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By S. M. H. Haddad, M. Saghaeian, R. Hejazi, V. Sheikhzadeha, A. H. Baladastian, A. Dehghani Ahmadabadi

Sulfide impurities in iron ore concentrates play an important role in designing pelletising and steel making plants. Therefore attempts are made to keep the sulfur content of the final concentrate produced by the plants as low as possible. Generally, in the beneficiation process of iron ore concentrate, the removal of sulfur is performed through magnetic separation systems, followed by reverse flotation. The sulfide content of the iron ore concentrates originated from two main sources, including pyrite and pyrrhotite. In this research, in order to compare the floating capability of these two types of sulfide minerals, two iron ore concentrates with different sulfide constituents, pyrite or pyrrhotite, were selected. Reverse flotation tests were done separately on these samples under similar conditions. Process parameters considered for the tests included pH (2, 4, 6, 8 and 10), collector consumption (150, 200, 250, 300 and 350 g/t) and frother consumption (40, 50, 60, 70 and 80 g/t). Potassium Amyl Xanthate (PAX) and Methyl Isobutyl Carbinol (MIBC) were the collector and frother used in the tests, respectively. For modelling and optimising process parameters, the Central Composite Design (CCD) method was applied to the test results. Empirical coded equations were obtained for responses involving weight recovery, Fe recovery, Fe grade and S grade. Finally, comparison of test results revealed that the elimination recovery of pyrite sulfides was far greater than pyrrhotite sulfides, and it was possible to remove 84% sulfur content of the pyrite sample compared to minus 30% for the pyrrhotite sample. Keywords: Reverse flotation, pyrite and pyrrhotite, sulfur removal, iron ore concentrate, beneficiation plant

Jan 1, 2020

By R. B. Khumalo, T. Chauke, T. Mtshali, F. K. Mulenga, B. Makgate, N. M. Chiloane, T. Moyane, V. C. Madanda

While high production rates are important for the profitability of a mine, the influence of geotechnical engineering cannot be ignored. In block caving, a high-stress level is required for cave propagation; this is one of the core elements for ore recovery. Therefore, stress distribution and geological structures play a major role in the planning and layout design of the mine. This paper explores the influence of stress and geological features on the design of the mine from the feasibility study phase. The geology and stress measurement of the mine were determined through logging and overcoring, respectively. This study found that while production rate is the primary operational consideration, the long-term layout design of the undercut face advance, face angle, drawpoint spacing, and undercutting sequence is mainly governed by the stress orientation and major geological structures. Moreover, widely spaced drawpoints result in isolated draw zones, consequently, resulting in ore loss and early dilution whereas closely spaced drawpoints affect the stability of the major apex pillar. This paper also provides insight into how operations can leverage stress distribution to optimise mine layout and safety in massive mining methods.

Nov 24, 2025

By H. Zhong, S. Wang, Q. Lin

To improve the flotation performance of chalcopyrite collector, 2-(tert-butoxy)ethyl xanthate (TBEX) and its derivative O-(2-(tert-butoxy)ethyl)-N-ethyl-thionocarbamate (TBEETC) were designed and prepared by the introduction of a 2-(tert-butoxy) ethyl group into xanthate and thionocarbamate. TBEX and TBEETC were both prepared via the one-pot method with superior efficiency, which has significant commercial implications. The micro-flotation tests demonstrated that compared with sodium isobutyl xanthate (SIBX) and O-isopropyl-N-ethyl-thionocarbamate (Z-200), TBEX and TBEETC both possessed better collecting ability and selectivity for chalcopyrite. DFT calculations and XPS were utilised to investigate the flotation mechanism involving TBEX or TBEETC and chalcopyrite. The results demonstrate that although 2-(tert-butoxy) ethyl group does not interact with minerals directly, its introduction reduces the energy of HOMO, so that they can better accept electrons instead of donating electrons which leads to better interaction with copper atoms rather than iron atoms. Keywords: Chalcopyrite, flotation, thionocarbamate, xanthate, synthesis

