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By D. J. Young

Alloys used at high temperature must resist both creep and corrosion. Design for corrosion resistance is based on the formation of a slow-growing, protective oxide scale by selective oxidation of an appropriate alloy component, usually chromium or aluminium. A successful scale will exclude other corrodents, notably carbon, which can otherwise cause extremely rapid corrosion at high temperatures. Selective oxidation of an alloy component necessarily lowers the concentration of that metal in the alloy subsurface region. Under thermal cycling conditions, mechanical damage to the scale leads to renewed oxide growth and accelerated alloy depletion. Eventually, a point is reached where diffusion of a corrodent into the alloy becomes competitive with the outward diffusion of alloy metal to repair the protective scale. Two examples of alloy failure by carbon attack are considered. In the steam cracking (pyrolysis) process, centrifugally cast tubes of heat-resisting alloy are exposed to a gas stream of hydrocarbon and steam, at a carbon activity of unity. Formation and repair of the surface chromia scale causes alloy depletion, Kirkendall void formation, and subsequent internal precipitation of chromium-rich carbides. Their formation makes chromia scale formation much more difficult, and generates internal stress. Eventually, the tubes fail by creep rupture. In other processes (e.g. steam reforming, heat treatment), synthesis gases are supersaturated with carbon at intermediate temperatures. Once the alloy's protective scale is breached, carbon attacks the depleted substrate. In the case of ferritic alloys, it forms a surface scale of Fe3C. As this scale thickens, the supersaturated carbon precipitates as graphite within its outer regions. The resulting volume expansion causes disintegration of the cementite in a process known as metal dusting. In the case of austenitic alloys, no metal carbide is formed. Instead, carbon dissolves in the depleted metal to diffuse inward and precipitate as graphite within the metal matrix. Again, volume expansion causes disintegration of the alloy, and metal dusting results. Dusting occurs at an extraordinarily rapid rate, and leads to failure by section loss or even penetration.

Jan 1, 2013

By Lon D. Santis

The Code of Federal Regulations Title 30, Parts 56, 57, 75, and 77 require that detonators and explosives be separated by four inches of hardwood or equivalents when transported together in mines. This standard was developed to protect the explosives from initiation by the more sensitive detonators. The research reported here is an attempt to quantify the fire protection offered by four inches of red oak and other materials. Boxes with a volume of 6.75 cubic feet were made from four-inch thick rough green oak (RGO), two-inch thick RGO plied, two-inch thick #1 common (dried) red oak plied, and a metal/plywood composite. These and boxes meeting the Institute of Makers of Explosives' (IME) Safety Library Publication No. 22 were tested in bonfires. The boxes were instrumented with thermocouples, filled with detonators, and placed over a kerosene fire imparting about 16 kilowatts per square meter heat flux for up to 3 hours. Tests showed that the wood boxes protected the detonators for over an hour with variations between the different trials. In the IME 22 container tests, detonators began exploding in as little as 17 minutes in one test and not for 2-/12 hours in another test. Detonators in the metal/plywood boxes began to explode in about 15 minutes but with minor alterations, were able to contain the detonators. The test results show that the exterior of an IME 22 container significantly affects its thermal properties. Defects in the form of cracks and the manner in which the container is closed have a significant effect on the performance of a detonator container in a fire.

