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By J. Leon-Torres, D. M. Stefanescu, P. A. Curreri, S. Sen

"Experiments were performed under terrestrial gravity (lg) and during parabolic flights (10·2 g) to study the solidification and macrosegregation patterns of Al-Cu alloys. Alloys having 2% and 5% Cu were solidified against a chill at two different cooling rates. Microscopic and Electron Microprobe characterization was used to produce rnicrostructural and macrosegregation maps.In all cases positive segregation occurred next to the chill because of the shrinkage flow, as expected. This positive segregation was higher in the low-g samples, apparently because of the higher heat transfer coefficient.A 2-D computational model was used to explain the experimental results. The continuum formulation was employed to describe the macroscopic transports of mass, energy, and momentum, associated with the solidification phenomena, for a two-phase system. The model considers that liquid flow is driven by thermal and solutal buoyancy, and by solidification shrinkage. The solidification event was divided into two stages. In the first one, the liquid containing freely moving equiaxed grains was described through the relative viscosity concept. In the second stage, when a fixed dendritic network was formed after dendritic coherency, the mushy zone was treated as a porous medium.The macrosegregation maps and the cooling curves obtained during experiments were used for validation of the solidification and segregation model. The model can explain the solidification and macrosegregation patterns and the differences between low- and high-gravity results."

Jan 1, 1999

By M. K. Pathak, A. K. Mukhopadhyay, D. C. Panigrahi

Changes in machinery operating and design parameters often result in unexpected vibrations or changes in the vibration patterns. Vibration in a system is an undesirable element that can cause machinery distress. Potential damage can be prevented by identifying the vibration level that is due to the changed operational parameters. This is necessary for the safe and reliable operation of plant equipment. This paper presents a documented study on vibration events that resulted from alterations in operating and design parameters in a mine ventilation fan and analyzes the causes by defining the sequence of events that led to its performance deficiency. This paper is based on experimental effort to study the vibration behavior of a ventilation fan under varying operating conditions.

Jan 1, 1999

By S. Neven

The smelting of copper anode slimes, a material which contains mostly lead, silver, copper and selenium, has been practiced for many years with a view to recovering the silver and associated small amounts of gold. However, a theoretical understanding of the process has been lacking and this handicaps efforts to improve and intensify smelting operations. In the past few years work has been done in this area and this work will be reviewed in the paper. The underlying thermodynamics of the oxidation of silver-copper selenide mattes has been developed and used as a basis for the construction of a computational thermodynamics model which attempts to predict the composition of all condensed phases during the course of smelting. The model will be outlined and its successes in matching experimental data, as well as its current deficiencies, will be considered. Supporting work on the thermodynamics of silver solubility in slags, on activity-composition relationships in the Ag-Se system and work in progress on the oxidation state of copper in the slags will be reviewed. These projects are designed to provide further detailed data which will improve the robustness of the thermodynamic model.

Jan 1, 1999

By M. E. Rossi

Reconciliation of production information is critical to evaluating the effectiveness of the predictive models, and to allow for optimization of mining operations. Whether mining open pit or underground, mine-to-mill reconciliations can be one of management's better tools to perform proper accounting, and a very useful evaluation and optimization tool. This paper proposes a set of criteria and objectives for a typical reconciliation program; also presents a stepwise, logic approach to performing reconciliations, and discusses the benefits and costs associated with the up-keeping of the information. It also highlights some of the potential pitfalls involved, and methods used to avoid collecting misleading information. These issues are illustrated with an example of a model-to-mine-to-mill reconciliation program being implemented at an operating mine; the program involves multiple predictive models (Long-term and Short-term block models), different open pit and underground mines, stockpiling, and at least 23 different mill streams. This paper presents the initial results of the program implemented at Minera Michilla S.A.

Jan 1, 1999

By J. A. Madonna

Independent prospectors and small to large-scale exploration company personnel have requested, and are in need of, guidance in geochemical field sample collection methods which will provide the most reliable results during chemical analysis. In cooperation with analytical laboratories, experienced geochemical exploration scientists and mining companies a systematic collection procedure has been developed. The procedure consists of collecting uncontaminated, water, sediment and rock chip samples of the appropriate quantity and/or dimensions to meet the needs of analysis.

Jan 1, 1999

By J. Drelich

An improved experimental procedure to measure contact angle has been consolidated with coal surface preparation involving polishing with abrasive paper, alumina powder, and a cloth, followed by ultrasonic and mechanical cleaning. Specifically, the captive-bubble measuring technique has been compared with the sessile-drop technique and the former has been recommended for the examination of the hydrophobic properties of coal surfaces. Results of the research program, which is currently under way, on the examination of the effect of the nature, amount, size and distribution of mineral inclusions in coal on its wettability are briefly reviewed.

