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By M. Hopf, E. Rossouw

Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able to consistently identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed). Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa.

Jan 1, 2006

By L. Jiang

The evolution of twinning in an AM30 Mg alloy was examined by uniaxial tension and compression testing at temperatures from ambient to 250°C and a strain rate of 0.1/s. The samples were cut along the extrusion direction from extruded AM30 Mg alloy tubes. Specimens deformed to various strain levels were examined by optical microscopy and electron backscattered diffraction (EBSD) techniques. The results indicate that the initial extrusion texture plays an important role in the formation of different types of twins and that the twinning behavior also depends on the strain path. Contraction and double twinning are the dominant twinning mechanisms in uniaxial tension, while extension twinning prevails in uniaxial compression. The different twinning behaviors are shown to be responsible for the sharply contrasting strain hardening characteristics of the experimental flow curves.

Jan 1, 2006

By M. Hagfors

On the underwater testing of explosives, the measuring system consists of water filled test pond, tourmaline based pressure sensor, measuring cable and measuring unit, which supplies the DC current to the pressure sensor. Depending on the length of the measuring cable, it is always possible that some signal damping may occur in case the measurements are carried out without the signal amplifier to keep the measuring system as simple as possible. Therefore the length of the measuring cable should always be as short as possible.

Jan 1, 2006

By Leonard J. Friedman

The recovery of sulfur dioxide from metallurgical gases for the production of sulfuric acid has been an effective means of reducing sulfur dioxide emissions from non-ferrous smelters. Sulfuric acid has been produced from gas originating from fluid bed roasters, electric furnaces, reverberatory furnaces, flash smelting furnaces, Pierce Smith and flash converters, sinter machines, etc. The gas from each of these sources has a unique set of variables that affect the design and operation of the sulfuric acid plant. In addition, the sulfuric acid plant itself has been evolving, with new equipment designs and materials. This paper will review each of the unit operations in the gas cleaning and contact sections of the metallurgical sulfuric acid plant, discussing various equipment designs, materials and the handling of gas stream variables and impurities. The paper updates to 2006 previous works on metallurgical sulfuric acid plants by the authors.

Jan 1, 2006

By J. Fujioka, Y. F. Gu, C. Cui, D. Ping, A. Sato, H. Harada

"A new kind of cast & wrought (C&W) Ni-Co base superalloys named as ""TMW alloys"" are developed recently for compressor or turbine disks of gas turbine engines in High Temperature Materials 21 Project at National Institute for Materials Science (NIMS) in Japan. These Ni-Co base superalloys combine the characters of two kinds of y- y' two-phase alloys (Ni-base and Co-18at%Ti alloys) and have higher tensile strength and creep resistance than C&W UNDIMET 720Li superalloy."

Jan 1, 2006

By H. Yavuz

Closed form solutions assume opening shape to be circular to simplify the calculation of the ground response curve for the design of underground openings. However, in mining and civil engineering works, non-circular openings are commonly excavated. Therefore, there is a need to estimate the ground response curve for such openings. In this respect, a simple model for circular, arch and rectangular shape underground openings subject to a hydrostatic stress field is the aim of this study. A comprehensive numerical modelling, using the finite difference method, based on numerical modelling code FLAC version 4.0, was carried out. In addition to shape of an opening, the effect of rock mass strength, opening size, in situ stress on strain (tunnel deformation to tunnel radius) of the opening in response to applied support pressures was investigated parametrically by developing models for each specific condition. The strain results for each excavation shape obtained from this large number of models against the normalized strength of rock mass and internal support pressure with in situ stress magnitude were evaluated by multiple regression analysis. As a result, a model that was well correlated to data was developed for an overall estimate of the ground response curve depending on relevant effecting parameters. The regression coefficients of the model were given for estimating both roof and sidewall response curve of each excavation shape. The model was verified by statistical tests and by an analytical solution. Diagrams were also established to highlight the influence of relevant parameters and to estimate the support pressure for a stable opening staying within the acceptable limits of strain. Strains occurring in a rectangular opening are found to be larger than those in the arch and circular openings for the other fixed parameters. In the mean time, larger strains occur around an arch shape opening than a circular opening.

