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By T J. Callaghan

The Avebury nickel mine in Western Tasmania is a disseminated nickel sulfide deposit hosted in intensely metasomatised Cambrian ultramafic resulting from later Devonian granite related hydrothermal activity.Variable metasomatism of the ultramafic has formed two distinct gangue mineral assemblages. Less metasomatised ultramafic is comprised of fine grained black antigorite with minor disseminated chromite, magnetite and pentlandite. Intensely metasomatised ultramafic is altered to a pale grey or green, coarsely crystalline tremolite/actinolite and diopside assemblage with minor magnetite, chromite and sulfides. Both gangue mineral assemblages are frequently intermixed in ore grade mineralisation.The bimodal gangue of either serpentinite or metasomatised ultramafic presents challenges to drilling, mining, resource estimation and mineral processing as they possess very different physical properties. Mineralised serpentinite has a mean bulk density of 2.8 g/cc and the ultramafic skarn a mean bulk density of 3.2 g/cc. Physically, the ultramafic skarn is hard to break percussively creating difficulties in the crushing circuit and reducing mine development rates. However, it is non-abrasive and grinds readily, resulting in increased diamond drilling rates and increased mill throughput. Conversely the serpentinite gangue is softer and breaks easily resulting in accelerated development rates and crushing circuit throughput. However, its fibrous nature reduces grinding efficiency, increasing bond work indices and reducing diamond drilling rates.Predicting the ratio of serpentinised to metasomatised ultramafic is possible through use of the resource blockmodel, assisting mine scheduling, predicting mill throughput rates, energy consumption and grade control drilling rates.CITATION:Callaghan, T J, 2017. Challenges of bi-modal gangue mineralogy in mining geology, in Proceedings Tenth International Mining Geology Conference 2017, pp 23–26 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

The Peko copper orebody is associated with a body of magnetite rock which it has partly replaced. The primary ore averages about 9 per cent. copper and 4 dwt. gold per ton and locally IS much richer. It consists essentially of chalcopyrite and unreplaced magnetite, with lesser amounts of pyrite, marcasite, pyrrhotite, cobaltite, bismuthinite, native bismuth and native gold. The earliest formed mineral is wolfram, and the latest formed is goethite, so that the temperature of deposition ranged from about 5000 C. to 1650 C. or lower.Oxidation extends to 270 ft., which is 100 ft. below the present water level. The oxidized ore consists of cuprite and native copper, and has replaced more or less massive chalcocite of a former zone of secondary sulphide enrichment. The present zone of secondary sulphide enrichment extends from about 270 ft. to 310 ft. depth.INTRODUCTIONThe Peko mine is about 6 miles south-west of Tennant Creek township in the Northern Territory, adjacent to a small outcrop of hematite rock that projects above an otherwise featureless "bull-dust" fiat.The copper-gold orebody being developed in this mine did not outcrop. It was first detected in 1950 by a surface diamond-drill hole (DDH.1), which intersected primary copper ore at a depth of 400 to 425 ft. This ore contained from 4 to 11 per cent. copper and 1 to 25 dwt. gold per ton. Since then a shaft has been sunk, and crosscuts and development drives have been opened on the 210..ft., 300-ft. and 400-ft. levels, which are also connected by winzes. Two diamond drill holes sunk from the 400-ft. level have intersected theorebody at about 450 to 460 ft., and a winze from the 400-ft. level intersected the lode from 445 to 500 ft. At this point it is 54 ft. wide, and averages 9 per cent. copper. More recently an inclined surface drill hole (Peko No. 1) has cut the lode at 856 ft. to 921 ft., equivalent to a vertical depth...

