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By S van der Sluijs, M van Ende, Y Tang, A Emami

This paper presents a phenomena-based model for investigating the possibility of scrap melting in an Open Slag Bath Furnace (OSBF) for green ironmaking. The goal of this study is to enhance the circularity of the steelmaking process by utilising scrap as a green source of iron in OSBFs. The model takes into account the fundamental differences between OSBFs and traditional processes such as Electric Arc Furnaces (EAFs) and Basic Oxygen Furnaces (BOFs). The model considers three primary regions where scrap heating and melting occur: the solid feed pile, slag and hot metal. It accounts for factors such as the furnace geometry, scrap charging mechanism and specific heat and mass transfer properties of the reactor. The model was validated using literature data and was used to investigate the heating and melting behaviour of individual scrap particles under various process parameters. The study finds that the scrap melting process in OSBFs involves three stages: shell formation, shell remelting and subsequent melting of the parent scrap. The carbon content of the scrap and the liquid hot metal plays a critical role in determining the melting behaviour. Depending on the carbon concentration and temperature, the melting process can be heat transfer controlled or mass transfer controlled. The paper also examines the scrap feeding methods in OSBFs, including direct charging into the slag or charging through a feed pile. The model provides insights into the melting rate of scrap compared to Direct Reduced Iron (DRI) in OSBFs and highlights the role of carbon in this process. Overall, this phenomena-based model contributes to the understanding of scrap melting behaviour in OSBFs and provides valuable insights for optimising the circularity and efficiency of green ironmaking processes. The findings of this study can inform the design and operation of OSBFs, paving the way for increased utilisation of scrap as a sustainable feedstock in the steel industry.

Jun 19, 2024

By Haslam C. O, Los V. L, Abramson G. J

The technology applied by lonex Pty Ltd provides an important breakthrough in geochemical exploration, enabling the discovery of concealed mineral deposits to great depths below surface. Most mineral discoveries have been made in areas of outcrop or relatively shallow cover; deposits at greater depth have been beyond the range of conventional geophysical and geochemical methods. Quite apart from the need to explore to greater depths in regions of major current or past production, most continents have vast areas where prospective host rocks are concealed by more recent material. There are numerous case studies where Ionex methods have located deeply-buried metal deposits, up to 500 m below surface, beneath thick younger sedimentary, volcanic, or transported cover. Research leading to the development of this technology was initiated by Dr I S Goldberg at the Rudgeofizika Institute in St Petersburg (CIS), and the methods have been employed there - and in other countries - for many years. Ionex technology became available in Australia in 1993. It comprises: ò geochemical and geoelectrochemical sampling and ultra-high-sensitivity analysis for mobile and weakly-bonded elements (I S Goldberg); ò the delineation and interpretation of regional zones of enrichment and depletion of the prime elements within geoelectrochemical systems (GES) (I S Goldberg); ò the investigation and interpretation of the three-dimensional geochemical zoning within geochemical anomalies (G J Abramson); and ò multi-variate computer modelling of the geochemical fields and systems (V L Los). lonex technology has been adapted to the environmental conditions in Australia with the participation of C 0 Haslam.

