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By G. Kang

The ferroalloys industry has generated historically substantial solid waste. The accumulated waste causes serious problems to the environment. However, it is possible to transform the solid waste into an environment-friendly resource to serve the human being. Consequently, the construction of plants that are ?environment-friendly? and that accommodate ?recycling? has become a target of most ferroalloy producers in the world to ensure sustainable development. This paper introduces the practice of Shanxi Jiaocheng Yiwang Ferroalloys Works, the biggest manganese metal producer in China, in the development of an ?environment-friendly and recycling? process. The process includes power generation using coal gangue, waste from local coal mines; hollow bricks manufacture using slag and fly ash from the power station; cement production using slag from ferroalloy smelting; recovery of ferrous and non-ferrous elements in the dust from the furnace gas cleaning system; application of silica dust in construction and so on. The final objective of the plant is to realize zero discharge of solid waste. The profit of the ?environment-friendly and recycling? process compensates in part for the operational expense of the environment facilities.

Jan 1, 2004

By J. Nell

An overview is given of the matte melting process used for the beneficiation of South African platinum group metal (PGM) ores. Most producers use six-electrode furnaces to melt the concentrate and Pierce Smith converters to oxidize excess iron sulphide from the furnace matte. Concentrates from two reef types (the so-called Merensky and UG-2 reefs) dominate the feedstock supply. Concentrate from the Merensky Reef is low in chromium and does not pose significant melting problems. Concentrates from the UG-2reef contain much higher levels of chromium, which results in the formation of chromium-rich spinels during melting. This is attributed to the low solubility of chromium in furnace slag under typical operating conditions (an oxygen partial pressure of 10-8?10-9bar at temperatures of 1550°C to 1600°C). During the converting process, care is needed to avoid excessively oxidizing conditions, which result in cobalt, nickel and copper losses to the slag. High nickel losses result in the formation of Fe2NiO4 (trevorite), which often forms solid solutions with FeCr2O4and Fe3O4. In future, the main challenge in the processing of South African PGM ores will be to cope with ever-increasing levels of chromium in the concentrate. A short-term solution to the problem would be to melt the concentrate under slightly reducing conditions to promote the formation of CrO, which is more soluble in the slag than Cr2O3.A longer-term solution to the problem would be to abandon the current matte-smelting process in favour of an alloy-based process, which would offer total flexibility with respect to the amount of chromium that can be tolerated in the feed. Keywords: Merensky, UG-2, furnace, slag, matte, converting, spinel, chromium

Jan 1, 2004

Council for 1999/2000 President J.R. Dixon President Elect M.H. Rogers Vice Presidents Senior Dr L.A. Cramer Junior A.A.B. Douglas Immediate Past President R.P. Mohring Honorary Treasurer J.A. Cruise Members of Council B.C. Alberts Dr N.A. Barcza N.J. Barkhuysen R.D. Beck M.J.P. Bierman Prof. A.N. Brown D. Cockcroft Dr M.B. Cortie Dr L.A. Cramer J.A. Cruise E.G. de Villiers J.R. Dixon A.A.B. Douglas F.M.G. Egerton J.P.W. Fisher C.E. Fivaz K.J.R. Ford Prof. G.A. Fourie R. Graham Dr R.G. Gürtunca Dr R.V.R. Handfield-Jones* M.C. Harris J.P. Hoffman H.E. James P.J. Knottenbelt R.P. Mohring H.G. Mosenthal G.Y. Nisbet N.M. O'Brien R.G.B. Pickering Prof. R.P. Plewman S.J. Ramokgopa Prof. R.E. Robinson M.H. Rogers D.A.J. Ross-Watt Prof. R.F. Sandenbergh Dr H. Scott-Russell C.B. Sheppard D.A.A. Smith Dr T.R. Stacey Dr O.K.H. Steffen D.J. van Niekerk J.C. Viljoen J.N. Wallington

Jan 1, 1999

By H. B. Arntzen, P. O. Grøntvedt, T. Lindstad, R. J. Ishak, M. Syvertsen

Better utilisation of electric power and coke is vital in reducing production costs and CO2-emissions in production of ferromanganese. All FeMn smelting operations consume 10 to 30 % more carbon than the carbon needed to reduce MnO and FeO to metal and the carbon contained in the alloy. Potassium which re-circulates and builds up in the furnace has been shown to be the main culprit causing both excessive carbon consumption, by catalysing the Boudouard reaction, and increased electric power consumption. The reaction between CO2 and ordinary metallurgical coke or coke impregnated with potassium has been studied at temperatures from 800 to 1100°C in a thermobalance apparatus. Ordinary coke did not react to any great extent at temperatures up to 1000°C, whereas the addition of potassium (2-10 %) resulted in a huge increase in reaction rates. The ultimate goal is to fit the results into a reaction rate model containing the equilibrium constant for the solid-gas heterogeneous reaction between CO2 and a free active site on the carbon reactant producing CO and adsorbed oxygen (an occupied site). The model includes the partial pressures of CO and CO2, a reaction rate constant that is a function of both the total number of reaction sites of carbon, and the potassium content. The potassium dependency is taken care of by introducing activity coefficients for the carbon sites. As the first step towards such a model, a regression line for the Boudouard reaction rate has been established.

