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By J. -C. Tricket, W. A. Düweke, S. Kock

The high-resolution three-dimensional (3-D) seismic reflection data acquired for Impala Platinum between 1998 and 2002 in the western Bushveld Igneous Complex form an integral part of Impala?s mine planning and development programme. These data are of sufficiently high quality to provide unprecedented 3-D models of the geological structure of the Merensky Reef and UG2Chromitite Reef, from which the mine deduces the size, geometry and distribution of mineable blocks. Conversely, the seismic data details zones of un-mineable ground caused by structural disturbances in the form of potholes, fault zones and pegmatoid intrusions. Furthermore, variations in dip and strike are well imaged, allowing the mine planners to optimize the mine design and layout. Current interpretation work is focused on enhancing the accuracy of these geological model seven further through the analysis of ?seismic trace attributes.? Preliminary testing on the Impala Platinum 3-D seismic volume has shown that attribute analysis has the potential to illuminate a number of geological reef disturbances that are otherwise ?invisible? in the original seismic time volume. Potential areas of improvement include inter alia: ?Improved definition of major fault zones ?Improved definition of zones of reef depression (?slumping?) ?Identification of reef terracing and/or reverse dip.. Keywords: 3D reflection seismics; Impala Platinum Ltd; seismic attribute analysis; Seismic Micro Technology (SMT); rock solid attributes; dip-azimuth; instantaneous phase and similarity.

Jan 1, 2004

By J. F. T. Agapito, L. J. Gilbride, K. Hollberg

Room-and-pillar mining at the Big Island Mine uses narrow, yield (i.e., load transferring) pillars to achieve high resource recovery and productivity. Two flat-lying 3- to 3fi-meter (10- to 11fi-ft) seams are mined. The interburden between the seams is about 10 meters (33 ft) and the cover depth is 250 to 330 meters (820 to 1,080 ft).Most of the mining has been single-seam, but two-seam mining will begin in the near future. Yield pillars minimize stress transfer between the seams. However, it is important that good long-term stability be maintained to prevent subsidence over a large portion of the mine beneath the Green River channel. Three stress issues impacting stability are discussed in this paper: (1) higher-than-gravity vertical pre-mining stresses, (2) time-dependent stress transfer or arching, and (3) stresses induced by strata gas. Although the stress environment and behavior is not fully understood, steps have been taken in mine design and operations to minimize impacts to stability. Stress determinations have been very important to verify analytical predictions used in mine design and in long-term stability assessment.

Jan 1, 2004

By C. Righi, R. Carli

In modern steel continuous casting technologies mould fluxes are well-known to assure lubrication required by tribological system of mould-solidifying strand shell, and to provide crystalline phase solid film, contributing to control heat extraction between strand and mould wall. Actual cooling rates during normal continuous casting mould operations are far higher than critical cooling rate of the liquid slag. Indeed, DTA measurements point out that even relatively small cooling rates of 30?50 K/min are high enough to give exiguous formation of crystals. In this paper, contribution of devitrification in defining crystalline phase formation of industrial basic mould slag, used in continuous casting of crack-sensitive steel grades, has been investigated by means of non-isothermal experiments study. Devitrification has proved to play a major role in mould flux crystallization in a working environment explaining the higher amount of crystalline phase formed in plant sample in comparison with lab sample from DTA analysis with typical cooling rate of 5?20 K/min. The amount of crystalline phases formed ranks as follow: Cuspidine > Combeite > Gehlenite. Kinetic analysis of DTA non-isothermal experiments has provided kinetic parameters through Kissinger and Ozawa methods, as Avrami constant resulting to be n ?2 and activation energy of Cuspidine crystallization resulting to be EC= 315 kJ/mole. The effect of addition to the parent material of oxides as MnO, TiO2, ZrO2, Al2O3 and Fe2O3near to saturation point has proved to affect, in certain cases, crystallization behaviour of mold flux. In particular, MnO, TiO2, ZrO2oxides produce a relevant dump of crystallization of Combeite and Gehlenite phases, while Al2O3and Fe2O3do not appreciably affect crystallization. Key words: Mould flux, crystallization, devetrification, DTA non-isothermal analysis, Kissinger and Ozawa methods.

