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By S. E. Olsen, K. Tang

The complex heterogeneous equilibria associated with the production of manganese ferroalloys have been simulated by employing recently developed thermochemical databases. The non-ideal Mn-Fe-Si-C alloy and the MnO-SiO2-Al2O3-CaO-MgO-FeO slag system have been modelled separately by the compound energy and cellular model. A large number of experimental thermodynamic and phase-equilibrium data were used to evaluate the model parameters for the liquid and solid Mn-Fe-Si-C phases. In addition to the liquid metal phase, solid mixture phases occurring in the Mn-Fe-Si-C system have also been studied. Over 500 measured equilibrium data have been utilised to verify and calibrate the model calculations. The paper will present typical simulation results, from activities of components to multicomponent heterogeneous equilibria. Good agreements can be obtained for many important technological parameters such as carbon solubility, phase relations and equilibrium diagrams, element distribution as function of temperature and slag composition etc. Application of the present models to the silicomanganese production will be demonstrated in this paper.

Jan 1, 2004

By J. A. Kromhout, J. Trouw, A. A. Kamperman, M. Kick

Mould powders play an important role in the stability of the continuous casting process. The main functions of mould powders are to provide sufficient lubrication and to control the horizontal heat transfer. Because process control of thin slab casting is more stringent, it is generally assumed that mould powder properties become more critical as well. In 2000, the Direct Sheet Plant at Corus IJmuiden (DSP) was commissioned, incorporating a thin slab caster designed for casting speeds up to 6 m/min. During commissioning, several operational problems with mould powders were encountered i.e. insufficient liquid pool depth and the formation of rims/lumps. To investigate the operational mould powder problems, some of the mould powders were characterized using physical and mineralogical methods. The results were linked to operational experiences. It was concluded that for thin slab casting, a stable slag formation is obtained with a proper choice of free carbon and an even distribution of the carbon particles within the granules. The physical properties of mould powders are not as critical as expected when the additional mineralogical requirements are taken into account. Keywords: mould powder, characterization methods, thin slab casting.

Jan 1, 2004

By M. Somerville, S. Sun

The liquidus temperature and viscosity of a range of melter slags produced in South Africa were determined. Drop-quench experiments were carried out on the supplied plant samples to determine the liquidus temperature and phase relations at sub-liquidus temperatures. The temperature measurement range covered 1300°C to 1630°C. Results from these experiments show liquidus temperatures for the melter slags to be in excess of 1500ºC with the chromium containing spinel as the primary crystalline phase. At lower temperatures, an olivine or pyroxene phase co-existed with the spinel phase. The viscosity of the slags was determined over a temperature range of 1350 to 1550°C, under a controlled atmosphere. Results show two orders of magnitude variation in the viscosity (0.2 to 20Pa s) with strong effects of slag chemistry and temperature. Slags with lower SiO2and Cr2O3concentrations were more fluid. Slags with the lowest FeOx and highest SiO2concentrations were the most viscous. These observations are in accord with general behaviour of silicate slags. While the presence of a spinel phase may have an effect on the viscosity of the melter slags, results obtained to date indicate a much stronger effect due to the presence of an olivine or pyroxene phase at lower temperatures. Keywords: phase equilibria, liquidus, viscosity, slags, olivine, spinel, pyroxene

Jan 1, 2004

By A. Ochieng

Solids suspension influences the quality of mixing and energy requirement in a solid-liquid system, both of which determine the efficiency of industrial processes such as nickel precipitation. Nickel solids concentration distribution in a stirred tank was investigated using computational fluid dynamics (CFD) and experimental methods. The concentration distribution of the nickel solids was compared with that of sand and glass. The laser Doppler velocimetry (LDV) method was used to measure the velocity field for the liquid-only system and an optical technique was employed to determine the axial solids concentration distribution. Regions of in homogeneity in the tank were identified. It was found that, for a given solids loading, the solids concentration distribution depended on both particle size and particle size distribution. High solids loadings were investigated and a difference in the concentration distribution pattern was obtained with nickel, flint glass and sand particles. The CFD simulation results highlighted problems that could be associated with some conventional experimental methods of determining solids concentration distribution in a stirred tank. Keywords: nickel; CFD; simulation; mixing; solids suspension.