Jan 1, 1955

By Abishev D. N, Balakirev V. F, Davydov G. I

The problem of recovery of cobalt products from poorly oxidised nickel ores (Kempirsaisk deposit) and pyrite concentrates with a low content of cobalt (Sokolovsk-Sarbaisky deposit) has not been solved to the present time in Kazakstan. The balance reserves of nickel ore of the Kempirsaisky deposit make up more than 35 million tons with a nickel content of 1.13 per cent and cobalt content of 0.05 per cent; besides there are 110 millions tons of out-balance ores (Anon, 1995). In a tailing dump of Sokolovsk-Sarbaisk Mining and Productional Association more than 320 million tons of tailings of wet magnetic separation have accumulated, which contain 7.2 per cent of sulphur, 0.022 per cent of cobalt, 0.012 per cent of nickel, 0.094 per cent of copper, 0.079 per cent of zinc, 16.45 per cent of iron, and from which a high quality pyrite concentrate car) he separated through flotation, containing 48 - 50 per cent of sulphur, 44.15 per cent of iron, 0.141 per cent of cobalt, 0.07 per cent of nickel, and 0.10 per cent of copper. The well-known technological flow charts for cobalt and nickel recovery from the tailings of sulphide-magnetite ores dressing (to give pyrite concentrate) and from oxidised nickel ores, are not profitable at the existing prices for metals, but are not worthless and require significant capital investments for the realisation of their value. The flow chart `sulphate roasting - leaching - solution processing' is used widely for combined processing of cobalt-containing pyrite ores and concentrates.

Jan 1, 1996

By B Kilgariff

Flotation has been in use at Broken Hill for nearly 100 years, and the process has gone through many different optimisation studies over that time. This paper reviews the current flotation practice at the Perilya Broken Hill Mine, and details one of the recent optimisation studies conducted using mathematical modelling and simulation tools. The optimisation study consisted of surveys of the lead and zinc circuits, mapping of the floatability components of the ore and developing models of the lead and zinc circuits. The models were then used to conduct simulations to simplify the circuit. The study allowed plant personnel to identify optimum operating conditions for their current flotation cells, as well as possible improvements in circuit configuration and cell capacity.

Jan 1, 2005

To enable ammonium nitrate-fuel oil (AN-FO) to be used on an equal weight basis with nitroglycerine explosives, smaller diameter bore holes became necessary with consequent modifications to drill steel and burden on holes. Detonation of AN-FO in small diameter holes proved successful both with and without primer charges but some alterations were required to adapt anoloders to the smaller holes.Important factors in training all operators in the new charging method were the retention of improved fragmentation, avoidance of excessive overbreak and keeping wall rock dilution to an absolute minimum. The successful storage of ammonium nitrate in climatic conditions with daily temperature fluctuations above and below the critical 90°F has been achieved.INTRODUCTIONTechnical aspects of ammonium nitrate-fuel oil (AN-Fa) blasting agent are well covered in recent literature. This paper deals primarily with the manner of its introduction as the principal explosive underground at Great Boulder Gold Mines Ltd. and with the many problems encountered in the process. Following reasonably successful experimental firings in June 1962', using granular ammonium nitrate and an anoloder, permission was granted by theWestern Australian Mines Department to carry out test work in selected areas of the mine. The permit allowed for fuse firing only, and for a mixture of AN-Fa containing between 5t and 6 per cent fuel oil, with an adequate primer.The use of AN-Fa on an equal weight basis with nitroglycerine explosives, involved smaller diameter holes with alteration to ground burden and modification to drill steel.Initial tests indicated that it was apparent that AN-Fa could not replace gelignite on an equal weight basis if the...

