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By Noriaki Kurita, Norihiko Fulcatsu, Teruo Ohashi

"An electrochemical sensing device for hydrogen in molten metal has now been available owing to the development of the proton conducting solid electrolyte made of ceramics of metal oxide. The structure of the sensor and the theoretical limitations of its applications are discussed based on the electrochemical properties of the electrolyte used. The practical performance of the sensor is reviewed from the results of test measurements at the plants of aluminum and copper melting industries. The effectiveness of the sensor to the process control of continuous casting of copper is also discussed.IntroductionSince the in-line monitoring of the amount of oxygen dissolved in molten metal was realized by using the oxygen concentration cell based on zirconia solid electrolyte a similar method has been expected to be developed for sensing of hydrogen, which is a very important element of gas species in liquid metals, especially, in aluminum and copper. In 1981; Iwahara and coworkers found the dominant proton conduction at a high temperature in some perovskite-type oxide (1). Since then, the effort has been made to apply this proton conducting material as the electrolyte of the hydrogen concentration cell for high temperature use. The hydrogen sensor for liquid aluminum of this kind was first produced in 1991 (2) and released commercially from TYK Co., Ltd. Recently, we have developed the mother one usable at higher temperature such as copper and silver melting processes (3). In this note we discuss their structure, design and applicable limitations based on the electrochemical properties of this new type electrolyte. The performance of the sensor and benefit to use it to control the melting process is also discussed"

Jan 1, 2000

By Y, Li Jianxiong, Hu Hua, Gu Desheng

After having briefed the technical and economical advantages of continuous mass mining in underground metal mines, the authors discuss the four stages of research and development of continuous mass mining in China. The four stages are: vibrating ore drawing in a stope, continuous mass mining in a stope continuous mass mining without rib pillars in an area and continuous mass mining in whole mine. The authors briefly review the research achievements of the first and the second stage; Combining the key national research project of the æNinth Five Year PlanÆ ù æThe experiment and research of continuous mass mining without rib pillarÆ, the authors introduce in detail the technological condition of mining, the design ideas of continuous mass mining, the design scheme of mining, the technology of mining. the equipment of mass mining, the chief research achievements and so on. The success of research of continuous mass mining without rib pillar indicates the arrival of the third stage of research. The introduction of continuous mass mining will promote the technology revolution of mining in China remarkably. The authors also point out that the development direction of continuous mass mining of the 21 century is continuous mass mining in whole mine, which is the fourth stage of research.

Jan 1, 2000

By K. Narayan Prabhu, W. D. Griffiths

"Heat transfer during the unidirectional solidification of a cast iron alloy against cast iron chills was investigated using an inverse modelling approach. Chills of thickness 100 mm and 10 mm were used, to simulate gravity die cruiting conditions and the use of chills in sand moulds. In both cases transient heat transfer, measured by the interfacial heat flux and heat transfer coeffieient; declined from initially high values in the first few seconds of solidification, to values about an order of magnitude lower which persisted for the remainder of the experiments. In the case of the thin chill it became saturated with heat until it was no longer in a position to extract further heat from ·the casting. These results were interpreted by studying the resistance to heat transfer from the casting offered by the ·casting-chill interface and the chill itself for example, the thermal resistance of the casting-chill interface can be influenced by the deformation of their respective surfaces and their subsequent relationship.IntroductionDie casting cast iron offers several advantages such as energy savings, higher mould yield, and better surface quality over the sand casting process1 • The process is· environmentally' friendly because of the elimination of the sand. However the design and construction of metallic moulds is expensive and a faulty die design may result in a defective casting: A simulation based process design of die castings would enable die designers and solidification modellings to try better designs of dies on the computer and arrive at a cost effective solution more quickly. This has numerous benefits for the die caster, as he would be able to produce sound castings with very short lead times.The success of a solidification model to predict accurately the thermal history and the location of hot, spots inside a solidifying casting depends to a large extent on the heat transfer data prescribed at the metal/mould interface. Many measurements of the heat transfer coeffident (or the heat flux) between a solidifying aluminum alloy and a chill have shown that the heat transfer coefficient is a function of most of the variables of the casting process2 - 8. However heat transfer studies during the solidification of ferrous alloys are rather limited. The high temperatures involved suggest that the contribution due to radiation heat transfer cannot be neglected."

