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By R. T. Jones

Keywords: Pyrometallurgy, DC arc furnace, myths, history, hollow electrode, radiation, resistance, flicker, AC DC arc furnaces are widely used for steel scrap melting as well as for reductive smelting of ore fines. Industrial smelting applications include the smelting of chromite to produce ferrochromium, the smelting of ilmenite to produce titania slag and pig iron, and the recovery of cobalt from non-ferrous smelter slags. A number of myths and misconceptions are widely held, especially regarding: the age of the technology, the use of a hollow electrode, arc stability and shape, arc and bath radiation, interaction between the arc and molten slag, electrical behaviour of arcs and slags, a comparison between AC and DC furnaces, DC reactors, the lifespan of bottom electrodes, and the applicability of DC arc furnaces to various metallurgical systems.

Jan 1, 2011

Published experimental data on thermodynamic behaviour of cobalt-containing slags have been reviewed and used in validating a recently developed thermodynamic model. The results from the exercise show that the model provides a reasonably good description of behaviour of cobalt in multi-component slag systems. The models for cobalt containing slags, matte and oxide solid solution phases were incorporated into CSIRO?s multi-phase equilibrium (MPE) package, which was used to calculate the equilibrium distribution of cobalt between matte and slag phases under various conditions. The results agreed well with the experimental data. Furthermore, the good agreement between the calculation and the plant data indicates that the operating conditions of industrial smelting and converting processes are close to equilibrium. Two diagrams showing the effects of slag chemistry and SO2and O2partial pressures on the distribution of cobalt between phases were generated for conditions similar to smelting and converting processes. These diagrams provide some useful guidelines for developing new strategies to improve cobalt recovery.

Jan 1, 2004

By M. D. G. Salamon

It has been noted in recent years that the pillars in some bord-and-pillar workings scale or spall. In due course this process may result in the collapse of the affected panels. This paper presents a methodology for assessing the long-term behaviour of such workings, employing a simple model of pillar deterioration by scaling. It is assumed that scaling causes a gradual reduction in pillar width, hence the safety factor of pillars reduces in time. It is also postulated that the process of scaling will be arrested if the coal rubble around the pillar reaches a critical height. The probability that the pillars will survive for a certain period of time, or indefinitely, can be estimated. This can be accomplished by using the log-normal distribution proposed by Salamon and Munro4todescribe the distribution of the apparent safety factor values at failure. If an estimate of the rate of scaling is known, it is also possible to quantify, using a Monte Carlo technique, the expected life of the pillars. The method also facilitates pillar design by specifying a probability of survival for a given number of years or, alternatively, for an indefinite period. Using the limited pool of available data, analyses show that the proposed model does not appear to be inconsistent with observed behaviour of pillars in the Vaal Basin. The crucial parameter is the rate of scaling. Back calculations from eleven cases suggest that the rate of spalling in the Vaal Basin is about 0.2 m/year. It is noteworthy that two further cases in the same area give significantly higher rates (0.85 m/year). Some underground observations in the Witbank area indicate considerably lower rates in the order of 0.02?0.04 m/year. Further areas for study are recommended. These include a study of old workings to determine the extent and rate of scaling in the various coal fields, an investigation into the possible relationship between scaling and the chemical composition of the coal. In addition, model studies will be required to assess the practical impact of the research findings.

Jan 1, 1998

By A. Boniface

The International Tunnel and Underground Space Association (ITA) has a number of working groups (WG) that meet at least once a year. One of these is WG12, ?Use of Shotcrete?, of which the author is a member. The purpose of this paper is to draw attention to a number of topics that were discussed at the WG12 meetings held in April and September 2008; and also to a number of other matters that arose from the presentation of thirty-four papers at the 5th International Symposium on Sprayed Concrete held in Lillehammer, Norway between 21 and 24 April 2008.

Jan 1, 2008

By J. Morkel

During research on mainly the weathering of kimberlite, it became evident that its mineralogical composition is an important factor in the complex process of physical and chemical disintegration. The mineralogy of tuffisitic kimberlite breccias from two localities, the Cullinan and Venetia mines, is compared with special reference to the occurrence of associated clay minerals. The clay mineral composition influences the engineering properties of these rock types. It is illustrated how the presence of swelling clay components can be confirmed by ethylene glycol treatment and chlorite minerals by heat treatment using X-ray diffraction. Smectites are present in both tuffisitic kimberlites, dominant at Venetia while chlorite is more frequent at Cullinan. More tuffisitic kimberlite breccias samples from venetia were also characterized. It was found that kimberlite disintegration is correlated with the presence and abundance of smectite.

