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By J. J. Cilliers, J-A. Lamamy, J. N. Rasera, K. Hadler

Production of oxygen on the moon can be achieved by reduction of lunar soil. One such reduction technology, hydrogen reduction, favours a high proportion of ilmenite in the feedstock. Ilmenite is present in lunar soil as a minor mineral phase, but it can be upgraded using electrostatic separation. This study presents the results of a preliminary investigation into the operating parameters and sensitivities of a free-fall electrostatic mineral separator for lunar applications. Samples of ballotini and ilmenite as well as simple binary mixtures of the two were tribocharged on copper and passed through a uniform electrostatic field. The field is varied to change the electrostatic force acting on the particles. The proportion of material reporting to the positive electrode collectors, negative electrode collectors or the central collector was measured to determine the separation performance. The data confirmed that the charge transferred from the tribocharger to each species is in agreement with the triboelectric series; ballotini was found to charge positively on copper and ilmenite negatively. Particle-particle contacts were dominant, however, resulting in a somewhat symmetrical particle distribution in the collectors. These findings indicate that the copper tribocharger design requires optimisation in order to substantially increase particle-wall contacts. Four binary mixtures with feed grades of ilmenite ranging from 5% to 20% were prepared and tested. This study found that a higher ilmenite head grade resulted in a higher concentrate grade (26.3% from a head grade of 20%) with low recovery (3.4%). In contrast, the lower feed grade resulted in a low concentrate grade but higher recovery. The mass yield of ilmenite was 1.4 times greater for the highest-grade feed than for the lowest. A subsequent study into the reprocessing of middling fraction found a nearly constant relationship between cumulative grade and recovery. This is the first investigation into the effect of feed grade on the concentrate grade and recovery for lunar mineral processing. Keywords: Lunar resources, beneficiation, electrostatic, SRU, ISRU

Jan 1, 2020

By C. K. Chabedi

"This paper discusses the difficulties associated with the potential exploitation of the deep multi-seam resources east of the Daarby fault in the Waterberg coalfield. The resources occur at a depth greater than 250 m and the thickness of the coal is roughly 110 m, but the top 50 m comprises coal intercalated with shale and the bottom 60 m contains five seams with sandstone and shale partings. Various factors affecting multiple seam mining at these great depths are discussed with reference to lessons learned from local and international experience on multi-seam mining. Field geological and geotechnical data was utilized to assess the stability of the roof of the seams. There is no specific rock mass rating for the Waterberg area, therefore approximate coal mine roof rating (CMRR) values were used to propose appropriate support strategies. Analysis of Multiple Seam Stability (AMSS) was used to analyse the strength of the parting or interburden between the various seams, the mining sequence, and the interaction between the various seams.The research indicated that it is possible to mine seams with a low CMRR at high mining rates using longwall mining, although support for gateroads is expected to be expensive, time-consuming and onerous to install, and will impact gateroad development rates. It will not be possible to simultaneously mine zones in close proximity and failure of the interburden is predicted, thus dangerous mining conditions are anticipated. However, it will be possible to mine just two of the eleven zones using longwall mining. IntroductionThis paper discusses the difficulties associated with the potential exploitation of the deep multi-seam resources east of the Daarby fault in the Waterberg coalfield using bord and pillar and longwall mining. Figure 1 illustrates the location of the Waterberg coalfield relative to other coalfields in South Africa, while Figure 2 shows the areas containing deep and shallow resources. The Waterberg resources are expected to contribute to South Africa’s future energy requirements, and are currently exploited at the Grootegeluk open pit mine. Grootegeluk produces coal mainly for a power station, with the higher quality product supplied as metallurgical coal. The deposit is technically unique and challenging, being a multi-seam coal deposit with a total of 12 seams over a thickness of 110 m as shown in Figure 3, including Zone 5. There is currently limited knowledge on the multi-seam mining of the deep Waterberg resources. Multi-seam mining utilizing the bord and pillar method has been practised in South Africa before, but at a depth of less than 100 m in the Witbank coalfields. Multi-seam mining in thin seams has also been performed in the Natal coalfields at a depth of less than 160 m, but mostly using bord and pillar mining and secondary mining (partial pillar extraction)."