Jan 1, 2004

By Daniel Hodouin, Claude Bazin

"A graphical method to assess the size reduction by grinding is presented and illustrated with data collected from laboratory grinding tests and industrial grinding circuits. The method lies between the graphical comparison of size distributions and the population balance model. The method is easy to apply and provides a quick way to compare grinding mill performances under various operating conditions and processed ores. The application of the method to industrial mills shows that a grinding mill operation could present an invariant behaviour that can be exploited for simulation purposes.INTRODUCTIONThe size reduction of particles by grinding has been studied for decades and several books were published on the subject. Most of the recent studies focus on the modelling of the ball, semiautogenous and autogenous grinding mills operation (Napier-Munn et al., 1996) because accurate simulators can be used for design, optimization and control. Although the development of realistic simulators is progressing, the trial and error method is still used by many operators to identify optimum operating conditions for a grinding machine.Laboratory tests allow the characterization of the material submitted to grinding and the analysis of various operating conditions, such as ball size or shape, mill speed and slurry concentration of solids, on particle size reduction. Similar tests can be conducted in a plant, but results are often difficult to analyze due to errors associated with sampling and sensor accuracy. This paper presents a graphical method to assess the degree of size reduction carried out by a grinding machine. The paper consists of three sections. The first section describes the method and the following sections illustrate the method with data taken from laboratory and industrial grinding machines."

Jan 1, 2004

By Z. Zhang

The author recently has reviewed the publications on the slag-related research in China since the Sixth International Conference on Molten Slags, Fluxes and Salts in June, 2000. In fundamental aspects, the physical property predictions and measurements, slag-metal reactions, slag-refractory reactions have received close attention, and are briefly described here in this report. More than half of slag-related publications deal with plant investigations due to the requirement of technological improvements and environmental protection. In the present paper, the research on slags in various treatments related to clean steel production and the utilization of the waste slags is briefly reviewed.

Jan 1, 2004

By E. Fritz

This paper reviews the history, developments and 10 milestones of the oxygen steelmaking processes, with a special focus on conventional autothermic converters, high-speed converters with a blowing rate up to 5 m3n/t min and allothermic converters with coal addition, post combustion and the possibility to increase the scrap rate up to 50%. Related operating results are introduced. A new process route, which is based on hot metal and chromium ore, is outlined. The cost advantage for the production of 304 stainless steel grade is higher than 100 USS/t. The synthesis of EAF and oxygen converter steelmaking, a comparison of decarburization rates, refining combustion burners for optimized oxygen-management in EAF and an example for a large advanced EAF are outlined. Possibilities of flexible steelmaking and the growth and outlook of worldwide oxygen steelmaking are described.

Jan 1, 2004

By V. Fiedler, H. Lachmund, R. Bruckhaus

"After producing some 50 million tonnes of crude steel the two BOF vessels at Dillinger Hüitte steel plant had to be replaced in 2000/01 due to large deformations. The new vessel design was optimised after a number of theoretical evaluations.Refractory investigations were carried out as well as temperature measurements of the shell to provide a basis for selecting a suitable steel grade. This was found in a DH-GTS development - P420M HT - with high strength at elevated temperatures and excellent weldability and made it also possible to build the vessel without any cooling system.After putting the first vessel into operation the metallurgical results showed no remarkable improvement compared to the old vessel, and were therefore not satisfying. With the help of cold model investigations the arrangement of the tuyeres was modified to improve the flow conditions and the interactions between oxygen jet and the heterogeneous plume of the bottom stirring gas. Further optimisations were obtained by a variation of lance tips and a newly developed lime addition model."

Jan 1, 2004

By S. Caron, P. Radziszewski

Industrial practice in mineral processing shows that an important problem in understanding and monitoring in-mill parameters is due to the lack of fundamental knowledge and appropriate sensors. However, over the last decade, Discrete Element Method (DEM) modelling has shown an interesting potential in describing the fundamentals of grinding mill behaviour, in improving the understanding of internal grinding mill dynamics, and in developing solutions to industrial practice. With the objective of bringing this modelling technology into the concentrator control room to assist operators, this paper aims to describe the main elements needed to apply this emerging and developing technology to on-line mill performance monitoring.

Jan 1, 2004

By Premil Agarwal, Alok R. Patnaik, Pulak Dhar, Prakash C. Patnaik

In this study, a physics based model has been presented, considering the growth of the thermally grown oxide (TGO) layer on the bond coating of a thermal barrier coating. Using diffusion equations, a model has been developed to physically describe the oxidation process. The mathematical equations representing the diffusion formulations have been solved numerically. The computed results show the depletion of Al in the bond coating as it diffuses both towards the super-alloy substrate and towards the TGO produced in between the bond coating and the ceramic TBC top layer.

