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By C. van Buuren, R. F. Sandenbergh, P. J. Pieterse

Gold extraction from double refractory ores using conventional cyanidation has proved challenging due to the presence of carbon within the ore. Carbon particles may adsorb leached gold resulting in gold losses to tailings, i.e. preg-robbing the gold. Some of the preg-robbed gold may be recovered by the application of the HiTeCC process on CIL tailings. The process developed by Metso Outotec involves caustic conditioning of the tailings followed by high temperature desorption and simultaneous adsorption onto virgin activated carbon of the aurodicyanide. The aim of this paper was to develop a model for the HiTeCC process which could be used to support design and optimisation of the process, based on the adsorption characteristics of the preg-robbing and activated carbons. It was found that accurate experimental isotherms can be used to predict the behaviour of preg-robbing adsorbents. Comparing the sorption isotherms for preg-robbing ores and activated carbon indicated similar dependencies on temperature and ionic composition. Applying boundary layer diffusion models coupled with experimentally determined isotherms for preg-robbing ore and activated carbon, the HiTeCC process was successfully simulated at experimental and plant scale. Gold recovery of the HiTeCC process is most sensitive to the temperature of desorption and gold loading of the activated carbon, with increased temperature improving recovery. The gold loading of the activated carbon in the process should always be maintained lower than that of the normalised pregrobbing carbon gold loading to ensure favourable conditions for adsorption onto the activated carbon. Caustic conditioning stabilises adsorption and is therefore not necessary during the desorption stages of the process, but potentially improves recovery during adsorption. Keywords: Preg-robbing, refractory gold ores, HiTeCC, aurodicyanide

Jan 1, 2020

Rock mass classification systems are extensively used in rock engineering design work, and mine design is no exception. Among the systems most widely used for mining-related design work are the NGI 0-system (Barton et al., 1974), the RMR system (Bieniawski, 1976), the MRMR system (Laubscher and Taylor, 1976) and, more recently, the GSI system (Hoek et al., 1998). Classifying the rock mass is widely seen as being the fieldwork required to characterize the rock mass and enable the application of empirical design methods associated with the different classification systems. This paper argues that it is fundamentally important to recognize the distinction between rock mass characterization and rock mass classification. These two processes should, in most cases, be separated from each other. Rock mass characterization should be used to determine the intrinsic properties of the rock mass independently of the application; i.e. independent from the infrastructure to be designed, the size, shape, and orientation of the excavation(s) or pillar(s), etc. Rock mass characterization should also be compatible with most classification systems and empirical design methods to be used. Rock mass characterization is the background fieldwork required to perform rock mass classification and/or engineering design work. Rock mass classification is the subsequent step to the characterization, and an integral part of the design process. Parameters that vary according to the design, such as the relative orientation of geological structures compared to the opening or the mine-induced stresses, should be calculated as part of the rock mass classification and design process, rather than during the rock mass characterization process. The failure to distinguish between rock mass characterization and rock mass classification can lead to major design errors and poor results.

