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By M Ranjan, C R. Borra, P Palai, P P. Sahoo

Change in mould slag composition during casting of medium alloy steel is caused by the redox reaction between molten steel and mould flux. Mould flux generally contains a certain amount of SiO2, but elements such as Al, Mn and Ti in high/medium alloy steels reduce SiO2 in the mould flux, causing remarkable changes in the composition of the mould slag. As a result, the properties of the mould slag change greatly as continuous casting proceeds. This causes casting instability, process abnormality and casting defects. Effect of Ti as an alloying element in steel on mould slag is studied extensively through high temperature laboratory measurements and plant measurements. TiO2 gets picked up by the mould slag up to 3 per cent during casting a steel grade containing 0.1 per cent Ti. This changes the mould slag composition and results in decreasing the slag viscosity by up to 10 per cent and decreases slag break temperature by 30–40°C.

Aug 21, 2024

By S Maritsa, E K. Chiw, S M. Masuka, ika, T Chisahwira

The challenges facing the iron and steel industry on a global scale include depletion of resources, excessive energy consumption and CO2 emissions. The demand for iron products in Zimbabwe is increasing due to massive infrastructural development like the expansion and improvement of mines, transportation systems and water reticulation systems. In Zimbabwe, cast iron is mainly produced from recycling scrap metals. However, there is currently a shortage of scrap, which has resulted in the vandalism of state-owned properties such as bus terminals and railway wagons and lines. Nevertheless, Zimbabwe is rich in limonite ores, which are idle, and it is the aim of this research that this ore be effectively used to produce feed for the blast furnace. The Blast furnace is still the dominant route for producing cast iron where sintering and coking processes are the main routes for preparing the Blast furnace feed. Sintering limonite ore fines produce a product of poor grade because of the high value of loss on ignition that has a negative impact on Blast furnace efficiency. Furthermore, the sinter plant and the coke making plant are a source of huge environmental pollutants. Since low-grade Zimbabwean coal fines are also available in abundance, they were used in the preparation of the composite materials ensuring maximum utilisation of this resource. Results showed that the limonite ore-carbon composite pellets sample with the binary basicity ratio (CaO/SiO2) of about 0.27 and coal addition of 2.5 wt per cent achieved above the minimum physical quality requirements for pellet of drop number of at least 4, a dry compression strength greater than 2.2 kg/pellet and an indurated compression strength greater than 250 kg/pellet. Limestone was used as the binder avoiding the addition of more impurities from bentonite since the limonite ore has a high SiO2 content of about 8.78 wt per cent.

Sep 18, 2023

By V Srinivasan, P Knights, C T. Farrelly

By 2025, with the widespread industry adoption of remote operation centres and advanced analytics, mining companies will find themselves making better, more informed decisions across the value chain. Process automation will drive significant business integration and reorganisation. Better collaboration between functions will make cross value chain optimisation a reality. Wherever possible decisions will be automated, based on analytical models and embedded in an enterprise decision management (EDM) architecture. This will take care of many of the minor day-to-day or the minute-to-minute decisions that consume operators and managers today. More flexible information technologies and architectures derived from the extensions to Web 2.0 and service oriented architecture (SOA) will solve many of the integration issues of today. The ongoing business imperatives for doing more with less people will make true collaboration with partners such as mining contractors, equipment vendors, transport providers, suppliers and maintenance contractors commonplace throughout the industry. All these organisations will be linked in and share common goals and objectives in real-time while providing visibility of internal constraints and available capability, allowing optimised decisions to be made across the extended enterprise. Humans will increasingly move to a more supervisory role and will use advanced collaboration to quickly solve complex abnormal issues that span the value chain out to the extended enterprise. The open collaboration and communication models instilled in the workforce through the widespread use of social networking technologies will drive thought leadership far beyond current æbest practiceÆ thinking. This will encourage the mining industry to extract the business value from rapidly converging fields of study such as environmental sciences, neuroscience, psychology, engineering, information technology and business finance. The future of mining will see a more uniform distribution of data savvy workers between the ages of 20 - 40, forcing a change in current operations. This group will drive the adoption of ubiquitous computing, augmented reality, presence and digital labelling. The enterprise will shift from a relatively static disparate set of functions to a digitally aware, integrated and interactive environment with information available, in context and just in time, to those who need it. The networked virtual enterprise will therefore be a reality.