Jan 1, 1999

By G. Duncan

Distinct trends in grinding mill technology have emerged in recent years. In an effort to optimize overall mill performance for the needs of the End User, broad measures of logistical speed, process flexibility, operational risk, and overall costs now exert greater influence on the specification of grinding equipment. As a result, innovative alternatives to conventional grinding mill structures, supports, drives, feed, and discharge configurations are now being offered and selected with greater frequency. This paper investigates these trends in grinding mill technology, utilizing optimization and decision-theory techniques. In particular, the paper considers how specific advances in process design, product engineering, manufacturing techniques, and mining operations continue to relax technological constraints, enabling further mill innovation. In this context, a methodology is presented, illustrating how proper selection and specification of grinding mill components and configuration can target an optimization of the four End-User performance measures listed above..

Jan 1, 1999

By J. Gray, J. Peck

As the turn of the century approaches, traditional open pit mining methodologies and processes are being modified through the introduction and use of new technologies. As in other industries, the personal computer is dramatically changing the traditionally conservative mining industry by allowing mines of varying size and capacity to increase their productivity and efficiency through the use of easy to use, office software. Computer-based monitoring and control systems are also being used more frequently to measure and optimize, in real-time, the performances of operating equipment. When communicated to an end-user, this information can provide accurate and timely answers to questions of how much, where, when, and by whom. This capability forms the foundation of a more comprehensive, proactive management and planning facility where, ultimately, information acquired from the producing equipment will be used to optimize and control machine and human activities. As these technologies mature and become essential tools in a mine, they will eventually serve as the basis for more robotic and autonomous mining operations.

Jan 1, 1999

By Nico Steenekamp

At Lonrho Platinum in South Africa, ores from both the Merensky and UG2 reefs of the Bushveld Igneous complex are treated by flotation and smelting to produce a nickel-copper matte which serves as a collector for the platinum group metals (PGM' s). The nickel-copper matte was originally shipped to Norway for treatment and recovery of the contained base metals, with the return of the PGM rich concentrate to South Africa. The Lonrho Platinum Base Metal Refinery was commissioned in 1985. The original process employed a Shenitt Gordon design. The converter matte is treated in a refinery which utilises both atmospheric and pressure leaches for the dissolution of base metals to produce nickel sulphate crystals, copper cathode and a PGM concentrate. This paper refers to flowsheet and operating changes as well as improvements within the Base Metal Refinery.

Jan 1, 1999

The development of a robust belt sampling strategy and protocol inunderground gold mines is a fundamental requirement for effective grade quality control, ore accounting and mine-mill reconciliations. As part of the ore management system, a belt sampling system has been developed by the author, which is used to predict monthly gold grade and its error for underground/belt/mill reconciliation and grade control. This paper presents the step-by-step development of the belt samplingstrategy and sample preparation protocol at Target, an underground gold mine in South Africa. The belt sampling system at Target consists of an underground belt transporting run-of-mine material into an underground transfer point, a weightometer, a two stage crushing system, a tube splitter and a catchment device. The design allows run-of-mine ore on the belt to be sampled automatically by a go-belt sampler. GyÆs sampling theory of particulate materials forms the basicframework of the belt sampling strategy. The theory is used to quantify the optimum sample mass of broken material to be taken from the belt and to predict its reliability. It is also employed to determine the Fundamental Sampling Error (FSE), time interval between samples and particle size requirements of the final underground belt sample. Further, GyÆs sampling theory provides the means of analysing the crushing processes, splitting, segregation error, analytical variance, and the best sample preparation protocol. Although the belt sampling strategy developed in this study was forWitwaterstrand gold ore, the process is entirely general and may be very successfully used in any underground or surface mine.

Jan 1, 1999

By Milorad Cirkovic

Kinetics of copper concentrate oxidation in roasting processes in a fluidized bed reactor has been studied at temperatures between 600°C and 720°C using particles of 0.038 to 2.5 mm in average size. The analysis of composition of samples has been done by chemical methods. Phase composition has been determined by Siemens X-ray equipment with Cu anticathode and Ni filters at a voltage of 40 kV and a current of 18 mA. The content of sulphur has decreased from 33.23 to 19.02 mass percent with the increase of temperature, but the content of Fe304 has increased from 0.15 to 17.14 mass percent. The new mechanism of copper concentrate oxidation in a fluidized bed reactor is proposed in this study. It has been shown from the mathematical model that the velocity of oxidation of copper concentrate between 600°C and 720°C is virtually controlled by the rate of diffusion of 02 through the layer of reaction product.

