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By J. M. Cardoso, E. F. Quadros, A. Chiarini, F. Fernandes, G. Vilela, J. Ireno, L. C. Agostini

Based on the geological-geometric characterization of the basaltic rock at the site of a factory for chemical products situated in the Southern region of Brasil, and on results of a significant number of packer tests, the principal directions of flow were estimated, taking into consideration the intersection and the orientation of the joints and the amount of contaminant flow measured in each interval. The tests were performed using the multi-packer hydraulic multitest probe of IPT (HMTP) instrumented with an electric conductivity meter. A method of analysis for three-dimensional evaluation of the amount of contaminant flow in the area was proposed for future mitigation of the problem. Basé sur une caractérization géologique-géotechnique de la roche basaltique existant sur un site dune fabrique de produits chimiques située au sud du Brésil et sur les resultants dún nombre significantif déssais du type packer, les directions principales d´écoulement ont été estimées en considerant l´intersection et orientation des joints et la quantité de contaminant mesurée sur chaque intervale d´essais. Ceux-ci ont été realizes en utilisant une sonde multipacker developée au IPT – São Paulo (HMTP) instrumentée avec un mesureur de condictivité électrique. Une méthode d´analyse 3-D pour l´évaluation du transport du contaminant sur ce site a été proposée pour une future mitigation du problème. Auf Grund der geologischen Struktur des Basalts auf dem Gelände einer chemischen Fabrik in Südbrasilien und der Ergebnisse einer ansehnlichen Zahl von Pumpversuchen wurden die Hauptfließrichtungen bestimmt unter Berücksichtigung des Kluftgefüges und der in jedem Intervall gemessenen Menge kontaminierten Wassers. Die Versuche erfolgten mit dem im IPT entwickelten Verfahren (HMTP) mit Mehrfachpackern und elektrischen Leitfähigkeitsgebern. Ein analytisches Verfahren zur dreidimensionalen Ermittlung der Mengen kontaminierten Wassers wurde für die künftige Befassung mit dem Problem entwickelt.

Jan 1, 2003

By D. Norval, J. J. Dunkley

The process of atomisation is introduced and related to granulation. Some processes applicable to ferroalloys are discussed, along with their limitations and advantages. Examples of applications of atomisation to the processing of ferroalloys, including ferrosilicon and ferromanganese for use in the welding industry and as injectable additions to steel or cast iron are also presented. The economics of the process and the impact of process scale are discussed, along with criteria for process selection and system design.

Jan 1, 2004

By A. J. Van Der Merwe, N. A. Barcza, M. Boyes, N. R. Clarke

Oriel Resources has with the support of SRK (Cardiff) and DRA and Mintek (South Africa) carried our a Definitive Feasibility Study (DFS) to recover high grade chrome ore from its Voskhod deposit very close to Chromtau that is near to Aktobe in Kazakhstan. Voskhod is a large podiform ore body that contains nearly 20million tons of chromite grading about 48% Cr2O3 and with a Cr/Fe ratio of over 3/1. Selected bore hole core samples were obtained from the confirmation drilling programme during the DFS phase of the project in 2005 for pilot plant test work to design the mineral beneficiation plant. The chrome ore is characterised by four main types, namely high grade lumpy and chip sized ore, high-grade fine ore, lower grade (subordinate) lumpy ore and lower grade fine ore. Gravity separation tests carried out by Mintek showed that the large density difference between the high grade (at over 3.7t/m3) and lower grade ore (at less than 2.97t/m3 ) should ensure very good separation in the DMS drum and DMS cyclone stages resulting in high recoveries of Cr2O3 - rich chromite ore products. Very high chrome ore grades of up to 64% Cr2O3 and Cr/Fe ratios of 4 to 1 were obtained at an 80% mass yield from selected samples of lumpy and chip ore size fractions. The overall predicted recovery from the design work on the mine and plant is expected to be closer to about 70% of the ROM (Run of Mine) feed. DRA has completed the design of the mineral processing plant to recover about 900 kt/a of chrome ore from the 1.3 Mt/a of ROM feed. The plant has been sized to handle up to 1.5 Mt/a and will also be able to address the variability in ore feed as different regions in the deposit are mined. The lumpy high-grade product and the chips size fraction is expected to grade around 48% Cr2O3 and the fine concentrate between 56 and 58%Cr2O3 The ratio of products is expected to be about 70, 15 and 15 percent respectively but will vary to some extent during the expected 20 year life of the mining operation based on including the associated adjacent Karaagash deposit together with the Voskhod deposit. The prediction of the product split from the processing plant depends on many factors such as the geology, mineralogy, mining, handling and metallurgical processing. An overall process flow model has been developed that covers the ROM ore, the various types of chrome ore feed to the mineral beneficiation plant, the projected products and the subsequent smelting of the chromite ores to produce High Carbon Ferrochromium. The model allows the optimisation of the quality of the chrome ore in terms of Cr2O3 content, Cr/Fe ratio and recovery to be studied. This information can also be evaluated in terms of the economic requirements for smelting High Carbon Ferrochromium (HCFeCr) at a given location. Oriel is planning to supply chrome ore to Ferrochrome plants mostly in China and Russia. The use of the model will assist to maximise the value of the Voskhod project to its owners and also assist the users of the chrome ore in selecting the appropriate supply quality to meet their needs for a given smelter operation. The smelting of high grade Voskhod ore requires a limited addition of about 5 to 7% quartz to flux the MgO and Al2O3 and about 25% coke as a reducing agent to produce an alloy containing from about 65 to 74%chromium depending on the Cr/Fe ratio.

