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By G. Akdogan, T. P. Kekana, Q. G. Reynolds

The DC arc plasma gasifier concept is currently under development at Mintek for testing the feasibility of producing syngas from waste coal fines and dry steam. The technology is intended for the valorisation of low-grade discard coals into market-quality syngas, which may then be used for largescale electrical power generation to address current grid supply challenges in South Africa. Other potential applications include feedstock for petro-chemical plants, fuel for transportation vehicles, domestic and industrial heating, and others. The proposed concept of a DC arc plasma gasifier was developed based on a plasma torch, metallurgical-based and entrained flow coal gasifiers. The principles of design and operation of the proposed gasifier are based on the concept of the Westinghouse Plasma Corporation (WPC) gasifier where the torches are substituted by graphite electrodes from which electric arc plasmas are generated. The DC section of the gasifier will be designed considering Mintek’s experience in the sealing of the furnace as carried out in the Mintek Thermal Magnesium Process. As part of the building blocks of a full conceptual design, the feasibility of the DC arc plasma gasifier was investigated through testing and modelling of its critical elements as proof of concept. The main activities of this work included pilot scale evaluation of the arc behaviour in the presence of dry steam, modelling of the temperature distribution within the reactor and explosibility studies on three different coal dust samples. Keywords: DC arc plasma gasifier, explosibility index, lower explosion limit, minimum ignition energy

Jan 1, 2020

By G-L. Wu, S-W. Wu

"The hot deformation behaviour of Nb-Ti microalloyed high-strength steel was investigated. Hot compression tests were conducted in the temperature range 900 to 1100°C under strain rates of 0.1, 1, and 5 s-1. Dynamic recrystallization (DRX) occurs as the main flow softening mechanism at high temperature and low strain rate. The hot deformation activation energy was calculated to be about 404 699 J/mol. The constitutive equation was developed to describe the relationship between peak stress, strain rate, and deformation temperature. The characteristics of DRX at different deformation conditions were extracted from the stressstrain curves using the work hardening parameter. The Cingara-McQueen equation was developed to predict the flow curves up to the peak strain. The processing maps were obtained on the basis of a dynamic materials model. The results predict an instability region in the temperature range 1010 to 1100°C when the strain rate exceeds 0.78 s-1. IntroductionThe 700 MPa grade HSLA steel is widely used in engineering machinery, automotive beams, carriages, and axle tubes, etc. (Pan et al., 2017 ). Generally, such grades contain a moderately high amount of Mn (approx. 1.4% and above), and microalloying elements like Nb, Ti, V, and Mo to impart the desired strength and toughness through solid-solution strengthening, precipitation hardening, and grain refinement dislocation strengthening (Chen and Yu, 2012; Opiela, 2014). However, the production costs can be greatly reduced by replacing part of the Nb, V, or Mo with inexpensive Ti and adopting the compact strip production CSP process (Opiela, 2014; Chen et al., 2015). Furthermore, the microalloying technology coupled with new-generation thermomechanical control processing (NG-TMCP) has proved efficient for achieving the proper balance between strength, toughness, ductility, and formability by means of a suitable combination of chemical composition and thermomechanical treatment parameters (Shukla et al., 2012; Wu, Zhou, and Liu, 2017).In hot forming processes, the complex microstructural evolutions are often induced by multiplicative hot deformation mechanisms, such as work hardening (WH), dynamic recovery (DRV), and dynamic recrystallization (DRX) (Zhang et al., 2014; Liang et al., 2015). Dynamic softening behaviour during hot processing has generated considerable interest because component properties are influenced significantly by its corresponding microstructural evolution (Wu et al., 2010). During deformation in the DRX process, deformed grains are replaced with substructures and newly formed fine and uniformly distributed grains. This occurs only when a critical strain for the onset of DRX is reached, and at the same time, the minimum rate of energy dissipating is reached (Ferdowsi et al., 2014). DRV occurs at a high strain rate and low temperature, reducing the stored energy greatly and making DRX difficult (Liang et al., 2015). The microstructural changes during DRX are sensitive to the processing parameters, such as strain rate, deformation temperature, and strain (Zhang et al., 2014; Ferdowsi et al., 2014). Therefore, in order to optimize the hot processing parameters, it is important to understand the behaviour of hot deformation visà- vis control of microstructural evolution."