By G F. Brent, R D. Hart, C Carr, F Felipe

In underground operations, where copper, gold and other metals are mined, the open stopes can be backfilled to stabilise surrounding workings. This fill may consist of tailings from the processing plant, usually mixed in slurry with a binder such as ordinary Portland cement (OPC). Extensive use is made of tailings in OPC-based paste fill, cemented hydraulic fill or cemented aggregate fill applications. A large underground operation such as the Mount Isa Copper Operations utilises over three million tonnes of backfill per annum. Geopolymers offer an alternative binder system with significant environmental advantages over OPC. Geopolymers are formed by polymerisation of aluminosilicate precursors in an alkali medium. They generally form products with superior strength characteristics as well as increased resistance to degradation, particularly under acidic conditions. Geopolymers have lower carbon dioxide emissions associated with their manufacture than OPC and offer further potential advantages, such as the use of less water and more waste materials. The application of geopolymers to weak material systems such as mine backfill has not been widely studied. The aims of this investigation were to assess a range of Australian mine process wastes for suitability as feedstocks in fill applications and to construct a range of these cemented minefills using a geopolymer binder. The physicochemical characteristics of each of the wastes are discussed as well as how they ultimately contribute to the geopolymer cement through direct replacement of OPC. Results from various tests on the candidate geopolymer fill formulations are presented and the potential of such fill formulations to replace OPC in mine backfilling operations is highlighted. The significant potential contribution to reducing greenhouse gas emissions from the use of geopolymer-based mine backfill across the industry is noted. Conversion of a single mine, such as the Mount Isa Copper Operations, is shown to match the reductions in greenhouse gas emissions due to the current total installed photovoltaic electricity generation capacity of Australia. A similar examination of wastes available to a gold mine could potentially yield new binders for use in established or new fill systems.

Jan 1, 2007

By Jim Peterson

Raising equipment that is commonly used include handheld drills such as Jacklegs or Stopers, Alimak raise climber also using handheld drills, drop raises using long-hole drills whether top hammer or ITH drill systems, Raise Bore machines and gang hammers or cluster drills such as the V-30 MRI attachment tool. Sometimes as a community we forget successful techniques used in the past and need to rediscover them.

Jan 1, 2014

Research into the mechanisation of ore winning from the very narrow reefs characteristic of South African gold mines has been conducted from as early as 1964 through the Chamber of Mines Research Organisation (COMRO) but with limited success. However, the Council for Scientific and Industrial Research (CSIR) has recently re-evaluated the potential for the mechanisation for the narrow tabular gold mines. It has been determined that there are approximately 22 000 tonnes of gold left in-situ in channel widths of less than 500 mm in thickness. The extraction of ore from such reefs requires a complete paradigm shift in that the current mining cycle (drilling, blasting, cleaning and supporting) is not feasible since such a stoping width would not allow the workers entry into the stope. Consequently, a non-entry form of mining is required. With this target in mind CSIR has invested in a project called the Nederburg Miner which seeks to identify new technologies for drilling, rock breaking, cleaning, and materials handling, the application of which will enable non-entry mining of very narrow ore bodies. The intention is to develop a fully automated system that will not require human involvement at the stope face. The outcomes of research into this proposed system will not only extend the life of South African gold mines but will also enhance South Africa's reputation for excellence in mining research. This paper presents the new technologies under consideration and potential methods for their application into an integrated non-entry mining system.

Jan 1, 2008

By C. G. Anderson

"As demand for copper and precious metals continues to grow, the need to develop new supplies increases. In the imminent future, the new large global ore bodies are more complex, with enargite, tennantite and tetrahedrite as the abundant contained mineralogy. These resources also contain considerable gold and silver. As such, direct treatment by conventional smelting is prohibitive due to the potential environmental impacts and copper quality issues. This paper outlines the effective application and associated economics of industrially proven Alkaline Sulfide Leaching (ASL) hydrometallurgical technology to an enargite concentrate for selective removal and recovery of arsenic, antimony, gold and silver, leaving a clean high-grade copper concentrate. The fundamentals behind the technology are described, along with those of hydrometallurgical arsenic fixation and stabilization. Flowsheets and unit operations are elucidated, along with an in-depth economic analysis. INTRODUCTION Hydrometallurgical methods can be employed for treatment of gold-, arsenic-, antimony-, tin- and mercury-containing materials, concentrates and ores, as well as complex ones containing any number of metals (Conner & Anderson, 2013). The alkaline sulfide leaching (ASL) system is one of these. It is essentially a mixture of sodium sulfide and sodium hydroxide with other meta-stable alkaline species as required. This is a unique hydrometallurgical system beause it is a very selective lixiviant for the distinct leaching of tin, gold, antimony, arsenic, tellurium, silver and mercury (Anderson, 2000, 2001a, 2001b, 2002, 2003, 2012, 2014; Anderson & Twidwell, 2008a, 2008b, 2010; Anderson et al., 2004, 2005; Glazkov & Tseft, 1961; Gnatyshenko & Polyvyanni, 1961; Nadkarni et al., 1975; Nadkarni & Kusik, 1988; Polyvyanni, 1963). Worldwide, ASL technology has been employed industrially in the former CIS, China and the United States for the production of antimony (Anderson et al., 1992, 1994; Anderson & Krys, 1993; Holmes, 1944; Kaloc, 1967; Nordwick & Anderson, 1993; van Stein, 1971)."

