Search Documents

The scope of this paper has been restricted to the manufacture in Australia of seamless steel tubing, as the subject of buttweld tubing has already been dealt with by A. N. Hamilton in a paper delivered before the Institute in 1935.The earliest attempts to produce seamless steel tubes were based on the extrusion of lead piping, a process developed by Thomas Burr in 1820. However, the problems associated with the extrusion of white hot steel had to await the metallurgical knowledge of the twentieth century, and these early attempts were unsuccessful.The years 1840 and 1845 were noteworthy for the introduction of the first practical methods of making seamless steel tubes. In one process, a large circular plate was 'cupped' in a vertical press; in the other, a round steel billet was pierced for its entire length.The product from both these methods was then elongated by repeated reheating and rolling over an internal mandrel, in a circular pass mill.At this juncture, it should be noted that every process developed for the manufacture of seamless steel tubing can be divided into two parts. In the first part of the process, attention is centred on the conversion of the heated bloom into a short, thick-walled, hollow cylindrical forging; this product is then elongated in the second section of the process. It will be noted that these two sections are actually quite distinct, and in practice numerous methods exist for carrying out both functions. The first stage is generally referred to as 'piercing', the second stage being termed 'elongating.' In this paper, the author proposes to outline the various methods adopted for piercing and elongating; the reader is asked to note that although certain methods of piercing are almost invariably associated with only one method of elongating, the distinction between the two functions is, nevertheless, a vital one and should be noted accordingly.

Jan 1, 1947

By P M. Dight

Shotcrete usage in declines and developments has become pervasive as operators strive to achieve production improvements. Issues of mix control, fibreload, thickness control, temperature and curing conditions all play a part in the quality control. Often to overcome some of the quality control issues designers over specify the strength requirements in order to meet their operational constraints. Adherence to the standard civil testing requirements of 28 days moist cured at 21ºC without properly calibrating these results to the changing environment underground leads to contractual disputes. There are a number of standard tests specified including cylinder tests, cored tests, beam tests and round determinate panel (RDP) panel tests. The logistics of storing these samples and then transporting them to concrete testing laboratories without due regard to temperature changes with time can influence the results. All the samples can be readily handled by personnel except the RDP panel. The standard RDP panel is 800 mm diameter by 75 mm thick and requires an ITH machine at the mine and a fork lift at the laboratory to move it around. This paper will examine the possibility of a panel which provides scalable results to the standard RDP panel but can be easily handled by personnel and/or tested on site with suitable equipment. This allows for faster turn around and better quality control for the sample prior to testing. This enhances the identification of quality control issues at the mine and improves safety.

Mar 21, 2011

By Warner RE

SINCE 1952, when Elliott et a/ first applied the Sherwood correlation for flooding in chemical absorption towers to blast furnaces numerous investigators throughout the world have followed their example and much research effort has been spent to tighten the correlation and recently to extend investigation of flooding to side gas entry conditions. The widespread use of the Sherwood concept of flooding has been such that even the word itself has become an integral part of blast furnace nomenclature. The evidence for the applicability of Sherwood's relationship has been that the flooding limits calculated from blast furnace parameters lie approximately on the Sherwood line. However, the values of many of the variables for the blast furnace calculation are only estimates and at first sight one may wonder at such 'close' coincidence when some of the estimated parameters entering the Sherwood correlation are raised to the power of three or more, as for the bed porosity and the liquid surface tension. It is felt that the explanation of this result lies in the logarithmic: nature of the plot and/or the fortuitous can- cellation of the errors of the estimates in the calculations coupled with the fact that blast furnace fluid ratios lie within a very narrow range of values. The foregoing considerations should in their own right place doubt on the correctness of the Sherwood type flooding correlation applied to the blast furnace. Additional doubt regarding the existence of the Sherwood type flooding in the furnace has been cast by the results obtained in the Tokyo University experimental blast furnace. From the reasoning of both Standish and Colquhoun (p. 20) and Warner (p. 23) it is deduced that flooding in the traditional sense will only normally occur in the upper bosh (somewhere near the mantle), following softening as discussed by Palella et a/ on p. 75, and flooding in that zone is likely to result in furnace irregularity. On the other hand, the concept developed by Warner of slag hold-up above the raceways as a stable phenomenon not affecting furnace regularity is a process unique to the blast furnace and is not described by the Sherwood flooding theory. Recognising the considerable practical implications of slag hold-up above the raceways, this note further explores the physical process of slag hold-up. We envisage that bed of coke above the raceways in almost all blast furnaces would contain some slag held up by the gas pressure gradient. In general the slag would be contained in a ring and gas would bubble through in its ascent through the furnace. The force supporting this slag is the pressure gradient and obviously -much of the blast pressure is dissipated in supporting this structure.