May 1, 2019

By E. Saari, B. Musuku, K. Jansson

The quality of the concentrator plant process water is crucial for high performing mineral flotation circuits. Significant metal recovery and concentrate grade losses have been noticed particularly in more closed water loops. The recovery and quality losses have started to emerge mainly with decreased freshwater usage and because of changes in tailings management towards tailings thickening, paste, or dry stacking. These changes result in shorter, closed water loops with a rapid build-up of harmful components with negative impact on the beneficiation process. Consequently, water quality has a direct link to decreased product value and sales returns. Complete cleaning or water blending might not be the right way to achieve high recovery and high-quality products. Instead, the key is to understand what kind of water qualities are needed for the flotation of specific minerals. In this study harmful substances in various plant water streams were removed and/or modified by pilot-scale dissolved air flotation. Batch-scale mineral flotation tests with the untreated and treated water were then performed by using fresh ore samples and the plant’s own laboratory flotation procedure. The results indicate that because of dissolved air flotation, the mineral flotation recoveries were enhanced by 1‒3.3%. Keywords: Mineral recovery, metal recovery, mineral quality, process water, concentrator, beneficiation, mineral processing, flotation, process water treatment

Jan 1, 2020

By K. Naidoo, M. Pelser, J. Hagemann, K. C. Sole

The copper tankhouse at Rustenburg Base Metals Refinery is an essential component of the Anglo American Platinum value chain. The tankhouse uses starter-sheet technology that was adopted in the 1980s, so dependence on manually intensive labour and overall operational excellence has a significant impact on process performance. An efficient, stable, and sustainable electrowinning process contributes to minimising energy consumption and reducing operational costs, and enables improved product quality and increased throughput. Historic performance of this tankhouse has often been suboptimum over prolonged periods. An in-depth operational review of performance from 2018–2024 was carried out to understand challenges, risks, and high-impact factors that contribute to poor performance. Implementation of adherence to fundamental operational basics identified from global best practice, such as the frequency and quality of cell cleaning and maintenance, preventing backlogged harvesting or maintenance, preserving cell-top furniture conditions and integrity of electrodes, preventing short circuits and poor current distribution, and maintaining a high level of operational discipline, has since contributed to an era of exceptional performance. Root-cause analysis fault trees pertaining to poor current efficiency and high scrap rate are summarised. Current efficiency has significantly improved since 2021, now consistently exceeding 88%. The copper scrap rate, previously believed to be limited to a minimum of 4%, achieved a historic monthly low record of 2.06% in 2023. Chemical and physical quality has considerably improved, and cathodes exhibit minimal morphological defects.

Jun 27, 2025

By F. T. Cawood, M. N. M. Cudjoe

The ability to conduct real-time material tracking in mines has been a long-standing challenge. Technological innovations such as radio frequency identification technology (RFID) have over the years contributed to the effective tracking of material flow and reporting of metal content. This paper outlines the laboratory procedures and results from testing the suitability of microdot technology as a viable technique for real-time material tracking in mining. The paper clarifies the reasons for conducting the test and presents the material safety data sheet (MSDS) from a South African and Canadian perspective. Microdots from three aerosol systems were immersed in water, heated to 100°C, and crushed into coarse and fine material. These tests were used to ascertain if the technology could withstand mining conditions. A strength, weakness, opportunity, and threat (SWOT) analysis was used to evaluate and compare microdot technology with RFID. It was shown that microdot technology has some potential to track ore parcels because data integrity was retained after exposure to post-blast mining conditions. However, more improvement is required to digitally detect microdots before the technology can be implemented at scale in the mining industry.

