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By B. J. Kloppers, J. V. Z. Visser, C. J. Horn

"The long-term plan (LTP) in a mineral resource company is defined by the quality of the mineral resource and represents the result of a series of trade-offs to fulfil internal organizational as well as external business and legislative requirements, ensuring ultimate delivery on the defined organizational strategy.The LTP should as a whole align to a coherent and well-defined organizational strategy, working towards a clearly defined objective while still allowing a tactical response to short-term requirements of the organization. The ability to respond tactically to changes in environment, like the unprecedented five-month strike in 2014 on the platinum belt following the 2012 Marikana incident, is a measure of the flexibility of the plan given the agreed strategy.This paper describes the Lonmin process of linking company strategy with long-term planning, tactical planning, and the execution of the plan through an annual planning cycle to maximize organizational flexibility. This flexibility enables mining companies to respond to the many internal and external forces that impact on both strategy formulation and delivery of results that meet shareholder expectations."

Jan 1, 2015

By S. Jiansheng, H. Nakayama, D. Lu, A. Wang

ABSTRACT: New techniques and methods for 3D geo-mechanical model test are presented in this paper. The new model material NIOS with high density and low cost; the so-called DPSS (Discrete Principal Stress Surface) loading concept, the loading and monitoring system for the generation of the 3D initial stress field of the model test, also the special techniques and apparatuses for modelling the excavation of caverns located deep inside the model material, are developed and introduced. By adopting those new techniques, a very large 3D geo-mechanical model test with high comparability for a newly designed underground powerhouse has been successfully fulfilled. Key Words: 3D model test, underground group caverns, excavation process modeling. ZUSAMMENFASSUNG: Neue Techniken und Methoden für 3D geomechanischen Modellversuch wurden in diesem Artikel vorgestellt. Ein neues Modellmaterial mit hocher Dichte und niedrigem Preis, ein sogenanntes DPSS (Discrete principal stress surface) Ladenkonzept, ein Laden- und Überwachungssystem für die Erzeugung des 3D primären Spannungsfelds und überdies spezielle Techniken und Maschinen für das Ausbruch der tief in dem Versuchsmodell liegenden Kaverne wurden entwickelt. Bei Anwendungen dieser neuen entwickelten Techniken wurde ein sehr großer 3D Modellversuch mit großem Maßstab für ein geplantes unterirdisches Kraftwerk erfolgreich durchgeführt. Stichworte: 3D Modellversuch, unterirdischen Gruppekaverne, Ausbruchsmodellierung Résumé: le test de modèl de Nouvelles techniques et méthodes pour la géo-mécanique 3D est figuré dans ce papier. Le nouveau modèle de matériels NIOS avec la haute densité et le coût bas; la conception proposée de chargement DPSS (Discrete Principal Stress Surface), le système de chargement et de moniteur pour la génération de champs de stress initial du test de modèle, ainsi que les techniques et appareils spéciaux pour modeler les excavations de cavernes profondément localisées dans l’intérieur du matériel de modèle, sont développés et introduits. A travers l’adoptation de ces nouveaux techniques, le test de modèle de la géo-mécanique très large 3D avec la haute comparabilité pour actualiser une nouvelle étude de la centrale électrique sous-terraine a déjà accompli avec succès. Mots de clé: test de modèle 3D, groupes de cavernes sous-terraines, processus de modèle d’excavation

Jan 1, 2003

By T. J. Goff, G. M. Denton

Mintek has developed the EnviroplasTM process for the treatment of solid wastes from the metallurgical industry, especially steel plant dusts, without requiring agglomeration to produce inert slag and at the same time recover metal values such as nickel, chromium and zinc. The products that are generated in the plasma-arc process are usually a metal and a non-toxic slag, which are tapped from the furnace in liquid form. The metal is mainly composed of chromium, nickel and manganese. During the production of stainless steel between 30 and 70 kg of dust and fine waste is generated per ton of steel. Mintek has successfully processed around 1000t of AOD/EAF dust on a toll treatment basis in order to recover the contained Cr and Ni. The metal produced contained 18.5 per cent Cr, and 5.5 per cent Ni. All slag samples tested conformed to US EPA regulations for disposal. The chromium and nickel recovery to metal was 90 and 98 per cent respectively, on a once through basis i.e. no baghouse dust recycle. Slag tapping temperatures varied between 1650°C and 1750°C. The average actual energy requirement excluding furnace heatlosses of smelting steel plant dust with anthracite as reductant was 1.36MWh/ ton of dust. The total mass of feed reporting to the off-gas stream was 10 per cent. The average ZnO content of the fume was 35.5 per cent.