Jan 1, 2000

By Y. Pokhvisnev, S. Vandariev, A. Yatshenko-Juk, V. Valavin, V. Romenets

The technology of the liquid-phase reduction process known as Romelt was developed in the Moscow Institute of Steel and Alloys in 1979. The pilot plant was constructed at the Novolipetsky Steel Works (Russia) in 1984. Investigations into processing zinc-containing blast oxygen furnace dust and slag from the Lead and Zinc Works at the pilot Romelt plant proved the perspective of using this technology for processing zinc and lead-containing materials. In this article, the description of Romelt technology, basic technological information of trials at the Romelt plant using zinc-containing materials, compositions of charging materials, metal, slag, gas and dust are presented. The influence of flue gas composition on the composition of zinccontaining dust is shown.

Jan 1, 2000

By R. Sripriya, Ch. V. G. K. Murty, N. D. Rao, P. V. T. Rao, A. Ramu

Studies were carried out to improve the performance of hydrocyclones at Tata Steel's chrome ore beneficiation plant in Sukinda, India. The optimal cut point of the hydrocyclones was determined in the laboratory using a stub cyclone. In the tests, the operating and design variables, including spigot diameter, density of feed slurry and inlet pressure, were varied. Subsequently, plant trials were carried out, and attempts were made to develop a model of the hydrocyclone using the Rao, Lynch and Plitt model. The cyclone efficiency was represented by the parti¬tion curve, and the performance was evaluated mathematically from a reduced efficiency curve, represented by the equation:

Jan 1, 2000

By Himaki Nakano, Kenji Hara, Toshiaki Tsuru, Shunsuke Kawano, Takeshi Ohgai, Hisaaki Fukushima, Shigeo Kobayashi, Tetsuya Akiyama

"Electrodeposition of Fe-Ni and Zn-Ni alloys from aqueous solutions is one of the well-known examples of anomalous codeposition in which less noble metal deposits preferentially. In this paper, the electrodeposition behavior of these alloy systems was compared between the methanol and aqueous baths. In Fe-Ni system, the significant suppression of the deposition rate of more noble Ni was observed over a wide range of electrolysis conditions in both methanol and aqueous baths. However, the electrodeposition of Zn-Ni alloys showed the typical feature of normal type codeposition in the methanol baths, which was completely different from that in aqueous sulfate baths. The difference in the electrodeposition mechanism between Fe-Ni and Zn-Ni alloys was discussed on the basis of the alloy deposition behavior in the baths in which the activity of water was varied:INTRODUCTION'It has been well known that Fe-Ni alloys show an excellent soft magnetic property. Therefore, thin films of this alloy have been used to fabricate the'-various magnetic devices. For the production of Fe-Ni thin films, dry processes such as sputtering, PVD and CVD are 'employed frequently and the resulting films showed a preferable property as a magnetic material. Electrolyses as a production technique of thin films, on the other hand, has the advantage over other processes in its cheaper production cost due to the simplicity of the production unit The Zn-iron-group metal alloys such as Zn-Ni and Zn-Fe electrodeposited on a steel sheet ale known to exhibit excellent corrosion resistance and therefore the electrodeposition of these, alloys has been applied to the production of surface treated steel sheets mainly for automotive body panels.According to Brenner (1), the electrodeposition behavior of Fe-Ni and Zn-Ni alloys was' classified into the' 'anomalous type. In this type of codeposition, less noble metal, i.e. Fe for Fe-Ni and Zn for Zn-Ni system, deposits preferentially and the change in -the alloy composition- with the variation of electrolysis conditions was unpredictable because of their obscure deposition mechanism. Since most properties of the alloys mainly depend on their composition, the composition of the deposited' alloys must be controlled strictly. Therefore, it is neces5al)' to clarify the mechanism of anomalous codepasition in Fe-Ni and Zn-Ni systems: Several mechanisms have been proposed so fur, and among them the hydroxide .suppression mechanism (2), (3) has been regarded most plauslble depend on their composition, the composition of the deposited' alloys must be controlled strictly. Therefore, it is necessary to clarify the mechanism of anomalous codeposition in Fe-Ni and Zn-Ni systems: Several mechanisms have been proposed so far, and among them the hydroxide suppression mechanism (2), (3) has been regarded most plausible. According to this mechanism, it can be predicted that the codeposition behavior depends greatly on the characteristic of water solvent in this study, using methanol as a solvent, the electrodeposition behavior of the anomalous codeposition was investigated to discuss the validity of the hydroxide suppression mechanism."

Jan 1, 2000

By V. B. Chernyavsky, Ladokhin S. V.