Jan 1, 2006

By Vasil Kopaleishvili

The bainitic Fe-C-Si alloys with optimum content of retained austenite serve as ?containers? for storing of hydrogen. Both the vacancies of fcc lattice and the possibility of forming hydrides of silicon and other alloying elements will be used. The idea is based on our scientific hypothesis. There is the silicon threshold (Si=0,50%) in "Fe-Si" system and Fe-C bainitic alloys, above which it causes self-organized phenomena: sudden increase of hydrogen solubility and amount of retained austenite in the alloy after ??ß transformation, formation of two supersaturated solid solutions <a??r>, "rejuvenation? and its reverse process. Rapprochement of iron atoms when Si=0,50%, causes appearance of new covalent forces where uncompensated electrons of 3d-subshell are involved and it provokes synergetic phenomena. They ?free? silicon atoms from the previous bonds. After that silicon itself becomes a getter of hydrogen using vacancies (14) of 3P2(6)d0(10) subshell and it results in sudden increase of hydrogen solubility in metal. Simultaneously sudden decrease of iron activity takes place. That in its turn ?releases? the carbon. Thus, its redistribution, controlling the bainitic transformation, is hastened. It stipulates for creation of ?brittle bainite" B[a(C,H)+?r(C,H)] after ??ß transformation. While weathering of metal, "rejuvenating", hydrogen diffuses in ?islets? of retained austenite and ?relaxed bainite? (B[(C)+?r(C,H+H)]) is obtained. When heating austenite ?(C,H) is obtained, and after cooling ?brittle bainite? is obtained, etc. Presented scientific hypothesis explains the available experimental facts ("rejuvenation? and its reverse process, graphitization, weldability, forming of flakes, reaching high strength, etc.) in a new manner, as well as, gives real opportunity for creating of new trends in many fields, e.g. iron based HAA. Provisional data having been obtained are encouraging.

Jan 1, 2006

The AusIMM is concerned about the longer tem sustainability of the minerals sector in Australasia. Our contention is that the sustainability of the sector is at risk if we do not: &nbsp; ò encourage more exploration in Australasia by removing impediments and&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; &nbsp; increasing incentives; ò fund our university and research centres appropriately to increase both our &nbsp; prospectivity, and our processing efficiencies; and ò manage our human resources better. &nbsp; This paper will focus on how we can better manage our human resources to assist in ensuring sustainability of the sector in Australasia . &nbsp; From a production point of view: &nbsp; Economic output = f (Land, Labour, Capital, Environment) where Land refers to all of the natural resources used in production. As well as land itself it includes water, forest, fisheries, oil, gas and mineral deposits. Labour refers to the skills and capabilities used by humans in the production process. Capital describes all of the manufactured aids used in the process of production1. The challenge for management is to ensure maximum efficiency and effectiveness of labour in the production process whilst maintaining sustainable development. &nbsp; The 1992 Rio Summit defined sustainable development as maintaining and enhancing: &nbsp; ò natural capital û defined as all natural resources, both environmental and &nbsp; those of traditional economic value; ò manufactured capital û made by human kind, including produced goods,&nbsp;&nbsp; &nbsp; infrastructure and built environment; ò human capital û defined as the health, well being, intellectual capabilities and &nbsp; spiritual welfare of individuals; and ò social capital û defined as social relations and consultations within and &nbsp; between societies, their norms and functionality2. &nbsp; The minerals sector in Australasia has successfully focused on the technical aspects of each of these components of sustainable development with primary attention applied to natural capital and efficient utilisation of manufactured capital. The technical aspects of human capital and social have also been addressed through an emphasis on occupational health and safety and interaction with local communities however I suggest that, to date, insufficient emphasis has been placed on labour (human capital) to maximise economic output1. &nbsp; It has become increasingly common practice to identify land as natural capital, labour as human capital and capital as physical capital. That is labour has been treated as a commodity rather than an opportunity to create a comparative advantage and this will be the greatest challenge for mine management to show leadership over the next decade of the 21st Century. &nbsp; This paper will outline characteristics of the sector which are relevant to the management and utilisation of labour, outline the outcomes of recent AusIMM surveys, review the reasons for the current and future anticipated skills shortages, some innovative responses to the challenges and finally, suggestions on how mine management can show leadership.

