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By K. Arnold

AngloGold Ashanti has been proactive in the field of energy management for many years. AngloGold Ashanti is a signatory to South Africa?s National Energy Accord of 2005 calling for a15% reduction in energy consumption by 2015 for the mining sector. This target also supported our internal targets that were already set. AngloGold Ashanti?s seven South African mines consume on average 440 MW. Due to the dynamics of gold mines, and the large numbers of relatively small energy efficiency initiatives and awareness campaigns made measurement and verification of energy efficiency very difficult at a macro level since some initiatives could get lost in the fluctuating load profile. This paper will discuss the methodology and process followed to quantify the impacts of the combined energy efficiency initiatives at macro level. It will quantify the energy efficiency impacts in megawatt-hours (MWh), financial, and equivalent carbon emissions (CO2e) reduction with reference to our baseline year, 2004, for the Vaal River and West Wits mine clusters.

Jan 1, 2009

By Tianfei Liao

Extensive site investigations revealed that abandoned shallow mine workings exist under a site planned for construction of a major new facility. Since the mine voids were susceptible to collapse, they were stabilized by grouting. After completion of the mine remediation, three types of deep foundations (micro-piles, auger-cast piles, and drilled piers) were considered for this site. Micro-piles spread the load via the bond between the pile and the bedrock. Without significant length socketed in rock, the axial load of auger-cast piles and drilled piers has to be concentrated on end bearing. Although spreading the load is preferable in this environment, economic consideration dictated the choice of drilled piers for construction.

Jan 1, 2009

By Agne Rustan

The 9th International Symposium on Rock Fragmentation by Blasting was held in the Granada Conference Centre, Granada, Spain from the 14th - 17th September 2009. The Symposium was preceded by a 1 ½ day Workshop on “Vibrations from Blasting” organized by the initiator Dr. Alex Spathis and his colleague M. J. Noy, both employed at Orica Mining, Australia. Prof. Josè Sanchidrian at the “Universidad Politécnic de Madrid” in Madrid, Spain was the main organizer for both the Workshop and the Symposium. A record number of participants came (292) from a record number of countries (41). There were a total of 14 papers in the Vibrations from Blasting Seminar and 96 papers and 2 Keynote Addresses in the Fragblast 9 Symposium itself. The aim with this paper is to present some results from Fragblast 9 which are of interest for a large target group. One very important result from the Fragblast 9 meeting was that it was decided there that Fragblast 10 will be held in November 2012 New Delhi India.

