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By J. Danoczi

Specially designed X-ray machines are used extensively on diamond mines for the recovery of diamonds from ores. These machines are extremely expensive and, at present, there are no reliable methods of determining if the equipment is performing efficiently. The objective of this work was to manufacture translucent X-ray diamond simulants, which would emit varying but known luminescence signals when exposed to X-rays. These X-ray diamond simulants could then be used to determine the efficiency of diamond recovery operations.

Jan 1, 2008

By K. Ford, R. Urquhart, D. Hobbs

CIS countries are home to some of the world's largest producers of chrome, manganese and silicon ferro alloys and leading suppliers to world export markets. The region's ferro alloys production is rising faster than demand from its domestic steel industry - unit alloy consumption in domestic steelmaking is in fact falling as process efficiencies improve - and there is significant spare capacity available to increase production. CIS producers enjoy certain strategic advantages in the production of ferro alloys - for example, captive ore sup-plies, low power and labour costs - but must also meet certain challenges - such as lower labour productivity and greater distance to market than some of their competitors. CIS producers are ambitious but new investment is needed to upgrade some aging plants and overhaul outdated process technologies if they are to be more competitive with the world's leading producers and address the environmental issues that are now moving up the agenda. This paper describes the structure of the region's ferro alloys industry and discusses its advantages and disadvantages by alloy and by country. It considers how the ongoing process of restructuring and new investment in the industry might move forwards, based on its strengths and weaknesses, technical and environmental factors and the strategies of the main players. It asks how the industry might maximise its substantial potential - in particular, for the production of chrome and manganese ferro alloys - and examines the implications this holds for all global ferro alloys players.

Jan 1, 2007

By T. Nishi, D. Teguri, K. Saitoh

In recent years the requirement for high carbon ferro-manganese (HCFeMn), which is the key product of our company, has increased due to bullish demand for steel products. In our Tokushima works, we have 2 closed types of electric furnaces (1F and 2F), with which we are manufacturing HCFeMn. In order to meet the increase in demand, we made various modifications to these furnaces and we tried to increase the furnace operating loads. Especially for 1F, we deepened the furnace. In this paper, we report the results of this modification. The operational situations of the above-mentioned two furnaces are different because they have different individual profiles. As for 1F prior to modification, the depth of the furnace was one meter shallower than2F, because 1F was designed for the manufacturing of SiMn. On the other hand, our Tokushima works specialized in HCFeMn 14 years ago. However, the profile of 1F was not optimized for HCFeMn. In comparison to 2F, 1F was more difficult to stabilize due to the smaller tolerance for the adjustment of the electrode length, the metal / slag level, and the coke-mixing ratio. We deepened 1F by 770mm by disposing of the furnace rolling mechanism. We consequently achieved a 10% increase in production capacity. This meant the operating load was enhanced from 24.5MW to 27MW, the furnace became more stable and the tapping speed of both metal and slag increased, all which made the tapping easier than before.

Jan 1, 2007

By G. I. McPhail

The authors have conducted several investigations into the prediction of the beach profile of high-density tailings and have found that there are a number of important considerations that need to be taken into account over and above the reliability of the beach profile prediction methodology. These considerations relate to the chemistry of the slurry and specifically the influence of pH and flocculation, both of which have a significant influence on the rheology of the slurry at the discharge point. A number of examples are discussed and a potential testing protocol that will assist in assessing the influence of chemistry ahead of the beach profile predictions is presented. A methodology for assimilating the results of the testing into the likely field situation is discussed, and suggestions are made on application of the results in beach profile prediction. The suspected influence of residual flocculation on the stratification

Jan 1, 2012

Mineral Resource Throughput Management is based on the extraction of the maximum potential value from an ore reserve with the emphasis to generate maximum ROI and ROR (return on reserve). A steel producing company in India implemented MRTM to significantly improve their ROI and ROR. The value chain of this company consists of their own iron ore and coal mines, ore washing plants, sinter plants, steel plants, and sales and marketing division. The target for the mines was to produce at a stable and predictable rate and at specific quality requirements. These requirements were set to improve productivity and ROI of the steel plant. The implementation constituted the alignment of the reserve potential, total production chain, human resources and management culture at the mines with the requirements of the steel plant. Many typical mining practices were challenged and changed. Production targets regarding lump vs. fines ratio, consistent product tons, quality targets such as Fe, Al content and moist, and standard deviation on the quality targets were not achieved. A reverse distribution model with release mechanisms to satisfy the demand were developed and implemented at the mines. A stable and predictable flow of mine product with quality standards well within the required standard deviation targets were achieved. The contribution from the mines to significantly improve the Net Profit, ROI and ROR of the company were reached.

