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By S. A. Abdel Sabour

Strategic decisions in the mining industry are made under multiple technical and market uncertainties. Therefore, to reach the best possible decision, based on information available, it is necessary to integrate uncertainty about the input variables and model financial risk of the project?s merit measures. However, this provides few useful insights to decision-makers unless accompanied by modelling management responses to uncertainty resolutions. It is widely acknowledged that conventional decision-support methods based on static, no-change, discounted cash flow (DCF) techniques such as net present value (NPV) and internal rate of return (IRR) tend to provide inaccurate value estimates. This could mislead the strategic decision-making process and result in significant value losses. This paper aims to model financial risk related to uncertainty about market variables such as metal prices and foreign exchange rates. Other sources of risk that are related, for example, to geology and production costs are not considered in this work. The article outlines a flexible financial model that integrates uncertainty about market variables and management flexibility to react to uncertainty resolutions into mine project valuation using a real-options valuation technique based on Monte Carlo simulation. Significance of information generated from this simulation-based flexible valuation model to the strategic decision-making process is tested using an illustrative case study of a Canadian mining project. The project is a typical multi-metal, open pit mine that produces copper and gold. In this case, there are three uncertain market variables, which are: copper and gold prices and US$/CAN$ exchange rate. Financial valuations are carried out using both the conventional static DCF method and a flexible real-options model. In the flexible model, management flexibility to decide whether to go ahead with the next expansion or terminate production operations is integrated. Results show how the flexible financial model can enhance the decision-making process.

Jan 1, 2009

By A Tawadrous, B Wheeler, D S. Preece, S A. Silling

The two key results of rock blasting are fragmentation and movement of geomaterials. Movement/flow of the blasted rock is often referred to as heave. Moving rock with explosives rather than mechanical equipment can improve mining efficiency. Such is the case with coalmine cast blasting. Controlling and directing rock movement through explosive deck delay timing can greatly improve ore recovery by segregating ore and waste. In both cases, understanding, predicting and controlling heave is an important element of successful blasting.Computer programs for predicting 2D blasting-induced heave have been used in mining for decades, helping to drive the innovation of new and more efficient mining methods, ie cast blasting. The past few years have seen the advent of 3D distinct element modelling of blast-induced heave. This is an important advancement because most blasting situations are three-dimensional in nature, especially when controlling the direction and intensity of rock movement through explosive deck delay timing.This paper documents the first full-scale blasting simulations in 3D with distinct element models that include hundreds of blastholes and in excess of a million particles, made possible with parallel processing. Surface mineral blasting is the focus of this study which treats the effect of blasthole delay timing on ore recovery. Ore waste and dilution resulting from typical row-on-row delay timing will be demonstrated. Also demonstrated will be the ore recovery possible with delay timing designs that significantly enhance ore/waste segregation. This type of high fidelity modelling and the use of electronic detonators makes possible the sculpting of rock blasting muck into separate piles of ore and waste.CITATION:Preece, D S, Tawadrous, A, Silling, S A and Wheeler, B, 2015. Modelling full-scale blast heave with three-dimensional distinct elements and parallel processing, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 127–136 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By Harald Ulrik Sverdrup, Anna Hulda Olafsdottir

The long-term supply of nickel to society was assessed with theWORLD7 model for the global nickel cycle, using new estimates of nickel reserves and resources, indicating that the best estimate of the ultimately recoverable resources for nickel is in the range of 650–720 million ton. This is significantly larger than earlier estimates. The extractable amounts were stratified by extraction cost and ore grade in the model, making them extractable only after price increases and cost reductions. The model simulated extraction, supply, ore grades, and market prices. The assessment predicts future scarcity and supply problems after 2100 for nickel. The model reconstructs observed extraction, supply and market prices for the period 1850–2020, and is used to simulate development for the period 2020–2200. The quality of nickel ore has decreased significantly from 1850 to 2020 and will continue to do so in the future according to the simulated predictions from the WORLD7 model. For nickel, extraction rates are suggested to reach their maximum value in 2050, and that most primary nickel resources will have been exhausted by 2130. After 2100, the supply per capita for nickel will decline towards exhaustion if business-as-usual is continuing. This will be manifested as reduced supply and increased prices. The peak year can be delayed by a maximum of 100 years if recycling rates are improved significantly and long before scarcity is visible.

