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By H. C. M. Gordon

IT is essential to the success of any mining op::ration that the roadways through which the material wrought and ocher materials and supplies are to be transported should be kept in such condition that this transportation cart be effected rapidly and without difficulty. The longer the roadway and the greater the tonnage to be taken over it, the more necessary it becomes chat the construction and maintenance of the road be such chat traffic delays can be reduced co a minimum. le is proposed co deal with the development and construction of roadways serving longwall operations and, since a recreating system of longwall is worked, as a rule, only where roadways driven in the solid coal can be readily maintained, the discussion will be confined co advancing longwall roads which are driven through areas from which the coal seam has been totally extracted. In order to construct a roadway through extracted ground in such a manner that it will remain in a state of reasonably good repair without undue maintenance, it is necessary chat everything possible be done to bring the overlying strata co a state of equilibrium as quickly as this can be effected, and the operations should be so planned that future workings will not disturb the equilibrium so set up more than can be avoided. Obviously, the readiest way to obtain a stable roadway is to develop it by tunnelling through a settled waste. However, this cannot always be done, as some of the roadways must be developed and constructed as the walls progress, but level or lateral cut-offs can be constructed in this manner. Main-slope roads can be developed in a similar manner after the coal has been extracted and a waste formed for at !east five hundred feet on either side of the line of the permanent roadway from temporary subsidiary roads developed for this purpose along one or other of the flanks of the waste to be formed. This interval must be obtained in order chat the lacer extraction of the seam will not set up movements in the waste immediately overlying or adjacent to the constructed roadway, thus upsetting the equilibrium of the strata and distorting the road.

Jan 1, 1940

By J. R. D. Gravel, D. A. Poland

"The induration of iron ore pellets has always utilized prefired pellets to protect the pallet cars from the environment of the induration furnace. This paper presents the process used to obtain superior upper sidewalls. These heat resistant castings are used on induration pallet cars, and their life improvements by as much as 400% is a significant step towards the reduction of the prefired (or hearth layer pellets.) The benefit to the industry in the removal of the hearth layer is improved overall productivity. IntroductionThe Iron Ore Company of Canada (IOC) operates with production facilities located in Labrador City, Newfoundland and Sept Iles, Quebec. It has recently been acquired by North Limited, an Australian based resource oriented company. Prior to its acquisition, IOC has examined several methods of operational cost reductions. One of these was an examination of indurrating pallets. Pallets are composed of numerous assemblies and sub-assemblies. The examination of the upper sidewalls began as an intent to increase the operational life of the component. The anticipated net effect was to be a reduction in the overall pallet maintenance cost. All of the components and assemblies have undergone a severe scrutiny. IOC has found that the success of the project has depended upon not only the technical competency of all parties involved, but also upon the ability to share risk, to be innovative, and to find a partner with whom the development can proceed without fear and yet with accountability. IOC has found in Cast Steel Products (CSP) such a partner in the field of pallet development. This paper will undertake to explore the progression into the arena of partnering between IOC and CSP. CSP and IOC met in the fall of 1994. The work of re-engineering the pallets began with an initial order for 36 pallets in March, 1995. The work on the upper sidewalls involved segregation of the effect of alloy development versus physical geometry development. The nature of partnering between the two companies allocated alloy development to IOC and physical geometry development to CSP, yet no advancements were made in either area without the close co-operation or the involvement of both partners."

Jan 1, 1999

By K. Law

"The Hatch Product Transport (HPT) system is a highly flexible and configurable route selection and sequencing system for controlling large bulk material handling facilities. The system has a generic control algorithm that can be configured to suit any material handling facility. It can also be easily reconfigured to cater to plant expansion or modifications without incurring significant disruption to the existing production, costs in testing, and re-commissioning, thus achieving cost savings throughout a facility’s lifecycle.This new material handling control system has been installed at BHP Billiton’s Port Hedland iron ore terminal to facilitate its expansion to beyond 100 Mt output capacity."

