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By Jim Gunderson

Jan 1, 2004

By E. Bane Kroeger

Rib failure is a hazard that has resulted in many injuries and fatalities in underground coal mines, especially in soft coal seams. Conventional rib control methods including rib boarding, shotcreting. steel meshing and geogridding, are fairly expensive and time consuming to install. Some methods, such as rib boarding, have met with marginal success at controlling rib failure. Under this research, the Rib Strap System (RSS) introduced by Dr. Chugh in 1999, was modified and new components were added. Both bench scale and full size prototypes were tested in the labs at SIUC to determine the best materials for fabrication and easier methods for assembly and installation. This laboratory research has developed new methods of securing the strap ends to smaller rib hoards, a new device to post-tension two straps together, and a technique for replacing straps without having to drill new rib bolts or for retrofitting straps to rib hoards that are already in place. The method used to secure the strap end to rib boards developed during bench-scale testing was dubbed the wrapped staple technique. It is very simple, requiring only 10-15 staples, with the end of a strap secured to a rib board in about 45 seconds. Several different prototype designs for a new device to join the strap ends together and tension the strap were fabricated and tested in the labs at SIUC. The device, dubbed the rib strap buckle, was very easy to install and held the straps firmly. One specific buckle design worked extremely well during testing and exceeded all expectations. The laboratory research also developed a method of replacing a damaged rib strap that can also be used to add rib straps to existing rib boards. The technique uses nails, spacer blocks, and band clamps to secure the new board and strap. This technique was developed to allow one person to replace a strap using only a hammer and screwdriver, negating the need to drill and install a new rib bolt using mine equipment such as a roof bolter or scoop. In addition to the technical feasibility, the cost of materials for the rib strap system was compared to the rib boarding method currently being used at a mine in the Illinois Basin. The mine is using 20 rib boards on each pillar at cost of about $223.60. The costs for the rib strap system depend on the materials chosen for fabrication but for the base case, were about $97 per pillar.

Jan 1, 2004

By B. Zhu

With the challenge of clearing steel production and increasing of the productivity of converter, the application of hot metal pretreatment technology in torpedo car become a key process in the steelmaking. In this article, the technologies, production and development trend of Al2O3-SiC-C bricks for torpedo cars in China are reviewed, the current application situation and main requirements for the Al2O3-SiC-C bricks are also addressed.

Jan 1, 2004

By M. Tangstad, B. Monsen, H. Midtgaard

The increased attention towards reducing emissions of fossil CO2 due to its potential global warming effect has resulted in a focus on renewable resources, as charcoal. Since charcoal is produced from growing wood it does not contribute to global warming. This paper gives a brief review of consequences of and reasons for using charcoal in the silicomanganese (SiMn) production. Results are presented from practical SiMn smelting experiments, on a pilot scale, using charcoal as reduction material and comparing with coke. As slag- and CO2-reactivity are important for furnace performance these features have also been measured.

Jan 1, 2004

By Zhitong Sui, Feng Zhang, Li Zhang, Tie Ou, Guangqiang Li

Researches on the recovery of iron, manganese and the removal of phosphorus from converter slag were reviewed. The carbon thermal reduction experiments were carried out by induction heating the mixture of converter slag and graphite powders at 1650°C and 1800°C in a graphite crucible. It was found that 62.7% of the phosphorus in converter slag was reduced into carbon saturated iron alloy, 32.8% of that was vaporized and only 4.5% of that remained in the final product. Totally 95.5% of the phosphorus in converter slag was removed. Almost all iron and manganese was reduced to form carbon saturated alloy. It was found that the free lime in converter slag can react with carbon to form calcium carbide at 1800°C. The main phases in the reduced converter slag are dicalcium silicate and tricalcium silicate with small amount of calcium carbide.

