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There is an increasing demand for refrigeration as mines progress deeper. Mine refrigeration plants have special requirements in terms of their duty and application. There are no national or international standards applicable for the testing of these plants. There have been numerous examples of plants failing to meet their required nominal capacity, but with the plant owner being unable to enforce the design duty on the manufacturer, due to a failure to unambiguously specify testing or accepting criteria. This paper discusses some of the reasons for performance shortcomings and describes a methodology for developing and specifying performance criteria, when inviting design and/or construction tenders, and a method of performance and acceptance testing once the plant has been built and commissioned. These guidelines encompass the full range of performance duties expected from a mine plant, including stable operation at maximum and minimum plant capacity, and under the various combinations of extremes of high and low condensing and evaporating pressures. A description of a methodology for developing a computer-based mine refrigeration plant model is also presented as part of the performance testing criteria. The methodology is illustrated with reference to the actual performance and acceptance testing process used on the worldÆs largest bulk air cooler (R67) at the Enterprise mine at Mount Isa, Australia.

Jan 1, 2005

By D A. Williams, P J. Chapman

The acceptable rate of rise of the tailings beaches on upstream-raised tailings storage facilities (TSFs) is critical to life of mine planning. This is illustrated through a case study in Western Australia presented in this paper. Accurate estimates of expected beach slopes, the maximum rate of rise at which the tailings can be placed, and the dry density that the tailings solids will achieve after deposition (stored density) are required in order to design TSFs that will allow upstream raises to be constructed safely and economically. Where operations have been occurring for some time, these three parameters are able to be measured and can be well-defined. If process plant throughputs are proposed to increase through mine expansion, for example, increasing the rate of rise of the tailings can compromise the potential for upstream TSF raising, thus influencing the viability of such an expansion, the timing for its implementation, and significantly increase costs.This paper outlines how rate of rise can be a key constraint, and that ‘rules of thumb’ that are typically applied may not result in the outcomes they were meant to achieve. An example of an experimental method to justify an increase to the ‘rule of thumb’ ~2.5 m/year limit for gold tailings in a semi-arid climatic setting is discussed, followed by rate of rise modelling that ultimately framed the decision-making process for a mine expansion. The rate of rise modelling method was adopted to carefully distribute tailings deposition across four TSFs, comprising nine separate tailings cells, in order to maintain appropriate rates of rise. The implications resulting from various deposition splits are presented, including the need for expansion. In addition, this paper outlines the effect of rate of rise on the state (density) of the tailings after deposition, and provides commentary on how anecdotally acceptable rates of rise, based on the aforementioned ‘rule of thumb’ of 2.5 m/year may not provide assurance of geotechnical stability through the tailings achieving a dilative state, as has been thought in the past. An example of the influence of rate of rise on the state of the tailings, with respect to air-drying and the critical state line (CSL) for the material, is presented. The data indicate that reducing the rate of rise may allow a higher dry density to be achieved through air-drying (evaporative desiccation), sufficient to move the material from the contractive to the dilative zone (i.e. from above the CSL, to sufficiently below it).CITATION:Chapman, P J and Williams, D A, 2018. The importance of rate of rise in life-of-mine planning of an upstream raised tailings storage facility – a case study, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 350–360 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By L Chaffey, M Buckland

The minerals industry has enormous potential to positively contribute to sustainable development and many leading companies have concluded that their long-term success is directly linked to their ability to leave a lasting positive legacy. While there are many examples of success, there have been failures as well and much work has been done in recent years to define the role of the minerals industry in sustainable development and identify the key elements for success. In the past, our sector could point to the taxes and royalties it paid, the exports it generated and employment it created and felt confident that its contribution would be recognised and duly acknowledged. This is no longer the case. Critics of the industry have highlighted resource-rich countries that have failed to capitalise on their resource wealth and have arguably lower standards of living than their resource-poor peers û the æresource curseÆ hypothesis. Recent research has done much to clarify the factors that contribute to a countryÆs success or failure and all stakeholders in the industry now need to include these learnings in their approaches going forward. We know that our long-term success relies on embedding a company- wide approach to sustainable development into all aspects of our business operations. In this paper we highlight BHP BillitonÆs experience in the development and implementation of policies and systems designed to enhance our contribution to sustainable development. We detail the business drivers for excellence in this area and the key external codes and initiatives that have shaped our approach. The values-based BHP Billiton Charter, Sustainable Development Policy and associated Health, Safety, Environment and Community (HSEC) Management Standards are central to our approach. Implementation is reviewed through our HSEC audit program. One area in which we have placed particular emphasis is our approach to community development. BHP Billiton has a corporate target to contribute one per cent of its pre-tax profit on a three year rolling average to voluntary community programs. As our profit stream has increased with the minerals boom this is approaching an A$100 million commitment. In our paper we detail how we are working to ensure we maximise the value of this contribution for our communities and our shareholders.