Jan 1, 2010

By D. Fenn, A. du Kanda, D. Dukhan

"SynopsisGibb Consulting Services was contracted by Eskom Line Engineering Services to conduct an investigation to determine the absolute displacement to date and infer the current rate of displacement of unsurveyed colliery backfill.At the test site, where a 400 kV power line is to be constructed, neither the surface nor the backfill material had been monitored and it was not possible to state whether the surface will be subject to future settlement that may compromise surface infrastructure. Therefore indirect methods of estimating current and future displacements needed to be found to act as a proxy for a comprehensive long-term settlement monitoring exercise and provide a reasonable estimate for the settlement that has occurred in the decades of mining.The innovative solution was to recover essentially undisturbed core from backfill using a sonic drill rig and use the measured dry density values from the samples as a proxy for the rate and absolute displacement in the backfill.The success in obtaining an essentially undisturbed backfill core and the clear relationship of the backfill density with age and depth allowed the conclusion to be issued that the power line infrastructure can be constructed over the backfill; with a warning that once the water table recovers after mining ceases some collapse settlement may occur.With this method, the amount of settlement can be predicted and, if proven conclusively, provides a way to confidently release huge areas of currently waste ground for future surface infrastructural development.IntroductionIn coal mining, it is normal mining practice to backfill the newly mined-out voids with the excavated waste rock and soils. As there is no requirement for the mining companies to uniformly compact the spoil or accurately monitor surface or inter-backfill displacement, these backfilled voids are prone to differential compaction and consolidation settlement. They are therefore avoided as sites for future surface infrastructure work, especially for linear structures such as roads, railways, and power lines."

Jan 1, 2015

By A. C. Moorgas, J. Divall

This study investigates the feasibility of using waste iron slag, the by-product from a mineral sands processing works, in road construction. The study includes the different options investigated for the treatment of a leachate that is produced during the cooling of the iron slag, prior to processing. It also reviews the reasons for choosing the current treatment option that is being trialed. Cooling the iron slag with water results in the formation of a leachate with a high pH and high sulphide concentration. This leachate can seep into the ground and, over time, it will contaminate the ground water. A system was designed to collect and treat the leachate to prevent contamination of surrounding natural water sources. Numerous leachate treatment options were investigated to find cost effective method of treatment After cooling, the iron slag is passed through an iron recovery plant and the unsaleable product is placed on a dumpsite. Rain percolates through the dumpsite, which can result in the formation of a leachate that can contribute to a contaminated plume. After extensive testwork, it was found that the dumpsite, which was leached of contaminants, could be screened and used as a G5material (specifications in Table II) in road construction. The initial challenge was to establish that this material was environmentally safe for use in this particular application. Approval from the Department of Water Affairs (DWAF) was required for the testwork and then for the long-term use of this material in the construction industry. The following challenge involved establishing a market for the material. Construction companies in the area were reluctant to change to a new product that was not naturally occurring. The economics of this project are extremely sensitive to transport costs and hence only projects within a specified radius can be supplied with the Black Top Gravel (BTG). This project is not are venue generator, but it does save the money that would be required to manage the dump, and it reduces the closure costs.

Jan 1, 2003

By S. E. Cook

This article uses the case of the Royal Bafokeng Nation to argue that royalties and dividends from mineral resources, if managed well, can provide direct benefits to the surrounding community even while the state collects its share of mining revenues through taxation. The key to this model is the effective management of the resource income flowing into community coffers. Where some of this income may fund urgent interventions in the community, a portion of the income can also be used to establish an intergenerational wealth fund to meet the needs of future generations. As a depleting resource, minerals like gold and platinum are not a sustainable source of income, and must be replaced over time by more regenerative income streams. These strategies and dynamics are manifest in the Royal Bafokeng Nation?s status as both community and quasi-municipality, a labour hosting and a labour sending community, a mine operator and a mine owner. The Royal Bafokeng Nation also owns one of South Africa?s largest community-based investment companies, which channels revenue derived from platinum deposits into a broad investment portfolio that in turn funds an aggressive social development program for 150,000 people living in twenty-nine rural villages.

Jan 1, 2013

By M. Hooman, W. M. Marx, R. C. W. Webber-Youngman

This paper discusses a study that investigated different underground bulk air heat exchanger (>100 m3/s) design criteria. A literature review found that no single document exists covering all design criteria for different heat exchangers, and therefore the need was identified to generate a guideline with decision analyser steps to arrive at a technical specification. The study investigated the factors influencing heat exchanger designs (spray chambers, towers, and indirect-contact heat exchangers) and the technical requirements for each. The decision analysers can be used to generate optimized, user-friendly fit-for-purpose designs for bulk air heat exchangers (air cooler and heat rejection). The study was tested against a constructed air cooler and heat rejection unit at a copper mine1. It was concluded that the decision analysers were used successfully. This tool (decision analysers) can be used by engineers for the efficient and cost-effectively design of heat exchangers.