Jan 1, 1965

Large GDP increases in the Pacific Rim countries have been accompanied by similarly large increases in demand for oil products. In the case of residual fuels, this demand has been tempered by the substitution of other energy products such as coal or gas.In the region's developing and newly industrialised nations, it has not been possible to make the very large investements in infrastructure which allow other energy sources to be used for transportation. As a result, GDP growth has been mirrored in the demand growth for automotive fuels. Other non-sustitutable products such as lubricants have also benefitted by the region's GDP growth.The combination of a number of years of sustained growth, coupled with increasing quality requirements is now stretching the upgrading capacity of the region's refineries. If, as seems likely, the region continues to enjoy a high GDP growth rate, then this will be accompanied by increasing reliance on finished products coming out of the Middle East. The owners of the most simple form of refinery in which crude is simply distilled and the naphtha reformed into petrol will face major capital investments. If they decide not to bear this cost, they will face increasing problems in selling their surplus residual fuel oil at an economic price. Quality will become an increasingly important issue. Not only in the well publicised areas such as unleaded petrol, but also for products such as lubricants which play a major role in the efficiency of modem equipment. Quality of service such as hours of opening, ease of access, and service station facilities will also become increasingly important as the oil companies use these to attract customers and gain brand differentiation.

Jan 1, 1990

By S Coward, S Jackson, S Moayer, J E. Vann

The variability and uncertainty of mineralisation, coupled with subsequent uncertainty in mining and processing, is often paid scant regard or overlooked during the evaluation of mining projects. In many instances, when the project transitions to the operational phase, the reality of feed or product variability and the consequences of unquantified uncertainties throughout the value chain become obvious. The outcome is the familiar picture of frequent ramp-up underperformance and failure to deliver on planned targets and objectives.Both mine and exploration geologists are expected to generate mineral deposit models that are based on an integration of diverse sources of data. These multifaceted deposit models already play a pivotal role in the design, development and optimisation of mining project value, and the trend to a fully digitally engineered future means that this importance is increasing. It is therefore vitally important that tools be made available to the geologist (as well as mining engineers and metallurgists) that enable them to characterise and assess variability and uncertainty via appropriate deposit models and thus articulate their impact on potential project configurations and decisions. Scenario-based project evaluation (SBPE) provides a framework for full and proper analysis of the downstream impacts of inherent deposit variability and uncertainty on project performance.SBPE has been developed by the authors over several years and aims to propagate geological uncertainty and variability through the mining value chain. The outcomes of SBPE can be tested against future external scenarios capturing financial, economic and socio-political factors that also drive project performance. Stochastic representations of the orebody (via conditional simulation (see Chilès and Delfiner, 1999)) that explicitly incorporate variability and represent uncertainty are propagated through the value chain on a block-by-block basis (ie on a much more granular basis than traditional project evaluation approaches).Conventionally, metallurgical processes are modelled with deterministic equations (eg regression models) based on limited data. The SBPE approach allows for the modelling of process performance uncertainty using geometallurgical sampling fully. Multiple outcomes of SBPE are passed through financial modelling, which can also incorporate stochastic components, thus allowing full quantification of the risks and opportunities of a set of project alternatives. The value of the SBPE system is that once a base case has been established, multiple engineered alternatives coupled with external scenarios are easily evaluated and compared in terms of incremental value.A new case study of SBPE is presented that shows how, by analysis of the various aspects of variability and uncertainty, project managers are able to focus on the areas that have the greatest ability to reduce risk and/or add significant value. This can lead to sufficient flexibility being built into operations that allow operators to cope with the real orebody delivered to the plant.CITATION:Jackson, S, Vann, J E, Coward, S and Moayer, S, 2014. Scenario-based project evaluation – full mineral value chain stochastic simulation to evaluate development and operational alternatives, in Proceedings Ninth International Mining Geology Conference 2014 , pp 21–32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By J Battista, J Grace, I Brunton

The need to better understand and develop strategies to improve instantaneous shovel productivity at the Cadia Hill Open Pit Mine (CHM) instigated the development of the æShot to ShovelÆ project. This project has involved the implementation of a drill and blast (D&B) information management system to capture current and future experience. Equally important has been the manual monitoring of shovel productivity and direct use and analysis of high precision GPS and productivity data logged by ModularÆs Dispatch System. The analysis of this type of data was facilitated with the application of GIS based software (ie MapInfo). This has shown to be a powerful medium to display, interpret and assess this type of spatial information on a blast-by-blast basis. Cadia HillÆs well-defined D&B processes supplemented with the application of the above systems are providing a unique capability to assess and better understand the impact of both muckpile conditions and operator proficiency on instantaneous loading productivity. This is facilitating the definition of appropriate optimisation strategies in both drilling and blasting and operator proficiency training. This paper gives a summary of the work conducted in the æShot to ShovelÆ project, describes the engineering tools being implemented and discusses preliminary findings and their practical implications.