Jan 1, 2006

By J Bean

Iluka Resources Ltd developed the Jacinth-Ambrosia Mine (Jacinth) in the Eucla Basin during 2009 and 2010. In this arid climate the operation relies on hyper-saline groundwater from a palaeochannel for process and potable water supplies. The water is hyper-saline, acidic and mildly reducing, with high ferrous iron concentrations. Ferrolysis commences on exposure of water to oxygen, resulting in increased acidity and the conversion of dissolved ferrous iron to insoluble ferrihydrite. The unstable groundwater forces a careful balance between interventions relating to maintaining pipeline efficiency, corrosion protection and processing aspects. Providing an oxidising environment at the head of the pipeline will result in the precipitation of akaganenite and goethite in the pipeline, which over time reduces pipeline efficiency. However, sending too much ferrous iron forward may reduce processing performance.The processing plant experiences changes in water chemistry in response to the variability of iron concentrations and pH within the pipeline, and the spatial and chemical variability of ore. As the main orebody at Jacinth contains little buffering capacity a source of carbonate in the overburden is carefully used to allow the cost-effective control of process water pH.This paper highlights the importance of understanding the chemistry of saline make-up water, ore, and overburden when designing water treatment facilities and heavy mineral processing facilities.

Oct 5, 2011

By H Asche

The proposed Rockwater Power Project is a hydropower development on the Waitaki River in the South Island of New Zealand. The proposed development will have an installed capacity of 250 MW with a peak flow capacity of 260 m3/s. The project commences at Lake Waitaki and extends some 35 km downstream on the north bank to a surface power station at Stonewall. Flow is returned to the Waitaki River via an outfall channel.The tunnelling for the project is through Greywacke, which comprises Permian and Triassic age marine sediments that are well indurated and weakly metamorphosed. The rock mass is jointed and sheared and there are frequent faults, which range up to hundreds of metres in width. Three 12 m diameter tunnel boring machines (TBMs) are proposed to excavate the 35 km long tunnel.The paper describes the development of the tunnel alignment, rock mass classification, design of the support, rock and hydraulic loads, support installation options and construction sequencing.The alternatives of rock bolts and shotcrete and segmental lining were both investigated and are discussed. Support using rock bolts and shotcrete offers the potential of rapid construction with minimum support cost when the ground conditions are good, but delays due to support installation increases with deteriorating ground conditions. In contrast, segmentally lined tunnels offer greater certainty in cycle time with reduced program risk. Both options are described and discussed.The horizontal alignment is affected by the presence of major fault zones, which are either avoided, or pretreated by driving conventional tunnels through in advance of the TBM delivery, topographical constraints with the rugged topography and operational hydraulic constraints. Construction requirements, future power station operation and the minimisation of leakage from the tunnel have all impacted on the vertical alignment.The number and sequencing of TBMs to be used is discussed in terms of program time and risk minimisation.

Mar 8, 2011

By M G. Millad, M Zammit

The Kipoi Central (KPC) copper project is located in the Katanga Province in the Democratic Republic of the Congo and is presented here as an example of an operating mine where the Mineral Resource was initially estimated by uniform conditioning (UC) and subsequently updated to localised uniform conditioning (LUC). This paper discusses the implementation of an estimate run using LUC and compares the results based on resource definition drilling to those obtained by close spaced grade control drilling and actual mill production.UC is a nonlinear geostatistical technique designed for recoverable resource estimation, typically using wide spaced exploration and resource definition drilling. The primary output of UC is the grade, tonnage and metal above a series of user-defined cut-off grades for a particular selective mining unit (SMU) block size. The UC approach is considered to provide a more accurate representation of the recoverable grade and tonnage at SMU support for non-zero grade cut-offs than would typically be achieved by a traditional linear estimator such as Ordinary Kriging. LUC is a relatively new approach involving the post-processing of a UC estimate and is used to spatially present the grade distribution predicted by UC at the SMU scale.This study demonstrates that the calculation of a more accurate and realistic grade-tonnage relationship for small SMU sized blocks is possible at the exploration stage using LUC, provided that the necessary theoretical and practical conditions for implementation of this technique exist.CITATION:Millad, M G and Zammit, M, 2014. Implementation of localised uniform conditioning for recoverable resource estimation at the Kipoi Copper Project, Democratic Republic of the Congo, in Proceedings Ninth International Mining Geology Conference 2014 , pp 207–214 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By D Semini, B Newcombe

