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By Lene Hansen

Sulphuric acid plants now and then see unexpected increases in SO2 emissions. Our experience is that it is not always easy for the acid plants to pin point the exact reason for the SO2 increase. Sometimes a catalyst bed is sacrificed even though reliable emperature readings and gas analyses could have verified satisfactory activity, hence the leaking heat exchanger is never discovered and after the shutdown the SO2 emissions are still too high. This paper will look into some basic catalyst management tools: Good record keeping is a necessity for collection of representative catalyst samples, reliable operating data is an inevitable starting point for all analysis and trending of operating data is a must for plant optimisation and troubleshooting. In addition these catalyst management tools will give a continuous updated knowledge of the catalyst status in each bed providing the basis for a more effective replacement strategy. The most typical reasons for increasing SO2 emissions will be presented together with easy guidelines for cross-checking of operating data, temperature optimisation and good record keeping.

Jan 1, 2009

By Lene Hansen

Sulphuric acid plants now and then see unexpected increases in SO2 emissions. Our experience is that it is not always easy for the acid plants to pin point the exact reason for the SO2 increase. Sometimes a catalyst bed is sacrificed even though reliable emperature readings and gas analyses could have verified satisfactory activity, hence the leaking heat exchanger is never discovered and after the shutdown the SO2 emissions are still too high. This paper will look into some basic catalyst management tools: Good record keeping is a necessity for collection of representative catalyst samples, reliable operating data is an inevitable starting point for all analysis and trending of operating data is a must for plant optimisation and troubleshooting. In addition these catalyst management tools will give a continuous updated knowledge of the catalyst status in each bed providing the basis for a more effective replacement strategy. The most typical reasons for increasing SO2 emissions will be presented together with easy guidelines for cross-checking of operating data, temperature optimisation and good record keeping.

Jan 1, 2009

By Z. Botha

Sheryl Sandberg, the COO of Facebook, published a book titled 'Lean In', where she invites women to sit at the table. In summary, to 'sit at the table' entails not only embracing opportunity, but to actively seek out opportunities in leadership positions. Sandberg points out that, unfortunately, apart from institutional obstacles, a woman's own perceived limitations have a negative impact on her leadership ambitions. To create an environment where diversity will flourish, where everyone has a seat at the table and everyone has a voice, safety must be established first. To establish safety within a diverse team, there is power in relationships and connections. This study will first and foremost review theories in literature as to why diversity and inclusion are so important and the value that diversity brings to our industry. The study also recommends a few focus areas for improving diversity and inclusion in the industry.

Sep 1, 2022

By A. Ndibalema

Blasting is one of the primary functions in any mining operation. Despite the fact that it generally constitutes between 30% to 40% of the mining cost, blasting also affects the cost-effectiveness of down steam activities such as load and haul, safety, tyre life for haul trucks, crushing and milling. Over the past three decades, significant progress has been made in the development of new technology in an attempt to reduce costs and increase efficiencies and productivities of blasting activities. Mine to mill project concepts have paved the way for such developments. Other advancements have included sophisticated computer modelling technologies for blast design and performance analysis. There are many factors that affect the cost of blasting. These can be divided into two categories; controllable and uncontrollable. The latter includes costs related to depreciation, exchange rates and government legislation with the former category including contractor versus owner blasting costs, efficiency and productivity issues and product quality. Controllable factors have one common denominator which can determine their outcome; direct site management influence. Excavator digging rates and final floor conditions give a good measure of blasting performance, and alternatively cost effectiveness. This paper is aimed at benchmarking against a blast optimisation database, understanding the relationship between costs and identifying opportunities for improvement. Understanding the cost drivers allowed a typical cost model to be developed for the current mining operation at Geita and this was used to drive continuous improvement with emphasis on closing the information loop.