Jan 1, 2004

By Axel Preusse

In the Ruhr district, pipelines of public and private infrastructure are made of cast iron, steel, plastics or asbestos cement. Legal framework, technical regulations and normative standards define which pipeline materials may be used for the transmission of which kind of product Thus ground water endangering substances as well as inflammable or explosive products are only permitted to be transported in steel-made pipelines. Ground movements, due to underground mining, are transmitted via the soil to the pipeline and cause extra strain within the steel pipeline (Figure I). In extreme cases durable deformations may occur, characterized by an oval profile or a fold in the pipeline. To avoid or minimize damages, balancing elements are installed into the concerning pipeline, reducing the ground movements which might otherwise cause damages. [ ] The distance between the balancing elements is not arranged by random, but by a calculation method developed in a doctoral thesis [Spielberg, 1999] which represents the actual available standards in science and technology. The calculation method considers all relevant influencing variables with impacts on the movement behaviour of steel pipelines in mining areas, such as technical data of pipeline design (e.g. steel grade, wall thickness, weld seam quality), soil conditions (e.g. friction), laying depths of the pipelines, the operational impacts (working pressure, corrosion) and the mining impacts. As of today, mining has caused no damages to steel pipelines protected by this calculation method.

Jan 1, 2004

By M. Specht, D. Pörzgen, W. Lorenz, A. /. Buhr, R. P. Racher

The introduction of the near net-shape casting process at CORUS Staal IJmuiden in January 2000 required changes of secondary metallurgy processes including a development towards more aggressive slag compositions in the steel ladle. Therefore the steel ladle lining has been changed from fired andalusite bricks to magnesia-carbon bricks and, most recently, to fired spinel bricks to withstand the severe slag conditions. In comparison to the andalusite bricks the new steel ladle linings have a higher thermal conductivity. This requires the capability to keep the lining warm by ladle preheaters to sustain the overall thermal stability of the steel ladle in case of interruptions during hot cycling of the ladles.

Jan 1, 2004

By J. Björkvall, L. Bååth, D. Malmberg, J. Malm

Microwave technology has for decades been a tool for astronomers to map and understand the complexities of the universe its composition and extent. It is also used on a laboratory scale by spectroscopists to examine properties of atomic and molecular compounds. In this novel work we will introduce microwave technology to be used for the investigation of liquid slag structures. The preliminary results indicate that the alteration of the slag composition could be correlated to the measured microwave refractive index. Investigations have been performed in the Al2O3-CaO-SiO2slag system. Keywords: Microwave technology, slag, structure, liquid, Al2O3-CaO-SiO2

Jan 1, 2004

By T. Markus, K. Hilpert

Discharge vessels of advanced light sources are made of translucent polycrystalline Al2O3(PCA).These tubes contain salt mixtures, which essentially consist of metal halides. The salt mixture is present as a melt at the coldest spot of the vessel under operating conditions and vaporizes partly. The temperatures of the coldest spot range between 1200 K and 1300 K, depending on the lamp performance. The maximum wall temperatures range up to 1500 K and for special purposes up to1700 K. Important constituents of the melt are alkali halides AX (A = Na, Cs, X= Br, I) and rare earth metal halides LnX3(Ln = Dy, Ho, Tm). Severe corrosion attack on the wall material is observed in the PCA discharge vessels. The aim of this work is to elucidate the corrosion mechanism. Annealing experiments under well defined temperatures were carried out in order to understand the complex chemical corrosion processes. Two different annealing vessels were used, one for experiments under isothermal conditions with a temperature of 1473 K and one for experiments with a linear temperature gradient from 1450 K to 1600 K. The vessels were filled with salt mixtures of different compositions and annealed for 1000 h. The corrosion attack was characterised by XRD, analytical electron microscopy, high temperature mass spectrometry, and chemical analysis of the salt melts. The results of our investigations show that the corrosion attack is caused by vapour species and by the salt melt. The most severe corrosion is observed in vessels filled with mixtures of alkali halides and rare earth metal halides. No corrosion of the alumina is practically observed if pure alkali halides or pure rare earth metal halides are present in the annealing vessel. Keywords: thermodynamic, corrosion, lamps, metal halide salt

