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By A. M. Venter

"SynopsisThe availability of advanced characterization techniques is integral to the development of advanced materials, not only during development phases, but in the manufactured components as well. At Necsa, two modern neutron diffractometers equipped with in-situ sample environments, as well as complementary X-ray diffraction instruments, are now available as User Facilities within the National System of Innovation in support of the South African research and industrial communities. Neutrons and X-rays, owing to their different interaction mechanisms with matter, offer complementary techniques for probing crystalline materials. Both techniques enable nondestructive investigation of phenomena such as chemical phase composition, residual stress, and texture (preferred crystallite orientation). More specifically, the superior penetration capabilities of thermal neutrons into most materials allows for the analysis of bulk or localized depth-resolved properties in a wide variety of materials and components. Materials that can be investigated include metals, alloys, composites, ceramics, and coated systems. In particular, depth-resolved analyses using neutron diffraction complements surface investigations using laboratory X-rays in many scientific and engineering topics. The diffraction techniques can add significant downstream value to the anticipated nuclear industry development activities.IntroductionMaterials characterization is central in understanding the relationship between the structure, properties, and performance in order to engineer materials that fit the performance criteria for specific applications. This is conveniently represented in the form of a tetrahedron, generally known as the material science paradigm (Figure 1).The availability of advanced characterization techniques is integral to the development of advanced metals, not only during development phases, but in the form of manufactured components. At Necsa (South African Nuclear Energy Corporation), modern X-ray and neutron diffraction instruments are now accessible to the South African research and industrial communities. These facilities enable nondestructive investigations of materials and components that could add significant downstream value to the anticipated nuclear industry development activities."

Jan 1, 2015

Grains are subject to contamination by mycotoxins which are metabolic by-products of various fungi. The fungal infestations produce local concentrations of the mycotoxins thousands of times higher than the average. These facts make the sampling of the grain for assessment of the mean mycotoxin levels potentially very difficult. In the context of sampling theory, this morphology of the infestations creates a very high distributional and intrinsic heterogeneity of the grain shipment. The distributions of mycotoxin concentrations in seaborne shipments that exist at loading and the number and intensity of infestations that develop under shipping conditions are unknown. All grain shipments carry spores that may give rise to mycotoxin-producing colonies; moisture and temperature determine the final extent of the problem. This paper develops the value of the sampling constant with respect to intrinsic heterogeneity based on data on observed Ochratoxin A (OTA) concentrations in individual wheat kernels. A useful relationship between the distribution of mycotoxin concentrations on a kernel to kernel basis and the distribution of concentration over subsamples is developed.

Jan 1, 2009

By K. M. Primrose

Electrical tomography has developed rapidly over the last few years in its sophistication and practical use to enable three-dimensional information on the distribution of phases within flowing mixtures to be observed1. This paper reviews the current state of application from the industrial perspective, drawing on applications case studies based on scaling studies in the laboratory right through to installations on plant. In the laboratory, applications have looked at scale-up of mixing2 processes involving gas-liquid and solid-liquid suspensions3 with a particular interest in verifying computational fluid dynamics simulations or in checking scale-up design4,5. In the processing plant, the circumstances are usually bespoke and may range from simple detection of the degree of homogeneity of a flowing mixture through to the need to measurement a sophisticated batch process such as crystallization, sedimentation, filtering and drying. Examples drawn from the chemical and pharmaceutical industries will be presented and related to the benefits that can be gained through application of the method.

Jan 1, 2008

By V. Léveillé

As new legislation drives metallurgical plants to lower SO2 emissions, plant managers face the challenge of keeping their costs under control. The Cansolv® SO2 Scrubbing System has been broadly adopted in the non-ferrous industry as a cost-effective solution for smelter operators to meet the new SO2 emissions targets. The Cansolv® SO2 Scrubbing System is an a mine-based regenerable process that selectively absorbs SO2 from a variety of gases, including dilute smelter gases, such as furnace and converter gases. The system produces a pure, water-saturated SO2 by-product stream, which can then be directed to the front end of a sulphuric acid plant for conversion to sulphuric acid. When deployed in a smelter complex, the Cansolv® SO2 Scrubbing System may also be used to process acid plant tail gas, allowing single absorption sulphuric acid plants to achieve emissions an order of magnitude lower than that of a double absorption acid plant with a lower capital investment. Depending on inlet gas temperature, SO2 emissions in the treated gas can be controlled to as low as 55mg/Nm3. This paper will describe some of the applications where customers have or are planning to use the Cansolv® SO2 Scrubbing System, as well as which features and cost advantages for the treatment of smelter gases were important in the technology choice.