Jan 1, 2016

By D. He, A. Yaacoubi, A. Baçaoui, K. Boujounoui, A. Abidi, K. El Amari

The effects of utilizing recycled tailings pond water from the flotation plant at the Mining Company of Guemassa (MCG) on galena recovery and selectivity towards chalcopyrite (RPb-Cu) , sphalerite (RPb- Zn), and pyrrhotite (RPb-Fe) were studied at bench scale. The results showed that recycling the tailings pond water in the lead circuit without addition of fresh water gave a good flotation performance in terms of lead recovery (Rpb) (75%) and selectivity towards the other metals: RPb-Cu (54%), RPb-Zn (60%) and RPb-Fe(65%). This allows the water to be recycled at least four times. However, increasing the d80 from 100 μm to 160 μm currently used at the MCG plant had a negative effect on the lead flotation performance.

Nov 30, 2022

By E. Marè, D. R. Groot, R. Engelbrecht, T. Coetsee

Hydrogen peroxide is often used as an oxidising agent in experimental waste electronic equipment (WEE) leaching work. However, the high cost of peroxide is a negative factor in its consideration in further process development. A few studies have reported on the efficient application of peroxide addition schedules to ensure optimum reagent consumption. Large quantities of unleached substrate material contained in WEE feed material result in a large dead volume of material in the leaching reactor. This factor necessitates fast reaction rates to enable the use of a high feed material throughput reactor to enhance overall project viability via hydrometallurgical processing. In this study the effects of hydrogen peroxide addition schedules on base metal leaching efficiency and solution temperatures were tested at laboratory scale. The results showed that overall peroxide consumption can be optimised to lower levels by matching peroxide additions to the particular feed material’s leaching behaviour. A simplified integrated model for peroxide decomposition is used to explain its effect on solution temperatures and leaching rates. Keywords: Peroxide consumption, waste electronic equipment, copper leaching, integrated model

Jan 1, 2020

By M. Kumral, S. Li, M. Balci, Z. Shao

Main haulage roads play an important role in the performance of underground mines because of the cost of transportation of the extracted ore, equipment, and workers. During mine development, these roads are designed through manual tools or CAD-based software. However, the optimisation of these roads is still a complex problem due to some constraints such as minimum turning radius and maximum gradient. By utilising Dubins path theory, three elevation cases; namely low, medium and high are defined, considering gradient constraint as well as the minimum turning radius in a three-dimensional space. The shortest path between two points can then be found by the three-dimensional Dubins path algorithm with elevation constraint. As a further step, a three-dimensional Dubins path algorithm with elevation constraint for multiple points is also developed for multi-point cases. The effectiveness of these algorithms is tested through case studies in order to determine the optimal path between different points.

Sep 1, 2021

By R. G. Diale, H. R. Chauke, T. M. Ledwaba, P. E. Ngoepe

FeCo alloys play an important role in soft magnetic materials with a wide range of technological applications due to their high saturation magnetization and Curie temperature. However, these alloys have low ductility at room temperature. The ductility can be improved by the ternary addition of elements such as V. A density functional theory supercell approach was used to generate B2 Fe50Co50-xVx (0 ≤ x ≤ 50) structures and the properties were evaluated at different atomic percentage compositions to determine the ductility at room temperature. The structures were fully optimized to obtain better equilibrium ground-state properties such as lattice parameters and thermodynamic properties for both binary and ternary systems. The stability of Fe50Co50- xVx was evaluated from the heats of formation, elastic properties, and phonon dispersion curves. Furthermore, magnetic strength was evaluated from magnetic moments. It was found that all structures are thermodynamically stable due to the negative heats of formation. The calculated Pugh’s ratio and Poisson’s ratio confirm that alloying with V effectively improved the ductility. It was also found that Fe50Co50-xVx showed a positive shear modulus for the entire concentration range investigated, in agreement with phonon dispersion curves. The ternary addition of V to the FeCo system resulted in reduced magnetic strength due to a decrease in magnetic moments. These findings reveal that B2 FeCo-V alloys can be used as components and actuators for the automotive industry.