Apr 2, 2022

By E. J. Y., G. J. McLachlan, E. Amini, Koha

Inferring individual component flotation rates from recovery-time data of ore complexes is important in optimising and designing minerals processing plants. However, existing two-component first-order flotation models are computationally intensive to solve using conventional non-linear least squares regression. In this paper, a Convolutional Neural Network (CNN) is used to approximate the inverse function which predicts the two-component first-order model parameters using recovery-time data. This paper compares the accuracy and computation speed of the proposed CNN against traditional non-linear least squares regression on 1 million generated data based on a known two-component firstorder kinetic model. It is shown that using a CNN is possible to approximate the inverse function for the non-invertible two-component model with recovery-time as an input matrix for convolution operations. The CNN method is 450 times faster to compute than the Trust-Region (TR) non-linear least squares regression algorithm. However, the CNN model is less accurate compared to the TR algorithm overall. Keywords: Flotation kinetics, convolutional neural network, inverse problem, modelling and simulations

Jan 1, 2020

By L. Zhou, J. Qiu, M. Tang, J. Wang, G. Dai

Coal spontaneous combustion in longwall gobs is a major concern in coal mines. In comparison to other hazards, this phenomenon is difficult to detect. Fifteen factors influencing coal spontaneous combustion in longwall gobs were identified from the literature. The logical relationships between these factors were evaluated and quantified by decision-making trial and evaluation laboratory (DEMATEL) and interpretive structural modelling (ISM) methods. A four-level hierarchical structure model was established. The research shows that combining DEMATEL and ISM can reveal the key factors that influence coal spontaneous combustion in longwall gobs and establishthe interactions and relationships among these factors. The results can provide the basis for preventing and controlling coal spontaneous combustion in longwall gobs.

Jun 10, 2024

By D. Sethuram, P. G. Koppad, S. Iyengar, R. Shobha

TiB2 and CeO2 particle-reinforced Al6061 hybrid composites were manufactured using stir casting and hot rolling techniques. The base alloy and composites were hot-rolled at 500ºC and a 50% reduction was achieved through 12 passes. The effect of varying TiB2 and CeO2 particle additions on the microstructure and mechanical properties of the Al6061 matrix was studied. Scanning electron microscopy showed uniform dispersion of both the reinforcements, with good interfacial bonding. Microhardness and tensile properties like yield and tensile strength were found to be higher for hybrid composite with 2.5% TiB2 and 2.5% CeO2 compared to Al6061 alloy and other hybrid composites. The increased tensile strength is attributed to good dispersion and interfacial bonding between the particles and Al6061 matrix. Fracture analysis using a scanning electron microscope revealed ductile fracture for the Al6061 alloy and mixed characteristics of ductile-brittle fracture for hybrid composites

Oct 1, 2021

By J. Loubser

The concept of caring is in most cases confused with material needs and not psychological needs. By giving employees a job, most managers think that employees should be grateful and return the favour by being loyal, productive and working safely. Other managers hold the view that employees can be lucky to have a job. To show and demonstrate that management are caring for the safety of the workforce requires involvement, dedication and commitment. Obtaining the trust and respect of the workforce should be the main thrust of any organization because within trust and respect lie the secret of optimal safety performance. In the last 70 years, all the fatalities and serious injuries that occurred in the mining industry can be traced back to one thing, non-caring. The same safety non-compliances are still observed, reported and planned against as 70 years ago, and strange as it may sound, the same injuries occur the same way. The question could be asked: Does the mining industry need more risk assessments? More codes of conduct? More engineering. Or does the mining industry need more caring?

Jan 1, 2010

By A. Yamik

This research study includes studies carried out on the recovery of unburned carbon in the ashes of Tuncbilek Thermal Power Plant. Bottom ashes have been identified by X-ray diffraction and X-ray fluorescence. These samples are potentially of class F type and have significant amounts of unburned coal. According to the ash amount that units in the thermal power plant produce, and the analyses of the samples mixed, which used certain amounts in flotation tests, it was found that the bottom ash includes 91.47% ash in dry form and 8.53% combustible matter, and the lower calorific value is 491 kcal/kg. Optimum flotation conditions to get the unburned carbon were subsequently determined by examination of the optimum flotation grain size, pulp density, collector type and amount, depressant type and amount, frother type and amount, agitation speed, and froth-taking time. While the lower calorific value of the thermal power plant bottom ashes of the 3rd , 4th and 5th units and the mixed bottom ash sample was, respectively, 959, 469, 279 and 491 kcal/kg in dry form, it increased to 2490, 1312, 786 and 1348 kcal/kg in the product obtained as a result of flotation in optimum conditions. Key words: ash, conventional flotation, unburned carbon