Jan 1, 2008

By J Pan

This case study assesses the application of Mine-to-Mill optimisation combined with Whittle Consulting’s Prober<sup>®</sup> economic optimisation for the purpose of economic value uplift in open cut base and precious metal operations. The study extends the application of these optimisation methods to incorporate the recent practice of Ultra High Intensity Blasting (UHIB) developed by Orica Mining Services. The case study deposit known as “Marvin” is a copper/gold porphyry resource that is commonly used in optimisation software training and industry case studies. It has many similarities to Newcrest’s Cadia Hill open pit mine in NSW. Prior desktop research and industrial trials employed static assessments of Mine-to-Mill effects. No prior work other than a Whittle Consulting client study, has sought to assess the impact of variable fragmentation on enterprise economic value. This study examines the use of variable blasting intensity as a driver of economic value maximisation over the mine’s life.CITATION: Howe, S and Pan, J, 2018. Application of enterprise optimisation considering ultra high intensity blasting, in Proceedings Complex Orebodies Conference 2018, pp 14–20 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

A simulation model of the load and haul process where the loader cycle has been subdivided into its individual components is used to consider the benefits derived from improved drill and blast methods. Field data from a Hunter Valley mine is u

Jan 1, 1998

By M Pernechele, U König

Most of the operating steelmaking capacity currently relies on conventional, coal-based steelmaking processes. Currently, direct reduced iron (DRI) is only produced in regions where energy is available at low cost. To align with net-zero emissions goals, steelmaking capacity must transition to loweremissions steelmaking technology. Direct reduction of iron ore will get one of the preferred methods in the future due to its high technology readiness. New reduction technologies include hydrogenbased direct reduction processes. To ensure optimal efficiency during DRI production and to cope with newly developed technologies, processes need to be monitored more frequently and accurate. Traditionally quality control of raw materials and DRI has relied on time consuming physical testing, wet chemistry or the analysis of the elemental composition. The mineralogy of DRI that defines its properties is not frequently monitored. Process monitoring and quality control of DRI is possible by using modern X-ray diffraction (XRD) methods. In addition to the metallic iron content (Femet), metallisation (Metn) and the total carbon content (Ctot), XRD analysis also identifies the overall mineralogical phase composition. This allows additional information about the reduction process and enables fast counteractions on changing raw material mixtures. The benefits of the quantitative determination of the phase composition and the calculation of process critical parameters to produce DRI will be demonstrated with a case study

Sep 18, 2023

By Rozman L. I

This paper describes the latest open pit optimisation techniques,which now go beyond merely finding an optimal outline. The paper starts by briefly reviewing pit design techniques before optimsation. It then goes on to describe the pit optimisation procedure and the extensions to it which allow the automatic generation of nested families of pits. Next, the properties of families of nested pits are examined and the paper explains how they can be used to simulate certain mining sequences and schedules. Finally, we describe an actual study which was done using this kind of Software.

Jan 1, 1991

By Hatherly P, Luo X, Balusu R, Gale W

Ongoing, collaborative research between CSIRO's Exploration and Mining and Strata Control Technology has resulted in a better understanding of rock failure mechanisms around longwall extraction. Failure has occurred further ahead of the retreating face than predicted by conventional longwall geomechanics theory. In some cases significant failure has been detected several hundred metres ahead of the face position with demonstrated influences of minor geological discontinuities. Shear, rather than tensile failure has been the predominant failure mechanism in the environments monitored. Validating technologies of microseismic monitoring and new face monitoring techniques have assisted the development of predictive 2D computational modelling tools. The demonstrated 3D consequences of failure has assisted in the ongoing direction of the project to further investigate these effects.

Jan 1, 1998

By Y G. Anoman

This paper discusses the operating model within Endeavour Mining Corporation regarding the options of owner mining against contract mining. It’s based on the concept of ‘are we carrying out the most efficient mining’ regarding cost and performance. This question can only be answered through an extensive contract mining tender process and conducting a comprehensive comparison to evaluate the transition viability. Karma mine, located in Burkina Faso, is the subject of this paper. The Tender model included sales of equipment, parts and tooling associated with the traditional Load and Haul Schedule of Rates (SOR). The methodology focused on the structure of the tender process, which consists in the development of a SOR based on haulage profiles and mining schedule. This is a new Endeavour framework that allowed the bidders to compete on an even level. This was performed using a systemic analysis which encompassed all the elements involved in a transition such as the Human Resources (HR), taxes and customs implications, directs and non-direct costs (Finance and interest on assets, depreciation, insurance), contractor risk profiling. It was assessed against the normalised internal pricing tender-based. This paper gives an insight into how a West African mining operation addressed the sensitivities of the HR functions against the commercial aspects. This was one of the most successful transitions in West Africa and was carried out during the COVID crisis. The outcome of this project has created value by detailing a lesson learned model for both commercial and HR aspects. This discusses the commercial comparisons along with the internal model with the underlying HR functions as a risk factor that could have jeopardised the continuation of the operation. This resulted in a smooth transition with the additional cash flow generated by the sale of the parts and equipment turned Karma into a viable operation.