Jan 1, 2006

By W. B. Agocs

"IntroductionWITH THE DISCOVERY of natural radioactivity at the end of the 19th century, and the design of equipment for the detection of this phenomenon, radioactivity surveys bad their inception. Early in the 20th century it was found that almost all rocks are radioactive to a certain degree. This radioactivity is due to the nuclear disintegration of six naturally radioactive elements: potassium, thorium, uranium, rubidium, samarium, and lutecium.The radioactivity of these elements manifests itself by the emission of some concentration of alpha, beta, and gamma 'rays'. Of these, the alpha and beta 'rays' are, respectively, helium atoms and electrons, while the gamma 'rays' are short wave length x-rays generated in the nuclear disintegration by the transformation of mass into energy.The alpha and beta rays, being particles of matter, are stopped ve• easily by material barriers, but gamma rays are extremely penetrating and they will pass through a foot or more of rock or several inches of lead.The radioactivity may be detected by the causing of ionization by the radiation. The radiation detectors may be divided into four classes: ionization chambers, proportion al counters, and Geiger counters, all of which use gas for ionization, and scintillation counters, in which a solid is ionized. The basic principle of all these detectors is the same; the difference lies in the method used to measure the degree of ionization produced by the rays. Currently, the scintillation counter is displacing, the other instruments in radioactivity surveying."

Jan 1, 1955

By J. Ander

About fifteen years age some mines in western Canada commenced using Diesel engines, partly for development work but also for operations on quite a large scale. In the Eastern mining field, the Diesel engine made its appearance some eight years ago and has since, at quite a number of mining plants, proved to be a reliable and economical prime mover. As a result, it is today used more extensively than could have been foreseen only a few years ago, and it is reasonably safe to predict that the next few years will see the Diesel engine utilized to a still greater extent in the Canadian mining industry. It is not much more than thirty years since the first Diesel engine was put in operation. During the early years of this century, the Diesel engine took, so to say, its first faltering steps in public service. Since then it has reached a high state of perfection, and its importance has grown in a most remarkable way, until today it is used in practically every field where power is required. It is slowly but surely superceding steam for a great many purposes, as, for instance, for ship propulsion. While in 1921 only about 8 per cent of all tonnage launched was motor-driven, the proportion had grown to 38 per cent in 1927, and for 1929 it was slightly over 45 per cent. Some of the finest passenger liners afloat are Diesel-driven. In the early days, Diesel engines were built only in comparatively small units. Today engines with a capacity per unit of up to 10,000 horsepower, or even more, are being built for marine and stationary purposes.

Jan 1, 1930

By D. W. R. Haysom

"I AM CONSCIOUS of the honour you pay me by having invited me to address you on the subject of the Rehabilitation of the Sydney Steel Corporation. The true architect of the revival and rehabilitation is Robert Burns Cameron. Because of the numerous myths which have grown up around what seems to be the miracle of the revival of the Sydney Steelworks, I propose to go back to the time when they came under the full control of the Province, on the 1st of January, 1968. Late in 1967, the decision was taken by Premier G. I. Smith to keep the Steel Plant running for at least another year, in an endeavour to see whether the enormous losses being sustained by Dosco could be reduced to a level which would permit their continuing operation. When that decision was taken, Dosco was to continue management until the 30th of April, 1968, and in the intervening period, the Provincial Government would seek management of the right calibre to ensure that an objective view of the Steelworks operations could be secured. By a combination of circumstances which can only be described as most felicitous, the man selected for the task was R. B. Cameron. He very quickly determined that to permit Dosco to continue management of the Steelworks until April 30 could only result in heavy losses to the Province and a consequent deterioration in the already critical financial position and a declining morale of the worke"

Jan 1, 1972

By M. P. Davies

"Risk, the product of probability and consequence, is an integral part of mining. Whether evaluating exploration priorities, determining property acquisition potential, reviewing the components of an operating mine or assessing environmental/closure issues, the concept of minimizing risk is central to economic and technically appropriate decision making.Until recently, risk evaluations have tended toward a strongly mathematical basis. With this previous trend, it was essential to establish precise probability density functions to all assessed components or issues where often little information was available. The combined effect of the seemingly complex analyses with corresponding insufficient data often resulted in either a poorly executed risk evaluation or no evaluation whatsoever; either result not acceptable for optimal decision making. This paper presents a simple and practical procedure to carry out risk assessments for the mining industry. Although simplistic in nature, the power and usefulness of the technique is immense. The basis for the procedure involves combining deterministic assessments (often “gut feel”) with appropriate probabilistic descriptors. The resulting procedure, termed Potential Problem Analyses, or PPA, can be used anywhere an evaluation of risk will assist in optimizing technical and/or economic decisions. As will be shown, a key element of the PPA procedure is the multi-disciplinary input the framework allows which makes the method ideal for a teamwork approach to decision making."