Jan 1, 2012

By A. J. Vietti

"Drought conditions and the possible lack of sufficient raw water supply are a constant reminder to the Southern African diamond miner of the need to minimize raw (new) water input while maintaining or expanding mine throughput.Since water input volume is directly related to water output (loss) volume, mainly to the tailings, it is obviously beneficial to dewater the tailings as much as possible. However, this may not always be as easily achieved as first thought. Owing to the unique mineralogy of each kimberlite deposit and the unique chemical profile of each raw water source, dewatering of the slurry is not a standard process that can be applied equally across the entire diamond industry.This paper presents a first-step strategy that kimberlite diamond mine operators should consider and apply to meet and exceed their watersaving targets. Introduction A common metric for measuring water use efficiency in a metallurgical plant is the amount of raw water used per ton of head feed treated (m3/t). The metric includes all water recycled from the dewatering process and from the tailings storage facility (TSF), and the only inputs are tons of ROM ore and cubic metres of raw water make-up to replace water lost to evaporation, seepage, and lock-up at the TSF (Figure 1).The volume of new raw water available to the process is not unlimited and a maximum monthly allowance is typically set during the mine permitting process. Consequently, if the volume of water lost exceeds the volume of new water available or alternatively, in times of drought where the allowable volume is unavailable, the plant has no other option but to reduce throughput.However, if the plant operator is able reduce the volume of water lost to the TSF, the plant will have additional capacity to either increase tonnage throughput or sustain nameplate capacity during periods of severe drought. The obvious conclusion, therefore, is to reduce the volume of water lost to the tailings by improving the efficiency of the dewatering process (typically gravity thickening) simply by increasing the density of the tailings being discharged. In practice, however, the unique mineralogy of each kimberlite deposit and the chemical profile of the raw water source used imply that at some mine sites, solid/liquid separation (or settling) of tailings slurries at the dewatering process is more easily achieved than at others. In these cases, simple practical steps such as firstly improving the flocculant reagent make-up and dosing control, and secondly focusing on thickener discharge control, are the only requirements for enhancing water recovery at the dewatering circuit. At other mine sites however, solid/liquid separation of the tailings may not be achieved at all, in which case efforts to increase water recovery by improving reagent dosage and thickener control would be fruitless unless the colloidal properties of the thickener feed slurry are modified."

Feb 1, 2019

By J. O. Roux

The Impala Platinum Limited Base Metals Refinery in Springs, South Africa, refines convertor matte containing base metals and PGM?s (platinum group metals) using a hydrometallurgical process. In addition to a PGM-rich concentrate that is further refined, the Base Metals Refinery produces nickel (in powder or briquette form), copper cathodes and cobalt powder. Five leaching stages are utilized to remove the base metals and impurities from the PGM concentrate. The project described in this paper involves a radical redesign of the second stage leach autoclave with the aim of reducing maintenance costs and downtime, increasing throughput and ensuring a safer working environment. The second stage leach process at the Base Metals Refinery, produces a PGM-rich residue through the extraction of copper and any remaining base metals from the first stage leach solid residue material. Leaching is performed in an autoclave operating at a pressure of 600 kPaG and a temperature of 140°C to 150°C. Concentrated H2SO4 is added to the feed to produce a solution with a free acid content between 10 and 30 g/L and a pH of less than 2. Oxygen is passed into the 1st and 2nd compartments of the autoclave. As a result of the aggressive, highly oxidizing conditions within the autoclave, the original design utilized a heavy wall carbon steel shell with lead lining and two layers of acid bricks. The bricks acted as a wear resistant material and ensured a low surface temperature at the skin of the lead lining, whereas the lead lining acted as a corrosion barrier to protect the steel shell. These brick lined autoclaves were heavy, maintenance intensive and prone to catastrophic failure. A radical autoclave redesign was needed to reduce the high costs of manufacturing, installation and operation. Finite element modelling was used to optimize the design and various high alloy materials were investigated for the application. Based on extensive test work, the carbon steel shell was replaced with duplex SAF 2205 stainless steel in the new design. The use of this highly corrosion resistant material, eliminates the need for the lead and brick linings and reduces the wall thickness requirements substantially, resulting in an increase in the available volume for the same external shell dimensions. The vessel is welded in circular sections to form an elongated, impermeable, cylindrical body, with several agitator nozzles and compartments. The first new duplex stainless steel unit has been in continuous operation for more than 24 months and its performance has exceeded the highest expectations. The design was so successful that a patent has been registered. The major benefits of the new stainless steel design include increased throughput, improved performance, less downtime and a safer working environment. Lead has been eliminated and replaced with a more environmentally safe material, and the total lifespan of the vessel has been extended. In addition, the autoclave project has made significant developments in advancing the field of welding and optimizing the integrity of welding quality standards in South Africa.