Jan 1, 2004

By D Engelhardt, G Lane

The Cadia mine has shifted from an open pit operation to the Cadia East underground panel cave. The resulting increase in milled tonnes, more competent ore and the decrease in fines production through shifting to panel caving were predicted to require an increase of over 25 per cent in installed power. This expansion was accomplished via the installation of secondary and high pressure grinding rolls (HPGR) crushing of the ore, with the semi-autogenous grinding (SAG) mill receiving a combination of primary, secondary and HPGR crushed feed. This design, criteria and rationale for selection was presented at the SAG Conference 2011. This paper reports on the initial impact of secondary and HPGR crushing on the circuit performance with the new panel cave feed.CITATION:Engelhardt, D, Lane, G and Powell, M S, 2014. Cadia expansion – the impact of installing high pressure grinding rolls prior to a semi-autogenous grinding mill, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 233–240 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By D Johansson, C Yi

Blasting techniques are widely used to fragment rock masses into smaller pieces. Numerical modelling is an efficient method employed by many researchers in the blasting field. It is difficult for a conventional continuum-based approach such as the finite element method (FEM) to model the rock fragmentation by blasting and the expansion work on the rock by explosive and its detonation products. In this paper, the particle blast method (PBM) was employed to model the behaviour of the detonation and a bonded particle model (BPM) was used to model the brittle material to be blasted. A mortar cylinder with a centrally placed hole for the explosive was modelled and the results were compared to the experimental data. The blast process from crack initiation to fragment formation was analysed. The influence of coupling ratio on fragmentation was also investigated.CITATION:Yi, C and Johansson, D, 2015. Discrete element modelling of blast fragmentation of a mortar cylinder, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 793–798 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By R Fanni, D Reid, M Kulessa

Recent updates to Australian industry guidelines emphasise the importance of the assessment of liquefaction potential of tailings. This includes assessment of the cyclic liquefaction potential, and the post-seismic strength of tailings expected to undergo strength loss from seismic loading. Despite this increase in focus, a relatively small number of Australian tailings appear to have been characterised through cyclic and post-cyclic testing. This paper presents the cyclic characterisation of four Australian tailings, consisting of iron ore, lateritic nickel, vanadium and bauxite residue. Material was obtained either from surficial tube sampling or through remoulding samples in the laboratory from slurries. Testing consisted of monotonic, cyclic and post-cyclic tests for each material. For three of the materials, laboratory-scale shear vane testing was also performed to provide a comparison to post-cyclic strengths from direct simple shear.The results indicated cyclic resistances consistent with the results of other tailings presented in the literature. The lateritic nickel tailings provided the greatest cyclic resistance of the four materials tested, followed by the vanadium tailings. This was somewhat consistent with expectations for material behaviour based on index properties. Post-cyclic strengths were seen to decrease as cyclic strains increased, consistent with typical observations in the literature. Following significant cyclic straining, in some instances the post-cyclic strengths approached those obtained through residual shear vane testing. This provides further insight into the strain-dependent nature of post-cyclic strengths for some materials. The implications of these observations on the post-seismic stability condition are discussed.CITATION:Reid, D, Fanni, R and Kulessa, M, 2015. Cyclic and post-cyclic behaviour of four Australian tailings, in Proceedings Tailings and Mine Waste Management for the 21st Century, pp 207–214 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By M Flis

