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By Oliver Schulz

This paper presents the latest references of the Siemens VAI slab casting technology. Following the connect & cast philosophy Siemens VAI has developed technological packages suitable for installation in existing casters of any original supplier, as well as for complete new machines. A major demand on new machines is to adapt quickly to different market demands. This requirement for flexibility can be divided into two actual trends. Firstly into casting a broad range of steel grades, thicknesses and width on the same machine and secondly having installed slab, bloom and billet caster in one steel plant to deliver all different types of needs on the market. Depending on the condition of the existing machine the focus of modernization ranges from the substitution of single components featuring state-ofthe-art technology to complete caster revamping projects. In this paper concepts and references for short machine outages and fast caster ramp-ups at moderate investment costs are presented.

Jul 30, 2018

By Thomas Germershausen

Worldwide BOF-based steel plants are faced with demanding environmental requests and rising energy costs. For cleaning of primary gases from the BOF the scrubbing technology is worldwide adapted. For wet-scrubbers there is a direct relation between pressure loss and achievable clean gas dust content. Subsequently main energy consumers within Gas Cleaning Plants are the driving fans. To evaluate actual performance and to identify optimization measures extensive field measurements at existing Gas Cleaning Plants were performed. The operational results from various BOF plants worldwide will be presented and benchmarked. As a conclusion, advanced control strategies for reduced energy consumption and lower environmental impact were developed and implemented.

Jul 30, 2018

By Patrik Bloemer

Reliable and accurate furnace bath level data during the melting process is invaluable for good decision making and furnace optimization, while obtaining such information rapidly and safely on a regular basis is of paramount importance. This paper shows how a melting process problem was identified as a concern, how a solution was sought and how a real-time measurement system was tested by simple modification to an existing temperature sampling manipulator. Also how, with furnace power on or off, taking reliable hot heel, fill and running levels could be used to assist melting control, aid decision making and improve safety.

Jul 30, 2018

By Norbert Asamer

At various stages during the hot rolling process, the different rolled products – blooms, billets, bars, respectively sections, but also slabs or plates – need to be cut. While the cross sections of these products are being reduced during each rolling pass, the lengths are being increased accordingly. Thus, it becomes necessary to cut the products to shorter lengths suitable for the next steps of production by state-of-the-art designed dry abrasive cut-off machines.

Jul 30, 2018

By Filippo Verlezza

The 3-roll technology is a recognized process applied to SBQ production. The main aim of this paper is to show the latest developments on this technology including other equipment´s that also contributes for a better performance on SBQ coils production.

Jul 30, 2018

By Karl Berger

The paper gives a comprehensive overview of the historical development of various metal rolling technologies and also describes the influence to industrial and socio-economic developments. The rolling of steel, in particular of rails, beams, rebar, strip and plate has enabled the large scale transport and travel, the building of bridges and buildings, the manufacturing of ships and cars. All this has changed the face of the world significantly. Further the paper approaches technological highlights in the design, manufacturing, drive and control of modern mills and the various types developed to create industrial economic units for the different markets and customers’ requirements. An outlook of future challenges is as well discussed in the paper. Various solution approaches for the rolling technologies, from continuous improvement of existing plants to more radical new concepts like endless rolling, near net-shape casting and rolling are approached. A positive conclusion is drawn that rolling technologies will remain a valuable area for engineers with scientific and economic challenges, but also a clear vision for positive contribution to further industrial and social development.

Jul 30, 2018

By Paulo Eduardo Melo da Cunha

Com um cenário de constante mudança na área e logística, uma demanda cada vez maior por transporte rápido, eficiente e a baixo custo, muito se tem exigido dos gestores de logística na solução, otimização e implementação de soluções criativas para desatar o nó logístico existente hoje no país. A falta de infra-estrutura tanto interna, quanto externa tem dificultado o trabalho e comprometido os resultados globais das empresas. Muitos trabalhos já foram realizados, mas as constantes mudanças, aumento dos volumes transportados em cada modal, a falta de planejamento governamental, tem exigido novas formas de trabalhar. Um relacionamento mais próximo dos fornecedores de transporte, com grande envolvimento dos clientes e áreas comerciais é fundamental para os bons resultados e é desta forma que buscamos otimizar o fluxo ferroviário para a região da grande BH.