Jan 1, 2009

By D. S. van Vuuren

Industrial production of titanium occurs via the batch-wise reduction of titanium tetrachloride (TiCl4) with a reducing metal, being magnesium in the Kroll process, or sodium in the Hunter process. In the search for low cost titanium, the CSIR is developing a continuous process to produce titanium powder directly via metallothermic reduction of TiCl4 in molten salt, dubbed the CSIR-Ti process. The move to a continuous process has been attempted by a number of organizations, but was until now always met with failure, due in no small part to challenges inherent in the process chemistry. The reaction between TiCl4 and the reducing metal can occur directly, when TiCl4 or any titanium sub-chlorides present, comes into contact with suspended or dissolved reducing metal. The reaction can also occur indirectly, without any physical contact between the reacting species, via an electronically mediated mechanism. The reaction mechanism via electronic mediation can cause TiCl4 to react at the outlet of the feed port, rapidly causing blockages of the TiCl4 feed line. The electrical conductivity of the metal reactor can also cause the electronically mediated reaction to favour the formation of titanium sponge on the reactor walls and internals, rather than titanium powder. Various methods were investigated to overcome the problem of blockages in the TiCl4 feed line, e.g. mechanical removal, sonic velocities, dilution of the TiCl4 and the use of ceramic feed lines. This article discusses problems experienced with the continuous feeding of reagents, and various methods attempted are shown and discussed. Information is also given on the morphology, chemical composition and suitability of the final titanium powder for powder metallurgical application as presently produced by the CSIR-Ti process. Keywords Titanium dioxide, titanium nitride, carbo-thermic reduction, ilmenite, slag, tunnel kiln, residence time.

Jan 1, 2011

By C. D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900s. This versatile product displaced the expensive and easily poisoned platinum-based catalyst in nearly all applications by the 1930s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has worldwide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development programme dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and preheater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

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 C. Musingwini, C. Beaumont

"Kansanshi mine, located in northwestern Zambia, uses conventional openpit mining to produce primarily copper, with gold as a by-product. The ore is extracted from a deposit with highly complex mineralogical suites that are difficult to process, sometimes leading to poor recoveries. The mine was using an ore classification system called ‘Mat-Type’, which classified various ore types into 22 different quality categories, ranging from poor to good quality. Ore with poor recovery was classified as ’poor quality’ ore and directed to long-term stockpiles. Due to a lack of proper integration between the technical and functional areas forming the mine value chain, Mat-Type unintentionally misclassified ore. A geometallurgical analysis was therefore undertaken to review Mat-Type and a new geometallurgical ore classification system, called ‘OXMAT ’, was developed to replace Mat- Type.When implemented, OXMAT eliminated nine of the 22 ore categories and the remaining 13 ore categories could now be more accurately and consistently defined, leading to a significant change in the quantity of ore being mined. OXMAT demonstrated that within a defined test volume of the geological model, waste tonnes could be reduced by 19% while ore tonnes could be increased by 17%. This paper therefore demonstrates the value created through integrated geometallurgical modelling. IntroductionKansanshi mine is located in northwestern Zambia, approximately 10 km north of the provincial capital Solwezi and about 160 km west of Nchanga mine in the Central African Copperbelt (Broughton and Hitzman, 2002). The location of Kansanshi mine relative to other major copper deposits in the Copperbelt is indicated in Figure 1.Kansanshi mine uses conventional openpit mining methods to exploit copper- and gold-bearing veins hosted in a structurallycontrolled mineral deposit. Mining is carried out in two areas of the deposit, the Northwest and Main pits. A third area of the deposit, called Southeast Dome, is currently not being exploited (Figure 2)."