Jun 10, 2024

By B. Hart, B. K. Gorain, A. Chattopadhyay, S. Dimovc

This paper presents a detailed and systematic approach to metallurgy diagnostics using an integrated novel gold deportment technique for complex copper-gold and refractory gold ore bodies. This uantitative gold deportment for these complex ore bodies is a challenging task due to reasons such as lower grades, high variability of visible and invisible gold content in different sulphides and iron oxide phases, significant presence of disseminated and composite carbonaceous matters along with associations of various copper sulphide phases. Gold mostly occurs as "invisible gold" (sub-microscopic gold) as solid solution or as colloidal-sized particles in different sulphides and other phases. The dominance of invisible gold and presence of highly preg-robbing and finely disseminated carbonaceous matter adversely affects gold recovery in flotation and leach circuits. Studies were initiated on various complex ore deposits and also on samples representing various process streams. Some case studies are presented in this paper to demonstrate the value of a high confidence gold deportment methodology in developing insights for problem diagnostics and to identify opportunities for metallurgical improvements. A systematic and holistic approach involving different fields of expertise is critical for successful development and delivery of solutions for complex ore bodies. Keywords: Integrated gold deportment, complex copper-gold ores, double refractory gold ores, carbonaceous matter, diagnostic metallurgy, preg-robbed surface gold

Jan 1, 2020

By C. N. Eze, C. K. Ezeh, O. Nnabuife, N. M. Ugwoju, S. C. Enemuor, V. Okechukwu

In this study, the efficacy of Providencia vermicola KUBT-1 in the leaching and beneficiation of Agbaja iron ore was evaluated under varying conditions of temperature, ore particle size, and pH. Agbaja iron ore is a Nigerian low-grade ore containing about 43%–52% iron and a high amount of gangue materials, including phosphorus (1.4%–2.0%) and sulphur (0.12%). The study was organised in triplicate in shake flasks with 48 samples. One millilitre of washed cells of Providencia vermicola KUBT-1 suspended in normal saline at 0.5 McFarland standard (108 cells ml-1) was introduced into each flask containing 50 g of sterilised ore in 100 ml of bioleaching medium, and the samples incubated at room temperature for eight weeks. The levels of upgraded iron, mobilised sulphur, and phosphorus were determined by atomic absorption and ultraviolet spectrophotometric analyses, respectively. Results showed that a particle size of 0.8 mm was optimal for iron upgrading and sulphur mobilisation while 1.0 mm ore size was optimal for phosphorus mobilisation. Up to 89.60% of the iron was upgraded while phosphorus and sulphur were mobilised, leaving residual values of 0.223% and 0.02%, in the ore, respectively. The organism produced best beneficiation results at a pH of 2.5 and a temperature of 3ºC. Correlation analysis with the Pearson’s correlation model showed a positive correlation between iron upgrading and sulphur-phosphorus removal (r =1.000, and r =0.967), respectively. These results present Providencia vermicola KUBT-1 as a promising candidate for large scale leaching and beneficiation of Agbaja iron ore.

Dec 15, 2025

By K. Shame, H. H. Thiele

South Africa holds approximately 70% of the world’s total chrome reserves. Chromium is an important raw material for the production of stainless steel and ferrochrome alloys. Over the years, China’s ferrochrome market has been dependent on chrome ore imports from South Africa. In 2018, China imported about 75% of its chrome ore from South Africa. With the low platinum price and the rising demand for stainless steel, a growing demand to evaluate new beneficiation technologies for fine chromite was identified. Gravity separation of fine chromite (<75 μm) is inefficient, due to the limitations of the technology to upgrade fine particle size distributions. Potential for the recovery of chromite, specifically fines (<75μm), lost to UG2 PGM flotation tails, but also from MG and LG6 spiral circuit tailings exist. Flotation of podiform chromite ores from India and Kazhkhstan is successful in generating saleable product grade, following acid or alkaline flotation routes. Application to South African stratiform chromite is being evaluated, with the emphasis on evaluating reagent type, optimising dosages and the effect of pH in optimising flotation performance. Flotation can unlock additional value from chromite tailings material. The effect of ore characteristics such as gangue mineralogy, particle size distribution and headgrade are reported. The performance in terms of product quality and yield are evaluated and compared. The impact of this paper will not only prolong life of mine and increase revenue but will also alleviate environmental burdens associated with tailings dams. Keywords: Chromite, flotation, fine material, performance optimisation