Jan 1, 2015

By S. Asokan, CVGK Murty, R. Upadhyay

The principal mineral sources of titanium are rutile, anatase (both TiO2), ilmenite (FeTiO3) and leucoxene (a weathered ilmenite of variable concentration of TiO2 but similar to pseudorutile Fe2Ti3O9). These titaniferous minerals along with their value added products like Synthetic Rutile and TiO2 slag constitute ?Titanium Feed-stocks? for TiO2 pigment, Ti metal and welding electrodes industries. Unlike in other industries, the demand driver for titanium minerals is not the metal, but the TiO2 pigment ?a specialty chemical. Of the total titanium feedstocks usage in the world, about 93 % is consumed in TiO2pigment, with only about 3 % is utilized in metal production. India?s heavy mineral sands resources are among the largest and also one of the richest grades in the world. The country?s Ilmenite resource base stands at 348 million tonnes of Ilmenite (18% of the total world reserves)along with 18 million tonnes of Rutile, 21 million tonnes of Zircon, 8 million tonnes of Monazite, 107 million tonnes of Garnet and 107 million tonnes of Sillimanite. Though the grades (Total Heavy Minerals (THM) present in the sand) of Indian deposits are relatively rich, the contained ilmenite are termed as sulphate grade with 50-53% TiO2 (Chavra deposit of Kerala and Ratangiri deposit of Maharastra are an exception with 60% of TiO2). While superior grades with adequate reserves lead to a cost advantage in ilmenite production, the lower TiO2 percentage allows the direct use of Indian ilmenite only in the production of TiO2 pigment through sulphate route and for the chloride pigment production; such ilmenite is required to be upgraded either to Synthetic Rutile (SR) or TiO2 slag. However, in order to produce TiO2 slag in India at a globally competitive cost, the issues like high power tariff, inadequate infrastructure, expensive logistics, less enthusiastic market preferences, supply-demand gaps are to be adequately addressed. This paper deals with some of the above issues and possible solutions thereto in production of TiO2 slag from Indian ilmenite.

Jan 1, 2007

On the Hauraki goldfields, within the limits of Cape Colville Peninsula, the Paheozoic rocks are confined to the district north of a line drawn from Mercury Bay on the east coast to Rocky Point on the shore of the Frith of Thames. South of Kennedy's Bay they are developed on the east coast only at Kuaotunu, at which place gold mining is carried on in sandstones and slates of this age. Between Tapu Creek and Coromandel there is, along and adjacent to the shore of the gulf, a very considerable development of PaJreozoic and in part of Trias rocks, and between the Tiki Stream and the northern end of Tokatea Hill, along the western slope of the main range, lies the special area of the Palreozoic or carboniferous rocks that have more particularly to be dealt with in this paper. The same formation has a large devolpment between Cabbage Bay and the northern slopes of Moehau, and appears to the water marge on both sides of this part of the peninsula.In this part they are of special interest as having, on the west spur of Moehau, a considerable variety of dyke rocks intruded into the sedimentaries, the interest in which is increased by the fact that these dykes theIllselves are of Palreozoic age and correspond to the dykes that are so' abundant in the Tokatea-Tiki area. It is this Tokatea-Tiki area as a goldfield, and its rocks as distinguished from later volcanic' products' on other parts 'of the peninsula...