Mar 1, 2019

By J. B. A. Solar Menéndez, M. A. Martínez Fidalgo, L. A. Alvarez-Santullano

1. ANTECEDENTS This present communication refers to the results of the research project entitled "Training in the correct use of chemical oxygen self rescue apparatus and also an analysis of apparatus autonomy", carried out under the auspices of the Specific Collaboration Agreement signed between the Industry Council of the Principality of Asturias (Spain) and INSALUD (National Silicosis Institute, Spain). The antecedents of this project lie in work undertaken by the National Silicosis Institute aimed at optimising efficiency in the use of chemical oxygen self rescuers through improvements in worker training. To be precise, by means of Agreements drawn up between the above-mentioned parties, a simulator was designed and incorporated as the basis of a training station within the " Fundación Barredo" of the Industry Council of the Principality of Asturias. This has been operative since the year 2001 and, up to the present, 2300 Asturian coal mine workers have been trained there. What prompted this activity was the observation of various errors in the use of the self rescuers, deriving from their innate characteristics, especially with respect to the sensation of discomfort - the high temperature and humidity of the breathed oxygen, resistance and inconvenience - and limited autonomy. It was precisely this insight that, in critical situations, lack of familiarity with the conditions of discomfort likely to be experienced during the evacuation process might lead to rejection of the equipment, with fatal consequences, that has justified the setting up of this training and simulation centre. The centre is able to provide all mine workers with the necessary training, and experience of the characteristic sensations experienced when using such equipment (Fig.. 1).

Jan 1, 2003

By D. Govender

Theoretical flotation models suggest that there is a positive relationship between bubble-particle collision rates and turbulent kinetic energy dissipation. Fine particle flotation performance is generally enhanced by increased collision frequency and hence higher energy dissipation. Contrarily, increased turbulence in the rotor-stator region is related to higher detachment frequency of the coarser size range. Therefore, the optimal modes of recovery for the ?fine? and ?coarse? size classes appear to be diametrically opposed. Industrial applications have previously confirmed that applying greater power to flotation slurries yields significant improvements in fine particle recovery. However, recovery of the coarser size class favours a different flotation environment. An improvement in the flotation kinetics of the fine and coarse size classes, provided there is no adverse metallurgical influence on the intermediate size ranges, is obviously beneficial to the overall recovery response. Managing the local turbulent kinetic energy dissipation, and hence the power imparted to the slurry, offers the benefit of targeting the particle size ranges exhibiting slower kinetics. FLSmidth recently introduced the practical implementation of this concept. In principle, it decouples flotation regimes where fine and coarse particles exhibit preferentially recovery. In the case of naturally aspirated machines (Wemco®), it is referred to as Hybrid Energy Flotation? and incorporates at least three phases: ? Standard flotation machines (standard energy input, rotor speed (r/min), rotor size/type) at the beginning of the row, where flotation is typically froth-phase limited and operational and set-up parameters have a limited influence on the recovery ? Higher-powered flotation machines (high rotor speed, high-power rotor size/type) at the end of the row to improve fine particle recovery ? Lower-powered flotation machines (low rotor speed, low power rotor size/type) to enhance coarse particle recovery. A CFD-based flotation model is used to highlight the effect of turbulent dissipation energy on attachment and detachment rates. Preferential collection zones for ?fine? and ?coarse? particles are predicted for both forced-air and naturally aspirated machines. The greater predominance of UG2 ore types, coupled with the skewed feed distribution of platinum group metals (PGMs) to the finer size fractions, suggests that PGM flotation circuits are not designed for optimal recovery across the size distribution. The application of the hybrid energy concept to PGM flotation offers a possible shift towards a more efficient flotation circuit solution through a managed distribution of energy.

Jan 1, 2012

By G. Lyman

The cross-belt sampler is a device that is very widely used even though it has not been ratified by the Standards associations. This paper is concerned with the bias testing of two cross-belt sampler designs against stopped belt samples and a cross-stream cutter at the belt end. The bias analysis is carried out using size distribution as the analyte and conventional t-testing and the Hotelling T squared test, which are compared for their effectiveness. The paper considers the issue of detectable bias and the statistical planning of bias tests.

Jan 1, 2009

By D. Bessinger, H. Kotzé, J. Beukes

Keywords: Pyrometallurgy, furnace, ilmenite, smelting, Ticor Ticor SA began with a detailed feasibility study in 1995. The Hillendale mine (situated between Richards Bay and Empangeni) and Mineral Separation Plant were approved in 2000. The smelter, just outside Empangeni, consists of two 36 MW DC arc furnaces that were commissioned in 2003. Experiences gained during the initial commissioning of the furnaces proved valuable in later commissioning work, as shown by the increase in ramp-up rates. The capacity of the plant is 250 kt/a TiO2 slag and 145 kt/a of pig iron.