Base-metal sulfide refractory gold ores often contain a portion of ‘free’ gold that is amenable to recovery using gravity concentration methods, whilst the refractory portion of the gold is better recovered using flotation. The decision as to whether a plant treating a refractory gold ore should utilise gravity concentration or a flash flotation circuit (or a combination of both) within the grinding circuit is usually made at the design stage of flow sheet development. Very limited data is available in the published literature which provides an industrial scale comparison on which to base such a decision and conventional laboratory testing methods are often the only way of obtaining such data. The optimum processing route will also be mineralogy dependent.This paper presents the findings of operating a refractory gold plant with either flash flotation (normal operation) or a combination of flash and gravity recovery methods treating the cyclone underflow stream and will demonstrate the regions of the recovery profile that each contributes to. Size-by-assay analysis has been performed on a number of streams around the operating plant to gain an insight into the changes that occur when the gravity circuit is in operation in addition to the flash flotation circuit. A discussion around the implications to overall plant operation in combining the use of a batch process (gravity concentration) with a continuous process (flotation) is presented.CITATION:Newcombe, B and Semini, D, 2014. Interactions between flash flotation and gravity concentration – an industrial case study of a refractory gold concentrator, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 427–436 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

Teleseismic travel time residuals measured on 600-1000 km seismic arrays across the Rio Grande and East African rifts provide evidence for upper mantle low velocity zones beneath each rift of velocity contrast 6%-8%. Refraction studies show thinning of the crust below the rift axes. Regional uplift which extends hundreds of km either side of the axes, is isostatically compensated by negative density contrast at depth. Since the refraction argues against compensation by thickened crust, compensation in the upper mantle low velocity zones is suggested. Temperature effects alone can not explain the reduced velocities. Generation of a few percent of partial melt is the most probable source of the reduction. A passive extensional mechanism is investigated for the Rio Grande rift in which hot asthenosphere intrudes the lithosphere raising its temperature and generating moderate melting. It requires less than 1% extension to explain the melting but a prodigious 26% to raise the temperature from a pre-rifting continental geotherm to the solidus. Geological estimates find that extension is less than 10% over the uplift zone. Such a mechanism is possible only if the prerifting lower lithosphere geotherm lies closer to the solidus than that of stable continent. This is supported by the observed high heat flow in the Rio Grande rift uplift region which, given the long time constant for thermal diffusion, reflects elevated temperatures at depth well in advance of the onset of rifting.

Jan 1, 1987

This paper covers only the energy uses of natural resources and does not deal with non- energy uses, which in 1975 were of the order of 10 per cent of the total consumption of energy resources. The United Nations `J' Series of Statistics ex- presses each of the various forms of energy in terms of its coal equivalent in metric tonnes and this basis is followed in this paper. One tonne of black coal (referred to as tce) has been taken as the equivalent of the following. 29 X 109 joules or 27.5 X 106 Btu 0.68 tonnes or 4.8 barrels of crude oil 750 cubic metres or 26.5 X 103 cubic feet of natural gas 1 ò5 to 3.3 tonnes of peat or lignite (world average 2.54; Victorian brown coal 3 0) 8055 kWh (at 3.6 X 106 joules or 3412 Btu per kWh at 100% efficiency) 2660 kWh at 33% efficiency of generation 50 grams of uranium present in natural uranium reactors (see note later under nuclear energy) 0.8 grams natural uranium in breeder reactors Nuclear and hydro electricity are expressed as the coal equivalent required to produce, at 33 per cent efficiency, the same amount of electricity. In other words, electricity produced by these sources is converted to its coal equivalent at the rate of 2660 kWh = 1 tonne coal.

