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Solid. dense, air-cooled slag can fulfil most, if not all, the functions of natural stone for civil engineering purposes. The value of pumice, also, has long been appreciated, and processes for the manufacture of similar synthetic material for light-weight concretes and insulating fills have been developed in past years.Foamed slag is, in effect, blast furnace pumice and is often referred to on the European continent as metallurgical pumice. It is made by the treatment of molten blast furnace slags with a critical quantity of water during which process the slag cools and expands into a sponge-like mass. The connection between foamed slag and air-cooled slag is also considered and a basis for density control given.All blast furnace slag cannot be foamed to give a product which would comply with B.S.S.877; 1939 Foamed Blast Furnace Slag. A large proportion of the total output of molten slag lacks the necessary inherent properties. This investigation attempts to discover the conditions necessary for the production of foamed slag capable of meeting the British specification.EARLIER WORKIt was generally accepted (Parker, 1951; Gallai-Hatchard, 1955) that the spongy structure of foamed slag was caused mechanically by steam trapped in the slag when it was poured into water. It was assumed that slags which would not foam would not trap steam, because their viscosities and surface tensions were unsatisfactory, on account of temperature and/or composition. The earliest systematic investigation was made by Frisak (1923) who attempted to establish a limiting chemical composition for foamable slags. He decided that foamable slags covered most blast furnace slag compositions on the basis of silica, alumina, and lime, and further "that the replacement of lime by magnesia up to 15 per cent has no noteworthy effect on foamability, that moderate quantities of alkalis are not deleterious, that sulphur raises the foamability and that MnO is only deleterious in the presence of 1...

Jan 1, 1963

By A T. Yuniar, C A. Brannon, N D. Pascoe, H H. Firdausi

This paper describes the key components of the Grasberg Block Cave (GBC) mine design and the development and construction status of the mine. Drawpoint production from GBC will be initiated in 2018 following the closure of the Grasberg open pit. Full production of 160 000 t/d is planned for 2024, which will make it a 20-year time period between initial access development in 2004 and full production.Diluted ore reserves are about 1 Bt at a grade of 1.0 per cent Cu and 0.78 g/t Au. The mine plans some 2400 drawpoints on a 20 m × 30 m drawbell spacing in a 700 000 m2 footprint using the El Teniente layout. The drawpoint opening sequence includes five production blocks, the first two of which are scheduled to be undercut simultaneously in 2018. Ore is transported using diesel-powered load-haul-dumps to a series of orepasses and then delivered via loading chutes to a rail haulage system, which delivers the ore to a three gyratory crusher complex. Crushed ore is transported to the mill stockpiles via dual inclined conveyors.Development and construction of the substantial fixed facilities are now well underway. Primary access for personnel and materials is via the 6 km Ali Boediardjo (AB) adits. A service shaft will hoist personnel and materials from the AB adits level to the various operating levels. Shaft commissioning is scheduled for late 2015. The rail haulage system installation and construction is in progress and is due to be commissioned in 2017, which is timed to coincide with the commissioning of the ore handling system. Ventilation is provided through a series of large intake and exhaust drifts, and two of the four main fans have been commissioned. A 1600 L/s pumping system will manage drainage from the mine.Other key facilities include separate shops for rail and rubber-tired equipment, warehousing, a powder magazine, a main control centre and an underground concrete batch plant.CITATION:Brannon, C A, Firdausi, H H, Pascoe, N D and Yuniar, A T, 2016. Development and construction update of the Grasberg block cave mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 625–634 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Dave Marsh, John Goode, Niels Verbaan, Kevin Bradley, Henrie Notzl

The mineralogy of the Avalon Nechalacho deposit is complex with significant fractions of HREEs, Zr, and Nb found in refractory minerals such as zircon and fergusonite. Sulphuric acid baking followed by water leaching can be used to extract REEs from flotation concentrates, but acid baking does not completely "crack" the zircon and fergusonite, so the extractions of Zr, Nb, and HREEs are not high. An alternative flowsheet has been developed that is able to obtain significantly improved extractions of HREEs, Zr, and Nb from flotation concentrates or acid bake residues. This is accomplished by cracking the zircon and fergusonite minerals with caustic soda at high temperatures, followed by water washing to recover excess caustic soda and soluble sodium silicates and phosphates. REEs, Zr, and Nb in the solid residue can then be solubilized with HCl or H2SO4. This paper highlights some of the findings from an extensive laboratory program and discusses several flowsheet implications.