Jan 1, 2008

By G. Akdogan, S. M. Bradshaw, A. P. Van Wyk, T. Punt

Recycling has become an important part of the lithium-ion battery (LIB) life cycle due to the growing demand for energy storage in applications like electric vehicles and renewable energy. Recycling spent LIBs provides a secondary source for strategically scarce metals, like lithium and cobalt, helping to reduce the environmental impact of LIBs. Organic acids have been proven to be effective lixiviants with the benefit of reduced environmental impacts, amongst which citric acid has shown to exhibit similar extraction performance when compared to mineral acids. Leaching LCO and NMC batteries with 1.5M citric acid and 2 vol.% H2O2 at 95°C, 20 g/L for 20 minutes achieved 93% Al, 90% Co, 96% Li, 94% Mn and 94% Ni dissolution. The strong chelating property of citric acid affects the separation of the metals, providing unique extraction opportunities. The first extraction uses 12 vol.% D2EHPA at a pH of 2.5 and O/A ratio of 2 to separate 96.4% Mn and 100% Al from the PLS in two counter-current stages. Stripping the loaded organic with 1.25M citric acid at an A/O ratio of 3 allows for up to 91% stripping of the manganese in a single stage. The second extraction then separates 96.5% Li from the PLS in three counter-current stages using 20 vol.% D2EHPA at a pH 5.5 and O/A ratio of 5. The raffinate remaining after the second separation contains 48.4 wt.% Co and 50.3 wt.% Ni. Keywords: Hydrometallurgy, lithium-ion batteries, metal recycling, citric acid, solvent extraction

Jan 1, 2020

By N. B. Devi

The extraction of Cu(II) from HCl media using Cyanex 923 in kerosene was investigated. The effect of shaking time, aqueous phase acid concentration, extractant concentration, chloride ion concentration, various metal ions (Mn2+, Mg2+, Fe2+, and Ni2+), and temperature on the extraction were studied. Using 0.1 M Cyanex 923 the extraction of Cu(II) was 6.7 per cent from 3 M HCl, which increased up to 78.5 per cent with 6.5 M HCl and then decreased due to acid extraction by the extractant. The maximum extraction (97.5 per cent) was obtained with 1 M Cyanex 923 from 5 M HCl solution. A mathematical model has been developed to describe solvent extraction equllibria over wide ranges of concentration of extractant, acid, and chloride ions. The composition of the extracted species has been predicted on the basis of slope analysis results and extraction equilibrium modelling. The negative values of enthalpy change and entropy change confirm the exothermic formation of the extracted complex.

Jan 1, 2012

By D. Vogt

"Rock has been cut in the process of mining since before the invention of explosives. Today, we seek to return to cutting to reap the benefits of continuous operations for South African underground hard-rock mines, to improve speed of access to the orebody, and to improve the efficiency of mining operations.Development of new technology fits within a framework of engineering knowledge. By understanding the characteristics of the rock, the tools we use to cut it with, and the history of mining and rock cutting, we can see the genesis of the road-header, the longwall, and the continuous miner, all drag bit cutters. They have emerged as the solutions of choice for underground mining of softer materials such as coal and potash. In hard rock, the challenges are the forces required to break the rock, and the wear of the tools caused by the rock’s abrasiveness. Only disc cutters currently handle the challenges, and even then, often not economically. New materials like thermally stable diamond composite will help, as will combinations of mechanical cutters and other methods such as high-pressure water or high temperatures.It is not clear what will emerge as the consensus technique for hardrock cutting. Experience teaches that development is expensive and the market is small. Will mining companies partner with equipment developers to make the technological leap? Or will the solution come from a systems approach, not considered here?IntroductionBlasting is the dominant method of breaking rock for the purposes of mining. When used underground, blasting is part of a batch process. If rock can be cut rather than blasted, mining can become continuous, leading to process and efficiency improvements.Coal produced from underground mines is now predominantly excavated using mechanical means, but underground hard rock is still broken primarily by explosives.This paper traces the history of rock cutting, reviews the main physical processes that are or could be used, and comments on the future. It is written from the perspective of narrow-stope hard-rock mining typical of South African gold and platinum mines."

Jan 1, 2016

By A. Fouchee, N. Naudé, K. Schommarz

"This article presents laboratory test work conducted on an African haematite ore to determine the influence of the flotation pulp pH on the final iron grade and recovery. Results show that a combination of an isodecyl ether propylene amine/amino acetate and 1,3-propanediamine, N-(3-(C10-C16-alkyloxy)propyl)-derivatives collector is suitable for separating haematite from quartz. Higher iron grades were obtained at pH levels between neutral and pH 9. This underlines the importance of the surface charge effect of the ore on its flotation characteristics. The results serve as good baseline conditions for further optimization. IntroductionBeneficiation of iron ore by flotation is widely used in Brazil, India and China. In Africa, however, this practice is not yet commercially developed.The aim of this test work is to serve as a starting point by establishing suitable pH conditions for the development of a practically implementable reagent suite, which will then be included in a larger beneficiation circuit for producing high-grade iron ore sinter feed.In the literature, African iron ore types are graded as low-grade (60.0–62.9% Fe; 8.6– 12.5% SiO2 and insolubles), high-grade (66.0– 69.9% Fe; 0.8–4.5% SiO2 and insolubles), and meduim-grade as the remaining portion (Astrup et al., 1998). The low-grade ore used in this work contains less than 60% Fe.For Brazilian ores consisting of a combination of haematite and quartz, it is common to use corn starch as a depressant and ether amine blends as collectors with additional frothing characteristic (Araujo et al., 2005). Work by Turrer and Peres (2010) shows the possibility of using other depressants successfully as well.The main mechanism of the reverse flotation of quartz from iron ore is based on the electrostatic theory of flotation. This is due to the strong pH dependence of the zeta potential of the mineral edge planes on silicate particles (Fuerstenau and Pradip. 2005)."

