Search Documents

By G Turner-Saad

An improvement to cut-off grade optimisation theory based on geometallurgy has been completed. The improvement fundamentally consisted of taking into account mineralogical and textural characteristics instead of grades. These characteristics are related to the spatial variability of mineral abundance, association, particle size and liberation properties. Additionally, the improve- ment considered the spatial variability of mineral processing liberation and selectivity properties associated with mineralogy and texture. The enhanced optimisation enables estimation of the economic value of mining operations based on an optimum cut-off policy attributed to liberated and selected ore minerals.The enhanced optimisation was developed as an essential component of a joint cut-and-fill mining and mineral processing methodology based on mixed integer mathematical programming. The formulation considers static and dynamic modifying factors that vary over the projected life of mining. The objective function of the mathematical formulation consists of maximising the realistic expected economic value of concentrates or products of liberated and selected ore minerals, whilst minimises liberated and selected gangue minerals. The optimal solution is obtained when the objective function is subject to geological, mining, processing, marketing, smelting, refining, environmental and financial constraints. The methodology accesses geometallurgical multivariate resource models, which integrate the spatial variability of mineralogical and textural characteristics and mineral processing liberation and selectivity properties.The geometallurgical process concurrently optimises stope geometries, ore reserves, mining sequences, and mining and mineral processing production based on the enhanced cut-off of liberated and selected ore minerals. In addition, the process considers additive and non-additive transfer functions associated to mutually exclusive geometallurgical spatial domains. The transfer functions also take into consideration the blending of mineralogical and textural characteristics with mineral processing liberation and selectivity properties.This contribution presents an example of cut-off grade optimisation via mineralogical and textural characteristic, and liberation and selectivity processing parameter optimisation for a spatially variable orebody.

Sep 5, 2011

A simulation and animation model was constructed for the Stockton Coal Mine. This mine is located in the north western area of the South Island of New Zealand. This model was used to study the optimum size of the stockpile areas whilst achieving the correct product coal qualities. The model evaluated the impact on stockpile size and product coal qualities for both bulk and selective mining. The effect of modifying the amount of known clean coal quality was also investigated. The software used was GPSS/H« for the simulation and Proof Professional« for the animation. From the study, it was recommended to incorporate selective mining in future studies. The shipping plan needed to be modified for a better correlation between coal production levels, in situ coal resources and wash plant capacity.

Dec 6, 2010

By S Kakara, A Kamaraj, S S. Varanasi, B V. R Mandalika, M B. Shaik

The properties of top slags play a very important role in secondary steelmaking. Fluxes should be chosen based on the ladle furnace (LF) slag requirements like viscosity, melting temperature, sulfide capacity, etc. CaF2 and CaO-Al2O3-based synthetic slags are the most used fluxes in secondary steelmaking to improve slag fluidity and interfacial chemical reactions. CaF2 is obsolete due to fluorine pollution and CaO-Al2O3 based slags have 40–50 wt per cent Al2O3 and 30–40 per cent CaO which is not beneficial for desulfurisation. Yet another drawback is that LF slag disintegrates into fine powder during cooling due to phase transformation C2S (2CaO.SiO2). Hence, there is a need for the development of low melting fluxes with high CaO content and the capability to prevent slag disintegration. The current work studied the effect of 0–9 wt per cent B2O3 on physico-chemical properties and characterisation of LF slags. X-ray diffraction (XRD) analyses were carried out to identify mineralogical phases present in slag and Fourier-transform infrared spectroscopy (FT-IR) analysis was done to understand the changes in bonds of B2O3 added LF slag. The characteristic temperature of slag was determined by a hemispherical method using high-temperature microscopy. Empirical models were used to calculate viscosity, break temperature, and sulfide capacity. FactSage™, ver 8.2 (by GTT-Technologies) simulations were carried out to find the equilibrium phase fractions and percentage of liquid slag at different temperatures. New phases such as Ca11B2Si4O22 and Ca2B3O5 were formed in LF slag with B2O3 addition. Based on the results, 0.5–1.0 wt per cent B2O3 was found to be sufficient to prevent C2S-driven disintegration of LF slag. Also, the melting temperature and viscosity of LF slag were reduced by adding 3–8 wt per cent B2O3 due to the formation of BO3 planar triangular structure and low melting eutectics in slag. Liquid slag started forming at a temperature as low as 800°C when B2O3 is >6 wt per cent. It was found that the sulfide capacity, viscosity, and break temperature of the slag decreased with increasing wt per cent B2O3. Based on the analysis carried out, B2O3 can be a promising fluxing material in secondary steelmaking, for improving the desulfurisation kinetics and valourisation potential of LF slag.