Jan 1, 2006

South Africa remains the largest global producer of gold, accounting for 11.3 per cent of total world mine production, which amounted to 2520.2 t in 2005. The benefits and disadvantages associated with hedging practices in general, and among South African gold producers is examined. The wide variety and unique nature of risks faced by the mining industries provide a strong case for hedging. Only the principles of hedging, such as selling ounces of gold in the ground at a pre-agreed price for delivery at a future date as a cost-effective mechanism for price risk management, is discussed. Progressive and cumulative increases in the volume of forward sales in the major producing countries are considered by many to be the cause of the declining gold price over the past decade. In spite of negative publicity, forward selling continued as an industry-wide practice until recently (2002) when the global hedge book contracted by 352 t; contraction amounted to 158.6 t in first quarter of 2006. The objectives and benefits of hedging include continuity and stability of cash flows, stability in price achieved, reduction of frictional costs, and creating an effective management tool. The importance of a defined hedging strategy in reducing uncertainty about the hedging objectives is essential to a successful hedging policy. Historical patterns in hedging revenues at an industry level indicate five distinct periods during which the fortunes of hedgers have fluctuated. Finally, since 2001 the rising gold price and reduced price volatility through the consolidation in the global price means that the need to stabilize revenue flows is less urgent. This has meant that hedging is becoming progressively less important for the mining industry at large.

Jan 1, 2007

By P. Dennis, T. Pieters, A. De Kievit, S. Ganguly

TEMCO has been producing manganese ferroalloys in submerged arc electric furnaces for over 40 years. The furnace linings all along have been of conventional insulation type until 2001 when a freeze lining of UCAR concept was installed for a 20 MW Furnace. Continuous improvement of furnace lining performance has been a key component in improving the business competitiveness of TEMCO. The expected minimum campaign life of the freeze lining is fifteen years as compared to the ten years of the conventional linings. The success of the freeze lining is very critical to the quanta and direction of heat flow through the lining that control the freeze protection. Under freeze protection can lead to reduced lining life and over freeze protection, on the other hand, can lead to operating difficulties and loss of smelting efficiency. It was, therefore, necessary to develop a computer based system to monitor and control the freeze protection. The computer based monitoring and control system uses the basic principles of heat transfer, activeX object and heat flux from dual thermocouples and that is reviewed.

Jan 1, 2004

By C. S. Chenga

Sustainable development is currently an extremely relevant concept worldwide, especially in developing countries like South Africa. Mining and metals companies are also directly affected by the sustainable development agenda. The Mining Charter?s requirements as well as new legislation (Mineral and Petroleum Resources Development Act) expect, among others, for mines to support infrastructure and poverty eradication projects in the communities surrounding the mines. The aim of this paper is to, against the background of a qualitative study of mining communities in the North-West Province of South Africa, put forward some critical factors for the sustainability of social development projects in the mining sector.

Jan 1, 2006

By P. C. Schutte

The objective of ergonomics is to enhance the effectiveness and efficiency with which human tasks are carried out. Furthermore, the objective is to improve desirable human values. This can be achieved by enhancing safety, reducing fatigue and stress, increasing comfort, increasing job satisfaction, having greater user acceptance and thereby improving the quality of life. Mechanization has influenced the prevalence of injury, mainly due to the application of human physical effort as the power source. With mechanization, the operator?s function is now essentially one of control rather than being an energy source, however, the risk of injury has not diminished. Mechanization in itself has introduced inefficiencies, health risks and physiological stress. The major objectives of ergonomics are discussed through examples of acceptable and less successful implementation of ergonomics within mechanized mining. The influence of the machine system on the human is addressed and practical solutions to improve and optimize the interaction of the human and the machine are outlined. Furthermore, practical examples of control and display integration, anthropometric and biomechanic influences on design, orientation, posture and stereotypes are used to accentuate the advantages of the application of sound ergonomics principles to the specialized area of mechanized mining.

Jan 1, 2002

By W. A. Naismith

On 16 July 2004, at 07:10 a collapse of about 1.8 million m3 (about 4 ½ million tons) took place on the north wall on Nchanga Open Pit. This collapse was the result of a developing instability that was first identified when the benches in this area were exposed during September 2002. The NOP geotechnical and survey departments closely monitored the development of the failure. Control measures were implemented to reduce risk to men and equipment. These measures were continually improved and adjusted in reaction to observations and changing conditions. The purpose of this paper is to describe in detail the monitoring results that were obtained both by traditional methods and the novel slope stability radar system (SSR). Difficulties encountered in establishing critical deformation levels and deformation rates that can be used to predict the onset of collapse are described. Details of the monitoring and control measures, which led to the successful completion of mining in the area, are also described in this paper.