Jan 1, 2020

By D. Weijie, S. Kai, Y. Hu, X. Ning, M. Shiyi, W. Junpeng, Z. Guihong, L. Xianjie

Flotation is one of the most important processes in the copper production industry. The copper grade in the concentrate is a pivotal indicator of the flotation process performance. However, it is difficult to achieve real-time measurement through hardware sensors. Based on the production data provided by an industrial operation, a novel soft sensor based on multi-layer perceptron (MLP) is proposed for effective monitoring of this pivotal indicator. The proposed soft sensor uses the nonnegative garrote (NNG) to perform global variable selection for MLP, while a local search (LS) approach is incorporated to improve the model presented by NNG. Simulation results show that the proposed algorithm has higher prediction accuracy and better model simplicity than other algorithms. Furthermore, the variables selected are consistent with the field experience, and the developed model can provide reference of feedback control for the optimisation of the process. Keywords: Flotation process of copper ore, nonnegative garrote, local search, soft sensor, multi-layer perceptron

Jan 1, 2020

By J. de Korte, Z. Loubser

"SynopsisThe aim of a blending stockpile is to minimize the natural variation in properties of a material. Two simulation models were written, for coneshell and chevcon stacking, and used to investigate the influence of different stockpile parameters on blending efficiency. The coneshell model is used to show that blending efficiency is highly sensitive to stacked height, with lower output variances observed for higher capacities. Output variance in both models also decreased when the stacker movement increment was decreased. For chevcon stacking, increasing stacker speed significantly increases the blending efficiencies. Increasing the length of the blending tail also reduces output variation, but this parameter would need to be weighed against the accompanying decrease in buffer capacity.IntroductionEven in the most uniform deposit of materials in nature, material properties will vary. The degree of variation can be measured, and usually resembles a normal distribution. The aim of blending and homogenization operations is to minimize the standard deviation of this normal distribution (De Wet, 1994). In general, the reduction in variation will result in a more efficient and cost-effective downstream process. Cement plants need a precise blend of raw materials to ensure desired kiln performance; boilers used in power generation are optimized for fuels of a constant specification; and even though the separation density in a coal washing plant can be adjusted, a constant product quality cannot be produced from highly variable feed (Denny and Harper, 1962). The process efficiency, product quality, and environmental compliance depend on consistency of characteristics in the material fed (Kumral, 2005) Many industries involved in"

Jan 1, 2015

By M. Hopf

Numerous developments and improvements have been made to tap-hole designs. On the other hand, there are very specific designs in operation that have endured for many years without any modification. Nobody likes design changes because of risk - the risk of atypical wear, potential hazards, and costly repairs entailing enormous production losses. So the philosophy ‘never touch a running system’ is maintained, because among other things there is no efficient working monitoring technology for tap-holes. In the past few years a couple of new technical solutions have been investigated and developed. Not all theoretical solutions are possible in practice. However, metallurgists are inventive, and the last word regarding efficient working tap-hole monitoring technologies has not yet been spoken.

Jan 1, 2014

By G. Howell, J. Wates, A. Coetzee, C. J. MacRobert

The Global Industry Standard on Tailings Management (GISTM) requires mining companies to make four key appointments as part of their tailings management structure. These four positions are an Accountable Executive with policymaking responsibilities, a Responsible Tailings Facility Engineer with operational responsibility, an Engineer of Record to ensure facilities are designed, operated, and closed safely, and an Independent Tailings Review Board to assess safety drivers regularly. Little guidance on the traits of these individuals is available in a South African context. Consequently, the tailings community of practice was surveyed to develop a table of ideal competencies and establish the flexibility in meeting these traits.