Jan 1, 2020

By M. Bueno, T. Chavez Matus, M. S. Powell, S. Michaux, S. Luukkanen

Comminution tests are an essential element in the design of ore beneficiation plants. Many methods have been developed to assess the breakage characteristics of rocks to generate parameters for modelling. However, most of the existing methods are laborious, expensive and require large samples. Consequently, test work has been traditionally conducted with a few representative reference samples. On the other hand, geometallurgical modelling programs require an extensive amount of test work to allow understanding the variability of ore properties within the deposit and establish spatial geometallurgical domains that show the differential responses to mineral processing. Therefore, comminution tests for geometallurgy need to be more efficient in terms of time, cost and sample size. This paper introduces a new testing device (Geopyörä) which is capable of measuring forces and energy applied to rock particles during the breakage process. The new testing method uses smaller samples and can be up to 50 times faster than other commonly used tests in the industry. This paper presents the concept prototype and the preliminary test work results, which have been benchmarked against some of the industry standard tests, such as the JK Drop Weight Test (JKDWT), the SMC Test® and the Bond ball mill test. Keywords: Geometallurgy, comminution, ore breakage characterization, variability.

Jan 1, 2020

By Chris D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900?s. This versatile product displaced the expensive and easily-poisoned platinum-based catalyst in nearly all applications by the 1930?s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has world-wide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development program dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and pre-heater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

By Chris D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900?s. This versatile product displaced the expensive and easily-poisoned platinum-based catalyst in nearly all applications by the 1930?s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has world-wide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development program dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and pre-heater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

By W. S. Steinberg

In 1963, the full-scale engineering study for the development of an iron, steel, and vanadium plant was initiated. This was the birth of Evraz Highveld and its process flow as it is known today. Highveld started out as a steelworks that produced steel and vanadium-bearing slag from a titaniferous magnetite iron ore mined from its own mine site near Steelpoort. The process utilized co-current rotary kilns for prereduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to open slag bath (OSB) operation, in order to enable the maximum production of iron and vanadium while improving the control over operational parameters. The conversion proved to be highly successful and, since 2005, three furnaces have been converted to OSB operation. The fourth furnace will be converted in the first half of 2011. The conversion to OSB furnaces not only yields higher vanadium recovery to the metal at the iron plant, but also improves the overall throughput of the steel plant. This is the result of the higher carbon content of the liquid iron from the OSB furnaces, eliminating the need for anthracite addition to the shaking ladle process. This reduces the blowing time by approximately 60%. The conversion of the furnaces to OSB configuration is seen as an enabling technology change and a prerequisite to the implementation of other plant improvements that are envisaged. The long-term vision of EHSV is to convert five furnaces to OSB mode, and permanently decommission the two remaining submerged-arc furnaces. This will allow EHSV to maintain current steel and vanadium production but at a significantly improved overall efficiency.

Jan 1, 2011

By E. Ringdalen

Keywords: Pyrometallurgy, research, Norway, SINTEF, NTNU The Norwegian Ferro-alloy Industry and the model for research cooperation between SINTEF, NTNU, and the Norwegian ferro-alloy industry is presented as an introduction. The research within pyrometallurgy is illustrated by examples from characterisation of Mn-ores and characterisation of carbon materials. Examples from studies of reaction mechanisms in laboratory- and pilot-scale experiments are presented, in addition to an example of industrial off-gas measurements. Education possibilities at NTNU are also described.

Jan 1, 2011

In this study, the effects of slag compositions, slag amount, temperature, and carbon content of steel on the manganese and phosphorus distribution ratios during converter steelmaking were analysed using the classical regular solution theory, and industrial tests were performed using two 80 t top-and-bottom combined blown converters (duplex melting process). The results indicate that the slag amount, temperature, and carbon content in steel are the main factors affecting the manganese yield when converter slag compositions remain constant. The FeO content of the slag has a strong impact on the manganese distribution ratio, while the slag basicity and MgO content have no obvious effect. The calculations and experimental results show that the phosphorus distribution ratio increases sharply with increasing slag basicity R, but then decreases with the increase of MgO and MnO contents in the slag. The final slag in converter steelmaking should have the following characteristics: 3.5 < R < 4.5, 15% < (FeO) < 20%, and 6% < (MgO) < 8%. The slag amount should be controlled appropriately at the same time. The results of this investigation would be useful in deciding on the application of manganese ore in alloying and identifying the slagging regime in converter steelmaking.