Jan 1, 1997

Bacterial leaching of sulfide minerals are fairly well established in heap, dump and in situ leaching and the primary bacterial treatment of refractory gold concentrate using CSTR have gained industrial prominence in recent years. Three cultures, a mesophile T ferrooxidans (DSM583), a moderate thermophile Sulfobacillus acidophilus (strain YTF1) and a extreme thermophile (Sulfolobus strain BC65) were used for the biooxidation (pre-treatment) of the Porgera gold-bearing pyrite concentrate under optimum O2 and CO2 enriched air (30 per cent O2 and ten per cent CO2) based on volume ratios. The positive effect of using oxygen and carbon dioxide enriched air for the biooxidation of gold-bearing pyrite mineral was clearly demonstrated where an increase in Fe release rate by a factor of 2.8, 1.8 and 1.5 for DSM583, YTF1 and Sulfolobus respectively were observed compared with the shake flask tests. The lag phase observed with the other test conditions such as in shake flask or with air decreased by about 80 per cent for all three cultures. The average observed dissolved oxygen concentrations in the pulp for these tests were 8.7, 5.8 and 5.0 mg/L for DSM583, YTF1 and Sulfolobus respectively, indicating that O2 was not limiting in these tests. The pulp redox potential was observed to increase with time for all tests coincident with the leaching rate and reaching a maximum of 663 mV, however the maximum value differs for each strain, with DSM583 exhibiting the highest followed by YTF1 and Sulfolobus. Biooxidation of pyrite under optimum gas enrichment at different pulp densities showed near total Iron extraction occurred for pulp densities of three, ten and 20 per cent (w/v). At high pulp densities, more so at 40 per cent than 30 per cent (w/v), the leaching rate decreased rapidly for tests with YTF1 and Sulfolobus. Monitoring of dissolved O2 shows that O2 demand increased with increasing pulp density and the average dissolved O2 concentration observed for YTF1 and Sulfolobus at 40 per cent solids concentration was 1.0 mg/L and below, suggesting limiting oxygen and carbon dioxide conditions for these two cultures. The decrease in leaching rate observed at high pulp densities (30 and 40 per cent) under optimum gas enrichment was accompanied by low metal dissolution and low redox potential values which was attributed to shear stress due to attrition of cells by high solids concentration, toxicity of metal ions especially Ag and Fe and the formation of precipitates and jarosites as confirmed from XRD analysis of leach residues hence impeding the leaching process. Limiting conditions due to high pulp density and viscosity were only observed for YTF1 and Sulfolobus. The subsequent cyanide leaching for precious metals from the pre-treated pyrite concentrate in all cases shows the extent of gold and silver recovery increased with the degree of pyrite oxidation and Au and Ag recoveries in excess of 80 per cent were achieved compared with only 18.1 per cent and 35.9 per cent for gold and silver respectively when treated by direct cyanide leaching on the original, untreated concentrate.

Jan 1, 2004

The theory of declining optimimum cut-off grades is more than 25 years old, but for a number of reasons it is still not widely used in industry. A lack of faith in the veracity of estimated grades is not in itself a reason to abandon any attempt to optimise cut-off grades. The use of declining cut-off grades has been thought to cause high-grading, but in fact this is only true if an artificially high discount rate is used in the calculations. Perfect application of an optimum cut-off grade should ensure that only ore generating more than a minimum net return is mined, and that as much as possible of the ore capable of generating that return is mined. Therefore differing mining costs in different parts of some underground mines necessitate local modifications to cut-off grade. Optimisation of cut-off grade is of necessity an iterative process. Integration of that process into a feasibility study need not be excessively time-consuming. A number of approximations can be made to speed the optimisation (any attempt to achieve a high level of accuracy is probably doomed to failure by a lack of precise cost and price projections). A procedure is outlined for optimising cut-off grade during planning of a typical underground mine.

Jan 1, 1991

A major tool in the search for petroleum is reflection seismic mapping. The period which has seen most of the exploration in Victoria is also one which has seen major advances in this technology, from 1963 try present day. Seismic mapping can be divided into three interlinked areas - acquisition, processing, and interpretation. In acquisition the major changes have been from an explosive energy source in 1963 to gas exploders in 1968 and airguns in 1970. The number of recording channels has increased from 24 to 192, with digital recording introduced in 1966, and floating point recording in 1976.

Jan 1, 1982

By J Stipcevich, N Patel, J Faithful5, S Narendranathan, L Tatnell4

ENGIE, the current owner and operator of the Hazelwood Open Cut coalmine, are in the process of rehabilitating the mine site in preparation for mine closure. Bucket wheel excavators (dredgers) used during coal mining operations are in the process of being demolished, which involves the controlled felling of dredger components using explosives. With the mine located in close proximity to the Morwell township and other critical public infrastructure, it is crucial that the use of explosives and the possible implications for mine stability is well understood. The felling of Large Mining Equipment (LME) will apply an impact load immediately to the underlying coal benches with the adjacent coal batters potentially at risk also of adverse slope stability impacts. This paper presents the 3D stability modelling methods employed to successfully assess the potentially adverse stability implications associated with LME collapse.