Jan 1, 2009

The management of risks associated with slope instability is an essential process in the safe and economic operation of open cut mines. The ?slope stability radar? (SSR) has been developed to better manage those risks. The SSR remotely scans rock slopes to continuously measure any surface movement and can be used to detect and alert users of wall movements with sub-millimeter precision. The high level of movement precision and broad area coverage of the rock face can allow for a better understanding of the geomechanics of slope deformation, including magnitude of potential failures and additional warning time of impending instability. Additionally, radar waves adequately penetrate through rain, dust and smoke to give reliable measurements, 24 hours a day. SSR systems have been deployed in many metalliferous and coal mines throughout the world. Over 80 systems are currently being used with current operations in 17 countries. Greater than 200 rock slope collapses and waste dump failures (from several to millions of tones) have been monitored, with ?warning? precursor movements recorded by the SSR. This technology enables a radical change in the management of risks in open cut mining. This paper will present recent case studies of the SSR operation in coal and metalliferous mines. Slope Stability Hazards and Rock Slope Monitoring in Open Pit Mines Surface mining often creates excavation boundaries which are steeper than those would be created under natural processes in the same rock type. They are also undertake quite rapid stress changes during mining and are influenced by significant external forces such as blast vibrations and changes in groundwater. These conditions are likely to allow some degree of instability to develop in the pit slopes. The hazards associated with this instability of pit slopes can be extremely variable in character; ranging from small cobble sized rocks dislodging and falling from mine benches to complete collapse of entire pit walls. It is usually the position of mine geotechnical or geological staff to assess these hazards for mine operations. The assessment of hazards due to unstable slopes can be done by visual observation of precursor signs such as fracturing or rilling of loose material. A more reliable indicator of instability involves the quantitative measurement of outward movement and acceleration of material as an instability mechanism develops. There is strong evidence that small precursor movements of a rock wall occur for an extended period prior to rock slope collapse (Hoek and Bray, 1981). Development of a monitoring system, adopting acceptable slope deformation criteria coupled with warning systems and design of stabilization or risk reduction measures if appropriate has become a standard method of dealing with slope instability. Framework for Slope Hazard Management using the SSR A framework for the management of slope hazards is shown in Figure 1 (discussed in detail in Harries, 2007). Although this framework is specifically for use with the Slope Stability Radar, a similar framework could be developed for other monitoring technologies for monitoring slope deformation. An important point to consider is the sequential nature of the hazard management framework from selecting the context ? identifying hazards ? analysing hazards ? evaluating hazards ? treating hazards. [ ] Once the context of the system has been developed (for example ? to monitor for rapid bench scale collapse), the identification of hazards is the next stage in hazard management. Identification of slope hazards can be relatively straightforward due to the visual nature of the information that the SSR system produces. The areas of excessive wall deformation are highlighted in color maps of the mine slope with a co-aligned photographic image to review the actual site of interest. The responsible personnel must then analyses this data, usually reviewing the deformation style and rate, as well as the size of area that appears to be failing. This information can then be evaluated against organisation protocols (for example it may be only a small sub-bench failure that will be ?caught? by existing benches and hence can be categorized as a lower risk). Once these hazards are evaluated they can then be treated if required. Two major options are available to reduce the risk during this treatment option. We can reduce the likelihood of failure ? for example by buttressing the failure or de-pressurising of water pressures in a slope. However, the most likely plan of action is to reduce the consequence of the failure. One of the most successful opportunities to reduce the consequence of a slope failure is to ensure that no personnel or mining equipment is present at the location of a slope failure when collapse finally occurs. This has been the major benefit of the SSR system to the different mining operations around the world. SLOPE STABILITY RADAR TECHNOLOGY OUTLINE Slope Stability Radar system specifications and capabilities: ? Measurement precision +/- 0.1mm (std.) ? Perforated dish and other features enable it to operate in high wind conditions ? Measurement range is 1700 metres ? Scans 270 degrees horizontally and 120 degrees vertically ? 1 ? 30 minute repeat rate for area scans (varies according to area being scanned ? RF exposure (<0.05mW/cm2) is a factor of 200 below the acceptable limit for the general population (1 mW/cm2) ? Tolerant to vibration and mining equipment ? The system weighs approximately 1500 Kg ? Remote area power supply enabling unmanned, continuous 24/7 monitoring ? Real time monitoring

Jan 1, 2009

By L. Jones, S. R. Lawrence, A. R. Holloway

Whilst dense medium separation is best known for its ability to concentrate diamond and coal deposits, the process is now being employed in southern Africa as a pre-concentration step to improve the economics of platinum group metal and nickel ores. DMS plants built for these industries (such as the 1600tph unit at Tati Nickel, Botswana), are spearheading an expansion in this area by reducing mine and process operating costs yet maintaining economic metal recoveries. This paper provides an overview of DMS technology and examines the economic benefits available to North American operators and projects, with recent case studies as reference.

Jan 1, 2009

By B Lumsden

During periods of high metal prices and strong metal demand tailings retreatment can be economic. Most tailings retreatment operations are technically challenging, low margin operations, because the easily recovered mineral has already been removed, therefore, process improvements can potentially yield large economic benefits. The Hellyer tailings dam was owned by Intec Ltd and contained 10.9 million tonnes grading 2.8 per cent zinc, 3.0 per cent lead, 88 g/t of silver, 0.16 per cent copper and 2.6 g/t gold. In November 2006 the Polymetals Group, as operator, restarted the Hellyer plant to retreat these tailings. Within a few months the operation had stabilised and Polymetals was meeting budgeted targets of throughput, metal recovery and concentrate quality. Polymetals and Intec then investigated methods that would improve the metallurgical result for this difficult to treat tailings. Since the tailings are fine-grained with 80 per cent &lt;45 ¦m, magnetic aggregation of the paramagnetic sphalerite was evaluated. Magnetic aggregation of an oxidised tailings feed has not been tested before, nor had the technology been available when Hellyer ore was originally processed. Extensive statistical test work showed magnetic aggregation of the sphalerite fines in the zinc cleaner circuit increased total zinc recovery. The increase in the mean zinc recovery with magnetic conditioning was 3.63 per cent, at a statistical level of confidence of 97.8 per cent, and at the same mean zinc concentrate grade.