Jan 1, 2006

By B.E. Hall

Maximizing shareholder value has become a common aim for mining companies. This paper discusses the results of a number of studies developing strategic mine plans, covering a wide range of commodities, styles of mineralization, mining methods, and processing facilities, for single and multiple deposits. It has become evident that traditional methods and conventional wisdom often do not in fact achieve these goals. Operating policies at many mines ensure that shareholder value is not maximized. Changing the overall strategy can provide significant value gains. Typically, the new optimal plan involves a significant increase in the cutoff grade, at least in the earlier years. An increase in the underground development rate or open cut stripping rate is often associated with this, at least in the short term, to establish the new strategy. Cost minimization is found to be counter-productive. Counter-intuitive plans are often found to be optimal. For example, optimal cutoffs for different parts of an underground mine may be significantly different, even if mineralisation and cost structures are similar. Sub-optimal strategies are also frequently found to have a significantly greater financial risk than optimal plans, which have been found in many cases to be relatively insensitive to changes in major value drivers, such as metal prices. This paper shows how identifying and then operating within the framework of an optimal strategic plan can have substantial benefits over being continually driven by short-term tactical issues.

Jan 1, 2009

By Thermo Electron, Tim Sennett

Summary ?SamStat Development ?SamStat Description ?Accuracy ?Availability ?Cost of ownership ?Capital ?Installation ?Operating/Maintenance ?Case Studies ?Modikwa ?Combined concentrate sampling ?Cerro Verde ?State of the art sampling & analysis ?Ok Tedi Final Tails ?brownfields installation ?Conclusion

Jan 1, 2005

By P. A. Roberts

A modified in situ leaching method for extracting gold from oxidized gold ores using a non cyanide lixiviant is proposed. A non cyanide lixiviant is suggested because of the obvious concerns posed by injecting cyanide bearing solutions into the subsurface. Oxidized gold ores are the initial focus because earlier research on the use of sodium thiosulphate as a lixiviant under anaerobic conditions indicated that the presence of pyrite led to rapid thiosulphate breakdown. A reconnaissance research programme, involving ore characterization and hydrometallurgical testwork on samples from four Australian ore deposits and preliminary reactive transport modelling studies was carried out. This work showed that lixiviant-oxidant combinations of sodium thiosulphate and ferric EDTA, and iodide and iodine are both capable of extracting high percentages of accessible gold from the selected samples under anaerobic conditions. The ore characterization and reactive transport studies, suggested that both physical and chemical methods of permeability enhancement may be required to lift bulk permeability and the availability of gold for dissolution to sufficiently high levels to obtain adequate gold recoveries. Physical permeability enhancement could be achieved by blasting and/or hydraulic fracturing of the ore. Assuming that such methods prove to be both necessary and economically viable, the mining method would no longer be regarded as simple in situ leaching. Therefore, the term ?in place leaching? has been adopted for the proposed gold extraction system

Jan 1, 2009

By C. P. Naudé

Mechel, a large, integrated steel, stainless steel, and ferroalloy producer in Russia is committed to upgrading its facilities to world class pyrometallurgical process and environmental practice. Yuzhural Nickel currently uses shaft furnaces to produce a matte containing iron, nickel and traces of cobalt. This rather old technology is thermally inefficient and is characterized by high operating costs. Mechel has investigated suitable equipment and processes to upgrade the plant, and awarded a contract for the construction of a 12 MW DC smelter, located near the town of Orsk, to Bateman Engineering Projects in June 2008. The selection of DC furnace technology for laterite smelting can be considered as a strategic highlight for the pyrometallurgical treatment of low-grade lateritic ores, and could be the first industrial-scale implementation of this technology. This project has been designed to achieve multiple goals including the demonstration of the process and associated equipment technology at commercial scale, to confirm the scale-up design parameters of the forthcoming 2 x90 MW, twin electrode DC furnaces, and to prove the environmental emission superiority of closed furnaces. It also provides a valuable operator training platform. This paper deals with the process design, key technology building blocks and design features which have been incorporated to produce a pyrometallurgical vessel capable of (i) resisting slag superheat and chemical aggressiveness, (ii) process fine material without pre-agglomeration, (iii) achieve high nickel recoveries and(iv) being tolerant to the variations in chemical composition of laterite ore. The approach to increasing campaign lives between partial and complete rebuilds, through the use of composite furnace module (CFM) technology originally developed and patented by the University of Melbourne, is also followed in more detail. Unfortunately, results from hot commissioning and lessons learned from initial operation are not available because the project completion has been delayed due to the worldwide downturn in demand for commodities. Keywords DC furnace, ferronickel laterite smelting, corrosive slag, coppercooler technology.