Jun 2, 2022

By I. V. Filippova, Y. Foucaud, M. Badawi, O. Barrès, L. O. Filippov, S. Lebègue

Sodium silicate (Na2SiO3) is one of the most common reagents used in the froth flotation process, in which it is an efficient dispersant as well as a powerful gangue minerals depressant. Due to its high affinity with a lot of minerals, mostly silicates, it adsorbs on their surfaces and prevents the adsorption of the collectors, maintaining them hydrophilic. Hence, Na2SiO3 is widely used in the flotation separation of rare earth minerals, zinc minerals, iron minerals, scheelite, fluorite, apatite, and many other minerals. For decades, authors have demonstrated higher efficiency of Na2SiO3 when it is used in combination with sodium carbonate (Na2CO3), a common pH regulator. Among many well-known depressants, this system presented the best efficiency for many ores, including the Tabuaço scheelitebearing skarn studied herein. However, the mechanisms resulting in these strong positive synergistic effects are not well understood at the moment. Hence, the response surface methodology (RSM) was applied to this ore, considered as a case study, to optimize the depressing conditions and to study deeply the flotation behavior of this system. Strong synergistic effects between the two reagents were exhibited by the RSM, mostly affecting the scheelite, fluorite, and calcium-bearing silicates recoveries. This was attributed to surface carbonation of the minerals by Na2CO3, subsequently leading to a better depression by Na2SiO3. Overall, a 1:1 ratio between the two reagents displayed the best results in terms of WO3 grade and recovery. To gain understanding in the molecular mechanisms responsible for the aforementioned synergistic effects, FTIR studies were combined with state-of-the-art molecular modelling (Ab Initio Molecular Dynamics at 300 K) on fluorite, an archetype of calcium minerals. Keywords: Synergistic effects, scheelite, depressants, FTIR, DFT calculations

Jan 1, 2020

By Y. Ren, B. Yang

The magnetic field characteristics due to electromagnetic stirring in the secondary cooling zone of an extra-thick slab during continuous casting are numerically determined using Maxwell's equations, with particular emphasis on the distribution of magnetic induction intensity and electromagnetic force, as well as the influence of process parameters on the magnetic field. The orientation of the electromagnetic force is the same when the electromagnetic stirrers at the 30° and 60° posistions of the arc-shaped slab are powered in the same direction; otherwise, the orientation is opposite. The magnetic induction at the centre of the section of the stirrer's central axis at the 30° positio, as well as the current, frequency, and fitting formulae, are as follows: B = {0.075I.(1/A)-0.3} mT and B = {-1.75f.(1/Hz)+22} mT. The electromagnetic force and current fitting formula at the central point of the B-B section is F = {0.03168I2.(1/A2)-03.762I.(1/A)+326.7} N/m3, and the fitting formula of electromagnetic force and frequency at the centre point is divided into two segments. The first takes the form of a parabola: = {-21((f-4.3).(1/Hz)2)+970} N/m3, and the second segment is negative linear: F = {-1.65f.(1/Hz)+51.5} N/m3.