Jan 1, 1975

By Z Li, D Chalmers, J M. Tenney

This paper presents the findings and analysis of the investigation of effectiveness of thin spray-on liners (TSLs) as a gas management tool in underground coalmines. The project involves spraying TSL on the area surrounding gas drainage holes whereby the TSL acts as a thin membrane decreasing the permeability of the coal. This restricts air migrating through the coal seam and diluting gas from the drainage holes. There are a number of potential benefits from this technique but key points are that gas drainage holes produce gas with higher concentrations of methane. The design and execution of a field trial to investigate the effectiveness of a TSL on purity of in situ methane from gas drainage holes is presented in this report. For eight drainage holes, the results show an average increase in methane purity by 9.14 per cent and a reduction in air contamination by an average 7.93 per cent. Overall methane flow rate decreased by 27.6 L/s; however, flow rates were unreliable due to poor measuring equipment. For most holes, methane purity was not changed significantly; however, certain boreholes were responsible for most of the variation in methane purity. The boreholes showing a dramatic improvement in methane purity were likely those with intersecting cleats covered by the TSL. If the TSL was sprayed over more area, specifically in areas where the cleats are intersecting with holes, it is likely that purity of methane in the drainage holes will increase.CITATION:Tenney, J M, Chalmers, D and Li, Z, 2015. Thin spray-on liners potential in reducing dilution of in situ gas in underground coalmines, in Proceedings The Australian Mine Ventilation Conference, pp 323–328 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 31, 2015

By S P. Young, K R. Monro

Reducing metal prices have forced mining operations to become more efficient and innovate in order to do more with the existing base. Much of this effort has focused on improving the efficiency of load and haul operations. The key to this is to understand and quantify where delays and missed opportunities exist. Metrics such as utilisation of availability, efficiency utilisation and asset availability are helpful indicators of performance; however, uptime-based time usage models and performance analysis tools using productive operating time models help to identify additional improvement opportunities.Phu Kham is a copper-gold mine operated in the Lao People’s Democratic Republic (Laos) since 2008 by PanAust Limited. The mine is a single large open pit of 450 m depth, running a fleet of 51 100 t class rigid dump trucks and 300 t and 200 t shovels controlled with the aid of a fleet management system in order to achieve ex-pit material movements of 56 Mt/a.Commencing in late 2014, a range of initiatives were implemented in order to improve the efficiency of the mine haulage fleet. These include hot seating of all operator changeouts via changeout ramps, split shifting of crews to minimise queuing delays, maximising blast volumes and minimising blast event days to reduce blast exclusion delay events including opportune refuelling of equipment during blasting events, inspections of trucks during refuelling events, implementation of a dedicated haul road services team to help reduce wet weather related delays and infrastructure development for haul path efficiency improvements.These and other initiatives have allowed the mine haulage fleet utilisation of availability (UofA) to be sustainably increased from 85 per cent to 97 per cent (see Figure 1), efficiency utilisation to increase from 85 per cent to 90 per cent, and productive operating time (POT) to increase from 73 per cent to 84 per cent. The corresponding increases in efficiency of the haulage fleet has allowed an equivalent reduction of eight haul trucks from the fleet to meet continuing life-of-mine production requirements.CITATION:Monro, K R and Young, S P, 2016. Truck haulage improvements at the Phu Kham mine – the journey to 97 per cent utilisation of availability, in Proceedings International Mine Management Conference, pp 339-346 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jun 22, 2016

By D Kay, M Lovitt

Mass Blasts are generally required at the completion of longhole stoping cycles to maximise the recovery of ore from a specific orebody. During the course of mining, the practice is to leave pillars of ore to support the opening left by extracted ore and to mitigate stresses from working areas of the stope. These pillars usually contain ore that has been included in the resource evaluation and is highly valuable to the mining operation. Due to their stressed nature, the removal of pillars by conventional blasting techniques, through small blasts, can result in pillars being reduced beyond their critical size and ultimately failing, rendering the ore unrecoverable. The AurionGold Kanowna Belle Gold Mine operates a Mine to Mill philosophy. This philosopy requires the fine tuning of blasting to provide the best possibe ore feed at the highest grade for mill productivity. This means that ore to the mill must be well fragmented from blasting that provides high extraction rates from draw points, with minimal dilution from overbreak or fall off, and sized to maximise SAG mill throughput. The AT04 Mass Blast contained significant ore reserves which were required to meet gold production targets. KBGB needed the AT04 Mass Blast to perform as well as if not better than conventional stope blasts to maintain mill production. This paper describes the circumstances, planning philosophy, techniques, including the use of Electronic Initiation Systems and Bulk Emulsion Explosives, and results that provided a highly successful outcome.

