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By L. M. Tavares, H. A. Petit, P. P. Cavalcanti

Iron ore pellets experience degradation during handling due low energy impacts and stresses. These impacts lead to volume or surface breakage of the pellets, creating fine particles that accumulate along the process. Some of the particles are in contact with the air and are dragged as dust into the workplace or into the atmosphere. The aerodynamic size of the particles allows them to be potentially inhaled by the workers or to be carried to nearby communities. Dust emission becomes critical at specific locations, such as transfer chutes and stockpiles. This work models the dust generation that occurs in an iron ore pellet stockyard using a methodology that combines experiments to quantify the degradation of the pellets to mathematical modelling of the dust emission mechanisms in the stockyard. First, laboratory tests were used to characterise the amount of mass and the particle size distribution of the dust generated by degradation under controlled conditions. Second, the flow over a stockpile of an iron ore pellet company was simulated with the aid of computational fluid dynamics (CFD) simulations. Third, semiempirical equations linked the data generated by simulations and laboratory tests to estimate the dust emission in the stockyard. Finally, results were validated with measured field data, obtained with a novel online measurement tool. Results suggest that the approach is able to predict dust emission with sufficient accuracy and can be used for further implementation in the management of operations and decision making in order to reduce the environmental impact of the process. Keywords: Iron ore pellets, abrasion, dust emission, mathematical modelling

Jan 1, 2020

By F. M. L. Mulaudzi

Metal dusting is a corrosion phenomenon that occurs in strongly carburizing gas atmospheres at elevated temperatures. Reaction kinetics and product characterizations of Alloys 602CA and 800 were examined by scanning electron microscopy with energy dispersive X-ray analysis (SEM-EDX) and X-ray diffraction (XRD).The results showed that Alloy 602CA is more resistant to metal dusting than Alloy 800. Visual examination and SEM surface analysis showed that Alloy 800 suffered metal dusting attack after a relatively short exposure period. The amount of coke deposits increased on Alloy 800 with increased exposure from 96 to 336 hours. X-ray diffraction on the reacted surfaces identified graphite and austenite in both alloys and some iron oxides/spinel for Alloy 800.

Jan 1, 2012

By J. K. Pothal, S. Basu, R. Barik, P. K. Senapati, A. Dubey

The aim of this paper is to study the characteristics of limestone particles (size varies from 4 mm to 20 mm) during its transportation from open cast mines through pipes. The influence of four different size fractions of limestone samples (4–6 mm, 6–10 mm, 10–15 mm, and 15–20 mm) on pipe flow characteristics during vertical transport in a 100 mm NB hose pipe was investigated. The flow velocities in the vertically lifting pipe was varied from 0.95 m/s to 2.78 m/s and a rotary feeder of 2 to 4 tonne/hr. capacity was employed to feed the limestone samples to the lifting pipe. The pressure drop data for the different size fractions of limestone samples at different mixture velocities were analysed. The effect of input volume fraction and superficial velocity of limestone samples on hold-up ratio were discussed. It was indicated that there was no substantial increase in pressure drop of slurry samples in the studied range of concentrations (CW = 4.22% - 12.54%), particle size, and low to medium range mixture velocities with respect to water run head loss data. The hold-up for the larger size fractions (15–20 mm) of limestone samples was found to be significant as compared to smaller size fractions, which may be due to terminal settling velocities of individual fractions of the studied samples.

Mar 4, 2025

By H. Zhong, S. Wang, Q. Sun

The flotation performance of 2-(benzylthio)-acetohydroxamic acid (BTHA) to diaspore was first evaluated by micro-flotation tests. The adsorption mechanism was further investigated through adsorption experiments, molecular dynamics simulation, zeta potential and X-ray photoelectron spectroscopy (XPS). The results demonstrated that BTHA had a stronger ability to collect diaspore in comparison with another diaspore collector, benzohydroxamic acid (BHA), especially under the condition of weak alkalinity, the flotation recovery can reach 90%. The more negative interaction energy (ΔE) between BTHA and diaspore from molecular dynamics simulation results revealed that BTHA had an easier adsorption ablity onto diaspore than BHA, which matched with adsorption results. The zeta potential and XPS revealed that Al atoms might bond with -C(=O)NHOH by formation of Al-O bonds. Keywords: Diaspore, flotation; adsorption; 2-(benzylthio)-acetohydroxamic acid