Apr 16, 2024

1. Book review Technology of metal powders- recent developments, edited by L. H. Yaverbaum. New Jersey, Noyes Data Corporation, 1980. 400 pp. (Reviewer: B. K. Loveday) 2. New books The use of microprocessors, by M. Aumiaux. New York, Wiley, 1980. 176 pp. $25,50. Aluminium smelter technology, a pure and applied approach, by K. Grojtheim and B. J. Welch. Diisseldorf, Aluminium-Verlag GmbH (P.O. Box 1207, D-4000, Federal Republic of Germany). 146 pp. DM48. Coal-bridge to the future. New York, Harper & Row, 1980. $35. System modeling and response.. theoretical and experimental approaches, by O. Doebelin. New York, Wiley, 1980. 576 pp. $26. Environmental and climatic impact of coal utilization, edited by J. J. Singh and A. Deepak. New York, Academic Press, 1980. 646 pp. $39,50. Proceedings of the Third European Conference on Mixing, York, England, April 1979, edited by H. S. Stephens and C. A. Stapleton. BHRA Fluid Engineering (Cranfield, Bedford Mk43 OAJ, U.K.), 1980. 2 volumes. 500 pp. $50. Lignite technology, edited by P. Nowacki. New Jersey, Noyes Data Corporation, 1980. 228 pp. $42. The application of rock mechanics to cut-and jill mining. London, Institution of Mining and Metallurgy, 1980. Papers presented at the Fifth International Symposium on Jet Cutting Technology, Hanover, Federal Republic of Germany, June 1980, edited by H. S. Stephens and B. Jawis. BHRA Fluid Engineering (Cranfield, Bedford Mk 43 OAJ, U.K.), 1980. 438 pp. £38. World coal resources.. methods of assessment and results, by G. Fettweis. Amsterdam, Elsevier, 1979. 425 pp. $80,50. Geophysical and geochemical techniques for exploration of hydrocarbons and minerals, edited by M. Sittig. New Jersey, Noyes Data Corporation, 1980. 300 pp. $40. Financial Times mining international year book 1980. Longman Group Ltd (Periodicals and Directories Division, Longman House, Burnt Mill, Harlow, Essex CM20 2JE, England). £24 surface, £34 airmail. National Symposium on the Availability of Strategic Minerals, edited by M. J. Jones. London, Institution of Mining and Metallurgy, 1980. 109 pp. 3. NIM reports Report No. 1941 The recovery of chromite and platinum from the UG-2 Upper Chromitite Layer .of the Bushveld Complex at the Pandora Mine (first published 10th Mar., 1978). Report No. .2012 A mineralogical investigation of borehole cores from the Trompsburg Complex (first published 6th Apr., 1979). Report No. 2038 The leaching of sphalerite in acidic ferric sulphate media in the absence of elemental oxygen. Report No. 2052 An investigation of the impurities in native gold by neutron-activation analysis. Report No. 2056 The mineralogy and geochemistry of the copper, lead, and zinc sulphides of the Otavi Mountainland. Report No. 2058 A n elementary introduction to image analysis - a new field of interest at the National Institute for Metallurgy. Report No. 2059 Distributed computer control of industrial processes. Report No. 2060 The analysis, by atomic-absorption spectrophotometry, of activated charcoal.

Jan 1, 1980

A Special General Meeting, followed by the February General Meeting of the Institute, was held in Kelvin House, Johannesburg, on 18th February, 1970, at 4.30 p.m. Mr J. K. E. Douglas (President) was in the Chair. There were also present 24 Members: Messrs A. R. C. Fowler, R. C. J. Goode, Prof D. D. Howat, Messrs D. G. Maxwell, J. A. Nixon, P. W. J. van Rensburg (Council Members), C. A. Border, J. C. Fritz, E. K. Gibson, P. L. Grimbeek, S. D. Hill, D. A. Immelman, P. J. Uoyd, M. Mrost, C. S. Macphail, D. G. Malan, W. D. Ortlepp, R. S. Pearson, A. J. H. Pole, Dr W. S. Rapson, L. W. P. van den Bosch, R. A. von Maltitz and Dr A. Whillier. Eight Associate Members: Dr M. I. Brittan, Messrs J. Brett, I. E. Clarke, C. L. de Jongh, W. B. Evans, D. Loubser, R. C. More O'Ferrall and G. R. Still. One Graduate: Mr T. J. Kotze. One Student: Mr J. A. Cruise. Nine Visitors: including Dr N. G. W. Cook, Messrs M. D. Labuschagne, A. Nicoll, S. Sadowski, Dr A. M. Starfield and Dr H. Wagner. Secretary: Mr D. C. Visser. Total present: 45. SPECIAL GENERAL MEETING The President: "You will have received notices of the Special General Meeting and I declare it duly constituted. In keeping with the trend of overseas and local institutes, your Council recommends that we should change our membership classification as indicated in the notes of the meeting. The new grades are proposed to replace those presently in the Constitution and By-Laws. In terms of Clause 4.8 of the Constitution a special general meeting must be held for the purpose of considering and, if approved, adopting with or without amendments, the revision of the undermentioned clauses of the Constitution, which Council now recommends should read as follows. Clause 2.2 'Corporate Members shall comprise the grades of Honorary Life Fellow, Fellow and Member', these being the equivalent of Honorary Life Member, Member and Associate Member. Clause 2.6. 'Non-Corporate Member shall comprise the grade of Honorary Fellow, Graduate, Associate and Student.' Are there any questions in regard to this proposal? If not would someone propose that these clauses be amended and adopted?" Proposer: Mr A. J. Nixon. Seconder: Prof D. D. Howat. The motion was then adopted. The President: "It is recommended that Clause 2.15 should read, 'A Corporate of the Member of the Institute shall be entitled to use the following authorised letters designating the grade of Membership in Honorary Life Fellow and Fellow, F.S.A.I.M.M. and Member, M.S.A.I.M.M.' Previously we used the letters M.S.A.Inst.M.M. and your Council considered that we should adopt the simpler lettering. Could I ask someone to propose that this amendment be adopted?" Proposer: Mr R. C. J. Goode.

