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By L. A. Vermeulen, C. P. Campbell, D. D. Howat

The production 01material liner than 75 µm in a number of open-circuit mills was investigated. The mils ranged from laboratory rod and ball mils treating a variety 01 ores to large industrial rod mils treating gold and copper ores. It was shown that the dependence on feed rate 01 the production 01 material liner than 751J.1T1 can be accurately described by a simple formula that was derived in previous work. In some 01 the systems reviewed, it proved possible to assess the feed rate 01 ore to the mil at which the rate 01 production 01 material finer than 75 µm can be maximized.

Jan 1, 1991

By Y. Mao, D. Xie

The viscosity of TiO2-containing blast furnace slags may increase rapidly (commonly referred to as thickening) under strong reducing conditions in the blast furnace. To elucidate the mechanisms for slag thickening, measurements have been made of changes in the composition and rheological properties of TiO2-CaO-SiO2-Al2O3-MgO slags during the reduction process. The slag composition covered the range of 17–33 wt% TiO2, 9–19% Al2O3, 8–16% MgO and theCaO/SiO2from 0.8 to 1.4. The viscosities were measured using the rotating cylinder method at temperatures up to 1550ºC and the fusibility temperatures were determined from ‘breaks’ in the viscosity-temperature curves. The reduction of the slag was carried out in graphite crucibles at1500ºC for 2–6 hours The rheological properties of the slags during reduction were predominantly influenced by the slag basicity (CaO/SiO2), and the effect of other components depended largely on basic or acidic behaviour of the oxide. The reduction of TiO2in the slag by carbon was initially fast to formTi2O3, followed by further reduction to TiO and TiC. Correspondingly, the viscosity showed initially a slight decrease, followed by a gradual and then rapid increase. The thickening was found to be accelerated by an increase in TiO2content and a decrease in the CaO/SiO2in the slag. In addition to the existence of 1~3 wt% TiC, the thickened slags also had a significant amount of TiO (3~7 wt%), suggesting that TiO may play an important role in the ‘thickening phenomena’ ,possibly by forming solid solutions with TiC to significantly increase the number of solid particles in the heterogeneous slag. Keywords: TiO2slags, viscosity

Jan 1, 2004

By X. Pan

Slag-metal equilibrium experiments were conducted at 1500ºC and 1580ºC under 0.03 atm, 0.05atm and 0.83 atm CO partial pressures using silica and Cr-oxide crucibles. The complex slags belonged to SiO2-CaO-Al2O3-MgO-FeOx-CrOxand the metal phase to the Cr-Fe-C-Si-(S)systems. The carbon saturation of the metal phase was avoided using oxide crucibles and thus the results are pertinent to ferrochromium refining slags and processes. From equilibrium data and thermodynamic calculations the CrO /(CrO+Cr2O3) ratio in the slag was determined as 0.75, 0.80and 0.86 under 0.83 atm and 0.05 atm of CO pressure at 1500ºC and 0.03 atm and CO pressure at1580ºC respectively. The results clearly demonstrated that a higher chromium content of the metal results in higher Cr in the slag, and chromium in slag decreases with increasing SiO2. The results were also sensitive to the crucibles used as these oxide crucibles saturated the slag either with respect to SiO2or Cr-oxides. It was also demonstrated that the relative amount of CrO in the slag was higher when SiO2crucibles were used in accord with thermodynamic calculations. Iso-concentration curves for carbon and chromium of the metal phase in equilibrium with the slag were drawn on pseudo ternary SiO2–(AI2O3+CaO+MgO)–(Cr2O3+Fe2O3) diagram. The activity coefficients and activities of carbon and chromium of the metal phase were also calculated from the experimental data and available thermodynamics information and were plotted as iso-activity curves in the same pseudo ternary diagram. Keywords: Chromium, slag, equilibrium