Aug 21, 2024

By Kam KM, Tran B

Statistical techniques of Box and Jenkins (1976) have been used to assess the existing control schemes and determine the dynamics of flash smelting furnace at the Kalgoorlie Nickel Smelter. Pertinent process variables, such as, oxygen flow, flux flow, matte grade and iron to silica ratio in slag, were considered in the analysis using routine operating data collected over two periods of operation. Results indicate inadequate control of some of the important variables. Dynamic characteristic parameters (dead time and response time) between a set of input and output variables were identified to improve optimisation of the existing thermodynamic model used for flash furnace control.

Jan 1, 1996

By D E. Gadd

Since October 1972, New Zealand Steel Mining Ltd has loaded around ten million tonnes of ironsand concentrate from single-point mooring buoys located off-shore at Taharoa on the west coast of the North Island of New Zealand. Before the first off-shore loading system was installed a considerable research effort was applied to proving the slurry loading technique. Subsequently the system has been expanded and a new buoy, pipelines and pumping system were installed in early 1978. Since then 110 000 DWT class ore carriers have been loaded at rates of around 2600 tonnes per hour through twin submarine pipelines. This paper reviews the operation of the ship loading system and attempts to answer the question: 'If the Taharoa operation were to be planned in 1980, would the same research spending be necessary or have published research results since, made such practical tests unnecessary?'

Jan 1, 1980

By R G. Reddy, A Yahya

The sulfur distribution ratio (Ls) is an expression of the amount of sulfur in slag to the amount of sulfur in molten metal. The sulfide capacities calculated from Reddy-Blander (RB) model were used to calculate the sulfur distribution ratio (Ls). A new Reddy model for sulfur distribution ratio (Ls) was developed for modelling Ls for ironmaking, steelmaking, and secondary steelmaking conditions. Besides calcium oxide, the major component in the ladle furnace (LF) slags is alumina. The Ls was calculated for typical LF slags as a function of temperature and composition. The model calculated Ls values are in good agreement with the experimental and industrial slags data. The extremely low oxygen potential in these furnaces after fully-killed steel is favourable for desulfurisation. For any given slag’s composition and temperature, its sulfide capacity can be calculated a priori. The equilibrium sulfur distribution ratio between this slag and liquid metal in a particular vessel can also be calculated a priori. The Ls for ladle furnace (LF) slags is about twice those for blast furnaces (BF) slags and ten times those of basic oxygen furnace (BOF) slags. The desulfurisation of pig iron in BF and desulfurisation of steel in LF during secondary steelmaking are recommended. Steel desulfurisation in steelmaking furnaces is not effective. Since the model used to calculate the sulfur distribution ratio (Ls) is a priori, it is a useful tool for the iron and steel makers in improving the product quality and optimisation of the industrial furnace operations.