Jan 1, 2009

By T. P. Letsebe, L. Magwaza, T. A. Sethu, S. M. Rupprecht

"The authors were tasked with introducing safe and efficient drilling and blasting practices to a small artisanal mine located in the Eastern Province of Rwanda. The current mining methods employed at the mine are inefficient as rockbreaking is conducted utilizing hammer and chisel, or by drilling and blasting with no understanding of the rockbreaking process. The paper discusses the drill and blast cycle, as well as the associated activities necessary to support the mining cycle. The challenges and critical aspects in implementing drill and blast activities are discussed, as well as some of the technical aspects, i.e.drilling pattern, initiation and timing of the blast, and handling of misfires. Ancillary issues such as ventilation, training, communication, effective planning, logistics, and human relations are also examined. IntroductionRockbreaking accounts for 60% of the direct mining costs in small-scale mining. When drilling and blasting practices are poorly implemented the process becomes inefficient and dangerous. The introduction of a proven drill and blast system to artisanal mining offers a number of challenges, with safety being considered the backbone of any sustainable operation and a standard that cannot be compromised.The paper is based on a project at an artisanal cassiterite (tin) mining operation in a small village in the Kayonza District in the Eastern Province of Rwanda. A drill and blast programme utilizing industry best practice was introduced at an underground development end; a raise developed at an inclination of 23 degrees. The underground working is accessed via a 17 degree incline shaft with an operating length of 105 m and serviced by a single drum winder. The winder operates at a speed of about 3.5 m/min hoisting two 1 t wagons from the bottom of the incline to surface for tipping (Figure 1)."

Jan 1, 2017

By J. M. Paull, J. B. See

The rate of reaction between different carbonaceous reducing agents and silicon monoxide gas was studied by the use of a technique developed in Norway by Tuset and Raaness. Argon carrier gas was used to pass a known fixed concentration of silicon monoxide gas through an I1 cm3 sample of precalcined reducing agent at 1650°c. Silicon monoxide gas was generated by the heating of a mixture of silica and silicon carbide, and the progress of the reaction was followed by monitoring the carbon monoxide in the off-gas with an infrared spectrometer. The reactivity of silicon monoxide gas towards a number of carbonaceous reducing agents (charcoal, Iscor coke, Lurgi char, and petroleum coke) was shown to be similar to results obtained with the carbon dioxide reactivity test. The silicon monoxide reactivity test was able to indicate the extent to which fines were generated when the reducing agent was converted to silicon carbide. Of the reducing agents studied, Lurgi char appeared to be the most suitable for the production of ferrosilicon because it has a high reactivity towards silicon monoxide gas and high strength when converted to silicon carbide. So that industry could be given some indication of the suitability of certain reducing agents for the production of ferrosilicon and silicon metal, a reactivity scale similar to that of Tuset and Raaness was constructed that compares the volume of silicon monoxide gas required by a reducing agent to reach a carbon monoxide content of 10 per cent in the off-gas during the conversion of the reducing agent to silicon carbide. This scale assists in the selection of those reducing agents that require less silicon monoxide gas for conversion to silicon carbide, and that give savings in material and power costs because less silicon monoxide gas need be generated in the furnace.

Jan 1, 1979

By H. M. Krieg, M. J. Ungerer, C. G. C. E. van Sittert, D. J. van der Westhuizen

"The transition metals tantalum (Ta) and niobium (Nb) are of significant importance, for example in the nuclear energy sector where they are used as cladding materials, as well as in capacitors and specialized materials. For these applications a high-purity metal is needed. The separation of Ta and Nb is always a challenge since they are found together in nature and have similar chemical and physical properties, resulting in costly and laborious separation processes. A technology that has been used successfully for the separation of these metals entails solvent extraction (SX)1. While separation was achieved in a previous SX study using a sulphuric acid (H2SO4) medium with the extractants diiso-octyl phosphinic acid (PA) and di-(2-ethylhexyl) phosphoric acid (D2EHPA), due to the absence of speciation data for Ta and Nb it is not clear how the separation occurred.One method that might be suitable for determining the speciation of a reaction is molecular modelling. Calculations based on the densityfunctional theory (DFT) are now used not only for light elements and small molecules, but also metal complexes, heavy metals, and especially metal separation in SX2. In this study the aqueous phase used during SX was investigated by studying periodic systems of Ta, as a metal and in salt form, when it is in contact with H2O and H2SO4. The results were used to predict the reaction mechanism occurring during SX. Results showed that (i) in a 1:1 acid-water ratio, the deprotonation of H2SO4 was endothermic, (ii) in a 1:5 ratio deprotonation was exothermic forming HSO4 -, and (iii) in a 1:10 ratio double deprotonation occurred to form SO42- exothermically."