Jan 1, 2020

By R. D. Alorro, B. Tadesse, E. Aghaei

Cinnabar (HgS) and native mercury (Hg) are the most common naturally occurring forms of mercury found in most gold ores subsequently released into the environment during processing. Mercury and its compounds are extremely toxic and recognised as serious health and environmental hazards. This research investigates the possibility of mercury (Hg) removal from waste solutions from gold processing using iron-aluminium (Fe-Al) bimetallic particles. The synthesis of Fe-Al bimetallic particles using zero-valent aluminium and ferric chloride as precursors were performed following the optimisation of influencing factors. The presence of both metals in the prepared bimetals was confirmed by XRD analysis. The experiments for mercury removal by bimetals were designed using the central composite design and Minitab software based on two variables including contact time and adsorbent dosage. The best result of Hg(II) removal (>90%) was achieved using 4 g/L bimetals and contact time of 75 min. However, the statistical analysis of results indicated that these parameters have only a minor contribution to the removal of Hg(II) by Fe-Al bimetals. Higher bimetal dosage and contact time resulted in a higher Fe dissolution from the Al surface which can be attributed to the presence of nitrate (# $) ions in the solution. However, adding 0.1 M NaCl to the Hg solution had a positive impact on Hg removal by improving the conductivity and electron transfer within the solution. The Fe-Al bimetallic particles are promising substances for further testing of Hg removal from gold processing waste solutions with different conditions and constituents. Keywords: Mercury removal, gold processing, Fe-Al bimetals, optimisation

Jan 1, 2020

By S. T. L. Harrison, M. A. Fagan-Endres, M. D. Odidi

This paper investigated the ability of eight common hydrodynamic models – tanks in series (TIS); three compartmental model configurations (Comp-1, Comp-2 and Comp-3); advection dispersion (AD); piston exchange (PE); piston exchange-diffusion variant (PE-D) and piston dispersion exchange (PDE) – to simulate residence time distribution (RTD) data generated from tracer tests conducted on a packed bed composed of different size fractions of malachite ore. The chosen materials were packed into 0.1 m internal diameter columns to a depth of 0.155 m and drip irrigated at 5.11 L/ m2.h. The four size fractions tested were: 1 – 2 mm, 2 – 2.8 mm, 4.75 – 5.6 mm and 13.6 – 16 mm. Step-up tracer tests were conducted using potassium chloride. The results showed that an increase in the particle size of the malachite ore had little effect on overall bed porosity but resulted in significantly lower values of liquid holdup. Two of the monoporosity models tested, TIS and Comp-2, were the most affected by the changes in bed size fraction due to their inherent inability to cope with high degrees of non-ideal flow present in the larger particle systems. The dual porosity models performed relatively better with the dominant trend being a reduction in dynamic to total liquid holdup as particle size increased. Of all the models tested, the PDE and TIS models were the best and worst performers respectively, with R2 values averaging at 0.997 and 0.679 across all experiments respectively. Though the Comp-1, Comp-3 and PE-D models also performed well, the addition of the dispersion coefficient to take the axial spread of fluid molecules into account added a layer of complexity that allowed the PDE model to perform relatively better than the other dual porosity models. Keywords: Heap leaching, packing material, hydrodynamics, malachite, PSD, modelling