Jan 1, 2009

By Van E. Komurka

This paper presents a cost comparison of the driven pile foundations for two large Wisconsin Department of Transportation (?WisDOT?) projects in Milwaukee, Wisconsin: the Marquette Interchange South Leg, and the Canal Street Viaduct. The projects? geology is fairly similar, but their methods/approaches to pile foundation design and installation differ. Although the Marquette Interchange South Leg had deeper poor soils, its pile design was more-cost-effective than the Canal Street Viaduct?s. Potential reasons for cost differences between the projects are identified, and the effect of the different design and construction approaches on economics is discussed.

Jan 1, 2009

By Murali M. Gadde

Perimeter mining is a special form of very productive partial extraction method practiced at some mines in the United States. In the Illinois Basin mines where all major coal seams have weak underclay in the immediate floor, experience shows that any long-term ground control issues will arise due to floor failures rather than instability of the coal pillar itself. While there is a significant amount of work done on floor stability associated with regular pillars, no work has been done so far on the stability of perimeter pillars. This paper reports the results of a comprehensive study that was conducted for the first time on floor stability during perimeter mining in the Illinois Basin mines. A special plate template, which mimicked a common perimeter pillar configuration was created to conduct in-situ bearing capacity tests at five mines in three states of the Basin. Additionally, because of the complex shape of pillars created in perimeter mining that defies any closed-form solution, floor bearing capacity was studied using three-dimensional nonlinear numerical modeling. Based on these in-situ and numerical studies, some guidelines are provided for perimeter pillar stability analysis.

Jan 1, 2009

By M Dickie

During the 1980s and early 1990s low cost gold treatment plants were at the forefront of the Australian engineering and mineral processing business. This opportunity was the result of a high gold price and innovative design by emerging engineering companies in an expanding market. The low cost approach to gold plant design and project execution resulted in smaller and shorter life projects becoming viable and the multiplicity and fast track approach of the projects resulted in sharp learning curves. From the mid 1990s to the early 2000s the relatively low commodity prices and resultant reduction in minerals opportunities also resulted in innovative design in both small and large plants, albeit on a reduced scale. The innovation was associated with alleviating capital cost pressures for large capacity low-grade (eg NewcrestÆs Cadia) or small-scale (eg JubileeÆs Cosmos) projects to either improve NPV or to enable the project to be won and profitable in the competitive lump sum environment. Between 2004 and 2008 the engineering market became less competitive from an engineerÆs perspective due to the high demand for engineering services in a high price commodity market. The need for innovation remained but was driven overtly by shortages in water, power and personnel and long equipment lead times. This paper discusses some of the factors that contribute to the capital cost of a project and the scope for improving the likelihood of financing and increasing the project net present value (NPV). Case studies with recent large copper concentrator projects will be used to demonstrate how a value driven approach to project and plant layout can result in significant improvement in NPV.