Jan 1, 1997

By J. O. Wheeler

"DEFINITION OF THE REGION, ITS BOUNDARIES, AND PHYSICAL AND GE'OLOGICAL CHARACTERISTICSTHIS PAPER concerns the Western Cordilleran region, embracing most of British Columbia, the southern half of Yukon Territory and the southwestern most part of the District of MacKenzie. It excludes Vancouver Island and the Queen Charlotte Islands, which are discussed in a background paper on the Pacific Continental Shelf. The region is bounded on the south by the northwestern United States, on the west by the continental shelf and Alaska, on the north by the front of the Ogilvie Mountains, on the northeast by the axis of the MacKenzie Mountains and on the east by the Rocky Mountain Trench.The region is dominated by two mountain chains that con tain icefields and glaciers: the St. Elias, Coast and Cascade Mountains in the west; the Selwyn, Pelly, Cassiar, Omineca and Columbia Mountains in the east. The Intermontane region between these mountain chains consists of lower mountains and plateaus. In the mountains, the region above the timberline and many of the steep valley-walls provide good exposures of rock, but these areas are subject to rockslides and landslides and in winter to snow avalanches. Much of the Western Cordillera was covered by ice-sheets at various times during the Pleistocene epoch. Consequently, the larger valleys in the mountains and much of the Intermontane region contain much glacial drift and alluvium and only limited exposures of rock. This same terrain in the Southern Cordillera, however, is the most favourable for agriculture. Parts of the region, particularly in the two mountain chains, are heavily forested. Elsewhere, the forest cover is less, with grassland prevailing in the south and tundra in the north."

Jan 1, 1969

By Saikat Chatterjee, Xintong (Brett) Liu, Kinnor Chattopadhyay

Magnesia carbon bricks are commonly used in BOFs and are generally pre-heated before the BOF goes into service. Owing to very stringent emission regulations, the BOF pre-heating process need to be controlled and optimized so that, the emission standards are met. One of the major concerns in organic emissions are its stringent limits on emission rates and total volatile emissions. In the present work, an attempt has been made to integrate CFD and Thermodynamic models to predict the emission rate of volatile organics during the pre-heating process. A one dimensional heat transfer model was developed using visual basic and then integrated with thermodynamics calculations using FactSage 6.4. The parameters that affected organic emissions were the pre heating procedure, gas composition of the burner, heating rate and type of the burner. Typical composition of MgO-C bricks and binder materials were obtained from literature and vendor data sheets. Chemical reactions between organic materials, refractory and burner gasses were considered. The model predictions indicated that certain burner conditions could destroy all organics before it exits the vessel while other conditions needed the use of an after burner at the mouth of the vessel. The model was also able to predict the organic emission rates based on the chosen pre-heating profile. This kind of predictive model will be very useful for the steel industry and enable them to justify permit limit applications and stick to the limits by fine tuning their pre-heating process.

Jan 1, 2015

By Ken McIntyre, Trodel Wolf-Dieter

"Sirius Minerals is a UK based fertilizer development company focused on advancing into operation its polyhalite project in North Yorkshire, England. The operation is known as the Woodsmith Mine which has an estimated 2.7 Billion Tonnes of reserves and is currently in the construction phase. DMC Mining Services was selected to carry out the construction of four shafts for the project, a production shaft of 6.75m diameter to a depth of 1594 m, a ventilation shaft of 6.75 m diameter to a depth of 1565 m, and two additional shafts to support the construction of the material transport system (the MTS and Lockwood Beck intermediate) to 360m in depth for servicing the underground conveyor network for transport of product from the mine site to the costal port facilities located at Teasside. This paper will review the status of the project to date and the innovative approaches that DMC is utilizing to ensure a safe and successful shaft sinking project. INTRODUCTION The Woodsmith Mine in North Yorkshire is a Sirius Minerals-owned deep potash and polyhalite mine located near to the hamlet of Sneatonthorpe, Whitby in North Yorkshire, England, approximately 75 km east of York. The area of interest is more than 700 km2. The £3.2 billion project is to develop the Woodsmith Mine to extract polyhalite, and a tunnel system to transport it to a materials handling facility and harbour at Teesside. The site is the world's largest and highest-grade deposit of polyhalite and is expected to produce 20 million tonnes of polyhalite, potash and POLY4 per annum, as well as create over 1,000 direct jobs and many more indirectly. It has the potential to generate over £2 billion of annual exports for the UK. As the project will require mining to be undertaken in the North York Moors National Park, many objections were raised about the mine. Sirius Minerals has gone to great lengths to ensure that the project is sensitive to the local landscape, including: mineshaft head frames that will be positioned below ground to reduce their visual impact; surface buildings will be kept to a minimum; and the entire site will be landscaped and screened by existing woodland to blend in with the surrounding area. The project will also abide by strict environmental limits which govern our activity during the construction phase."