Aug 21, 2024

By E Jak, G Khartcyzov, M Shevchenko

The increasing complexity of ore resources and recycled materials in the feed of pyrometallurgical processes present a technical challenge to the metallurgical engineers working on maximising the recovery of the valuable elements and minimising the environmental impact of the processes. To address this challenge, the availability of computational tools that can predict the mass and energy balance in complex systems is required. Then the accurate description of phase equilibria in the complex multicomponent systems describing the chemistry of the pyrometallurgical processes becomes critical for the correct implementation of the indicated tools and facing the outlined industrial challenges. In the present study the distribution of selected elements (Pb, Zn, Fe, As, Sn, Sb, Bi and Ni) between oxide liquid and metal in the ‘CuO0.5’-CaO-AlO1.5 system in equilibrium with Cu metal at 1400°C (liquidus of CaAl2O4) was experimentally studied using the equilibration and quenching technique followed by the electron probe X-ray microanalysis of the resulted samples. The study covered a wide range of effective p(O2) over the system from 10-11 to 10-3.5 (corresponding to formation of immiscible CuO0.5-rich slag). To avoid loss of volatile elements (Pb, Zn, As, Sn, Sb and Bi), a correlation between ‘CuO0.5’ in oxide liquid and p(O2) in open system was obtained first, followed by studying the volatile elements distribution in closed conditions (Al2O3 crucible sealed in SiO2 ampoule), where ‘CuO0.5’ concentration was used as a marker to evaluate the effective p(O2) over the system. The experimental results were then used for the optimisation of the thermodynamic model parameters of the system as part of the integrated experimental and self-consisting thermodynamic modelling research program of phase equilibria in the Cu-Pb-Zn-Fe-Ca-Si-Al-Mg-O-S-(As, Sn, Sb, Bi, Ag, Au, Ni, Cr, Co and Na) gas/oxide liquid/matte/speiss/metal/solids system.

Jun 19, 2024

By J L. Mauk

The Sovereign, Jubilee, Scotia and Jasper Creek prospects occur in an area of ~3.0 km by 2.5 km (~7.5 km2) in the Hauraki goldfield. The prospects are hosted by andesitic to dacitic flows, autoclastic breccias and localised pyroclastic and air fall deposits. Jubilee and Sovereign prospects lie along the northern and southern parts of the Waitekauri Fault, respectively, whereas Scotia is located ~1 km to the E, and Jasper Creek a further ~1.2 km to the ENE. Wall rocks are typically intensely altered, although the degree of alteration becomes more variable east of Scotia and at Jasper Creek. Alteration minerals include quartz, adularia, albite, chlorite, pyrite, illite, interstratified illite-smectite, smectite and calcite. Several of these minerals have distributions that show distinct zonation with adularia most abundant at Sovereign and Jasper Creek, but restricted to shallow levels at Scotia. Illite occurs throughout Sovereign and Jubilee plus the western margin of Scotia where it grades into interstratified illite-smectite; smectite predominates at Jasper Creek. Veins are uncommon and typically narrow, but show distinct zonations. Quartz veins are more abundant at Sovereign and Jubilee, whereas calcite veins are more abundant at Scotia and Jasper Creek. Laumontite veins occur at Scotia, and rare clinoptilolite, mordenite and stilbite veinlets with calcite occur at Jasper Creek. Fluid inclusion in quartz and calcite homogenised between 141¦ to 272¦C and trapped a dilute solution with an apparent salinity of less than 2.6 weight percent NaCl equivalent. Homogenisation temperatures are hottest at Sovereign (average 241¦C) and Jubilee (average 239¦C), cooler at Scotia (average 204¦C) and coolest at Jasper Creek (average 162¦C). Calculated paleowater table elevations suggest the water table was 680 m to 750 m above sea level at Sovereign and Jubilee, 450 m at Scotia and 225 m at Jasper Creek. The current data suggest three scenarios that can explain why Sovereign and Jubilee are deep and hot, whereas Jasper Creek is cool, shallow and marginal; 1.   some or all of the prospects may represent separate overlapping hydrothermal system, 2.   a high-relief hydrothermal system on the side of volcano with an inclined water table and outflow towards Jasper Creek, and 3.   a low-relief hydrothermal system that has been either tilted or block faulted with greatest uplift and erosion to the west.