Jan 1, 2020

By S. Blancher, A. Perroton, H Smith, T. Nzima, T. Wallmach, V. Dieudonné

Chromite beneficiation is generally performed by crushing and density separation using spirals. At the Dwarsrivier Chrome mine spiral efficiencies seam to vary, the reason for which is not evident. This sometimes results in the production of low-grade products, which are sold at relatively low prices. This paper represents a Qemscan® study that investigated mineralogical reasons for these variations. Variations in liberation of chromite particles as well as variations in chromite compositions were investigated. The results showed that the so-called low grade chromite product can be improved to become a high grade chromite product by means of a refinement in mineral processing. A detailed Qemscan® database (SIP file) was developed to account for variations in chromite chemistries. It can be shown that chemical variations with respect to Cr, Al, Mg and Fe in chromite particles reporting to the scavenger tails are larger than in the high grade product. A combination of these chemical variations together with a decrease in liberation of chromite particles in the scavenger tails can potentially help to recover more chromite particles from this specific process stream.

Sep 1, 2021

By A. Fouchee, N. Naudé, K. Schommarz

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

Jan 1, 2016

By E. Molobi

"Studs are rods threaded on both ends and are used as mechanical fasteners for two or more components. Stud finds usage in industries such as automotive, construction and aviation. The advantage of studs is that they allow for disassembly of components during maintenance. Studs are continuously subjected to both tensile and shear stresses, depending on the application, therefore they should be manufactured from suitable materials that are capable of withstanding all these external forces. Studs are sometimes manufactured from re-sulphurized steel due to its improved machinability; however, there is a certain limit on the amount of sulphur, above which failure may occur. Premature failure of studs has been a common problem, but failed studs are commonly replaced with new ones without conducting failure investigations. The present work investigates the premature failure of two re-sulphurized steel studs used on a rocker arm assembly and recommends alternative materials. The investigation was carried out by conducting visual examination, microstructural analysis, hardness measurements, chemical analysis and a detailed scanning electron microscopy (SEM) investigation on the fracture surface.IntroductionTwo rocker arm studs used on a 16-cylinder diesel locomotive engine failed prematurely after being in service for less than 5 months. The rocker arm studs had a life-cycle of 5 years. The studs were manufactured from resulphurized steel. The paper aims to establish whether re-sulphurized steel is applicable for the manufacture of studs in the automotive industry.BackgroundLocomotives are classified as either electric or fuel-powered. Diesel locomotives are an example of fuel-powered locomotives. This type of locomotive uses a diesel engine as a means for propulsion. An engine converts chemical energy into mechanical energy required for traction. In an internal combustion engine a rocker arm is an oscillating lever that conveys radial movement from the cam lobe into linear movement to open and close poppet valves of cylinders (Husain and Sheikh, 2013). The rocker arms are secured on to the cylinder head by rocker arm studs."

Jan 1, 2016

By M. -A. de Ville d’Avray, J. Bosman, S. Brochot

Dense Medium Separation (DMS) technologies are used for light (coal, lithium) or heavy (chromite, iron ore, diamonds) minerals concentration, but also for ore pre-concentration (Pb/Zn) or waste (plastics). Dense media are mainly formed from a suspension of magnetite or ferrosilicon in water. Such DMS circuit design or optimisation requires a full and detailed material balance which can be obtained by the aid of modelling and simulation tools. This balance is not limited to ore and its valuable minerals, but also the recovery of the dense medium itself. If the density is the main property used for separation, the particle size plays a non-negligible role, and, more precisely, the liberation classes which can be associated to the washability curve. The paper presents how the modelling and simulation platform USIM PAC can answer this challenge with the set of models for DMS operating units such as drums or cyclones, and their associated screens (drainage, rinsing) and magnetic separators for medium recovery. Some examples for mineral concentration will illustrate this approach. Keywords: Process simulation, process modelling, dense medium separation, process optimisation

Jan 1, 2020

By S. R. Grobler, S. Bilessuris, M. E. Greenway

Ensuring that all the head ropes on a multi-rope friction winder share the load equally has been a design and maintenance issue since they were first developed. Accurate machining of the rope grooves is necessary to meet this objective. Early analysis of the change of rope loads for ropes in grooves that are mismatched in depth treated the grooves as rigid. Groove depth tolerances deduced from this analysis are stringent and difficult to achieve in practice. Test work indicated that the inherent flexibility of groove lining materials alleviates the load-sharing problem. However, no analysis of rope load changes due to mismatched flexible grooves has been published. In this paper we develop new equations for the rope load variation for flexible grooves. By allowing flexibility to reduce to zero, the corresponding rigid rope groove equations are obtained. New criteria for tolerable groove depth variations are developed from this analysis, which depend on the flexibility of the groove lining material.