Jun 21, 2022

By Brimblecombe P

Morwell Open Cut is a continuous mining operation employing 5 buck- etwheel excavators, I bucket chain excavator and 54 conveyors. The combined bunkering capacity at both client Power Stations represents less than 12 hours maximum coal demand. This creates an extremely dynamic operating environment, which is further complicated with significant variations in both excavating and transportation plant capabilities. To achieve set objectives, including- I adequate reserves, 2 coal supply reliability, 3 cyclic plant maintenance, 4 minimal cost of coal, scheduling of the operation requires constant monitoring and reappraisal. Investigations are in progress to develop a computer based scheduling tool capable of simulating the complex operating environment. A review of computer scheduling packages currently available within the State Electricity Commission of Victoria has found limitations making most unsuitable for the task. The type of package found to be most suited is a knowledge based system ('Expert System')capable of operating within a set of rules defined by the user. Work is proceeding on the development of a knowledge base to test the effectiveness of Personal Computer based `Expert Systems'.

Jan 1, 1989

By Wooller R

The 3-D regular block model used for long term mine planning at Hamersley Iron did not fulfil the requirements for short term mine planning in terms of accurate representation of geological structures, contacts and boundaries in the orebodies. A computer model, based on zone plans, is being created as a single orebody model for all phases of mine planning. The zone plan is the primary interface between the geologists and mining engineers. It is essentially a bench plan at mid-bench height showing geological structure, material type boundaries, the grade and physical characteristics of ore blocks. The method allows for the dilution of ore zones by waste material. The stratiform nature of the orebodies allows zones of varying grade to be readily delineated on the plans. The Zone Plan Model (ZPM) is the interface between geological and mine planning computer systems. It is the basis of all mine planning with applications including long and short term mine plans, reconciliations, general ore reserve estimations, pit design and general model enquiries. The system was designed to be user driven. The user has complete control at all times as all computer generated data are fed back to the user who may then elect to override the computer. Various controls were built into the system to ensure model validity and integrity. The system has proved to be invaluable as a tool for users with little or no computing experience.

Jan 1, 1986

By Jorgensen FRA, Moyle FJ, Turner TM

Laminar flow furnace techniques and thermal analysis were used to study the combustion of Kambalda nickel concentrate and Collie coal. The study was made to ascertain the suitability of the latter as a replacement for the fuel oil currently burnt in a flash furnace at the Kal- goorlie Nickel Smelter. The coal was found to ignite at temperatures between 500-600¦C which was the same as that required for the most reac- tive component of the concentrate, namely py- rite. The rates of reaction of both the coal and concentrate were dependent on oxygen con- centration. Sulfur dioxide hindered the combus- tion of concentrate and of coal, the effect on the concentrate being the more pronounced. The effects of moisture content and the tendency for spontaneous combustion of the coal were also noted.

Jan 1, 1982

By Atalla YM

Steel rolling mill product finishing pro cesses gradually become or often already are unsuited for current production and marketing conditions. Indications are made as to what has been done to (i) rectify situations of this kind and, (ii) to reduce both product finishing time and costs. The principal features of two separate case studies are reviewed, these being (a) the finishing-end of B.H.P.'s Newcastle o.2 Merchant Mill and, (b) a mixed functions finishing yard and warehouses group (known as he Merchant Mills Loading Yard) which has been perating for a number of years. The areas in ach case are identified as a system while the arious functions, principal product streams nd processing equipment are respectively iden- ified as sub-systems and system elements. etails are given of the models used in each Sub-system dependency on the system as a le is traced by means of an information and ision analysis or by time studies and the sonableness of the system elements is deter- ed by computer programming or by simple com- ison methods. The-accumulated data is used derive improved mill finishing-end or Load Yard,functioning concepts according to pro- rules whilst at the same time considering

Jan 1, 1975

The mechanisms of fragmentation in homogeneous materials and structured rock mass are reviewed. A method previously used to predict vibration damage to the remaining rock is extended and shown to be valid for the prediction of fragmentation in the rock mass removed by blasting. The effectiveness of different explosives in different types of rock blasting is discussed.