Jan 1, 2006

By James A. Finch, Stéphanie Somot

"The self-heating facility developed at the Noranda Technology Centre [Rosenblum and coworkers, 2001; 1995] has now been established in the Department of Mining, Metals and Materials Engineering at McGill University. A research program into mechanisms has been initiated (with support now from four industrial partners under Camiro). The first investigation is into the role of pyrrhotite (Po), the most commonly suspected mineral to trigger self-heating. Following a standard experimental protocol, self-heating was assessed on samples of Po mixed with sand as an inert material. With increasing Po content, self heating progressively increased but, interestingly, the samples visually appeared less and less oxidized. A high Po content, it was hypothesized, may give a more reducing environment favouring formation of H2S. The presence of this gas could be significant as it has a high exothermic heat of reaction with oxygen. The system was modified to test the hypothesis by including copper pieces and copper sulphate to react with (and therefore reveal) the gas as copper sulphide. Evidence is presented in support of H2S production, which to our knowledge has not been shown before and introduces a potentially important avenue of investigation into self-heating mechanisms.INTRODUCTIONSelf-heating of sulphide minerals poses potential environmental and safety hazards in mining of ores, and storage and transport of concentrates. While some conditions are known to be critical, the reactions remain poorly understood making self-heating difficult to predict and control.A major advance in measurement was introduced by Rosenblum and co-workers [Rosenblum et al., 2001; Rosenblum and Spira 1995]. A self-heating assessment method was developed and applied to various sulphide-bearing materials The method is based upon automated calorimetric cells with data acquisition, now available to McGill researchers and which have been used for the study reported here."

Jan 1, 2006

By Chu E. Ho

Key variables that govern the jet cutting process are examined based on fundamental theories of jet hydrodynamics and soil mechanics. Under normal conditions of jet grouting operations, lift speed and rotation speed are found to be of less importance than the depth of jetting, nozzle pressure, nozzle diameter, and the soil bearing resistance, with regards to their influence on jet cutting distance. An analytical equation linking the governing variables is proposed, which allows for the possibility of evaluating column diameters achievable in different ground conditions based on theoretical calculations. When used in conjunction with shallow jet grouting field trials, the equation can provide a means for extrapolating trial results to conditions at actual depths for production jet grouting.

Jan 1, 2006

By F. T. Cawood

Monitoring of the slopes of surface mines can prevent loss of life, loss of equipment, loss of production and possibly the loss of the mine. The effectiveness of such monitoring depends on the extent to which slopes give adequate advanced warning before failing, and on the ability of the monitoring system to detect such warning. In this paper an overview is given of slope monitoring requirements, from both the geotechnical and survey points of view, as well as the types of equipment and instrumentation that are available. Legal issues relevant to slope monitoring are also dealt with. It is concluded that conventional geotechnical and survey instrumentation will continue to have their place in slope monitoring. However, the slope monitoring scene has changed substantially in recent years. A real and volume-based monitoring equipment is now available and this has provided, and will continue to provide, the means to improve safety, and to enhance productivity in mining. Its benefit to slope management is substantial. In the near future it is expected that data obtained from such equipment will add a much needed new dimension to slope engineering, and be used to improve slope designs and to optimize slope angles.

Jan 1, 2006

By R. L. Pienaar

Paper written on project work carried out in partial fulfilment of B Eng (Min. Eng.) degree A study was conducted to investigated and compare the feasibility of two single level extraction layouts for an intact part of theorebody of the De Beers diamond mine, Koffiefontein. Two layouts were chosen and the tonnage profile, development schedule and production ring blast layouts were calculated by applying the information acquired through a literature study. Current principles used on the mine were also applied. The first layout chosen is described as a simple straightforward layout with 6 production tunnels spaced 15 m apart, and is referred to as Layout A. The second layout, named Layout B, is described as a complex chevron layout with 9 production tunnels spaced 15 m apart. This layout has a rim tunnel situated in the kimberlite ground, which is called a chevron and this made the layout more complex than Layout A. By comparing the financial results of the two layouts, it was found that Layout B is a more feasible option than Layout A. Sensitivity analyses show that both layouts are extremely sensitive to the revenue of the projects. Therefore it is recommended that Layout B can prove to be a source of additional tonnage to add to the total tonnage profile of the mine and to extend the life of mine by 20 months, only if certain financial/economic factors improve. There is, however, still some areas of the project that need to be investigated.