Jan 1, 2017

PRESENT Minutes of the Annual General Meeting, held on Friday the 20th August, 1971, at 7.45 p.m. in the Boulevard Hotel, Witbank. Mr J. Meintjies in the Chair, 15 Fellows, 7 Members, 2 Associate Members and 10 Visitors. Mr Meintjies extended a welcome to all the members and their wives, and the many visitors and their wives. A special welcome to Mr Robinson the outgoing President of the Institute and Prof. Howat the President Elect and Mrs Howat. The minutes were read and adopted. The Chairman read his Report for the past year and also the Financial Statement. Mr E. Jackson proposed the acceptance of the Financial Statement and Mr Winship seconded it. Mr Meintjies thanked Mr Vic Robinson for all the help he had given throughout the past year. He also thanked the outgoing Committee for their support, and the Secretary for arranging the function. Mr Meintjies congratulated Mr Alex Bain on his election as Chairman and asked him to continue with the meeting. Mr Bain thanked Mr Meintjies for the good work which he had done in the past year and then announced the names of the Committee for the ensuing year. A. Bain Chairman G. Carlyon Vice Chairman J. Meintjies Past Chairman I. Botha E. J. Jackson A. W. L. Brereton B. D. McNiece N. J. P. Coetzee A. N. Turner B. T. Hosking W. D. Winship Mr B. D. McNiece proposed a vote of thanks to the retiring Chairman. The meeting closed at 8.10 p.m. Dinner was served and after coffee Mr Vic Robinson gave a most amusing and informative review of the Institute's activities. Mr Bain thanked Mr Robinson for his address and Prof and Mrs Howat and Mr Robinson for coming down to Wit bank for our Annual General Meeting.

1. Reviews Extraction metallurgy, by J.D. Gilchrist. 3rd ed. Oxford, Pergamon, 1989. 431 pp. £50.00 (hard cover), £14.95 (soft cover). Reviewer. Prof. M.D. Brayshaw. Reviewer. Prof. M.D. Brayshaw This third edition bears testimony to a work that contains much of value for lecturers, students, and practising metallurgists. Mineral processing in the United Kingdom, edited by P.A. Dowd. London, Institution of Mining and Metallurgy, 1988. 223 pp. £25.00. Reviewer: Prof. M.D. Brayshaw It came as both a pleasure and a challenge for a resident of South Africa (with its volume and diversity of minerals) to review a book focusing on the beneficiation of ores from the sparsely endowed mineral chests of the United Kingdom. 2. Recent issues Rock mechanics. Theory and applications with case histories, by W. Wittke. Translated from German by R. Sykes. Berlin, Springer-Verlag, 1990. 1076pp. DM248. McGregor's quick reference to the JSE. Pretoria, Juta & Co., 1990. R39,95. McGregor's economic alternatives. Pretoria, Juta & Co., 1990. 400 pp. R34,95. 3. New journals Journal of Materials Chemistry, edited by A.R. West and J. Leader, and published two-monthly by The Royal Society of Chemistry (Blackhorse Road, Letchworth, Herts SG6 IHN, OK). £195 per year, starting in 1991. New Materials World, published monthly by Lawrence Cooklin (15 Selvage Lane, Mill Hill, London NW? 3SS, OK). £180 per year. Mendeleev Communications 4. Books from The Institute of Metals The following were published recently, or are to be published soon, by The Institute of Metals, 1 Carlton House Terrace, London SWl Y SOB, OK. Illustrated case histories of marine corrosion. 1990. Modern steelmaking methods, by C. Moore and R.I. Marshall. 2nd ed. 1990. Grain boundary fractures, by S.F. Pugh. 1991. 160 pp.