Jan 1, 2004

By John O. Marsden

Technology development has played a crucial role in the minerals industry throughout history. The development of new technology allows mankind to produce metals and minerals at progressively lower cost of production in real terms, and therefore at progressively lower prices, improving their availability, accessibility and utilization worldwide. However, the developers of such technology are not guaranteed to reap the benefits from this effort: There is an expectation that technology developers will gain an advantage over their competitors. Is this a short-term benefit that results from a temporary cost or efficiency improvement, or is it a sustainable longer term "edge" that prevails even after metal or mineral price has been eroded by the implementation of a major step change technology? This issue is examined by reference to several case study examples in the copper industry. BACKGROUND The development and adoption of new technology has played a crucial role in the commodity minerals industry throughout history. As new, cost-efficient technologies are commercialized, the cost of production decreases, and this enables lower grade ore to be processed profitably. This in turn increases the availability and supply of the metal or mineral of interest, and ultimately (in a free market environment where the supply- demand balance determines price) inevitably decreases the metal or mineral price. This leads to the question: Why should mining companies invest in (new) technology development if the result is a decrease in the product price? The answer is to achieve competitive advantage, where the application of new technology enables one or more

Jan 1, 2004

By B Hooper

Deep cuts in CO2 emissions will be required to stabilise and, in the long term, decrease CO2 concentrations in the atmosphere. Technologies for capturing CO2 from major stationary sources (power stations, industrial plants, etc) and storing that CO2 for long periods of time is one of few near term options for decreasing CO2 emissions. This transition to low carbon intensity energy and possibly the hydrogen economy through renewables and in the long-term technological developments such as artificial photosynthesis.Capture of CO2 from post combustion emissions can be done using a range of technologies though costs are currently high and dependent on the concentration of CO2 in the emissions. Techniques include solvents, pressure swing adsorption and the use of membranes. Options for decreasing capture costs by increasing the concentration of CO2 in the emission stream include the use of oxyfuels (in pulverized fuel types boilers) and by moving to integrated gasification combined cycle (IGCC) operations either simply for power generation or for poly-generation opportunities. Once the CO2 has been captured it can be stored using a variety of methods. Storage in the ocean has been suggested but is considered an unlikely option because of environmental uncertainties and political opposition. Mineral storage is a niche opportunity. The greatest potential lies in geological storage of CO2 and this option is commanding increased attention from the Australian and international community.In Australia, the Cooperative Research Centre for Greenhouse Gas Technologies (CO2CRC) is an important new initiative that will support energy companies and energy intensive industries in meeting challenges posed by greenhouse gas issues and assist them in their efforts to reduce their emissions profile.The progress of geo-sequestration and the challenges in the capture and separation of CO2 in the process industries are discussed.

Jan 1, 2004

The Sams Creek gold deposit near Takaka in northwest Nelson was discovered in 1974 by CRA Exploration (CRAE) geologists. CRAE recognised the potential of the area and subsequently undertook a comprehensive exploration programme of geological mapping, soil and rock-chip sampling, geophysical surveys and diamond drilling. Exploration defined sporadic gold mineralisation contained entirely within a deformed and hydrothermally altered, peralkaline granite porphyry dyke with a seven kilometre strike length, and up to 60 m thickness. Rock chip samples indicated extensive and economically significant gold grades over approximately one kilometre strike of the dyke at Main Zone prospect. CRAE completed 30 diamond drill holes at this prospect and defined a limited resource. Oceana Gold Limited recommenced active exploration at the Sams Creek Project in late 2002, focusing on improving the geological understanding and known resource at Main Zone. Completion of 1041 m diamond drilling successfully increased the estimated resource to 10.7 Mt @ 2.12 g/t Au containing 729 000 oz at a 0.7 g/t cut off. A further campaign of 1560 m diamond drilling was undertaken in 2003 - 2004 to extend the resource and test the continuity of high grade mineralised zones. Deeper intersections of the porphyry dyke indicated geometrical complexity and grade variability similar to that observed at shallow levels. Recent research suggests that Sams Creek can be geologically classified as a variant of intrusion-related gold systems, and therefore comparable to some other, very large gold deposits. However, due to the rugged terrain and dyke geometry, surface drilling is reaching the limits of viability at Main Zone. If infill drilling continues to be successful then an underground decline may be developed to facilitate further exploration. Potential also exists along strike, where other significant gold anomalies are known but largely untested by drilling.