Jan 1, 2014

The effect of composition on electrical conductivity (resistivity), viscosity and liquidus temperature of the slags encountered in electric smelting of PGM containing suphide concentrates is reviewed, along with the relationsip between slag composition, slag-matte separation and metal losses to slag. Optimization of slag composition at furnace temperature is attempted on the basis of opposite and parabolic trends of the viscosity-conductivity relationships of the slags. The importance of surface tension of slags is emphasized using available and estimated information which are grouped into a useful correlation. These values are coupled with or incorporated into slag viscosity plots to illustrate the correlation between the two factors, which influence slag-matte separation as well as refractory attack. The electrode in the slag-resistance furnace is the central factor in the design and operation of the furnace by its role of conveying the smelting power. The obvious parameters are the size and positioning in the slag bath, which are defined by slag resistively, furnace resistance, cell constant and power input. The flow of heat generated by the electrode current determines the energy distribution and furnace dimensions creating viscosity profiles, which in turn affect flow conditions. Thus the flow of slag and matte are discussed in conjunction with the furnace geometry, stirring action of the electrodes, buoyancy and electromagnetic effects. The action of the electric furnace as a settler is discussed. The rectangular furnace is considered as a channel reactor in this analysis, and the action of the electrodes is described to indicate a balanced settling rate in the area of electrode action. Discussion of the design and production capacity of the electric furnace, with reference too perating current, power input, furnace dimensions and electrode size, are based on considerations derived mainly from slag properties such as its resistively, viscosity and liquidus temperature.

Jan 1, 2004

By J. M. A. Geldenhuis

This work is concerned with studying possible reactions in the ilmenite furnace which may control the product quality of both slag and metal. Two different approaches were followed: comparing actual furnace slag compositions with the calculated equilibrium values and using commercial oxygen probes to measure the effective partial oxygen pressure in the slag and metal. It appears from a comparison of actual furnace slag compositions (in terms of the distribution coefficient of vanadium) with equilibrium values, that the TiO1.5-TiO2reaction may fix the effective partial oxygen pressure for the vanadium reaction. This possibility was tested using commercial oxygen probes (traditionally applied during steelmaking) to measure the effective oxygen partial pressure of both the slag and liquid iron in Iscor?s 3MVA pilot plant ilmenite furnace. From these measurements, it appears that commercial oxygen probes containing zirconia solid electrolytes can be used to measure the effective oxygen potential of both the slag and liquid iron. This oxygen activity correlates well with the FeO content of the slag. The results, furthermore, clearly illustrate that equilibrium conditions are not attained in the ilmenite furnace during the production of high titania slags, since the effective oxygen potential of slag and metal differ substantially.

Jan 1, 1999

By P. Mokwena

Paper written on project work carried out in partial fulfilment of BSc (Hons) in Chemical Engineering Diamond synthesis has attracted a great deal of interest because of its exceptional properties and various applications. In this study, the chemical catalytic vapour deposition (CCVD) method was used to synthesize diamond films using acetylene as carbon source and hydrogen as carrier gas at a temperature of 1000°C, and their thermodynamic stability was studied. Photographic analysis revealed that these products are diamond films, Ramman spectroscopy confirmed that they are graphitic while confocal laser scanning microscopic image analyses proved that these diamonds films have structural defects due to iron impurity from the catalyst precursor. The quantity of diamonds films produced is also proportional to the acetylene to hydrogen ratio but these films are larger in size at lower acetylene to hydrogen ratio. Thermogravimetric analyses showed that transformation of these materials begins at 25°C but could not be used to determine if a temperature range below 25°C exists. The stability of these CCVD-synthesized diamonds also increases below 25°C when stored at different temperatures.