Jan 1, 1999

By J. M. Mutmansky

The usual method employed to determine the direction of flow in a connecting airway in advance is to conduct a survey between the two existing nodes being connected by means of the new airway. It is then assumed that airflow will take place from the node with higher pressure to the node with lower pressure. The purpose of this paper is to examine this direction-of-flow problem --using properties of the system characteristic curve for a two-terminal network --and specify some conditions that ensure that flow will take from the higher-pressure node to the lower-pressure node. It is concluded that the only requirement is that all characteristic curves of fans in the network should be strictly decreasing. Five numerical examples illustrate some important properties of the direction-of-flow problem.

Jan 1, 1999

Electronic Detonators have made significant strides over the last few years, both in quality of product and performance in different blast applications. The precision and flexibility of the SMARTDET units provides the mines with a powerful means of controlling blast results, giving both cost and productivity improvements. The SMARTDET Electronic Detonator System, robust and easy to use, has been successfully deployed over the last 18 months in improving mine productivity and creating safer working conditions in both quarrying and long-hole stoping. The key to the improvements has been the precision and flexibility of the electronic timing, and the ability of the mine personnel to grasp the concept quickly and use it effectively.

Jan 1, 1999

Over the last ten years geological and mining software products have evolved greatly. Software companies developing such products have focussed almost exclusively on the development of technical aspects of the applications, addressing geological, ore reserve estimation and mine planning problems. These specialist applications, and the many other new technologies that are being developed by a myriad of niche developers, are an essential part of todayÆs hi-tech mining operations. Technology is also being used in many other areas to improve the mining process and there is no doubt that tremendous advances are being made in all these fields. Yet there is something missing. The manner in which the technologies are used and implemented has led to the creation of many independent and inefficient æislands of technologyÆ where a variety of products from different vendors are used to address different, but related problems. Problems occur with unreliable information, data duplication, data redundancy and transferring data between applications that may be incompatible or even run on different computer platforms. These problems impede the flow and availability of information and hamper day-to-day decision-making by mine management. A solution to this problem is to take a holistic view of all the various technical applications and incorporate them into a single information technology solution. This solution must encompass all of the information requirements of a mining operation and must provide facilities that address much of the modern thinking about mine management, including strategic mine planning, value management, key performance indicators, and maintenance of a mineral balance sheet. Gemcom is developing an Integrated Resource Asset Management System (IRAMS), which is an enterprise-wide integrated computer system that encompasses various applications typically found at a mining operation. The core component of the system is a common, open, industry standard database that can be shared by many users from each of the different departments at a mine. Around that central repository are the primary applications that provide the mine with information it needs to operate. Ensuring that the information is reliable, accurate, shareable, timely and consistent will eliminate many inefficiencies, and provide significant benefits to mining companies. In turn these benefits will lead to significant improvements in decision-making, productivity and profitability for the operation. The initial version of the IRAMS system is currently being implemented at the De Beers Venetia Mine in South Africa. The system is being built around a core repository using the Microsoft æBack OfficeÆ architecture, and incorporates key technical applications from Gemcom, Whittle, De Beers Technical Team, Wenco and JKTech. The benefits of enterprise-wide systems have long been recognised in the commercial arena and enterprise resource planning (ERP) systems such as SAP, JD Edwards and MIMS are becoming commonplace in the mining industry. The more forward looking software developers and mining companies realise the need for efficient management of the information gathered during the mining process and can see that the concepts used in ERP systems apply equally to the technical applications as they did to commercial applications. The use of IT in the mining industry has expanded tremendously over the last five years as enabling technology and management acceptance has become more prevalent, and there is considerable room for dramatic growth over the next five years. The evolution of geological and mining software has now reached the stage where mines will yield the greatest returns by integrating the applications used in each area of their operations.

Jan 1, 1999

By Robert S. Gärtner

The selective aluminum extraction by 3 different calixarenes (p-tert-butyl-calix[4]arene-tetra¬2-acetic-acid-ethyl-ester, p-tert-butyl-calix[4]arene-tetra-2-acetic-acid and p-tert-butyl-calix-[4]arene-di-2-acetic-acid-ethyl-ester) from an industrial pickling bath solution was studied. The pickling bath solution contained hydrofluoric and phosphoric acid as its main components. The aluminum removal was not successful and also no significant extraction of trace metals present was observed.