The Razorback Iron Ore Project is a high tonnage, low-grade magnetite deposit that defines a new iron ore district in South Australia. Known since the 1960s, the deposit has come into its own as the iron hungry world demands not only larger tonnages, but higher grade and cleaner magnetite concentrate ores that counterbalance the increasingly dirty haematite ores that are coming into production.Razorback is hosted by the Neoproterozoic Braemar Iron Formation, a tillitic unit that is part of the Adelaidean Geosyncline sedimentary sequence. At Razorback, this formation forms the southern limb of the Pualco Syncline, dipping at 42° to the north and outcropping along a prominent ridge. The formation consists of a series of alternating bedded tillitic and interbedded magnetite units that represent cycles of glacial advances and retreats. Seven cycles, resulting in seven stratigraphic members, are recognised. Members B, D, and G are the thickest, at 30 - 70 m each, and are the target of current investigations. While the bedded magnetite has the highest iron content, typically 35 per cent Fe, the tillitic unit, at typically 26 per cent Fe, has similar iron content in the ground mass but is diluted by the inclusion of iron-poor granite and metasedimentary dropstones. The mineralisation forms a simple dipping tabular body with only minor faulting, folding and intrusives. Grades, thickness, dip, and outcropping geometry remain very consistent over kilometres of strike, presenting an excellent mining proposition.Razorback differentiates itself from other Australian magnetite projects in a number of important ways. It is not a banded iron formation (BIF); it will have low crushing and grinding costs; and it is located in an infrastructure-rich area close to open-access, high capacity rail, to a selection of ports and to gas, electricity, labour and engineering services. Royal Resources has announced an Inferred resource of 277 Mt @ 25.9 per cent Fe. The company is targeting a resource of 500 - 1000 Mt to support a 10 Mt per year concentrate production. Davis Tube Recovery work shows that the ore is capable of producing a concentrate of over 68 per cent Fe with very low deleterious elements. Metallurgical testing confi rms the ore is soft, and with near-zero initial stripping ratio the project will have a low opex. With access to existing critical infrastructure, capex will also be low, ensuring Razorback will be a highly competitive iron producer in this emergent mining district.

Jul 11, 2011

By T Muzondo, C Prins, D De Vaux, R Schouwstra

The Mogalakwena Platinum Mine in the northern limb of the Bushveld Complex is Anglo American PlatinumÆs only open cast operation exploiting the Platreef. The Platreef, which extends along the basal contact of the Bushveld Complex, is geologically and mineralogically a much more complex orebody than the Merensky and UG-2 reefs. Changes in the footwall and the genesis of the Platreef translate into a number of rock types being present. These rock types vary in hardness and recovery potential and present challenges to metallurgical staff trying to optimise the concentrator. A true understanding of the implications of treating these rock types is required if the maximum value from this orebody is to be obtained.In order to more accurately forecast production and incorporate ore variation in the mine plan and comminution and flotation circuits, a geometallurgical approach to managing the operation has been used and is being further developed.CITATION:Schouwstra, R, De Vaux, D, Muzondo, T and Prins, C, 2013. A geometallurgical approach at Anglo American PlatinumÆs Mogalakwena Operation, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 85-92 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By B Flynn, P Knights

Low-loaders or 'floats' for relocating equipment in surface mines are limited to a capacity of approximately 350 t. In the iron ore industry it is desirable to be able to rapidly relocate excavators in order to maintain production rates within appropriate quality limits. In addition, the ability to rapidly relocate heavy equipment raises the possibility of improving the quality of repairs by performing maintenance in controlled shop conditions. However, many iron ore operations operate hydraulic excavators in the 600 to 800 t range, with newly released excavator models exceeding 800 t. These excavators are too large to float using conventional technology. This paper examines the potential for using multi-bogie transporters to relocate large hydraulic excavators in surface mines. Recent innovations have seen the development of modular transporters which can be coupled together to achieve larger platform areas. When separated, and with their drive bogies neutralised, these units are able to be towed behind prime movers and relocated between mines via public roads. The potential cost savings for relocating a Terex RH170 excavator in an open pit coal mine are examined. In the first six months of 2008, the analysis showed the potential for a 38 per cent reduction in total travel time with a corresponding revenue increase of approximately $350 k. The paper recommends that a feasibility study be conducted into offering a heavy equipment relocation service within the Pilbara region.