Jan 1, 2004

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 S. A. Scott

Mintek developed the MinataurTM leach-solvent extraction-precipitation technology as a cost effective, easily operated alternative to conventional gold refining processes. The technology was first commercialized at the Harmony Gold Refinery in 1997 to produce 99.99 per cent gold product and has subsequently led to development of various value-addition steps including the casting of various investment bars, gold wire drawing and gold potassium cyanide powder production. In addition to refining gold to high purity, if an appreciable amount of silver is present in the feed material it is also refined to 99.99 per cent purity. The major advantage that the Minataur? technology has over other gold refining processes is the relatively low gold lock-up and reduced operating costs. The operating cost1as at April 2001 for the expanded Harmony refinery (24-ton per annum gold production) was approximately half that of conventional smelting and toll refining. The extractant employed for solvent extraction is relatively cheap and highly selective for gold, making the technology attractive in situations where significant quantities of platinum group metals or base metals are present.

Jan 1, 2004

By W. Dziurzynski

Transient states of the air parameters in mine workings occur as the effects of natural and technological disturbances, and in particular as a result of changes in ventilation conditions, caused by alteration of the mine workings geometry, state of fans performance or emission of gases. Particularly significant are those transient states caused by disturbances resulted from catastrophes, since they are frequently associated with violent phenomena that may be a danger for life and health of the staff working underground. The paper presents a number of examples of transient states of the air parameters in mine workings after a catastrophe, like the bump in the ZABRZE-BIELSZOWICE coal mine. Registration of air disturbances by the monitoring systems of ventilation in mine workings in the area of disaster both at the moment of a catastrophe occurrence and later during the rescue operation, enabled to track out the incident and identify the circumstances and reasons of those tragic events which caused death of 18 miners during last two years. Furthermore, computer simulations of processes occurring in mine ventilation network make effective research tools to be applied in practice, among others for the study of accidents and disasters.

Jan 1, 2003

By J. S. Harington

Our purpose is to record and to explain the widely changing numbers of the huge total of black workers on the gold mines of South Africa over the century from 1896 to 1996. These men were recruited from up to twenty territories, and their contributions are examined. The major areas providing labour over this long period have been Lesotho, the former Transkei within South Africa and Mozambique. From 1989 to 1996, for instance, these three areas accounted for over sixty per cent of the total labour force (tlf). Our principal Figure 1 shows the tlf fluctuating through time to reach a peak of 480 000 in 1988. Irregular falls are also documented with the most serious in 1995 to 180 000. Based on this graph we consider the political, economic, sociological and historical reasons behind these changing employment opportunities. These have included external world-scale events such as war or depression, as well as internal changes of national economy and policy. We show the importance for numbers employed of the discovery of gold in the Orange Free State in 1946, the influence generally of the ?Winds of Change? and the firm maintenance by the State of law and order. Varying gold production costs and profitability against high tax rates, allied with increasing wages and a lack of development capital, have led in the last decade to employment falling by fifty per cent, despite an actually higher value of gold output. Finally, this analysis considers the role of the migrant labour system as it affects, and is affected by, conditions in the gold mining industry, with special reference to its less than humane consequences in the numerically dominant territories of Lesotho and Transkei.

Jan 1, 2004

By B. J. Vorster

AngloGold South Africa region currently consists of twelve gold plants. These plants use a combined total of $20 million of cyanide per annum. Of this, the major portion (60%) is consumed at two Ergo dump retreatment plants. Historically the primary motivation for cyanide control at Ergo has been one of leach/cost optimization. However, more recently, with the increased public awareness of cyanide in the environment, a secondary but increasingly important motivation for control has been to ensure that only the minimum amount of cyanide is added to the process whilst not compromising leach performance. Following a brief overview of the Ergo process, the methodology in determining the amount of cyanide to be added is described. The paper then traces the developments in cyanide control from very basic manual systems to the current automated control system. In line with the increasingly sophisticated control systems, developments also took place in regards to the method of cyanide analysis. The development of these analysers is also discussed. Whilst cyanide is one of the major drivers, if not the major driver of gold dissolution, it cannot be viewed in isolation particularly with respect to the relationship between cyanide and oxygen as ascertained from the Elsner?s well-known equation. Consequently, in order to control cyanide addition, knowledge of the relative cyanide/oxygen profiles is necessary. Various means investigated at Ergo for pulp oxygenation have therefore been included for the sake of completeness. Finally a comparison is made of the control achieved from the current system compared to the original manual system. The knowledge and experience gained at Ergo is now being used to draw up guidelines for the installation and optimization work at the other AngloGold plants. The net effect of this will be reduced cyanide consumption for the region, which also, apart from the obvious economic benefit, translates into a reduced environ-mental risk.