Jan 1, 2019

By Nelson C. White

This paper summarizes the present state and future prospects of the potash industry, with special reference to its impact on production in Saskatchewan.

Jan 1, 1968

By S. H. Logan

Mr. B. Neilly: A week or so ago the Secretary was good enough to forward me an advance copy of this paper by Mr. Logan and it was suggested that I comment on it at this meeting. At that time I was not very certain that I would be here, so I committed my thoughts to paper. As a matter of courtesy to Mr. Logan, I sent him a copy of my proposed remarks and I would like to give you just what I sent to him. Appreciating fully Mr. Logan's ability and many sources of information, one naturally hesitates to question anything seriously set forth as his considered opinion. Neither does one of my political stripe like to accuse him of being too 'conservative.? However, in places his paper reminds me of another general manager of a Canadian bank. While I was still Secretary of the Ontario Mining Association, this general manager wrote asking for our forecast on the current year's mineral production, stating that he proposed to refer to such production figures in his annual address to his shareholders. The request was considered very complimentary to the Ontario Mining Association and, in my opinion, justified a great deal of serious study and effort. Finally, the estimate was prepared and forwarded, showing a modest increase over the previous year's total. Picture our surprise and chagrin on reading his address to find that he predicted not an increase but, if you please, a decline of over $10,000,000. Before I cooled off I wrote asking the basis of such a prediction and got a reply to the effect that men in his position had to be ultra conservative in picturing the future.

Jan 1, 1931

By F. S. Su, P. Z. Pan, X. T. Feng, F. Yan, W. W. Ji

"This paper aims to simulate the spalling failure behavior in hard rock based on a self-developed numerical model, i.e. a rock discontinuous cellular automaton (RDCA). A crack initiation and propagation criterion is proposed based on the plastic strain, which is used to link the continuity and discontinuity during the failure process. The discontinuities of rock, such as cracks and other internal boundaries, are represented by discontinuous displacement functions, i.e. tip enrichment and step enrichment. The partition of unity is used to improve integral precision of the elements intersected internal boundaries, which is traced by a level set method. Arbitrary crack geometries can be conveniently represented and it does not require any remeshing in the modeling of crack initiation, propagation and coalescence. Numerical modeling of excavation in hard rock using RDCA is conducted. The spalling failure process of hard rock induced by excavation is well simulated. The depth and shape of hard rock spalling failure are good agreement with in situ observation.INTRODUCTIONThe excavation in rock mass is more and more popular. At the same time, the disasters, such as rock burst, rock spalling and falling etc, induced by excavation are quite prominent. Numerical modeling is an important way to help us understand the failure mechanism of rocks. Many numerical methods have been used to simulate the excavation of rock mass. For example, the finite element method (FEM) (Karakus and Fowell, 2003), the discrete element method (DEM)(Cundall and Strack, 1979, Labra et al., 2008), Finite difference method (FDM)(Zhu et al., 2009), Element Free Galerkin Method (Belytschko et al., 1994), Discontinuous displacement analysis (DDA) (Shi, 1988) and Boundary element method (BEM) (Katsikadelis, 2002, Chen and Hong, 1992) are commonly found in the stability analysis of excavation in rocks. In the modeling of crack propagation or excavation, most of these methods are tedious since the internal boundaries have to be consistent with the element boundaries. And in many cases, the remesh has to be conducted. In recent years, people are interested in particular types of FEMs, such as the extended finite-element method (XFEM), the particle discretization scheme finite-element method(PDS-FEM(Hori et al., 2005, Oguni et al., 2009)), the combined finite-discrete element method (FEM/DEM) (Munjiza and Wiley, 2004, Cai, 2008) and spectral-element method(Gharti et al., 2012) etc."