Jan 1, 2008

By J. W. van der Merwe, K. G. Moloko

Furnace wall tubes from 600 MW subcritical boilers at three coal-fired power stations were sampled and the fireside deposits examined to determine the mechanism of fireside corrosion. This involved an indepth investigation into the morphology and composition of the fireside deposits and the conditions of the furnace that enable this type of attack. SEM-EDS analysis revealed high concentrations of oxygen, iron, and sulphur, QEMSCAN and XRD analyses identified the presence of Fe3O4, Fe2O3, FeS, and FeS2. Differential thermal analysis showed thermal activities at temperatures of 500–600°C, 900–1100°C, and 1100–1250°C, which are associated, respectively, with FeS2 oxidation to FeS and Fe2O3, at 475–525°C, formation of aluminosilicates at 925–1100°C, and melting of FeS around 1190°C. The absence of sodium and potassium eliminates the contribution of molten alkali sulphates to the corrosion. The consistent coexistence of iron sulphide and iron oxide is indicative of the substoichiometric conditions in the furnace, while the detection of pyrite suggests that the coal is not completely combusted, which points to a poor combustion process. These observations were affirmed by gas analysis at one of the stations, where very high levels of carbon monoxide were measured at the furnace wall (≥ 14 000 ppm) and furnace exit (≥ 3500 ppm). The high CO concentrations are indicative of limited combustion caused by limited O2. These reducing conditions promote the formation of FeS-rich deposit, which is the corrosive species responsible for degradation.

Jun 1, 2021

By Y. Wang

Arsenic-bearing acidic effluent from hydrometallurgical processes contains many harmful metal ions and must be appropriately treated before discharge. In the present study, arsenic, copper, zinc, aluminum, and magnesium were co-precipitated by means of the Fenton reaction. The precipitates obtained under different conditions were investigated to determine their stability. The results indicate that pH value and hydrogen peroxide (H2O2) dosage have significant effects on the removal of various elements. Arsenic, copper, zinc, and aluminum (but not magnesium) can be removed at pH 5–6 and anH2O2/As mole ratio of 2 at ambient temperature. The precipitates were mainly amorphous and granular with particle size in the micrometre range. The arsenic concentration in leachate from the toxicity characteristic leaching test was 3.6 mg/L, which proves that the precipitates are effective in fixing arsenic.

Aug 3, 2023

By D. Orynbassar, N. Madani

This work addresses the problem of geostatistical simulation of cross-correlated variables by factorization approaches in the case when the sampling pattern is unequal. A solution is presented, based on a Co-Gibbs sampler algorithm, by which the missing values can be imputed. In this algorithm, a heterotopic simple cokriging approach is introduced to take into account the cross-dependency of the undersampled variable with the secondary variable that is more available over the entire region. A real gold deposit is employed to test the algorithm. The imputation results are compared with other Gibbs sampler techniques for which simple cokriging and simple kriging are used. The results show that heterotopic simple cokriging outperforms the other two techniques. The imputed values are then employed for the purpose of resource estimation by using principal component analysis (PCA) as a factorization technique, and the output compared with traditional factorization approaches where the heterotopic part of the data is removed. Comparison of the results of these two techniques shows that the latter leads to substantial losses of important information in the case of an unequal sampling pattern, while the former is capable of reproducing better recovery functions.

Aug 1, 2021

By T. Bruce, R. C. A. Minnitt

Mining operations are generally reluctant to install high-cost sampling systems at operations that have been functioning for many years. The principal objection to installing appropriate equipment to extract correct and representative samples in process flows is the time and costs involved. The Theory of Sampling (TOS) provides a structured framework for identifying and quantifying the errors and bias associated with any sampling event, but this may be insufficient to initiate substantial investment in correctly designed sampling equipment. Financial losses arising from substandard sampling installations are usually disregarded because the value-add from a good quality sampling solution is invisible, but the cost is quite obvious. Depending on the needs, a less-than-perfect or fit-for-purpose sampling solution may be acceptable, provided the magnitude of sampling errors is understood and the assay results are interpreted accordingly. Categorical levels of acceptable accuracy and precision can be established depending on the sampling position in the mining value chain and the nature of the decisions to be made. The objective benefits of proposed fit-for-purpose sampling solutions should be presented to relevant decision-makers in such a way that adverse subjective decisions are countered so that appropriate solutions are implemented. Practical examples of the benefits from motivating the implementation of fit for purpose sampling solutions at sampling facilities around the world are provided.

