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Secondary steelmaking (or ladle metallurgy) has been developed as a post- steelmaking ladle treatment to produce steel of superior quality. Its rapid growth has resulted from quality improvements, productivity increase, operational flexibility and process route economics. Advances in secondary steelmaking are very impressive during the past decade, and many commercial systems have been developed for performing one or more of the following unit operations: degassing, atmosphere regulation, reheating, refining with synthetic slag, rinsing gas treatment, injection of solid materials and alloying. The metallurgical requirements imposed by the current competitive steel market include more precise analysis tolerances, minimum level of detrimental elements, improved cleanness, demanding service performance and better processability. In most cases, these requirements could only be realized by the application of appropriate secondary refining facilities. Continuing developments in simplicity of design, cost advantage, quick cycle time, improvements in peripheral services such as refractories, instrumentation and in-situ analysis, extensive exploration of new applications, and the use of computer, can be expected. An exciting future is predicted for the widespread adoption of secondary steelmaking to perform most of the major refining functions over a variety of steel quality. It will also become a vital link in the total steelmaking process for production of tonnage steel at the large integrated steelworks and the mini-steelmills.

Jan 1, 1986

The Ocean Drilling Program is the largest international geoscience project in the world, and the state-of-the-art drill ship, the JOIDES Resolution, is permanently at sea. Each year there are six scientific cruises (Legs) which each last approximately two months. These legs are designed by geoscientists from the 19 countries that subscribe to ODP. Australia and Canada share ODP membership under the banner of the AUSCAN Consortium. The Australian Secretariat of the ODP is housed at the Department of Earth Sciences at James Cook University, along with the AUSCAN Consortium office. The Canadian Secretariat is presently based at the University of Toronto. Both secretariats have major research interests in the ore deposits, both ancient and modem, and so there is currently a major drive by the AUSCAN ODP Consortium to make available data and technological information to the minerals industry. This type of information includes data from drilling hydrothermal sites such as the hydrothermally active TAG black smoker complex on the Mid-Atlantic Ridge, drilled during Leg 158, and the Middle Valley sulphide deposit, on the northern Juan de Fuca Ridge, which was drilled during Leg 139.

Jan 1, 1996

By Daziel M, Corke P

Unit cycles in mining have not changed for many years. Productivity increases over the past three decades have mainly been achieved by using larger and heavier machines. This investment in size has probably reached the point of diminishing returns and increased productivity in the future will have to be generated by other means. One way of achieving this is through automation of selected unit operations, eg dragline overburden removal, truck haulage, ground support installation and secondary breakage. Although, in the past few years, there has been significant progress in this direction, we are still a long way away from even partial automation - especially in hard rock mines. This paper addresses the technical obstacles facing mining automation; suggests ways by which these obstacles may be overcome and identifies the role of industry groups and research providers in this process.

Jan 1, 1997

The physical phenomena which influence gas flow in the bosh and hearth of a blast furnace are discussed including the hold-up of slag as a mechanism which can result in a flooding condition. An equation is defined which describes the limitation to wind volume arising from the flooding condition. Implications of the various factors influencing bosh and hearth gas flow on furnace operation are discussed. Coke quality is shown to be the most important factor in the aerodynamics of these zones and coke requirements are defined for the Port Kembla No. 5 BF which has an inner volume of 2670 m3.

