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By M. Sephton

Slat-band chains, currently manufactured from Type 430 ferritic stainless steel, are used as conveyors in various industries. A process to strengthen these chains?with the aim of prolonging the lifetime of the conveyors?was developed recently. The process entails heat treating the cold-worked chain at 475°C,strengthening the material by precipitation of the Cr-rich phase a? at relatively long periods of aging. In the present work, it was found that increasing the interstitial content by solution heat treatments (at 880°C or 930°C) prior to cold rolling and aging, causes an increase in strength at shorter aging times as a result of the precipitation of chromium-rich carbides and nitrides. The solution treatments can introduce martensite into the microstructure if carried out at a sufficiently high temperature. This, along with the deformation caused by cold work, also increases the strength. Corrosion resistance is not affected by the treatments, but ductility is lowered. However, calculated critical crack lengths indicate that solution treatment at a temperature below the Ac1allows for a larger critical flaw size, and that the lifetime of the chains will probably be determined by fatigue. Although the duration of the service of the chains are reportedly controlled by wear, with these treatments the tensile strength of the material is increased to within acceptable limits for conveyor chains. The tensile strength is an indication of the wear or abrasion resistance of a material. It is expected that after the treatments, the wear resistance will be improved, but since embrittlement occurs, the fatigue resistance is lowered. It is concluded that the preferred processing route for the chains would be solution treatment at 880°C, fast quenching to trap the interstitial atoms, cold rolling and then aging at 475°C for 8 minutes.

Jan 1, 1997

By P. J. van der Walt

Some 30 years ago exposure to dense-medium separation in South Africa, culminated in the adaptation of the process for the treatment of -0.5 mm fines. The first commercial plant at Greenside Colliery apparently operated for some 18 years. Three further plants followed, including one treating tin ore. It is gratifying to learn, therefore, that there is renewed interest. The objective of making the process easier to operate (?more practical??) is commendable but the cumbersome technical approach could be counter productive. Perhaps a brief outline of the original thinking might be helpful when analysing the problem.

Jan 1, 2003

The results of a series of physical model studies of the stability of jointed rock slopes carried out some years ago are described. These models were tested under centrifugal loading. Four ?geological? structures were tested; all had the same joint orientations and strengths, but the relative spacing of the joints was different. The results showed that the mechanisms of failure of the slopes varied for the different models, and the gravitational loads at which failure developed also varied. The following conclusions are drawn from the results of the physical model tests: ?the mechanism of slope failure is by progressive deformations throughout the slope ?the ratio of the spacings between the different sets of discontinuities exerts considerable influence on the slope failure ?in the models tested, the intact material strength had no noticeable influence on the stability of the jointed rock slopes(note that for hard rock, similitude conditions indicate a prototype slope height of 300 to 400 m, and therefore intact rock failure might not be expected under simple gravity conditions, i.e. no tectonic stresses) ?rock slope failures are three-dimensional and in general are not amenable to two-dimensional simplification ?knowledge of the orientations of discontinuities in the slopes does not allow prediction of a unique failure surface, nor of a volume of failure. The volume of failure is determined to a large extent by the plan configuration of the slope.

Jan 1, 2006

By M. Bhandari, D. Norval

The bulk of plain carbon steel is produced through conventional Basic Oxygen or Electric Arc Furnace routes where the development of the AC Ladle Furnace has made it possible to also produce alloy steels. Smaller Ladle Furnaces have limitations such as lower efficiency; high electrode consumption and diminutive yields rendering them uneconomical to operate and making the processing of low carbon steel grades difficult due to carbon pick up. The demand for special steels and alloys with strict specifications is increasing while commodity prices remain competitive. The production of special steels and alloys have specific process control requirements and the development of the induction melting furnace (IMF) has made it possible to produce smaller batches economically. Refining and alloying of the melt in the IMF further enhance the efficiency. The INDUREF furnace offers increased productivity and flexibility through increased thermal efficiency and can be utilised for holding molten metal for further processing such as granulating, atomising, nitriding, alloy additions and desulphurisation of Ferro-alloys and steels. The system utilises a specially engineered ladle which is placed in an induction-heating assembly comprised of a stationary water-cooled copper coil and lamination packs. The addition of equipment for vacuum degassing and decarburisation of steels and alloys is also feasible. Benefits are: ? No electrode consumption or carbon pick-up ? Lower installation, operation and maintenance cost. ? No line-flicker facilitates operation on a weak power grid. ? Good power factor and balanced load ? No skull formation and reduced refractory consumption ? Higher yield of Fe-alloys ? Automatic controlled stirring

