Search Documents

By R. P. Goel, P. N. Chaudhary, R. K. Minj

The bulk of high carbon ferromanganese produced in India continue to have more than 0.35% phosphorus since they are produced by carbothermic reduction process. The low phosphorus manganese ores are depleting fast and ferromanganese manufacturers will have no option but to use medium and low grade ores having high phosphorus content resulting in high phosphorus in the product. A systematic study was taken up at NML to solve this problem. Initially, a thermodynamic analysis was carried out for which Ba-P-O ternary predominance diagrams were constructed at several temperatures to predict the most suitable conditions for selective removal of phosphorus from high carbon ferromanganese. These conditions required a usage of a flux having a high level of basicity, moderate oxygen potential as well as low melting temperature. The experimental results showed that it was possible to remove phosphorus from high carbon liquid ferromanganese from 0.56%to 0.18% using BaCO3 based fluxes at the rate of 16-wt% of the ferromanganese charged. However, the Mn loss varied in the range of 2-5%. The objective of the subsequent study carried out at the laboratory scale was to optimize the flux consumption as well as minimize the Mn loss with effective dephosphorization by using BaO based calcined pellets instead of BaCO3 based powders. It was felt that the handling of pellets under plant conditions would be easier and also eliminate the loss of flux as a dust, which occurs when powder is added. These pellets were forced towards the bottom of the melt for better efficiency. For this purpose, a plunging system was designed and fabricated in-house that helped in reducing the flux consumption to less than 5% and also improved the kinetics of the process. The desired results were achieved within 10 minutes of the addition of the flux. The know-how is ready for transfer to interested parties and authors are willing to conduct large scale trials with them.

Jan 1, 2007

By P. L. Duncanson, J. D. Toth

Since 1995, when "freeze lining" refractory systems were introduced to the ferroalloy industry, they have gained in popularity, due to the freeze lining?s reputation for reliability, safety, and the contribution it makes to profitability. As with many popular and effective technologies, however, the freeze lining has spawned low-cost pretenders that claim the "freeze lining" name. On the surface they appear to contain some of the components of the technology, such as thermally conductive materials, but they fail to incorporate all of the principles that define a true Freeze Lining. The term "freeze lining" refers to the refractory system?s ability to maintain a temperature profile that is low enough to freeze a layer of process material on its hot face, which insulates the refractory and prevents direct contact with molten metal and slag. In doing so, the common wear mechanisms found in the submerged arc furnace - chemical attack, erosion, and thermal stress - can be prevented. These wear mechanisms are all related to high temperature; thus, they are prevented by maintaining low temperatures. Certain refractory properties and design concepts are absolutely necessary for the lining system to function as a true Freeze Lining. The paper explains these requirements and why they are important - the Truth of freeze linings - and further explains why systems that ignore one or more of these requirements cannot claim to be freeze linings, thereby exposing the Myths.

Jan 1, 2004

By FJ Fourie

This paper describes the concept and development of the use of a uni-delay shock tube system in the timing and initiation of the development rounds, specifically in flat development. It was extended from stoping and now constitutes the only initiation system is use at Kopanang mine. The two explosives initiation systems in general use in underground mines are the conventional fuse-igniter cord system, and the more modern Long Period Delay shock tube system, better known as the numbered LP system. Both are well accepted but have many drawbacks which can result in poor breaking and substantial wastage of the blasting material. Both of these deficiencies cause an increase in the cost of a blast. Hitherto, the limited number of delays available has complicated the use of shock tubes in development blasting. Over eighteen month period to the end of 2007, a project team comprising members from Kopanang Mine and AEL developed a method for the use of a uni-delay shock tubes to time any development round. These uni-delay shock tubes are better known as Reef Masters® or EZ-Stopers® depending on the supplier, and the system has particular application in flat development. During the project, two new shock tube system components were designed, tested and manufactured; namely Splitters and Starter Packs. The system has been successfully tested and implemented in both on-reef and off-reef development ends. At Kopanang, it has now been rolled out across the entire mine. Other AnglogoldAshanti mines are conducting trials and implementations into production sections. Initial results indicate improvements in the ground conditions and excavation profiles. The cost of blasting is showing a downward trend. The authors consider that the system is a tool for use in further blast optimization and will contribute to rationalization of the explosives commodities basket on mines.