Jan 1, 2009

By T. Geyer

The Carbon Disclosure Project (the pre-eminent global initiative for institutional investor collaboration on climate change) groups the business risks (and opportunities) related to climate change into four categories: 1. Regulatory risks from tightening legislation (and opportunities for companies that can make the carbon market work for them), e.g. rising costs for carbon and energy-intensive processes. 2. Competitive risks & opportunities generated by a possible decline in customer demand for carbon/energy intensive products (and opportunities from a consequent rise in demand for efficient / low carbon products). 3. Reputational risks from perceived inaction on climate change (and benefits to those perceived to be ?solutions providers?). 4. Physical risks from changes to climatic patterns, e.g. asset damage from extreme weather events; project delays; water scarcity; resource risks as certain crops become no longer viable in certain areas and new supply chains become necessary; and potential human and socio-political impacts. All of these are already having repercussions for businesses in certain sectors and geographies. The understanding of specific impacts of climate change is still evolving but it is clear that climate change will have a material impact on the value of many businesses, either directly or indirectly. Many commentators and analysts consider that rising energy costs are likely to represent the most direct and immediate investment risk that climate change and the resulting regulatory responses will create for business in the near term. However, it is already possible to identify numerous examples of competitive and reputational risks and opportunities that are leading to significant value creation or destruction in business: the success of the Toyota Prius; the rush by the UK?s leading supermarket retailers to ?green? their brands; and the surging fortunes of companies involved in the manufacture of renewable energy generation equipment, are all manifestations of this trend. In addition, the potential physical impacts of climate change are also making themselves felt in certain sectors: an example is the Australian wine industry, suffering after an extreme and prolonged period of drought. THE PROJECT This paper describes a project undertaken for a multinational mining company to examine the physical risks from climate change across its international business operations. The study addressed 163 components of the business and included operating sites (mines, smelters, and refineries), key transport routes (road and rail) and port links. The inclusion of the transport networks and ports is extremely important; key transport routes (e.g. a key railway link) may often be impacted (e.g. by flooding) far more than individual sites due to their large geographic exposure and multiple potential failure points. Extreme weather events causing loss of life and major economic damage continue to be front page news. According to the World Meteorological Organization, January to July 2007 ?was marked by record weather extremes in many regions across the world.? Inevitably, the associated phenomena are starting to impact business and investments, not so much as deal breakers, but in changing the parameters of risk management and the approaches required to devise mitigation measures. EXAMPLES OF EXTREME WEATHER EVENTS No one event can be presented as directly attributable evidence of climate change, however climate change projections suggest that the frequency and severity of many extreme weather events can be expected to increase in a warming world. In August 2003, a heat wave struck Europe, with temperatures as high as 42°C (108°F). As summer temperatures in much of northern Europe rarely exceed 30°C (86°F), the area was unprepared for the disaster, and many thousands of deaths occurred. In August 2005, Hurricane Katrina caused catastrophic damage along the Gulf Coast of the United States, forcing the effective abandonment of south-eastern Louisiana (including New Orleans) for up to two months and damaging oil wells that resulted in increased oil prices. Katrina killed over 1,800 people and caused at least $75 billion in damages, making it one of the costliest natural disasters of all time. This was followed in September, by Hurricane Rita which left 119 people dead along the U.S. Gulf Coast, causing $9.4 billion in damage. In January 2006, hundreds of people were killed when Russia, Eastern Europe and Scandinavia experienced the coldest weather for decades. In summer 2007, dramatic floods in the south central region of England, UK left 350,000 people without drinking water and many without electricity. Transport infrastructure was severely disrupted; combined with floods which occurred earlier in the summer in Yorkshire (North England), the damage is estimated to total over £2 billion. ASSESSING RISKS FROM CLIMATE CHANGE To date, only a minority of companies have attempted to quantify the risks from climate change. However, investors are seeking greater disclosure of climate change related risks and opportunities and it is expected companies that can demonstrate they are prepared for climate change will attract higher market valuations. Climate Change Threats A variety of climate change threats were examined for their potential to have a potential measurable impact on the mining company?s business operations. Those considered most significant were included in the study and are shown in Table 1 (see Appendix A). Certain threats can be considered as being cyclical in nature and the future predictions may suggest a change in the frequency and severity of such events (e.g. storms/hurricanes, rainfall, drought). However other threats are associated with a gradual change over time (e.g. loss of glaciers, loss of permafrost, sea level rises). A slightly different approach is needed to address this differing nature of the threats, as described subsequently. Climatic Regions Much of the research and data associated with climate change is collected and reported on a regional basis. An example of the climate change impacts predicted for a number of climatic regions is shown in Table 2 (see Appendix A).

Jan 1, 2009

By John R. Bartels

Jan 1, 2009

By Qingzhu Li

The brewing industry byproduct, spent grain (SG), was evaluated for its ability to adsorb Ag(I) from aqueous solutions. Ag(I) adsorption was dependent on solution pH, contact time, adsorbent dose, initial Ag(I) concentration and temperature. The kinetic data were well described by pseudo-second-order kinetic model, indicating that chemical adsorption was the rate-controlling step. The equilibrium data followed Freundlich isotherm rather than Langmuir isotherm, suggesting heterogenity of the adsorption sites on spent grain. Ag(I) desorbed from Ag(I)-loaded spent grain was also evaluated in this study. HCl, NaOH, Na2S2O3 and ultrapure water were chosen as eluants and desorbed Ag(I)-loaded spent grain for 30min, Ag(I)-loaded spent grain desorbed in 0.1M Na2S2O3 exhibited higher elution efficiency as compared with other eluants. The results indicated that application of spent grain for adsorption and recovery of silver from aqueous solutions was feasible.