Jan 1, 2010

By S. A. Ziebold

There is often a need to increase capacity through existing mist eliminator installations without significant tower modifications. Often there is not enough extra space outside existing vessels unless more expensive changes can be justified. Also, plant downtime must be considered. The challenge in retrofitting is to overcome velocity limitations inherent in the design while at the same time extend performance capability. The solution most often is to create new ways to add extra filter area while remaining constrained to the existing space. This strategy, however, can dangerously backfire if basic design principles are not followed. Mist eliminator design is a complex integration of many conflicting performance parameters. Often the objective is to increase scrubbing capacity while maximizing collection efficiency and service life and minimizing operating pressure drop (energy cost), particle regeneration (re-entrainment) and overall maintenance costs. Results of plant retrofitting using mesh pads, impaction fibre beds and diffusion fibre beds are presented based on actual plant projects. Often the retrofit project can be more effective by increasing the scope and combining other new plant equipment with the upgrade such as new tower components. In some cases, the type of mist eliminators can be upgraded from impaction type (velocity dependent) to Brownian diffusion type (velocity independent) if additional downstream protection or reduced emissions are desirable, especially at turndown rates. Trade-offs between different fibre bed types and styles are discussed as they relate to performance and maintenance.

Jan 1, 2007

By J. Petersen, H. Naderi, H. Zare, M. H. Nikzad, M. Karimi

In the copper electrorefining process, the dissolution of anodes is significantly reduced or even stopped when the passivation phenomenon occurs. The results of this phenomenon are increasing energy consumption, residual formatting, and voltage levels in the cell. In this study, the electrochemical behaviour of blister copper in the presence of sodium persulfate (PDS) was studied. The electrochemical methods of LPR, Tafel, and Electrochemical Impedance Spectroscopy (EIS) were used. The results showed that the addition of sodium persulfate activates the electrode surface and increases the open circuit potential. In the presence of PDS, the polarisation resistance of the electrode shows an increasing or decreasing tendency, based on the PDS concentration. This tendency is probably due to the formation of surface layers (such as slime layer or copper sulfate) and dissolution of this layer at various concentrations of PDS. The lowest polarisation resistance of 1.8 ohms and the highest corrosion current of 60.6×10-3 and 36.6×10-3 A/cm2 from LPR and Tafel techniques respectively were obtained at the concentration of 40 g/l PDS. Based on the results of potentiodynamic and electrochemical impedance spectroscopy tests, the addition of sodium persulfate to the solution reduces the corrosion resistance, therefore the passivation time of the blister copper anode increases. Keywords: Blister copper, electrorefining, sodium persulfate, anodic passivation

Jan 1, 2020

By J. C. R. van Schoor

In this study the applicability of a batch press to predict the energy consumption and particle size distributions for medium-pressure roller presses was investigated. The relationships between energy consumption, feed size and product size are discussed with reference to Hukki?s interpretation of Bond?s and Rittinger?s laws, as well as the particle size parameter used. It was found that the comminution laws have limited utility for the characterization of the performance of the medium-pressure roller crushers or the batch press used, and also depend on the particle size distribution indicator used. It was also found that the batch press is not a suitable simulator for medium-pressure roller mills as it was notable to predict the energy requirements, or to predict the size distributions that would be obtained for the ores evaluated.

Jan 1, 2012

By D. Van Dyk

Horizontal rotating mills are being used all over the world in different mineral and power generation industries. David Brown South Africa, with over 140 years of experience in gear manufacture and design, has been supplying these industries with innovative designs at exceptional quality. The gearing systems associated with these industries are challenged daily with operating conditions that are not always fully understood. Failures are therefore experienced, over time in the industry, which cannot always be fully explained. David Brown South Africa has developed a gear monitoring system, the Intelligent Gearing System, in association with Transmission Dynamics (UK), in order to monitor and analyse these operating conditions in real time. The system has been designed on the principles of Six Sigma, incorporating Design for Six Sigma. The purpose with this system design is to monitor the operating conditions on the pinion, record the information and analyse the data in relation to the rate of fatigue damage to the girth gear and pinion. This is done in real time and unattended. The output from the Intelligent Gearing System can be fed back into the operating system of the mill user, in order to display an alarm for operating conditions exceeding the design criteria as well as information on the rate of fatigue damage due to these operating conditions. When the mill operating and the effect on the fatigue life of the mill gearing components, conditions are better understood, mill users can forecast critical spare holding levels with an increased accuracy. The Intelligent Gearing System also allows early actions to remove reasons for system overloads.

Jan 1, 2006