Jul 29, 2018

By C Nucifora, M Landers, J Jones, G Maddocks, K Mandaran, A Forbes, W Wilson, S Newman

Glencore’s Mount Isa Mines Limited (MIM) operates the Mount Isa open cut and underground copper (Cu) and zinc-lead (Zn/Pb) mines near Mount Isa in Queensland, Australia. Tailings from processed Cu and Zn-Pb ore is contained in a 1,315 ha shallow (< 35 m deep) multi-cell valley fill tailings storage facility (TSF). Static geochemical testing conducted by MIM over the life of mine (LoM) verifies that the Cu, and Zn-Pb tailings has a wide range in sulfide content and diverse mineralogy with significant acid neutralising capacity (ANC) in some samples. The tailings are predominantly classified as potentially acid forming (PAF) using static analytical methods. Kinetic leach testing using free draining columns and humidity cell tests simulating tailings placed on the surface of the TSF suggest that the tailings samples are likely to remain non-acid forming (NAF) for 10 to 40 years under aerial exposure, and much longer than this under saturated conditions within the TSF. During this period of weathering, as ANC is depleted, the neutral pH drainage may contain elevated concentrations of some elements including sulfate, manganese and zinc. Only when the ANC is depleted would the tailings then begin to produce acid drainage. CITATION:Mandaran, K, Jones, J, Nucifora, C, Maddocks, G, Landers, M, Forbes, A, Wilson, W and Newman, S, 2018. Mount Isa Mines Rehabilitation Materials Sampling and Analysis program for closure planning, in Proceedings Life-of-Mine 2018, pp 138–140 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By G R. Hancock, M J. Saynor, J B. C Lowry, K G. Evans, M Narayan

Tools such as landform evolution models (LEMs) provide a means of predicting how a landform may evolve over extended periods of time. Here, we utilise the CAESAR-Lisflood LEM to assess a proposed rehabilitated landform of the Ranger Uranium Mine in the Northern Territory of Australia (Figure 1). The environmental requirements for the closure of the mine state that the final landform must be able to physically isolate tailings material from the environment for a period of at least 10,000 years (Australian Government, 1999). However, uncertainty exists as to the reliability of model predictions representing thousands of years.In this study, we use model predictions from an undisturbed pre-mine landform to calibrate the parameters used in model simulations of a post-mining rehabilitated landform over a simulated period of 1,000 years. Specifically, we vary environmental conditions such as rainfall, presence/absence of vegetation and surface particle size characteristics in a series of model simulations to determine their impact on the respective landforms, to revise model input parameters as required. A simulated period of 1,000 years was used as it represents a period in which long term landform evolution patterns and trends may be established and identified. CITATION:Lowry, J B C, Narayan, M, Evans, K G, Saynor, M J and Hancock, G R, 2018. Using an undisturbed landform to calibrate long-term predictions of the evolution of a rehabilitated landform, in Proceedings Life-of-Mine 2018, pp 133–137 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By R L. Grogan

Regulators of deep-sea mining projects are becoming increasingly hesitant about the concept of adaptive management as a tool to facilitate compliance and continuous improvement. Adaptive management is a relevant and useful instrument to ensure that the mine plan is successfully implemented throughout the life of mine, in parallel with optimum environmental performance and compliance.CITATION:Grogan, R L, 2018. Adaptive management in deep sea mining – looking like you know what you’re doing when it’s never been done before, in Proceedings Life-of-Mine 2018, pp 20–22 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By H J. J Boshoff