Jan 26, 2021

By J. B. Boisvert, W. Board, C. R. Mooney

"Traditional geostatistical modelling methods are difficult to apply to heavy-tailed deposits because the extreme positive skew of the grade distribution leads to bias. The focus here is on an innovative method of modelling the high-grade population by conditionally simulating discrete volumes (nuggets) of gold with marked Poisson and Cox processes. Capping and other ad-hoc manipulation of the assay data is not required; however, an intensity map for the point processes is required. The method is demonstrated on a dataset from an epithermal deposit and demonstrates an improvement in reducing smearing and controlling the skew of the grade distribution.RÉSUMÉ Les méthodes traditionnelles de modélisation géostatistique sont difficiles à appliquer dans des gisements dont la distribution de la teneur est à queue lourde car l’extrême asymétrie positive de la distribution de la teneur génère des biais. Dans le présent article, l’accent est mis sur une méthode novatrice de modélisation de la population à haute teneur par la simulation conditionnelle des volumes discrets d’or (pépites) au moyen de procédés marqués de Poisson et de Cox. La limite d’utilisation et d’autres manipulations ad hoc des données ne sont pas requises; toutefois, il faut une carte des intensités pour le processus ponctuel. La méthode est démontrée sur un ensemble de données d’essais provenant d’un gisement épithermal et elle montre une amélioration dans le lissage du flou et dans le contrôle de l’asymétrie de la distribution de la teneur."

Jan 1, 2015

By D. Hodouin

Jan 1, 1978

By A Lyon

The minerals industry, as many other industries, has a wealth of indicators and a thriving æindustryÆ in their development, measurement and reporting. It is natural for this to occur for a new endeavour. However, perhaps it is time for the community concerned with minerals industry indicators to ask whether we have achieved a certain maturation whereby proliferation of indicators may be replaced by a more disciplined and constrained approach. In many natural and engineered systems, thermodynamics provides well-understood and tested constraints. Indicators that are uninterpretable in this framework are not considered acceptable. This paper provides initial evidence that such a formalism may be possible for mine sustainability. The formalism developed does not claim to have the rigour of thermodynamics. However, it does provide a first step towards formalising selection of indicators on the basis of their true comprehensibility. A set of simple equations is developed that represent the conventional five capitals (actually we use six because we separate renewable and non-renewable natural capital) and how they are linked. This is coded into a simulation model. The base equations are then used to develop a system level indicator of sustainability performance, which is asserted to be a reflection of the mineÆs reputation. We define a least sustainable state, termed æmaximum revenue mining (MRM)Æ in the system and define the degree of system sustainability as how far the system is from the MRM. We then introduce a simple mechanism whereby different actors can express differing views on the emphasis for the distance from MRM. Sustainability thereby becomes a non-unique thing that is defined by a distance from MRM and a set of preferences across the capitals.

Jan 1, 2009

By A Lines

This paper addresses a gap in longwall multi-seam interactions and their predictions, providing a case study for future multi-seam operations for both anticipated conditions and a method for understanding the changes in stress regime. Multiple panels were modelled with the results analysed and compared to panel experiences to validate the parameters and properties. The software chosen (LaModel) is a numerical modelling package designed to model stresses and displacements on thin deposits. It utilises a displacement-discontinuity variation of the boundary-element method and has been used extensively throughout both the United States and Australia in multi-seam operations. Analysis of the results demonstrates a clear correlation with the above workings and regions of significant strata instability. This provides the opportunity going forward to analyse new models and incorporate into mine planning and geotechnical designs. Continuous site-based assessment should be undertaken at multi-seam operations to better understand and quantify likely vertical stress levels within the workings. With a detailed analysis of models prior to extraction and a review of models post extraction. Further research is required as LaModel is limited to vertical stress and it is likely that interactions impact both the horizontal and shear stress regime. 3-dimensional modelling could further assist in this understanding, combined with a thorough stress monitoring regime. CITATION:Lines, A, 2018. Modelling multi-seam interactions for longwall mining, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 185–195 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By R Steinhaus, D M. Frantois-Bongarton, P W. Cleary, G K. Robinson, M D. Sinnott

Multotec Process Equipment and Dominique Frantois-Bongarton have a patent for a mineral sampling device, which they call a æTrue-Belt SamplerÆ. This uses a plough, which is rotated about an axis parallel to a conveyor belt to throw material off the belt. A fixed sample cutter takes a sample from the material thrown off the belt.Discrete element modelling has been used to consider a range of plough designs, plough speeds, positions for the cutter relative to the plough, cutter apertures, cutter designs and frictional properties, prior to the building of a physical prototype. This modelling work will be discussed, both as an illustration of the role of modelling in the development of new materials-handling devices and in order to explain the likely strengths and weaknesses of this new type of sampling device.CITATION:Robinson, G K, Sinnott, M D, Cleary, P W, Steinhaus, R and Frantois-Bongarton, D M, 2012. Modelling of a ætrue-belt samplerÆ - A new device for sampling from a conveyor belt, in Proceedings Sampling 2012 , pp 33-40 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 21, 2012