Jan 1, 2004

By J. F. Papp

In the United States, chromium has been consumed in three major markets: chemical, metallurgical, and refractory. The predominant end use for chromium in the United States is in the metallurgical market as an alloying element in the production of stainless steel. In addition to being a major stainless steel-producing country, the United States is a major world producer of chromium-containing chemicals and has used substantial amounts of chromite ore for refractory applications. Chromium use is not easily further subdivided within the chemical and refractory industries because there is insufficient publicly available information to do so; however, chromium use can be subdivided among metallurgical industry uses based on the American Iron and Steel Institute (AISI) reported shipments of stainless steel by market classification (agricultural, aircraft, automotive, etc.). It is the goal of this study to determine the distribution of U.S. chromium apparent consumption among major markets in the United States. The distribution is expressed in the form of dimensionless fractions that are computed based on documented chromium consumption by major market. The distribution of chromium among markets within the metallurgical market is computed in a similar manner. Distribution factors are first computed for the major markets, then for markets that are subdivisions of the metallurgical market. The distribution of chromium among major markets has changed substantially over the time period of analysis. The fraction of chromium consumed by the metallurgical market has increased while that of the chemical and refractory markets has declined. Within the metallurgical market, the service industry market accounts for the greatest fraction of chromium consumption followed by transportation. Electrical, machinery, and fabricated products markets account for a substantial share of the metallurgical chromium consumption.

Jan 1, 2004

This paper reviews the history of refractory materials, highlights the development of refractory technology over the years, draws attention to the technology behind these materials, and comments on future developments in this field. By walking the path with refractory materials, from their initial uses in BC times, to the composite materials that are used nowadays, and the nanotechnology developments that are currently taking place in this field, the reader will come to agree that refractory materials are indeed very ?cool?! Keywords: refractory materials; bricks; monolithic materials.

Jan 1, 2008

By Ian MacKenzie

Over the past twelve years, professionals such as architects, engineers, accountants, and attorneys have not had to pay a great deal of attention to GST. The fees charged to clients (outputs) have not been subject to GST, but they have had to pay GST on al purchases of materials and taxable services relating to their activities.

Jan 1, 1990

By M. Stephton, L. A. Cornish, R. Süss, N. B. Maledi, J. H. Potgieter, L. Chown

In today?s gas turbines, the emphasis is on saving energy and reducing the amounts of pollutants emitted. This can be attained only by designing alloys with higher melting points and the capability to retain mechanical integrity at increased temperatures. The development of nickel-based superalloys (NBSAs) has reached its limit, as the alloys are operating at critical temperatures close to their melting points. Further increase in the operating temperatures will result in dissolution of the strengthening phases and even melting. Recent trends are towards developing materials that are adequately strong but have much higher melting points and corrosion resistance than the NBSAs that are currently in use. Studies conducted on Pt alloys with similar structure to the NBSAs have presented mechanical results that are promising. This has led to further development of these alloys as a replacement for NBSAs. The operations of gas turbines are usually limited by hot corrosion, which could lead to catastrophic failures. Increased temperatures have an adverse effect on the corrosion of the alloys by making the environment more aggressive. Hence, during a material selection process, the corrosion behaviour of any selected material for a highly specialized application such as gas turbines needs to be assessed. Generally, coatings are applied to combat degradation by salt deposits, hence coated and uncoated NBSAs were selected as benchmark alloys. Corrosion mechanisms and kinetic studies of the Pt alloys were conducted. High temperature hot corrosion (HTHC) tests were conducted at 950°C for540 hours. Analysis of the corrosion products was conducted using a Raman spectrometer, scanning electron microscope with energy dispersive X-ray spectroscopy (EDS) optical microscopy, and X-ray diffraction study of the phases that formed. Both coated and uncoated NBSAs failed under the test conditions. Samples were covered with a porous non-adherent greenish layer which is characteristic of NiO. Pt alloys displayed superior corrosion properties compared with the benchmark alloys.