Jan 1, 2005

By F. T. Cawood

This research report was produced in response to the release of the Mineral and Petroleum Royalty Bill. It involved are view of the mineral investment environments of selected countries in order to form an opinion on the appropriateness and competitiveness of the proposed royalty structure for South Africa. Many emerging countries have recently attracted a significant share of foreign investment, as a direct result of changes in policy. These are, by implication, the least risky and most favourable destinations for the ?investment dollar?. The five most competitive countries, namely Chile, Argentina, Peru, Mexico and Brazil have been identified as succeeding with their policy visions of creating favourable domestic investment environments. The investment rules of these countries served as a basis for the compilation of a Competitive Investment Framework (CIF). This is a template of best practice against which other investment environments, such as that of South Africa, can be measured. The framework indicates that mineral royalties should ideally be no more than three per cent, demonstrating that the regime proposed in the Royalty Bill is out of step with international best practice. Mineral royalties can never be viewed in isolation and in the assessment of the rates proposed in the Royalty Bill, one must consider the total taxation package. Such assessment appears in Section 5 of this report, demonstrating that there is reason for concern if National Treasury were to impose the rates stipulated in the Royalty Bill. The alternatives, conclusion and recommendations of the review appear in Sections 9 and 10. These are the result of independent analysis and assessment of the fundamental principles. It is done through the application of a Competitive Investment Framework that avoids the highly subjective and emotional views that often accompany a process like this.

Jan 1, 2003

By H. Aykul

The choice of which mining method to use at many large surface coal mines is often dicated by what machinery is available or what experience the mine management can offer. One of the most significant surface coal mines in Turkey is owned and operated by the Turkish National Coal Board, located to the west of the city of Kütahya. The Seyitömer Lignite Enterprise (SLE) extracts low quality coal, the majority of which is supplied to an adjacent power station. The coal seems at SLE contain bands of ash which under normal mining conditions are extracted with the coal. This increases the ash content of the run of mine coal and results in lower efficiency at the power station and financial penalties for SLE. In this paper, therefore, selection of the best possible equipment and production method was identified to achieve high selective mining at SLE. The research found that two different high selective mining methods were suitable for selective excavation of the B3 seam, which were hydraulic excavator and truck and surface miner and truck combinations. It was also found that high selective excavation could provide the desired coal quality at 52% lower costs when the whole process (excavation, transportation, processing, etc.) was considered. Keywords: coal mining, surface mining, selective mining.

Jan 1, 2007

By M. Hopf

The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However, even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able consistently to identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed).Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa. Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway

Jan 1, 2006

The coal-based power generation industry faces increased pressure from all sectors to improve its environmental performance. This is due to increased awareness of and concerns regarding greenhouse-and acid-gas emissions, toxic metal releases (to both air and water) and water availability. A methodology to assess this industry?s environmental performance is needed. Such a methodology should assess all environmental impacts accurately, recognizing the irspatial and temporal dependence, and taking into account the social acceptability of technologies employed. Here, we develop a methodology to determine the environ-mental impact associated with solid wastes generated by this industry, and apply this to the specific case of ash management. More specifically, the case study compares the environmental footprint of an ash deposit for a number of operational water management scenarios. The methodology considers leachate generation processes from ash impoundments to obtain a time-dependent concentration profile of mobile constituents at the interface between the ash impoundment and the surrounding environment. This leachate prediction modelling is subsequently linked to plume dispersion modelling tools to determine the fate and transport of leached components, predominantly salts, into groundwater. Together, these provide a measure of the extent to which a land mass is affected by leachate migration from the deposit. To determine the exact boundary between regions of acceptable and unacceptable risk to the environment, we use Ecological Risk Assessment concepts. In this way it is possible to obtain a time dependent affected land footprint which could be used as an indicator of the environmental impact of solid waste management practices. This information can be included in a set of environmental criteria which form the basis of an overall environ-mental impact assessment, using tools such as Life Cycle Assessment (LCA). The value of LCA is that its structure is consistent with accepted models of environmental decision making, where different approaches to valuation in impact assessment assist in prioritizing impacts on the basis of their perceived significance. The proposed ?affected land footprint? metric represents a significant improvement over current LCA impact indicators for solid waste management practices. Keywords: Environmental Impact Assessment, Environmental Risk Assessment; Life Cycle Assessment; coal ash; leachability; salinity

Jan 1, 2002

By S. M. Bradshaw

The principles of microwave heating are discussed with reference to dielectric properties, heating phenomena and microwave equipment. Microwave regeneration of granular activated carbon for the carbon-in-pulp process is examined on a laboratory scale, with special attention being given to highlight the problem areas and specific considerations related to microwave heating. Results indicate that microwave regeneration of carbon with 40% moisture on a wet basis by heating to 650°C with steam addition regenerates the carbon to virgin carbon activity levels but with a higher abrasion resistance. A preliminary economic assessment showed that the capital cost for 120 kg/h microwave unit would be R540 000 with an annual operating cost of R 320/t carbon. These figures yield a return on investment of 12%. The aim of this paper is to provide an introduction to microwave heating and to illustrate its application to the microwave regeneration of granular activated carbon for the carbon-in-pulp (CIP) process.