Jan 1, 2005

By P Bergin, J M. Galvin, J Harris, J Li, P Kirsch, M Shi, B Hebblewhite, B Whittaker, R Mitra, D Sprott

Controlling unwanted ground movement is critical in mining as well as many other highly hazardous environments, such as construction and tunnelling. Sharing knowledge about effective hazard management is paramount to improving health and safety and operational outcomes across industries, and some industry sectors have embraced this openness as part of the way that they do business. In 2010, the Australian Coal Association Research Program funded the RISKGATE project to build a body of knowledge for managing a broad range of hazards across mine sites, lease areas and mine infrastructure within a mine-life or product life cycle perspective (eg from exploration through to decommissioning, or design through to operation). The RISKGATE body of knowledge was assembled from Australian coal industry experts through a semi-structured bowtie analysis-based action research workshop cycle. By capturing operational knowledge from industry experts, RISKGATE serves to provide a cumulative corporate memory at a time of high personnel turnover in the coal industry.This paper presents an overview of RISKGATE topics within the geological and geotechnical domain (strata underground, ground control open cut, outburst, coal bumps and bursts, tailings dams and inrush) with a summary of individual topic structures, as well as showing the contrasts and inter-relationships between these ground management topics. The online user can access information about the causes, controls and consequences related to a priority unwanted event (ie the point at which control of energy is lost) and use this information as a prompt for the development of risk assessments, incident investigation, audits of practice/plans/procedures and for training and development.The paper concludes with a discussion of how RISKGATE can be adapted to other mining domains (eg coal outside of Australia, hard rock mining worldwide, construction, tunnelling) and the opportunity for application of this body of knowledge and the RISKGATE action research process for knowledge management in other highly hazardous environments.CITATION:Kirsch, P, Hebblewhite, B, Sprott, D, Harris, J, Li, J, Shi, M, Whittaker, B, Galvin, J M, Bergin, P, Mitra R and Williams, D, 2014. RISKGATE – shared coal mining knowledge for managing risks across ground management, in Proceedings AusRock 2014: Third Australasian Ground Control in Mining Conference , pp 247–254 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 5, 2014

Newmont Waihi Operations is participating in the initiation of a community liaison forum in association with the local district council. The objective is to provide a forum for the free and regular exchange of ideas, concerns and information, and through improved communication seek to achieve a more comprehensive set of solutions to community, operating and closure issues associated with Martha Mine. A similar liaison forum has been operated on two previous occasions during earlier phases of the present mine's operation. This paper deals with the practical aspects of setting up a liaison forum to act as an effective conduit between regulators, mine operators, local businesses and the community. The mechanisms and procedures for identifying community issues and concerns are dealt with. The actions and structures required to ensure effective ongoing community 'buy in' at all levels are discussed. Corporate philosophies are addressed. Specific examples from Martha Mine, Waihi New Zealand will be used to illustrate the paper. This will include a brief explanation of previous and current community issues, Newmont Waihi's operations both at Martha Mine and the proposed Favona underground mine, and the practical issues involved in setting up a liaison forum.

Jan 1, 2003

The introduction of many new hydraulic ally and pneumatically powered impact breakers over the past few years demonstrates the growing interest in this technique of breaking rocklike material. The most practical method yet devised to increase the blow energy range of hammer type impactors without incurring weight penalities, is to cushion the impact of the hammer on the tool. This has been achieved in one impact breaker by means of replenisible fluid cushions between the tool and the hammer, and blow energies up to 27,000 joule (20,000 ft. lbs.) have been achieved. Impact rock breaking is becoming an important alternative to the use of explosives in the mining and the construction industry. The design of impactors is discussed and manufacturers data is presented for most of the machines now available. A review of the research and mechanics of breaking rocks with impactors is presented and the benefits of high energy impactors are discussed. The relative merits of three impactor design types are explored with regard to achieving high blow energy.

Jan 1, 1978

By Simpson D, Skopakow J

This paper is one of the series of papers relating to the Melbourne Underground Rail Loop and specifically describes the structural and architectural design of Museum Station. Structural arrangement, loads and design methods of the major temporary and permanent works are briefly described for the main station and entrance works. Planning of the station concourse area, booking halls and entrances are described together with the selection of finishes for all above and below ground areas.