Jan 1, 2016

By R. P. Plasket, D. A. Ireland

Ancillary smelter operations and sulphuric acid manufacture at Impala Platinum Limited by R. P. PLASKET. Pr. Eng.. M.Sc. (Chem. Tech.). Natal (Fellow) and D. A. IRELAND. Pr. Eng.. B.Sc. (Chem. Tech.). Natal (Member) The de-watering, spray drying, and converter operations at Impala are described, aspects that may be new to the minerals industry in South Africa being elaborated. Air-pollution control necessitated the installation of a sulphuric acid plant to limit the emission of sulphur dioxide to the atmosphere. Closer control of the smelting and converting operations was required for successful operation of the acid plant on the inherently Iow and varied concentration of feed gas from converter blowing. Approximately 82 per cent of the sulphur entering the smelter is converted to sulphur dioxide, of which 67 per cent is fed into the sulphuric acid plant.

Jan 8, 1976

By M. Yavuz

Determining the most convenient plant location is one of the most commonly encountered problems in engineering applications. This paper presents a fuzzy multiple attribute decision making (FMADM) model which is developed for the selection of the optimum plant location for natural stone factories in the mining industry. The criteria affecting the decision making process in natural stone industry were determined to solve the plant location problem in the FMADM model. To determine the optimum plant location for a new natural stone factory, which is planned to be established by a mining firm located in the Eskisehir region of Turkey, an analysis was carried out by incorporating the method and the analytic hierarchy process (AHP) method. The analysis shows that the Yager?s method can easily be applied to the selection of plant location in the natural stone and mining industry when the difficulties encountered in the application process of the AHP method is taken into account. Keywords: Natural stone, plant location, decision making, Yager?s method, analytic hierarchy process (AHP).

Jan 1, 2008

By H. Cevizci

In this study, a newly developed plaster stemming method is studied and compared with the usual dry drill cuttings stemming method for surface blasting in mines and quarries. Drill cuttings are generally used in open pits and quarries as the most common stemming material since these are most readily available at blast sites. However, dry drill cuttings eject very easily from blastholes without offering much resistance to blast energy. The plaster stemming method has been found to be better than the drill cuttings stemming method due to increased confinement inside the hole and better utilization of blast explosive energy in the rock. The main advantage of the new stemming method is the reduction in the cost of blasting. In one series of blast tests, blasting costs per unit volume of rock were reduced to 16 per cent by increasing burden and spacing distances. Also, better fragmentation was obtained by using the plaster stemming method. Blast trials showed that plaster stemming produced finer material. In the same blast tests, +30 cm size fragments reduced to 5.4 per cent of the total, compared to 37.7 per cent in the conventional method of drill cuttings stemming. With this method of stemming, vibration and air shock values increased slightly due to more blast energy being available for rock breakage, but these increased values were small and under the permitted limit for blast damage criteria.

Jan 1, 2012

By B. Genc

Improving student success rates without compromising the quality of graduates is one of the biggest challenges expanding university programmes are facing in South Africa. By establishing a new Mine Design Laboratory (MDL) for higher learning in Mining Engineering, the School of Mining Engineering at the University of the Witwatersrand (Wits Mining) has achieved one of the important goals in its five-year strategic plan, i.e. to improve throughput in all years of study. Although the establishment of the laboratory has been a costly exercise, results so far have shown an improved success rate in most subjects taught in the facility. This paper outlines the design and equipment of the laboratory, the facilities incorporated, a comparison with the old laboratory, and the performance of students?all of which indicate how important it is to have proper facilities to improve the teaching of, and learning by, large classes. Through this initiative, Wits Mining has taken an important step that will contribute to addressing the skills shortages in the mining industry.

Jan 1, 2012

By E. L. Atkinson, G. W. Leach

The paper discusses the reasons for the introduction of load-haul-dump (LHD) units into Greenside Colliery, and the circumstances leading to the replacement of conventional mechanized equipment on a trial basis in the mining operations on No. 2, 4, and 5 seams. An outline is given of the factors governing the selection and introduction of these units into coal mining, and the associated mining and engineering aspects involved in the optimization of their use. Operating statistics comparing the performance of conventional and LHD equipment are included.