Jun 22, 2022

Bendigo Mining operates a 600 000 t/a comminution, gravity, flotation and leaching processing plant for the recovery of gold from their Kangaroo Flat Operation, in the Bendigo goldfields. The free gold and gold bearing sulfi des present are typically coarse grained and hence are highly amenable to gravity recovery. Plant operating data is consistently showing that over 78 per cent of the feed gold is recovered in a circuit, consisting of inline pressure jigs, inline spinners followed by free gold tabling and intensive leaching of tabling tails. The circuit receives coarse crushed product from high pressure grinding rolls and the grinding mill discharge, which allows material to be re-circulated through the gravity process until the particles are small enough to enter the flotation circuit. A plant audit was completed on 26 November 2009 designed to give an indication of the overall operational characteristics of the gravity circuit including single pass efficiencies of associated equipment. The techniques, results and challenges of such a survey are discussed.

Aug 1, 2010

By Luke K. A

Pressure on production at New Zealand China Clays has led to the development of a dewatering control loop for fine halloysite china clay. The development was based on the analysis of data from the automation of plate and frame filter presses. The analysis of the data has led to process changes, and the ability to quickly solve dewatering problems. As a result of control in the dewatering circuit press times have reduced on average 117% and output has increased proportionally.

Jan 1, 1989

By Soma T

Pyrite and Cu-concentrate were roasted in vertically suspended state in an externally heated tube. Tubes of three different lengths of reaction zone were used for three different reaction times. Roasted ores were submitted to chemical analysis and the extent of roasting reactions was determined. In case of pyrite, extent of roasting reactions was not affected much by reactor length and heating temperature (above 500¦C), but was considerably by ore/air ratio. Micro- scopic and XMA examinations led to the conclus- ion that pyrite particles decomposed to pyrrho- tite and then pyrrhotite was oxidized to give Fe-S-0 melt, magnetite and hematite. The extent of reaction was not uniform in all particles but had a wide distribution from unreacted pyrite to completely oxidized particles. Combustion of Cu-concentrate from Kuroko complex sulfide ore ) was unstable under a uniform wall temperature of 450¦C, but proceed- ed rapidly at temperatures above 500¦C. Sticking of roasted ores to the wall of the reaction tube induced choking of the tube, caused by melting of roasted ores, at tempera- tures above 950¦C. Enrichment of oxygen exterted less influence on reaction rate than heating temperature of the tube. Particle size of ore had a big effect on reaction rate.

Jan 1, 1980

The Beaconsfield Gold Mine within the township of Beaconsfield in northern Tasmania has been established in recent years to exploit a known resource in the Tasmania Reef which was mined to a depth of 450 m below surface between 1877 and 1914 yielding 850 000 ounces of gold. Activity at Beaconsfield over the past 30 years has involved drilling to assess the resource and rehabilitation of the top 100 m of the Hart Shaft that had collapsed since the original closure. More recently the mine has been dewatered to the 375 m Level and work is well advanced establishing infrastructure aimed at recommencing production during 1998 - 99. This paper reviews geotechnical studies undertaken to-date and provides a brief overview of some practical methods of analysing ground conditions. It pursues simple observation and analysis as a tool for assessing mine design and ground support options without recourse to extensive monitoring and measurement and avoids the use of elaborate models before the basics are understood.