Jan 1, 1981

By S-C Shim, H-R Lee, Y Kang, H Shin

Since iron oxide and silicon oxide are major gangue components in various types of ore, FeO-SiO2 base slag, ie fayalite slag, has been often encountered in pyrometallurgical processes of non-ferrous metals. During most matte production processes such as the smelting of Cu, Pb, and Ni, the FeOSiO2 based slag is inevitably formed and plays an important role in refining crude metal as well as engineering aspects. Recently, similar pyrometallurgical approaches have been attempted in the recovery of valuable metals (Ni, Co, Cr) from wasted secondary batteries. Thus, the viscosity of the FeO-SiO2 based slag has great significance in properly controlling smelting processes. However, when molten metal or matte does not coexist with the slag during the measurement, there has been a serious difficulty in maintaining Fe valance and consequently, the slag composition. In the present research, the viscosity of molten FeO-SiO2 slag was measured in 1573~1673 K using a rotational viscometer. In order to keep the state of iron oxides, the oxygen partial pressure was controlled using CO/CO2 gas mixture. The optimised ratio of CO/CO2 could be calculated using Fe/Fe2+ and Fe2+/Fe3+ equilibria at each temperature. The composition of the slag, particularly Fe valance, after the measurement was analysed with the aid of an inductively coupled plasma – optical emission spectroscopy (ICP-OES) and an automatic potentiometric titrator. The measurement showed that the FeO-SiO2 slag has considerably low viscosity values in the molten state, and it sharply increases as the temperature decreases. In spite of the careful oxygen partial pressure control, a part of Fe2+ was found to be oxidised to Fe3+, with a maximal case reaching about 20 per cent. The increase in viscosity of FeO-SiO2 at low temperatures can be attributed to the composition change due to an unavoidable Fe2+ oxidation. In addition, the relationship between the change in the viscosity and the liquidus temperature of FeO-SiO2 based slag was discussed to understand the composition dependence of viscosity.

Jun 19, 2024

By M Darby, B Burdett, F Lovell

The results of the process control improvement project aimed at improving the quality of Australian Bulk MineralsÆ (ABM) iron ore pellets produced by four vertical shaft furnaces are very positive. These results are achieved through process stabilisation and optimisation, improvement in process monitoring and taking early corrective actions when operating variables were outside the target ranges. A number of benefits are obtained from this project. These benefits include: More consistent and improved pellet quality. The average cold compression strength (CCS) value of pellets produced during the eight-month trial is 260 kg/pellet, which is 16 kg/pellet higher than that produced during the 12 months prior to the trial (244 kg/pellet). Reduction in the heat input by eight per cent, from 727 MJ/tonne to 668 MJ/tonne. Reduction in bentonite rate by six per cent, from 7.1 kg/tonne to 6.7 kg/tonne. Increase in the furnace throughput rate by four per cent and additional production of 10 000 tonnes per annum through process stabilisation. Better understanding of the process behaviour. This knowledge is valuable not only for setting the target operating conditions but also for developing the ABM expert system to control the process.