Jan 1, 1903

By Nobuzwe Makhotla, Sasha Boskovic, Steve Hearn

"Mineral separation efficiency in flotation depends, to an extent, on the type of frother used. Huntsman develops and manufactures unique frothers which are suited for mineral processing applications. This paper discusses the Huntsman approach to understanding the industry’s flotation frother requirements to optimise frother selection and introduce the Huntsman’s POLYFROTH® frother range. Specific case studies where the frothers are used are discussed. INTRODUCTION Froth flotation is a process of using bubbles to separate minerals based on their relative affinity for water. Bubbles are induced in the slurry through aeration. Chemistry is used to aid the flotation process and chemical reagents are added to enhance the separation process. The flotation reagents include frothers, collectors, surface modifiers and pH regulators that control physical and chemical conditions of solid, air and liquid phases, respectively. As described by Harris (1976), the key effect is that of bubble size control by way of preservation of the generated bubble size, which is attributed to the coalescence inhibition by the presence of the frother on the bubble surface. Following this, the frother must stabilize the froth phase. Frothers are also added to create optimal conditions for bubble creation and stability by decreasing the surface tension of the water. Depressants may be added, depending on the ore treated, to assist the hydrophilic particles to stay in the water phase. Clay particles may need to be dispersed to prevent them from attaching to the bubbles. Hydrophobic particles attach to the bubbles and are carried to the surface of the slurry where froth is formed. It is important for these bubbles to have the mobility to carry the mineral to the launder where the concentrate is collected. Types of Frothers There are generally three main groups of frothers used in froth flotation. Alcohol Type These frothers have a molecular structure that usually includes 5 to 8 carbon atoms in a hydrocarbon chain and their solubility in water is limited. Methyl isobutyl carbinol (MIBC) belongs to this category and is widely used in the industry. The weaker alcohol-type frothers are more selective and typically suited to finer particles. There are three sub-categories under this group: aliphatic, cyclic and aromatic alcohols."

Jan 1, 2015

By William M. Gleason

The war in Vietnam stretched into another decade, an American President was at the brink of impeachment, the earth was given its own day, twin tower monuments of American ingenuity were completed in New York and would stand high above the Manhattan skyline for 31 years. Inflation, oil shortages, low commodity prices and America’s 200th birthday were part of the decade — it was the 1970s. For the mining industry, the demands of the decade would be high and the challenges would be significant. Because of the many challenges that lined up in front of it, the mining industry was forced to work smarter and more efficiently. The industry also expanded its borders in search of new resources and struggled along with the rest of the world through a fuel crisis, inflation and a recession.

Jan 1, 2007

By Kelly E. G

NZ Steel's flushing slag typically contains 1.2 per cent V203. Extraction of vanadium from powdered slag using a salt (NaCI or Na2CO3) roast/leach process was investigated. With NaCl, optimum extraction conditions were a charge containing 10 per cent NaCI, roasting in air at 875°C for 4 hours, followed by leaching in dilute H2SO4. Extractions were typically 30-50 per cent. NaCI roasting did not chemically attack the slag; the phase transformations that occurred were due to high temperature oxidation. Slag particle size had a significant effect on extraction.Optimum conditions for extracting vanadium by Na2C03 roasting were 20 per cent Na2CO3 in the charge and roasting in air for 3-4 hours at 850-875°C followed by water leaching.Na2CO3 roasting involved chemical attack that resulted in the formation of perovskite (CaTiO3) and carnegieite (NaAISiO4).The extent of vanadium extraction depended on the amount of Na2CO3 added and the original slag SiO2 content.Compared to the separate roasting treatments, simultaneous treatment with NaCI and Na2CO3 gave lower vanadium extraction, while requiring considerably higher roasting times and temperatures.