Jan 1, 2001

The Modified Zincex® Process, developed by Técnicas Reunidas, is highly flexible dealing with a wide range of pregnant leach solutions. No matter if those solutions are produced from primary or secondary raw materials, and/or are based on conventional leaching, pressure leaching, heap leaching or bio leaching the result is always high-purity zinc product. The zinc solvent extraction unit within the process is a very effective barrier for impurities and a buffer for the composition of the pregnant liquor. This unit achieves an extremely pure aqueous extract that can be converted into different final products. All of them are characterized by fulfilling the highest purity standards. Also, there is the possibility to adapt the global process to a wide range of pregnant liquor compositions and various production capacities up to a zinc production limit over 150 000 t/a with a single solvent extraction plant.

Jan 1, 2002

Open cast mining has been practiced in South Africa since the late1970s under near ideal geotechnical conditions. In the past decade, with the exhaustion of the traditional South African coal fields, geotechnical conditions have deteriorated. In addition, the nature of the open cast coal mining industry is changing from the conventional strip mining of virgin coal seams to the extraction of underground coal pillars by buffer blasted highwalls. These industry changes have resulted in the need to re-examine the manner in which geotechnical engineering is applied to highwall design. This paper proposes a geotechnical design rationale for open cast highwalls. Furthermore, the rationale takes cognizance of the various geotechnical hazards associated with conventional strip mining and pillar extraction by buffer blasted highwalls. The need to use geotechnical domain models and blasting geotechnics, as proactive tools for rock fall reduction, are also discussed.

Jan 1, 2001

By M. A. W. Bryson

It is well documented that a significant amount of the new PGM (Platinum Group Minerals) production that is coming on stream now, and over the next few years, is to come from the UG-2 reef. Clearly the reservations, or perhaps the perceived reservations, attached to the processing of this ore are no longer there. What were the metallurgical issues that delayed the exploitation of the PGM values from this reef? Traditional furnaces treating Merensky concentrates were not able to accept the concentrate produced from a UG-2 plant due to the relatively high chromite content of this product. The chromite reports to an insoluble spinel phase that accretes in the furnace, resulting in the necessity to shutdown and dig the furnace out periodically. This was clearly not an attractive economic option, so producers stayed away from it in the early days. The Merensky ore had all higher base metal credits anyway, and you needed them to get a matte fall, so there was no driving force to look seriously at the UG-2 reef. Platinum demand at this time could be easily met from the Merensky ore, so the motivation to tackle more complex ores was not there. The low price of PGMs meant that these operations were not particularly profitable and there was little effort directed at improving the operations. Concentrators were generally not run very efficiently and the emphasis was on cost reduction through increasing milling rates.

Jan 1, 2004

By Dolly Chakraborty, S. Ranganathan, S. N. Sinha

Pre-reduction of chromite outside the submerged-arc furnace (SAF) can significantly lower the specific power consumption in the SAF process. Conventional processes for the pre-reduction of the ore operate at relatively high temperatures, at 1400-1500°C. It is possible to enhance the rate of reduction at low temperatures by optimizing the flow rate of inert gas over the reaction site. The influence of the flow rate of inert gas on the rate of reduction of chromite ore was investigated. The rate of reduction initially decreased wit the flow rate of the gas. It increased subsequently at higher flow rates to be followed by a decrease again. There was an optimum flow rate at which maximum reduction could be obtained. It was possible to achieve high levels of reduction at 1200°C by optimising the flow rate of the gas. The degree of reduction obtained was comparable to that obtained at 1400-1500°C, by conventional process routes.

Jan 1, 2007

Mineral Resource Throughput Management is based on the extraction of the maximum potential value from an ore reserve with the emphasis to generate maximum ROI and ROR (return on reserve). A steel producing company in India implemented MRTM to significantly improve their ROI and ROR. The value chain of this company consists of their own iron ore and coal mines, ore washing plants, sinter plants, steel plants, and sales and marketing division. The target for the mines was to produce at a stable and predictable rate and at specific quality requirements. These requirements were set to improve productivity and ROI of the steel plant. The implementation constituted the alignment of the reserve potential, total production chain, human resources and management culture at the mines with the requirements of the steel plant. Many typical mining practices were challenged and changed. Production targets regarding lump vs. fines ratio, consistent product tons, quality targets such as Fe, Al content and moist, and standard deviation on the quality targets were not achieved. A reverse distribution model with release mechanisms to satisfy the demand were developed and implemented at the mines. A stable and predictable flow of mine product with quality standards well within the required standard deviation targets were achieved. The contribution from the mines to significantly improve the Net Profit, ROI and ROR of the company were reached.