Jan 1, 2008

By P. Venter, N. Naude

"Coal mining is a thriving industry and 53% of the coal mined in South Africa is used for electricity generation. Mechanization has made coal mining more efficient, but fines generation has subsequently increased. Up to 6% of the run of mine material can report to the -200 µm fraction. Common problems associated with fines handling include dust formation, storage problems, and high moisture levels. A method to turn this material into a saleable product instead of stockpiling it can add value to a company.Briquetting is a pressure agglomeration method where loose material is compacted into a dense mass (FEECO International, 2014). The briquettes must be able to withstand rigorous handling and transport operations without disintegrating. This study aims to investigate the optimum binder and moisture conditions required to produce a mechanically strong briquette using two different binders - a PVA powder (binder A) and a starch powder (binder B).It was found that for binder A the optimum moisture level was 12% to 14%. At this moisture level the greatest compression strength gains were observed, and low amounts of fines produced in impact and abrasion tests. The minimum amount of binder added while still obtaining a strong briquette was 0.5% binder A. For binder B the optimum moisture level was also 12% and the minimum amount of Binder B to be added was found to be 1%. Briquettes that were dried outside reached their peak strength after about four days, whereas the briquettes that dried inside took about 20 days to reach their strength plateau. Hardly any degradation took place on the surface of the binder A film after exposure of 300 hours of artificial weathering. Thermogravimetric analysis confirmed that neither binder A nor binder B will add to the ash content of the coal fines, as both binders totally decompose above 530°C.Binder B yielded stronger briquettes after 15 days and also generated less fines. It is therefore superior to binder A and would be recommended for further use.Paper written on final year project work carried out in partial fulfilment of B.Eng degree in Coal Beneficiation"

Jan 1, 2015

By J. Persson, N. G. Bliss

Electric furnaces used for smelting and those used for scrap melting exhibit different performance profiles in terms of electrical characteristics. However, the underlying principles are the same for either case. The rationalization of these variables is a major concern for furnace operators and designers. This paper presents the results of a two year study of high speed real time data from a number of electric furnaces around the world, covering a very wide range of design philosophy and product manufacture, to provide a better mathematical insight into rationalizing the furnace operation.

Jan 1, 2004

By C. N. Harman

Steel is the most versatile material which has made the progress in every aspect on this earth possible. There are hundreds of varieties of steel because for each application it has to be made with specific properties to get the most optimum usage. It is well known that the basic constituent of steel is iron. But it is the proportion of other elements in it, which give each type of steel certain specific properties. These elements are added in liquid iron inform of Ferro alloys to get the desired composition and properties. Thus, Ferro alloys are important additives in the production of steel. It can be said that no steel can be made without use of one or more of the several Ferro alloys. They form the backbone of steel. Thus, the Ferro alloys industry is vitally linked for its growth and development to that of the steel industry. Ferro alloys industry in India has never been globally competitive, despite its rich ore deposits and low-cost manpower, essentially due to a) Insufficient availability and high cost of electric power b) Increasing ores and reductants cost c) Non-availability of low ash, low phos. coking coal in the country for the production of desired coke with low ash, and low phos. contents, making import of such coke at a high cost imperative d) High-cost and insufficient infrastructural facilities (both road and rail) for rapid transportation of ore from mines to plants e)Stiff competition from producers and exporters of Ferro alloys in other countries like South Africa, Kazakhstan, China, Russia, Australia etc. due to global trade agreement which has made drastic reduction in customs duty on imports necessary. f) Wide fluctuations in the International price of Ferro alloys depending on demand versus supply. To over come these challenges plus adhering to stringent pollution control norms innovations are inevitable in the process technology, and plant equipment design, along with frequent changes in product mix, to be more cost-effective. An attempt is made in this paper to address the innovations that took place in the past and those that further need to be made, considering the future of this industry.