Jan 1, 2009

By Mark Osborne, Ray D. Peterson, C. Edward Eckert

"The theoretical melting energy requirement for a typical hypoeutectic aluminum-silicon alloy is approximately 520 BTU/lb. It has been demonstrated, however, that even a state of the art secondary processing-automated lost foam casting operation can exceed this value by at least an order of magnitude when the actual thermal energy input from melting to solidification is monitored. Metal transfer and holding operations constitutes over 65% of this expenditure. The authors present relative benchmark energy expenditure information by unit operation for an offsite melting/lost foam casting line with a daily throughput in excess of 100,000 lbs. Efficiency improvements through optimization of the current process, and anticipated energy values at the culmination of a U.S. Department of Energy sponsored project to develop, integrate and demonstrate an advanced melting, transportation, and dispensation system will be cited.IntroductionThe size of the U.S. aluminum remelt pool was approximated to be 14.21 billion kg (31.27 billion pounds) by a recent study?, with the engineered castings (foundry) sector accounting for 3.25 billion kg (7.16 billion pounds) or 23% of that total. This study considered overall process yield and all major contributors to scrap. The values cited, therefore, are more meaningful than simply tabulating annual pounds shipped by sector.The foundry sector consists of Sand Castings, PM Castings and Die Castings categories appearing in Figure 1. All other categories comprise the wrought alloy sector. Wrought alloy production enjoys an energetic benefit from both scale and a relatively continuous operation. Many foundry operations, however, operate in batch mode at less than design metal throughput with characteristically longer melt holding periods. Since any detention of molten metal beyond melting represents an overhead use of energy, melt holding (secondary) energy expenditures can appreciably inflate melting energy requirements in the foundry."

Jan 1, 2009

Impala Platinum?s No.16 Shaft mine is currently under construction and is expected to reach full production of 256 500 tons per month by 2014. Mining will start at 1 260 m below surface with a maximum mining depth of 1 535 m where virgin rock temperatures of 56.6°C will be experienced. As a result of depth, high virgin rock temperature and narrow reef mining, an expected total of 31.5 MW[R] of air cooling capacity will be required to achieve acceptable underground conditions. This will be achieved by cooling mine intake air in a single dedicated air cooling installation located on surface. The compact installation includes air cooling spray chamber, refrigeration machines, condenser cooling towers, evaporator and condenser water reticulation as well as all electrical and control systems. Construction and commissioning of the first phase of this air cooling installation has recently been completed on a turn-key contract basis.

Jan 1, 2009

By R. B. Berg

Montana sapphires were first discovered in alluvial deposits in the Helena area in 1865 and subsequently were discovered in other alluvial deposits in southwestern Montana and also in a lamprophyre dike at Yogo in central Montana. From about 1900 until the late 1930?s, when synthetic sapphire began to come into widespread industrial use, Montana sapphire mines produced large quantities mainly for watch bearings with lesser production for the gemstone market. The Yogo deposit is now mined for the gemstone market and two of the alluvial deposits are mined to produce sapphires for the fee-sieving of sapphire-bearing gravel and for the direct sale of gemstones. The generally pale-colored sapphires from the alluvial deposits in southwestern Montana are heated to enhance their colors whereas the generally blue sapphires from the Yogo deposit require no treatment. Markets for sapphires from both the alluvial deposits and the Yogo deposit are strong. In spite of reported historic production in excess of 70 tonnes, mineable resources appear to remain at most major deposits. Also abundant untested lamprophyre dikes in central Montana may host sapphires similar to those at the Yogo deposit.

Jan 1, 2009

By S. E. Phillipson

Underground mine mapping is a critical component of understanding the controls on ground instability. Many relatively localized examples of ground failure are associated with geologic features, such as faults, joints, compaction zones, or sedimentological transition zones. In contrast, long-running, directional roof falls are associated with regionally directed horizontal stress fields, which are induced by tectonic plate interactions in the earth?s crust. When stress-related features are distinguished from geological features, underground mapping can be an effective method for inferring the direction of horizontal stress at individual mines. Comparisons with data compiled in the World Stress Map confirm that underground mapping can be a valid method for determining the orientation of maximum principal horizontal stress at a variety of scales, ranging from individual mines to an entire mining district or coal basin. Comparisons are presented between the maximum horizontal stress directions inferred by MSHA?s Roof Control Division through underground mapping and the azimuths of maximum horizontal stress in the World Stress Map database for North America?s Pennsylvanian-aged Appalachian, Illinois, Black Warrior, and Arkoma Basin coal fields. The comparison indicates that azimuths are similar for both data sets, even where variations in the direction of horizontal stress are present. It is interpreted that inconsistencies in direction are attributable to near-surface affects such as deeply incised stream valleys, or to fault zones that represent heterogeneities in the crust.