Jan 1, 1990

For the last 4 years political leaders have found a new subject on which they can safely generalize wihout creating opposition. That sub- ject is commodity prices. Since the four-fold increase in OPEC crude oil prices, public atten- tion has focussed as never before on the subject of commodity prices. To advocate stabilizing com- modity prices is akin to supporting motherhood or peace or better schooling. Everyone gives lip service to the concept that stable commodity prices are desirable. It is easier to state the principle than to achieve it. Prices that are stable in terms of one currency may be clearly unstable in terms of a different currency. This has become a troublesome matter since 1971, when the world's leading trading currencies were set free to float in relation to each other. To illustrate: consider copper prices in the interval between the end of 1974 and the end of 1977. During those 3 years, the copper price in pounds sterling on the London Metal Exchange rose by 25 per cent. During that period, however, in terms of the USA dollar equivalent, the price was unchanged. And during that period, in terms of the German mark equivalent the price shrank by 13 per cent while the Japanese yen equivalent f.11 1k

Jan 1, 1978

By Quinlan M. J, Ratcliffe J. S

Chemical kinetics is a dependent process which usually correlates the rate at which a reaction proceeds with the mechanism descriptive of the manner by which reactive particles interact. Given the latter, the object gen- erally is to find the reaction rate dependency in terms of an intensive property of the system - number of reactive particles present, and of the energetics of the system - usually temperature. Chemical kinetics depend on a dem- onstration that reaction considerations alone control the phenomenological process under study. For these rea- sons, chemical kinetics are usually involved in homogeneous gaseous systems. Even in liquid homogeneous sys- tems earliness or lateness of reactant mixing rather than chemical kinetics may be controlling. Considerations of transport phenomena are involved in heterogeneous systems and often control the observable rate:an additional problem in such systems is to apportion the rate due to mass transfer - usually a linear process - and that due to reaction which may be linear or non-linear. Experimentally, conditions are often chosen so that only one consideration controls but this becomes more difficult where solid phases are involved. Kinetic modelling involves considerations of chemical kinetics, transport phenomena, and factors attributable to the physical environment in which the process takes place. The latter two considerations may be quite different as between experiment and plant. The kinetic model may be a mathematical representation of a conceptual mech- anistic model of the reaction. Alternatively, it may be an empirical relationship resulting from, for example, some curve fitting procedure applied to experimental data. The latter approach may be necessary where the system is particularly complicated.

Jan 1, 1975

By Fabjanczyk M. W

A limitation to present theoretical roof reinforcement design methods is the inability to derive accurate and quantitative information about the roof rock condition and the action of reinforcement at various excavation stages. To obtain the information required to assess roof rock stability, detailed monitoring of the in-situ behaviour of reinforcement and roof strata is required. Reliable instru- mentation and techniques have been developed for use in underground coal mines to identify the geometry and magnitude of displacements occurring in roof rock and the forces generated in reinforcement. The use of such instrumentation allows an accurate assessment of the in-situ capability of reinforcement and the mode of reinforcing action developed. In-situ monitoring can supply data required for the practical design of reinforce- ment and assess the potential stability of current designs. The use of such data together with mine wide appraisal of rock and stressfield considerations, can allow roof reinforcement to be designed on the basis of a predicted roof Response.

Jan 1, 1986

By Cudmore JF, Rowlands D

Incidents associated with spontaneous combustion of coal have resulted in the loss of many lives and considerable capital and equip- ment. Nevertheless, the factors controlling the propensity of coal to spontaneous combustion are not clearly understood and there is a need for research to study the effects of rank, petrog- raphy, moisture contents, etc. This has been attempted in a study of the propensities of selected Queensland coals to spontaneous combustion. An adiabatic calori- meter was constructed to study the self-heating of a large number of coals. Chemical and petro- graphic analyses of the coals were determined and an attempt was made to relate these propert- ies to the self-heating characteristics of the coal. The results show a strong relationship between rank and self-heating characteristics and that petrographic composition of coal may also be of importance. Some observations on the application of the laboratory results to the practical situation are made as are recommendations for future research.