Pit lakes, as a final void after completing open cut mining, are in most cases unavoidable. Initial mine designs and approvals require consideration and assessment of closure objectives, legislation and stakeholder acceptance to ensure suitable understanding of the closure liability. Mining companies undertake studies and engineering during the planning, operational and closure stages of mining to identify closure options for the final voids, which would be sustainable. Without adequate planning prior to and during the life of the mine, options during the closure stage become limited resulting in costly closure works or long-term liabilities. Engineering consultants provide a specialist service in the assessment of long-term pit lake water levels and characteristics. Ongoing advances in mining methodology and technology, coupled with improved data collection and data management aid in a better understanding of the complexities in estimating long-term pit lake water levels and characteristics. Closure objectives developed during the planning stage sets the requirements for long-term pit lake water levels, which could require maintaining a water level and pit water or discharge water quality. A variety of approaches could be used to assess these closure scenarios each requiring specific data and methodologies. Typically, limited data is available during the planning stage, which results in assumptions based on past experience and relevant case studies. Closure assessments are revisited during the life of mine and leading up to the closure stage, during which additional site-specific data is available improving the accuracy of the assessments.CITATION:Boshoff, H J J, 2018. Assessment of approaches, data requirements and methodologies for estimating long-term pit lake water levels, in Proceedings Life-of-Mine 2018, pp 28–31 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 25, 2018

By R Williams, M Baxter, D Zink, R Cunningham

The purpose of this paper is to discuss the efficient operation of a tailings dewatering circuit comprising a thickener and filter press through proper control and automation. It is common to see thickeners and filter press circuits each with their own control systems. This can cause multiple issues when trying to increase efficiency and reliability of the tailings management process. By automating the thickener and filter press controls, you are eliminating any delays and inconsistencies caused by human error and process variations. When done properly the system can maintain a consistent product as the feed characteristics change. Previously, operators would have to monitor the process parameters and adjust the system accordingly. This can now be accomplished using state of the art process control equipment that continuously monitors and adjusts critical variables using Programmable Logic Controllers (PLC) and Proportional Integral Derivative (PID) loops. The paper will detail the control theory used to maintain these systems, highlight other benefits of having a fully integrated plant such as predictive maintenance and remote diagnostics as well as present examples of how these have been implemented in field examples.CITATION:Baxter, M, Cunningham, R, Williams, R and Zink, D, 2018. Tailings process optimisation through automation and controls integration, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 416–421 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By L P. Trout, D G. Reid

PanAust Limited (PanAust) has successfully constructed and commissioned two mining operations in Lao PDR over the past decade and undertaken major studies for three new mine developments. The management of potentially acid generating mine waste and tailings in close proximity of local communities sensitive to water discharge quality have been recurring themes that have confronted PanAust’s project study, development and operational teams. Further compounding challenges, such as the effects of intense annual tropical monsoonal conditions, staging of embankment raises and regular lifting of spillway structures, integrating mine waste and tailings management into production plans and ensuring the long term stability of structures, have been addressed by implementing leading practice management solutions.A recognition of the criticality of managing the substantial business risks associated with these crucial activities led to the early establishment of a governance structure to ensure that the highest standards are embraced for planning and execution. Importantly, these are guided and monitored by a panel of highly experienced and qualified international specialists reporting directly to PanAust’s Managing Director – the Tailings Independent Review Panel. The stewardship process has been effective in identifying potential shortcomings in management systems and has led to enhanced executive commitment to risk informed designs, assurance and overall process rigour.CITATION:Trout, L P and Reid, D G, 2018. PanAust Limited’s approach to mine waste and tailings stewardship, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 135–155 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By D J. Williams, S Islam

Worldwide production of black coal amounts to about 8 billion tonnes. Perhaps 20% of this annual production is washed to improve its quality, generating perhaps 250 million tonnes of coal tailings annually, generally in the form of a slurry. The coal tailings slurry is typically thickened to about 25% solids by mass prior to disposal to a tailings storage facility (TSF), and hence comprise mostly water (about 85% by volume), plus sand, silt and clay-sized mineral particles and carbonaceous material. While the tailings settle and consolidate on deposition in the storage facility, their high moisture content makes them prone to run-out should the tailings dam fail, and makes rehabilitation of the tailings difficult. Hence, it is important to understand the consolidation and shear strength of coal tailings. Laboratory consolidation testing of coal tailings from a slurry to a soil-like state has been carried out in a purpose-built, large-scale, slurry consolidometer, instrumented with load cells and pore water pressure (PWP) transducers. Laboratory vane shear testing of coal tailings produced at different gravimetric moisture contents has also been carried out. The test results have allowed a regression model to be developed relating the peak vane shear strength of the coal tailings to their gravimetric moisture content.CITATION:Islam, S and Williams, D J, 2018. Consolidation and shear strength of coal tailings slurries, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 62–71 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By C A. Cooper, G A. Suter