Jan 1, 2005

By N Guresin, R Dunne, S Blanco

This paper presents the results of research work conducted to assess if aqueous solutions of sulfur dioxide (SO2) can be used to treat roaster calcine leach residues such that recovery of gold in this material can be achieved with subsequent application of the thiocyanate (SCN-) leaching system. The project is mainly aimed at assessing an alternative use for sulfur dioxide gas generated during flotation concentrate roasting. The calcine leach residue sample used in the study contained 2.56 g/t gold. The reason for this high level of residual gold is thought to be due to gold surface passivation by thin iron oxide films, presence of gold in solid solution with refractory iron oxides and encapsulation of gold in the structure of these iron oxides.The study was conducted in three stages. The first stage was the characterisation of a sample from a roaster calcine leach residue. The second stage in the project was a set of leaching tests to assess the feasibility of using aqueous solutions of sulfur dioxide to reductively dissolve refractory iron oxide mineral phases contained in the calcine. The final objective was to assess the efficiency of thiocyanate, a gold complexing ligand stable under acidic and oxidative conditions, to extract gold liberated during sulfur dioxide leaching.The study showed that the reductive sulfur dioxide treatment of the calcine leach residues followed by oxidative thiocyanate leaching to extract gold was not a particularly efficient process as only around 20 per cent gold could be extracted. Leaching the calcine residues by any of these systems separately also extracted the same amount of gold (12 - 14 per cent) implying that irrespective of the solution potential, the acidity helps dissolution of gold encapsulating minerals, mostly hematite, but at a very slow rate. The findings on the topic in the literature and during this study show the requirement for further technical investigations and economical analyses on two cases. The first case is to roast gold concentrates to produce magnetite rather than hematite followed by sulfur dioxide and thiocyanate leaching of magnetite containing calcines. The second case is to apply a magnetic concentration process to conventional roast-cyanidation calcine residues to produce a gold-rich magnetite concentrate that can be further treated with sulfur dioxide followed by thiocyanate leaching.For both cases, the best evaluation of the sulfur dioxide leach system in extracting residual gold from calcine leach residues will require a detailed economic analysis to find out the balance between the value of the gold recovered and the loss of revenue from acid production. There are a number of roasters that do not produce acid. In these cases, a portion of the unwanted sulfur dioxide gas can be used to recover gold in magnetite containing calcines as an economic incentive.CITATION:Guresin, N, Blanco, S and Dunne, R, 2013. Leaching roaster calcine leach residues with aqueous solutions of sulfur dioxide and thiocyanate, in Proceedings World Gold 2013 , pp 129-136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

The combustion characteristics of Australian coals which contain high inertinite have been studied in a laboratory drop tube furnace and a Thermogravimetric Analyser. The pyrolysis chars and combustion residues were microscopically characterised using a modified coal petrography technique. Results indicated that the overall burnout of inertinite-rich Australian coals under pulverised fuel combustion conditions could be generally within a range of 97 - 99 per cent burnout. The studies showed that poor coal burnout cannot be generally related to high inertinite content in the Australian coals. The extent of coal burnout varies from coal to coal and vitrinite as well as inertinite may contribute to the unbumt chars in combustion residues. Combustion conditions had greater influence over char formation and coal burnout than the coal properties. However, under similar pf combustion conditions, coal rank and coal maceral composition had a strong influence over the coal combustion behaviours and final coal burnout. Simple correlations using coal properties may be used but with caution to determine coal volatile release and burnout at high temperature and rapid heating conditions.

Jan 1, 1991

Enhancement of Energy Efficiency in Fine Grinding of Copper Sulfide Minerals Using a Pilot-Scale Stirred Media Mill - IsaMill The mineral liberation size of run of mine ores has dramatically reduced over recent years. As a result, the demand for fine grinding which is the most energy-intensive form of grinding has markedly increased in the minerals industry. Furthermore, the fine grinding costs increase exponentially with decreasing product particle size. As a result of the increased energy requirement for fine grinding, it is desirable to optimise fine grinding processes such as stirred media milling (ie IsaMill) to enhance energy efficiency, throughput and the product fineness. In the present study, the influence of slurry rheology, grinding media type and grinding media-to-feed size ratio on energy efficiency in a pilot-scale IsaMill was investigated under certain industrially relevant pulp processing conditions. It was shown that a critical rheological state existed, below which the energy required to achieve an 80 per cent passing (ie P80) 20 ¦m product size was unaffected by shear rheology (ie apparent viscosity and shear yield stress) whilst above which the grinding energy required increased dramatically with increasing shear rheology. Colorado River sand (3.35 mm) showed higher energy efficiency than MT1 ceramic media (2.5 mm) for a target P80 of 20 ¦m in the solids concentration range of 38 to 55 per cent by weight, but the former experienced more than four times the wear rate of the later. The high wear rate of the Colorado River sand may be due to its much lower hardness. For feeds with an 80 per cent passing (ie F80) 70 to 110 ¦m, 2.0 or 2.5 mm MT1 media appeared to be more energy efficient than 3.5 mm MT1 media whilst a media-to-feed size ratio of 41 to 53 is applicable for ~50 ¦m (ie F80) feeds for efficient grinding.

