use, in Proceedings Life-of-Mine 2012, pp 33-42 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 10, 2012

By M Castello, P Bouchard, M Sabsabi, A Blouin, B Nguegang Kamwa, M Constantin, K Fytas, M Laflamme, K Rifai, F Vidal

Canada’s Quebec province operates 26 metal mines, 19 of which are producing gold and generating over C$1.8 billion (US$1.3 billion) annually. In all those mines, numerous samples of rock are collected and analysed daily in laboratories in order to determine their gold content. However, laboratory results are generally available within 48 hours of sampling (depending on the number of samples received by the laboratory and the priority of the results), thus potentially slowing down mining activities. In an attempt to find a solution for delayed laboratory results, Laval University, in partnership with the National Research Council Canada (NRC), the National Institute for Scientific Research (INRS) and four mining companies (Agnico Eagle, Canadian Malartic, Hecla Québec and Iamgold) have launched the Laser-Induced Breakdown Spectroscopy (LIBS) project for in situ real-time mining sample analysis. This work aims to minimise the amount of LIBS point sampling necessary to be representative of a full scan of the analysed area. Eight sampling patterns are investigated. A statistical analysis of the data was performed by varying the pattern steps. Results show that two of the patterns, 1 and 5 (single diagonal crossing the stratification of the samples with opposite slopes) minimise the amount of point sampling while remaining representative. The most successful results are obtained from steps which are greater than 6. In terms of the type of material, pattern 5 and steps 9 are better for core sampling, while pattern 1 and steps 8 are better for rock sampling. The geological explanation for these results is the heterogeneous distribution of gold in the sample which seems to be more homogeneous in the rocks than in the core sample due to the small rock size. In terms of the mineralisation, pattern 5 is better for mixed sulfides and quartz veins, and steps 8 and 9 are better for quartz veins.CITATION:Nguegang Kamwa, B, Rifai, K, Laflamme, M, Constantin, M, Castello, M, Vidal, F, Bouchard, P, Fytas, K, Blouin, A and Sabsabi, M, 2017. Sampling strategy by statistical analyses of LIBS data in the context of a portable gold analyser, in Proceedings Tenth International Mining Geology Conference 2017, pp 221–232 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By H J. Stedman

A Transient Electromagnetic (TEM) geophysical survey was trialled in Bowen Basin Permian coal measures overprinted by Cretaceous intrusion. The trial’s intention was to compare whether TEM could assess residual coal more accurately and economically than drilling.TEM results were promising but had limitations. TEM did not compare to drilling for defining coal thickness or relative level definition. However, TEM resolved conductive anomalies laterally; providing a qualitative picture of remnant coal.Three material types and associated conductivities occur within the trial area: overburden (sandstone/siltstone), intrusive sills and heat affected coal.Ground conductivity was analysed by measuring decay of residual current within the TEM loop. Fast decay related to resistive overburden and intrusion, attenuated decay related to conductive coal.Generally speaking, carbon content governs coal resistivity where good quality, low ash, bright coal is more resistive relative to dull, high ash coal. Though in the trial area, relative to intrusion and overburden, coal was found to be the most conductive of the three materials.By modelling conductive anomalies, a general picture emerged of remnant coal regions. Subsequent highwall exposure reconciled with conductive TEM anomalies.CITATION:Stedman, H J, 2017. Findings from a transient electromagnetic trial for heat-affected coal, in Proceedings Tenth International Mining Geology Conference 2017, pp 233–238 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By S Versace, D Arnott, D Bojcevs, A Shaw

The George Fisher deposit is a significant sediment hosted silver-leadzinc resource located 2 km north of the Hilton Mine in NW Queensland. The George Fisher feasibility project involved the completion of underground and surface drilling programs to delineate Measured and Indicated Resource which could be converted to an Ore Reserve through mining and commercial studies. The geological information which was collected and used for the feasibility study included a major program of diamond drilling, predominantly from underground sites, but with some drilling also completed from surface. All drillcore was geologically and geotechnically logged, sampled and assayed. Data was also collected from underground cross-cut and drive development which was mapped for rocktype, ore distribution, structure and geotechnical condition. This new geological data, generated during the Pre-Feasibility and Feasibility stages, was combined with results of all previous drilling campaigns in the George Fisher area to produce a comprehensive database on which geological modelling and Resource estimation could be based. To allow fast and accurate collection and utilisation of data from the drilling program, digital collection processes were used where possible. This resulted in rapid data entry into the project database, significantly enhanced data quality, 100 per cent data ownership within the project team and increased productivity levels. Processes used during the project data collection program are described, lessons learned are related and suggestions for ænext timeÆ are listed using the benefit of hindsight.

Jan 1, 1998

By D Readett

The most critical variable in the successful establishment of the Murrin Murrin Heap Leach plant was the effective agglomeration of the Ni laterite ore. This paper describes the test work undertaken to establish the key agglomeration parameters including state of the art testing and analysis procedures. These parameters were then utilised to establish the key design and operational concepts for the world’s first commercial scale Ni laterite heap leach. Following the technical and economic success of the operation, the actual operational data is compared back to the original test work data.

Aug 8, 2011

By G Stovpchenko, G Jianjun, L Medovar

Electroslag remelting (ESR) today and into the future, will still be the main process for producing high-quality ingots by suppressing segregation, not just refining chemical composition from impurities. This paper analyses state-of-the-art electroslag refining with a focus on ESR with consumable electrodes, and recent technology with liquid metal supply (ESR LM) in view of their refining abilities and development trends, taking into consideration that the size of the ingots required by industry continues to grow, and the composition of new materials sophisticates to withstand increasingly higher mechanical and temperature loads . The yield of suitable metal in large ingots produced by conventional casting is low due to problems of element segregation by height and crosssection. For example, conventional ingots for nuclear powerplant rotors today reach nearly 700 t in weight. Attempts to directly replace such giant ingots with big-diameter ESR ingots weighing approximately 400 t were also unsuccessful because of growing segregation. Modern ESR equipment and technologies produce 200–250 t of ingots of satisfactory quality, reaching 2.5 m in diameter, implementing the change of consumable electrodes during remelting to increase ingot length. Another way to mitigate segregation is to enlarge the smaller diameter ESR ingot by a 500– 800 mm coaxial layer to the desirable diameter by ESR in the current-supplying mould (CSM). Modelling and experiments prove that refining from impurities and non-metallic inclusions at ESR most effectively occurs at the slag bath and liquid metal pool interface because the ESR LM has provided the same desulfurisation. ESR’s special refining capabilities in CSM come from the much longer time of LM residence shown at titanium purification from hard-melting nitride inclusions that are unremovable in vacuum arc remelting (VAR) and electron beam melting (EBM). Implementation of ESR technologies in CSM, especially with LM supply, is prospective to produce heavy enlarged and hollow forging ingots with prevented development of segregation due to dividing cross-section and reducing overheat of solidifying metal.

Jun 19, 2024