By M. Saghaeian, R. Hejazi, L. Hosseini, M. V. Sheikhzadeh

Blaine number has long been used to evaluate the pelletising ability of iron concentrate in the industry. Much information and practical data are available about the effect of Blaine number on pelletising efficiency of different concentrate types. But not many researchers have focused on the effect of Blaine increasing method on pelletising behaviour of coarse concentrates. In this paper the effect of two different grinding methods (i.e. HPGR and Ball Mill) on physicochemical properties of coarse magnetic concentrate green and fired pellets were investigated. Microstructural studies by Field Emission Scanning Electron Microscope (FESEM) showed that the concentrate for which the Blaine number had been increased through HPGR grinding, has flake-like morphology. In contrast, increasing the Blaine number through ball mill grinding results in more granular particles. Two samples were prepared using HPGR and ball mill. The Blaine number of the HPGR product and ball mill product were 900 cm2.gr-1 and 1200 cm2.gr-1 respectively. The results revealed that pellet properties of this HPGR product are comparable to that of the ball mill product; this is due to the fact that the flake-like morphology leads to enhanced pelletising performance of coarse magnetite concentrates. Keywords: Iron pelletising, Blaine number, HPGR, ball mill, coarse particles

Jan 1, 2020

By V. Quezada, Á. Astudillo, L. Valásquez, M. Garcia

Seawater has become a viable alternative for different uses in copper hydrometallurgy. In this paper we review the main physical and chemical characteristics of seawater and how these influence copper production. Reliable data on the use of continental water are reported, and the current use and consumption of seawater in the Chilean mining industry is analysed, indicating the main areas of use and the main problems encountered. Additionally, the influence of the elements in seawaterthat have the most influence on the extractive metallurgy of copper are considered. The Chilean copper mining industry currently consumes approximately 4.1 m3/s of seawater, which corresponds to 25% of the total water used. The use of seawater for the leaching of copper sulphide minerals, such as chalcopyrite, is beneficial because it provides 20 g/L of chloride, thereby improving copper dissolution kinetics.

Jul 5, 2023

By S. Heukelman

Zincor uses O2 enrichment (up to 26% O2 in the fluidizing air) to increase the processing rate of zinc concentrates in the fluidized bed roasters. The aim of this study is to determine whether O2 enrichment can be reduced by introducing micro-pelletized concentrate into the feed blend, while maintaining current roaster feed rates and calcine quality. It was found that, with a load of 20% micro-pellets introduced into the feed blend, that O2 enrichment could be reduced by 60%. It was determined that entrained particles spend on average between 0.46 hour and 2.44 hour in the roaster, compared to particles remaining between 3.93 hour and 4.00 hour in the bed overflow. This compares well with a radioactive tracer test performed by Spira. The required reaction time for micro-pellets was found to be less than the residence time inside a Zincor roaster. The result achieved indicated that the average particle residence time inside the roaster was increased successfully in order to compensate for the longer reaction time required to roast micro-pellets at lower levels of O2 in the fluidizing air.