Jan 1, 1975

By P Moser, P Schimek, F Ouchterlony

This paper summarises the findings of 27 model-scale bench blasts in magnetic mortar, which were conducted from 2011 to 2014 at the blasting site of the Montanuniversitaet Leoben.The aim of the study was the investigation of the influence of blasthole delay times in small-scale bench blasts on the face characteristics and cracking damage created in the surrounding rock, which affects the fragmentation in subsequent rows.The test specimens or blocks, which were produced out of magnetite concrete, were roughly 1:100 in scale to normal bench blasts. The confinement of the testing blocks at the sides and back ensured the similarity to normal bench blasts with regard to the wave transmission into the surrounding rock. The specimen contained three or four rows with five blastholes each and were shot row by row, with virgin (undamaged) material in row 1 and increasingly damaged or preconditioned material in the following rows.The tested delay times varied between 0, 28, 73 and 140 µs, which corresponds to 0, 0.4, 1.0 and 2.0 ms/m of burden.The evaluation of the material properties showed that the use of magnetite concrete eliminated the inhomogeneous behaviour of rock, but some unexpected differences of the individual production cycles were still detected.The characteristics of the bench after each blast was evaluated along three horizontal lines out of a 3D model of the bench face. The tested delay time sequences of the virgin (first row) and single preconditioned blasts (second row) produced more overbreak for longer delays, while the third-row shots resulted in a smoothened surface independent of the chosen delay.The introduced damage after every blast was evaluated by an observation of irregularities on the newly blasted bench face. The visible cracks at the top of the testing blocks were documented and divided into several crack families according to their angle, length and origin. The remaining block was broken out of the blasting site after blasting, cut into several horizontal and vertical slices and dye penetrant spray was used to visualise the cracks created. Some of the detected crack families showed an influence of the delay time. The calculated mean crack density and mean crack intersection density showed that longer delays resulted in a higher degree of damage.The fragmentation results were well reproduced by the basic three-parameter Swebrec function. The observed improvement of fragmentation in the second- and third-row blasts was linked to the preconditioning of the burden for the following row while blasting the actual row. With the exception of the simultaneously initiated blastholes, the blasts showed coarser fragmentation for the shortest delays, while the longest delays generated the finest fragmentation.CITATION:Schimek, P, Ouchterlony, F and Moser, P, 2015. Influence of blasthole delay times on fragmentation as well as characteristics of and blast damage behind a remaining bench face through model-scale blasting, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 257–266 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By Bunting HR

Developments since 1959 in major excavators to meet the high outputs of overburden and coal under the changing nature of the Morwell Coal Deposits of the Latrobe Valley are described. Particular reference is made to investigations of designs of the bucket wheel head configurations for the digging of flat batters on high faces, and examples are given of the wide use ofmodelsin these studies.An explanation is given of considerations leading to selection of the Long Boom or the Compact type of bucket wheel excavator for various applications. The past decade has seen increasing manufacture in Australia of components for excavators and similar machines. The measures undertaken to integrate these components with those from overseas (Germany) are described. A section of the paper deals with advances in Electrical Engineering for large excavators in Australia and its interdependenee with mechanical design and construction. Finally, as an example of the versatility of the bucket wheel excavator a description is given of a recent application for the mining of mineral sands in Northern N.S.W.

Jan 1, 1970

By K Friese, H P÷llmann

Clinoptilolites, modified with sodium, produced a material which has been tested for the ability to remove Hg (II) from aqueous nitric acid. The amount of adsorption depends on contact time, acid concentration of aqueous solution and initial mercury concentration. The study of the kinetics of mercury uptake revealed that all sorbents exhibit a fast rate of sorption. The highest sorption capacities were observed for sodium forms, and were up to five times higher than for the unmodified zeolite. The maximum sorption capacity toward mercury is determined as 0.093 ¦g/g at an initial concentration of 10.0 ¦g/L for a clinoptilolite from Tsagaantsav deposit (Mongolia). The sorption of Hg (II) has an ion-exchange nature and consists of three stages, ie the adsorption on the surface of microcrystals, the inversion stage and the ion exchange in the interior of the microcrystal. Sorption capacity decreases with the increase of mercury concentration. The presence of other metal ions such as Cd (II), Cu (II), Ni (II) and Zn (II) increases Hg (II) uptake capacity. Finally, sorption for Hg (II) was investigated in batch systems to evaluate the short-term stability of the sorption properties.

Jan 1, 2008

By Moyes A. J

The Intec Copper Process uses a strong chloride electrolyte at atmospheric pressure and 80 - 85¦C to produce high purity, 99.99 per cent copper granules and elemental sulphur. A recent, exhaustive study by an independent, major Australian corporation has shown the capital cost of an Inter plant to be approximately half that of a copper smelter at the 200 000 tpa capacity level and approximately half the operating and capital cost at the 50 000 tpa level. The Inter process costs were also shown to be greatly superior to the best available leach/SX/electrowin technology. The process utilises a multi-stage counter current leach at 80 - 85¦C with the addition of air at atmospheric pressure to precipitate iron as a goethite type compound, followed by a two-stage purification process separating impurities in metallic- and other forms. Purified cuprous chloride/sodium chloride solution is fed to an electrolytic diaphragm cell where high purity copper granules are produced at current densities of 1000 - 1500 A/m2 withoutthe need for conventional electrode stripping. Power consumption is approximately half that of the cupric route. The product is suitable for the direct powder metallurgical conversion of the granules to products such as wire or strip. All the steps in the 'furnace free' conversion of copper mineral to product have been demonstrated The process can treat low grade and contaminated concentrates without penalty, thereby offering greater returns to the miner. Lead, zinc and silver may be recovered as metals, with the high oxidation potential of the electrolyte allowing extraction of gold at high efficiency. The gold is selectively precipitated on activated carbon with negligible copper and silver contamination.