Jan 1, 2004

In constructing a financial model of a project significant effort is expended on capital and operating cost estimation, commodity price forecasts, and choice of discount rates while uncertainty in the primary input, the reserve, is often completely overlooked. The aim of this paper is to highlight the impact of uncertainty in the resource/reserve estimation process on the assessment of the financial performance of a project. Four qualitative processes have an impact on resource/reserve uncertainty. These stages are: 1.Ore definition 2.Geological interpretation 3.Resource estimation 4.Ore reserve estimation and mine planning. Each stage contains a number of tasks that may be considered as key performance activities (KPAs). Optimizing the manner in which these KPAs are completed can remove a great deal of uncertainty and error from the resource/reserve process. Examination of these KPAs within a company can also provide an insight to the quality of the information underlying the project. This will allow the company to identify any shortcomings in the data and to assess the resulting risks (Gilfillan, 1998). A hypothetical financial model based on a gold operation has been used to estimate the potential effect of resource/reserve uncertainty on revenue. Monte Carlo simulation has been employed to simulate a number of hypothetical scenarios: 1.a base case scenario which assumes no major errors or biases, but contains realistic margins for uncertainty that would exist in any project where work is being completed to the limit of best endeavours 2.a poor sampling scenario which assumes poor sampling practice and lack of understanding of sample preparation 3.a poor resource estimation scenario which assumes poor modelling and inappropriate choice of interpolation technique, and 4. a ?typical? scenario which represents a project where the majority of KPAs are not performed as best as they could be. The results show that realistic uncertainty ranges can generate changes in the estimate of potential revenue of plus or minus 30%.Therefore, it is important to allow for errors in these processes in any financial analysis or feasibility study. It is recommended that, when building a financial model, are view of relevant resource/reserve KPAs be carried out and appropriate ranges for uncertainty be applied to provide a range of potential outcomes. These outcomes can then be factored into the detailed cash flow analysis in order to ensure that technical uncertainty is built into financial decisions.

Jan 1, 1999

By D. J. Greeff

By making use of genetic programming, empirical models for metallurgical processes can be evolved that are more cost-effective than models determined by means of classical statistical techniques. These methods explore populations of candidate models assembled from sets of variables, parameters and simple mathematical operators, and do not require explicit specification of model structures. The application of the proposed strategies is illustrated by means of a case study pertaining to the leaching of nickeliferous chromite ores. Modelling of the nickel and cobalt extraction from the ores yielded models of similar accuracy compared to those obtained by non-linear regression and artificial neural networks. However, in the case of the iron extraction from the ores, the genetic programming model was significantly more accurate than both the regression and neutral network models.

Jan 1, 1998

By C. Kasatuka

Globalization creates investment opportunities for enterprises around the world. Attracting foreign investment has been a key challenge for economic growth in developing countries. Corruption, political instability, armed conflict, and other internal problems affect foreign direct investment (FDI) inflows negatively. A framework of criteria provides a basis for comparing non-commercial risk (NCR) among twenty-three mineral economies. Countries competing for foreign direct investment inflows are ranked from least to most risky. This study compares Inward FDI Performance Index (IND) with NCR ratings in developing countries and shows that risk is increasingly mitigated by means of appropriately structured insurance. Given the option for countries with similar mineral potential, investors will generally invest in the country that offers lower non-commercial risk. Keywords: foreign direct investment, non-commercial risk, developing countries.