Sep 1, 2021

By B. Friedrich, A. Birich

Gold has been a metal of special importance for mankind for several thousand years. Its outstanding chemical resistance is an important property of this noble metal, but becomes a disadvantage when it comes to gold recovery. The established processes are based on highly aggressive and toxic reagents. Different alternative leaching reagents with a significantly lower toxicity proved to be promising alternatives in the last decades. Major research activities in this field focused on gold ores, so that leaching of secondary resources were not described sufficiently. Based on literature research and extensive experimental investigations, a reagent assessment was conducted for hydrometallurgical gold recovery from electronic waste. It was found that besides thiourea and halides, thiosulfate in particular represents an alternative of major relevance. A variety of different electronic waste (e-waste) specimens were investigated to identify suitable leaching conditions. As a result, an almost complete and selective gold recovery in less than 48 hours from different electronic waste types and components was achieved by thiosulfate leaching. Within the experiments conducted, it was found that the leaching behaviour of cyanide alternative lixiviants differ strongly from leaching of primary ores. Keywords: Gold leaching, cyanide alternative, thiosulfate, electronic waste

Jan 1, 2020

By T. Bezuidenhout, J. D. Visagie

In recent years the requirements for a barrier system between the waste body of tailings storage facilities (TSFs) and the natural ground (NG) has necessitated the use of HDPE-lined TSFs in South Africa and other countries. The addition of an HDPE liner creates an interface between, inter alia, the tailings and surrounding soils on the footprint of the TSF. It is known that low-strength materials beneath slopes can cause slope instability. One method which can theoretically mitigate this instability of a lined TSF is the addition of stability bunds along the footprint of the TSF. Altering the profile of the footprint to include slope changes which oppose the direction of the failure creates passive slices in a limit equilibrium analysis. The passive slices actively oppose the movement of active slices, resisting the mobilization of tailings, thus greater active slice forces are required to develop a failure surface running along the liner interface. Two scenarios are presented and compared. The first scenario retains the ground profile unaltered and the second scenario includes stability bunds along the ground profile. An in-depth assessment is made of the interslice forces and the interface shear stresses for each scenario. The theoretical background is discussed in greater detail to determine the mechanisms of reinforcement provided by the bunds.

Jun 2, 2022

By J. Pelders, G. Nelson

"Fatigue is a significant concern in the mining industry as it is a causal or contributing factor in many incidents and accidents. Fatigue can be caused by work- and non-work-related factors. There is a lack of information about associations between demographic and other non-work factors, and fatigue. This study aimed to assess associations between demographic, work, living, and socioeconomic conditions, and lifestyle characteristics, and fatigue at a platinum smelter in South Africa. Eight interviews with management and two focus groups with production workers were conducted, and 75 questionnaires were completed by production and other workers. Both work- and non-work-related factors were considered to be causes of fatigue. These factors included overtime, shift work, high workloads, activities performed outside of work, age, race, housing tenure, diet, sleep disorders, stress, and job satisfaction. In general, higher levels of fatigue were reported by younger participants, those who rented accommodation, ate less healthily, had a sleep disorder, and those with high levels of stress and low job satisfaction. As various demographic, lifestyle, and wellness-related factors were associated with fatigue, both work and non-work contributors should be addressed in fatigue management plans. BackgroundFatigue may be defined as ‘a state of impaired mental and/or physical performance and lowered alertness arising as a result of, or a combination of, hard physical and mental work, health and psychosocial factors or inadequate restorative sleep’ (BHP Billiton, 2005). Williamson et al. (2011) define fatigue as a biological drive for recuperative rest. Sleepiness and fatigue are related, and the terms are often used interchangeably. However, sleepiness, more specifically, can be defined as sleep propensity, or a person’s tendency to fall asleep (Hossain et al., 2003; Shen, Barbera, and Shapiro, 2006).Increasing levels of fatigue and sleepiness are associated with lapses in attention, errors, response slowing, fluctuations in alertness and effort, and impaired attention, working memory, long-term memory, decision-making, and creativity (Alhola and Polo-Kantola, 2007; van Dongen and Dinges, 2000). Fatigue is also associated with adverse effects on mood and impulsive behaviours (Alhola and Polo- Kantola, 2007; Minkel et al., 2011; Schwarz et al., 2013). It is a significant concern in the mining industry as it is commonly identified as a causal or contributing factor in many accidents and injuries (Schutte, 2009). Fatigue can also lead to long-term health problems, including digestive problems, heart disease, stress, and mental illness (Shaw, 2003)."