By Ngonidzashe Chimwani, David Glasser, Diane Hildebrandt

"Milling circuits play an important role in achieving the desired product; tonnage, size distribution and properties, since they are directly linked to the comminution energy consumption for the whole process. A grinding model with a mathematical simulation was developed for an open milling circuit with a scalped feed from a hydro-cyclone. The circuit was optimized by determining the optimal conditions in terms of energy consumption which would produce a floatable product having a desired size range (i.e. -75 +9 µm) for a platinum-bearing ore. The simulation results showed an operating region comprising the best combination of the ball filling and mill speed to achieve the highest production of a floatable size class, with the minimum energy consumption.INTRODUCTIONBall milling is usually conducted in closed circuits in order to achieve a desired product size without material overgrinding. The technological importance of optimising milling circuits cannot be overemphasised (Toneva and Peukert, 2007). Previous work has brought significant insights into the benefits of modelling milling circuits (Austin et al., 1984; King, 2012; Toneva and Peukert, 2007). However, the ability to model these circuits is dependent on the performance of the classifiers and the fidelity of the grinding mill model used compared to the actual circuit (Toneva and Peukert, 2007). Austin et al. (1984) identified five types of milling circuits as shown in Figure 1 namely; the grinding circuits employing mill in an open circuit, normal closed circuit, reverse closed circuit, open circuit with scalped feed, and, the combined closed circuit. Depending on the presence of the first classifier, the second, or both as well as their corresponding loops (streams), the combined circuit (e) can reduce to; an open (d), a normal closed (b), an open circuit with scalped feed (c) or a reverse closed circuit (a). In the case of an open circuit, the mill is operated without being directly influenced by a classifier. The normal closed circuit does not have the first classifier and therefore the make-up feed is the actual feed stream. Conversely, the reverse closed circuit keeps only the first classifier. The open circuited with scalped feed has only the first classifier but does not have the second one. The overflow stream from the classifier is mixed with the mill product to form the final product for the downstream process."

Jan 1, 2016

By B Yeganeh, A Sam, A Kohsari

The base of separation at Gol-e-Gohar iron ore plant (Sirjan in the south of Iran) is magnetic separation after milling. Magnetic separation in the plant is divided into two parts: dry magnetic separation and wet magnetic separation. Sixty-five per cent of the plant production belongs to the dry magnetic separator section. Therefore, investigation of this part of the plant is necessary. Prediction of plant production is one of the most important subjects in mineral processing plants. That means, before feed enters the plant, specification of production has been calculated with laboratory methods. The purpose of this paper is the prediction concentrate quality has achieved from the dry magnetic separator. The content of iron in the final dry concentrate will be predicted, with laboratory, pilot and modelling methods, before feed enters the plant. Different variables are used in this approach, which consist of: speed of the first dry magnetic separator (rougher), speed of the third dry magnetic separator (cleaner), iron content in plant feed, size of 80 per cent passing of feed, size of 20 per cent passing of feed and iron content in pilot dry magnetic separation concentrate that performs in a standard manner. The artificial neural network is used for modelling and one of its branches is the radial basis network (RBN). Iron content in magnetic separating concentrate in plant will be introduced as the target and will be calculated with the RBN method. In the RBN method, a set of data enters to neural network and they will be trained and simulated. Finally, the target will be predicted. Ultimately, the original target (actual iron content) and the predicted target (predicted iron content) compare and error of them will be calculated. The obtained result is acceptable and satisfactory.