Jan 1, 2004

By C E. Loayza, R M. Pinto, J G. G=mez

The Yanacocha District is located 20 km north of the city of Cajamarca, in the Northern Andean Orogenic belt of northern Peru.Gold production may have occurred as early as Incan times (Paverd, 2000), but modern exploration that began in the 1960s targeted only copper and silver. Newmont Mining Corporation, BRGM and Compa±fa de Minas Buenaventura began exploring for gold in 1983, with Newmont as operator.Initial drilling took place in 1985. By 1992 a reserve of 1.28 million ounces was reported (Teal et al, 2002).Production began at the Carachugo deposit in 1993.Current reserves are 31.7 million ounces at $US 325 per ounce at a grade of 1.03 ppm (Newmont Annual Report, 2003).The operating company, Mineral Yanacocha SRL (Newmont 51 per cent, Buenaventura 44 per cent and International Finance Corporation five per cent) produced 2.85 million ounces in 2003, making Yanacocha one of the largest gold mining operations in the world. The district is made up of a series of epithermal, high sulfidation style gold deposits and one gold-rich gravel deposit (La Quinua), aligned in a NE trend.La Quinua is not discussed in detail in this paper. The bedrock deposits are hosted in a Miocene volcanic package, the Yanacocha Volcanic Complex that also trends NE.Re gional NW striking Andean faults intersect the NE striking Trans-Andean Chicama-Yanacocha structural corridor (Turner, 1997), localising the district mineralisation. These two structural orientations dominate the district, controlling breccia and intrusion locations, and gold mineralisation. Discontinuous EW oriented fracture zones are interpreted as extensional and locally are important in controlling gold mineralisation.

Jan 1, 2004

By Z. Lin, M. Isac, R. I. L. Guthrie

The kinetic and thermodynamic efficiencies of chromium recovery from the slag in an AOD process during the slag de-oxidation period with ferrosilicon is a complex process affected by slag basicity, temperature, the dissolution kinetics of the reducing agents, and intermixing of the slag/metal/alloy addition phases within the vessel. The present work focused on a study and simulation of the fluid dynamics and mixing behaviour of ferrosilicon additions in the AOD process for the production of stainless steel. In order to visualize the mixing behaviour, a two dimensional slice model of an AOD vessel was first built and filled with ZnCl2solution and then covered with silicone oil in order to represent the bulk liquid steel and slag phases, respectively. The injection of argon/oxygen process gases was simulated using air or helium. Particle trajectories and intermixing of the phases was monitored with a high-speed camera. To simulate the 75FeSi additions, glass spheres were used. A three-dimensional version of the AOD model was then constructed in order to confirm the adequacy of the slice model. Similar particle mixing behaviour was observed. Both models demonstrated that the ascending gas/liquid plume created two asymmetric mixing zones: a smaller rapidly re-circulating mixing zone adjacent to the side-wall locating the tuyere(s), and a larger mixing zone in the main part of the vessel. The process efficiency during the reduction period is governed by the thermal behaviour of ferroalloy as well as the mixing efficiency in the main large mixing zone. To enhance the recovery efficiency for chromium, small Fe-Si particles are suggested, given their wide distribution within the slag phase, and their large interfacial areas and rapid melting times for Cr2O3reduction from the slag. Keywords; modelling, ferrosilicon, chromium oxidation, AOD steelmaking.

Jan 1, 2004

By W. Banda

Paper written on project work carried out in partial fulfilment of Phd. (Process Engineering) degree* The recovery of cobalt and copper from waste slag was studied in a plasma DC-arc furnace in reducing conditions. Three fluxes, CaO,CaF2, and TiO2, were investigated for their influence on selective recovery of cobalt into an iron-rich alloy. A further investigation on the influence of furnace power on the reduction of slag to recover cobalt to the alloy showed that a change in power setting had an unexpected effect on the recovery of metals to the alloy, in that selectivity of base metal recovery over iron recovery decreased at an increased power level. Keywords: DC-furnace, reduction, nonferrous, slags