Jan 1, 1991

By N. A. Barcza

An investigation was conducted into the reactions between the slag system MnO-CaO-MgO-SiO2(AI2O3) and the alloy system Mn-Fe-Si-(C). Synthetic slags representative of plant melts and a plant alloy were reacted in alumina crucibles at temperatures of 1400°C, 1450°C, 1550°C, and 1600°C. In similar experiments, slags were used that comprised a South African manganese ore with various amounts of lime and several synthetic alloys with various silicon contents and manganese-to-iron ratios. These experiments were conducted in a vertical molybdenum-wound resistance furnace with full temperature control. Slag-to-alloy ratios were also varied during the tests. The rate of reduction of Mn.O3 and the MnO from the slag by the silicon in the alloy was extremely rapid, most of the reaction being completed within five minutes. The strongly exothermic nature of the reaction resulted in considerable generation of heat at the slag-alloy interface, causing convectional stirring of the contents of the crucible and promoting the rate of reaction. Equilibrium was usually attained after fifteen minutes. The major limitation governing the recovery of manganese is the need for the silicon content of the alloy to meet a maximum specification of 2 per cent. Higher concentrations of silicon in the final alloy of between 8 and 12 per cent favour good recoveries of manganese from the slag, but, since such an alloy is not salable, lower recoveries must apparently be tolerated. In alloys of 2 per cent silicon, low activities of the silicon are responsible for poor recoveries of manganese. The activity of MnO in the slag can be increased by moderate additions of CaO and small amounts of MgO, i.e., by an increase in the basicity of the slag.

Jan 1, 1979

By M. Dworzanowski

The difference in the magnetic properties of minerals is the basis for magnetic separation. All minerals can be generally classified as ferromagnetic (strongly magnetic), paramagnetic (weakly magnetic) or diamagnetic (non-magnetic). Magnetic separation can be conducted dry or wet. The majority of the applications of wet magnetic separation in the mining industry are based on the wet drum magnetic separator. The wet drum magnetic separator has been in use for over 50 years and its design is based on a rotating drum installed inside a tank. Inside the drum are stationary, permanent magnets arranged in an arc to provide the magnetic field. These magnets can be of the ceramic ferrite type providing a low intensity magnetic field or of the rare earth type providing a high intensity magnetic field.

Jan 1, 2010

By K. B. Owusu, W. Skinner, R. K. Asamoah, J. Karageorgos, M. Zanin, C. Greet

High Pressure Grinding Rolls (HPGR) are mostly used prior to pelletising processes to increase the specific surface area (SSA) of iron ore concentrate. For expressing SSA, the Blaine index is utilised as one of the most important dimensional properties of iron ore pellet feed. ISO 21283 is a standard test method that explains the manual of Blaine air-permeability apparatus for determination of this parameter. In this standard, the disaggregation method is based on passing the minus of 1 mm samples from the 0.150 mm sieve. The disaggregation process has an effective role on the results of Blaine airpermeability test especially for regrinding HPGR products. In this research, firstly the Blaine index of samples was measured without disaggregation. Following this, disaggregation was done by passing the minus of 1 mm samples through three sieves with different dimensions, 0.150, 0.090 and 0.045 mm, separately, and the Blaine index was calculated for each one. Finally, lab-mill with rubber balls, called Jar mill, was investigated as another option. Screen analysis and image analysis with SEM were performed to evaluate the effects of the sample's disaggregation on the size distribution and agglomeration of samples. The results showed that the disaggregation method with sieve size 0.150 mm, according to ISO 21283, was not applicable for HPGR products because the particles were still stuck together. In addition, the disaggregation method with the sieve size 0.045 mm or with Jar mill offered reasonable results. Keywords: Disaggregation, Blaine index, specific surface area, regrinding HPGR, ISO 21283, Jar mill