Jan 1, 2004

By T. Lindstad, S. Gaal, S. Hansen, S. Prytz

The SINTEF SiO-reactivity test, developed by Tuset and Raaness in the 1970?s, is a recognised method of characterising the ?reactivity? of carbonaceous reactants, used in the ferrosilicon and silicon metal industries. Recently, the test has been updated, which has resulted in the development of an extended and improved SINTEF SiO reactivity test. This has included updating the test reactor, control system, data-logging, handling and preparation of carbonaceous materials to be tested and measurement procedure. The scientific basis has been re-assessed, resulting in a new interpretation of the test results. The repeatability of the test has improved significantly, especially through system automation. In the ?old? test, the kinetics of the reaction: SiO(g) + 2C(s) = SiC(s) + CO(g) for a specific carbonaceous material was characterised solely by the ?R10? parameter, the volume of SiO(g) which passes un-reacted through the coke-bed as the concentration of CO in the outlet gas decreases from 18 to 10%. As both the kinetics and obtainable conversion of SiO to SiC for a reductant is of importance to the ferroalloy producer, the new SINTEF SiO reactivity test ranks carbon materials both according to degree of conversion and reaction rate. From research carried out on the test in the past couple of years at SINTEF and NTNU, it has also become clear that some of the reactions taking place in the test reactor are more complex than previously assumed. As an example, it was previously assumed that the condensation reaction of SiO gas in the condensation chamber of the test reactor can be described as: 2 SiO(g) = Si(l,s) + SiO2(s). However, it has been established that the side-reaction: CO(g) + 2Si(l) = SiC(s) + SiO(g) causes approximately 10% of the total volume of CO to react to SiC and SiO2 in the condensation chamber. This means that some back-reaction i.e., the reverse SiO-generator reaction 3SiO(g) + CO(g) = 2SiO2 + SiC also takes place in the condensation chamber. In the new SINTEF test, the %CO versus time curves are therefore corrected in order to describe the effect of the reaction between SiO(g) and C(s) studied i.e., SiO(g) + 2C(s) = SiC(s) + CO(g). A correction-formula for this purpose is presented.

Jan 1, 2007

By A. V. Pavlov, V. A. Grygorian, Kossyrev, A. E. Semin, A. Korostylev

A new way of producing low-silicon ferrosilicon from iron-ore materials in a new type of aggregate-oxygen reactor is presented. The oxygen reactor process is based on using the calorific combustibility and reducibility of carbon materials inside the aggregate. The key to the process is successful post-combustion of carbon monoxide above a layer of a solid coke bed. Initially the possibility of production of grades of ferrosilicon containing 20 to 25% Si (FeSi20-FeSi25) was studied on a laboratory model of the oxygen reactor. Quartz sand and iron ore concentrates (from Russia and India) were used in the laboratory tests. This test work demonstrated that a ferrosilicon grade FeSi15 could be obtained directly from raw iron ore (containing 75.9 % Fe2O3 and a maximum of 23.8 % SiO2) without using rich iron-ore concentrates. The process was successfully tested on a pilot furnace at Serovsky metallurgical plant. Very promising results and efficiency parameters were achieved. The consumption of materials for 1t of ferrosilicon (15 % Si) production was as follows: 1567 kg raw iron ore, 591 kg of coal (in a composition of ore-coal briquettes), 299 kg of coke (for coke bed formation), and 815 m3 of oxygen.

Jan 1, 2004

A diverse selection of rockbolt designs and resin anchors are available for use in underground mines. Research in recent years at the UNSW Mining Research Centre led to the construction of a rockbolt pull-testing facility. This facility has subsequently been upgraded, commissioned and initial test work has been completed to verify the pull-test process. A test program has been completed with the objective to understand the load transfer mechanism and improve the general performance of rockbolts. This paper describes the results of this research. Une sélection diverse de dessins du rockbolt et ancres de la résine est disponible pour usage dans les mines de métro. Faites des recherches ces dernières années à l'UNSW que le Centre de la Recherche Minier a mené à la construction d'une facilité de l'essai de la traction du rockbolt. Cette facilité a été améliorée par la suite, le travail de l'épreuve en commission et initial a été complété pour vérifier le processus de la traction-épreuve. Un programme de l'épreuve a été complété avec l'objectif comprendre le mécanisme du transfert de la charge et améliorer la performance générale de rockbolts. Ce papier décrit les résultats de cette recherche. Eine verschiedenartige Auswahl an rockbolt-Designs und Harzankern ist dafür verfügbar, benutzen Sie in unterirdischen Bergwerken. Forschung in letzten Jahren beim UNSW-Bergbau Forschung Zentrum führte Ruckerprobung-Einrichtung zur Konstruktion eines rockbolt. Diese Einrichtung ist anschließend befördert worden, ist beauftragt worden und wird abgezeichnet, prüfen Sie, die Arbeit ist vervollständigt worden, um den Ruckprüfung-Prozeß zu verifizieren. Ein Prüfungsprogramm ist mit dem Objektiv vervollständigt worden, den Lastübertragungsmechanismus zu verstehen und die allgemeine Aufführung von rockbolts zu verbessern. Dieses Papier beschreibt die Ergebnisse dieser Forschung.

