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Changes in reductant and energy inputs which are required to adjust the slag composition in an ilmenite smelter to a higher or lower FeO content are calculated. The calculated changes are based on the assumption that solidification equilibrium with the freeze lining constrains the slag composition to follow a eutectic groove in the TiO2-FeO-TiO1.5phase diagram. Calculated equilibrium conditions along the eutectic groove are presented, and form the basis of the calculations. The inputs of energy and carbon need to deviate strongly from the steady-state values to adjust the slag composition. The inputs required at any given time depend on the desired rate of change of the slag composition, and the current slag composition. The steady-state relationship of a change in energy input of 5 kWh corresponding to a 1 kg change in carbon input also holds for the changed inputs during transient changes in FeO content. Keywords: Ilmenite smelting, freeze lining, solidification, eutectic

Jan 1, 2003

By T. D. Mailula

Paper written on project work carried out in partial fulfilment of M.Sc.(Chemical Engineering) degree Chromite and talc are two major gangue minerals in platinum bearing UG2 ore processed from the Bushveld Complex in South Africa. During flotation, talc is effectively depressed by the addition of depressants. Chromite, on the other hand, is considered to be hydrophilic, its recovery is believed to follow water recovery and therefore recovered by entrainment only. In certain cases it has been shown that chromite can be activated by the reagent suite and hence is made amenable to true flotation. The aim of the work was to investigate the effect of the addition of copper sulphate as an activator and the effect of the depressant type and dosage on the recovery of chromite. The results of these experiments showed that copper sulphate, at higher dosages, activated the chromite. Low dosages of copper sulphate resulted in no chromite activation. This was observed at low depressant dosages of both IMP4 (guar gum) and KU5 (carboxymethyl cellulose (CMC)). When the depressant dosages were increased, at higher copper sulphate dosages, it was observed that the activated chromite was depressed by IMP4, but that the activation was still significant with the use of KU5. The activation of the chromite is attributed to the form of the copper species present in the solution and on the mineral surfaces at pH = 9 enhancing collector adsorption and thereby increasing hydrophobicity. These species were not measured directly and it is recommended that this should be further investigated using surface mineral techniques. Keywords: flotation; depressants; chromite; copper sulphate

Jan 1, 2003

By M. M. Makhofane

Anhydrous zirconium tetrafluoride can be used as a precursor for the manufacturing of nuclear-grade zirconium metal. This can be done by fluorinating plasma-dissociated zircon with ammonium bifluoride in a batch reactor. This paper describes the batch process. It was proved that anhydrous zirconium tetrafluoride can be manufactured by this route as confirmed by X-ray diffraction. The process shows potential for scaling up to the kilogram scale and possibly the tonnage scale.

Jan 1, 2012

By P J. Fourie, J R. Walklate

Gravity separation techniques have been in use in the mineral sands industry for decades; from the Reichert cone to Wilfley tables, Wright sluices and the Kelsey Jig, all attempting that elusive perfect gravity separation. Just as the gravity separation industry evolved, Richards Bay Minerals also evolved in their use and approach to gravity separation. This paper discusses the history of gravity separation at Richards Bay Minerals and briefly comments on future developments. History Primary Concentration Richards Bay Mineral?s (RBM) first mining concentrator and mineral separation plant commenced operation in 1977 to process ilmenite, rutile and zircon bearing dunal deposits along the northern Natal coast. The orebody contained a greater proportion of non-valuable magnetic heavy mineral in the SG range of 3 to 4 compared to West Australian and Florida USA deposits, making mineral separation more difficult(1). The deposit was mined using two dredges feeding a floating 2000 tph concentrator. Concentrator feed was screened and fed to two four-stage circuits consisting of primary, scavenger, cleaner and recleaner Reichert cones [see Figure 1]. The primary units were fed at a rate of 80 tph and a density of 60% solids by weight.

Jan 1, 2006

By A. Ebrahimabadi

Roadheaders are very versatile excavation machines used in tunnelling, mine development, and mine production for soft to medium strength rock formations. Performance prediction is an important factor for successful roadheader application and generally deals with machine selection, production rate and bit consumption. Among many different parameters, brittleness is also one of the material properties related to breakage characteristics and can be used as a cuttability parameter from a mechanical excavation point of view. The main objective of the research study is to contribute the brittleness of rock excavated to construct a new empirical equation for predicting the performance of roadheaders in different material and operational conditions. In this regard, a new performance prediction model for medium duty roadheaders based on a brittleness index (BI) is presented. In this study, rock mass brittleness index (RMBI) is defined in order to investigate the influence of BI on roadheader performance. RMBI is an index which can be used to relate the intact and rock mass characteristics to machine performance. Results demonstrated that RMBI is highly correlated to instantaneous cutting rate (ICR) (R²=0.94). Moreover, through the further analysis and normalization, the pick consumption index (PCI) was introduced as a parameter having a good relation with pick or bit consumption rates (PCR) (R²=0.79). Finally, the new predictive models for ICR and PCR showed very good correlations with the actual measured values. Keywords Performance prediction, roadheader, brittleness index, mechanical excavation.