Jan 1, 2020

By D. van Rensburg

Jointed rock slopes are generally stable, as there is no freedom of movement for blocks of rock. In an open- pit mining environment, blasting opens up space into which blocks of rock can fail, resulting in the common occurrence of slope failure. Prior to the blasting of a trim pattern, the immediate highwall is scaled, where loose rock material is removed by means of a mechanical scaler. As mining of the pit progresses, the height of the scaled highwall from the pit floor progressively increases. These highwalls are never scaled again for the remainder of the pit life, and time-dependant deterioration contributes to these highwalls becoming subject to rockfall and, sometimes, slope failure. This paper documents the development of a South African innovation, a remote-controlled mechanical highwall scaler, a world first for the mining industry. The scaler will enable open-pit highwalls to be scaled from crest to toe whenever the need arises. It will reduce the risk associated with highwalls and deliver on the Anglo American promise of producing safe, profitable platinum.

Jan 1, 2012

By T. G. Pedro, Q. Gonzalo, R. E. Roberto

Anionic surfactants, such as oleic acid and sodium oleate (OLE), and cationic surfactants, such as dodecyl amine-hydrochloride (DDA), are used as flotation collectors of spodumene. However, recovery is poor even if activating ions are used because gangue minerals are also activated. Some reports demonstrate that OLE/DDA mixtures act as a selective collector to enhance spodumene recovery. From mostly macroscopic tests, it has been argued that anionic OLE and cationic DDA form electroneutral complexes, which are adsorbed on the mineral surface through chemisorption; however, no molecular evidence has been presented. Therefore, the adsorption mechanisms of the collector mixtures remain mostly unknown. It seems necessary to first study the behaviour of these surfactants confined in salt solutions, to determine auto-associations when they are pure and cross-associations when mixed, the transition from monomers to micelles, and the structure of the micelles and the effects of pH, temperature and concentration. In this paper, ab initio calculations are first used to determine the surface charge distribution of OLE and DDA separately. Then molecular dynamics simulations are used to determine the conformation, aggregation, and diffusion of these pure and mixed surfactants in freshwater and saltwater with the ionic strength of seawater in a pH range. In particular, it is interesting to determine the various associations that result in mixtures of both surfactants and the impact of alkali and alkaline earth metal cations on the structures formedp. Cations influence the order of the structure and orientation of water dipoles, reducing the mobility of water, ions, and surfactant molecules. This knowledge is critical to improve the molecular understanding of the adsorption mechanisms on minerals. Keywords: Computer simulation, molecular dynamics, flotation, collectors, saltwater

Jan 1, 2020

By M. Khodadazadeh, K. G. van den Boogaart, T. Leißner, L. Tusa, J. Gutzmer, R. Gloaguen, M. Kern

Ore sorting is a technology that is increasingly used to process primary raw materials. Timeconsuming and expensive empirical state-of-the-art test work is carried out to assess whether the use of ore sorting for the enrichment of a particular ore makes technical and economic sense. With the innovative simulation-based approach presented here, it is possible to direct the selection of a suitable sensor based on quantitative mineralogical and textural data, thus avoiding much of the empirical studies. Required data can be collected quickly and cost-effectively using available methods of automated mineralogy. The obtained parameters such as mineral grain size distribution, modal mineralogy, mineral area and mineral density distribution have been utilised in this study to simulate the prospects of success of ore sorting, applying different types of sensors. Empirical tests with commercially available sensor systems have been conducted to experimentally validate the predictions of the simulations. The estimation of the target mineral grade can be further optimised by the use of machine learning algorithms for the integration of automated mineralogy data and sensor data. The approach can easily be adapted to other types of raw materials and thus has great potential to become a key technology for the optimisation of processing experiments. Keywords: Automated mineralogy, hyperspectral imaging, machine learning, ore sorting