Jan 1, 2003

By Dhananjaya Senapati, E. V. S. Uma Maheswar, C. R. Ray

Carbothermic process of Ferro Silicon production is primarily a slag-less process. However, slag formation is observed in the regular operation as experienced by almost all the Ferro Silicon Producers in different pro-portions. The problem of slagging in the furnaces may be due to: a)Variation in the input burden charge material quality b)Fluctuations in the Carbon balance and/or c)Fluctuations in the Electrode penetrations The problem will be more severe in nature with the increase of the size of the furnace. The operation performance of the furnace gets badly affected if the slag formed in the furnace is not removed from the bath in time and to the maximum extent possible. It is, therefore, very essential to know the characteristics of the slag formed in the Ferro Silicon Furnaces, besides eliminating the very cause of formation itself; and to find the routes of draining of the same from the furnace bath effectively. This paper envisages the effects of using the LIME STONE in the Ferro Silicon Burden in stabilizing the 48MVA Furnace for improved performance and better consistency. Quality fluctuations in the available Raw Materials are compared with that of the requirements for the Ferro Silicon production. The furnace operational data is compared for 12 months period each for the period corresponding to the before and after usage of lime stone in the burden and found encouraging results in the performance. Implications of use of Lime Stone in the burden on the quality of the output alloy are also studied.

Jan 1, 2007

The Annual General Meeting of the South African Institute of Mining and Metallurgy was held in Kelvin House on Wednesday, 24th August, 1977. Dr M. D. G. Salamon (President) was in the chair and declared the meeting open at 16h00. Obituaries The President: It is my sad duty to announce the death of the following members of the Institute : C. G. Evans, J. P. Rees, Life Fellows ; S. R. Bryant, H. MacConachie, M. Mrost, and A. W. van Zyl, Fellows; L. T. Campbell-Pitt, F. W. Collins, A. J. Duncan, I. G. Evans, F. W. Kleinschmidt, P. L. Vaughan, R. W. Wallace, and H. Wason, Members. As a mark of respect to the memory of the deceased and in sympathy with the bereaved, I would ask you to rise and observe a few moments' silence. Minutes The President: May we confirm the minutes of the General Meeting held on 23rd March, 1977, as published in the June issue of the Journal? Agreed.

Jan 1, 1978

By T. Nghipulile, G. Dzinomwa, J. Kurasha, M. Amwaama, B. Mapani, K. Maweja, T. E. Moongo

The effect of mineralogy on the grindability was investigated using three copper ores – two sulphides and one oxide. The dominant copper minerals were identified by optical microscopy and mineral chemistry derived from SEM-EDS analysis. The sample designated sulphide 1 was borniterich, sulphide 2 ore was mainly chalcopyrite, and the oxide ore was predominantly malachite and minor azurite. The gangue minerals were identified using semi-qualitative XRD analysis. Sulphide 1 contained more than 80% (w/w) of quartz compared to about 70% in the other two ores. The Bond work indices were 13.8, 21.6, and 17.3 kWh/t for sulphide 1, sulphide 2, and oxide ore respectively. This suggested that the chalcopyrite-rich ore is the hardest, while the malachite-rich ore has intermediate hardness, and the bornite-rich ore is the softest. The brittleness indices of the ores were calculated using the chemical composition of the gangue, and a good correlation between brittleness indices and Bond work indices was observed, which highlights the importance of the gangue composition in determining the fracture behaviour of the ores. There is scope for further investigation into the relationship between ore mineralogy and comminution behaviour using other breakage characterization techniques.