Jan 1, 2011

By H. Saroglou

Anisotropy is a characteristic of intact foliated metamorphic rocks (slates, gneisses, phyllites, schists). Testing was used to establish the anisotropic behaviour of selected gneissic rocks. The effect of anisotropy on various mechanical properties (strength, deformation) and dynamic properties (wave velocity) was examined. The rock samples were also tested at successively higher confining pressures in order to evaluate the effect of anisotropic behaviour at high overburden pressures.

Jan 1, 2004

By K. Schwerdtfeger

Data are presented on the effect of iron oxide on the electrical conductivity of CaO-SiO2-FeO-Fe2O3melts, and on limiting current and impedance in direct current or alternating current charge transfer at iron electrodes. The strong influence of iron oxide content can be utilized for in situ determination of total iron oxide content and Fe3+/Fe2+ratio. The possible probe designs are presented and the principles and procedures of the measurements are explained. Keywords: in situ probe for iron oxide determination in steelmaking slags, electrical conductivity of CaO-SiO2-FeO-Fe2O3slags, direct current over voltage and alternating current impedance at iron/slag electrodes.

Jan 1, 2004

By A. S. Macfarlane

The South African Institute of Mining and Metallurgy was approached by the Australian Institute of Mining and Metallurgy to present a paper on the current practice in terms of the valuation of mineral projects and properties, given the development of a Code for the Valuation of Mineral Properties, developed in Australia (the VALMIN Code), and a similar Code in Canada (the CIMVal Code).This paper is the result of research and investigation into the matter, in terms of the reporting of Mineral Resources and Reserves, financial reporting practice, the Listing Rules of the Johannesburg Securities Exchange, and various practices in valuation. The paper establishes that a strong linkage has already been established between the SAMREC Code for the reporting of Mineral Resources and Reserves and the Listing Rules, and that, for completeness, a Code for Valuation needs to be developed. This Code will be similar to its international counterparts, with the necessary inclusions which are relevant to South Africa, and will provide guidelines and definitions on matters such as transparency, materiality and competency in valuation. It proposes that a multi-stakeholder steering committee be established under the auspices of the SAIMM, to deliberate and design a process for establishing such a Code.

Jan 1, 2002

By T. A. Ngcobo

Paper written on project work carried out in partial fulfilment of BSc Eng (Mining)degree The purpose of this report is to assess the risks faced by mines in dolomitic compartments in particular Kloof 8 shaft. The dolomites of the West Rand comprise one of South Africa?s most natural water resources, and overlie the reefs of the richest gold mines in the world. The pumping of water from the dolomitic aquifers to prevent flooding has caused the natural water table to subside, and the resulting cavities within the dolomite rock formations that overlie many gold deposits sometimes collapse, causing sinkholes. These impacts of the mining industry could worsen over time if preventative measures are not taken. This report discusses these impacts in detail, more specifically the risks to which operations in dolomitic compartments are exposed. A risk analysis was carried out to access the risks that the organization could face and it was this analysis that allowed one to examine the best methods to combat the problems. Other factors such as geological features and seismic events were also considered for the evaluation. To aid with the completion of this work various resources were utilized. A literature study was undertaken, information was gathered from various experts who specialize in dolomitic studies, evaluations were conducted and conclusions reached. The results from the project indicated that preventative measures should be implemented and correct procedures put in place to prevent any disasters.

Jan 1, 2006

By R. Webster

"Daniel Krige’s influence on soil science, and on soil survey in particular, has been profound. From the 1920s onwards soil surveyors made their maps by classifying the soils and drawing boundaries between the classes they recognized. By the 1960s many influential pedologists were convinced that if one knew to which class of soil a site belonged then one would be able to predict the soil’s properties there. At the same time, engineers began to realize that prediction from such maps was essentially a statistical matter and to apply classical sampling theory. Such methods, though sound, proved inefficient because they failed to take account of the spatial dependence within the classes.Matters changed dramatically in the 1970s when soil scientists learned of the work of Daniel Krige and Georges Matheron’s theory of regionalized variables. Statistical pedologists (pedometricians) first linked R.A. Fisher’s analysis of variance to regionalized variables via spatial hierarchical designs to estimate spatial components of variance. They then applied the mainstream geostatistical methods of spatial analysis and kriging to map plant nutrients, trace elements, pollutants, salt, and agricultural pests in soil, which has led to advances in modern precision agriculture. They were among the first Earth scientists to use nonlinear statistical estimation for modelling variograms and to make the programmed algorithms publicly available. More recently, pedometricians have turned to likelihood methods, specifically residual maximum likelihood (REML), to combine fixed effects, such as trend and external variables, with spatially correlated variables in linear mixed models for spatial prediction. They have also explored non stationary variances with wavelets and by spectral tempering, although it is not clear how the results should be used for prediction. This paper illustrates the most significant advances, with results from research projects."