Jan 1, 1978

By R Williams, M Baxter, D Zink, R Cunningham

The purpose of this paper is to discuss the efficient operation of a tailings dewatering circuit comprising a thickener and filter press through proper control and automation. It is common to see thickeners and filter press circuits each with their own control systems. This can cause multiple issues when trying to increase efficiency and reliability of the tailings management process. By automating the thickener and filter press controls, you are eliminating any delays and inconsistencies caused by human error and process variations. When done properly the system can maintain a consistent product as the feed characteristics change. Previously, operators would have to monitor the process parameters and adjust the system accordingly. This can now be accomplished using state of the art process control equipment that continuously monitors and adjusts critical variables using Programmable Logic Controllers (PLC) and Proportional Integral Derivative (PID) loops. The paper will detail the control theory used to maintain these systems, highlight other benefits of having a fully integrated plant such as predictive maintenance and remote diagnostics as well as present examples of how these have been implemented in field examples.CITATION:Baxter, M, Cunningham, R, Williams, R and Zink, D, 2018. Tailings process optimisation through automation and controls integration, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 416–421 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By C J. Greet, S Jacques

In most instances, the application of high-chrome grinding media results in an increase in the recovery of the valuable mineral(s). The authors have published data from a number of plant-based case studies, which indicate that it is not unreasonable to expect a recovery increase in the vicinity of 1.5 to 2.0 per cent for a copper ore. It is of interest to understand where the increase in recovery is coming from. That is, is the additional copper recovery the result of improved fine particle flotation or is it due to an improvement across all size fractions?This paper aims to answer this question. Laboratory flotation tests were completed using forged steel and a high-chrome alloy on a volcanogenic massive sulfide copper ore. The unsized data indicated that the application of high-chrome grinding media to this ore resulted in an improvement in both copper recovery and copper concentrate grade. A detailed kinetic analysis of both the copper sulfide and gangue minerals was completed that clearly shows that the change to a more inert grinding media produced significant increases in the flotation rate constants (both fast and slow) across all size fractions. It is also possible to observe that the change in pulp chemistry has resulted in a decrease in the flotation kinetics of the -20 micron pyrite, while the coarse pyrite recoveries have increased, presumably because of an increase in the flotation of the chalcopyrite/pyrite composite particles.CITATION:Greet, C J, Jacques, S and Kinal, J, 2014. Recovery-by-size kinetic analysis to determine where metallurgical improvements occur when converting to high-chrome grinding media, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 217–224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By J H. Park, R R. Kim, H S. Park, H J. Kim

This study focuses on the recovery of valuable metals, specifically silver (Ag) and palladium (Pd), from copper-containing sludge (with copper content less than 20 per cent) generated during PCB processing and from spent petrochemical catalysts used in vapour decomposition during oil refining processes. The present results indicate that an increase in the mixing ratio of alumina-based spent catalyst leads to a decrease in the recovery rate of Ag and Pd. The recovery rates for Ag and Pd range from 84 per cent to 96 per cent and 80 per cent to 98 per cent, respectively. This trend is attributed to the increased emulsification of copper droplets containing Ag and Pd in the slag. The emulsification is caused by the decrease in the settling velocity of the copper droplets due to the increased viscosity of the slag as well as by the decrease in the slag-metal interfacial tension due to an increase in sulfur content at higher mixing ratio of spent catalyst.

Jun 19, 2024

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 <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

In May 2000, Kanowna Belle Gold Mines (KBGM) carried out a detailed Truck versus Shaft Haulage Study. The study showed that whilst the shaft option had many operating cost benefits the capital costs were too high, therefore the truck option was selected. In May 2001, the concept of achieving æshaft typeÆ benefits without the capital costs was floated. This is achieved by separating the hoisting of ore from other mining activities. The general concept is that material from underground is transported to a central location and then transported to the surface by a special truck fleet, thus removing the dependency between trucks and loaders, providing the mine with surge capacity and decreasing operating costs. At KBGM these advantages have been gained by installing an ore pass system with a plate feeder at its base that directly loads trucks. This provides the mine with a haulage system with enough surge capacity to remove the interdependency between trucks and loaders. The plate feeder is situated just off the decline which creates the opportunity to use larger more reliable, lower cost trucks. A number of truck types were considered for the truck loop including Elphinstone AD55Æs which are the truck type being used on site prior to the truck loop, CAT 775EÆs and power trailer road trains. This paper covers the philosophy behind the truck loop, the truck selection process, project installation and commissioning, people issues and the benefits expected by the operation. As of May 2002, the project is nearing completion, with decline haulage expected to commence in July 2002.