Jan 1, 1982

By Elaine T. Bowers

The Sunnyside single-entry project pioneered the use of single entries for longwall development in this country. During the 10-year course of the project, an immense amount of information was gathered. Over three miles of entries were observed primarily through instrument groupings placed in strategically located areas or "rooms." Nearly 1,200 instruments were monitored to gain information on the behavior of coal entries during development stages and through the mining of two longwall panels. This was one of the most extensively documented projects undertaken by the Bureau, The data gathered has a great potential for scientific research especially in the area of longwall mining. This Bureau of Mines report presents the ground control data gathered, in the form of computerized plots. Roof-to-floor deformation and load on cribs and roof bolts make up the bulk of the data, which is presented as load or deformation versus time. The plots are organized, generally, by the three main entries involved and, specifically, by the individual areas or rooms in those entries. No major attempt will be made, in this paper, to analyze the data other than to identify its source arid its history.

Jan 1, 1983

By W. A. Naismith

On 16 July 2004, at 07:10 a collapse of about 1.8 million m3 (about 4 ½ million tons) took place on the north wall on Nchanga Open Pit. This collapse was the result of a developing instability that was first identified when the benches in this area were exposed during September 2002. The NOP geotechnical and survey departments closely monitored the development of the failure. Control measures were implemented to reduce risk to men and equipment. These measures were continually improved and adjusted in reaction to observations and changing conditions. The purpose of this paper is to describe in detail the monitoring results that were obtained both by traditional methods and the novel slope stability radar system (SSR). Difficulties encountered in establishing critical deformation levels and deformation rates that can be used to predict the onset of collapse are described. Details of the monitoring and control measures, which led to the successful completion of mining in the area, are also described in this paper.

Jan 1, 2005

By N Clarke, G R. Ballantyne, M S. Powell, P Elms, A Anyimadu

AngloGold Ashanti Ltd nominated Sunrise Dam Gold Mine as a case study via their involvement with the long-running Australian Mineral Industry Research Association (AMIRA) International P9P research program (AMIRA, 2015) . A group of researchers from the Global Comminution Collaborative (GCC) conducted a comminution circuit survey and review together with a large group of graduate metallurgists, senior metallurgists and operators. Fundamental and applied research understanding was used to identify productivity and efficiency improvements around the crushing and grinding circuits. The limitations of current scientific knowledge were identified through this process and this will allow future research to be more focussed on what is required by industry.The comminution circuit at Sunrise Dam comprises three stages of crushing followed by two stages of ball milling. The secondary crusher and primary ball mill classification were identified as the primary limitations of the circuit. The secondary crusher was found to be underperforming through overall equipment efficiency (OEE) analysis and an improved chamber design was identified by Chalmers University. This improved design will promote higher power utilisation, choke feeding and a finer crushed product for the milling circuit. The primary ball mill product is classified by a combination of a trommel, 3 sieve bends and a hydrocyclone. The combination of poor classification and coarse, competent feed led to a situation where the primary mill was overfilled with rocks, reducing grinding rate due to cushioning of impact. Size specific energy (SSE) benchmarking methodology was used to identify that a 10% increase in throughput could be achieved with improved primary classification.CITATION:Ballantyne, G R, Clarke, N, Elms, P, Anyimadu, A and Powell, M S, 2015. Application of research principles to identify process improvement at Sunrise Dam Gold Mine, in Proceedings MetPlant 2015, pp 221–229 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By Edward Walter

Rock excavation for tunneling projects occurs on a regular basis in the Cleveland area. These tunnels are being constructed to increase the capacity of the sanitary sewer system. Controlled blasting must be performed to remove rock in a number of phases of the project. The rock excavation for construction of a junction chamber is just one case where blasting is the safest and most efficient method available.