Jan 1, 2006

By P. J. Brereton-Stiles, M. S. Rennie, N. Singh

Ferroalloy producers are large-scale users of electrical energy, which in many countries is in short supply and increasingly expensive. Preheating and/or pre-reduction using natural gas, recycled furnace gas or coal fines have lowered the specific use of electricity, but the high energy concentration necessary for most reduction processes can be achieved only by the use of high electric currents. Most countries have insufficient electricity to supply the demands of industry and the domestic consumer, particularly during certain periods of the day and certain times of the year. The generation and distribution of electricity is a large-scale expensive business, which is financed and managed directly or indirectly by government bodies in most countries. Both economic and political imperatives determine how much electrical energy is made available to whom and at what price. In South Africa demand is set to outstrip supply within the next few years, and the local supplier Eskom has moved from a traditional demand tariff pricing structure to a time-of-use tariff pricing so as to limit peak demand usage. This will mean a substantial increase in electricity cost to those users unable or unwilling to reduce consumption during peak periods. The optimal use of the available electrical energy depends both on the process, the furnace size, the configuration and infrastructure of each plant and its cost structure. As the cost and availability of electricity is set to change dynamically, the management of the situation becomes a real time control and optimisation problem. This paper discusses some the process and operational constraints associated with low- or no-load conditions and how to manage the situation. Electrode management will be one of the key issues.

Jan 1, 2004

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 A. Basçetin

Equipment selection in mining engineering is one of the most important decisions that affects the mine design, production planning and economic parameters in open pit and underground mining. Mine planning engineers generally use their intuition and experiences in decision making. Mostly, linguistic variables (the weather is raining, soil is wet, etc.) come into question and decision-makers may not know how these variables are computed. Since the advent of the fuzzy set theory, these uncertainties are easily interpreted in the decision-making process. The development of computer technology and programming of colloquial language with expert systems have considerably reduced decision-makers? burden. This paper reviews the development of a computer programme software called EQS (EQuipment Selection) that automates equipment selection in mining engineering using fuzzy set theory. The EQS with an introduction of the concepts and theories of multiple attribute decision-making, the fuzzy set theory, and EQS applications to mining industry problems with case studies are presented

Jan 1, 2006

Despite the wealth of information available on phase equilibria of oxide systems there remainmany gaps and inconsistencies in our knowledge base. From an industry perspective there is anongoing need to adequately describe the phase chemistry of slag systems in order to optimizeprocess performance and improve productivity. Since this chemical behaviour cannot be predictedfrom first principles it follows there is also an ongoing need for accurate experimental data. The advances made in recent years in the capabilities of sophisticated analytical and measurement equipment have made it possible to develop new experimental techniques for the direct determination of phase equilibria in low order and complex multi-component slag systems. In addition the development of powerful computer modelling tools makes it possible to provide more comprehensive descriptions of the phase chemistry, to present the information in a range of perspectives, and to critically analyse the various types of related thermodynamic and structural information available. This review provides an overview of the types of information that can be used to determine phase equilibria in slags systems, analyses the influence of uncertainty and the relative importance of these types of data, and describes the advantages and limitations of the various experimental techniques that can be employed to obtain this information. Examples of recent studies are provided that demonstrate how an integrated approach to the determination of phase equilibria in complex systems, involving the use of targeted experimental studies and systematic thermodynamic model development, can lead to a better utilization of our current research capabilities and resources and more accurate descriptions of these systems. Keywords: slags, phase equilibria, experimental techniques

Jan 1, 2004

Splashing and wave formation has been studied experimentally by using one-seventh water model of CLU (Creusot-Loire Uddeholm) reactor with two different tuyere configurations by using paraffin and water as simulated slag and simulated metal respectively. Experimental results have been discussed in terms of total splash volume, relative slag volume in splash (dispersed-slag phase holdup in splash), wave frequency and wave amplitude with respect to gas injection rate and tuyere configuration at bath heights between 0.25m and 0.38m. Gas flow rates ranged from 0.00599m3/s to 0.01312 m3/s. The results of splash measurements showed that splash volume increased with increasing gas flow rate and decreasing bath heights for both tuyere arrangements. However, off-centre configuration resulted in relatively higher amounts of splash. The slag volume in splash (Dph in splash) was also found to increase with decreasing bath heights and increasing gas injection rates. The high speed photography revealed that the frequency and wave amplitude increased with gas injection rate. The experimental results also showed that the frequency and vertical displacement of the rotating wave increased when the tuyere orientation became off-centered. This might be used to explain why off-center configuration resulted in generating higher splash volumes than the center configuration.