Mar 30, 2023

By L. Holappa

Ferroalloys like FeCr and FeMn are mostly produced in submerged electric arc furnaces. Typical for these processes is that the amount of slag is quite high. The role of slag for the process is thus very essential and specific chemical, physical and electrical properties are required. Slags in FeCr process are Al2O3-MgO-SiO2based with minor contents of CaO and CrOx. Slags in FeMn process are principally similar originating from silicate minerals but can have quite a large composition range depending on the manganese ore and its gangue minerals. Characteristic for FeMn process is that the slag is rich in manganese oxide up to above 30%. A common feature is that the ?ore oxides?, CrOx and MnOxin slag are not only divalent oxides but also containing some higher valent of Cr3+ and Mn3+, respectively. In FeMn production conditions the slag consists mainlyMn2+. This is a clear difference from CrOx containing slags in which both two and three valent coexists in slags in FeCr process conditions. Oxidation state of the slag depends on the ambient oxygen partial pressure and temperature in the examined process. Thermodynamics of slags in ferroalloys production are discussed in terms of phase diagrams, activities and oxidation state of chromium and manganese oxides. Further, slag properties influencing reduction kinetics and furnace operation i.e. viscosity and electrical resistivity are discussed. Keywords: review, slags, ferroalloys, ferrochromium, ferromanganese, thermodynamics, physical properties.

Jan 1, 2004

By S. Ganguly, R. Kononov

Carbothermal reduction of manganese oxides and manganese ores in the solid state was studied in hydrogen, helium and argon at different temperatures, ore compositions and carbon to manganese oxide ratios. Wesselsore (South Africa) and two grades of the Groote Eylandt ore (Australia) with different level of impurities were examined. Ores were characterised by XRD, X-ray fluorescence, optical microscopy and scanning electronmicroscopy. Isothermal and temperature programmed carbothermal reduction experiments were conducted in a fixed bed reactor in a vertical tube furnace, with on-line monitoring of gas composition by the CO-CO2 infrared sensor. The reduced samples were characterised by XRD, SEM and LECO analyses. Extent of reduction was calculated using data on the off-gas composition, and LECO carbon and oxygen contents in the reduced sample. Manganese oxides in the ore were reduced to a-Mn and carbides Mn23C6 and Mn7C3 depending on the carbon to ore ratio. The reduction rate of manganese ores in hydrogen was higher than in helium and argon. Key words: Manganese, Carbothermal Reduction, Hydrogen, Argon, Carbon Monoxide, Helium, Kinetics.

Jan 1, 2007

By S. E. Olsen, K. Tang

Slag-metal and slag-metal-gas heterogeneous equilibria involving MnO-containing slags have been simulated using recently developed Mn-based alloy and IRSID oxide thermochemical databases. A large number of experimental equilibrium data have been used to verify the calculation results. The experimental slag-metal and slag-metal-gas equilibria in MnO-SiO2binary, MnO-SiO2-CaO and MnO-SiO2-Al2O3ternary, MnO-SiO2-CaO-Al2O3quaternary andMnO-SiO2-CaO-Al2O3-MgO higher-order system can be reproduced within experimental uncertainties. The influence of temperature, CO partial pressure and slag chemistry on the Mn-and Si-distribution equilibria have been quantitatively evaluated. This leads to a sound basis for optimizing the manganese ferroalloy production processes. Key words: MnO-containing slag, manganese ferroalloy, equilibrium simulation, thermochemical database

Jan 1, 2004

By J. M. Richards

For most of the 20th century optical petrography has been the primary petrological and mineralogical tool used to characterize coal. The development of quantitative SEM-based techniques, e.g. QEMSCAN®, for coal began only about a decade ago. The application of these techniques for coal lagged behind other commodities, but they are currently being developed with the aim to provide ?one complete analysis? for coal. Quantitative SEM-based techniques are supplemented by quantitative X-ray diffraction (XRD). Recent indications are that these more modern techniques cannot replace the ?standard? petrographic and chemical evaluations, but rather complement them where and when required. The great advantage of quantitative SEM-based techniques is that they are very rapid, with the result that large volumes of samples can be processed on a routine basis. This is ideal for coal type identification, since the results can be used in the creation of ?intelligent? composites. This can lead to the more speedy evaluation of coal deposits by reducing the number of samples on which detailed metallurgical and characterization test work is required, without an increase in the overall statistical error of the resource model. Coal petrography, however, remains important for the prediction of the coking characteristics of certain coals and coal products. As a consequence it is therefore important that any coal laboratory be able to produce data with confidence. This requires strict quality control and assurance protocols that adhere to international standards. Keywords coal petrography, coking strength, scanning electron microscopy, QEMSCAN®.