Jan 1, 2007

By V P. Elpatyevskaya, V S. Arzhanova

Main geochemical problems concerning the environment and mining industry interrelation are connected with the transformation of natural water chemistry by mining wastes. The investigation of many mines in Primorye, the southern part of the Russian Far East, showed that their mining waters have high concentrations of heavy metals and aluminium. Water acidity is primarily connected with the amount of acid-forming sulphide minerals in ores and also depends on the neutralising capacity of rocks. Considerable quantity of metals occur in the waters in dissolved form. Metal concentrations in mining waters exceeds the natural levels by two to five orders of magnitude and can't be reduced to the background levels even after multiple dilution. It is necessary to develop and put into practice new technologies so that to reduce the geochemical impact upon the environment.

Jan 1, 1995

By G C. Bolton

Experiments were conducted to access the feasibility of removing zinc from lead slag by sulfation or chlorination or both. Gaseous sulfation with sulfur dioxide and oxygen released only 50 per cent of zinc even under the most severe conditions. Sulfation with concentrated sulfuric acid by a fast-leach process released 95 per cent of zinc while pug-roasting released a maximum of 78 per cent of zinc. Chloridization with NaCl in the presence of sulfating gas released 50 per cent of zinc, while direct chlorination with chlorine gas and oxygen released 85 per cent of zinc and 100 per cent of lead in a chloride condensate containing little impurities.

Jan 1, 1980

By D Caley

During the response to the Moura No 4 disaster, use was made of the New South Wales Mines Rescue Service’s ‘Mineshield’ inertisation equipment. The equipment had to be transported from Newcastle, approximately 1400 kms, and the liquid nitrogen a similar distance. The time taken, and therefore availability of the liquid nitrogen, became a significant problem. Operational issues were also experienced during use. Typically the liquid nitrogen is converted to a gas (vaporised) before being injected into the mine. However, as the propane gas tanker used for the vapourising unit was delayed, an attempt was made to inject the liquid nitrogen directly down uncased boreholes. This proved unsuccessful.Following the Moura No 4 disaster and the Moura No 2 disaster, recommendations were made relating to having inertisation capacity for the Queensland coal mining industry. Today the Queensland industry has multiple options available for inertisation, including the high-volume GAG and smaller volume units such as boilers and membrane separation units. Although it ultimately aided re-entry into Moura No 4, most likely due to the issues associated with supply to Central Queensland, liquid nitrogen has not found favour within the Queensland industry as an inertisation tool.Coregas has commissioned an air separation plant in Mackay, improving the availability of liquid nitrogen to Central Queensland. Based on the availability of this nitrogen, recent sealing operations at Kestrel have trialled using liquid nitrogen and associated vapourising units. This paper details the practical application and findings of using liquid nitrogen during routine longwall panel sealing.CITATION:Caley, D, 2017. Using liquid nitrogen for the inertisation of goafs, in Proceedings Australian Mine Vent Conference 2017, pp 35–40 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 28, 2017

By G. F. Vander Voort

The accident at Unit No. 2 of the Three Mile Island nuclear reactor (TMI-2) on 28 March 1979 was the worst nuclear accident in US history and crippled the nuclear industry. An international Vessel Investigation Project was formed to assess the integrity of the vessel. However, it was not possible to remove specimens from the lower head until January?March 1990. Fourteen of the fifteen specimens removed by electrical discharge machining were from under the debris pile that accumulated on the lower head due to melting of approximately 19 000 kg (45%) of the core. Specimens were previously cut from the lower head of a cancelled reactor of very similar size and design destined for Midland, Michigan. These specimens were subjected to controlled heating cycles with peak temperatures from 800°C to 1100°C for periods of 1 to 100 minutes. The initial study qualitatively compared the structures in the 15 specimens from TMI-2 to the control specimens from the Midland lower head. The writer used the same specimens and employed microindentation hardness traverses, electron microprobe analysis, and selective etching followed by quantitative metallography (by image analysis) to obtain a far more detailed description of the thermal exposure experienced.