Jan 1, 2007

By R. Flatabø, K-E. Johansen, L. Hunsbedt, P. M. Cowx, J. A. Bustnes

Eramet and Tinfos are two producers of manganese alloys in Norway, which have worked hard for several decades to improve both the internal and external environment. Furnaces producing ferro- and silico- manganese alloys generate large amounts of off-gas that contains substantial amounts of dust, heavy metals and organic by-products. The dust is separated from the gas in venturi scrubbers by washing with water. The water is cleaned and recirculated, and the surplus water coming from moisture in the raw materials, is discharged to the adjacent fjords after further treatment. Emission figures show that the discharge of suspended solids, manganese, zinc and PAH (polycyclic aromatic hydrocarbons) have been reduced substantially over the last three decades as a result of process improvements and installation of state of the art environmental control measures. The two plants were the first world wide to install mercury cleaning of the off-gases from the furnaces. Mercury emission reduction has exceeded 90%. Concerning other environmental issues, such as utilisation of off-gases for energy recovery and chemical purposes, both plants have achieved good results. Major effort in the environmental work has come from the plants themselves, but other players like FFF, The Norwegian Ferroalloy Producers Research Association, and SFT, The Norwegian Pollution Control Authority, have contributed to the achieved results.

Jan 1, 2007

By H. Jang, Y. Kawamura

Unplanned dilution and ore loss directly influence not only the productivity of underground stopes, but also the profitability of the entire mining process. Stope dilution is a result of complex interactions between a number of factors, and cannot be predicted prior to mining. In this study, unplanned dilution and ore loss prediction models were established using multiple linear and nonlinear regression analysis (MLRA and MNRA), as well as an artificial neural network (ANN) method based on 1067 datasets with ten causative factors from three underground longhole stoping mines in Western Australia. Models were established for individual mines, as well as a general model that includes all of the mine data-sets. The correlation coefficient (R) was used to evaluate the methods, and the values for MLRA, MNRA, and ANN compared with the general model were 0.419, 0.438, and 0.719, respectively. Considering that the current unplanned dilution and ore loss prediction for the mines investigated yielded an R of 0.088, the ANN model results are noteworthy. The proposed ANN model can be used directly as a practical tool to predict unplanned dilution and ore loss in mines, which will not only enhance productivity, but will also be beneficial for stope planning and design.

Jan 1, 2015

By T. G. Carter

Support system design for tunnels and underground excavations has for many years relied heavily on the use of rock mass classification systems and the Hoek-Brown failure criterion as a means for characterizing rock mass behaviour. Because of their development, both the GSI system and the Hoek-Brown criterion admirably characterize most ?normal? rockmasses from the viewpoint of their behaviour for rock excavations. They, however, run into difficulties when applied at the two ends of the rock competence scale. This is largely because block size and incipient strength are such that rockmass behaviour in these domains tends not to be controlled by interblock shear strength but rather by material strength. At the low end of the rock competence scale (UCSi <<15 MPa and GSI generally <30) discontinuities play less of a role and rock mass strength tends to matrix strength. Similarly, at the high end of the scale (GSI >>65, mi>>15), because discontinuities are now widely spaced, block size becomes so significant that again, intact material behaviour rather than the fracturing becomes the dominant factor controlling rock mass strength. In this paper several case examples are presented to illustrate the application of the high-end (spalling) and low-end (weak ground) transition Hoek-Brown relationships proposed by Carter, Diederichs and Carvalho (2007) as a basis for better defining rockmass behaviour at the extreme ends of the rock competence scale.