Nov 1, 2013

By R. Boom, J. Halder, B. Snoeijer, B. Deo, A. Overbosch

Operational data of BOF and the slag samples for different starting conditions of phosphorus(0.06–0.26 per cent P) and silicon content (0.3–1.2 per cent Si) of hot metal have been analysed. The contribution of parameters that are well known to affect phosphorus distribution at tap, like basicity, temperature, FeO content of slag, slag mass etc., is investigated through the models of ionic theory of slag, optical basicity, regular solution approach and molecular theory of slag. The best overall results are obtained by the model based on molecular theory of slag in which several operational parameters are also incorporated. The investigations of different slag samples, based on optical, SEM, EPMA and X-ray studies, reveal the effect of MgO and Al2O3on slag morphology and phosphorus distribution in different phases. It is important to consider phosphorus distribution ratio in the solid and liquid part of slag. The solid part of slag, which is mostly dicalciumsilicate, can contain up to 5 per cent phosphorus. The phosphorus content of the liquid part of slag may depend upon the phosphorus content of hot metal or phosphorus load of slag. It is found that incorporation of effect of dicalciumsilicate in the model improves the accuracy of prediction. For better process control, the addition of iron ore towards the end of blow must be avoided while treating high phosphorus hot metal or during the production of ultra low phosphorus steels. Keywords: steelmaking, BOF, phosphorus distribution, slag morphology, MgO, Al2O3,dicalciumsilicate, process control, models

Jan 1, 2004

By E. Kapilashrami, S. Seetharaman

Refractory/metal interactions and associated reactions are significant during casting as they can lead to inclusion formation. High-temperature interactions between aluminosilicate refractories and molten steel were studied in the present investigation using the sessile drop method. The changes in the contact angles between molten iron with well-defined oxygen levels and substrates of silica, mullite (3Al2O3?2SiO2) as well as commercial refractories were measured in the dynamic mode. In all cases, the reaction led to slag formation. The experiments were performed under isothermal conditions at 1823 and 1873 K. A known and constant oxygen partial pressure was imposed above the iron drop, through appropriate CO-CO2-Ar mixtures. For all substrates, the contact angles started decreasing due to the lowering of the surface tension of iron, as oxygen was imposed on to the system. When a critical level of oxygen was reached, slag started forming at the drop/substrate interface and at this stage, the contact angle dropped suddenly. Subsequent behaviour of silica and mullite was observed to be different, with SiO2showing a non-wetting behaviour. In the case of SiO2substrate, there were also deep erosions along the periphery of the drops and there was slag accumulation at the sides of the metal drop, probably due to Marangoni flow and/or SiO(g) formation. SEM and EDS analysis of the substrates revealed that the formed slag was fayalite. The thermodynamic criteria for slag formation and possible mechanisms of the reaction are discussed in the light of the experiments. Key words: silica, mullite, fayalite, corundum, slag formation, sessile drop.

Jan 1, 2004

By Jochen Petersen, Thandazile Moyo

"The oxidative leaching of chalcopyrite in ammoniacal solutions has been evaluated using electro-analytical techniques. The anodic dissolution process has been established to be a seven-electron transfer process under nitrogen in ammonia–ammonium sulphate solutions and ammonia–ammonium carbonate solutions. The number of electrons transferred in the carbonate and sulphate salts suggests that the sulphur is oxidised to a thiosulphate intermediate and the copper and iron released as Cu+ and Fe2+. The Cu+ and Fe2+ is subsequently oxidised in solution in non-Faradaic reactions. The deportment of Fe2+ and S2O32- is affected by choice of the ammonium salt used in the leaching process. In the perchlorate salt, only five electrons are transferred, however observations made on the mineral surface after leaching do not support the formation of elemental sulphur. Scanning electron microscopy and energy-dispersive spectroscopy analysis of the mineral surface suggest presence of an iron–sulphur surface layer completely free of copper under the ammonia–ammonium sulphate conditions, an iron-rich surface layer under ammonia–ammonium perchlorate solutions and absence of surface layer build up under ammonia–ammonium carbonate solutions. INTRODUCTION Hydrometallurgical processes for copper extraction provide a viable route to recover the metal from mixed and low-grade ores, as well as overcome the environmental challenges faced by the traditional pyrometallurgical processes. Chalcopyrite is not only the most abundant of the copper sulphides, but also the most stable, making it recalcitrant to hydrometallurgical processes. Hence, hydrometallurgical processing of chalcopyrite continues to be an attractive area of research due to the vaguely understood surface chemistry of the mineral in different aqueous media. Different approaches to hydrometallurgical treatment of chalcopyrite can be carried out. These include thermal treatment prior to leaching, direct leaching and direct electrochemical leaching (Venkatachalam, 1991). Direct leaching of chalcopyrite can be carried out in various solution systems, as reviewed by Roman and Benner (1973) and Venkatachalam (1991). Ammoniacal solutions are attractive and effective lixiviants that form stable amine complexes with some base-metal cations while rejecting iron. Leaching of chalcopyrite in ammoniacal solutions in the presence of an oxidant is possible due to the stabilisation of copper(I) and copper (II) by ammonia at elevated pH levels. In oxygenated ammonia solutions, it has been suggested that chalcopyrite dissolves according to Equation 1 (Beckstead & Miller, 1977a):"