Jan 1, 1998

Elongates are commonly used as stope support in South African gold and platinum mines. To evaluate the effect of the inherent strength, stiffness and yield variability associated with elongates, a statistical method is presented which addresses and quantifies the support performance at various levels of certainty. The analysis, which is based on a normal distribution, makes use of force-deformation curves determined from multiple laboratory compression tests on the same support type. The applicability of the method is illustrated making use of actual performance capabilities of various types of elongates. In order to ensure a high probability that support units installed underground exceed the standard support performance curve established by means of laboratory tests, the statistical mean of a suite of tests based on the same support type is downgraded. The ?correction factor? is a function of the mean and standard deviation of the test data, as well as the sample size of units deemed to control the local rock mass stability. It is shown that downgraded performance curves based on a high probability (90 to 95percent) of support units exceeding this performance level are suitable to ensure that the design of support systems will in variably meet the design criteria. In the highly discontinuous hangingwall rock mass typically associated with intermediate- and deep-level mining operations, the interaction between adjacent support units is comparatively limited (at the support spacings commonly used). Therefore, the appropriate sample size (n) of the support units controlling the local rock mass stability should be n= 1. In shallow mining conditions, sample sizes of up to n=5 may be warranted, depending on the spacing of joints and other discontinuities in the hangingwall.

Jan 1, 2001

The aim of this research was to study the absorption characteristics of thermally dried fine coal from South African collieries. After milling to ?150 µm and pressure filtration, the samples were subjected to either air drying or thermal drying at 150°C. The samples were then put into a climate box at 28°C and at three different relative humidity levels, namely 30, 60 and 94 per cent. It was found that the equilibrium moisture content of thermally dried coal at a specific relative humidity was lower than that of air dried coal. The relationship between the equilibrium moisture content and relative humidity is described by 1 ? RH = exp (-KTMen). There was no relationship between the volatile matter content and equilibrium moisture content, but there was an increase in the equilibrium moisture content of the coal with an increase in mineral content. The moisture uptake rate increased with an increase in temperature and a decrease in particle size. A model is discussed that fitted the experimental data and gave a good prediction for changes in the conditions. There was no evidence of greater moisture absorption by thermally dried coal. Keywords: Fine coal, thermal drying, drainage, South Africa, drying

Jan 1, 2002

By H. J. Glass

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

Jan 1, 2003

In recent years several mine researchers have studied the optimization of cutoff grade with the purpose of maximizing Net Present Value (NPV). The best and most popular one is the Lane algorithm. Based upon the Lane algorithm it is possible to calculate the optimum cutoff grade for mine, mill, and refinery capacities for single metal deposits with variable grades. The Lane algorithm cannot be used in multiple metal deposits. The reason is that, while in single metal deposits six points are possible candidates for the optimum cutoff grade, in multiple metal deposits an infinite number points are possible candidates for the optimum cutoff grades and objective function evaluation of these infinite points is impossible. In this study the Golden Section search method was used to calculate optimum cutoff grades of multiple metal deposits for the same conditions as Lane assumed in single metal deposits. Based on this method, grade-tonnage distribution uncertainty space of problem is guessed. In the next step, by selecting test points in uncertainty space and evaluating the objective function at these points, a part of uncertainty space will be eliminated. The procedure is then repeated until the uncertainty space has been sufficiently reduced to ensure that the optimum cutoff grades have been located to the required accuracy. Key words: Optimum cutoff grades, Optimization, Net Present Value (NPV), Golden Section search method

Jan 1, 2003

By V. Pawlowsky-Glahn, E. Pardo-Igúzquiza, J. J. Egozcue, R. A. Olea

Compositional data constitutes a special class of quantitative measurements involving parts of a whole. The sample space has an algebraic-geometric structure different from that of real-valued data. A subcomposition is a subset of all possible parts. When compositional data values include geographical locations, they are also regionalized variables. In the Earth sciences, geochemical analyses are a common form of regionalized compositional data. Ordinarily, there are measurements only at data locations. Geostatistics has proven to be the standard for spatial estimation of regionalized variables but, in general, the compositional character of the geochemical data has been ignored. This paper presents in detail an application of cokriging for the modelling of compositional data using a method that is consistent with the compositional character of the data. The uncertainty is evaluated by a Monte Carlo procedure. The method is illustrated for the contents of arsenic and iron in groundwaters in Bangladesh, which have the peculiarity of being measured in milligrams per litre, units for which the sum of all parts does not add to a constant. Practical results include maps of estimates of the geochemical elements in the original concentration units, as well as measures of uncertainty, such as the probability that the concentration may exceed a given threshold. Results indicate that probabilities of exceedance in previous studies of the same data are too low.

Jan 1, 2015