Jan 1, 2011

By E. Vascotto, S. M. Rupprecht, H. C. Grobler

Shaft sinking survey practices in Southern African mining operations have been refined over many decades to meet the stringent accuracy, safety, and productivity demands of deep vertical excavation. However, much of this specialised knowledge remains poorly documented, and the decline in new shaft sinking projects presents a risk that these proven practices may be lost to future generations of mine surveyors. This paper reviews and synthesises current survey control methodologies employed during shaft sinking operations, with particular emphasis on the establishment and maintenance of surface and underground control networks, shaft verticality control, and elevation transfer. Traditional techniques, such as plumb-wire plumbing systems, steady brackets, and calibrated steel shaft tapes, are discussed in detail, alongside quality control principles and common sources of error affecting coordinate transfer. The paper further examines the integration of modern technologies, including total station resections and LiDARbased laser scanning, highlighting their benefits, limitations, and practical constraints in active shaft environments. By documenting both established and emerging practices, this review aimsto preserve critical institutional knowledge, support consistent survey standards, and provide guidance for accurate spatial control throughout the shaft sinking lifecycle.

Mar 30, 2026

By A. Eitzenberger

This paper describes a study of seismic records from the Kiirunavaara mine footwall which were interpreted in relation with numerical models developed outside the study. Seismic data was retrieved from a portion of the mine and filtered with respect to the ratio between energy carried by an event's P (primary) and S (secondary) waves (Es/Ep ratio), local magnitude, and active mining depth. The data was analysed using Es/Ep ratios and Gutenberg-Richter graphs to determine the event origin, mechanisms, and minimum magnitude cut-off. The magnitude completeness was identified by studying the b-value stability and b-value differentiation between origin sets. It was shown that, by separating seismic events into the origin components shear, complex, and tensile based on Es/Ep ratios, a representative value for the magnitude completeness can be identified for a catalogue with a convex cumulative log curve. The majority of the events were shown to be of shear-slip origin based on the recorded Es/Ep ratios, with pure tensile events constituting only about 10% of the recorded data. Spatial and temporal event location patterns were studied and compared with numerical modelling results. The comparison showed a correlation between shear-slip seismic events and volumes experiencing high differential stresses in the lower part of the footwall. In the upper part of the footwall the results did not reveal any clear correlation between observed damage in drifts and seismic event locations. The concentration of seismic events in the lower portion of the footwall is discussed in the context of rock mass displacements. The results indicate a possible connection between mine seismicity at depth and damage observations in the drifts in higher non-seismic areas by seismic softening and subsequent lateral expansion of the rock mass.

Jan 1, 2017

By O. Barron, C. Felix

In 2023, polymer electrolyte membrane fuel cell membrane electrode assemblies accounted for about 62% of the global fuel cell market share and this demand is expected to grow. Commercialisation requires technologies capable of cost-effective, high-volume manufacturing. The membrane electrode assembly is crucial and represents a significant cost to polymer electrolyte membrane fuel cell manufacturing. Manufacturing the electrode components for membrane electrode assemblies at high volumes can reduce production costs while delivering on the forecasted industry demands. Roll-to-roll is a mature coating technology applied in various manufacturing industries such as batteries, printed electronics, microelectronics, photovoltaics, printing, paper consumables, etc., with significant potential for polymer electrolyte membrane fuel cell manufacturing. While the high-volume production process for membrane electrode assembly manufacturing differs from laboratory-scale, the membrane electrode assembly structure remains unchanged. Roll-to-roll is a continuous coating process with speeds of 10 m/min being achieved. In this work, MicrogravureTM and slot-die coating methods have been adopted and have shown promising outcomes for producing gas diffusion electrodes for membrane electrode assemblies. An overview of the MicrogravureTM and slotdie coating methodologies is provided, and a discussion on preliminary results and challenges are presented. Work on MicrogravureTM gas diffusion electrode manufacturing has already achieved comparable performance with spray-coated gas diffusion electrodes. The influence of coating parameters and drying on the coated catalyst layer quality is discussed.