Jan 1, 2015

Control of flotation processes is mostly managed by plant operators, who assess the performance of the plant based on their own experience and other heuristic rules. These rules tend to be subjective or ill-defined, since most of them are concerned with the structure of the flotation froth, such as colour, bubble size and shape distributions, froth mobility and froth stability. These phenomena are very difficult to quantify objectively, and inexperience on the part of the operators, human error, etc., can lead to significant inefficiencies in plant operation. In this paper the development of a fuzzy system to support the control decisions of plant operators is described, which leads to significantly smoother control action and more stable plant operation than could be obtained with crisp sets of rules or manual control strategies. Keywords: flotation, fuzzy logic, image analysis, genetic algorithms, rule induction

Jan 1, 2000

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 C. Balci

Specific energy is defined as the amount of work required to break a unit volume of rock and is used to predict the performance of mechanical miners. It is obtained from full-scale rock cutting experiments, which require large block samples, experienced personnel and expensive equipment found in only a few research centres in the world. Estimation of the optimum specific energy, at which a given geological formation is excavated at optimum cutting geometry in the most energy efficient manner, from mechanical rock properties to predict the performance/efficiency of roadheaders is the basic aim of this study. The mechanical rock property tests require only core samples, which are easier to obtain and to test. In this context, full-scale rock cutting tests are performed on 23 different rock, mineral and ore samples including sandstone, claystone, tuffite, chromite, trona and copper collected from some operating mines in Turkey. The optimum specific energy values are obtained for each sample. Physical and mechanical property tests are performed on the core samples obtained from the same samples to determine uniaxial compressive strength, indirect (Brazilian) tensile strength, static and dynamic elasticity moduli, Schmidt hammer rebound values, density, and Cerchar abrasivity index. The relationships between the optimum specific energy and the mechanical rock properties are analysed using statistical methods. The results indicate strong relationships between the optimum specific energy and the mechanical rock properties. The strongest relationships are found by using uniaxial compressive strength and tensile strength. The performance models developed in this study are in good agreement with the empirical models previously developed for roadheaders and can be used reliably for prediction purposes. Keywords: Mechanical excavation, roadheader, performance prediction, rock cutting, optimum specific energy, mechanical properties of rocks.

Jan 1, 2004

By N. Ragoonanthun

Paper written on project work carried out in partial fulfilment of B.Sc. (Mining Engineering) degree This report investigates the optimization of a raiseline in order to open up the ore reserve quicker. The project was carried out at Mponeng Mine (an Anglogold shaft formerly known as Western Deep Levels 1 Shaft and South Mine, in Carletonville). The project was divided into two focus areas namely: ?To design an optimum layout of a raiseline, which includes the scheduling of all activities for the establishment of the infrastructure. Consideration was given to the blasting practice, mining cycle, orepass placement and slusher positioning. Two designs were carried out on the above basis. ?The design of a ledging operation/practice to match the optimized layout of the raiseline. The ledging cycle design involved a thorough investigation into the possible use of drill rigs, Electronic Delay Detonators (EDD) blasting technology, longer drilled holes, Threshold Blasting (THROB),and water jet cleaning.

Jan 1, 2003

By M. Gous

Namakwa Sands is a heavy minerals mining and beneficiation business in the Anglo Base Metals Division, and operates along the West Coast of South Africa. The business encompasses mining, mineral concentration, separation, and smelting operations. The smelting process comprises the carbonaceous reduction of ilmenite to produce titania slag with a TiO2 content of 86%, and iron with a carbon content of 2.5%. The Namakwa Sands smelter, situated near the Saldanha Bay harbour, commenced smelting operations in 1994, when a 25 MW DC-arc furnace was commissioned. The smelting operations were expanded in 1999, with the commissioning of a second 35 MW DC-arc furnace. Despite the fact that ilmenite smelting poses a technical challenge in terms of the high temperatures required, the physical characteristics of the slag, the constraints placed on the feedstock, and the tight product specifications, Namakwa Sands has continually increased slag production since 1995. High furnace feed-on utilization and furnace stability, complemented by continuous improvement drives, will be thevehicle to drive performance in the short-term, with longer-term performance enhancements due to strategic process development. Keywords: Pyrometallurgy, Namakwa Sands, ilmenite, DC-arc furnace, titania slag, pig iron