Jan 1, 2020

By J Taguta, B. McFadzean, P. E. Ngoepe, M. G. Mulaudzi

Computational modelling methods and isothermal titration calorimetry (ITC) were employed to investigate the interaction of a pyrite surface with thiol collectors. Modelling work was conducted in the presence and absence of water. Microcalorimetry was employed to investigate the resultant energy of interaction pyrite as a result of mineral-collector interactions. Sodium ethyl xanthate (SEX), diethyldithiocarbamate (DTC) and diethyl dithiophosphate (DTP) were investigated in this study. The results showed that the calculated surface energies and morphologies for FeS2 showed that (100) and (111) are the most stable surfaces. The morphology also indicated the appearance of the (100) and (111) surface facets and no presence of others. The calculated adsorption energies between thiol collectors and the pyrite surface were always more exothermic than the experimentally determined ones. When comparing different ligand types with the same alkyl chain length, the heat of adsorption of diethyl-DTC was greater than that of ethyl xanthate and diethyl-DTP for pyrite. Experimentally, the diethyl DTP barely adsorbed onto the pyrite surface and this may be due to a different mechanism of action. In computational calculations, water adsorption was found to reduce the reactivity of the Fe atom for the interaction with thiol collectors, and bring the adsorption energies closer to the magnitude of the experimental values. Keywords: Computational modelling, microcalorimetry, experimental and thiol collectors, adsorption energies

Jan 1, 2020

By F. S. Hoseinian, D. Deglon, L. leal Filho, M. Safari, T. C. Souza Pinto

This paper investigates the effect of chemical and physical operational parameters on the reverse flotation of Timbopeba itabirite iron ore in a pilot-scale pneumatic flotation cell. Operational parameters include collector and depressant dosages, feed rate, superficial gas velocity and solids concentration. Results show that increasing collector dosage results in an increase in quartz recovery, particularly for the coarser quartz where recovery increases by nearly 30%. Increasing depressant dosage results in a decrease in both quartz recovery and hematite loss, for the coarser hematite particles. Increasing the feed rate has no effect on quartz recovery or hematite loss, suggesting that the pneumatic flotation cell is not residence time constrained. Increasing the superficial gas velocity results in an increase in quartz recovery to an optimum at a Jg of around 0.6 cm/s after which it decreases significantly, particularly for the coarser particles where recovery decreases by as much as 50%. Decreasing the solids concentration does not affect quartz recovery but results in significant decreases in hematite loss. Here, fine and coarse hematite loss decreases from around 25% to 12% and 10% to 2% respectively. Superficial gas velocity and solids concentration are operating parameters which have the largest effect on the flotation performance of the pneumatic flotation cell. Results suggest that this flotation cell should be operated at relatively low superficial gas velocities and solids concentrations. However, these are pilot-scale findings and would need to be tested at an industrial-scale where different operating conditions may be optimal. Keywords: Operational parameters, reverse froth flotation; entrainment; iron ore