Jan 1, 2015

By P. K. Hofmeyr

Base Metal (Cu, Ni, Mo, Zn, Co etc.) analysis traditionally has been very slow in conventional analytical laboratories which can lead to additional costs being incurred in waiting time of drill rigs or mining excessively off-reef. Recent developments in the automation of analytical laboratories now allow for very rapid turn-around times for base metal analytical data which can help reduce such costs as well as reduce the unit costs of the analyses themselves. 2.0 CONVENTIONAL ANALYTICAL LABORATORY PRACTICE Conventional analytical laboratories are necessarily are very manual. Sample preparation is slow and laborious, samples are moved from stage to stage manually and, typically, all samples are processed in batches so a sample which is the first to be, say, milled has to wait for the complete milling of the batch before it advances to the next stage eg. mixed with wax prior to pelletising for XRF analysis. Inevitably this results in long sample data turn-around times for laboratories handling large numbers of samples. Manual sample preparation can only be accelerated by increasing staff which increases costs and can lead to additional errors being introduced. Cleaning of sample preparation equipment, eg. crushers and mills, between samples is essential to avoid cross-contamination between samples and this is slow and labour-intensive. In manual sample preparation the correct sample numbers staying with the samples is totally dependent on the efficiency of laboratory operators. It is extremely difficult to detect when errors have occurred due to the switching of sample numbers during the sample preparation stages. Running duplicates and QC samples at best is only partially successful in detecting when sample number switching errors have occurred. Errors of this nature and cross-contamination problems due to incomplete cleaning of sample preparation equipment tend to occur when laboratories are working at pressure due to high sample numbers and when supervisors are not present during 24/7 laboratory operations which is often required on plant process control laboratories. These problems are common to all conventional analytical laboratories and their magnitude is dependent on the level of control and efficiency of QC systems practised by individual laboratories. The disadvantages of conventional manual analytical laboratories can be summarized as follows:- 1. Labour-intensive which is costly especially when multiple shifts have to be used during 24/7 operations.

Jan 1, 2005

By Ö. Erdem

The investment decision making process in the insurance and finance industries is affected by new advances such as simulation techniques. These advances have improved the discounted cash flow method (DCF). In DCF, a dynamic and flexible model construction is not possible because it does not consider uncertain conditions. Each project should be evaluated taking into account the related uncertainties because the related uncertainties determine the characterization of the project. Related uncertainties can be processed in dynamic DCF, which is applicable to both financial and non-financial industries with different kind of uncertainties, such as power generation and petroleum projects. The dynamic DCF method can estimate net present value (NPV) while managing related project uncertainties with a simulation method like Monte Carlo Simulation. The simulation method is preferred because its output is unbiased. Therefore, a more realistic financial evaluation of the project can be concluded. In spite of the improvement of dynamic DCF, this project evaluation method is not used frequently in mining industry. However, the mining industry is ideally suited to this concept because it is highly dependent on estimations such as orebody size and ore grade. During the project evaluation stage, these uncertainties can be included with the dynamic DCF method. This study aims to contribute to increasing the usage of this method in mining projects. A copper reserve in Turkey is selected as a case study to apply uncertainty assessment for the evaluation of NPV.

Jan 1, 2012

By P. Mbele

Iron ore concentrate is not easily transported to, or processed in, ironmaking plants, therefore it is necessary to agglomerate. This paper will determine the possibility of agglomerating Sishen concentrate into suitable ironmaking feedstock. Pelletizing is one of the conventional and preferred agglomeration processes for iron ore concentrate investigated at Kumba Value-In-Use Laboratories. Sishen concentrate was mixed with binder, and then pelletized using a laboratory pelletizing disc; afterwards the green pellets were indurated at high temperatures to give strength high enough to survive handling and lessen disintegration in the shaft during ironmaking. Sishen pellets have satisfactory physical and metallurgical properties which make them suitable feedstock for the direct reduction processes. These were tested under Midrex shaft operational conditions and performed well, with a metallization of 94.47% being attained.