Jan 1, 2004

By I R. F MacCulloch

Bacterial oxidation of sulfide minerals is a familiar and commercially available process to enhance gold recovery with problem ores. Pintail Systems, a Colorado, USA based company had developed bio-processes for gold recovery based on natural mineral formation and transformation in a global mineral cycle. The biological recovery of precious metals from ore involves a number of mechanisms that are dependent on the metal-mineralogical association. These processes include: partial bio-oxidation of sulfide ores; oxidation of gangue minerals exposing gold to leaching; surfactant properties of bacteria/nutrient solutions that improve wettability of ores and solution contact with leachable gold and silver; and microbial production and excretion of trace amounts of gold lixiviants, and bio-fracturing or biological alteration of ore minerals. Pintail has demonstrated enhanced recovery of precious metals during cyanide detoxification of spent heaps at the end of mine life. Biological recovery processes also have the potential to be applied to in situ mining technologies. The in situ process application could recover gold from subgrade deposits, small deposits or those ore bodies with uneconomic stripping ratios for conventional mining. In situ biomining can be accomplished at a fraction of the cost of conventional mining and leaching and does not have the environmental liabilities associated with many conventional gold lixiviants.

Jan 1, 2004

By A. Saigal

A finite element analysis based investigation using DEFORM software was undertaken to model the extrusion of 15% alumina and 15% silicon carbide reinforced aluminum metal matrix composites. The study dealt with predicting the extrusion load as a function of ram displacement and initial billet temperature. The finite element simulation was also used to determine the maximum extrusion load, temperature distribution, maximum temperature, strain rate, velocity and stress distributions in the billet during the hot extrusion process. The constitutive equation used was of the type: Z = E exp(Q RT) = A{sinh(ao-)}" where Z is the Zener-Hollman parameter (temperature compensated strain rate), s is the strain rate, Q is the activation energy, R is the gas constant, T is the absolute temperature, a is the flow stress and A, a and n are constants. Based on the work of Davies et al and McQueen and Konopleva, the values of Q (KJ/mol), a (MPa-1), n and A for aluminum 6061 composites reinforced with 15% alumina and 15% silicon carbide used are 181, 0.024, 4.15 and 1.33x10'2 and 233, 0.052, 2.60 and 1.26xl0'4, respectively. Even though the individual parameters are quite different, it was found that the predicted maximum extrusion load, temperature distribution, maximum temperature, strain rate, velocity and stress distributions are quite similar and differ by no more than 1-2 percent between the two composites indicating that the deformation behavior is primarily controlled by the matrix material and is not a function of the type of reinforcing ceramic particulates.

Jan 1, 2004

By M. E. Rossi, J. E. Camacho

"Geostatistical conditional simulations are becoming increasingly popular as tools that provide models of uncertainty at different stages of a mining project. They have been used as grade control tools in daily operations to assess the uncertainty of mineable reserves at the project’s feasibility stage, and to assess mineralization potential in certain settings. Other applications include assessment of recoverable reserves, resource and reserve classification, and drill hole spacing optimization studies. All large-scale applications of conditional simulations intend to benefit from the correct (or accurate) characterization of uncertainty, adequately describing the variability observed from the data and its effect on the final objective.The objective of this paper is to compare the ad-hoc uncertainty model provided by a traditional classification scheme with the probability intervals resulting from a conditional simulation model. It is argued that the uncertainty model derived from the use of classification schemes is of little practical use to the mining company or operation. The paper emphasizes differences in uncertainty based on the size of the mining unit considered, the extraction method, and local geological differences. Most importantly, it discusses confidence intervals for these mining units, as compared to the relative precision envisioned by a typical classification scheme.The application described in this paper is taken from a medium-sized Cu open pit and underground mine in northern Chile, and demonstrates the impact of several variables on the resulting conditional simulation models. It also compares a more traditional resource classification scheme applied, and the wide difference in local confidence intervals for each mining unit."

Jan 1, 2004

By Robert Lee, Pertti Paavola

Automated vibration monitoring and web-based data distribution has proven itself on the largest single construction project ever undertaken in Finland. The excavation for the Kamppi Center Project in the center of Helsinki was completed in November of 2003 and involved the removal of over 200,000 m3 (260,000 yd3) of rock and over 1,700 individual blasts. A system was installed, incorporating 37 discrete monitoring points located throughout an underlying metro station, and other surrounding underground and surface facilities. After every blast, vibration data was automatically transferred from the monitoring network to a server database. Stakeholders were able to access and review vibration reports on a password-protected website within 90 seconds of each blast. This allowed engineers to verify that recorded levels were in compliance with established limits, before proceeding with subsequent blasts. The data was also imported into a semi-automated Scaled Distance tool for analysis using linear regression techniques. This was used to determine, and adjust for trends in blast-induced vibration.Copyright