Jan 1, 2007

By W. W. de Graaf, M. J. Ntsekhe

Klipspruit Colliery is experiencing coal losses, which leads to a negative impact on coal production and subsequently loss in revenue. This study aimed to identify the possible causes of coal losses in the No. 4 upper and lower seams. The objectives were to identify potential sources of coal losses through a literature survey, to identify areas where the coal losses occurred, to determine factors affecting coal losses, and to identify the most cost-effective methods to reduce coal losses. Highwall losses, top-of-coal losses, and coal edge losses were identified as the major areas of coal loss at Klipspruit. These losses were mostly attributed to the drilling and blasting practises of the pre-split, interburden waste, and the coal seams. Recommendations include re-visiting the current pre-split design and the tolerances adopted for the interburden and coal seam drilling and blasting design. It is furthermore recommended that Klipspruit implement a continuous improvement plan for the drilling and blasting and refresher training for the blasting crew and operators.

Jun 10, 2024

By K. Kasas, J Kermeci, S. Vujic, S. Secei, P. Kermeci

On the ‘Majdan III’ open pit mine, supplying with brick clays the production plants of the industry of building material ‘Potisje-Kanjiza’ from Kanjiza, a modern ECS (excavator-conveyor-spreader) complex was built, integrating four bucket excavators, six conveyors and one spreader into a whole. This complex connects the mineral-exploitation unit with the final brick-products plant of the company. Monitoring and management of the ECS complex is carried out by modern computer-supported information-management system (IMS) implementing most modern measuring-regulation, computer and GPS equipment. It was concluded that, for safety reasons, the functions of the IMS should be developed by a component of active visual monitoring of the ECS complex. For this purpose, the task of making a project on intelligent system for visual monitoring of the ECS complex was entrusted to the Department of Computer Application at the Faculty of Mining and Geology, University of Belgrade. This paper gives a review of basic project solutions. Keywords: Automation, process management, information management technology, visual system, intelligent systems, TV monitoring, surface exploitation, clay, Majdan III, Potisje-Kanjiza.

Jan 1, 2003

By M. H. Farjadi, J. Azari

Cost analysis of chrome ore reduction is one of the important issues facing ferrochrome producers in today?s competitive environment. Much of this depends on quality and various ratios in the actual ore. The latter can have a direct bearing on electricity consumption and optimum efficiency of the furnaces. While the industry has been successful in reducing costs by designing larger and more efficient furnaces, the role of the optimum blend of ore has perhaps been given less emphasis. This paper will discuss the general specification and metallurgical characteristics of various chrome ores for producing high carbon ferrochromium on industrial scale. By analysing the results obtained from smelting, including chromium recovery and energy consumption, the determining parameters in total cost of ferrochromium i.e. chrome ore; reductant and energy consumption can be optimized. Our study is based on actual experiences obtained from Faryab Ferroalloy Plant over a period of approximately three years.

Jan 1, 2004

By C. G. Anderson

"As demand for copper and precious metals continues to grow, the need to develop new supplies increases. In the imminent future, the new large global ore bodies are more complex, with enargite, tennantite and tetrahedrite as the abundant contained mineralogy. These resources also contain considerable gold and silver. As such, direct treatment by conventional smelting is prohibitive due to the potential environmental impacts and copper quality issues. This paper outlines the effective application and associated economics of industrially proven Alkaline Sulfide Leaching (ASL) hydrometallurgical technology to an enargite concentrate for selective removal and recovery of arsenic, antimony, gold and silver, leaving a clean high-grade copper concentrate. The fundamentals behind the technology are described, along with those of hydrometallurgical arsenic fixation and stabilization. Flowsheets and unit operations are elucidated, along with an in-depth economic analysis. INTRODUCTION Hydrometallurgical methods can be employed for treatment of gold-, arsenic-, antimony-, tin- and mercury-containing materials, concentrates and ores, as well as complex ones containing any number of metals (Conner & Anderson, 2013). The alkaline sulfide leaching (ASL) system is one of these. It is essentially a mixture of sodium sulfide and sodium hydroxide with other meta-stable alkaline species as required. This is a unique hydrometallurgical system beause it is a very selective lixiviant for the distinct leaching of tin, gold, antimony, arsenic, tellurium, silver and mercury (Anderson, 2000, 2001a, 2001b, 2002, 2003, 2012, 2014; Anderson & Twidwell, 2008a, 2008b, 2010; Anderson et al., 2004, 2005; Glazkov & Tseft, 1961; Gnatyshenko & Polyvyanni, 1961; Nadkarni et al., 1975; Nadkarni & Kusik, 1988; Polyvyanni, 1963). Worldwide, ASL technology has been employed industrially in the former CIS, China and the United States for the production of antimony (Anderson et al., 1992, 1994; Anderson & Krys, 1993; Holmes, 1944; Kaloc, 1967; Nordwick & Anderson, 1993; van Stein, 1971)."