Jan 1, 2020

By A. W. S. Schumann

G. H. HENDERSON INTRODUCTION It is a pleasure to have read Mr Schuman's wide ranging and highly informative paper and also to congratulate him. Before proceeding to give views on the use and preservation of coal in South Africa, it is perhaps apposite to look at the South African scene on the world canvas. Mr Schuman's figures in his Table I are highly revealing. The Table shows expected consumption, export and import demand in the year 1980 by the continents of the world. The Republic of South Africa is shown as one of only four exporting countries at that date, although in the interim, Australia has become an exporter and will continue to grow as an exporter of coal. Huge fields have been proved in recent years. There is reason to think that for some years, coal and its economical uses have been under-estimated. The importation of oil carries a constant question mark and the exciting possibilities expressed in the uses of Dranium a decade ago for power generation, appear to have met with some setback. Present indications are that breederreactors will be delayed until about 1990. The capital cost of such reactors, too, is enormous. By 1980 it has been estimated that 20 per cent of the energy required by the leading ten nations of the world will come from nuclear power, but 80 per cent would then remain for fossil fuels and hydro generation. COAL DEMAND AND USAGE It is of interest to record that coal production in all the countries of Europe has declined markedly in the last 25 years. This is due to competition from oil, gas and nuclear power and also for sociological reasons; but there are signs that efforts will be made to resuscitate, at least in some measure, the mining of coking coals for which there is a strong and growing demand. Possibly all hard coal now mined in Germany has coking properties and that country is self-sufficient in this commodity. Germany might perhaps consider selling coking coal to her neighbours and importing additional coal for power-raising purposes. It has been frequently stated in American publications that the coal reserves of the D.S.A. are sufficient for 1 000 years. What that means, I do not know, but it is at least an indication that America has huge reserves of coal. Domestic and export demand in the U.S.A. in 1968 exceeded production for the first time. In 1969, the United States' output amounted to some 556 million tons, an increase of less than 2 per cent on the previous year. The output achieved fell short of demand, domestic and export, by more than 7 000 000 tons. This has caused and is continuing to cause anxiety in the U.S.A. In many countries young men for a number of reasons, largely environmental and social, are not coming forward in sufficient numbers for mining requirements and the same pattern has revealed itself in the Republic. This is, indeed, alarming because mining men in large numbers will be required to meet the estimated tonnage requirements set out in the following Table: It is difficult to visualise the replacement of these coal requirements either by oil or by nuclear fuels. The coal must be mined and men are required for the purpose. Unless a greater section of the population is allowed to participate in the more responsible aspects of mining, there is a serious likelihood that demand will not be matched by output. In addition to local demand, a lively export trade is possible. Exports are dependent on the future capacity of the South African Railways and Harbours and on Government policy. An export figure of 10000000 tons per year during the decade can be visualised and this figure would raise total estimated sales production to a figure of over 100 000 000 tons in 1980. At this point, it is necessary to examine the desirability or otherwise of exporting coal. How much coal

Jan 11, 1970

By R. W. Ottermann, N. D. L. Burger, A. J. von Wielligh, P. R. de Wet, J. L. Steyn

Underwind and overwind protection system concepts for mine hoist shafts were developed in conjunction with and for the Safety in Mines Research Advisory Committee (SIMRAC). End-of-wind operation of mine hoists is the most hazardous aspect of mine hoisting, carrying the highest risk of loss of life, injuries to workers and loss of production. Systems operating mechanically and with local actuation were developed. This was done in order to remove the increased risk associated with dependency on remote or external energy and information supply associated with most existing protection systems. The proposed underwind protection system concept absorbs the energy of motion of a conveyance overrunning the design lower limit of travel by drawing a metal strip through a set of rollers. This action causes dynamic cyclic plastic bending of the strip material that converts the kinetic and potential energy of the conveyance into strain energy of the metal. In the concept design a pair of cable slings attached to the strips catch the overrunning conveyance and transfer the retardation force. The proposed overwind protection system concept absorbs the energy of motion of a conveyance overrunning the design upper limit of travel by early detaching of the conveyance from the hoist cable. This detaching is carried out via an additional humble hook activation mechanism fitted at a sufficient height below the spectacle plate to allow the conveyance to retard to standstill under gravity before it would crash into the spectacle plate. The conveyance so brought to rest is prevented from falling by means of jack catches on the conveyance interacting with a rack (toothed profile) fitted on the guide rails in the retardation zone. Scale models (1:10 scale) of both protection systems were designed for conformance with established retardation standards. The retardation standards were limited by the requirement of passenger safety in retarding cages. The models were then built and tested in a 1:10 scale shaft model. Retardation performance close to the required levels was achieved. The retardation distance required should allow such systems to be retrofitted to most existing shafts. Given the simplicity and robustness of the designs

Jan 1, 2003

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