Jan 1, 1999

By A E. Waltho, W J. Shaw

Predicting the physical characteristics of various ore types has for long been a difficult problem during mining. Grade control practices tend to concentrate on the chemical grade of the ore. Estimation of physical characteristics such as beneficiation behaviour is commonly limited to the simplistic application of historical averages. Large amounts of geochemical data are often gathered during the exploration and mining stages of a project, especially in ferrous and base metal deposits. In addition to the elements of principal economic interest, samples are often analysed for suites of gangue constituents to determine whether the mineralisation lies within target specifications. This multi-element data is often put to no other use than this simple chemical classification, yet it may present the geologist or metallurgist with valuable insights into the mineral content and physical characteristics of the deposit. Normative mineral estimates have been used as a method for characterising igneous rocks for almost 100 years. The method establishes and applies a set of sequential rules, by which the chemical components of a sample are assigned to mineral components. Provided that it is possible to make some realistic assumptions about the mineral species likely to be present in a rock unit or deposit and their paragenesis, this approach can be extended to a variety of mineral deposits. The geochemical data that are routinely collected when, for example, drilling iron ore and base metal deposits, can be used to derive estimates of normative mineral content. These estimates can be used to characterise physical or metallurgical aspects of the ore, such as density, beneficiation behaviour and metal recovery. This paper examines the application of normative mineral estimates to a variety of practical resource characterisation problems. The potential for predicting the lump and fines proportions of iron and manganese ores is also discussed.

Jan 1, 1999

By S. Seetharaman

The present paper presents. the concept of micro-models and illustrates the application of the same in the simulations metallurgical processes. Development of micromodels requires access to accurate thermodynamic, thermophysicaland kinetic information for the relevant systems with suitable models to extrapolate the data as functions of temperature and composition. Experimental measurements and modelling of the thermodynamic properties, sulphide capacities and viscosities of oxide melts carried out in the department are presented. The incorporation of these models in process models, with special reference to ladle refining of steel is illustrated. Typical example of micro-modelling of solid-gas reactions is also presented.

Jan 1, 1999

By Benjamin P. Hay

Complexation of a metal ion to a ligand often results in structural changes that introduce steric strain within the ligand. A design criterior:1 for ligands that will complex metal ions more strongly is to choose Iigar:1d architecture, that minimizes this strain. This paper describes how molecular mechanics models can be used to define the degree of ligand binding site organization in terms of' ,strain energies associated with conformational reorganization and distortion of the binding conformer. This approach yields a method to predict how modifications to ligand structure will affect metal binding affinity.

Jan 1, 1999

By A E. Annels, I P. Hodkinson an, S P. Barr

Narrow vein systems represent an important source of gold, which have generally been exploited by small to medium sized companies. Their evaluation poses particular problems because of their grade and geological complexities. The determination of grade is arguably the most important activity in resource estimation, as it is generally grade and not tonnage that makes an orebody. This is particularly true of narrow vein-gold deposits whose resources are generally relatively small, though medium to high-grade (6 - 40+ g/t). They often display extreme grade anisotropy in all directions. Two grade populations are generally observed; 1) low, often subeconomic, background grades and 2) high-grades associated with discrete ore shoots. It is possible for gold to be distributed within the wallrocks as well as within the vein. Extremely high-grade values typify this style of mineralisation and require special consideration during grade estimation to determine if top cutting is valid or not. Estimation of both width and accumulation in 2D on vertical longitudinal projections or inclined planes have historically been used to evaluate narrow veins. Resource estimates based on traditional 2D methods is still widespread, but has in some cases been replaced by computer-based 3D modelling. Grade estimation methods are well-known, ranging from classical to geostatistical. Historically, classical methods such as inverse distance weighting have been used, though geostatistical indicator kriging methods are sometimes applicable. Geostatistical studies are driven by the production of reliable variograms, which in narrow gold veins is often problematic. It is generally difficult to define resources from drillhole intersections beyond the inferred and indicated categories with any confidence. In the majority of cases underground development is required to define measured resources and ore reserves. Trial mining/bulk sampling is often used to test estimated grades and also provides important data on ground conditions and the parameters relating to the proposed mining method required for ore reserve definition. Regular reconciliation should be undertaken between the estimated stope grades, grades indicated from stope/truck sampling and grades realised in the mill in order to determine whether correct evaluation strategies are being applied. The important feature of narrow vein-gold deposits is their strong geological controls; in response to this, geologists must understand the geology as best as possible.

Jan 1, 1999

By Toshihiko Emi

The quest for cleaner steel is driven by increasingly stringent requirements from the manufacturing and construction industries. Key issues are the occurrence and removal of inclusions; These are discussed in the context of the unit processes of deoxidation, refining, transfer and casting of molten steel. Process thermodynamics and kinetics are also discussed. Recent progresses achieved and problems yet to be solved are elaborated, and an integration of the unit processes into a system to produce extra clean, steels with better performance is presented.

Jan 1, 1999