Jan 1, 2004

By D Craw

Interactions between structure and lithology in the Hyde-Macraes Shear Zone controlled the style of gold mineralisation at the Macraes mine. Large volumes of rock in some mine pits have most gold disseminated in hydrothermally altered schist, rather than in quartz veins. Mineralisation was initiated in the latter stages of metamorphism. Pods of massive schist rich in quartz and feldspar are surrounded by more fissile schist consisting of interlayered micaceous and quartzofeldspathic schist. Later shears have been partly controlled by the micaceous schist, and anastomose around pods of more massive schist. Micaceous schist was replaced by pyrite and arsenopyrite, accompanied by recrystallisation of phengitic muscovite under lower greenschist facies conditions. Gold occurs in sulfides and with microcrystalline quartz formed during minor silicification. Massive schist is locally mineralised along sulfidic microshears which have phengitic muscovite largely illitised under sub-greenschist facies conditions. Mineralised massive and micaceous schists were overprinted by cataclastic shears, with addition of graphite and more sulfides. Mineralisation occurred during a transition from ductile to brittle deformation regimes as the schist was uplifted in the late Jurassic.

Jan 1, 2004

By K. Shitogiden, Y. Samada, T. Miki

Steelmaking slag contains nutrition such as Si, P and Fe for acceleration of phytoplankton growth. Phytoplankton can fixate carbon dioxide more than any other species on earth. Hence, suppression of CO2 can be achieved by applying the potential of steelmaking slag as the nutrition for their propagation. When it is considered to supply nutrition from steelmaking slag to seawater, we must avoid dissolution of hazardous elements or change of pH of seawater by steelmaking slag addition into seawater. The protection against dissolution of fluorine into artificial seawater has been studied based on dissolution behavior of steelmaking slag and synthesized substances into artificial seawater in the present work. The dissolution mechanism of fluorine from steelmaking slag and buffering action of pH change are discussed by using stability diagram in seawater.

Jan 1, 2004

By Ann Barron

For millions of people, cold weather is a fact of line – and one that can make a major challenge out of just getting to work. But for those working in the blasting industry, a number of obstacles are created when old man winter blows in. In addition to the obvious concerns regarding personal protection, Mother Nature can throw some very nasty weather at the blasting crew trying to travel with explosives products from the magazine site to the job site. As such, divers need to be familiar with cold, ice, and snow driving conditions both on and off the blast site. It’s critical to know what to expect before you leave. Keep informed of the latest weather and road conditions as they change often; it will help you make the right choice in clothing and driving habits. Remember bridges and overpasses will freeze first even in temperatures above or near the freezing mark due to the effects of wind chill. Plan to take extra time to and from the job site.

Jan 1, 2004

By M. C. Bluteau, G. P. Demopoulos

Arsenic reports in the effluents of many non-ferrous metallurgical operations. The production of scorodite, a crystalline ferric arsenate, is considered as an attractive option for the fixation of arsenic from aqueous effluents. However, scorodite solubility and long-term stability in the pH region of interest for tailings disposal have not been thoroughly investigated. In this study the long-term stability of scorodite in the pH 5 to 9 region and the mechanism of scorodite dissolution were studied. Construction of eh-pH diagrams indicated that scorodite stability is highly dependant on the nature (stability) of co-existing iron-hydroxide/oxyhydroxide. It was also found that when scorodite dissolves, a ferrihydrite phase having very small particles size (nano-scale) forms and that the growth and crystallization of this material are delayed by the presence of arsenate even under accelerated (75°C) ageing conditions. Around neutral pH and ambiant temperature (22°C) scorodite seems to reach an equilibrium with ferrihydrite after 48 weeks yielding soluble arsenic concentrations < 5 ppm.