Jan 1, 2008

By K. P. Davey

In 1998 an initial objective was given to the author, to process valuable off grade High Carbon Ferro Manganese (FeMn) metal fines profitably. The previous attempts that had been made to re-melt these metal fines through the furnaces had resulted in poor furnace operation, mainly to do with lack of electrode penetration and furnace bed permeability. It was decided that the method to resolve these problems was to agglomerate the metal fines. During the study on the agglomeration of the metal fines, a decision was made to use furnace baghouse dust and stockpiled furnace baghouse dust and sludge (DSF) as a ?filler? in the metal fines. The primary reason for using baghouse dust was to eliminate an environmental hazard, whereas the secondary reason for using the DSF was to utilize manganese units contained in the dust. The off-grade metal fines and dust were compacted using a brick press, with cement and aluminum rich plastic clay as a binder, to obtain agglomerate that was cost effective. Through the re-melting of the agglomerated off-grade metal fines, it was realized that this agglomerate concept could have other uses, that of replacing ores on the furnace, at a lower cost. The agglomerate recipe was changed to create an agglomerate that had a high manganese to iron ratio, this replaced Comilog ore on the furnaces, thereby reducing overall furnace unit costs. Future work concerning agglomeration, is to reduce furnace costs further through agglomerating .0.5mm ultra ore fines and .0.3mm Gloria and Nchwaning sludge. Using this agglomerate replaces a portion of the Gloria and Nchwaning lumpy ore on the furnaces at a lower cost. This would eliminate problematic material that exists at the ASSMANG Manganese mines.

Jan 1, 2004

By G. O. Rading, B. O. Odera, M. J. Papo, R. Couperthwaite

"Platinum-based alloys are being developed with microstructures similar to nickel-based superalloys for potential high-temperature applications in aggressive environments. Since the chemistries of nickel and platinum are similar, Pt-based alloys can be made with gamma prime ~Pt3Al precipitates in a gamma (Pt) matrix. Currently, the Pt-Al-Cr-Ru system is one of the bases for developing Pt-based alloys, where Al allows the formation of thePt3Al precipitate and also gives protection from the alumina scale formed, Cr provides oxidation resistance and stabilization for the L12~Pt3Al phase, and Ru provides solid solution strengthening in the (Pt) matrix. Four Pt-Al-Cr-Ru-V and two Pt-Al-Cr-Ru-V-Nb alloys were made, with compositions based on a quaternary alloy, ~Pt82:Al12:Cr4:Ru2, which hadpreviously been identified as having optimum properties. Four of the as-cast alloys had the targeted two-phase structure of ~Pt3Al and (Pt), and two were single-phase ~Pt3Al. Vanadium partitioned more to (Pt) than to~Pt3Al. There was an improvement in hardness compared to the quaternary alloys. The best addition of V was ~15 at.%; higher additions resulted in brittle intermetallic phases of the Pt-V system. The effect of Nbcould not be ascertained because of its high losses."

Jan 1, 2015

By J. N. Van der Merwe

In the process of pillar extraction, pillars are seldom if ever extracted completely. The pillar remnants, or snooks, play an important role in the extraction process. At the working face, they need to be stable to provide a measure of support in the immediate area. Further back, they have to fail in a controlled manner to prevent undue load build-up on the pillars that have not yet been extracted. The stability condition at the working area is the result of interaction between the stability of the pillar and that of the roof rock. It is shown that the primary mode of roof layer failure is by bending induced tension. Direct tension can be excluded in most practical conditions, and only in exceptional cases will the first failure be in shear mode. Panel spans required to cause the first goaf to be formed, predicted using analytical considerations, are of the same order as has been observed in practice. Once the first goaf has formed, the horizontal stress is reduced and failure will occur at more frequent intervals. It is shown that bending induced tension is the most likely mode of failure in an unjointed roof layer. In roof layers with a high frequency of weak or uncemented jointing, failure can be expected to occur at spans equal to the joint spacing. In this context, failure will occur at the smallest of the spans required to induce tensile roof failure and the joint spacing. A fundamental procedure to evaluate the likely roof layer failure in a stacked beam system is developed. This can to be used to estimate the loading condition on snooks. It is shown that snooks assist in stabilizing the immediate roof beam. The sizes and positions of the snooks relative to the position of the next pillar to be stooped, control the magnitude of the contribution to stability. The further the snook is from the next pillar, and the larger it is, the greater the contribution to the stability of the immediate roof. Under the condition of loading by the immediate, continuous roof beam, the position and size of a single snook controls the load acting on it. The closer it is to the nearest solid, provided that the roof overhang extends beyond the snook, the greater the load on it. However, once the immediate roof beam fails, the loading conditions change. The snook is then loaded by the tributary area load. A procedure is developed to assess the condition of snooks for different situations. Using the fundamental considerations developed in this paper, snooks can be designed to be stable during the active mining phase in their immediate vicinity, but to fail once the next line of pillars has been extracted.