Jan 1, 2006

By N. Anacleto, S. Ganguly

Reduction of Groote Eylandt (Australia) and Wessels (South Africa) manganese ores using CH4-H2-Ar gas mixture was investigated in a fixed bed laboratory reactor in the temperature range 1000?1200oC. The extent and kinetics of manganese ore reduction as a function of gas composition and temperature were determined by on-line off-gas analysis using mass-spectrometer and dew point sensor. Morphology of ores and its change in the course of reduction was examined by optical and scanning electron microscopy. Phases of raw materials and reduced samples were analysed by XRD and EPMA. Manganese oxides were reduced to carbide Mn7C3. High extent and rate of reduction by methane-containing gas in comparison with carbothermal reduction were attributed to high carbon activity in the reducing gas, which was in the range 15 - 50 (relative to graphite). The reduction rate of Wessels manganese ore increased with increasing temperature. Reduction rate and extent of Groote Eylandt manganese ore achieved maximum at 1050oC. The decrease in rate and extent of reduction of Groote Eylandt ore at higher temperatures, particularly at 1150-1200oC, was due to sintering and formation of semi-liquid silicate slag. The optimum conditions for the reduction of manganese ores were established as follows: a) temperature: 1150-1200oC for Wessels and 1050-1100oC for Groote Eylandt ores, b) methane concentration: 10-15 vol%, c) hydrogen concentration: above 30 vol%, (d) size: 1-3 mm. An addition of lime (10-15 wt% CaO) to the Groote Eylandt manganese ore increased melting temperature of slag and significantly increased the rate and extent of reduction at elevated temperatures.

Jan 1, 2004

The acoustic signals emitted from a laboratory-scale ball mill were used for the estimation of the comminution of two complex sulphide ores, viz. Merensky and UG2 ores from the Bushveld Igneous Complex in South Africa. The digital acoustic signals were transformed to power spectral densities that could be related to particle size distributions (-75 µm to 4000 µm) in the mill by use of continuum regression. This approach is more general than principal component regression methods or Kalman filtering used previously and resulted in significantly more accurate calibration in the case of the Merensky ore, where approximately 93.4% of the variance in the particle size distributions could be explained. With fewer data available, the variance in the particle size distributions in the UG2ore could be explained less accurately (82.4%), but still satisfactorily. In addition, smaller particle sizes (less than 300 µm) could be modelled more accurately in the case of the UG2 ore.

Jan 1, 2000

By H. J. Glass

Collection, preparation, and analysis of blasthole chippings is expensive. Frequently, interpolation of grades at unsampled locations is considered using techniques like kriging. A pre-requisite for kriging is that an experimental variogram is established. In order to assess the quality of the experimental variogram, a measure is developed in this paper. The measure is derived from analysis of the time-honoured expression relating the variance, semivariance, and covariance. It reflects the weighted average deviation of the summed semivariance and covariance from the biased variance. The proposed measure allows assessment of the influence of key variables on the quality of the variogram. Using simulated data, it follows that the quality improves with an increasing number of samples, increasing density of the sampled locations, increasing regularity of the sampling pattern, and increasing uniformity of grades in the absence of correlation. Application to real data shows that the minimum number of samples could coincide with a marked decrease in the value of the measure. Establishing a threshold value is subject to further research. Keywords: variogram, variance, covariance, semivariance, minimization, sampling.

Jan 1, 2003

By M. A. Amarante

Beneficiation studies were conducted on a Portuguese feldspar ore, in order to obtain final products capable of being used in the ceramic industry. A simple scrubbing operation is enough to break the lumps in the feed. The ore deposit contains ca 35 x 106tonnesfrom which, by screening, three main products could be obtained. This paper focuses on the beneficiation of the 500/74 µm fraction, which constitutes about 27% of the ore, assaying 9.42% Al2O3,equivalent to approximately ca 46% feldspar, with a mean iron content of 0.29% iron oxides. Magnetic separation and froth flotation testwork was carried out, in order to decrease the iron contamination and increase the feldspar content. Magnetic separation alone decreased the iron content of the feed to values between 0.04 and 0.08% iron oxides with an average yield greater than 90%. Flotation with HF, provided a feldspar recovery of 45?46% with a concentrate assaying 17.6% Al2O3. The use of H2SO4, gave a recovery of 35?36% of feldspar concentrate, assaying 16.1% Al2O3. However, economic and environmental advantages of using sulphuric acid may compensate for the lower mass recovery. The iron content of0.12% iron oxides in these concentrates, could be reduced to 0.04?0.05%, by further magnetic separation.