Jan 1, 2015

By S. Pal, A. K. Lahiri

Most of the compounds present in slag are surface active. This gives rise to foaminess of slag. The foam life and foaming index are normally determined by the draining rate of slag through the plateau border, so the foaming index is directly proportional to slag viscosity and inversely proportional to slag density and bubble diameter. When a small amount of a strong surface active compound like P2O5or Cr2O3is present in slag, however, the foam life increases significantly and the above relationship is not obeyed. The strong surface active compounds reduce the draining rate from the film between the adjacent bubbles so the film draining controls the life of the foam. The thickness of the film, Marangoni force, viscosity of the slag, and diffusion of surface active compounds determine the film draining rate. The interplay of these factors leads to very low or high film draining rates and affects the film and foam stability significantly. Keywords: slag, foam, foaming index, film draining

Jan 1, 2004

By A. Kondratiev

A structurally-based viscosity model for fully liquid silicate slags has been developed and applied to the Al2O3-CaO-‘FeO’-SiO2system at metallic iron saturation. The model links the slag viscosity to the internal structure of melts through second nearest neighbour bonds concentrations taken from the quasi-chemical thermodynamic model. This viscosity model describes experimental data over the whole temperature and composition ranges within the Al2O3-CaO-‘FeO’-SiO2system at metallic iron saturation and can now be applied to other industrial slag systems.

Jan 1, 2004

By R. J. Hundermark, L. R. Nelson

The critical importance of tap-hole design and management to furnace performance and longevity is explored through examining some of the specific matte, metal and slag tapping requirements of non-ferrous copper blister and matte converting and smelting, ferroalloys smelting and ironmaking systems. Process conditions and productivity requirements and their influence on tapping are reviewed for these different pyrometallurgical systems. Some critical aspects of the evolution of tap-hole design to meet the diverging process and tapping duties are examined. Differences and similarities in tapping practices and tap-hole management are reviewed. Finally core aspects of tap-hole equipment and maintenance are identified that are considered important to securing improved tap-hole performance and life, so pivotal to superior furnace smelting performance.

Jan 1, 2014

By G. Cockburn

Nkomati Nickel JV exploits the ores of the Uitkomst Complex near Machadodorp in the Waterval Boven district in South Africa?s Mpumalanga Province. Due to factors such as the remote location, stellar growth in production, opencast mining methods, and ore characteristics, a number of innovative processing options were selected. Nkomati has undertaken numerous initiatives over the last few years to improve plant running times, metallurgical performance, and operational profitability. Great emphasis has been placed on effectiveness of management control systems. A number of initiatives such as short interval control and time?in-state metrics have been implemented. A focus on improvement on availability and asset utilization of key items of equipment has been particularly effective. While the ores are remarkably similar to the Merensky and UG2 reefs, the relatively high base metal sulphide content and mineralogical characteristics make metallurgical treatment somewhat different to the ores of the Bushveld Complex. The low head grades and flotation kinetics distinguish Nkomati from other base metal operations. Numerous milling and flotation optimization initiatives have resulted in dramatic improvements in throughput, recoveries, and concentrate grades. This paper discusses the metallurgical, operational, and management challenges and the outcomes obtained.

Jan 1, 2014