Jan 1, 2013

By S. Mostaghel, S. Nicol, M. Y. Solar

Once upon a time, the process engineer developing the design criteria for a new saprolite ferronickel smelter had it easy: most ores were around 2.5% Ni, with a Fe/Ni ratio of 4 to 5 and a SiO2/MgO ratio of about 1.6; to use the French word: garnierites. The ferronickel grade selected was the conventional 20 to 25% Ni and the impurity levels could be predicted from well established [C], [Cr] and [Si] vs (FeO) graphs. However the process engineer can no longer depend on statistics to design smelters: Ni grades are decreasing while the goethite contents are increasing; SiO2/MgO ratios vary from 1 to 3; and Al2O3 concentrations are reaching levels that cannot be ignored. Mechanistic models must be developed to select or predict essential parameters such as kiln and furnace reductions, ferronickel grade, slag losses, metal and slag liquidus, operating temperatures, etc. But these models must be simplified so that they can be used on a routine basis; and they must be calibrated against a wide range of commercial operations in order to yield the most realistic predictions possible. The present paper proposes one possible approach, using FactSage as a basic source of thermodynamic data. The predictions thus obtained are compared to actual performance for two well documented operations, as well as to the predictions made with other tools that might be more accessible.

Jan 1, 2014

By Ö. Kaya

The removal of gangue minerals from three different graphite ores (Inebolu, Akdag?madeni and Çoraklidere) from Turkey by acid leaching was studied. Acid leaching experiments were applied to the flotation bulk concentrates, which were obtained in determined optimum conditions after preliminary flotation tests. The effects of acid type, acid concentration, leaching temperature and leaching time on the dissolution of gangue minerals were studied. The most suitable leaching conditions were determined to be 20% HCl + 4% HF for acid type and concentration, 85 ºC for leaching temperature and 4 hours for leaching time. After removing the gangue minerals at these optimum conditions, the total carbon contents of the samples from Inebolu, Akdag?madeni and Çoraklidere increased from 23.51% to 40.07%, from 37.93 to 60.47% and from 42.28 to 59.47%, respectively.

Jan 1, 2009

By C. Sawmliana, P. Pal Roy

Near-field blast vibration response of restrained pipelines either buried or exposed was studied during rock excavations at sensitive locations for Stage-II (4x500 MW) commissioning work in a super thermal powerplant of the National Thermal Power Corporation Ltd. (NTPC) of India. The existing running plant of capacity 1000 MW has many important installations including pipelines of varying diameters. These pipelines were very close to the blasting locations (mostly within 12m). Blast optimization and consequent monitoring of vibrations were carried out simultaneously for more than 250 experimental blasts conducted by the authors. This paper emphasized, particularly, on the safety of pipelines and their responses due to repeated blasting impacts. A few guidelines supported by theoretical derivations are provided for futuristic research.