Jan 1, 2001

By Guillermo A. Vidal

With the introduction of monitoring technologies, process computers and Web services on Industrial Facilities the need for electrolytic processes automation has been set. Recently designed facilities have substantially improved plant layouts, automated cathode processing and copper harvesting. Despite these advancements only limited progress has been accomplished on the electric current distribution of the process. Lately a number of proposals focused on preventing short circuits and balancing cathode currents have emerged. Among these are the AZSA intercell, the Outokumpu double contact, and the Optibar InterCell Plus. Although these intercell bars are clearly superior to the conventional bar, little or conflicting data is available about their merits relative to each other. Consequently, selection of the best intercell bar for most applications is accompanied by uncertainty, which can lead to less than optimum results. A critical evaluation of the performance of the aforementioned bars on the basis of the application is provided, thereby giving the framework and guidelines for the selection of the best bar for each application.

Jan 1, 2003

Several factors contributing to the loss of fibre during treatment are a function of the paragenesis of the veins. The occurrence, of magnetite from the cap rock within the veins prevents complete fiberization. There is a marked similarity between these veins and those in the Koegas-Westerberg area of South Africa.INTRODUCTIONAn investigation of the mineralogy of the Wittenoom Gorge crocidolite veins was undertaken in the latter part of 1962 at the request of the Colonial Sugar Refining Co. Ltd. It was anticipated that such a study might reveal the cause or causes of the lack of recovery of some asbestos during beneficiation. Some interesting features of the mineralogy and paragenesis of the crocidolite veins become apparent, but it is emphasized that the investigation is far from complete, as the study did not extend to the field occurrence.The samples examined were selected from the mill and from the untreated ore.GEOLOGICAL SETTINGWittenoom Gorge is situated on the Fortescue River in the Hammersley Ranges of Western Australia and is one of several gorges in these ranges, on the sides of which 'crocidoIite asbestos is known to occur. The Hammersley, Ranges consist essentially of a series of quartzites, shales, ferruginous quartzites and dolomites. These' rocks are part of the Nullagine Formation (Proterozoic) and are usually either horizontal or gently folded. In some 'areas small beds of riebeckite as well as crocidolite are known to occur interbedded in the sequence.Riebeckite is a monoclinic amphibole, the formula of which may be stated as Na2Fe2"Fe2" (OH) 2Si8O22, and crocidolite is a fibrous variety of this mineral. This formula...

Jan 1, 1963

By M. Hopf

The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However, even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able consistently to identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed).Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa. Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway

Jan 1, 2006

By M. M. K. McCrank

"PRACTICAL SAMPLING TECHNIQUESIt is important to achieve reliability when sampling heterogeneous materials where there is a difference in composition, and non random distribution of the constituent particles. Throughout the design, construction and installation of sampling systems it must be borne in mind that the sampling point must be capable of:-allowing each particle in the stream an equal opportunity to be sampled.-accepting and collecting as large a volume or mass of material as necessary to satisfy the requirements of particle counting statistics.-establishing a sampling plan so that the sample is representative of the whole to a defined standard of accuracy.Design ConsiderationsFactors that may influence the design of the sample point include:-the mass, or volume flow rate of the material being sampled-the size and shape of the material or flowing stream-the physical condition of the material being sampled (i.e. temperature, wetness, size consist, density).-the chemical composition of the material being sampled -the location of the sample point and the space available for installation, extraction, reduction where necessary, secondary sampling, and return of the sample rejects downstream.-whether the process to be sampled is in an existing plant or one yet to be designed and built.-ease of access for servicing and maintaining the equipment.-whether the sampled material must be collected continuously or intermittently.-whether an existing sampling method is likely to be adequate or whether a new technique has to be developed."

Jan 1, 1989

To ensure that its voice is heard in the development of policies and plans under the Resource Management Act, the mining industry is challenged to participate in their preparation. This paper outlines a number of practical ways in which the industry can participate in debate on sustainable management and how it can be put into practice within the industry.

Jan 1, 1992