Jan 1, 1979

By K. A. G. Blendulf

The paper describes tests on horizontal-belt filters for the filtration of gold and uranium. The promising results led to the installation of 17 such filters (ten of them 120 m2 in size) in the mine's metallurgical plants, and their operation is discussed. Although several problems were encountered both in operation and maintenance, it is concluded that, with correct operation and suitable filter cloths, exceptionally good metallurgical recoveries can be achieved at filtration rates twice to three times higher than those on rotary filters.

Jan 1, 1997

By A. M. Starfield

Discussion J. de V. Lambrechts (Fellow): The author's paper is a brilliant follow-up of an earlier paper by Starfield and Dickson.1 I have no quarrel with Dr Starfield's computerization of a complex problem, but I do not believe that he is getting quite the right answers from his programme. My impression is that his predictions about wet bulb temperature increases in very deep mines are over optimistic; in other words, that it will be hotter than Dr Starfield predicts. This is putting my views in a nutshell. This is not the occasion on which to indulge in lengthy argument about the original paper by Starfield and Dickson, but the present paper is, after all, based directly on that earlier paper and if the one fails, the other cannot succeed. I did level certain criticisms at the first paper and cannot say that the authors' replies were very convincing. I do not think it is a sin to admit that I belong to the old school which believes in thorough field experimentation and practical trials and no amount of mathematical manipulation or physical theorizing, no matter how excellent, can make up for inadequate practical confirmation. This, as I see it, is still the crux of the matter. The original paper by Starfield and Dickson still rests on somewhat scanty practical evidence and I would be much happier if Dr Starfield's computer programme, based on the Starfield-Dickson model, had been checked against a large mass of observations in the practical mining situation. This is what both Wiles2 and myself3 had tried to do previously. What we lacked in mathematics and/or computer aids, I think the present paper by Dr Starfield lacks in practical substantiation. This is no condemnation of the author's paper which, taken by itself, is excellent but I think the final stage is still lacking, namely the bringing together of theory and empiricism in a manner acceptable to all. This may be wishful thinking on my part but I hope, within the next year or so, to come up with a modified Starfield-Dickson model in such a way that the computer answers will agree in the majority of cases with the few hundred field observations which are already on record. It might be a case of applying the proverbial 'Cook's Law' to the Starfield-Dickson model! REFERENCES 1. STARFIELD, A. M., and DICKSON,A. J. 'A study of heat transfer and moisture pick-up in mine airways.' J. S. Air. Inst. Min. Metall., 68, (5), 1967. 2. WILES, G. G. 'Wet bulb temperature gradients in horizontal airways.' J. S. Air. Inst. Min. Metall., 59, (7), 1959, p. 339. 3. LAMBRECHTS, J. DE V. 'Prediction of wet bulb temperature gradients in mine airways.' J. S. Air. Inst. Min. Metall., 67, (11), 1967, p. 595. R. Hemp (Visitor): Dr Starfield's paper has very effectively rounded off one particular aspect of the general problem of heat flow in mines. The ease with which this computer programme can be used to calculate temperature increases in horizontal airways must lead to its wider use in ventilation planning and, in developing this rapid method, Dr Starfield has indeed rendered a valuable service to the mining industry. One could consider further instances of heat flow in airways in which the availability of a rapid computer method would be desirable, e.g. the flow of air down a shaft, where there is an increase in temperature due to adiabatic compression, as well as an increase in virgin rock temperature as the depth increases. However, this particular case would not present any new problems and would merely require an extension of the exisitng work. I should like in this contribution to talk about an aspect of environmental control in mines which, I think, will become more important in the future. It is well known that wet bulb temperatures are subject to fluctuations underground. In some instances, particularly in stopes, the fluctuations, both with time and position, can be considerable. The theoretical work which has been carried out on temperature increases has been aimed at the prediction of mean temperatures, and no account has been taken of fluctuations around this mean. It is questionable whether this approach will, on its own, be sufficient, particularly when temperature increases in stopes are considered. The fluctuations in air temperatures underground arise from two causes. The first of these would be the fluctuations in surface conditions, and here one could list random, diurnal and seasonal fluctuations. The second cause is the multitude of things which vary in a mine and here one could list variations in air flow quantity, sources of evaporation, heat transfer from pump and compressed air columns and, particularly in the stope, variations in air flow patterns. Fluctuations arising from surface temperature variations should be amenable to calculation, and here one envisages figures relating the decay of temperature variation with distance to factors such as air flow quantity. Fluctuations resulting from changes in the mine are perhaps more difficult to tackle theoretically and the best approach could well be to analyse underground observations. In this connection, there is a good case to be made for the increased use of statistical methods in the analysis of underground temperature measurements, and it might be of value to look at current air-conditioning practice. When carrying out cooling load calculations for a particular location it is customary to use design wet bulb