Jan 1, 1997

By T Trott, G Lumley

"The mining industry suffers from a shortage of professional and other workers. Research and analysis has demonstrated a close correlation between high performance in productivity, maintenance and safety. There is also a significant correlation between engagement and performance. It is the hypothesis of the authors that mines can use a strategy of establishing themselves as a high-performance mine to attract and retain high caliber professional people: step 1 is to become best practice in equipment performance (productivity, maintenance and safety) step 2 is to brand the mine as æbest practiceÆ by sharing what has been confidential performance and outcome information with the general industry.Previous research has shown that many professional people are attracted by the prospect of a high achieving site because of the learnings and the support for continually doing better. In addition, a link has been established in previous research between productivity and safety. Operators and drivers are attracted to sites which have fewer dangerous people operating or driving. Good management delivers exceptional performance and a work site which high caliber managers and operational personnel people want to work at. The strategy requires commitment and proper execution but it can work. The strategy needs a specific approach and this paper will discuss this. A case study is provided from a mine which over a nine month period increased dragline performance by 15 per cent and reduced stress on the boom by 30 per cent. This mine paid the employees (professional and operational) $25 000/a less than the major mines but the operators and professional people would not leave; in fact, people were happy to be paid less to work there.CITATION:Lumley, G and Trott, T, 2012. Using best practice operations as a strategy for attracting and retaining professional people, in Proceedings International Mine Management 2012, pp 35-52 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 20, 2012

The need to estimate the block size distribution of a jointed rock mass is of great importance in the design of blasting rounds to attain a pre- established fragmentation. Other Geomechanics topics, such as ,hydraulic behavior of rock-masses, as well as the determination of their strength properties, also require the accurate prediction of a rock-mass composition in terms of block size taking in due account the three dimensional interference of joints and other geologic discontinuities. In this paper, a method for computing the block size analysis of a jointed rock mass is described, using as input the common geologic data (dip and strike) of fracture planes existing in a rock bench prior to blasting.

Jan 1, 1977

Roadheaders have had a chequered history in hard rock excavation in Australia since their introduction into the country in 1972. This has resulted in a poor reputation among both clients and contractors and subsequent reluctance to design tunnels and underground space around their performance characteristics.This has now changed because of the introduction into Australia of a new breed of Roadheader, the Mitsui. This paper sets out the history of development of the Mitsui range of Roadheaders. It describes the process which resulted in the introduction of this new machine, its performance to-date and the characteristics which have contributed to the success of the machine. The combination of these factors have led to a change in attitude to the use of Roadheaders in underground excavations.

Jan 1, 1993

By J D. Pease, J M. I Tuppurainen, P D. Munro

This paper examines how legislation and regulation can be external drivers of technical change in mineral processing and extractive metallurgy and how the industry can respond. Two examples are considered; the production of copper metal from concentrates and the cyanide process for gold production.The Clean Air Act (1970) in the USA initiated a wave of attempted innovations in the extractive metallurgy of processing copper sulfide concentrates to meet forthcoming standards on sulfur dioxide emissions. Interestingly, a satisfactory technical solution existed (flash smelting and gas capture) but had not been widely adopted.Nearly fifty years later the primary copper industry finds itself with new challenges. One major challenge is how to deal with the increasing level of arsenic in copper concentrates. Most countries impose an upper limit on arsenic in imported concentrate; typically, 0.5% As or less. Higher arsenic concentrates can be blended with cleaner ones to meet the limit, but this tactic cannot be used indefinitely as the average arsenic level of global concentrates rises inexorably. Further, smelters (often in urban locations) cannot be expected to deal with both ever-increasing arsenic in the feed and stricter restrictions on emissions and disposal. A rising “inventory” of primary copper deposits are already constrained from development by high arsenic concentrate. These deposits will need to be developed if future copper demand is to be met. An economic and technical solution to arsenic is needed. The gold industry may also face challenges in the use of cyanide, by far the dominant lixiviant used in gold and silver production. Public perception has driven restrictions on the use or transport of cyanide in some jurisdictions. History suggests that such pressure is only likely to increase. While there are several alternative lixiviants, none can yet match the utility and economics of cyanide.Such important issues will not be resolved by incremental change or new equipment items. They require development of new process technology - a tectonic event rather than an incremental change. It requires sustained effort (and expenditure) over decades and is very unlikely to result from “business as usual” for producers, suppliers or academics. Past major process developments were driven by a dire need for economic survival or by legislative change. What will drive the future changes?CITATION:Munro, P D, Pease, J D and Tuppurainen, J M I, 2017. Technology change by regulation – a cresting wave?, in Proceedings MetPlant 2017, pp 45–58 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By B Roache, J O’Brien, M Gray