Jan 1, 2002

By C Quirion

Agnico-Eagle Mines Limited, Laronde Division, operates the deepest single-lift shaft in the western hemisphere. The initial Penna hoisting plant was designed for a production rate of 1800 tonnes per day (t/d) from a 2240 m deep shaft. Exploration success, while sinking the shaft, led to a decision in 1998 to increase the production rate to 4500 t/d of ore from a loading depth of 2200 m. The new production rate was achieved by increasing the size of the rope and reducing the rope static factor from the existing 5.0 required by regulation to a static factor using the formula 25 000/(4000 + L) contained in a draft document that would eventually become SABS 0294 in South Africa. The formula permits Laronde to use a static factor as low as 4.0. The upgraded Penna hoisting system is the first hoisting plant outside of South Africa to meet the South African requirements. This paper describes the conversion of the hoisting plant to the lower rope selection factor in the year 2000 and the operating and maintenance issues experienced since then.

Jan 1, 2005

The planned extraction of deeper copper ore at Isa Mine has necessitated a review of existing equipment and methods to contain costs and improve working conditions. Mining is in progress for a crushing-conveying system to serve the deeper southern areas of the 1100 Orebody. This system will permit direct tipping of ore to the crushers and conveying of the crushed ore by cable belt conveyor to existing shaft loading facilities, a distance of about 2 km. To develop part of the conveyor drive a new machine will be used, the Robbins MM120 Mobile Miner, a joint development project between The Robbins Company and Mount Isa Mines Limited. The Mobile Miner uses a rotating cutting wheel to excavate headings 3.7 m high and from 4.7 m to 7.5 m wide. To ventilate the deep crusher complexes and associated development at high virgin rock temperatures, a refrigeration plant will be built on surface to reticulate chilled water underground. Bulk cooling of air to the 3000/3500 Orebodies and the southern crushers will be combined with the reticulation of chilled service water to the lower workings of the mine.

Jan 1, 1984

The need for formalised geotechnical reporting has not been fully explored at many operations. With the continuing need to provide safer and more efficient workplaces, the requirement for good geotechnical reporting systems (as with other reporting systems) has become of greater importance.Historically, the risk from rockfalls has been the largest cause of fatal injuries in the underground mining industry. The response of the ground to mining is generally poorly documented at many mines. At Olympic Dam, it was found that the existing corporate hazard and incident reporting (HIR) procedure did not record enough specifics about geotechnical issues. A separate and more specific geotechnical reporting process was set up to address this problem.This paper examines the role that geotechnical reporting plays at the WMC Resources Olympic Dam Mine; from reporting and rectifying day-to-day geotechnical issues that affect the operation to documenting and analysing longer term trends.

Jan 1, 2004

By Kennewell G. J

This paper aims to present the evolution of the mining method in the Prince Lyell orebody. Initial strategy and practical experience are detailed as are the reasons for and benefits of changes to the method since 1972 when underground mining began. This section of the paper starts with ten series and concludes with 40 series which was completed in 1989/90.In addition, to update the series of papers written by various authors over the past ten years on Mount Lyell, a review of the experience in the current 50 series lift of mining will be given. As well, the basic planning guidelines are discussed for 60 series - the final lift of the Prince Lyell orebody.

Jan 1, 1992

Average annual growth in consumption of primary energy in Australia over the past 10 years has been 5·5 per cent compared to a world average of 4·1 per cent.Over the next 10 years growth rate is expected to increase to 6 per cent per annum due largely to the rapid development in the mineral processing industry.By the end of the 19705 natural gas is expected to supply more than 9 per cent of Australia's primary energy market. Coal will supply 40 per cent and petroleum products 47 per cent. Nuclear energy will make its appearance but will make only a small contribution in the period.Australia has adequate reserves of natural gas and coal to supply its needs in the 1970s and beyond. However the newly developed reserves of crude oil, while supplying 60-70 per cent of requirements in the initialyears, will need regular and sizable additions if they are to keep pace with the expanding consumption. For Australia to become self sufficient in the period 1970-1990 it is estimated that new discoveries will need to approximate ten times the volume of recoverable reserves found in Australia to date.

Jan 1, 1971

EIA is a test of a development proposalÆs legitimacy and asks two questions: not only æis the proposal competent?Æ but also ædoes the proposal have moral authority?Æ For reasons of miningÆs historic importance and of a scientific and technological industry culture, traditional EIA has focussed on the first on these, an increasingly misplaced priority in a changing world.This paper explains why competence alone is not enough and examines the second of the two questions: what is meant by a projectÆs moral authority, why does it matter, why has it taken so long to become an issue and what, in practical terms, can project proponents do about it.