Jan 1, 2014

By L. M. Sekhukhune

The atmospheric leaching of copper-bearing matte by acidic ferric chloride solution was studied at the laboratory scale. The aim was to achieve maximum copper and nickel recovery by investigating the mechanisms of leaching, as well as identifying the effect of temperature, and concentration of ferric chloride and oxygen. Djurleite (Cu1.96S), hazelwoodite (Ni3S2), and Ni alloy were the primary phases detected in the matte. The quantitative composition of the matte was Cu 31%, Ni 50%, S 13%. Fe and Co constituted 2%, with platinum group metals (PGMs) accounting for 0.5%. A maximum nickel extraction of 98% was achieved using two-stage oxidative leaching at 90°C and 11 g/L Fe3+ as compared to 65% under non-oxidative conditions. A copper extraction of 99% was achieved in the first 45 minutes using two-stage non-oxidative leaching, and copper was recovered from solution by cementation. Three processes took place simultaneously throughout the leaching process, namely: dissolution, cementation/ metathesis, and oxidation. The leaching process was found to be diffusioncontrolled.

Jan 1, 2014

By C. Kasatuka

Globalization creates investment opportunities for enterprises around the world. Attracting foreign investment has been a key challenge for economic growth in developing countries. Corruption, political instability, armed conflict, and other internal problems affect foreign direct investment (FDI) inflows negatively. A framework of criteria provides a basis for comparing non-commercial risk (NCR) among twenty-three mineral economies. Countries competing for foreign direct investment inflows are ranked from least to most risky. This study compares Inward FDI Performance Index (IND) with NCR ratings in developing countries and shows that risk is increasingly mitigated by means of appropriately structured insurance. Given the option for countries with similar mineral potential, investors will generally invest in the country that offers lower non-commercial risk. Keywords: foreign direct investment, non-commercial risk, developing countries.

Jan 1, 2006

By C. Kasatuka

Globalization creates investment opportunities for enterprises around the world. Attracting foreign investment has been a key challenge for economic growth in developing countries. Corruption, political instability, armed conflict, and other internal problems affect foreign direct investment (FDI) inflows negatively. A framework of criteria provides a basis for comparing non-commercial risk (NCR) among twenty-three mineral economies. Countries competing for foreign direct investment inflows are ranked from least to most risky. This study compares Inward FDI Performance Index (IND) with NCR ratings in developing countries and shows that risk is increasingly mitigated by means of appropriately structured insurance. Given the option for countries with similar mineral potential, investors will generally invest in the country that offers lower non-commercial risk. Keywords: foreign direct investment, non-commercial risk, developing countries.

Jan 1, 2006

By J. Petersen, T. Moyo, J. Dinga

The leaching of chalcopyrite in ferric sulfate media is notorious for its slow and inhibited kinetics. Different methods have been proposed to improve the kinetics, including the use of organic compounds as additives to the leaching media. In this study, the enhancing effect of methanol, ethanol, 1-propanol, and 2-propanol on the leaching of chalcopyrite in aerated acid ferric sulfate solutions using different reactor systems was investigated. The results revealed a clear improvement of copper dissolution by methanol and 1-propanol relative to tests with no additives under similar conditions. Operating a continuous-flow mini-column reactor yields surprisingly good results, potentially related to the maintaining of a consistent leaching micro-environment on the mineral surface. Scanning electron microscopy studies showed that the alcohols result in the removal of surface deposits formed during the anodic dissolution, potentially thus facilitating improved cathodic reduction of the ferric ion to drive the anodic dissolution.

Jan 1, 2023

By R. Degel

Keywords: Pyrometallurgy, DC furnaces, electric smelter, FeCr, FeNi, FeMn, Si metal, ferro-alloys, platinum production, circular furnace, energy recovery system In 1906, the first submerged-arc furnace was supplied by SMS Siemag. Since then, the division has become established in various industries such as ferro-alloys and non-ferrous metals, and in numerous other special applications. During the evolution of this technology, more efficient units with longer lifetimes were developed. Today, especially the potential of DC-based smelters, raises worldwide attention, with some projects having already started to implement this kind of technology. This paper evaluates SMS Siemag?s general viewpoint regarding the potential application of DC smelter technology and possible options for the ferro-alloy and non-ferrous industry. SMS Siemag is currently executing a FeCr project in Kazakhstan, where four of the world?s largest closed-type DC smelting furnaces, with a power input of 72 MW, will be installed. These furnaces include the latest technological features of modern DC smelters, which are described in this paper. SMS Siemag has started a long-term research and development project allowing a direct comparison of AC versus DC technology on a large scale, using a recently installed 1 MVA test furnace at the IME at the University of Aachen, in Germany. For open-type ferro-alloy and Si-metal furnaces, SMS Siemag has developed an energy recovery system, which is presented in this paper.

Jan 1, 2011