Jan 1, 2005

By M. Tanaka, K. Aoki, T. Mori, H. Morioka, K. Iwano, T. Kanagawa

To estimate the detailed characteristics of the rock around the cavern during excavation, new monitoring technique for dynamic properties of the rock has been applied. In this paper, micro-seismic monitoring and AE monitoring technique are applied to the excavation of large underground rock cavern and the result was discussed to clarify the acutal behavior of EDZ around the cavern. Zur Einschätzung der Gesteinseigenschaften um die Ausschachtung herum haben die Autoren eine Technik eingesetzt, mit der die physikalischen und dynamischen Änderungen im Gestein um den Schacht während der Ausschachtung beobachtet werden. In der vorliegenden Studie wurde zur mikroseismischen Überwachung ein AE Überwachungsverfahren eingesetzt und die Autoren berichten über die Veränderungen in den Gesteinseigenschaften um die Ausschachtung herum. Dans le but d&apos;évaluer en détail les propriétés des roches qui forment les parois des cavernes creusées, les auteurs ont utilisé une technique de mesure permettant d’observer les modifications physico-dynamiques des roches aux alentours de la caverne pendant son excavation. Dans le cadre de cet article, une technique de surveillance de l’agitation et du bruit microséismiques a été mise en œuvre et les auteurs font état de la modification des propriétés de la roche environnante.

Jan 1, 2003

By R. Katzenbach, M. Vogler, U. Adamietz

Abstract The design of deep excavation pits in rock mass is dependent as well on the mechanical properties of the rock mass as for example the orientation and the type of discontinuities like bedding planes, joints and fissures, the length of the discontinuities (persistence), the grade of weathering, the strength of rock mass, and the shear strength in the discontinuities, etc., and also on the respective boundary conditions specific for the project, and here especially the geometrical boundary conditions. The basic mutual influences and interactions between these boundary conditions are explained and exemplary presented at an excavation pit with a depth of 18,5 m, situated at a slope with a surface near groundwater table. Résumé La planification des excavations profondes dépend aussi bien de la qualité mécanique du roc, par exemple la location de la texture de la surface de moindre résistance, le degré de rupture, le degré de décomposition, la dureté du roc et la résistance limitée au cisaillement de la texture de la surface de moindre résistance que des conditions limitées spécifiques pour le projet, ici en particulier des conditions limitées géométriques. Les influences et interactions essentielles et mutuelles entre les conditions limitées isolées seront expliquées et présentées à l’aide d’une excavation 18,5 m de profondeur, située sur une pente où le niveau des eaux souterraines est près de la surface. Kurzfassung Die Planung tiefer Baugruben im Fels hängt sowohl von den mechanischen Eigenschaften des Fels wie z.B. der räumlichen Lage des Trennflächengefüges, dem Durchtrennungsgrad, dem Verwitterungsgrad, der Gesteinsfestigkeit sowie der Scherfestigkeit des Trennflächengefüges als auch von den projektspezifischen Randbedingungen hier insbesondere von den geometrischen Randbedingungen ab. Die wesentlichen gegenseitigen Einflüsse und Interaktionen zwischen den einzelnen Randbedingungen werden aufgezeigt und an einer 18,5 m tiefen Baugrube in Hanglage mit oberflächennahem Grundwasser vorgestellt.

Jan 1, 2003

By J. van der Merwe, D. Tharandt

The corrosion behaviour of 304L stainless steel laser-cladded with various amounts of ruthenium (Ru) was evaluated in solutions of sulphuric acid and sulphuric acid plus sodium chloride at 25°C and 45°C by open-circuit potential and cyclic potentiodynamic polarization tests. In general, the addition of Ru to the stainless steel increased its corrosion resistance in 1 M H2SO4, as well as in 1 M H2SO4 plus 1 wt% NaCl. This was observed for a number of parameters such as corrosion rate, corrosion potential, open-circuit potential, and current density. However, increasing the amount of Ru added beyond a certain level did not result in further improvement in corrosion protection. For each environment there is an optimal Ru concentration for the best corrosion protection. For example, in 1 M H2SO4 at 25°C, 2.44 wt% Ru shows the least active surface in terms of corrosion. Further research into ruthenium coatings on stainless steels is recommended.