Jan 1, 2012

By Q. Cheng

This paper introduces the multi fractal interpolation method (MIM)developed for handling singularities in data analysis and for data interpolation. The MIM is a new moving average model for spatial mapping and interpolation. The model decomposes the raw data into two components: singular and nonsingular components. The former can be characterized by a localized singularity index that quantifies the scaling invariance property of measures from a multifractal point of view. The latter is a smooth component that can be estimated using ordinary kriging or other moving average models. The local singularity index characterizes the concave/convex properties of the neighbourhood values. The paper utilizes a binomial multiplicative cascade model todemonstrate the generation of one- and two-dimensional data with multi-scale singularities which can be modelled by asymmetrical multifractal distribution. It then introduces a generalized moving average mathematical model for analysing and interpolating data with singularities. Finally, it is demonstrated by a one-dimensional case study of de Wijs’ data from a profile in a zinc mine, that incorporation of spatial association and singularity can improve the interpolation result, especially for observed values with significant singularities.

Jan 1, 2015

By A. Singh

The control of flotation plants is by no means trivial. Flotation is one of the most interactive minerals? processing operations. The interactive nature of flotation circuits results in oscillations of levels and hence of grades and recoveries. Also, poor level setpoint tracking and disturbances have negative influences on grades and recoveries. The result is an unstable plant with limited scope for optimization. An advanced controller, FloatStarTM, has been developed to provide tight control and to reduce the amount of disturbances in flotation levels. It has been shown on a number of plants that the system results in faster and better setpoint tracking, better regulatory control and faster settling times after start-ups and disturbances. The successful stabilization provided by FloatStar has made it easier to investigate the area of optimization on flotation circuits. Mintek has identified the need for a more meaningful set of setpoints or aeration rates to use as a basis for control than levels and have advocated flow control by looking after residence times. When the feed conditions change, the ideal solution would be an algorithm or strategy that finds the new optimum conditions rather than just having an unguided hunt from the previous point. A multivariable flow-optimizing algorithm, a new module in FloatStar, has been developed to calculate optimum level setpoints and/or aeration rates that will aim to optimize the residence times, mass pulls and circulating loads within a flotation circuit. Keywords: flotation, regulatory, FloatStar, start-up, disturbance, residence times, circulating loads

Jan 1, 2003

By C. F. Vos, J. D. Miller, J. C. Davidtz

Small replacements of C12-trithiocarbonate (C12-TTC) for dithiocarbonate (DTC)/dithiophosphate(DTP) in a reagent suite for the flotation of platinum group metals (PGM) have significantly improved the rejection of gangue. Coupled to this is an improvement in kinetics, grade and recovery of PGMs. In a pilot-plant trial, after a 5 mole per cent replacement of the current DTC/DTP collector combination by C12-TTC, large opaque bubbles were replaced by small clear ones. In addition, a similar flotation response was realized with one-third of the current depressant dosage. During a preliminary plant trial on underground UG2 ore, the initial rougher concentrates were characterized by higher PGM concentrate grades and this was in part due to improved chromite rejection. The concentrate produced from the TTC trial also exhibited a much finer particle size distribution. The overall circuit performance, which included secondary regrind and flotation, showed an increase in concentrate grade of approximately 44% while the tailings grade remained unchanged

Jan 1, 2006

By C. Righi, R. Carli

In modern steel continuous casting technologies mould fluxes are well-known to assure lubrication required by tribological system of mould-solidifying strand shell, and to provide crystalline phase solid film, contributing to control heat extraction between strand and mould wall. Actual cooling rates during normal continuous casting mould operations are far higher than critical cooling rate of the liquid slag. Indeed, DTA measurements point out that even relatively small cooling rates of 30?50 K/min are high enough to give exiguous formation of crystals. In this paper, contribution of devitrification in defining crystalline phase formation of industrial basic mould slag, used in continuous casting of crack-sensitive steel grades, has been investigated by means of non-isothermal experiments study. Devitrification has proved to play a major role in mould flux crystallization in a working environment explaining the higher amount of crystalline phase formed in plant sample in comparison with lab sample from DTA analysis with typical cooling rate of 5?20 K/min. The amount of crystalline phases formed ranks as follow: Cuspidine > Combeite > Gehlenite. Kinetic analysis of DTA non-isothermal experiments has provided kinetic parameters through Kissinger and Ozawa methods, as Avrami constant resulting to be n ?2 and activation energy of Cuspidine crystallization resulting to be EC= 315 kJ/mole. The effect of addition to the parent material of oxides as MnO, TiO2, ZrO2, Al2O3 and Fe2O3near to saturation point has proved to affect, in certain cases, crystallization behaviour of mold flux. In particular, MnO, TiO2, ZrO2oxides produce a relevant dump of crystallization of Combeite and Gehlenite phases, while Al2O3and Fe2O3do not appreciably affect crystallization. Key words: Mould flux, crystallization, devetrification, DTA non-isothermal analysis, Kissinger and Ozawa methods.