Mar 1, 2019

By S. W. Jacobsz, Y. Narainsamy

Several high-impact tailings dam failures around the world in recent years have placed a renewed focus on the stability of tailings dams and pointed to potential shortcomings in traditional drained design and safety evaluation procedures. A need to consider undrained shear strength in the design of tailings facilities has become apparent. However, there are specific requirements that need to be met before undrained shearing occurs. In South Africa, the last major failure was likely the Merriespruit disaster in 1994, which leads to the question of whether the conditions required for undrained shearing are readily applicable to South African tailings dams. This paper describes research at the University of Pretoria that has recently commenced to further investigate the conditions required for undrained failure to occur. The research includes laboratory and field testing to replicate these conditions in the laboratory and relate them to those found in an active tailings dam.

Jun 2, 2022

By S. Swanepoel, A. V. Cherkaev, Q. G. Reynolds, M. Erwee

Ferrochrome (FeCr) is a vital ingredient in stainless steel production and is commonly produced by smelting chromite ores in submerged arc furnaces. Silicon (Si) is a componrnt of the FeCr alloy from the smelting process. Being both a contaminant and an indicator of the state of the process, its content needs to be kept within a narrow range. The complex chemistry of the smelting process and interactions between various factors make Si prediction by fundamental models infeasible. A data-driven approach offers an alternative by formulating the model based on historical data. This paper presents a systematic development of a data-driven model for predicting Si content. The model includes dimensionality reduction, regularized linear regression, and a boosting method to reduce the variability of the linear model residuals. It shows a good performance on testing data (R2 = 0.63). The most significant predictors, as determined by linear model analysis and permutation testing, are previous Si content, carbon and titanium in the alloy, calcium oxide in the slag, resistance between electrodes, and electrode slips. Further analysis using thermodynamic data and models, links these predictors to electrode control and slag chemistry. This analysis lays the foundation for implementing Si content control on a ferrochrome smelter.

Mar 14, 2024

By J. Pelders, F. Magweregwede, S. M. Rupprecht

Increased depths of conventional gold and platinum mines, longer travelling times as working places move further from the shaft, and ancillary activities taking place in the mining cycle reduce the useable time spent at them workface. Current shift lengths of 8 hours 20 minutes may no longer be adequate ton complete required mining activities.The impact of mineworker commuting times on shift work is also not well understood. The aim of this research was to draft a framework to optimize shift cycles in order to maximize productivity, health, safety, and wellness in the South African mining sector. The framework was informed by a review of the literature, case studies at a local gold mine and platinum mine, and a workshop with industry experts. The findings indicate potential advantages of extended shift lengths and continuous operations, such as improved productivity, asset utilization, and employee morale. However, concerns included fatigue and the associated safety hazards, particularly when working longer shifts, night shifts, and numerous consecutive shifts. Job demands, personal factors, and commuting times are further considerations when scheduling shifts. The ideal shift system for the mining sector should holistically consider and balance operational requirements, health and safety, and employees’ and their families’ requirements, and suit the unique needs of each operation. Changes in shift cycles will require a structured change management process, which involves all stakeholders, and could help to enhance the viability of the South African mining sector.