Jan 1, 2015

By L. J. Leach

Quench and tempered Cr-Mo plate steel was found not to contain a fully martensitic structure as a result of either slow slack quenching or insufficient hardenability at the cooling rates used. The resulting microstructure contains bainite in combination with martensite. It is necessary to examine the implications of bainite for the toughness of the final product. Loss of toughness arises primarily from the inter-lath carbides that typically form in upper bainite. An investigation into the effect of upper bainite in a martensitic matrix of a steel grade containing 0.17% C, 0.1% Cr, 0.54% Mo, and 20 ppm Bindicated lower toughness than in a fully martensitic structure.

Jan 1, 2013

By T. Lindstad, S. Gaal, S. Hansen, S. Prytz

The SINTEF SiO-reactivity test, developed by Tuset and Raaness in the 1970?s, is a recognised method of characterising the ?reactivity? of carbonaceous reactants, used in the ferrosilicon and silicon metal industries. Recently, the test has been updated, which has resulted in the development of an extended and improved SINTEF SiO reactivity test. This has included updating the test reactor, control system, data-logging, handling and preparation of carbonaceous materials to be tested and measurement procedure. The scientific basis has been re-assessed, resulting in a new interpretation of the test results. The repeatability of the test has improved significantly, especially through system automation. In the ?old? test, the kinetics of the reaction: SiO(g) + 2C(s) = SiC(s) + CO(g) for a specific carbonaceous material was characterised solely by the ?R10? parameter, the volume of SiO(g) which passes un-reacted through the coke-bed as the concentration of CO in the outlet gas decreases from 18 to 10%. As both the kinetics and obtainable conversion of SiO to SiC for a reductant is of importance to the ferroalloy producer, the new SINTEF SiO reactivity test ranks carbon materials both according to degree of conversion and reaction rate. From research carried out on the test in the past couple of years at SINTEF and NTNU, it has also become clear that some of the reactions taking place in the test reactor are more complex than previously assumed. As an example, it was previously assumed that the condensation reaction of SiO gas in the condensation chamber of the test reactor can be described as: 2 SiO(g) = Si(l,s) + SiO2(s). However, it has been established that the side-reaction: CO(g) + 2Si(l) = SiC(s) + SiO(g) causes approximately 10% of the total volume of CO to react to SiC and SiO2 in the condensation chamber. This means that some back-reaction i.e., the reverse SiO-generator reaction 3SiO(g) + CO(g) = 2SiO2 + SiC also takes place in the condensation chamber. In the new SINTEF test, the %CO versus time curves are therefore corrected in order to describe the effect of the reaction between SiO(g) and C(s) studied i.e., SiO(g) + 2C(s) = SiC(s) + CO(g). A correction-formula for this purpose is presented.

Jan 1, 2007

Current mine production planning, scheduling, and allocation of resources are based on mathematical programming models. In practice, the optimized solution cannot be attained without examining all possible combinations and permutations of the extraction sequence. Operations research methods have limited applications in large-scale surface mining operations because the number of variables becomes too large. The primary objective of this study is to develop and implement a hybrid simulation framework for the open pit scheduling problem. The paper investigates the dynamics of open pit geometry and the subsequent material movement as a continuous system described by time-dependent differential equations. The continuous open pit simulator (COPS) implemented in MATLAB, based on modified elliptical frustum is used to model the evolution of open pit geometry in time and space. Discrete open pit simulator (DOPS) mimics the periodic expansion of the open pit layouts. Function approximation of the discrete simulated push-backs provides the means to convert the set of partial differential equations (PDEs), capturing the dynamics of open pit layouts, to a system of ordinary differential equations (ODEs). Numerical integration with the Runge-Kutta scheme yields the trajectory of the pit geometry over time with the respective volume of materials and the net present value (NPV) of the mining operation. A case study of an iron ore mine with 114 000 blocks was carried out to verify and validate the model. The optimized pit limit was designed using Lerchs-Grossman?s algorithm. The best-case annual schedule, generated by the shells node in Whittle Four-X yielded an NPV of $449 million over a 21-year mine life at a discount rate of 10% per annum. DOPS best scenario out of 2 500 simulation iterations resulted in an NPV of $443 million and COPS yielded an NPV of $440 million over the same time span. The hybrid simulation model is the basis for future research using reinforcement learning based on goal-directed intelligent agents.