Jan 1, 1992

The design and construction of a 2.5 million tonne per annum ship unloading system at the PWCS export coal terminal in Newcastle, NSW, has further increased the flexibility and sophistication of Australia's largest coal export facility. The system comprises a new unloading wharf serviced by a self unloading vessel, conveyor stream and multi compartment ground level storage shed. Coal is reclaimed from this shed by the largest portal scraper ever installed under cover. The system also provides additional flexibility by receiving coal from the existing PWCS road receival to improve scheduling. The PWCS can now simultaneously handle 11 coal types and receive from rail, road and sea at almost 15000 tonnes per hour.

Jan 1, 1987

By Clarke B. N

The Olympic mine is currently and development to 1988. The mine practice is, and number of factors. Dam copper-uranium-gold undergoing construction start production in May ventilation design and will be determined by a These include: 1. Mining method and degree of mechanization. 2. Presence of radon emanating material. 3. High virgin rock temperatures at relatively shallow depths. 4. High ambient air temperatures in Summer.

Jan 1, 1988

The research, development and testing of a Blast Control Plug (U.S. Pat. #4,754,705) funded by the U.S. Department of Energy is described. The plug's function is to improve blasting efficiency through the enhancement of stemming effectiveness and thereby reduce drilling and blasting costs. The plug comprises a solid unit placed in the blast hole within the stemming column above the explosive. It is designed for use with back filled drill cuttings or any other suitable material The research and development program comprised the testing of the plug in small diameter holes in competent rock for both bench and crater blasting configurations and full scale field trials in multiple hole and row blasts using blast holes of from 76 to 387 mm in diameter. Test measurements included stemming displacement and velocity, face movement and extent, peak air over pressure and ground surface peak particle velocity. Data acquisition equipment included a Spin Physics SP2000 high speed video motion analysis system, and acoustic and seismic monitoring units. Substantial reductions in stemming ejection velocity or ejection elimination were achieved whilst reducing stemming length by up to 35% over conventional practice. Peak air blast pressures were also reduced by between 8 and 25 dB. A strong inverse relationship between rock face movement and stemming ejection velocity was found. The implications of the importance of stemming effectiveness in blasting and computer blast simulation is also addressed.

Jan 1, 1990

Cerro Matoso (CMSA) in Colombia produces ferro-nickel from lateritic ore containing approximately three per cent nickel, using a Rotary Kiln - Electric Furnace (RKEF) process, in which the calcining of the mineral within the kiln is second in importance only to the smelting of the mineral in the Electrical Furnace. This article discusses the installation and operation of an expert system to control the kiln of CMSA. In the CMSA process, the run-of-mine ore is crushed, homogenised, dried and mixed with a small percentage of coal, before being heated up to 900¦C in a rotary kiln in the presence of natural gas mixed with air in a controlled proportion (air/gas constant ratio). The final objectives of the process are the following: ò To reduce to a minimum the iron and nickel oxides in order to convert these into metallic ions; this is a reduction process to facilitate largely the smelting in the electric furnace. Since the reduction is made with natural gas, it is much more economical than the subsequent complete reduction in the electric furnace, since electrical energy is much more expensive by unit of processed mineral. ò To heat the mineral as much as possible to facilitate the subsequent smelting. ò To eliminate totally the moisture content of the ore. An expert system with fuzzy logic was commissioned in 1994 for the control of the kiln and it has operated with good results ever since.

Jan 1, 1996

By Knight J. L, Baker G

The Wonthaggi coalfield is in South Gippsland, about 90 miles southeast of Melbourne. It is situated on the down-faulted block of the South Gippsland highlands that lies south of the Kongwak fault, between the Powlett River and the sea (Fig. 1). The coal, which is of Jurassic age, occurs in two small, and intensely faulted, limnic basins, that lie on either side of a concealed ridge of Silurian sediments. The coal was first found as thin seams outc1'opping in the cliffs at Cape Paterson, but the seams that are worked at Wonthaggi are concealed beneath a veneer of Cainozoic sands that covers the Jurassic strata, and were found by boring.The c9al seams are worked by the State Coal Mine, which was opened in 1909 to ensure a supply of coal for the Victorian railways, following a prolonged strike in the Newcastle field of New South Wales. The total production from 1910 to June, 1943, amounts to 13,918,800 long tons of coal. The coal seams are faulted to a degree unknown in most coal...