Jan 1, 2006

By J. T. Kalala

Energy consumption and wear of grinding media and liners are the major cost factors in milling plants. Since the beginning of the last century, much effort has been directed at the prediction of the power draw as affected by the mill operating conditions. This paper explores the prediction of the liner wear using the discrete element method (DEM). A mathematical model taking into account adhesion, abrasion and impact wear which occur in dry mills is derived in order to predict the loss of material on liners. The mathematical model is implemented in the DEM code using an objective function in order to produce realistic simulated profiles. Our DEM simulated predictions are compared to published experimental and industrial data. Keywords: modelling; discrete element method; liner wear

Jan 1, 2004

By R. G. B. Pickering

Over the last few years Lonmin Platinum and Sandvik have embarked on a unique partnership of collaboration through a systematic approach to developing equipment to mechanize and automate narrow reef platinum mining. After the initial design and manufacture of the equipment the key aspect is the integrating equipment, people and method into a mining system. Another key aspect of mechanization is the optimization of equipment utilization, and this philosophy has ensured continual evolvement of mining methods. This paper describes the trials and development that have resulted in the mining method described as Lonmin mechanized breast.

Jan 1, 2007

The corrosion behaviour of a low carbon steel was investigated in synthetic seawaters with and without Sr2+. It was found that strontium substitutes for calcium in aragonite, rather than precipitating as discrete strontianite (SrCO3). The aragonite deposits that formed in the presence of Sr2+ were finer than those that formed in the absence of Sr2+. It is believed that an increase in the strontium content of aragonite induces a decrease in its solubility, which in turn results in a higher nucleation rate of the precipitates. Furthermore, the growth rate of aragonite is decreased by the presence of Sr2+in the solution. It is concluded that Sr2+is an essential ingredient in any artificial seawater when calcareous deposits are investigated on steel. Keywords: corrosion, seawater, calcareous deposits, strontium, aragonite.

Jan 1, 2007

By G. J. van Tonder

The use of Molecular Recognition Technology (MRT), a highly selective separation technology using specifically designed ligands (such as macrocycles), has been demonstrated to be an effective treatment process for removal of several ions that are commonly found in many hydrometallurgical circuits as well as in environ-mental treatment operations. Ions removed by MRT include base, heavy and transition metals, precious metals, halides, and alkali/alkaline earths. A MRT pilot plant run was conducted at Zincor to demonstrate the cobalt/nickel purification of zinc electrolyte, and to recover saleable pure cobalt/nickel sulphate solution. The MRT process holds various advantages, which include the elimination of a catalyst such as arsenic trioxide, conventionally used in cobalt and nickel cementation. SuperLig® 138 can be used to remove cobalt and nickel from120?170 g/l Zn-solutions at pH 1?2. The Zincor MRT application demonstrated its capability of concentrating large volumes o copper barren impure solution at low cobalt and nickel concentration levels in the feed, to small solution volumes at high cobalt and nickel concentrations. Around 99.5% of the cobalt was removed from solution with cobalt impurity levels in feed varying between 10 mg/l and 26 mg/l.

Jan 1, 2002

By H. Preßlinger, H. Hiebler, K. Klepp, W. Posch, M. Mayr

It was investigated in which form sulphur is bonded in ladle slags. For this purpose, the mineralogical phases of the ladle slags were qualitatively and quantitatively evaluated by means of a microprobe. This slag characterization allowed reconstructing the bonding of sulphur into the phases of the ladle slag. Moreover, the reaction process with regard to the ionic theory as well as the structural formula for the mechanism of sulphur bonding were discussed. The bonding of sulphur into calcium aluminate slags is determined by the sulphide ion content in the slag as well as by the ratio of (CaO)/(Al2O3). Calcium sulphide separates only if the slag contains a large number of sulphide ions. When Ca12Al14O33is separated, the sulphide ion is successively integrated into the lattice. The crystal lattice of Ca12Al14O33is characterized by an open, three-dimensional anionic network composed of aluminium-oxygen tetrahedrons linking the edges. In this network, large interstitial spaces are formed, which may be filled with calcium ions on the one hand and statistically with a free oxygen or sulphide ion on the other hand. Key Words: ladle slag, structure, phases, calcium sulphide, calcium aluminate, desulphurization

Jan 1, 2004