Jan 1, 1997

By A. More, J. Bullón

Metal casting is one of the most important operations in ferroalloys factories. After the tapping of the furnace and the depuration of the metal, the preparation for customers with cooling, crushing and sizing begins. In total production costs, this contains around 8 % of the total cost of the metal, depending on the value of the fines and other important parameters. From an investment point of view, this represents around 20% of the total capital for a new furnace. Casting onto a water-refrigerated copper plate is not new for molten metals. In steel, continuous casting machines are normal in every factory. Water granulation casting exists at some ferroalloys plants. However, the majority of plants and production technology still use the technology of lumping, crushing and sizing. This technology is time consuming, produces fines and requires a relatively large work force. In 2001, Ferroatlantica put into operation a new water-cooled copper casting-machine, which seems to be a very convenient solution to solve all these problems. It is in operation at a silicon factory; the same place where the new ELSA electrode was developed for silicon metal production. This paper describes our experiences using it.

Jan 1, 2004

By S. Sarac

In this study, graphical and mathematical methods used to determine operating points in single or multiple fan ventilation systems are summarized. The problem is mathematically formulized for parallel connected fans in which analytical solutions are not possible. For n number of parallel connected fans, a non-linear equation system that consists of n number of non-linear equation sis derived. The Newton-Raphson method, which is a numerical analysis method, is adapted to solve this non-linear equation system and the solution steps are given as an algorithm. A computer program based on this algorithm is written and its applicability is proved.

Jan 1, 2000

By M. -O. Suk, S. -K. Jo, S. -C. Shim, J. T. Kim, S. -H. Kim, C. -W. Seo, J. -S. Kim

An equilibrium study was carried out at 1873 K to ascertain the effect of carbon in CaO-SiO2-Al2O3-MgO-MnO-FetO slag systems on their FetO and MnO activity coefficients, representing the slag?s thermodynamic potential for steel reoxidation. Both ?FetOand ?MnO showed not only a sharp increment, but also a simultaneous slow decrement by increasing carbon content in slag, suggesting opposite roles of the carbon according to its stable forms. XPS (X-ray photoelectron spectroscopy) was introduced to clarify the stable forms of carbon in slag. XPS results prove that carbon dissolves in slag as carbonate, and carbide ions under oxidizing and reducing atmospheres, respectively. It was concluded that carbonate ions increase ?FetOand ?MnO, and that carbide decreases them. This paper suggests an application method of the present results to actual ladle refining processes, in order to enhance steel cleanliness without decreasing (FetO + MnO) content in slag. Keywords: carbon, slag, activity coefficient, FetO, MnO, carbonate, carbide, XPS, reoxidation, cleanliness

Jan 1, 2004

By R. Scott

This article describes and evaluates the establishment of Kuyasa Mining including the search for a suitable deposit, the ongoing lack of finance, and market constraints. Despite the dramatic initial growth and success of their Ikhwezi Colliery near Delmas, Mpumalanga, Kuyasa?s experiences offer some sobering arguments for significant changes to mineral rights ownership, the attitude of financial institutions and government policy if South Africa is to have a dynamic and successful junior and small-scale mining sector.

Jan 1, 1998

By M. Q. W. Jones

This paper summarizes important features of a compilation of thermal properties of stratified rocks from Witwatersrand gold mining areas. The database consists of more than 1000 thermal conductivity measurements, more than 700 density measurements, and nearly 100 heat capacity measurements. Most important rock types and stratigraphic units are well represented. Heat capacity does not differ significantly from one rock type to another, and density is relatively uniform although particular rock types are characterized by distinct average values. Different rock types also have distinct thermal conductivities, but this parameter varies by a factor of four to five. Primary factors controlling the thermal properties are mineral composition, degree of metamorphism, and porosity. In addition, the temperature dependence of thermal conductivity and heat capacity of quartzite may significantly decrease the thermal diffusivity of this rock at deep mining levels.