Jan 1, 2015

By T. Lindstad, V. Myrvågnes

In the production of high silicon alloys, carbonaceous materials like coal, coke, charcoal and woodchips are utilized as reducing agents. Primarily based on historical prices of charcoal compared to fossil reduction materials, the Norwegian Ferroalloy Industry has mostly been using coal and coke (char) as carbon source. The most important role of the carbonaceous material is to react with the SiO gas to produce SiC. The ability of the reduction materials to bind SiO gas can be measured and the value is recognised as the reactivity of the carbon source. This reactivity is one of the most important parameters in the smelting process in order to obtain a high yield of metal. The reactivity of the carbon materials is directly correlated to the material properties. It is known that the rank of the coal influences the SiO reactivity where low rank is beneficial. Coals of the same rank have however proven to have varying reactivity. In order to investigate how the micro-constituents of coal influence the reactivity towards SiO gas, three single seam unwashed coals of different origin which fulfil the requirements of the Norwegian Ferroalloy producers have been chosen. As the structure in the carbonized product is a function of petrographic constitution and carbonization parameters, the coals have been separated into different density fractions. The various density fractions of the same coals proved to have significantly different petrographic composition. The coals were carbonized according to a procedure simulating the conditions the coals experience when charged to an industrial furnace. Chemical-, physical- and petrographical properties of both the coals and the resultant chars have been thoroughly examined and correlated towards the SiO reactivity.

Jan 1, 2007

By C. Lottering

Copper sulphate solutions are produced during the pressure leaching of first-stage leach residue in a typical base metal refinery process. Apart from impurities such as selenium and tellurium, this leach solution also contains other precious metals (Rh, Ru, and it) due to dissolution in the pressure leaching stage. Selenium and tellurium are removed from the leach solution by precipitation with sulphurous acid, since these elements negatively affect electrowinning. This study investigates the feasibility of modifying the Se/Te precipitation process step to achieve significant rhodium precipitation in addition to selenium and tellurium precipitation, in order to reduce the rhodium inventory of the process. Thiourea, S02, formaldehyde, formic acid, and sodium thiosulphate were evaluated to determine which of these reagents would achieve the highest Rh precipitation. Based on these screening tests, SO2 and thiourea were selected to be used as precipitation reagents in optimization tests. During these optimization tests, the operating temperature (80 to 150°C) and the amount of reagent added (80 to 140 per cent excess) were varied to evaluate the effects that these operating conditions have on the precipitation behaviour of Rh as well as Se, Te, Cu, and Ni, and to propose appropriate operating conditions. It was found that thiourea resulted in good Rh and Se precipitation (typically in excess of 90 per cent), but precipitated noticeably more copper and nickel from the solution than when SO2 was used. In addition, thiourea had poor Te removal characteristics. SO2 achieved a maximum of 70 per cent precipitation of the rhodium. Faster kinetics and a larger extent of Te precipitation were, however, observed when using SO2 compared to thiourea.

Jan 1, 2012

By J. Drzewiecki, J. Kabiesz

Coal mining using longwall methods of mining can lead to intense disturbances of undermined roof strata. The disturbances may extend beyond the extraction area and the resulted rock mass deformations will appear differentiated. In the case of stiff and undermined roof strata, the energy stored in these rock masses may be frequently dissipated in the form of high-energy seismic tremors. Such events can occur if these strata should fail or „free themselves” either from the constrainment of rock environment or from adjacent strata. It has also been found that the amount of the stored energy closely depends on the size and/or slenderness of these strata. Thus, it would be possible to apply specific preventive measures to reduce the energy of mining – induced seismic tremors. The methods are based on artificial disintegration of the structure of energy – storing strata. One of the most efficient methods is a method of directional hydraulic fracturing, which is regarded as an alternative solution from the traditional blasting and hydraulic methods.