Jan 1, 2007

By J. Engelbrecht

South Africa?s re-entry into the fast moving and competitive global economy calls for some careful strategic planning and a good deal of co-operation between suppliers and end-users. The issues that need addressing are generally well known and include: ?South Africa was ranked 45th out of 46 i.r.o. productivity ?SMMEs contribute 1% to exports compared to 40-60% for the ?tigers? ?High unemployment ?Limited skills of the majority of workers ?Slow growth rate of the economy ?The vast majority of suppliers are not world-class ?The vast majority of suppliers are not export or marketing orientated. In order to survive, all parties, i.e. government, labour and business, will have to play their part.

Jan 1, 1999

By S. Dessureault

Computer Integrated Mining (CIMG) is a process of using computer networks to transform islands of enabling technologies into a highly interconnected mining system. CIMG involves the integration of advanced technologies at various levels in the mine business to achieve higher flexibility, better quality of processes and control, and improved profitability. Justifying the benefits of CIMG are difficult as many of the advantages are derived from improved flexibility, quality, and control. Justification is based on the evaluation of the benefits to be gained, compared to the required capital investment. Management tools used in mining are currently inadequate in assessing the value of advanced technology whose benefits are primarily qualitative. A key aspect of successful implementation is management acceptance, which has to be won through the capability to justify the technology?s financial costs and the true value of all of its benefits. The manufacturing industry faced similar justification difficulties when adopting advanced technology in factories. A significant amount of funding and research was invested in developing management strategies and approaches to justification. Many of the problems that faced the transformation of the manufacturing industry in the late Eighties and early Nineties are now facing mining. The solutions derived for manufacturing may help mining in its transition to an increased reliance on integration technology. Reviewing the industrial history of computer integrated manufacturing identifies several tools and strategic frameworks that can be adapted for mining. Keywords: Computer integrated mining, justification techniques, CIM, information technology.

Jan 1, 2004

By G. Konak

In-pit crusher location selection has had an important role recently, since increasing diesel prices. One way of reducing the haulage costs is to shorten the truck haulage distance by bringing the truck dump point into the pit. This study covers the work done on the optimum crusher location definition for a company that produces aggregate near Izmir, a city of Turkey located in the west. This paper will discuss the effects of pit geometry and mine access requirements on optimum crusher location selection that are mainly based on the establishment of minimum haulage distance. The method will be introduced first and then the computer algorithm developed for this study will be discussed later in the paper. Keywords: in-pit crushing, optimum location selection, optimizing haulage, computer aided design.

Jan 1, 2007

By K. I. Afewu

A modified approach to the implementation of Gy?s sampling theory is discussed and used to design a procedure for sampling crushed gold ore feed to metallurgical process plants. The approach involves calibration of certain ore-specific parameters. These parameters were calibrated for two different crushed gold ores en route to grinding mills in process plants. The model predictions were compared with the predictions from Gy?s original model. Far smaller masses of samples are required by the modified model than by Gy?s model at the same relative variance. The representativeness of the sampling procedure if normally distributed errors are assumed was also calculated. These procedures and evaluations lead to significant savings on cost of handling and preparation of the samples and to a quantifiable degree of confidence in the analytical results for the process plant.

Jan 1, 1998

Existing processes for the recovery of platinum group metals (PGM) from UG-2 ores place stringent requirements with regard to chromite content upon feed material to the plant. An alternative hydrometallurgical process for which this is not an issue is proposed that involves reductive roasting of the ore followed by leaching with HCl/chlorine, ion exchange, and recovery of PGM from the ion exchange eluate by reduction. Problems associated with leaching of PGM are discussed and results of laboratory testwork for each of the process steps are given.

Jan 1, 2004

By J. A. Beukes, M. Marais

TICOR South Africa is a new titanium feed stock producer. In the Ticor South Africa plant the ilmenite feed to the smelter plant is roasted to enhance its magnetic properties. This allows for the magnetic separation of chromite from the ilmenite. The magnetization reaction relies on partial oxidation with both under- and over-oxidation causing insufficient magnetization. To subject the roaster plant feed material to the required physical conditions a circulating fluid bed (CFB) roaster is used. This paper describes the development of a laboratory model that will aid in the control of the CFB roaster.

Jan 1, 2003