Jan 1, 2015

By Cesar Carrasco

Mine reconciliation is the art and science of comparing predictions and real-world outcomes with the intent of revealing the true quality of performance of models, planning, mining, and mineral processing. When mine reconciliation is conducted in a systematic, transparent and sustainable way it can play a central role in the governance of Mineral Resource and Mineral Reserve (MRMR) estimation and reporting. The core processes of modelling, planning, mining, and processing need to be transparent to be able to demonstrate that MRMR are reliable predictors of mine performance and value. Transparency is also necessary for mine technical staff to generate meaningful analyses, conclusions, and business improvement actions that demonstrably maximise value for all stakeholders. Most mines have some form of mine reconciliation practice, however because there is no agreed industry standard, and because mine reconciliation is difficult for a variety of reasons, it is often unsustained and/or ineffective at delivering the required transparency of performance. To deliver true governance of MRMR and business value, mine reconciliation must be sustainable. There are two categories of issues that combine to make mine reconciliation extremely difficult to sustain, these are technical, and people related. Technical issues include defining standard terms, accurately tracking material flows, data availability/adequacy/quality, calculation of key performance indicators and tolerance limits, analysis, and interpretation of results, understanding limitations of modelling techniques, and defining appropriate actions that can deliver value. These technical challenges are non-trivial, however compounding these are a range of people issues that include personal agendas, scepticism, lack of knowledge and experience, poor teamwork, absent leadership, toxic workplace culture, staff turnover, ineffective communication, siloed organisational structure, and lack of deliberate change management. All these problems can be solved with clarity of purpose, definition of the process of mine reconciliation, discipline in following the process, appropriate resourcing, and commitment to success across the entire organisation. Outlined in this paper is a management system that delivers sustainable mine reconciliation by addressing both the technical and people issues described above. This approach can deliver significant value for a mine and adds a robust, defensible governance over MRMR estimation and reporting.

Oct 1, 2024

By John Ratti

Building on Canadian Capabilities for Space Resource Missions: Space resource science and technology mission building blocks Canadian historical perspective Status and future pursuits It takes Canadian Teamwork to succeed in space exploration! Space resource science and technology building blocks: Orbiting / Delivery Elements Spacecraft Sensors Landed elements Roving / Mobility, Autonomy Sample acquisition and handling Sensors, GN&C Science Operations Partnerships: Government ? Industry Between Industry With Academia and Scientists

May 1, 2013

By M. E. Moraes Castanho de Almeida, A. Ribeiro Cotri

Recovery of cobalt to produce high grade cobalt sulfate from cobalt concentrate by leaching and solvent extraction was investigated. The PLS typically contains Co 10g/l, Mg 2g/l, Fe < 10ppm, Mn < 200ppm, insolubles <100ppm and is extracted with 20wt% Cyanex??272. The typical strip solution contains Co 60g/l, Mg 0.03g/l, and was sent to the current process for the production of cobalt sulfate heptahydrate. The cobalt yield of the plant with two extraction steps was 92%, with three steps was 97% and with four steps 99%. The extraction stage used the concept of "scrubbing" in a countercurrent system. In the first stage of extraction pH was 4.8, and in the last stage of extraction pH 5.5 to promote the exchange of magnesium in the organic with cobalt contained in the PLS. Following the extraction, when using two scrubbing stages, Co/Mg selectivity between of 2,000-3,000 was obtained, and with three scrubbing stages, selectivity was greater than 6,000. The desired selectivity was reached when using a scrubbing configuration with O/A ratio of 10:1. The typical cobalt sulfate heptahydrate had the following composition: Co 20wt%, Mg < 0.01wt%, Fe < 5ppm, Mn < 0.01wt%, Cu < 0.01wt%, Zn < 0.01wt%.

Jan 1, 2014

By A. E. Moss

"IntroductionTHE WORLD-WIDE search for iron ore has been vastly accelerated during the past fifteen years .and Canada is playing a most prominent role in this prospecting boom. During this period, the search for .and development of iron ore deposits in Canada bas proven eminently successful and there is every indication that exploration will continue to be active for many years.This paper has been prepared primarily for the information of those who have bad little or no experience in iron ore exploration. For convenience, it is divided into three parts: ( 1) a brief discussion of the marketing of iron ores, with special reference to Canadian production; (2) a summary of the main features to be considered when prospecting for or evaluating a potential iron ore deposit; and (3) an outline of the methods and procedures used in the search for the direct-shipping iron ores in the Quebec•-Labrador iron ore field.The Iron Ore MarketDue to the tremendous tonnages of high-grade direct-shipping iron ore indicated in the iron ore fields of the Quebec-Labrador and Steep •Rock areas, it might be assumed that there would have been a sharp decline in iron ore prospecting in this country. On the contrary, the development of these two major fields, which must be classed among the world's greatest, has been responsible for much of the current activity. The search for high and medium grade magnetite deposits is being• conducted in many parts of the country and a number of these have reached the development stage. Production is being expanded from the known fields, such as Wabana in Newfoundland and Michipicoten in Ontario."