Jan 1, 2003

By C. Ware, R. Uken, G. Whitmore

The coastal dune cordon of northern KwaZulu-Natal is among the highest in the world reaching heights in excess of 180 m and up to 2 km in width. It comprises a complex system of Quaternary stacked dunes of various geomorphologies, types and ages (Sudan, 1999; Maud and Botha, 2002;Ware et al., 2001; Ware, 2003). The dunes contain economic heavy minerals that have been exploited for the last two and a half decades. Dune units have recently been defined based on sand composition and texture(Sudan, 1999; Ware, 2003). Despite this, little work has been undertaken on the clay-fraction (< 2 um). This work documents the weathering of dunes to form clays. From the documented clay assemblages and relative abundances, a simplified weathering sequence with increasing maturity can be summarized as follows: primary minerals ? illite + vermiculite ?illite +interstratifications ?illite + montmorillonite ?halloysite + interstratifications + kaolinite ?kaolinite. The dominant controlling factors in determining clay assemblages is pH and leaching conditions. The presence of carbonates results in an alkaline pH and high concentrations of Ca2+and Mg2+which favours the formation of montmorillonite and vermiculite. However, vermiculite tends to form under slightly acidic conditions and is indicative of palaeosols where organic acids produce localized acidic pH’s. In contrast to this, kaolinite will only form and concentrate when carbonates have been leached. Kaolinite dominated samples are considered very mature under current climatic conditions(Chamley, 1989). Halloysite represents a transitional phase between montmorillonite and kaolinite (Herbillon et al., 1981). Ion mobility and evacuation is also critical in determining clay assemblages. Past work and field studies indicate that the dune cordon acts as an open system, resulting in carbonates and mobile ions being readily leached and lost from the system. However, when prolonged weathering has caused an accumulation of fine-grained material, the permeability decreases substantially whereby mobile cations and silica cannot be readily evacuated. This results in the formation of montmorillonite rather than kaolinite, even when carbonates have been leached. Illite (sericite) is considered to alter directly from feldspars. However, dune stacking and geometries, vegetation, water fluxes, reworking and erosion complicates this sequence.

Jan 1, 2003

By H. B. Arntzen, P. O. Grøntvedt, T. Lindstad, R. J. Ishak, M. Syvertsen

Better utilisation of electric power and coke is vital in reducing production costs and CO2-emissions in production of ferromanganese. All FeMn smelting operations consume 10 to 30 % more carbon than the carbon needed to reduce MnO and FeO to metal and the carbon contained in the alloy. Potassium which re-circulates and builds up in the furnace has been shown to be the main culprit causing both excessive carbon consumption, by catalysing the Boudouard reaction, and increased electric power consumption. The reaction between CO2 and ordinary metallurgical coke or coke impregnated with potassium has been studied at temperatures from 800 to 1100°C in a thermobalance apparatus. Ordinary coke did not react to any great extent at temperatures up to 1000°C, whereas the addition of potassium (2-10 %) resulted in a huge increase in reaction rates. The ultimate goal is to fit the results into a reaction rate model containing the equilibrium constant for the solid-gas heterogeneous reaction between CO2 and a free active site on the carbon reactant producing CO and adsorbed oxygen (an occupied site). The model includes the partial pressures of CO and CO2, a reaction rate constant that is a function of both the total number of reaction sites of carbon, and the potassium content. The potassium dependency is taken care of by introducing activity coefficients for the carbon sites. As the first step towards such a model, a regression line for the Boudouard reaction rate has been established.

Jan 1, 2004

Work undertaken in the field of cut-off grade optimization has not advanced much beyond the work undertaken by Lane in 1988. His definitive work is based on the calculus of the Net Present Value criterion which is the most widely understood, consistent, and appropriate method by which sequential cash flows arising from the extraction of mineral reserves from an exhaustible resource can be represented. Although the mathematics is not complex Lane’s method is not a widely appreciated or applied approach to maximizing the value of a mining operation through selection and balancing of operational cut-off grades. Three stages in a mining operation namely, mining, processing and marketing were defined by Lane and the economics of each stage are identified and isolated to provide an optimum cut-off for each stage. Points of intersection along the present value curves for each stage of a mining operation are used to identify balancing cut-off grades at points where the capacity of the mining, processing and marketing stages is fully utilized and the Net Present Value of the operation is optimized. Data that simulate a small, deep-level Witwatersrand-type gold mine with an average grade of 6 g/t Au and a logrithmic variance of 1.2,are applied to the model to illustrate the benefits of representing cut-off grades in terms of present value curves for different segments of a mining operation. Keywords: Cut-off grade, Net Present Value, grade-tonnage curve, balancing cut-off grade, mining, processing, marketing.