Jan 1, 2002

By M Sciortino, J Korczak, J Muinonen, A St-Jean

The Dumont deposit is a large (1179 Mt reserve), low-grade (0.27 per cent nickel) nickel sulfide project located in the Abitibi region 25 km west of Amos, Quebec. Royal Nickel Corporation (RNC) acquired the project in 2007 and has since taken the deposit through to feasibility. The disseminated nickel sulfide and alloy mineralisation is hosted within the serpentinised dunite subzone of the Dumont Sill; a differentiated, pervasively serpentinised, ultramafic sill of komatiitic affinity. Pentlandite ((Ni,Fe)9S8), heazlewoodite (Ni3S2) and awaruite (Ni2.5Fe) are the dominant nickel-bearing metallic phases and can be recovered by conventional methods (flotation, magnetic separation). Non-recoverable nickel is also present within serpentine and olivine of the silicate matrix.A detailed mineralogical program including 1420 QEMSCAN« samples and 4400 electron microprobe points was undertaken to increase the understanding of the nickel deportment in the various recoverable and non-recoverable phases in a spatial context across the deposit. A total of 105 metallurgical tests have been performed under a standard procedure which have linked the mineralogy to metallurgical performance. This has allowed the creation and modelling of geometallurgical domains on a block-by-block basis to understand the recovery variation and metallurgical performance throughout the deposit. Understanding the spatial variability of Ni deportment in recoverable and non-recoverable phases through mineralogy is the key to understanding metallurgical performance, thus unlocking the value of the Dumont deposit and other large tonnage low-grade ultramafic nickel deposits.CITATION:Sciortino, M, Muinonen, J, Korczak, J and St-Jean, A, 2013. Geometallurgical modelling of the Dumont Deposit, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 93-100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By Medhurst TP, Trueman R, Hutchinson IN

A breaker line support (BLS) monitoring system, BLSmon, has been designed and constructed by the CSIRO and installed and commissioned at Laleham No.] Colliery, Queensland. This system was designed to record hydraulic leg pressure and canopy position measurements and relay these, in real time, to the surface. The system has shown itself to be capable of operating on the BLSs without any adverse affect on production. Analysis of the results of the monitoring exercise has shown that rate of change of leg pressures on the BLSs could be used as an aid in the prediction of adverse mining conditions. Under favourable mining conditions the supports were observed to initially unload from the set pressure, this unloading reduced with time and by the end of a typical lift cycle had either ceased or reversed slightly. This behaviour was considered to be due to one of four possible causes, these being; the compaction of floor debris, and/or compaction of the floor, and/or crushing of the roof and /or support creep. The actual cause can only be determined through detailed monitoring of both roof and support convergence. However observational data would suggest that compaction of debris and softened floor material beneath the supports was the most likely cause. The few positive loading rates recorded under these conditions were of short duration and occurred towards the end of individual lifts. Where mining conditions were unfavourable the negative rates of change of pressure, unloading of the support, were reduced throughout a lift, in both duration and magnitude, when compared with favourable mining conditions. Over the same period the positive rates of change were observed to be greater. The rate of change of loading and convergence can be utilised to identify the onset of instability in the lift area. However, before this facility can be utilised by the mine for the reliable prediction of instability more monitored data and sophisticated processing techniques are required.

Jan 1, 1992

By G McCullough, J Els, J Bassan

Integrated Remote Operations Centres (IROCs) have a crucial role in optimising a mine’s carbon emissions, especially as industry faces an imperative to achieve net-zero emissions on an accelerated timeline. To meet this time pressure, operations must adopt a comprehensive approach to energy-related carbon management and history has proven that modern technologies cannot be simply bolted into existing operations. An IROC is the most dependable solution to enable a swift transition from strategy to operational tactics that support carbon optimisation. Achieving net-zero emissions requires addressing significant energy management challenges such as fleet electrification, integration of renewable energy sources and large-scale energy storage. These challenges demand a profound change in planning, managing and executing work at large operations. The key to overcoming these challenges is an integrated approach incorporating collaborative decision-making across the value chain and more sophisticated planning approaches. Additionally, closer integration with downstream processing offers opportunities for carbon optimisation across the value chain. This includes the ability to supply tailored products that meet more varied feed-requirements of customers transitioning to less carbon-intensive processes and developing collaborative decision-making across the entire steelmaking value chain (by incorporating steelmakers, transport, coal/natural-gas/hydrogen supply, energy supply and iron-ore supply). However, this requires significant improvement in collaborative maturity and integrated decision-making capability. Finally, the imperative to reduce carbon emission demands the introduction of a range of new technologies into existing operations. The new technologies will increase the operational complexity of the mines and IROCs will need to evolve capabilities to manage the increase complexity and support the effective operationalisation and integration of these new mining technologies. This paper outlines the new capabilities required and the role of IROCs in effective integration across the demand value chain. The focus is on building on the mining industries’ existing IROC experience and augmenting with processes, technologies and lessons from other industries.