Jan 1, 2004

By Paul Kunze

For some of us, the most disagreeable part of being the blaster- in - charge is doing the required paperwork. Cost coding on time cards, drilling reports, magazine inventory logs, and blast records all eat into our time. When all goes well, which I suppose is 98% of the time, the blast records are submitted and filed, probably never to be seen again. Sometimes a progressive operation will use the information documented in the blast reports to evaluate blasting effectiveness and improve results. When the report is consistently used in this fashion, costs can be reduced and other efficiencies will be realized. A blast report in times past was a simple form that mainly was used to keep track of the drill footage and of the powder used in the shot. However, as the population and consequences of careless blasting increase, multiple levels of blast documentation are now being required nearly everywhere, during all phases of the drill and blast process. We are now compelled to create preliminary blast designs prior to commencing work. We are required to submit pre-blast plans before each shot, and we need to generate post-blast reports that document the details and results of each shot.

Jan 1, 2004

By T. Plikas, L. H. Gunnewiek, L. Oshinowo

"Electric furnace smelting is one of the principal unit operations for ferroalloy production, and increased process intensity, improved availability, minimal maintenance and a longer campaign life are common objectives for electric furnace operation in order to obtain favourable economics of production. Furnace designers have continued to develop innovative solutions, e.g., furnace cooling systems, that have allowed these objectives to be realised and CFD modelling plays a key role in the design process. Enhanced understanding of the energy transfer process in the furnace and the ability to develop, evaluate and optimize components of the crucible design to match process requirements are the key motivators for modelling.This paper provides an overview of recent applications of CFD to the design of electric furnaces. The aim is to illustrate what can be done, and identify areas where further work is needed in this field. Examples include furnace bath simulation, crucible cooling system design, taphole design, baking of Soderberg electrodes, off-gas systems, and fume control and building ventilation. It is argued that the trend is for numerical models to become more encompassing while at the same time more accessible, and therefore further improvements in furnace design will be realised with continued and well validated modelling efforts.IntroductionOne of the main processing steps in ferroalloy production is the smelting of ore in electric furnaces. The three-electrode, AC submerged arc furnace is most prevalent method for smelting in the industry, with shielded-arc and DC plasma arc furnaces achieving limited application (1,2). Commercial furnaces range in size from a few megawatts to more than eighty megawatts of supplied power, and operate with the objective of maximising the return on capital invested. Maximising productivity and energy efficiency are two pathways to achieving this objective, through process intensification, increased availability, minimal maintenance, and increased campaign life for the furnace and associated equipment. Concurrently, the need to reduce the environmental impact of metal production by controlling the emission of particulate emissions, greenhouse gases, and other harmful by-products must also be met."

Jan 1, 2004

By H. Hamza

Efficient and effective management of extraction process tailings is an essential ingredient for the continued success and development of Alberta's vast oil sands resources. Open-pit oil sands operations north of Fort McMurray recover bitumen from flotation circuits. Process tailings are managed in carefully engineered and monitored external tailings management facilities and in below-grade mine pits. In order to support reduction of production costs and improve upon established tailings management practices, CANMET has been working with the oil sands industry in a collaborative framework to assess the potential to integrate thickened tailings into oil sands extraction process flowsheets. Albian Sands has commercialized the process while others, including Syncrude Canada Ltd., continue to evaluate the suitability of the process for their operations. This paper provides an update on R&D work undertaken in recent years to assess and develop the potential of thickened tailings technology for the open-pit oil sands operators of northern Alberta. The aim of this work was to explore opportunities to optimize process efficiency and environmental sustainability by improving water and energy conservation and develop more alternatives for tailings management and reclamation.

Jan 1, 2004

U.S. Borax’s mine in California’s Mojave Desert is the source of nearly half the world’s supply of refined borates. These minerals are used in hundreds of products, including essential plant nutrients that increase crop yield and quality, and safe building products that protect homes from insects and the elements. Borax’s workforce is also safe. In fact, it is among the safest in the nation. In 2003, the company was recognized by the U.S. Mine, Safety and Health Administration (MSHA) for achieving the best safety record among large U.S. mining operations. It was also recognized by its parent company, Rio Tinto, for achieving the best record among its nearly 80 worldwide mining operations. Borax’s safety performance is five times better than the national average. And its workforce recently achieved more than two million hours without a lost-time injury.

Jan 1, 2004