Jan 1, 1981

The rapid industrialisation of the world was driven by an improved ability to utilise chemical energy. Unfortunately harnessing explosive energy did not come cheaply given the hundreds of lost lives. However, the modem explosives industry has made significant technological achievements, for explosives are now considered to be both safe and extremely effective. Upon closer inspection, it would appear the key to this achievement has been the development of initiation systems. While the focus may have been originally on safety, modem developments have concentrated upon harnessing the benefits of initiation control. Before attempting to gaze into the future, it is worth reviewing some of the significant advances that have occurred.

Jan 1, 1990

Jarrah Decline is currently the only underground operation at the Boddington Gold Mine, (BGM). The mine is located 120 km SE from Perth in WA, with mineralisation hosted within deeply weathered felsic and intermediate intrusions and volcanic rocks of the Saddleback Greenstone Belt (Morley and McBride,1995). Open cut operations commenced in April 1987 with a mill throughout of 3.OMtpa. A number of upgrades have since taken place, with the oxide material throughput currently milled at a rate of 7Mtpa. In 1992 a separate circuit, the supergene mill, was commissioned to treat copper material from the open cut and now ore from the Jarrah Decline. Current throughput in the supergene plant is 30,000 tonne per month, with a varied blend according to mill requirements. Total gold production from the Jarrah Decline in 1994 was 60,000 ounces from 90,000 tonne of ore.

Jan 1, 1990

By Sofoulis I

Recent studies in the Archaean of the Kalgoorlie-Norseman area show that the layered rocks can be subdivided into two main units, both containing basic igneous rocks and sediments. The lower unit is distinguished by the presence of acid volcanic flows and sills. In some areas, clastic sediments become coarser and,pas-s into conglomerates. This passage is accompanied by thinning of the beds. These features and their distribution suggest a basin of subsidence flanked-by areas of shallow-water deposition. -.

Jan 1, 1964

Answers to many questions arising in the different phases of exploration, estimation and production of a mineral deposit, can be found in the geostatistical theory of G. Matheron. It is shown that all these questions regarding sample size, number of samples, shape of drilling pattern can be answered as soon as the continuity of the mineralization is quantitatively characterized by means of a variogram. Next a formula which gives the variance of the error associated to any estimation procedure (i.e., any method and any sampling pattern) is given. Applications to the computation of the standard error of the'mean for various sampling patterns are shown, as well as how to use the formula to simulate several possible sampling strategies and choose the best one. Altogether it is shown how to answer the often heard question, "what happens if such and such sampling procedure is used?", rather than giving an hypothetical "optimal" solution.

Jan 1, 1976

By Isobe K, Muchi I, Hsieh YS

Theoretical and experimental studies have been made-to clarify the physical and chemical behavior of the tuyere combustion zone of blast furnace. Gas streamlines around this zone were visualized by the use of the two-dimensional equip- ment. Close agreement between the observed stream- lines and the calculated ones is found. The three- dimensional experimental studies have revealed that there exists a so-called dry zone in the neighbor- hood of the raceway and the trickling liquid be- haves approximately like a continuum. A kinetic model is develdped to describe the behavior of coke combustion in the tuyere zone. The model is based on the reaction kinetics, the differential balances of heat and mass, and the mechanics of gas flows. Regarding-the-axial distribution of gas composition in the tuyere zone, good agreement is obtained be- tween the model prediction and the data observed in a working furnace by the other investigators. Cal- culated results-show that the maximum consumption of coke occurs at the intermediate region of the raceway. For the blowing of oxygen-enriched or high -humidity blast, the position at which the maximum consumption of coke occurs is shifted toward the tuyere nose. Similar effect is found when the par- ticle diameter of coke in the tuyere zone is de- creased. The solid flow pattern around the tuyere combustion zone was visualized by the use of the two-dimensional equipment in which the sublimation of dry ice particles in front of the tuyere was

Jan 1, 1981