Jan 1, 1944

By Newell R

The situation in which a gas stream flows through a bed of solids is found in many extractive metallurgy operations. Examples include blast furnace smelting, sintering and pellet firing. In such cases the resistance of the bed to fluid flow and heat transfer is of major significance to the operation of the process. This depends on the structure of the bed, which in turn is influenced by the manner in which the materials are charged to the bed. In this work, packed beds of hematite pellets of two different sizes were prepared in which the pellets were charged as a uniform mixture and in layers. The porosity, flow resistance and heat front velocity were measured and compared for the different bed configurations. For layered beds, the overall porosity and heat front velocity increased while the flow resistance decreased when compared with the values obtained for the uniform mixture. The size of the layers also had an effect on flow Properties.

Jan 1, 1991

The traditional concept of optimum drill and blast is that it is achieved when ore is produced at the lowest unit cost and, because of the complexities of most mining operations, represents a band which extends either side of an overall cost m

Jan 1, 1998

By V Gumba, S Narendranathan, C Barker, R D. H Thomas, G P. Bungard

This paper presents the positive outcomes on an EPCM project, which was undertaken in a challenging environment, whereby the design team had to generate a design with a number of stringent serviceability criteria, any deviation from which would have had significant implications to the proposed design performance. The success of the design implementation within the tight time frame hinged upon the precise installation by a skilled contractor. The overall objective was achieved as a result of close collaboration between the designer and contractor ensuring all stringent quality assurance/quality control (QA/QC) aspects were met and opportunities to optimise design without compromising on performance were identified and implemented, resulting in a cost saving of over A$13 M.CITATION:Narendranathan, S, Thomas, R D H, Bungard, G P, Gumba, V and Barker, C, 2012. The importance of collaboration between designers and contractors in implementing a design in challenging conditions, in Proceedings Eighth Open Pit OperatorsÆ Conference , pp 97-102 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 18, 2012

The production of 100,000 tonnes per year of synthetic rutile from the processing of ilmenite, coal and copperas (iron sulphate) produces 200 cubic metres per hour of effluent water. A 2.0 hectare biological filter, comprising natural and man- made wetlands, has been built into the last stage of the effluent water treatment system. It is an area of shallow water (

Jan 1, 1988

By O Tiili, A Dixon

Many minerals processing plants need to have greater efficiency in current times and optimise their process performance in order to maintain high profitability. This is even more so in the current economic climate. In the case of large flotation cells, such as TankCell«-300 with over 300 m3 active capacity, ensuring consistent operation and optimal flotation conditions is particularly critical, given the high impact on overall process and throughput of such cells. As there are fewer cells to control and monitor, there is also a lower initial capital cost for instrumentation - the requirements, however, are higher. Despite such compelling reasons, instrumentation and basic control in flotation cells has not changed much in recent years. The standard is still to use traditional feedback (PI algorithm) controls for slurry level and flotation air. A new advanced instrumentation and control package for large flotation cells has recently been developed by Outotec and has been installed at Macraes.In addition to the standard basic instrumentation and control, the new system at Macraes consists of a froth image analysis system, a froth velocity control, and a level control system which utilises adaptive feedforward compensation. There are three TankCell«-300 cells in operation at Macraes since November 2007 and the new control system was commissioned in December 2007.The paper will include comparative data from pre- and postsystem installation and discusses benefits including optimised recovery, improved performance, as well as ease of operation.

Jan 1, 2009

This paper summarises the influence of slurry rheology on the grinding throughput of batch laboratory and continuous plant-scale mills operating in open and closed circuit configurations. The results of controlled changes in percent solids, particle size, slurry temperature, and viscosity control chemicals are demonstrated. An underlying rheological explanation of the above factors is offered which involves tying the specific rates of breakage that are occurring in the mill with the specific rheological character that the slurry is exhibiting at any given set of operating conditions. Some industrial scale operating guidelines are presented which have proven useful in increasing the net pro- duction capability of grinding circuits.

Jan 1, 1978

Whilst decisions to commit projects have traditionally been heavily influenced by hurdle rates for d.c.f. analysis, it is suggested that evaluation of competitors' costs may be a desirable additional tool.The MICAS system developed over the past four years is described. This computer system uses standard costs modified by District and Mine factors to allow estimation of individual mine costs. The data base contains more than 15,000 items of data and more than 6000 costs are calculated.Recent applications include use for competitive analysis, predictive analysis, statistical analysis, and comparative assessments with scopes ranging from a few mines to the whole Australian export industry. Some areas where care is necessary are outlined and potential further uses are discussed.

Jan 1, 1985