Jan 1, 2004

By S. Parada, P. T. Jones, M. Guo, S. Smets

The corrosion behaviour of a high-quality rebonded magnesia-chromite refractory in contact with a vacuum oxygen decarburization (VOD) slag with high Al2O3content (15?20 mass per cent) is investigated under VOD process conditions by rotating finger tests in a vacuum induction furnace. The refractory degradation mechanisms are studied by the characterization of corroded microstructures using scanning electron microscopy, equipped with energy dispersive spectroscopy. The influence on the refractory wear of the process temperature and the Al2O3content in the slag is discussed. Keywords: corrosion, magnesia-chromite refractory, VOD slags, vacuum induction furnace

Jan 1, 2004

By S. K. Murphy, K. B. Le Bron, A. K. Ward, S. Hayes, T. Rangasamy

A process for evaluating different options for extraction of mining blocks is presented. The process is described and an example of the application of the process to a case study is presented. Un procédé pour évaluer différentes options pour l’extraction de blocs d’exploitation est présenté. Le procédé est décrit et un exemple de l’application du procédé à un cas particulier est présenté. Ein Prozeß für das Auswerten der unterschiedlichen Optionen für die Extraktion von Abbaublöcken wird dargestellt. Der Prozeß wird beschrieben und ein Beispiel der Anwendung des Prozesses zu einer Fallstudie wird dargestellt.

Jan 1, 2003

By I. L. Follington

This paper describes the research and development programme to develop a prototype underground auger mining system aimed at developing and demonstrating an underground auger mining system able to provide economic access to thinner (<1.8 m) coal reserves of South Africa. Data concerning the performance of modern coal augers under South African coal mining conditions were gained from a proven surface auger which operated across a range of coal types. These data were analysed and considered in conjunction with historical information regarding previous attempts at building underground augers dating back to the 1950s. Drawing on these data a prototype underground auger mining system, the BryDet BUA 600 underground coal recovery auger, was designed and manufactured by the BryDet Development Corporation in collaboration with Eskom and Cutting Edge Technology Pty Ltd with support from Anglo Coal and the Ingwe Coal Corporation Ltd. The prototype BryDet BUA 600 underground coal recovery auger commenced trials in March 2000 at the Matla Mine near Witbank in South Africa. The initial trials were undertaken in an open cut to facilitate the commissioning and training associated with a prototype mining machine. A total of 30 holes was augered in the box cut before the machine moved underground. The prototype BUA 600 first achieved the target penetration depth of 80 m in its third hole. The prototype BUA 600 is a new underground mining system which has passed early testing with ?flying colours? and could provide access to extensive underground coal reserves unmineable by conventional mining techniques both in South Africa and elsewhere around the world.

Jan 1, 2001

By A. A. Debrah

Artisanal and small-scale mining (ASM) plays a fundamental role in the national and local economies of resource-rich countries in Africa. As such, more effort must be geared towards fostering this type of economic activity to sustain livelihoods in rural communities. Across Africa, efforts to operationalize ASM based on a sustainable development framework have been quite tedious and often ineffective. This is because most of these frameworks lacked context and an understanding of the continuum from the artisanal through small-scale and up to the junior miner, grouped under the general term ?ASM?. Driven by the need to contextualize some of the definitional issues in this niche sector, and gain a clearer understanding of their peculiar challenges, this paper aims to contribute to the debate on ASM by considering two of Africa?s resource-rich countries ? Ghana and South Africa. Since South Africa has made greater inroads in protecting the interests of small-scale miners, we thus draw comparisons from both countries? approach to ASM, outline the lessons learnt, and provide recommendations regarding the ways forward.

Jan 1, 2014

By I. Mc Dougall

Finite element models were generated of two submerged arc furnaces of different geometries. A 48MW circular furnace and a 68MW 6-in-line rectangular furnace were studied. The electrodes, raw material, slag and molten metal were included in the model. ANSYS/Multiphysics was used to predict the current density distribution in the electrodes, raw material, slag and molten metal as a result of the three phase AC current. The effect of the electrode immersion on the current path was studied. The ?proximity effect? caused a pronounced asymmetry in the electrode currents in the circular furnace, whilst the electrode currents in the rectangular furnace exhibited radial symmetry. The current distribution in the melt in both furnaces indicated that the bulk of the current flows between phases. The current density is greatest between electrodes. Results were compared to qualitatively similar published work, operating experience and results of furnace dig-outs.

Jan 1, 2007