Jan 1, 2004

By Hare S. M, Lumsdaine I, O&apos

Converter slag assaying 3.7 per cent Cu is produced by Mount Isa copper smelter at a rate of up to 180 000 tonnes per annum.Priority is given to the processing of ore, however concentrator capacity periodically exceeds that of the mine and the opportunity is taken to treat converter slag. It is processed in batch campaigns, typically through the Copper Concentrator, but the Hilton Concentrator has also been used. Slag and ore are kept as separate as possible, since each has an adverse effect on the flotation performance of the other.

Jan 1, 1993

By Van Weert G

Ferrous chloride solution pyrohydrolysis is a successful IICI regeneration process which is carried out in either a spray roaster or a fluid bed. Pyrohydrolysis is not restricted to ferrous chloride only, every metal chloride can theoretically be hydrolysed. In practice, however, the conditions for ferrous chloride pyrohydrolysis differ from those of many non-ferrous metal chlorides eg zinc, lead and cadmium. Hence, a pyrohydrolyser could function as a ferrous/non-ferrous separator, eg an iron oxide and zinc chloride separator. Most pyrohydrolysers operate on solutions, in which case more than 50 per cent of the process energy is needed for heating and evaporating water. However, this disadvantage would be diminished by feeding a slurry to the reactor. Against this background it was decided to investigate the chloridisation of zinc ferrite which is an iron bearing solid with a non-ferrous impurity, and subject to processing and disposal problems. Synthetic zinc ferrite was chloridised in a tube furnace. The gas atmosphere in the tube furnace resembled that of a fluid bed pyrohydrolyser and consisted of HCI, 1120 and nitrogen. Gas composition, temperature, residence time and sample mass were varied. The experiments showed that complete (99.6 per cent) zinc extraction from synthetic zinc ferrite was possible in a simplified pyrohydrolyser atmosphere at 1100 K in four hours. The zinc ferrite was converted into gaseous zinc chloride, and hematite and magnetite solids. It was also found that zinc removal from the zinc ferrite lattice caused not only rccrystallisation of the zinc ferrite into hematite, but also hematite crystal

Jan 1, 1993

By G D. McDonald

Flinders Mines is an ASX300 iron ore explorer and developer with a tenement package located in the Hamersley Ranges region of Western Australia, approximately 70 km north of Tom Price. Exploration over the past three years has identified a Global Resource in excess of 740 Mt at a grade of 55.4 per cent Fe (+50 per cent Fe cut-off). This resource is spread across multiple deposits and has been divided into a number of mineralisation type domains based on geometallurgical and geochemical boundaries. These domains are comprised of transported haematite rich detrital iron deposits (DID) and goethite dominant Channel iron deposits (CID) as well as in situ bedded Brockman iron deposits (BID). On the basis of differences in physical and chemical characteristics, the DID have been divided into four discrete units. The four DID units form a stratigraphic sequence with the iron grade increasing and the contaminant concentrations decreasing with depth. The upper DID unit is lower grade and currently unlikely to provide a marketable product, without signifi cant beneficiation. The lower three DID units, together with the CID and BID, are of a higher quality and have the potential to yield marketable ore. The ability to define and recognise these different units has resulted in a more reliable and robust geological interpretation and hence greater confidence in the resulting resource model. This has been evident in the excellent conversion of inferred to indicated resources.

Jul 11, 2011

By Y Chung, B Choi, H Lee

Numerous studies have explored refractory corrosion in the presence of slag and/or metal, utilising the Finger Rotating Test (FRT). Recent experimental results revealed that corrosion initially increased with rising rotation velocity but was then suppressed above a critical rotating speed, under conditions involving a two-liquid solution of slag and molten steel. This phenomenon indicated that the liquid/liquid interface movement occurred during spindle rotor. However, understanding of the phenomenon, known as the rod climbing effect, remains inadequate in the case involving slag, molten steel and refractories. To gain deeper insights, a simulation experiment was conducted on the phenomenon using silicon oil/water and the phenomenon was analysed using computerised simulation software (Ansys Fluent). Experimental modelling demonstrated that interfacial movement occurs even at low rotation velocity, as low as 200 rev/min, when the viscosity of silicone oil is at 100 cP. Computational analysis utilising the Volume of Fluid (VOF) method and a realisable k-ε turbulence model elucidated that interface elevation during rotor rotation arises due to viscosity disparities between the two fluids. Furthermore, this movement is more pronounced when the viscosity difference is lower. Additionally, the study findings suggest that higher density differences between two liquids suppress the phenomenon of interface movement.