Jan 1, 2009

The pilot scale testing of Australian coals for their NO, emissions was carried out at the ACTC to investigate the influence of coal properties, furnace conditions and different NO,, control strategies on NO,, emissions. The NOx emissions for the Australian coals tested were found to vary over a wide range and primarily depended on combustion temperature and excess oxygen conditions. These coals did not exhibit any fundamental difference in NOx levels to other world coals. Under similar combustion conditions, the conversion of coal nitrogen to NO. was found to be best correlated with coal rank parameter, R, max per centage. The use of staged combustion as a control strategy was shown to reduce their NOx levels by 56 - 77 per cent.

Jan 1, 1991

By P Ring, B Cooper, C Carr, G Laing

The Nova Ni-Cu-Co Operation, located in the Fraser Range of Western Australia, commenced commercial production in July 2017 only five years after discovery. Owned by Independence Group NL (IGO), the operation has successfully ramped up over an accelerated schedule and currently deploying leading technologies. This paper begins with a description of the Nova Operation, and its journey to achieve full production in such a short time frame. It includes discussions on development and production design, selection of fixed plant infrastructure, and the features challenges of running a low-pressure primary ventilation circuit. The paper also discusses key technologies that have improved overall safety for the underground workforce, and improved operational efficiencies. Investigations continue into the implementation of further technological applications for safety and productivity enhancements. This paper also discusses the findings from a study into transitioning from a diesel to an all-electric underground mining fleet, based on a review of Nova if it were to be developed today with the current EV offerings. The study indicates compelling savings will be available to future mines when considering development design, project schedule, capital outlay and operational savings, and the ‘next Nova’ is expected to be all electric.

Mar 15, 2021

By P Thompson, B W. Atkinson

Water treatment is not æcore businessÆ for mining companies.Just as mineral ores and coals are unique, each requiring detailed characterisation and pilot-testing to determine their optimum beneficiation route, so too are mine waters, each requiring careful assessment to determine the most appropriate treatment. There are many cases of æregret capitalÆ expenditure, whereby mines have installed off-the-shelf equipment only to find it inadequate for their purposes or grossly expensive and labour intensive to operate.Water may be required for potable purposes, ore processing, dust control and/or irrigation. A major driver will frequently be environmental constraints for off-site discharge. Mine water projects can become very complex, and detailed models need to be prepared and optimised to properly consider the raw water sources, the on-site storages, the on-site uses and the off-site discharges, as well as handling the residuals (by-products) of water treatment. By-products may be in the form of concentrated backwash streams or streams of elevated salt content. Careful management of the by-products is required to avoid recontamination of the source water.Regulators often drive mine owners toward reverse osmosis (RO) so that their discharges can be considered as æzero dischargeÆ in terms of potential pollutants. Such decisions need to be based on site-specific information rather than any form of æblanketÆ requirement. An analogy is that many humans like to consume mineral water rather than ænormalÆ tap water. Receiving environments also accommodate or even prefer their æmineralsÆ and so RO is neither warranted nor sustainable in many cases.This paper presents two case studies for operating mine sites, both of which have a significant excess of water requiring environmental discharge. The examples demonstrate a sensible balance between treatment type, environmental constraints, process implementation and residuals management. LIMN« æthe flow sheet processorÆ was used to model one of the case studies due to the complexity of the water system on that site.CITATION:Atkinson, B W and Thompson, P, 2013. Mine water - optimising for site and environment, in Proceedings Water in Mining 2013 , pp 9-14 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 26, 2013