Jul 2, 2022

By M. -B. Kime

This study applies attainable region analysis to optimise cobalt recovery from oxidised ores via reductive leaching with sulphur dioxide and sulphuric acid. The attainable region framework enables systematic visualisation of trade-offs between cobalt yield and sulphur dioxide loss, guiding reactor network design beyond conventional mass balance modelling. Experimental column leaching trials, supported by validation runs, were conducted under controlled flow and reagent conditions. Kinetic parameters for cobalt dissolution and sulphur dioxide consumption were used to simulate reactor trajectories and construct attainable region envelopes. To ensure hydrodynamic realism, residence time distribution tests confirmed partial plug flow behaviour with dispersion effects, justifying the use of hybrid reactor models in the attainable region simulations. The results revealed that increasing recirculation ratios improves cobalt yield while reducing sulphur dioxide losses, with attainable efficiencies exceeding 90% cobalt recovery and < 20% sulphur dioxide loss. Importantly, the study proposes practical reactor network configurations for future implementation, including staged percolation columns with intermediate mixing zones, oscillatory flow reactors, and modular fluidised bed systems. These designs offer scalable pathways to translate attainable region-based optimisations into industrial practice. Compared to traditional modelling, attainable region analysis provides a geometric decision support tool that captures multi-objective trade-offs and reactor interactions, offering novel insights for continuous leaching system design. This work advances the application of attainable region methodology in minerals engineering by bridging theoretical optimisation with practical reactor design, supporting sustainable cobalt recovery from both primary ores and recycled feedstocks.

Mar 30, 2026

The 114th Annual General Meeting of The Southern African Institute of Mining and Metallurgy was held at The Country Club, Johannesburg, Napier Road, Auckland Park on Thursday, 11 August 2011. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations, and also to recipients of awards, senior members of industry, Honorary Life Fellows, past-presidents, our members and other guests, among them the following: F. Cawood, President, Institute of Mine Surveyors of South Africa C. Roode, President, Mine Metallurgical Managers&apos; Association of South Africa M. Cresswell, Chairman, South African Coal Processing Society A. Hay, Immediate Past President, South African Institute of Electrical Engineers L. Gardner, President, South African National Institute of Rock Engineers J. Krynauw, President, The Geological Society of South Africa (GSSA)

Jan 1, 2011

By D. F. Malan, P. J. Le Roux

Almost no work has been published on the strength of pillars in mines exploiting the LG6/LG6A chromitite bands in the Western Bushveld Complex. The strength of these pillars is unknown, and the hard rock industry still uses the Hedley and Grant formula. Numerical modelling, using inelastic constitutive models, may be of some value in estimating the pillar strength, but this approach is difficult and prone to errors as many assumptions are made. This paper explores the alternative approach of the back-analysis of actual LG6/LG6A mining layouts, using displacement discontinuity codes to simulate the average pillar stresses on a mine-wide scale. From this, and underground observations, a ‘minimum’ pillar strength (K-value in the pillar strength formula) can be estimated. The codes TEXAN and Map3D are both used in the paper to simulate the actual pillar shapes and sizes in an LG6/LG6A mine. The results are encouraging as the two codes produced similar APS values for a complex pillar geometry. An estimated K-value of 77 MPa was determined for the LG6/LG6A pillars in this particular area. This is more or less similar to earlier work done for the UG2 chromitite seam, but higher than the K-value of 39 MPa for a linear formula obtained by other workers for LG6/LG6A pillars. Caution should therefore be exercised before using this higher value for all areas. The effect of element sizes and explicitly simulating the effect of the surface for shallow pillars is illustrated in the manuscript using both codes. The need for actual pillar observations and an iterative design process, which cycles between modelling and observations, is also emphasized.