Jan 1, 2004

By Peter Townsend, Sergei Diachenko, Allan Moss

The Palabora Mining Company has successfully extended the life of its operation by developing a 30,000tpd block cave underground mine below the now closed open pit. The process of transitioning from surface to underground mining has been technically, operationally and managerially challenging. This has been due to a number of factors; in particular, the development of a block cave in a very competent rock mass. The competence of the rock mass is clearly demonstrated in the open pit that preceded the block cave, one of the steepest deep open pit excavations in the world. With cave breakthrough, however, the pit was ?instantaneously? deepened by 400m causing a major failure of the northwest wall involving close to 100Mt of waste material.

Jan 1, 2006

By J. Stacey

This study was undertaken to generate a locally relevant guideline for the socio-economic aspects of mine closure for South African closure practitioners and decision makers. It should also represent a resource for interested and involved stakeholders. Mine closure, and its related post-closure social, environmental and economic characteristics, is part of the lifecycle of mining operations, given the finite nature of the ore resource. Many coal mines are anticipated to close in the next ten to fifteen years in Mpumalanga, as the epicentre of the industry shifts towards the Waterberg. Social aspects of mine closure have been historically underplayed, and under researched. Coaltech thus commissioned two studies, the first of which examined the closure dynamics of 36 mines in Mpumalanga and KwaZulu-Natal in 2006. A follow-up study (July 2007) focusing on Mpumalanga3,4 confirmed some of the results of the first study. It also contained broad guidelines for mine closure covering social and labour planning, job creation, the use of mine infrastructure, developmental incentives, and environmental rehabilitation.

Jan 1, 2010

By L. Lehasa

The purpose of the project was to investigate the challenges faced by Khutala Colliery pertaining to underground road construction and maintenance. Furthermore the influence of these challenges on productivity and safety requirements were taken into consideration. The operating standards required for the construction and maintenance of the 2 seam road transport infrastructure was investigated, together with reasons why the standards of operating procedure are not met. The Code of Practice put in place by Khutala Colliery was used to view the standard operating procedures. Leading practices on underground road construction were researched. The project aims to discover the gaps that Khutala Colliery must bridge to implement enhanced practices with regards to underground road construction. During the period of study, observations were carried out to determine whether the road construction standards of operating procedure were being adhered to at all times for both road construction and road maintenance. Khutala Colliery has put in place a traffic management plan, which includes safety practices and work policies that must be adhered to while travelling on underground transport roads.

Jan 1, 2012

By V. I. Zhuchkov, L. A. Smirnov, E. I. Arzamastsev, A. A. Babenko

A brief analysis is given for state-of-the-art of manganese and chromium ferroalloy production in Russia and their consumption by metallurgy plants. The main causes of low output of manganese and chromium ferroalloys, and ways to resolve the issue of ferroalloy production development are considered.

Jan 1, 2004

By H. Lagendijk, I. J. Reinecke

Mintek was contracted by Oriel Resources plc in 2004 to conduct a preliminary assessment study on smelting ferronickel from the large but relatively low grade Shevchenko nickel ore deposit in Kazakhstan. A detailed feasibility study (?DFS?) was awarded to Bateman BV following promising results from the preliminary assessment study (?PAS?) and small-scale pilot plant test work. As part of the DFS, a total of 450metric tons of ore was collected from three different locations in the deposit and shipped to Mintek. After sampling, the bulk sample was prepared for smelting. This comprised crushing, screening and calcining with each step done separately for the three different lots. The chemical composition of the ore from the deposit is relatively high in silica and therefore falls out of the MgO to SiO2 range that is normally processed by pyrometallurgical means to produce ferronickel. The main objective of the testwork was to demonstrate that a method could be found and successfully applied to smelt these siliceous ores and produce an acceptable nickel-containing alloy. A 2-m ID DC arc furnace was installed with a twin-cathode (electrode) configuration to replicate the proposed commercial-scale furnace and also incorporated an advanced design of water-cooled copper panels in the lower furnace sidewalls to withstand the aggressive nature of the high SiO2-containing slags. The reductant used was a high-volatile coal from Karaganda in Kazakhstan. The reductant addition was adjusted to achieve a 90% recovery of nickel. In the assessment of the process metallurgy, some deviation from equilibrium conditions was observed. This deviation is ascribed to the intermittent existence of a smelting bath partially covered with feed during the testwork. Optimization of smelting conditions should result in the metallurgy (slag metal equilibrium) being closer to the theoretical predictions and make the production of a 20% nickel alloy possible at 90% nickel recovery. The solution for the successful processing of these siliceous ores was found in the attainment of the necessary operational stability through the control of arc length, operating temperature, open-bath smelting conditions and flux additions of up to 10% dolime for the most siliceous of the three ore types. The test work carried out by Mintek provided the basis for the process flow sheet and engineering design of the DC arc smelting furnaces for the Shevchenko Nickel project.