Jan 1, 2006

By J. Dupre, A. Gontcharov, H. Pepin

Produced by the conventional TIG welding CMSX-4 welds had been studied. It was demostrated that microstructure of welds depended on filler materials, welding parameters and joint design. Epitaxial solidification of CMSX-4 clad deposits produced a directionally solidified structure while welding with the similar filler material. Defects free clad welds were obtained by TIG welding without preheating using similar and dissimilar filler materials.

Jan 1, 2006

By M. Machikicho, N. R. Shoko, J. Chirasha

Keywords: Pyrometallurgy, furnace, ferrochromium, alloys, Zimbabwe Zimbabwe Alloys was founded in 1949 by a consortium led by the John Brown Group. It was the first ferrochrome plant in Africa. The establishment of the refinery was necessitated by an increase in world stainless steel demand and the need to reduce cost by shipping alloy rather than chrome ore. The location of the refinery in Gweru was influenced by a number of factors, not least of which were the abundance of chrome ore deposits, access to inexpensive power from Kariba, the availability of reductant coke from Hwange, accessibility to ports (as the town was well served with rail and road networks second to none in the country), and of course cheaper labour costs. The production of Low Carbon Ferrochrome (LCFeCr) was commissioned in 1953 and produced from an Open Arc Furnace with a Submerged Arc Furnace producing Ferrosilicon Chrome (FeSiCr) that is used as a reductant in the production of LCFeCr. An experimental furnace was commissioned in 1958 to help with efficiency and control on larger furnaces. A second Submerged Furnace was commissioned in 1963. Three other Submerged Arc Furnaces were built between 1967 and 1974. Several mines were acquired between 1974 and 1984, as a strategic move to ensure the growth of the refinery. A briquetting plant was commissioned in 1977, enabling the use of friable ores to enhance the capacity of ore supplies and ore cost management. A plant to recover alloy from slag was established in 1994 to capitalize on market demand without large capital outlay that would be required to build other furnaces to increase capacity. Zimbabwe Alloys has created employment opportunities throughout the years. There have been direct employment opportunities at both the refinery and the mining divisions. With time, indirect employment was realised both upstream and downstream of the refining process, enhancing the livelihood of numerous people. Zimbabwe Alloys&apos; involvement with various labour skills has, of necessity, enabled it to develop a culture of safety at work, home, and play. Zimbabwe Alloys has contributed to society by participating and funding various local initiatives primarily to impact positively on societal needs. The latest development was in 1996, when Zimbabwe Alloys entered into a Technical Transfer Agreement with Japan Metals and Chemicals to improve the efficiencies and hence the profitability of the LCFeCr production process. A significant quantity of various alloys has been produced since inception, and significant foreign currency has been earned for the country. This was in spite of challenges that included the cyclic nature of market prices, the upheavals of sanctions affecting the macro-economic environment, and the challenges related to the deteriorating grade of chrome ore and reductant coke.

Jan 1, 2006

By Hao Li, Allan Moss, Richard K. Brummer

At the Palabora Mine, the transition to caving 400 m below the bottom of the 800 m deep pit resulted in a slope failure of the North wall that began in 2003, and is still mobile. This failure can be explained by the daylighting into the cave zone of a prominent joint set. The failure was modelled by the 3-dimensional code 3DEC, which is capable of modelling the nonlinear behaviour of discontinuum materials with large displacement.