Nov 27, 2024

The April General Meeting of the Institute was held in Kelvin House, Johannesburg, on 16th April, 1969, at 4.30 p.m. Mr R. C. J. Goode (president) was in the Chair. There were also present nineteen Members, including Messrs R. J. Adamson, F. P. Bath, J. K. E. Douglas, A. R. C. Fowler, P. Lambooy, D. G. Maxwell and J. A. Nixon, (Council Members), Messrs E. L. Atkinson, I. R. Chaston, J. L. Edwards, J. S. Hall, S. A. Hancox, A. F. Lee, W. K. B. Loftus, H. S. Simpson, A. N. Shand, R. A. Wilson, H. J. Wright and J. E. Van Leeuwen. Nine Associate Members, including Messrs O. Davel, G. Douglas, P. R. Garcia, D. J. Murphy, D. Rankin, G. Schwartz, H. N. Singer, S. Thompson and D. A. Viljoen. One Graduate Mr D. Bosley. Ten Visitors, including Messrs S. Adler, C. E. Alvey, B. J. Botha, K. Chant, L. W. Davis, R. N. Guest, R. V. Keet, E. G. Keown, M. D. Lourie and S. McMurray. Secretary Mr D. C. Visser. Total present: Fourty-one. MINUTES The President requested that confirmation of the minutes of the previous meeting be held over as they would only be appearing in the Journal of the following month. Agreed. MEMBERSHIP The President: "I have much pleasure in announcing that the names of the under-mentioned candidates, having been published in accordance with By-law 5.2.2, Council has elected them to membership of the Institute in the following grades: Members: Kenneth Sinc1air Rae, Ian Robert Malcolm Chaston. Associate Members: Norman Isaac Thomas, Ian Connell Robinson. Graduates: Simon Richard Jeremy Perkins, Bleddyn Reginald Lear, David Williams. Affiliate: Richard Robert Will. Students: Angus David McElwee, Clive Renard Archer, Peter Andrew Locke. MEMBER TRANSFERRED TO A HIGHER GRADE From Graduate to Associate Member: Patrick James Burns. I welcome the newly elected members to the Institute and congratulate the member who has been transferred to a higher grade." (Applause). GENERAL BUSINESS The President reminded members that a buffet supper at a cost of 55c would be available after the meeting. PAPER FOR PRESENTATION The President noted with pleasure that a strong contingent from De Beers and the Finsch Mine were present. He expressed gratitude to Mr Loftus for coming

By G. Nino de Guzman, L. C. Woollacott

The isotherms that are usually taken to represent the force &apos;driving&apos; the adsorption in carbon-in-pulp processes may change from contactor to contactor. This paper reports on an investigation into the extent to which this Isotherm shift is Influenced by the changes in oxygen and cyanide concentration that occur in operating plants. The impact of the isotherm shift on the reliability of simulation results is examined.

Jan 1, 1993

By T. Bednarski, L. Thomas, G. Banza, D. Muteba, P. Cole, M. Soderstrom

"In copper solvent extraction, aqueous-in-organic entrainment results in the carry-over of unwanted species into the electrowinning process with negative cost implications. The need to bleed is increased and the purity of the copper cathode is potentially compromised, depending on the impurities being transferred (Cl, NO3, Fe, Mn). In some cases, entrainment results in elevated levels of manganese in the electrolyte which can cause oxidative conditions to develop and degradation of the organic phase. Degraded organic phase detrimentally affects the physical performance of the copper solvent extraction process, contributing to even higher aqueous-in-organic entrainment. Aqueous entrainment may be minimized through good operating practices and maintenance of the organic quality, but the accurate measurement of entrainment remains a challenge. This paper presents coalescing devices designed to provide more exact measurements of aqueous-in-organic entrainment. IntroductionMany copper solvent extraction (SX) plants experience high aqueous-in-organic (A-in-O) entrainments but are unaware of the extent of the problem because entrainment is often not measured. Aqueous entrainment results in the carry-over of unwanted species into the electrowinning (EW) process and the need to bleed to maintain acceptable concentrations in the electrolyte. The costs associated with the bleed are exacerbated in copper plants where aqueous entrainment levels are high. Other than these direct costs, there are operational consequences of the build-up of certain species in the EW circuit that can have deleterious effects on plant performance.Minimizing aqueous entrainment in operating plants requires an understanding of the factors that affect entrainment levels. Both chemical and operational influences are discussed in this paper. The difficulty of obtaining a representative sample makes it challenging to obtain an accurate measure of aqueous entrainment from a continuous process like SX. Coalescing devices used to get a more precise measurement of A-in-O entrainment are useful to complete mass balances around the SX circuits. Alternatively, mass balances can be used to estimate aqueous entrainments and are helpful as a tool to troubleshoot operations with a view to improving plant performance."

Jan 1, 2016