May 27, 2025

By W van Drunick, S Naik

To date, Anglo Research has carried out several projects, based on the techniques developed in the AMIRA P9 (AMIRA International Limited), to develop comminution and flotation models for several Anglo Base Metals and, to a lesser degree, Anglo Platinum flotation plants. Plant optimization is thus achieved through steady-state sampling, model-fitting and simulation using the JK SimMet and JK SimFloat software packages. The surveys can vary depending on the needs of the plant/client. The survey can therefore include as little as a single piece of equipment, an entire milling/flotation circuit, or a complete circuit from primary comminution to final flotation concentrate (i.e. the ?integrated survey?). The presence of the AR team on-site usually precipitates in face-value observations that can lead to initial improvements. This stems from the knowledge-sharing on best practice that exists in parallel with the surveys. Numerous (reasonable) changes can then be simulated, thus indicating the optimization step most likely to result in the best efficiency improvements. The simulations can include changes in the flowsheet, ore characteristics, mill loads, grinding media size, change in grind, flotation residence time, air hold-up and several more. Plant surveys can result in process changes that provide the plant with either: higher plant tonnage, improved plant grind, additional flotation recovery and/or improved product grade. The additional benefit of performing an integrated plant survey is that the effects of an optimization change in the comminution circuit can be simulated using the flotation model. This paper describes a number of case studies where individual and integrated plant surveys were conducted by AR for Anglo Base Metals.

Jan 1, 2007

By V. Moodley

Strict implementation of International Standards for representative sampling of coal is difficult for routine monitoring, due to time, technical, and economic constraints. A large percentage of the total sampling variance arises from errors accumulated during the earliest stages of sample collection. Modified procedures on the precision of the final result leads to controversies between the sellers and customers for coal. Manual collection of coal samples violates the principle of correct sampling, that all fragments must have an equiprobable chance of being in the sample. In addition, manual size reduction of large numbers of samples is time consuming and involves human errors. A coal quality management procedure in alignment with the relevant ISO standards that describes the sampling protocol has been implemented, and current sampling and laboratory analysis of coal from base load mines (mines situated at the mouth of the power station) are well established. For import coal, sampling is performed during unloading by auto-mechanical sampling (AMS). Due to logistical and safety issues associated with multiple suppliers, Eskom opted for the coal to be sampled at source on a pre-certification basis. Online analysers provide a fast, accurate, real-time method of determining the total moisture and elemental composition of coal and is important to the coal industry for pricing, quality control, and reduction of SO2 emissions. Elemental analyses include S, Si, Al, Fe, Ca, Na, Mg, Mn, Ti, K and Cl. Measurement of S is dictated by the control of SO2 emissions from coal-fired power plants. Elements such as Na and Cl have adverse effects on boilers, causing fouling and slagging. Available online elemental analyser technologies include prompt gamma neutron activation analyses (PGNAA), recommended for major element determination, and pulsed fast and thermal neutron analysis(PFTNA), that is capable of measuring the major and minor chemical elements contained in coal. These systems utilize nuclear reactions to produce characteristic gamma rays that are used for identifying various chemical elements. By acquiring the gamma rays in three different time windows, there is a significant reduction of the background as compared with the spectra taken with a radio isotopic source.

Jan 1, 2009

By A. F. van der Merwe, R-D. Taylor, M. Jacobs, F. H. Conradie

Total bound moisture (TBM) is a typical quality indicator of industrial-grade gypsum. This gypsum is comprised of three distinct phases, namely anhydrite, dihydrate, and hemihydrate, of which only the latter is of much industrial use. TBM analysis is a lengthy laboratory procedure, and an artificial neural network (ANN) TBM inference measurement is proposed as a fast and online alternative. An ANN inference model for gypsum TBM based on plant data was developed. The inputs to the network were primarily focused on the plant's calciner, and different network topologies, data divisions, and transfer functions were investigated. Furthermore, the applicability of the TBM value as a quality indicator was investigated based on a gypsum phase analysis. A strong correlation between TBM and the gypsum hemihydrate and anhydrite content was found, validating the plant target TBM of 5.8% as a quality indicator. A network topology consisting of one hidden layer with logarithmic-sigmoid (logsig) and pure linear (purelin) transfer functions showed the best performance (R > 90%).

Oct 3, 2023