Jan 1, 2004

By H. J. McQueen

The modeling of the extrusion of 6061 alloy and its composites with 10 to 20 vol% Al203 or SiC by two techniques. The uniaxial finite element method FEM (DEFORM" ) provided force-stroke curves and temperature rise over the range 450-500 °C, 2.6-5mm/s and extrusion ratios of 31 and 64. The traditional technique considers ideal work and redundant work as well as friction and uses average temperatures and strain rates. The two techniques are used to clarify each other and to extend the analysis to 400 and 350 °C. The calculated efficiencies are compared to measured values in extrusion trials and to values derived for 7075 extrusion analyses. The analyses are based on constitutive equations determined by torsion testing tests.

Jan 1, 2004

By J F. Seale

The design of the settling pond for the Malvern Hills opencast coal project was based on a primary requirement to control runoff and sediment generated from the immediate 6 ha mine catchment, which included two seepages from old underground workings. The pond has been particularly effective in controlling turbidity in the outflow water, with the consent limit of 50 NTU being met on all but one occasion and normal levels of discharge less than 10 NTU. Water quality testing carried out at the time of consenting indicated that there were no acid-generation issues with the proposed mine site in dominant mudstone strata of the Broken River Formation, and that water from the old mine workings was near-neutral in terms of pH and well-buffered. However, it became apparent over the very dry summer of 2003 - 2004 that slaking of the exposed mudrocks in the mine batters was resulting in significant acidity generation, and outflow pH levels were well below the consent limit of 6.5 during and following periods of rainfall. Although these acidity problems have been remediated in the short-term by the use of lime products, it is clear that a programme of lithotype characterisation for AMD should have been undertaken and this has now been implemented. Design of long-term acid drainage control measures is being carried out, and will probably be based around the use of hydrated lime for pH control with enhancement of natural wetlands.

Jan 1, 2004

By A. Aitio

Sustainable development is one of the central themes of the work of the World Health Organization; chemical safety is one of its important components. For more than 25 years, WHO has had specialized units for assisting member countries in dealing with their problems in chemical safety. For one of the units involved, International Programme on Chemical Safety, a reorientation is in progress to make best use of existing resources, and to prioritise the work to optimally correspond to the needs of the member countries. The risk assessment work of IPCS, and specifically, the work on chromium and chromium compounds, are discussed.

Jan 1, 2004

By K. D. Peaslee, J. M. Soto, IéDé Smith, A. D. Saikia

Spinel-forming refractories reduce penetration of metal and slags through a tightening of the lining resulting from the volume expansion associated with spinel formation. Sintered spinel is often added to reduce the overall volume increase that results. Tests were carried out to evaluate the difference between performance in spinel¬forming and spinel-containing refractory mixes. Eight refractory linings, one (1) pure magnesia, three (3) magnesia-base spinel-forming and four (4) alumina-base spinel- containing dry vibratable mixes, were tested for four hours in contact with a low-carbon, low-manganese steel in a coreless induction furnace at temperatures in excess of 1600°C. Afterwards, sample were cut, and wear and penetration were measured. For magnesia-based mixes wear was minimized using 20-30wt. spinel formation although further experiments are required to determine the optimal value. For alumina-based mixes, there seemed to be an optimal ratio of spinel added to spinel formed that minimized penetration and wear at the slag line. Sidewall accretion occurred and the accretion was the highest for the mix with the ratio of spinel formed to spinel added near the optimum value. Therefore to design an optimum refractory mix the benefits of higher ratios of spinel added to reduce penetration and wear at the slag line will need to be balanced with the tendency to form accretions on the sidewalls of the furnace.

Jan 1, 2004