Jan 1, 2007

By Amar Prakash, V. M. S. R. Murthy, Ajoy Kumar Singh, Avinash Paul, John Loui Porathur

Weak, layered, and fragile rock mass formation, if not supported properly, is subject to roof failure thereby affecting safety and productivity in underground coal mines. Though Central Mining Research Institute – Indian School of Mines Rock Mass Rating (CMRI-ISM RMR) based well-defined support design guidelines are established, still occurrence of roof failures in underground coal mines is a real matter of concern for mining engineers and researchers. Numerical modeling techniques are successfully used by several researchers by simulating rock mass condition for stability assessment of mine openings. The analysis becomes crucial in case of weak and fragile rock formation. The present research envelops the determination of 31 cases of rock load by CMRI-ISM RMR under different geo-mining conditions followed by the development of modified Rock Mass Rating (RMR), i.e., rock mass rating dynamic ( RMRdyn) by incorporating P-wave velocity as a new parameter. The rock load determined using RMRdyn and numerical models was correlated and found in close agreement. In addition, the deviation in rock load determined by all the three approaches, i.e., CMRI-ISM RMR, numerical modeling, and RMRdyn, was compared with the actual field data. The percentage deviation obtained in RMRdyn and numerical modeling is less compared to CMRI-ISM RMR.

Sep 1, 2023

By Pedro Lobarinhas

In the present work a two dimensional computational model is derived for the description of the time dependent heap leaching process. The flow inside the heap is calculated using the diffusion equations for the flow in porous media. The soil conductivity is also estimated assuming a close packed structure for the grain packing inside the heap. These equations, with appropriate boundary conditions, are solved using a time step splitting scheme. From this calculation the amount of leaching reagent in contact with the ore at any position inside the heap can be calculated and, once coupled with appropriate reaction equations, the amount of metals extracted can be computed and leaching agent concentration updated. The model is tested with available experimental data and the results have shown to be in a very good agreement. The model predicts all the transient features of the data.

Jan 1, 1999

By P B. Hills

This paper discusses the computerisation of the drill hole database, some historical records and the creation of a three-dimensional model of the gold bearing structures for resource estimation and mine design at the Beaconsfield Gold Mine in northern Tasmania. The phase of the work reported here commenced in November 1997 and was completed in March 1998. The historical mining on the Tasmania Reef had reached a depth of 450 m below surface when work ceased in 1914. Production up to this time was 854 000 ounces gold. Recent activity has concentrated on testing depth extensions of the previously mined ore structure, to a depth of 1000 m below surface, and the establishment of an underground mining operation to exploit this resource. The lode structure at Beaconsfield is a typical mesothermal vein style deposit. Gold is contained within narrow quartz, carbonate and minor sulphide reefs or veins. Reef width is variable from a few centimetres to several metres with æsplitsÆ or bifurcations being common. The reef averages 2.7 m true width in the economic zones. The key feature of this style of mineralisation is that reef continuity can be confirmed by drilling to a high level of confidence, but the gold grades are somewhat more erratic in nature. The resource estimates were based entirely on drill data. The drill intercepts on the reef were coded for each split directly into a database and these allocations validated graphically. The distribution of grades and widths show an increasing gold grade with reef width for both the drill hole and historical data. The same histogram patterns, mixed populations and overall arithmetic average grade for the historical mine (at 21.52 g/t > 3 g/t Au) and new drill data (at 21.55 g/t > 3 g/t Au) would indicate that there has been no major change in the overall style or grade of the ore from the historically mined areas to the new resource. The reef, host geology, area of historical workings and resource zones at the Beaconsfield Mine were defined as a series of closed wireframes. The Tasmania Reef was modelled as five mutually exclusive wireframes, one each for the Main Reef, Footwall split, Second footwall split, Third footwall split and Hangingwall split. The data for this exercise was extracted directly from the drill hole database, stored in Microsoft Access format. The formation of the solids was largely automated with manual validation and refinements allowing for multiple runs using different interpolation methods and combinations of drill holes. A rotated 3D-block model in the plane of the Tasmania Reef was created to contain the grade model and allow for tonnage, grade and reef width estimates. An inverse distance squared (ID2) interpolation method was used with ranges of 25 m along strike and 125 m down plunge with blank areas infilled with 50 m by 250 m. Each reef split was filled separately using only drill intercepts from that split. The method was independently validated used MIK methods. Longitudinal sections have been prepared showing gold grade, reef width and width +grade. Estimates were also made for arsenic, sulphur and other minor elements. The long sections show three distinct mining zones. A method is presented for the conversion of the resources to reserves by the addition of mining parameters for minimum mining width, minimum pillar, cut-off grade and internal and external dilution. The selection is done on columns within the block model, and allows for all splits to be considered at once. Multiple runs can be made for varying combinations of parameters to test different mining methods and their impact on reserves, mine life and NPV.