Jan 1, 2007

By P. J. Bhonde, R. D. Angal

Conventionally low carbon ferromanganese is manufactured globally by refining high carbon ferromanganese in liquid state. This process is an expensive and lengthy technique. Hence, the present work was undertaken with the objective of understanding the feasibility and kinetics of the solid state refining of ferromanganese. The process involved transformation of carbon rich carbides viz. Mn3C2, Mn7C3 into metal rich carbide i.e. Mn15C4, Mn23C6 by subjecting the alloy powder to a flowing stream of carbon dioxide. Effect of the process governing parameters such as time, temperature, particle size, pressure on the extent of decarburization was studied. Without any loss of manganese in the form of fumes or slag, it was observed that, there was substantial reduction, viz. 65 per cent in the total carbon content, by this technique. Subsequently, the process was investigated to find out the mechanism of carbon removal. Depending upon the temperature and the particle size, it was found that the rate controlling mechanism changes from chemical reaction control to product layer (ash) diffusion control. The activation energy for each of the aforesaid mechanism was computed. The values thus obtained substantiated the aforesaid mechanisms.

Jan 1, 2004

By J. G. van der Watt

Due to increasing concerns of global rare earth element shortfalls in the near future, possible alternative sources of rare earth elements have recently become of economic interest. One such alternative is decanting acid mine water originating primarily from abandoned old mines in the Witwatersrand region of the Republic of South Africa. In this study, a novel way of rare earth element removal from the acid mine drainage was employed, making use of bentonite clay, which has very good adsorbent properties, as a rare earth element carrier material. The process can be economically viable only, if the elements can be selectively removed from the bentonite clay carrier material so as to yield reusable clay. Acid leaching was proposed to liberate the adsorbed rare earth elements from the bentonite clay. Accordingly, acid leaching experiments were performed to study the desorption of three commonly-found rare earth elements, namely neodymium, samarium, and dysprosium, from bentonite clay in the presence of sulphuric and hydrochloric acid. It was established that the three rare earth element species could be selectively removed as a group from iron, magnesium, and manganese metals through the careful manipulation of the pH. An investigation into the kinetic aspects of the rare earth element desorption process from the bentonite clay was also undertaken. The applicability of various kinetic models such as zero-order, pseudo first-order, pseudo second-order, elovich, parabolic diffusion, and power function were tested to describe the time-dependent desorption of rare earth elements from bentonite clay. It was determined that the pseudo second-order kinetic model represented the dissolution processes for neodymium, samarium, and dysprosium from bentonite clay the most accurately.

Jan 1, 2012

By H. T. Ozkahraman

It is important to know the breakage mechanism in materials since this knowledge influences the results of subsequent grinding operations. There are two distinct failure mechanisms in breakage: one is tensile micro crack generation at low stresses, which leads to macroscopic failure by disintegration, and the other is formation of shear zones under heavier dynamic impact forces, which generates more fines as seen in crush zones in blasting. Tensile fracturing simply breaks the material into fragments. It is seen as the disintegration of the specimen into two or more separate fragments. This happens under the absence of lateral stresses and the material is free to expand. On the other hand, compressive-shear breakage produces finer fragments due to shear stresses. The first mechanism is observed in laboratory tensile and bending strength tests and the second mechanism is observed both in laboratory brittleness tests and in situ blasting operations under dynamic impact forces. The friability of rocks and ores can be determined by a brittleness test. A test apparatus to determine the friability value has been designed to suit limestone strength characteristics used in cement production. The friability and stored strain energy values of barite, marble, limestone and bauxite have been determined and compared with the corresponding Bond work index (Wi) and grindability index (G) of these materials. The physico-mechanical properties of the tested materials have also been determined to investigate their effect on friability and grinding. The relationships obtained between the indices were in surprisingly good agreement, with high correlations (0.99 and 0.97). The Bond work index and grindability index can therefore be estimated from the friability value, which can be determined more rapidly than the Bond test. But for certain rock types such as andesites the relationships does not hold. Key words: comminution, tensile stress, shear forces, brittleness test, strain energy.

Jan 1, 2010