Equipment and continuous casting technology for the production of small diameter copper rods and tubes are described. Industrial copper wastes, such as scrap and shavings, were used as the charge. An electron-beam installation for rod and tube production includes a crucible with an electromagnetic stirring system and a pouring hole in its bottom, a bottomless mold, .and a special cooling system, which includes an oil and water cooling devices. For the first time in the electron-beam technology, rods of 8 mm and 14 mm diameter mm tubes of 14 mm external diameter and 7 mm internal diameter were produced through continuous casting by pulling them out of the vacuum chamder into the atmosphere with depressurizing the vacuum chamber. The production capacity of a single strand continuous casting machine was 200 mm/tnin for rod casting and 150 mm/min for tube casting.

Jan 1, 2000

By A E. Annels, G F. Johansen, B W. Cuffley

Nuggety gold-quartz reefs are characterised by localised, high-grades and in many cases coarse free-gold. Geometrical and grade complexities are often observed. The high-grade regions are generally erratic and have a low continuity; though may make the deposit economic. Viable grades are generally contained within discrete oreshoots, which are surrounded by barren/low-grade material. Drilling is an effective measure of geological continuity, however grade distribution can only be reliably obtained from underground development and bulk sampling. In general terms, only an inferred resource is likely to be estimated from surface drill data alone. Underground development, further drilling and probably bulk sampling will be required to delineate inferred and indicated resources. Closely spaced development with bulk sampling is likely to be the best way to determine a probable reserve. The resource evaluation process must driven by a clear geological model that should attempt to understand the controls to reef geometry and grade distribution. Geological interpretation has traditionally been undertaken in two-dimensions, though computer software is now being used to produce three-dimensional models. Grade interpolation has generally been undertaken using classical methods, typically weighted averages, zone of influence weighting and polygonal/sectional blocks. Tonnages can generally be calculated from diamond drill and development information with a reasonable degree of confidence. Grade is much more difficult to define with confidence because of its highly erratic and discontinuous nature. To account for variability it is recommended that a best estimate be reported within a grade range, as this more accurately reflects the uncertainties involved. Reporting should be undertaken within the framework of the JORC code, but should involve special consideration of grade reliability.

Jan 1, 2000

By G. P. Saseen, R. A. Haney

The US Mine Safety and Health Administration (MSHA) developed a model to estimate diesel particu¬late (dp) exposures in underground mines. The estimator uses in-mine measured dp concentrations or engine manufacturers' standardized emission data. Through a series of calculations, full-shift dp concentrations are estimated by applying standard engineering principles of ventilation, control technology and work cycle. This model, in the form of a computer spreadsheet, provides the mining industry with a method for estimating dp levels and determining the impact of various diesel particulate controls on occupational exposures to dp in underground mines. A detailed description of the estimator and several examples demonstrating the results are provided.

Jan 1, 2000

By Lynn B. Hales, Randy Ynchausti, Jeffrey D. Mckay

Many consider rougher flotation control to be more of an art than a science. Some have even thought it impossible to make process control decisions and changes without human interaction. Controlling flotation bank pulp levels to maintain consistent pulling rates in the face of changing feed slurry flow rates, varying mineral types, and inconsistent reagent additions can be daunting. However, an advanced supervisory control strategy was installed on the plant floor to control an industrial rougher flotation circuit with little or no operator interaction. Plant staff monitored the flotation circuit under supervisory control and reported benefits of up to 4% improvement in copper recovery above that achieved with an older supervisory control strategy. To accomplish this work, a novel use of instrumentation to solve a flotation bank pulp level control problem was employed, a new implementation approach was used to correct some flaws in the older approach, and careful attention was paid to a few key process control principles. This paper discusses important aspects of these activities.

Jan 1, 2000

By K. Morsy, S. S. Peng

This paper deals with the causes and mechanisms of massive pillar failure in a room-and-pillar mine that employed nine-entry panel system using supersection technique under a cover ranging from 91 to 168 m (300 to 550 ft). Chain pillar squeeze and large roof-to-floor convergence were first observed at the belt transfer point on the very inby side of the main entries. It propagated outby quickly and within 24 hours it had covered an area approximately 1,250 m long by 762 m wide (4,100 x 2,500 ft). The failure was caught and stopped by a solid barrier pillar. Using computer modeling, the study indicated that the massive failure was initiated due to a combination of undersized chain pillars in some panels and weak immediate floor. Also, the study shows that the massive pillar failure expanded to a large area because of no barrier pillars between some panels and between mains and panels. Based on the computer modeling, alternative mine plans have been proposed to avoid such problems.