Jun 19, 2024

By Brinkmann J. R

The relative effects of the two basic mechanisms contributing to rock breakage during blasting, shock and gas penetration, are neither well understood nor well characterized, and need further clarification. Blasthole liner (BHL) tests separate the two effects, and by enabling direct measurement of borehole expansion give insight into the shock/gas energy partitioning in rock confinement. The hydrodynamic code DYNA2D is used to simulate the shock effect of the detonation of emulsion in a stainless steel lined hole, and the predicted expansion is compared with experiment. Workers in the past have neglected near-blasthole phenomena and have calibrated models based on stress measurements remote from the blasthole. Extrapolation back to the blasthole has inherent limitations, and indeed, one of the deficiencies of these models is that they have not been able to predict correct borehole expansions, as observed in BHL experiments. DYNA2D has been enhanced by the ICI group with a detonation model which resolves the explosive reaction zone. As a preliminary step towards the ultimate goal of devising a practical damage model, simulations are used to predict the maximum expansion that would take place if the rock were to remain undamaged. Various material parameters are investigated and it is shown that calculated liner expansions are appreciably lower than measured values for high rock yield strengths, while greater than values for low yield strengths.

Jan 1, 1990

The need to solve the problems associated with spontaneous combustion, system of ventil- ation and methane drainage in gassy coal mines has brought about the development of mining and degassing methods which has made possible up to 80% gas recovery in retreating longwalls. Beneficial results also were obtained mostly in the double or multiple-entry systems, but for single-entry systems and for a seam thickness exceeding 3 m, gas recovery rate is still very low. With some single-heading systems, such as those where a return roadway is not maintained in the goaf behind the face line, a new methane drainage technology is practiced. Attempts were made to extract methane from roof holes drilled from offsets in the ribside of the longwall block. The inclinations and lengths of the boreholes were planned and designed on the basis of the geological and mining condit- ions encountered at the time and every second hole was terminated precisely at the point where the previous hole intersected the immed- iate roof goaf area above the face. There are mathematical relations approp- riate to the design of the above drainage systems to give optimum methane recovery under the given conditions. Some examples of drainage have reached 87% recovery and have attained 94% CH4 purity.

Jan 1, 1982

By M Zoorabadi

Overcoring is a common technique to measure in situ rock stress using the concept of stress relief. The strains measured during overcoring are used to calculate the stress tensor assuming continuous, homogeneous, isotropic and linear elastic behaviour. This approach does not recognise any effect of the thickness of the rock annulus produced during overcoring instead assuming that the stresses are entirely a function of the difference in strain between the start of the overcoring and the end with no regard to the transient strains produced. Three-dimensional numerical modelling was used to simulate the overcoring process and investigate the impact of core diameter on the transient stresses and strains during overcoring. This study showed that in thicker core, maximum transient axial stresses and strains occur when the drill bit approaches the measuring point and greater tensile axial stresses were produced when the annulus was thinner. CITATION:Zoorabadi, M, 2018. Numerical study of annulus thickness on overcoring stress measurements, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 274–278 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By R Jia, J T. Waldram

"The Caijiaying lead zinc mine is located in China, north-west of Beijing, in Hebei Province. The region experiences severe winters, below -35°C, and warm summers, up to 30°C. The mine and concentrator commenced operations in the second half of 2005 with a conventional tailings disposal system consisting of a tailings dam with peripheral ring main discharge and central water recovery. A second similar dam sharing one common wall was added later. In view of the extreme winter conditions tailings lines and ring mains plus spigots, together with return water lines, require insulation and electrical trace heating. The volume of process water trapped as ice in the tailings dam ponds each winter is significant. This seasonal variation presents a major difficulty in the management of process water availability. Although Caijiaying is an underground mine there was no backfill plant at the start of operations. As plant throughput increased more quickly than originally anticipated, tailings storage capacity became a prime concern. The construction of a backfill plant in 2007 reduced the pressure on surface tailings storage area requirements, but as suitable land on which to construct further tailings storage was both expensive and difficult to acquire, a more efficient use of the available area was required. Dry tailings storage, where flotation tailings are filtered to provide an immediate return of process water plus ‘dry’ tailings filter cake for stacking, provided an answer to both the land area required, and the water management difficulties. The paper details the reasoning behind the change and the benefits obtained at Caijiaying by moving from ‘wet’ tailings storage to ‘dry’ tailings storage.Citation:Waldram, J T and Jia, R, 2016. Caijiaying Dry Tailings Storage, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 379–382 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016