Admixture use in cement products is commonplace in the construction and mining industries. Many Australian mines have an operational concrete batch plant and stock hydration control and water reducing admixtures. The benefits of admixture use, especially in shotcrete is understood and well documented. Cemented rock fill (CRF) is used to fill stope voids and create stable vertical and undercut surfaces at some Australian mines. These mines generally mix rock fill with a slurry of cement and water without the use of admixtures. Recently published work on optimisation of CRF mixes has mainly focused on the strength increases associated with changes to the mix grading proportions by the addition of fines, but not focusing on the potential benefits of admixture use. Admixture use in CRF may be the simplest CRF optimisation method, as the admixtures will often be added by the push of a button at the batch plant. A CRF testing program was undertaken to test the benefits of admixture use in terms of strength gain, using hydration control additives (HCA) and high range water reducer (HRWR) admixtures. Rock fill gradings were strictly controlled in the test process to allow clear definition of the difference admixtures provide in compression at 28 days. The testing results define admixture associated strength gains in a 6 per cent general purpose (GP) cement by dry weight CRF mix (131 kg of cement/m3). Costings have been developed to allow a mine operator to understand the cost benefits of admixture use in CRF due to reduced operating costs. Operational efficiency advances and a suggested admixture implementation plan for CRF optimisation is offered.

Nov 29, 2022

By M Scoble, C Hughes, M Roberts

At 14 per cent, the representation of women working in the mining industry is the lowest among primary industry categories in Canada. Despite an increase in research and industry commitment to advance and retain women in the mining industry, the gender gap in mining organisations persists.This paper is based upon a recent Canadian survey of 163 highly qualified women (HQW) working in the mining sector. For the purpose of this research, HQW were defined as women with a BachelorÆs degree or higher. This research sought to identify career progression and retention patterns of women who in theory have the educational qualifications to advance into positions of leadership in mining operations. We considered why womenÆs advancement in mining organisations has stalled; examined the career development pathways of HQW; and investigated the interactions of mining workplace culture on HQWÆs career development and retention within the Canadian mining industry. Results?indicated two distinct career pathway trends for HQW. æThe specialistÆ; a career characterised by multiple professional scientific and technical positions, and æthe corporateÆ; a career characterised by professional administrative roles and roles in mid-level management. It was found that neither æcorporatesÆ nor æspecialistsÆ systematically progressed into senior management and executive roles. These findings suggest that HQWÆs careers in mining are stalled, despite a strong indication by respondents of interest in their professional career advancement. With regards to?workplace?culture, respondents indicated that blatant forms of gender discrim-ination have been reduced in mining workplaces; however, exclusion from informal networks, implicit bias and subtler forms of workplace discrimination persist. Consistent with previous mining sector research, improving work-life balance, work flexibility and mentorship were found as key drivers for HQW to advance and remain in the industry.CITATION:Hughes, C, Scoble, M and Roberts, M, 2012. Where are the women? Highly qualified women in the mining industry, in Proceedings International Mine Management 2012, pp 23-34 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 20, 2012

By D Eschebach, D Mathewson

A belt press filter (BPF) handbook containing practical information for the reference of plant designers and operators has been created as part of Australian Coal Association Research Program project C23040. The handbook combines research and experience with newer generations of equipment and circuitry. BPFs are increasingly finding application in the dewatering of thickener underflow tailings slurries due to changing environmental regulations, difficulty obtaining tailings storage facility approvals and limited water availability. Sources of BPF inefficiency and low availability stem from a lack of understanding of the key operational parameters that affect their performance. This lack of understanding typically leads to increased operational expenditure due to suboptimal reagent dose rates and increased maintenance costs, or decreases in plant availability due to excessively high filter product water contents and equipment failure. It is essential for the continued economically competitive operation of Australian coal handling and preparation plants that complex factors affecting BPF operational performance are clearly defined and understood. Installation and operation handbooks are often provided to sites with new installations, but these manuals are manufacturer- or even model-specific and are often focused on mechanical maintenance. The handbook identifies industry ‘best practice’ and improvements developed by other sites, such as extra spray bars, air system bleed valves, guarding designs, feed and filtrate protection screens and roller tensioning systems. Equations to predict optimum operating conditions – such as free moisture, belt tension and reagent dose rates, with simple feed-specific variable inputs – have been developed from site-specific test work. The correlations developed provide a benchmark for plants to attempt to achieve. This provides operators and process engineers with a tool to explain BPFs and assist them in optimising the performance of BPF dewatering plants of both contemporary and less modern design.CITATION:Mathewson, D and Eschebach, D, 2015. ACARP belt press filter design, operation and maintenance handbook, in Proceedings Tailings and Mine Waste Management for the 21st Century, pp 73–82 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015