Jan 11, 1969

By S. J. Webber

This paper reports on the use of the MINSIM-D stress-analysis program for the modeling of two large seismic events that occurred on the same fault eleven years apart. It was found that the first event (magnitude 5,2) could not be ascribed to purely mining-induced stresses, indicating that the largest seismic events probably result from the interaction of mining-induced stresses with large scale tectonic stresses. However, the stress changes induced during eleven years of mining were found to be capable of generating sufficient excess shear stress (ESS) to be responsible for the second event (magnitude 4,3), The upper limit for the magnitude of purely mining-induced events was found to be approximately 4,3.

Jan 1, 1990

By N. R. Shoko, J. Chirasha

Refractory design remains the most fundamental factor in furnace construction. Refractory design details and proven technology consideration is of paramount importance to come up with an optimum furnace life and to maintain productivity in the life span of the furnace lining. The failure to produce a technically or operationally durable refractory design lining could give rise to pre-mature deterioration of the refractory lining and furnace shell. The premature failure of the furnace lining will lead to extensive heat losses, furnace bath shift, change in taphole orientation and alteration of the Pitch Circle Diameter. A combination of these were experienced at Zimbabwe Alloys? new high carbon ferrochrome furnace. The Zimbabwe Alloys experience has shown an excellent furnace performance in the first two years of operation although signs of an anomaly showed within the first six months of the new furnace. Production slowed down due to induced problems from refractory failure causing furnace distortions impacting on the availability of the furnace and smelting capacity. This paper presents the lessons learnt, measures taken to deal with the premature failure and constraints within which the situation was managed.

Jan 1, 2007

By Pieter de Waal

The beneficiation equipment under the control of plant metallurgists exploits the differences in the physical properties between valuable and waste mineral components. In many cases, laboratory results are too late for process control and can only serve the purpose of "post" reports, the calculation of a mass balance and the issue of a quality certificate. As a result, experienced operators regularly adjust separation equipment based on the colour and texture of the various product streams in the beneficiation plant. Metallurgists quickly learn to recognise the different minerals in their ore body. The stereo microscope has been a valuable tool used by operators to quantify known mineral species. For many years it was the only practical method available for the purpose of process control and even for quality contro1. The modem spectroscope is far superior to the human eye and can rapidly detect a change in mineral composition. New generation optical scanners and digital signal processors can provide useful signals, related to mineral composition that can readily be applied for the purpose of process control. Successful case studies, covering dry in-line and slurry applications as well as in-plant fast spot analysers are presented.

Jan 1, 2014

By J. N. Van der Merwe

The South African coal-mining industry uses a uniform safety-factor formula for non-squat pillars, incorporating a coal-strength constant that was derived empirically by Salamon and Munro in the 1960s. The constant is 7,2 MPa. Since that time, collapses of pillars at relatively high safety factors have occurred in the Vaal Basin. Analysis of the post-1960s' collapses indicated that the strength constant for the Vaal Basin is 4,5 MPa. A crude method for the prediction of the minimum life span of pillars in the Vaal Basin is presented.

Jan 1, 1993

By A. Mainza

It is common practice in the mineral processing industry to use hydrocyclones for particle classification. However, classification in the UG2 platinum circuits using the hydrocyclone poses major challenges due to the differences in density between silica and chromite, the two major components of this ore. Silica,-the PGM carrying component, has an average density of 2.7 and the barren chromite component has an average density of 4.5. When conventional and flat bottom cyclone are used there is a misplacement of particles due to differences in density leading to inefficiencies in the classification by size. As a result of the density effect, coarse silica reports to the overflow, resulting in loss of recovery, and fine chromite reports to the underflow, resulting in loss of milling capacity and unnecessary production of fine chromite. A classifier based on a different concept was required in the classification of UG2platinum ore. The three-product cyclone, which is a hydrocyclone with two concentric vortex finders to produce three distinct products, has been tested in the UG2 ore application and indications are that misplacement of particles due to differences in the component densities can be minimized through the use of this unit. Industrial and pilot plant trials were conducted and indications are that the three-product cyclone can be installed to selectively produce a middlings stream that can be screened using Pansep screens to provide a screen oversize, which is predominantly coarse silica that can be preferentially reground to recover the PGM values contained in the coarse silica.

Jan 1, 2004