Jan 1, 2006

By D. M. Muir

Many plants produce iron(II)/(III) waste liquors which must be treated by neutralisation and precipitation to remove the iron. Iron can be precipitated as crystalline goethite or jarosite by controlled oxidation at low pH and as magnetite by controlled oxidation at high pH, but only at elevated temperatures (>70°C). This study focuses on the characterisation and settling properties of the iron oxides produced at ambient temperatures using various neutralising agents in order to improve the performance of thickeners. It was found that two-stage addition of caustic to FeC12 solutions produced a fast settling material characterised by Mossbauer spectroscopy and XRD as maghemite and magnetite. However, lime and magnesia additions resulted in more ferrihydrite formation and much lower settling rates because of the enhanced oxidation of Fe(II) by air. Settling rates decreased significantly as the proportion of Fe(III) to Fe(II) in the liquor increased. The mechanism of iron oxide precipitation is discussed together with some reasons for the different behaviour of the neutralising agents.

Jan 1, 2006

By L. A. Cornish, L. H. Chown, M. Matema, R. Süss, L. Glaner, A. Douglas

Mintek has been developing Pt-based alloys for high temperature applications in aggressive environments, for example, land-based turbine engines, to replace the currently used nickel-based superalloys (NBSAs). The Pt-based alloys have a similar structure to the NBSAs, and since Pt is more chemically inert and has a higher melting point, the Pt-based alloys can potentially be used at higher temperatures. The greater chemical inertness of the Pt-based alloys compared to the NBSAs means that coatings can be simpler, or perhaps not even used at all, depending on the environment. TEM work was done at NIMS, Japan, to investigate the changes in the microstructure o f Pt-Al and Pt-Al-Ir alloys at elevated temperatures using in-situheating up to1100°C. Initial casting trials showed that work needs to be done to optimise casting parameters before commercialisation can take place. Room temperature tensile tests were performed and results were variable mainly due to microstructural differences. The alloy hardnesses were in the order of 300-350HV with ultimate tensile strengths of ~800 MPa and elongations of less than 10%. These results are comparable to other alloys used at high temperatures, which is very encouraging. Keywords: platinum, super alloys, hardness, tensile

Jan 1, 2006

The Chamber of Minerals and Energy of Western Australia Inc (CME) is the peak resources sector representative body in Western Australia. The paper gives a summary of the role and objectives of the CME, including its history, structure and key program areas. Particular attention is given to the role of the CME in the Eastern Goldfields of Western Australia. The paper details the types of CME membership that are currently in existence. The paper argues that a strong and vibrant CME is vital to secure the resources sectorÆs growth and development in future years.

Jan 1, 2006

By C. M. Rule, A. K. Anyimadu, L. Knopjes

Ongoing development work on ultra-fine grinding for various applications at the Group?s concentrators has been conducted by Anglo Platinum over the last few years. Current potential applications for mainstream grinding and concentrate grinding are the subject of a group-wide research and development programme. The first 10 000-litre 2.6 MW IsaMill was jointly developed by Anglo Platinum, Xstrata Technology and Netszch for installation at the Western Limb Tailings Re-treatment project in Rustenburg, South Africa. The unit was commissioned in late 2003/early 2004, and has operated in an intermediate concentrate regrind application successfully since. This paper describes the operational performance to date, as compared with the original duty specifications and objectives. The first mainstream M10 000 IsaMill with a 3 MW drive will be operational in November2006 at the Potgietersrus Platinum (PPL) ?Platreef? Sandsloot Concentrator in South Africa?s Limpopo Province. Key Words: Western Limb Tailings Re-treatment Plant, IsaMilling, Platreef, Platinum, Palladium, PGMs, tailings.

Jan 1, 2006

By Guo H. Lei

Over the last four decades, barrettes have been ever-increasingly adopted as the foundations for tall buildings and heavy infrastructure projects all over the world. Many findings have been gained from practical applications and theoretical researches. In this article, a collection of literature is reviewed on the installation effects and load-carrying behaviour of barrettes derived from field and laboratory tests and theoretical studies. It covers many aspects, such as the ground deformations and stress changes caused by the installation of barrettes, the shaft resistance mobilisation behaviour, the construction effects on the shaft resistance, and the effects of pile spacing, pile shape and pile group layout on the load-carrying behaviour of barrettes.

Jan 1, 2006