Jan 1, 2009

By Katsuyoshi Kondoh

The utilization of silica particles originated in rice husks as reinforcements of magnesium composites was discussed. By using the solid state reaction of rice husk silica particles with magnesium powder, P/M magnesium based composites dispersed with the magnesium silicide (Mg2Si) and magnesium oxide (MgO) were fabricated. High-purity silica particles were originated from rice husks, one of the major agricultural wastes, via the citric acid leaching treatment and combustion in air. The effects of the silica particle characteristics such as size, crystalline and porous structures, on the reactivity of silica and magnesium to synthesize Mg2Si intermetallic were discussed. Amorphous silica was more useful for this reaction than crystalline one. The reactivity of rice husk silica was superior to that of the conventional mineral silica particles because of not only its amorphous structure but the larger specific surface area due to their pore structures. In the case of the green compact of the mixture of the rice husk silica and Mg powder, the silica particle size was not effective on the reactivity because the coarse particles were fractured into fine ones by cold compaction. The distribution of Mg2Si intermetallics of magnesium powder composites consolidated by SPS process was investigated by XRD and SEM-EDS analysis. Their mechanical and physical properties were also evaluated in detail.

Jan 1, 2009

By D. M. Walters

To achieve safe and healthy working conditions in shaft sinking operations, ventilation, and where necessary cooling, must be provided. These requirements are considered for sinking vertical, sub-vertical and decline shafts. Regulatory requirements, determining air volumes and amount of cooling required, the various ventilation methods used such as force, exhaust, twin columns, air reversal using four gate systems and the equipment required to achieve this, are discussed. Consideration is also given to the sinking of single and twin declines using diesel equipment, calculating the air volumes required to dilute pollutants and the various methods for achieving this. Also discussed is the importance of having early ventilation design input to the overall design of the mine. In many cases ventilation can be the prime determinant for the size and configuration of the shafts or declines that have to be sunk.

Jan 1, 2009

By B. K. Belle

The use of diesel engine locomotives in South African mines can be traced to Van Dyk Consolidated Mines Ltd on the Witwatersrand gold mines in 1928 as a replacement for battery locomotives. The advantages and disadvantages were recognized in those days, and surprisingly, there are no significant additions to this list, but only refinements. In the absence of any Occupational Exposure Limit (OEL) for Diesel Particulate Matter (DPM) in SA, the Mine Safety and Health Administration (USA) rule is currently being used as a benchmark for the ventilation engineering designs. This paper discusses the ongoing SA journey of measurement and limitations of exposure data for ventilation planning and regulatory purposes. The currently accepted DPM limits are based upon the belief that they are economically and technically feasible for the mines to reach and are not necessarily health based. For SA underground platinum mines, a median TC/EC ratio of 1.8 with a range of 1.2 to 5.8 was observed. For SA coal mines, a median TC/EC ratio of 1.44 with a range of 1.25 to 2.13 was observed. While it is common practice in the USA to use the ratio of TC/EC for metal mines to be 1.3, the ratio found in local platinum mines is 2.2 and for coal mines, the ratio was 1.53 which is lower than Australian studies, i.e., 1.96. It has been shown that a need for critical analysis of TC/EC ratios exists, and possible reasons for variance must be understood before stringent adoption of overseas recommended limits for DPM. It is hoped that the findings from this paper would provide input to scientific approaches in developing appropriate conversion factors, limits for DPM and also in ensuring appropriate error factors (currently 1.14 for TC and 1.2 for EC) for compliance determination.

Jan 1, 2009

By S. Eck

In previous work the influence of the casting speed on the flow field and the shape of the solidification front in an industrial 0.82 x 0.25 x 0.8 m³ bronze caster had been investigated. Both numerical and experimental model represented 1:1 the real caster geometry. A comparison of the results of both numerical and experimental models for the flow during the casting process showed a good agreement in the qualitative velocity fields (flow direction and vortex formation). This work represents a parameter study of the numerical model with variations of the turbulence conditions at the inlet in order to clarify their influence on the flow field in the caster. In order to find the best boundary condition at the inlet, the numerical calculations for water have been compared with the measured flow fields in the water model. The new boundary conditions were then applied to the numerical model of the bronze casting process.

Jan 1, 2009