Aug 1, 2021

By D. F. Malan, P. J. Le Roux

Almost no work has been published on the strength of pillars in mines exploiting the LG6/LG6A chromitite bands in the Western Bushveld Complex. The strength of these pillars is unknown, and the hard rock industry still uses the Hedley and Grant formula. Numerical modelling, using inelastic constitutive models, may be of some value in estimating the pillar strength, but this approach is difficult and prone to errors as many assumptions are made. This paper explores the alternative approach of the back-analysis of actual LG6/LG6A mining layouts, using displacement discontinuity codes to simulate the average pillar stresses on a mine-wide scale. From this, and underground observations, a ‘minimum’ pillar strength (K-value in the pillar strength formula) can be estimated. The codes TEXAN and Map3D are both used in the paper to simulate the actual pillar shapes and sizes in an LG6/LG6A mine. The results are encouraging as the two codes produced similar APS values for a complex pillar geometry. An estimated K-value of 77 MPa was determined for the LG6/LG6A pillars in this particular area. This is more or less similar to earlier work done for the UG2 chromitite seam, but higher than the K-value of 39 MPa for a linear formula obtained by other workers for LG6/LG6A pillars. Caution should therefore be exercised before using this higher value for all areas. The effect of element sizes and explicitly simulating the effect of the surface for shallow pillars is illustrated in the manuscript using both codes. The need for actual pillar observations and an iterative design process, which cycles between modelling and observations, is also emphasized.

Nov 27, 2024

By H. Manurung, I. M. Bendiayasa, W. Astuti, and H. T. B. M. Petrus, F Anggara, K. C. Wanta

The leaching kinetics of cerium (Ce) and yttrium (Y) in sodium-hydroxide-digested non-magnetic coal fly ash using acetic acid were investigated. The variables analysed were pH, solid-to-liquid ratio (S/L), and temperature. The results show that cerium and yttrium's maximum recovery was 57.33% and 58.36%, respectively, under leaching temperature of 90°C for Ce and 60°C for Y at pH of 1,74 and 10 g/mL solid-liquid ratio in 240 minutes. Increasing the leaching time to more than 120 minutes did not significantly improve the results. After the magnetic separation process, the ICP-OES analysis shows a slight increase in the concentration of cerium and yttrium on nonmagnetic components. The XRD and ICP-OES analysis for the sample before and after silicate digestion shows that 40% silicate was dissolved. The calculation of apparent activation energies of leaching using the Arrhenius law for the leaching of cerium and yttrium gives 22.72 kJ/mol and 35.84 kJ/mol, respectively. The kinetic leaching model of cerium and yttrium all fit Dickinson's new shrinking core model. The calculation results show that the leaching reaction is controlled by combining interface transfer and diffusion across the product layer.

Nov 6, 2024

By D. Orynbassar, N. Madani

This work addresses the problem of geostatistical simulation of cross-correlated variables by factorization approaches in the case when the sampling pattern is unequal. A solution is presented, based on a Co-Gibbs sampler algorithm, by which the missing values can be imputed. In this algorithm, a heterotopic simple cokriging approach is introduced to take into account the cross-dependency of the undersampled variable with the secondary variable that is more available over the entire region. A real gold deposit is employed to test the algorithm. The imputation results are compared with other Gibbs sampler techniques for which simple cokriging and simple kriging are used. The results show that heterotopic simple cokriging outperforms the other two techniques. The imputed values are then employed for the purpose of resource estimation by using principal component analysis (PCA) as a factorization technique, and the output compared with traditional factorization approaches where the heterotopic part of the data is removed. Comparison of the results of these two techniques shows that the latter leads to substantial losses of important information in the case of an unequal sampling pattern, while the former is capable of reproducing better recovery functions.

Aug 1, 2021