Jan 1, 2001

By S Robotham, P C. Stewart, K Maher

A data science based dilution study was conducted to identify the causes of dilution at South32’s Cannington Mine (Cannington), a large open stoping operation. In terms of industry benchmarks for unplanned dilution, Cannington is already performing very well, and so opportunities for improvement are more difficult to identify. The study is based upon back analysis of nearly 150 case studies from the mines reconciliation database, and has quantified the relative effect and significance levels for the following dilution parameters; time until paste filling, faulting and cable bolt reinforcement. Specifically, significant contributions were associated with faults and stope open duration. Quantifying the effect of faults on stability graph accuracy enabled a site specific adjustment to improve the predictive ability of the Cannington stability graph (unstable stope specificity improved from 63 per cent to 74 per cent). Despite Cannington’s already high levels of stope performance compared to industry benchmarks, data science methods have identified a complex interaction between identified dilution factors (ie stope open duration, presence of faults and cablebolting). Specifically, a third order Factorial ANOVA (Analysis of Variance) provided evidence that stope open duration reduces the effectiveness of cable bolts in faulted ground (average dilution = 2.1 m, p-value = 0.13). These results are consistent with site observations of a relationship between the stope open duration and the extent of failure when unravelling on a fault, even when cables are present.CITATION:Maher, K, Stewart, P C and Robotham, S, 2016. A data science approach to identifying and quantifying causes of dilution at Cannington Mine, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 491–500 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By Healy T. W, Dixon D. R

The present study 'of pure ZnS and NiS and ZnS (marmatite) by detailed electrokinetic methods has shown that by careful control of experimental parameters much new' information on sulphide-water interfaces can be obtained. Time-dependent processes of alteration of sulphide surfaces are foHowed by electrokinetic methods and indicate that the isoelectric point of the surface depends on elemental sulphur coverage, oxidation product coverage, and the conditions which promote or minimize such reaotions in the presence and absence of activator.

Jan 1, 1977

By J R. Manuel, J M. F Clout

The importance of goethite to Australian iron ore production is steadily increasing as the proportion of goethite-rich, martite-goethite bedded and channel iron deposits increases at the expense of declining production from high-grade microplaty hematite deposits. For this reason, an improved understanding of goethite in iron deposits, its genesis, goethite types and their physical and metallurgical properties is vital to maintaining optimum sintering and blast furnace performance in Asian steel mills.The terminology used to describe goethite in Australian iron deposits is currently highly variable. The discredited mineral name ‘limonite’ is still in widespread use as a field term for goethite and there are many misconceptions concerning goethite chemical grade and downstream physical and metallurgical properties. The goethite classification proposed here is based on geological and physical properties from which three types are recognised including brown goethite, dark brown-black vitreous goethite and highly microporous, friable yellow ochreous goethite.In practice, typical vitreous goethite with highly reflective surfaces and conchoidal fracturing, characteristic of the hard cap zone appears from X-ray fluorescence (XRF) and electron microprobe analysis to be significantly higher in Si (up to 18.7 wt per cent), Al (up to 3.5 wt per cent) and S (up to 0.14 wt per cent) compared to the generally very low (<1 wt per cent for Si and Al) levels of these elements in ochreous goethite and brown goethite. The data dispels the common misconception that friable earthy or yellow ochreous goethite is high in Al and Si and other chemical impurities. However, P was found to be consistently higher (mean of 0.112 wt per cent and up to 0.296 wt per cent) in ochreous goethite than brown goethite (mean of 0.011 wt per cent) or vitreous goethite (mean of 0.031 wt per cent). The highly porous microstructure of ochreous goethite is thought to have a much higher surface area, which may aid in preferential adsorption of P onto the ochreous goethite mineral surface.CITATION:Manuel, J R and Clout, J M F, 2017. Goethite classification, distribution and properties with reference to Australian iron deposits, in Proceedings Iron Ore 2017, pp 567–574 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 24, 2017

By J. Moskowitz

Construction of the new JFK International Airport Light Rail System (LRS) began in 1998 with a pre-construction load test program. This $1.2 billion design-build project consists of approximately 13 kilometers of elevated twin rail. The elevated rail system is supported on nearly 500 piers requiring deep foundations. The presence of underlying compressible and liquefiable soils as well as space constraints precluded the use of large spread footings. In the 1980's the Port Authority undertook extensive testing to evaluate various piles and drilled shafts types. The LRS piling sub-contractor and the Geotechnical Engineer conducted additional tests for this project to identify the most cost effective deep foundation type. Candidate piles types included: Monotube®, Tapertube®, and closed ended pipe piles. The tapered pile types were found to be the most cost effective and the project utilized both the Monotube® and Tapertube® piles. This paper presents the results of the load test program and the issues related to pile driving induced vibrations and ground movement.