Jan 1, 2000

By Arturo Carranza Edwards

Sedimento II oceanographic cruise, on board of the B/O El Puma, shows a new high anomaly or phosphate associated with shelf sediments from the south Mexican Pacific. Recently, were found two anomalies in the Gulf of Tehuantepec, that are located to the east of this new anomaly, that is related to muddy sands and rock fragment debris. The latter shows values of 17% P205. The phosphate occurrence is probably associated with red tides locations that usually are found in sites where sediments are phosphates enriched. These findings suggest that south Mexican Pacific is of potential interest for P205, in waters with high nutrients values. The possibility of a more regional occurrence of phosphate, from California to Chile is suggested.

Jan 1, 2000

By André Vien, Robert Edwards, Rob Perry

A metallurgical control application can only succeed if the system's lowest common denominator, its instrumentation and regulatory control is implemented and maintained correctly. This paper describes the basics of regulatory control implementation including some practical guidelines for instrumentation installation, operator interface design, loop tuning, and continuous loop performance analysis. Tuning and analysis techniques are illustrated by step-by-step industrial examples. A small investment in basic control pays dividends in better overall plant performance and provides a solid foundation for advanced control efforts such as expert systems.

Jan 1, 2000

By José D. T. Capocchi

Viscosity of liquid lead, tin, and Pb-Sn alloys has been measured by the rotational viscometer method in the temperature range from 50 K above their respective liquidus temperature to 823 K. The results are accurate to within ±1.0 %. The variation of viscosity with temperature followed the Arrhenius-type equation µ = µo.exp(Q/RT). The composition dependence of the isothermal viscosity and the activation energy for viscous flow have not shown anomalous changes at the eutectic composition of the Pb-Sn system.

Jan 1, 2000

By Dieter Wittenberg

The successful extension of the applications in which rockbolts can be used in the German coalmining industry is, because of the very great raining depth combined with a high degree of stress in the native rock, only possible on the basis of a comprehensive quality management system. The quality assurance system consists of material tests on the individual component parts of a rockbolt, of test rig trials of installed rockbolts, of suitability tests underground and of measures for quality assurance during roadway drivage. Only on the basis of exact knowledge of the way in which installed rockbolts function in the underground and possible sources of error and faults can quality assurance be guaranteed during roadway drivage.

Jan 1, 2000

By Sergio Cattalani, David J. Kerr, Harold L. Gibson

Abstract - The Horne mine was truly a world class Cu and Au deposit. Between 1927 and 1989, it produced some 260 t of Au and 1.13 Mt of Cu from 53.7 Mt of ore that averaged 2.22% Cu, 6.1 g/t Au and 13 g/t Ag. The total value of Au and Cu production from the Horne deposit at metal prices of US$300/oz Au and US$1.00/lb Cu is an outstanding US$5.2 billion. The Horne mine was also a company builder. After optioning the property from Ed Horne (Tremoy Syndicate) in 1922, the Thomson-Chadbourne Syndicate discovered the deposit in 1923 and quickly grew to become Noranda, one of the world’s premier mining companies. This discovery fuelled exploration and, along with subsequent discoveries in the Val d’Or-Cadillac camps, led to the "economic development" of northwestern Quebec. The Horne deposit influenced and continues to influence genetic models for volcanogenic massive sulfide (VMS) deposits. Early observations at Horne contributed to an epigenetic replacement theory for VMS deposits. The most recent genetic model for the Horne, invoking sub-seafloor sulfide replacement of silicified and sericitized volcaniclastic host rocks within a graben, has subsequently been proposed for another giant VMS deposit, the Kidd Creek mine. The Horne and Kidd Creek deposits show many similarities, such as localization within synvolcanic grabens, long-lived hydrothermal activity uninterrupted by volcanism, sub-seafloor replacement sulfides, stacked sulfide lenses, zone refining, silicified footwall rocks characterized by high positive ?18O values, and association with FIII rhyolites. Notable differences between the two deposits include the lack of andesitic, basaltic or komatiitic flows at Horne, different inferred water depths, high Au content at Horne versus negligible Au, but sub-economic to economic concentrations of Sn, In and Cd at Kidd Creek.