Jan 1, 1999

By A D. Campbell, G R. Power

The increasing availability of marker data in sublevel caving operations is changing the way draw can be managed to achieve positive recovery outcomes in these mines. This paper describes how marker data has been incorporated into flow simulations to help calibrate full mine ore recovery simulations for the forecasting and optimisation of recovery.Some flow modelling techniques do not use marker data, relying instead on the outcomes of physical and numerical experiments to guide assumptions about an idealised recovery flow shape. Other mines have access to marker trial data, but find it difficult to specifically link this marker trial information to their recovery models. This can make it difficult to create a link between the marker trial information and recovery forecasting and limits the potential value of the marker trials at the mine.In the simulations shown here, the marker rings are fully incorporated into the flow model, and can be tracked in the model. The model is compared against the real underground marker recovery information to give the user an indication of how accurately the flow settings in the model are reflecting the conditions in the experimental marker rings. An example of use of this system at an operational mine is included.CITATION:Power, G R and Campbell, A D, 2016. Modelling of real-time marker data to improve operational recovery in sublevel caving mines, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 105–110 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By A. Chagnes

This paper presents a modelling tool that can be used to predict the behaviour of solvent extraction processes. In particular, this model allows calculating metal extraction efficiency as a function of pH, solvent flowrate, stripping flowrate and aqueous feed flowrate in the mixers-settlers. This model is applied to the recovery of cobalt from acidic chloride media by using CYANEX® 272 as extractant diluted in kerosene. Keywords: Cobalt, mixer-settler, modelling, solvent extraction

Jan 1, 2020

By P. Myllykoski, J. Nylander

"A commercial program package called Crownoff for the simulation of temper rolling in four high mills has been verified against measured data. The agreement between measured and calculated transversal strain distributions of the strip was found to be good. Effects of the strip crown and work roll bending force on the strain distribution were simulated. The results showed that when a single ground camber of work rolls is used for all strip widths; the strip crown should be parabolic, excluding the edge drop. An increase or decrease of the strip crown by 30 % during a coil can be compensated by a 2 to 5 t change in the work roll bending force. The ability to control the strip crown by work roll bending was insensitive to strip width. IntroductionCold rolled steel strips are usually temper rolled after recrystallization annealing, which follows cold rolling. The purpose of temper rolling is to suppress the yield point, finish the strip surface and correct possible flatness errors. The presence of a yield point might otherwise cause problems during subsequent forming processes. The in homogenous yielding in non-temper rolled steels leads to the formation of Lüders bands in the strip surface.The rolling force is influenced by the rolling speed and changes in frictional conditions in the roll bite. Therefore it is very important to plan carefully the mill settings and control algorithms during rolling. The purpose of mill control algorithms is to ensure constant reduction and the best possible strip flatness during the entire coil.Correctly predicting the rolling force is important for determining the mill presettings. Torque, forward slip and power requirements are not usually critical, if the reductions are small. However, the large elastic deformations occurring in the roll bite make the physical description of the process difficult. Physical rolling models developed for cold rolling contain assumptions that lose their validity as the reductions decrease to the level of one per cent."

Jan 1, 1994

By Carl Bertrand, Patrice Nadeau, Claude Bazin

"Rio Tinto Fer et Titane processes the ore extracted from the Lac Tio orebody to concentrate the hemo-ilmenite (FeO.TiO2-Fe2O3) mineral that is subsequently smelted to produce pig iron and titanium oxide slag. The ore is crushed, heat treated (roasted) and concentrated using dry magnetic separators. This paper describes a model to predict the magnetic susceptibility of the roasted ore and its behaviour in the magnetic separation plant. The model uses a classification of the ore as a function of the size and magnetic susceptibility of the particles. A subsequent division into mineral species allows the simulation of the magnetic separation process. The model is used to assess various operating options when process disturbances occur.INTRODUCTIONOre processing operations consist of ore size reduction followed by the recovery of valuable species in a concentrate that is subsequently sold for its minerals or metal content. The concentration processes are based on the physical and/or chemical properties of the minerals contained in the ore. Flotation is typically used to recover minerals of base metals such as copper, zinc, lead or nickel. Iron ore and other dense minerals are typically concentrated by gravity separation processes. Magnetic separation uses the magnetic properties of the minerals to concentrate magnetite and other minerals, to clean coal concentrate and to recycle ferrosilicon for dense separation processes (Brophy, 1985).Magnetic separators can be divided into low and high intensity separators and high gradient magnetic separators (Gillet, 2008). Most of the low gradient magnetic separators are built as rotary drums that are operated in wet or dry conditions. Dry magnetic drum separators are used by Rio Tinto Fer et Titane in Sorel-Tracy, Canada to concentrate hemo-ilmenite from the ore extracted at the Lac Tio Lake mine near Havre St-Pierre, Canada. The analysis of production data suggests that process improvement could be achieved by identifying key variables for the control of the magnetic separation circuit and/or by modification to the circuit flowsheet. The use of a process model was considered to be an effective approach to conduct a preliminary analysis of the circuit with a view toward process optimization. However, the literature contains few detailed studies dealing with the modelling of magnetic separation processes."