The sizing of a starter dam for a Tailings Storage Facility (TSF) involves balancing many competing demands. It should cost as little as possible, be high enough to store tailings until the first raise can be constructed, it must be able to contain water safely, and it must be designed in such a way that the long-term integrity of the higher raises are not compromised, among other things. In addition to these demands there is the complication of the behaviour of the process plant, and the tailings during commissioning. Variations in slurry density, excess water in the TSF, initial settled density of the tailings, reliability issues, and beach slopes above and below water can all impact the way the tailings beaches are developed and ultimately impact the ability of the starter dyke to contain the required volume of tailings and water.The conventional approach to the design of a TSF starter dyke is to begin looking at the elevation required for a set of deterministic design parameters, find ways to reduce the size or volume of it as much as possible to reduce cost, and then possibly look at the sensitivity of some of the input parameters. This paper discusses a stochastic modelling approach for starter dykes that allows a wide range of design inputs to be simulated quickly, with an envelope of possible results produced. The sensitivity to different parameters can also be examined to understand which design inputs have the biggest impact on the required dyke sizing. By integrating the 3D TSF modelling tool Muk3D with GoldSim, it will be demonstrated how a wide range of scenarios can be evaluated and how that information can be used to make better decisions about the selection of design options.CITATION:Cooper, C A and Suter, G A, 2018. Starter dyke optimisation with Muk3D and GoldSim, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 466–475 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By B Miles, D J. Williams, J Ahn, T A. Vangsness

The flooding of open strip coal mines in the Bowen Basin and Hunter Valley Coalfields of Eastern Australia has the potential to soften the spoil and floor materials to produce “mud”. This mud can act as a slip plane or weak zone when spoil is dumped into it, resulting in geotechnical instabilities. It is therefore important to understand the mechanisms and degree of degradation likely to occur within coal mine spoil of different qualities.To investigate this, five clay mineral-rich coal mine spoil samples were collected from the Bowen Basin, and each sample was subjected to wetting and drying cycles to simulate degradation that could be expected on wetting-up in situ, with their particle size distribution analysed both before and after degradation. These results were compared with the results of a modified slake durability test, in which the entire sample was tested.The paper presents the results of the accelerated degradation and modified slake durability tests on each of the five spoil samples. These results were related to the physical and geochemical characteristics of the samples, which highlighted their importance. The modified slake durability test may be used to rapidly simulate the expected in situ degradation of coal mine spoil on wetting-up, enabling susceptible spoil materials to readily be identified.CITATION:Vangsness, T A, Williams, D J, Ahn, J and Miles, B, 2018. Accelerated degradation and modified slake durability testing of clay mineral-rich coal mine spoil, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 83–96 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By D Johns, L Murray

This paper discusses pore pressures in the embankments of tailings dams by comparing real world data with common design assumptions. Assessment of pore pressures has implications on material behaviour interpretation from CPT investigations and, therefore, on the design. For example, the assumption of hydrostatic pressure is conservative for limit equilibrium stability analyses but may be un-conservative in assessing the potential for contractive behaviour and strength loss during shearing. This paper presents some real world data, the investigation methods to determine the pore pressures, and subsequent interpretation of CPT data and material parameters such as the state parameter. It also examines the design implications of assuming a hydrostatic pressure distribution, by comparing results from that assumption with those obtained using the real pore pressures.CITATION:Johns, D and Murray, L, 2018. Characterisation of pore pressure in tailings dams and the implications for design, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 239–249 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By D J. Williams, A Shokouhi, A Naderian