Sep 13, 2010

By Huber A. L

Research and development into alternate gold and precious metals adsorbents has resulted in the development of a new technology named the AUROSAVE adsorption process (ARGOSAVE'" for high silver con- tent ores). Adsorbents called VITROKELE'" can be tailored for either Gold I (cyanide leach) or Gold III (halide leach) applications. VITROKELE consists of a chemically synthetic adsorbent carried on an inert substrate, often a polystyrene bead. It is suitable for both in- pulp and in-solution use. VITROKELE adsorbent offers certain advan- tages over both carbon and ion exchange resin adsorbents. This paper describes testwork on Australian ores and commercial solu- tions obtained from operating Australian plants demonstrating the kinetic loading characteristics, elution methods and other operating parameters of VITROKELE adsorbent in the cyanide system. Brief reference is made to VITROKELE in the Gold III system.

Jan 1, 1988

By Kissell F. N, Volkwein J. C

The U.S. Department of Interior's Bureau of Mines has the opportunity to visit many U.S. mines, including some that claim 2 to 5 times the national average of 334 raw tonnes/unit shift (tps) from a continuous miner section. In a project to assess the reasons for this high production, the Bureau conducted two studies. The first study focused on the 25 highest producing continuous miner sections. What stood out during the visits-was the quality of the labor-management relations. In each of the mines there was a positive labor/management relationship based on mutual trust and a sense that the employees were the company's most valuable resource. Discussions with labor revealed a universally positive attitude toward the company. Interviews with the mine superintendents invariably ranked the quality and attitude of workers as more important than anything else. Also during the mine visits of the 25- mine study, no engineering factors obviously stood out. Time at the face was greater than average, most were in coal over 1.52 m and the roof was generally good. Also, none of the 25 mines had to contend with high methane levels. Because this study found that a high percentage of mines were in seams less than 1.52 m thick, the second study examined thin seam mines only.

Jan 1, 1988

By H Kim, M J. Sun

Global steel companies are actively combating climate change by reducing carbon emissions. Traditional steel production, using the blast furnace (BF) – basic oxygen furnace (BOF) process, heavily depends on coal and emits substantial CO2. To mitigate this, companies are transitioning to the more eco-friendly DRP (direct reduction plant) – EAF (electric arc furnace) process, which lowers CO2 emissions. This study quantitatively evaluates the impact of increased hydrogen consumption on the carbon footprint of product (CFP) through an analysis of direct reduction process heat and mass balances. The study prioritises a comprehensive material balance based on mass conservation principles. The heat balance is calculated using differences in enthalpy through state energy properties, avoiding heat consumption. Validation using operational data from Hyundai Steel Dangjin works’ blast furnaces shows close alignment between calculated results and actual data, with less than 1 per cent error. This methodology facilitates a detailed analysis of the direct reduction process, offering insights into its feasibility and efficiency. Analysis of the operational impact by increasing the hydrogen ratio demonstrates reduced CO2 emissions and increased heat requirements due to the endothermic nature of hydrogen reduction, in contrast to the exothermic CO reduction. Possible solutions include raising reducing gas temperature or enhancing flow rate. The study effectively utilises designed heat and mass balances to assess material quantities and thermal balance under different operational conditions. It lays the foundation for the initial direct reduction process design, aiding in deriving and optimising operational parameters. Additionally, it provides valuable insights into the challenges of increased hydrogen, contributing to the production of greener steel by addressing these issues.

Aug 21, 2024