Jan 1, 2003

By Y. Poornachandra Rao, P. C. Sudhakar, L. Malakondaiah

NBV commissioned a 27.6 MVA furnace in the year 2005. This paper explains: a)Furnace design features b)Furnace process control, Direct slag granulation c)Continuous casting, Waste heat recovery, Sintering d) Gas cleaning plant, Protection of Environment. Keywords: Furnace Equipment, SiMn Production, Casting, Heat Recovery and Low hood

Jan 1, 2007

By S. E. Olsen, M. Tangstad

The main source of Mn in raw materials for SiMn production is Mn-ore and Mn-rich slag from the high carbon FeMn production. The amount of slag per tonne of SiMn metal is mainly determined by the ore/slag ratio. Increasing share of FeMn slag at expense of Mn-ore will lead to larger slag/metal ratio in the SiMn process. High volume of slag leads to an increased consumption of energy and probably to higher losses of metal inclusions in the final slag. Excavation of a SiMn furnace has shown that only modest pre-reduction of Mn-ore with CO gas seems to be obtained. Nearly all reduction of MnO was finished at the top of the cokebed. Dissolution and reduction of quartz obviously takes place in the cokebed zone after the main reduction of manganese oxide is finished. Probably the ?pick up? of Si in the metal is quite fast and takes place as the metal trickles down through the cokebed towards the metal bath. The distribution of Si between SiMn alloys and multicomponent MnO-SiO2-CaO-Al2O3-MgO slags is mainly determined by the process temperature, the silica content of the slag and its R-ratio = (CaO+MgO)/Al2O3. As an example, the equilibrium content of Si in the alloy will increase by about 6 % if the R-ratio is reduced from 2 to 1, provided constant temperature and silica content. The effect of temperature is also considerable. The equilibrium content of silicon will increase by approximately 6 % per 50°C in the temperature range 1550°C to 1700°C. The equilibrium content of MnO in SiMn slags depends first of all on the temperature and secondly on the silica content of the slag. At 1600°C the MnO content decreases from about 9 % at silica saturation to a minimum of about 3-4% when the silica content is reduced to about 40-45%.

Jan 1, 2004

By W. Barthel, B. A. Dippenaar, J. Malan

In its most basic form, the process of sintering is very simple, and has been in use since the turn of the previous century. However, while the basic process is simple, control of the process relies on a number of extremely complex interdependent process parameters and requires a thorough understanding of the effect of these parameters on production capacity and product quality. Further, as with many other processes, the process parameters and hence design details of visually similar installations are highly dependant on the specific feed materials. While the industry trend has been towards an increase of capacity in order to lower unit production cost, typically in Iron ore sintering plants, this approach is not always possible for other commodities because of the scale of operation. This paper seeks firstly to describe some design considerations of sinter plants; secondly, to report on results from testwork performed with a specific series Manganese ore blends; and last, to relate these results to the design of new small-scale Manganese ore sinter plants.

Jan 1, 2004

By Willem Le Roux

Occupational health and safety is regulated by statute and common law. South Africa has, like many other countries, legislated extensively on occupational health and safety. Despite the body of legislation, the common law continues to play an important role as far as it concerns contractual, delictual and criminal liability. Two major Acts regulate occupational health and safety viz. the Occupational Health and Safety Act, No. 85 of 1993 (?OHASA?) and the Mine Health and Safety Act, No. 29 of 1996 (?MHSA?). The MHSA applies to mines and works as defined and related aspects. OHASA applies to other industries but does not apply to employers and workplaces to which the MHSA and certain matters covered by the Merchant Shipping Act, No. 57 of 1951 apply. See section 1(3) of OHASA. 2 The employer?s health and safety obligations in terms of the MHSA 2.1 Section 2(1) of the MHSA provides amongst others, as follows: ?The employer of every mine that is being worked must: (a) ensure, as far as reasonably practicable, that the mine is designed, constructed and equipped: (i) to provide conditions for safe operation and a healthy working environment (ii) ... (b) ensure, as far as reasonably practicable, that the mine is commissioned, operated, maintained and decommissioned in such away that employees can perform their work without endangering the health and safety of themselves or of any other person?.

Jan 1, 2011