Jan 1, 2008

By A. H. Swart

Unplanned stope panel collapses occur on most near-surface and shallow mines in South Africa. Although these incidents often occur during blasting, they pose a major threat to the safety of underground workers and the economic extraction of orebodies. Most stope panel collapses occur due to excessive panel lengths (resulting in excessive stope spans) that are not designed according to a systematic design procedure or methodology. Instead, panel lengths are often dictated by the equipment in use and by previous experience under similar conditions. Hence, a rock engineering design methodology for the design of stable stope panels between pillars is of vital importance for optimum safety and production in shallow mining operations. Using the proposed design methodology described in this paper, rock mechanics practitioners and mine planners should be able to identify and quantify the critical factors influencing the stability of stope panels. The critical factors should then be used as input to the design of stable stope panels that will provide the necessary safe environment for underground personnel working in stopes. The proposed design methodology is an iterative process, which includes aspects such as rock mass characterization, estimation of rock mass properties, identification of potential failure modes, consideration of appropriate stability analyses and other elements of the rock engineering design process. This process continues after implementation. During monitoring, new data should be included in the database and the design process repeated on a regular basis. Design approaches included in the proposed design methodology include empirical methods such as different rock mass classification methods, analytical methods such as elastic and Voussoir beam analyses, kinematic analyses, probabilistic analyses, and numerical analyses. Keywords: stability, stope panels, design methodology, hardrock mines, shallow mining operations

Jan 1, 2005

By S. Lin

A new hydrogen production process, named the HyPr-RING, has been proposed. Fundamental concept of the HyPr-RING is integration of water carbon reaction, water-gas shift reaction and CO2 absorbing reaction in a single reactor. Firstly, thermodynamic analysis was done to judge the possibility to realize the process. It was found that high pressure and temperature condition, such as 20 MPa and 1000 K, is required to promote this integrated reaction. Next, experimental verification of the new process was done under the high pressure and temperature reaction conditions. As the results, integration of above three reactions in a single reactor can be done successfully and produced a large amount of hydrogen as estimated by thermodynamic analysis. Experiments showed that organic materials including coal, heavy oil, biomass, plastics can be used in this process. In the gaseous phase, no pollutants such asH2S, SO2, COS are detected so that gas cleanup system is not required for power generation when this process is used. Finally, a process design was made to estimate process efficiency. Theoretically, 1 mole of carbon can generate 2 moles of hydrogen and cold gas efficiency of this process estimated as more than 80 per cent. The process potentially reduces hydrogen production cost compared with the conventional hydrogen production methods. Keywords: Hydrogen, Fossil fuel, Energy, Process, Supercritical water

Jan 1, 2001

By K. Kasas, J Kermeci, S. Vujic, S. Secei, P. Kermeci

On the ‘Majdan III’ open pit mine, supplying with brick clays the production plants of the industry of building material ‘Potisje-Kanjiza’ from Kanjiza, a modern ECS (excavator-conveyor-spreader) complex was built, integrating four bucket excavators, six conveyors and one spreader into a whole. This complex connects the mineral-exploitation unit with the final brick-products plant of the company. Monitoring and management of the ECS complex is carried out by modern computer-supported information-management system (IMS) implementing most modern measuring-regulation, computer and GPS equipment. It was concluded that, for safety reasons, the functions of the IMS should be developed by a component of active visual monitoring of the ECS complex. For this purpose, the task of making a project on intelligent system for visual monitoring of the ECS complex was entrusted to the Department of Computer Application at the Faculty of Mining and Geology, University of Belgrade. This paper gives a review of basic project solutions. Keywords: Automation, process management, information management technology, visual system, intelligent systems, TV monitoring, surface exploitation, clay, Majdan III, Potisje-Kanjiza.

Jan 1, 2003