Jan 1, 2000

By Adrian J. Moore, Alan B. Richards

Airblast overpressure levels can commonly be increased by up to 20 decibels (dBL) by the effects of meteorology, due to inversions and wind shear. Existing atmospheric refraction models can provide a good evaluation of the effects of meteorology, but have been limited in the accuracy of their outputs by the accuracy of the meteorological data that is available for input. This paper uses case histories from open-pit coal mine blasting in the Hunter Valley area of Australia to provide examples of increases in airblast due to inversions, wind shear, and a combination of both. It gives details of our experience of the accuracy with which predictions and assessments can be made using meteorological data of various levels of accuracy, and on the design buffer that is required to prevent the exceedence of airblast limits. The accuracy of meteorological prediction and assessment will shortly be improved by the use of sounding equipment that gives continuous measurements of temperature and wind velocity at significant levels above the ground. The paper also gives details of an industry funded research project that aims to permit the effective use of this data at distances many kilometres (km) (miles) from the location of the sounding equipment, and to develop a short term predictive model that will permit the amount of meteorological reinforcement that will occur at firing time to be determined before a decision is made to tie up a shot.

Jan 1, 2005

By Frank Chase

Longwall mining has gained the reputation as being the safest extraction method in underground coal mines. However, one of the most difficult tasks associated with longwall mining is moving the face once a panel is completed. Based on Mine Safety and Health Administration (MSHA) fatality reports since 1996, longwall face recovery operations have claimed the lives of 5 U.S. miners and have resulted in numerous injuries. Recovery operations can be hazardous because they involve moving large pieces of equipment in very confined spaces. They are also conducted in highly stressed ground conditions due to front abutment loads generated by panel extraction. Shield removal is the most hazardous operation during face recovery because miners are constantly exposed to the unpredictable gob edge. To protect the miners, one or more walking shields, cribbing and/or other supplemental roof and standing supports are typically employed as breaker line supports as each shield is removed. At the Harris No. 1 Mine in southern WV, mobile roof supports (MRS?s) have been used in lieu of traditional walking shields on 17 face moves since 1997. MRS?s are shield-like support units mounted on crawler tracks and are commonly used during room-and-pillar retreat mining operations. For longwall recovery, the two biggest advantages that MRS?s have over traditional walking shields are that they are remotely controlled and are highly maneuverable. MRS?s have contributed to safer shield recovery and shorter move times at the Harris No. 1 Mine. This paper will address both the safety and the operational issues associated with MRS usage during shield recovery. It will also discuss new developments, including the use of the inherently safer battery powered MRS?s, which have been recently certified by the Mine Safety and Health Administration.

Jan 1, 2007

By D. R. Wilburn

The worldwide budget for nonferrous, nonfuel mineral exploration was expected to increase by 58 percent in 2004 from the 2003 budget, according to Metals Economics Group (MEG) of Halifax, Nova Scotia. The increase comes two years after a five-year period of declining spending for mineral exploration (1998 to2002). Figures suggest a subsequent 27 percent increase in budgeted expenditures from 2002 to 2003. For the second consecutive year, all regional exploration budget estimates were anticipated to increase. The worldwide budget for gold exploration achieved about 50 percent of the total amount budgeted in 2004.This was 68 percent, or US$715 million, higher than the reported 2003 budget. The 2004 worldwide exploration budget estimates for copper increased by 70 percent, orUS$237 million, to US$577 million from the 2003 budget. The budget for nickel exploration increased 52 percent, or US$89 million more than in 2003. The 2004 exploration budget for other mineral targets (primarily cobalt, heavy minerals, industrial minerals and silver) increased114 percent, or US$118 million.

Jan 1, 2005