Jan 1, 2011

By Z. Duran, M. Genc, B. Erdem, T. Dogan

This study aims to develop a model for particulate matter concentration during the loading process in open pit mining. The researchers conducted simultaneous measurements of particulate matter and meteorological parameters and collected samples to determine the moisture content of the loaded materials. The analysis used 7,895 measurement data points from gypsum and limestone quarries, employing two data analysis programs, SPSS® and Waikato Environment for Knowledge Analysis, to derive equations for predicting particulate matter release. In the modelling, particulate matter measurements were the dependent variables, while meteorological parameters, laboratory measurement results, and loader bucket capacities were the independent variables. The classical regression models did not adequately capture the dependent variable, thus, the researchers explored the decision tree approach for further modelling. The M5P algorithm was used to generate regression equations for the different data sets, and the findings showed that the models had a satisfactory degree of predictive capability. The number of fine particles released during loading is influenced by various weather factors. Temperature, humidity, wind speed, and station pressure can all affect the dispersal of these particles. Additionally, the moisture content of the loaded material and the capacity of the loading equipment contribute to this process. The M5P decision tree algorithm, which is rarely used in particulate matter concentration models, provides an innovative approach to developing local concentration estimates for non-coal surface mining.

May 8, 2026

By E. Tabosa, S. Vianna, K. Duffy, W. Valery, B. Andrade, L. Pyle, P. Holtham

Pneumatic flotation cells are high-intensity flotation machines with rapid kinetics, resulting in short residence times. Examples include the Jameson, PneuFlot and ImhoFlot cells. These cells do not use impeller-like mechanical cells. Rather, the air and pulp are mixed in a continuous stream of high fluid velocity through a downcomer or venturi to disperse the air into fine (approximately 0.5 mm) bubbles and maintain particle suspension. Froth wash water is often used to enhance concentrate grade, minimising recovery by entrainment. With the growing application of these types of cells, not only in cleaner stages (their traditional use) but also in pre-flotation and scalping duties, there is a need to predict their performance more accurately for circuit design and optimisation. No widely accepted model for pneumatic flotation cells is available and their metallurgical performance is often scaled up from laboratory and/or pilot plant testing by assuming fixed values for metal recovery, concentrate grade and concentrate percent solids. This paper describes a new approach to simulate pneumatic flotation cell performance and presents case studies demonstrating its applicability. Keywords: Pneumatic flotation, flotation modelling, flotation circuit design, flotation circuit optimisation, Jameson cell

Jan 1, 2020

By Pierre Montmitonnet, Yukio Shigaki, Jonatas Mezêncio Silva

A precise roll stack deformation model of a flat rolling mill is crucial for strip profile assessment as it depends strongly on the roll’s deformation. The need for more and more advanced products with stringent both geometrical and mechanical tolerances (e.g., Advanced High Strength Steels – AHSS), with thinner and harder steel strips, demands more advanced simulation models. The present paper addresses assumptions made in Finite Element Method (FEM)-based roll stack models on some important, yet barely discussed features: What is the impact on precision of the simplifications such as symmetry and anti-symmetry? Should roll neck boundary conditions in bearings be considered as fixed or simply supported? In this paper a hybrid model developed by the authors for a general flat rolling mill is used to assess those questions. This model runs much faster (100x in some cases) than a whole-FEM-modeled 6-high rolling mill with the elastoplastic strip deformation, thanks to its simplifications adopted. This model assumes a steady state rolling condition, and the roll stack is modeled with tridimensional finite elements, and the loads are calculated via a slab method adopting a plane strain state for the strip deformation (especially true for thin strips). An industrial 6-high cold rolling mill is modeled and results on the application of symmetries and different boundary conditions on the roll’s necks are presented. It is concluded that the application of symmetries and anti-symmetries for the 6-high rolling mill is possible for thin strips. And the way the necks are modeled does not impact on the final strip shape, though it influences the magnitude of the roll’s displacement. The coupling of the strip with the work roll applied assuming a symmetry plane of the arc of contact has little influence on the strip shape.

Oct 1, 2019