Jan 1, 1955

By A. Pearson, Auld. F. A., S. O. Colbeck

"To minimise mine shaft maintenance over the long-term, some potash mine shaft sinking projects have required the provision of a continuous fully welded waterproof steel liner over a substantial depth to achieve zero water ingress. This brings many challenges, including the implementation of a bottom-up construction sequence incorporating extensive waterproof welding and how to ensure the integrity of the welded liner when subject to substantial temperature fluctuations that are likely to occur with a composite steel-concrete liner placed within an artificially frozen shaft excavation. This paper highlights the key challenges and discusses multiple mitigation measures including vertical shaft movement joints and a combined structural-thermal analysis approach. INTRODUCTION Whilst the application of combined steel and concrete shaft liners using a fully welded steel liner is not new and has been used in several previous projects, most notably at Lanigan (Storck, 1968 & Roesner, 1980), recently the need to provide a continuously welded steel waterproof liner for over 800 m length of shaft for a potash mine has been considered. The need for a fully continuous welded steel liner arises from the perceived benefits of providing a fully dry shaft environment to; increase the life expectancy of the shaft; reduce routine maintenance particularly combatting salt accretion and minimising wash down practices; and improve long-term ground stability by preventing salt dissolution. Whereas previous projects have employed discontinuous sections of steel liner, when a fully continuous liner is employed longitudinal shaft strains from thermal changes result in significant deformations that must be either explicitly accommodated or resisted. Note, these thermal vertical expansion forces are more than capable of lifting the shaft collar and head frame structures should they be fixed in place. Typically, shafts are designed to resist vertical forces (collar loads and self-weight) by creating mechanical interlock with the adjacent ground. In competent rock this occurs incrementally with the construction of the shaft liner, and occasional hitch/crib structures are constructed as intermediate foundations to guarantee the transfer of vertical forces at distinct horizons. Usually this means cribs are constructed at first rock head, above the station level, and at the sump, although sometimes additional cribs are formed when entering and exiting weak strata or when a change in shaft liner construction is required."

Jan 1, 2019

By D. Ofstie, B. Kargutkar

BIM, or Building Information Modeling, is transforming the way metallurgical facilities are built, operated and maintained. BIM provides a digital representation of the facility, complete with all physical and functional characteristics - enabling collaborative planning, concurrent design, construction simulation, sustainable operations and predictive maintenance through a connected information model. Building on experience gained in other industries, Hatch is aggressively applying the BIM process to the mining & minerals processing industry to address inefficiencies inherent in traditional document-based information management. Intelligent 3D models support real-time quantity forecasting and cost trending by commodity type and construction work package. By linking procurement and schedule data, material availability and constructability reviews are visualized to verify construction critical path, ensure work front safety and minimize craft downtime. The BIM digital information model connects engineering, construction, commissioning and vendor data, aiding timely asset-centric handover to plant operating and maintenance systems.

Jan 1, 2015

By Antonius Prayoga

PT Smelting adopted the Mitsubishi Continuous Technology for its copper smelter plant which has been operating since 1998. Through a series of expansion projects, the plant annual production capacity increased gradually from 200,000 to 300,000 tons of copper. There were no significant modifications for the smelter to reach the 50% additional capacity. It was mostly achieved by intensifying the operation of the furnaces by increasing the oxygen content in the furnaces blowing air. Intensive smelting furnace operation caused shorter campaign life of some furnace refractory, especially the melt zone wall on furnace outlet. During each furnace relining, which is done once every two years, severe wall erosion was found. The worst condition occurred in 2007 when the smelting furnace experienced a melt leak through the eroded wall beneath the bath-line coolers. During the 2008 furnace relining, a modification was performed by installing vertical coolers behind the melt zone wall. Additional vertical coolers were installed during the 2012 furnace relining to extend the coverage area. The modification improved melt zone wall integrity significantly by keeping them safely within the two year campaign life. Recently a modeling study was done to estimate the influences of molten waves on furnace wall erosion. The aim of the study was to predict the impact of blowing parameters, such as blowing air velocity, on the melt wave character and wall erosion.

Jan 1, 2015