Jan 1, 2003

By S. Mundike

A scraper-based block cave method has been successfully applied to extract the Lower orebody at Nchanga since the 1950s. Since inception, scraper drifts and service ways have been supported using steel arch sets fabricated to a specific design from high strength manganese steel To reduce costs and to improve productivity, trials commenced in 2002 using fibre reinforced shotcrete as an alternative support method. One of the areas, the 2420 8E 1C trial drift, was subjected to abutment loading for several months prior to undercutting and cave mining. Shotcrete installed exhibited minor cracking shortly after application but very little deterioration thereafter. Following the success of the trial, the application of fibre-reinforced shotcrete was extended to other drifts. This paper describes the application of fibre-reinforced shotcreteat Nchanga and outlines design and quality assurance methods employed.

Jan 1, 2005

The slags produced by the Imperial Smelting Process (ISP) are based on the system ZnO-?FeO?-Al2O3-CaO-SiO2. The slag chemistry is important to the process since it determines the fluxing practice and the operating temperature of the furnace required to produce fluid slag. The paper presents the results of the first systematic experimental investigation of these ZnO-containing slags in equilibrium with metallic iron, and provides information on the primary phase fields and liquidus temperatures in these slags over the range of compositions used in ISP practice. A feature of the slags is the presence of alumina, which has a major influence instabilizing the spinel phase. This information presented in the form of pseudo-ternary sections ZnO-?FeO?-(Al2O3+CaO+SiO2) enabling the data to be readily used by plant engineers. Keywords: liquidus temperature, ISP, EPMA, ZnO-?FeO?-Al2O3-CaO-SiO2, phase equilibria.

Jan 1, 2004

By T. E. Pogue

This paper traces the co-operative initiative undertaken by South Africa?s gold mining companies through the Chamber of Mines Research Organization (COMRO) in development of hydraulic technologies. After a brief description of the structure of these technologies? development under COMRO?s stewardship, the paper turns to an overview of the structure of innovation within which these hydraulic technologies were developed. A central focus of this paper is systematic review on whether similar technologies are likely to emerge in the present system of innovation and the role played by innovation policy.

Jan 1, 2006

By A. F. S. Schoukens

The Mintek Thermal Magnesium Process (MTMP) was successfully demonstrated in November 2004. The pilot plant was operated continuously for 8 days, during which about 30 tons of magnesium producing recipe was smelted in a DC (direct-current) arc furnace at a feed rate of 525 kg/h. The furnace was operated at power levels of 700 to 850 kW, resulting in slag tapping temperatures of 1600 to 1700°C. Magnesium extraction averaged 77 per cent and was as high as 85 per cent during good extraction periods. The furnace generated 70 to 85 kg/h magnesium vapour that was delivered to the condenser where the temperature was controlled at 680 to 720°C. The novel condenser captured the magnesium in a liquid state, which was tapped periodically as required. In total, 15 magnesium-tapping operations were carried out, proving that online magnesium tapping can be consistently performed without any major difficulty. About 3500 kg of crude magnesium was produced with a quality that was similar to, if not better than, that of the Magnetherm?s crude metal. The condensation efficiency averaged 85 per cent, and peaked at 87 per cent, which exceeded the target of 80 per cent set for the pilot scale. A brief magnesium market study was also carried out. Magnesium demand is expected to keep on growing by 6 to 8 percent over the next 10 years and could reach 2 million tons by the year 2020. The growth will be mainly in the die-casting sector for light-weight automotive applications. China is likely to remain the dominant supplier of primary magnesium but competitively priced non-Chinese magnesium producers will be needed to sustain the anticipated growth of 6 to 8 per cent over the next 10 years. In addition, a prefeasibility study was undertaken for a commercial plant. The study confirmed the relatively low capitalcosts of the MTMP process, as well as the competitiveness of theoperating costs, as compared to the industrial electrolytic process.

Jan 1, 2006