By D I. Cliff

The loss of 11 miners in the 7 August 1994 Moura No.2 Underground Mine Disaster was the catalyst for major change in the way safety was managed in the Australian Mining Industry. The impact was felt across all sectors not just underground coal. It was the catalyst for the overhaul of the regulatory frameworks, moving away from prescription to management systems and risk management. This had a substantial impact on the way not only the industry operated but also on how the regulator functioned. It heralded the introduction of competency-based training across all levels of the mining workforce. Since that time major improvements in safety performance have occurred. However, hiding within the statistics are some disturbing trends. This paper aims to analyse the progress made in the past 30 years and identify the current and emerging issues. Automation is bringing major production and safety benefits, but at the same time other factors such as the reduction in workforce numbers and ever-increasing production pressures are leading to high turnover rates. This in turn causes to a loss of experience and expertise. In addition, and of particular importance, is the recognition of psychosocial wellness on workforce safety. Many of these factors are not unique to the mining industry however they may be exacerbated by the scale of mining, the remoteness of the mines and family unfriendly mining rosters.

Apr 16, 2024

By J W. Dong, Y M. Li, J L. Tian, Z H. Jiang

Electroslag remelting is widely used to produce various special steels, mainly because of its ability to provide high cleanliness and excellent homogeneity of ingot. Undoubtedly an optimal slag plays a key role in removing inclusions and enhancing the mechanical properties of a specific special steel. In order to improve the metallurgical performance of the slag in electroslag refining of die steel, a variety of slags have already been developed using traditional trial-and-error methods. Nonetheless, these slags may not be inherently optimal for the specific requirements of actual die steel refining processes. In this work, we have designed a CaF2-CaO-Al2O3-SiO2-MgO quinary slag system using genetic algorithms method aiming to remove the existing large size inclusions (D and Ds type) in high quality die steel. The comprehensive effects of five components (CaF2, CaO, Al2O3, SiO2 and MgO) were studied based on existing fundamental theory. The slag composition was screened considering the parameters such as melting point, electrical conductivity, calcium ion concentration, and appropriate viscosity etc. Furthermore, the candidate optimal slag was applied in the industrial production of die steel by electroslag remelting method. The detection results indicate that majority large inclusions (D and Ds type) have been successfully removed, showing significant advantage to traditional slags. This result has demonstrated the genetic method to be efficient and reliable. In addition, depending on the personalised demand of other steel and alloys, this method allows for the adjustment of the screening frameworks and processes to develop the candidate optimal slags. This method has not been reported previously in the field of electroslag composition design, and compared with the traditional trial-and-error method, the new method will save a lot of time and experimental costs.

Jun 19, 2024

By R Daiyan, G Burge, M Haider Ali Khan

Australia’s mineral and metal exports have a substantial carbon footprint, twice that of its domestic emissions, mainly due to fossil-fuel-dependent downstream processes like processing into secondary metals and their transport. The country’s vast renewable energy and low-carbon hydrogen potential offer a promising alternative to mitigate this impact. These resources can be leveraged to displace fossil fuel use and become embedded into the metals value chain. Ultimately, it will yield ‘Green Metals’ that can be scaled to reduce the environmental footprint and provide an avenue for Australia’s vast green resources to be embedded (incorporated during production and supply) in green metals that can be exported. One potential green metal is copper, which is in great demand and likely to drive global decarbonisation through renewable electrification due to its role as an energy conductor. Given that Australia is a large producer and exporter of copper, this paper provides a techno-economic model of the copper value and applies it to Queensland (a hub of Australia’s copper production) as a case study. The results show that under incumbent hydrogen (A$8/kg) and renewable energy costs, the cost of green copper would be A$9704/t (~10 per cent higher than current copper costs). Further analysis revealed that the cost of hydrogen is a major cost driver; therefore, if the cost of hydrogen can be reduced to A$2/kg (a 2030 target of the Australian government), the cost of green copper would become competitive. Furthermore, if a carbon pricing regime ($54–79/kgCO2) is introduced, green copper would become competitive at a hydrogen cost of A$3/kg. Altogether, these findings provide insights for a future green copper export opportunity in Australia. Additionally, as the next step, the model can be extended to include other metals and released as an open-source resource for assessing global green metal opportunities.

Sep 1, 2024