Jan 1, 2000

By Ray Jambakhsh, Gabrielle Bourget

In the summer of 1998, Ontario Hydro awarded a contract to demolish an obsolete and inefficient chimney by blasting. The Ontario Hydro Thunder Bay Thermal Generating Station (T.G.S.), is a fully operational hydro thermal generating station located in Thunder Bay, Ontario, Canada. The Chimney was a 356 ft (108 m) high freestanding structure constructed of reinforced concrete with a brick liner. Falling the chimney required careful planning due to the highly sensitive structures and equipment which surrounded it. Damage either sustained to the existing systems through ground vibrations or direct contact would have resulted in expensive power outage and/or lost production. The role of Explotech Engineering Ltd. on this project was to provide and evaluation of the proposed demolition procedure, defme the predicted and maximum seismic vibrations at sensitive structures including underground services, conduct pre-blast / post-blast inspections and recommend various safety precautions. The general contractor for the project, LeBrun Northern Contracting Ltd., of Thunder Bay, Ontario was responsible for all site preparations and post-blast clean up. All demolition blasting calculations and operations were conducted by Dykon demolition experts from Tulsa, Oklahoma. On September 13, 1999, the chimney was successfully demolished. Extensive analysis of the vibration records and visual post-blast inspections of the surrounding structures concluded that the demolition event induced no damage to any of the Ontario Hydro facilities.

Jan 1, 2000

By Koji Matsubara, Yoshiaki Iguchi, Shoji Hayashi

Iron ore particles of a limonite iron ore were reduced completely with H2 at 1023K to 1273K in a fluidized bed. Then, at 973K, the formed iron was exposed to HrH2S mixtures (sulfur activity, as=0.5) for 3.6ks and carbidized with CO-H2-H2S· mixtures at 0.1 MPa. During the carbidization, the particles of about 150mg were sampled at every 600s interval. The sampled particles were analyzed by XRD and chemical analysis for C and S to evaluate the content of Fe3C, Fe5C2, Fe and free carbon. The reaction extent is defined as fo=Xfc3C +xFc5c2; x is the molar fraction of Fe in Fe3C. The carbidization curves can be fitted very well to -ln(l-f0)=g(pb T)t; g(p; T) is the carbidization rate, i.e. the carburization rate on the pore surface of reduced iron. The rate is found to be nearly proportional to the specific surface area of reduced iron, a P 0 , which decreases with increasing the reduction temperature. The value of a P 0 does not change by the carbidization and the stability of the iron carbide product in the atmosphere increases with the temperature.

Jan 1, 2000

By T. Kamata, S. Takemoto, H. Takeuchi, M. Takayanagi, Y. Akahori, I. Jimbo

"A cooperative research work on the silver recycling process is underway between Matsuda Sangyo Co., Ltd. and Tokai University in Japan. Silver wastes treated here are mainly from photograph industries where the concentration of minor element is steadily increasing in the recent years. The waste materials are concentrated and the impurities are removed by evaporation and slagging. In this paper, the industrial practice of wastes treatment is introduced and the result of the laboratory studies on the removal of antimony and tin from the binary and ternary alloys will be discussed. Characteristics in the behavior of antimony and tin during the process are also discussed with the observation of practical operation.1. IntroductionPrecious metals such as gold and silver primarily come from mining practice and the byproduct in copper smelting. However, the recycled amount of these precious metals have been increased 1 along with the environmental restriction and the widely accepted idea of saving resources on the earth in the recent years.· Though the recycle process of precious metals are comparatively simple from other metals refining, the process has been getting more complicated as wastes treatment has to deal with more impurity elements which are intentionally added to the products. Among these additives, antimony is used in the film materials in the photography industries to suppress its inflammability. Tin is another concern ,that is also coming from photography wastes; These minor elements have become problematic during the recycle.The removal of these minor elements has been in operation at Matsuda through a traditional oxidation refinement process using a reverberatory furnace. However, the complexity of the charge makes the recycle process more tedious and troublesome. In order to investigate the minor element behavior in the complicated materials system during the silver recycling processes, a cooperative research work is undertaken between Matsuda Sangyo Co., Ltd. and Takai University in Japan. Silver wastes treated here are mainly discharged from photograph industries where the minor element contents such as antimony, tin and bismuth in those wastes are steadily increasing in the recent years. The liquid wastes containing silver are concentrated and then treated pyrometallurgically with solid wastes from other sources, where the impurities are removed ·by evaporation and slagging. The purpose of this study is to investigate detailed behavior of impurity elements in the silver. containing systems."

Jan 1, 2000

RICHARD D. PICK RMCI PRESIDENT 2000-2001 on behalf of the RMCMI Board of Directors and Officers of The Rocky Mountain Coal Mining Institute cordially invites you and your family to attend the 97th Regular Meeting and Convention to be held June 24 thru June 26, 2001 Steamboat Springs, Colorado

Jan 1, 2000