Sep 18, 2023

By D Beck

Open access to forecasts of mine geotechnical performance in the form of open databases of model results has been considered risky in the past, with a concern that the results will not be understood or will be misused. However, some modelling techniques allow very high similitude modelling of mine deformation and the results can be presented as deformation, damage and other parameters which are unambiguous and which all engineers can be more easily trained to understand. With some effort, sufficient reliability and quantifications of error are possible to overcome many of the issues.Allowing more members of the planning team to have direct access to forecasts of mine deformation will promote awareness of geotechnical issues and will act as a mechanism for improving mine designs. The models will also be more easily integrated into quality assurance programs, by providing a framework for understanding measurement results.The sufficiency requirements for undertaking simulation aided mining engineering will be presented, included some conclusions about requirements for training, quality standards and software development.

Mar 21, 2011

By V Rodríguez, M Hormaza, R J. Romañach, C Pinzón-de la Rosa

The authors have presented their ideas for developing a powder sampling device in the I-Corps™ program sponsored by the National Science Foundation (NSF). This is an intensive customer discovery program developed to increase the economic impact of the research sponsored by NSF.The I-Corps™ program requires performing at least 100 interviews with potential customers in various industries. These interviews are essential to establish the need for a particular product or solution, and identify potential commercialisation partners and competition. The interviews have revealed the absence of Theory of Sampling (TOS) principles in many companies. The interviews are designed to identify the difficulties associated with current sampling practices that do not meet TOS principles.The I-Corps™ program is a significant challenge for scientists who often avoid discussing a concept in fear of losing their research idea. The program teaches how to obtain information without releasing the important intellectual property related to a product development idea. The I-Corps™ methods have been used to discover the prevailing ideas on sampling in various industries.I-Corps™ also teaches how to present ideas to investors; another significant challenge for a scientist. We are currently learning to present sampling and TOS to investors and business development experts, and will share some of these experiences.CITATION:Pinzón-de la Rosa, C, Rodríguez, V, Hormaza, M and Romañach, R J, 2017. Theory of Sampling meets the National Science Foundation I-Corps™ program, in Proceedings Eighth World Conference on Sampling and Blending , pp 351–354 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2017

By G Stovpchenko, G Jianjun, L Medovar

Electroslag remelting (ESR) today and into the future, will still be the main process for producing high-quality ingots by suppressing segregation, not just refining chemical composition from impurities. This paper analyses state-of-the-art electroslag refining with a focus on ESR with consumable electrodes, and recent technology with liquid metal supply (ESR LM) in view of their refining abilities and development trends, taking into consideration that the size of the ingots required by industry continues to grow, and the composition of new materials sophisticates to withstand increasingly higher mechanical and temperature loads . The yield of suitable metal in large ingots produced by conventional casting is low due to problems of element segregation by height and crosssection. For example, conventional ingots for nuclear powerplant rotors today reach nearly 700 t in weight. Attempts to directly replace such giant ingots with big-diameter ESR ingots weighing approximately 400 t were also unsuccessful because of growing segregation. Modern ESR equipment and technologies produce 200–250 t of ingots of satisfactory quality, reaching 2.5 m in diameter, implementing the change of consumable electrodes during remelting to increase ingot length. Another way to mitigate segregation is to enlarge the smaller diameter ESR ingot by a 500– 800 mm coaxial layer to the desirable diameter by ESR in the current-supplying mould (CSM). Modelling and experiments prove that refining from impurities and non-metallic inclusions at ESR most effectively occurs at the slag bath and liquid metal pool interface because the ESR LM has provided the same desulfurisation. ESR’s special refining capabilities in CSM come from the much longer time of LM residence shown at titanium purification from hard-melting nitride inclusions that are unremovable in vacuum arc remelting (VAR) and electron beam melting (EBM). Implementation of ESR technologies in CSM, especially with LM supply, is prospective to produce heavy enlarged and hollow forging ingots with prevented development of segregation due to dividing cross-section and reducing overheat of solidifying metal.

Jun 19, 2024