Extracting alumina from bauxite involves the production of fine-grained waste known as red mud. The highly alkaline red mud is usually neutralised by applying sea water, thickened to between 25% and 30% solids by mass, before disposal to a Tailing Storage Facility (TSF). Hydraulic sorting, settling, self-weight consolidation, and desiccation are the processes contributing to the overall volume change of the red mud after deposition. Investigating the effect of these processes on the volume change behaviour of the fine-grained red mud is an important step in the estimation of the required storage volume of the storage facilities. This paper presents the results of a series of laboratory consolidation tests in a slurry consolidometer, and comparisons are made with field testing and observations.CITATION:Shokouhi, A, Naderian, A and Williams, D J, 2018. Assessing the volume change behaviour of red mud through laboratory and field testing, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 309–316 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By D J. Williams

The majority of surface tailings storage facilities continue to employ sub-aerial tailings slurry deposition. Surface TSFs are typically sized and operated in a way to minimise the initial capital cost of the facility, driven largely by the net present value approach to accounting. This generally leads to too small a storage, too fast a rate of rise of the tailings, and difficulties in managing supernatant water. In turn, this results in wet and soft tailings deposits of high moisture content and low density, and the need for frequent and costly tailings dam raises. Further, such tailings deposits often do not facilitate closure and rehabilitation of the facility. Globally, there are on average over two failures annually of such tailings dams, resulting in loss of life, damage to infrastructure and environmental impact downstream, and the loss of company shareholder value and reputation. Recent high profile tailings dam failures are threatening the mining industry’s financial and social licence to operate.Among the physical processes that tailings undergo on sub-aerial deposition are beaching, hydraulic sorting down the beach according to particle size and specific gravity, settling, consolidation, and desiccation on exposure to the sun and wind. Beaching and hydraulic sorting have proved difficult to test at laboratory scale and difficult to model, and are best assessed in the field. Settling, consolidation and desiccation may be assessed at laboratory scale, but to date there has been an absence of tests to form the basis for the design and management of tailings deposition, and ultimate closure and rehabilitation. The paper describes recent advances in tailings testing methods, including a purpose-built slurry consolidometer that tests the settling and consolidation of tailings from a slurry consistency, simulating increasing tailings depth to about 50 m; and a purpose-built instrumented column that tests the settling, self-weight consolidation and desiccation of a surface layer of tailings, also from a slurry consistency. Selected test results from these two apparatus are presented in the paper, together with brief descriptions of how they may be used to better design tailings slurry deposition. In addition, planned further advances in tailings testing methods are briefly described.CITATION:Williams, D J, 2018. Recent advances in tailings testing methods, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 8–37 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018

By M Barker, H Li

The total number of tailings accidents has reduced from over 50/decade in the 1960s-1980s to less than 30/decade in the 2000s to 2010s. However, the rate of significant tailings dam failures has not been reduced. The significant tailings dam failures the mining industry experienced in the recent history include: Merriespruit, South Africa, 1994; Los Frails, Spain, 1998; Kolontár, Hungry, 2010; Mount Polley, Canada, 2014; and Samarco, Brazil, 2015. The conventional Factor of Safety approach itself may not be enough to further reduce the rate of significant tailings failures due to its limitations such as uncertainty. For example, the same factor of safety could have a vast range of annual probability of failure for different tailings dams, and insufficient consideration of failure consequence. This paper presents a risk based approach for design with the objective being to minimise tailings dam failures, especially those significant tailings failures with high consequence and low probability. This approach includes risk based design and risk management using bowtie tools. In the risk based design, quantitative analysis will be used to estimate the annual probability of failure and the tolerable failure criteria is linked to the consequence category. Bowtie analyses will be used to understand hazards and risks and identify and select independent controls that are effective in preventing and mitigating catastrophic failures. In this paper, examples of risk based design and bowtie analyses are presented and discussed. CITATION:Li, H and Barker, M, 2018. Risk-based approach for minimising tailings dam failures, in Proceedings Mine Waste and Tailings Stewardship Conference 2018, pp 397–414 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 23, 2018