Jan 1, 2007

By B. R. Broekman, K. J. R. Ford

Over the last decade significant development and use has been made of a simulation model that describes the HCFeMn smelting operations in Assmang Ltd. This spreadsheet based, semi-empirical, predictive model is derived from data from the submerged arc furnaces at Assmang?s Cato Ridge, KwaZulu-Natal smelter site. Departures from the empirical base case mass balance due to changes in the ores, reductant feeds and operating parameters are accounted for by use of fundamental relationships and heuristic type ratios which are applied in an iterative manner in the model. The model performs a sequential set of calculations to iteratively converge on a fully consistent mass and energy balance solution, which predicts Mn alloy and slag output masses and compositions for a given set of feeds. 440 MWh per operating day is used as the basis of energy input. The paper describes the key model components, assumptions made and calculation approach. Added to the mass and energy balance is a cost and revenue balance, which allows prediction of the economic performance for each simulation. Substantial use of the model has been made in simulating the performance of the current Assmang HCFeMn furnaces for both smelter investigations and future production planning. The model has also been a valuable tool in the strategic analysis of the use of future Mn ores and has formed the vital link between mine ore grades (metal and slag elements) and the expected alloy output, grade and profitability. Additionally, the model has been used in benchmarking exercises to predict other Mn smelting operations with remarkable accuracy. The paper highlights some aspects of the approaches taken in using the model to benchmark Assmang?s own furnace performance and cost competitiveness with other producers. For Assmang the development and application of this modelling technology has led to transformation in understanding of the Assmang HCFeMn furnace operations and increased awareness of the potential of its Mn ore bodies.

Jan 1, 2004

By G. Denton, P. den Hoed, A. Luckos

The potential application of fluidized beds in several sectors of the ferroalloy industry is promising. They can be used in the direct reduction of iron ores to produce a feed for steelmaking, in the reduction of manganese dioxide to produce a lesser oxide for feeding to smelters, in the preheating of chromite for the production of ferrochrome, and in the calcining and pre-reduction of nickel laterites for the production of ferronickel. This paper discusses the potential of fluidized beds in theses processes and highlights the advantages of the technology over other technologies, such as rotary kilns. Two primary advantages?(1) that fluidized beds can treat fine materials and (2) that fluidized beds can be integrated with smelters in a way that allows for more efficient use of energy?may well see the technology gain prominence as more deposits of lower grade are mined and industries strive to use their resources more efficiently. In discussing the potential of the technology in the ferroalloy industry, this paper focuses on the application of fluidized beds in the smelting of chromite, nickel laterites, and manganese ores. Central to the successful operation of this technology is a knowledge of how particle properties influence the behaviour and design of fluidized beds.

Jan 1, 2007

By A. More, J. Bullón

Metal casting is one of the most important operations in ferroalloys factories. After the tapping of the furnace and the depuration of the metal, the preparation for customers with cooling, crushing and sizing begins. In total production costs, this contains around 8 % of the total cost of the metal, depending on the value of the fines and other important parameters. From an investment point of view, this represents around 20% of the total capital for a new furnace. Casting onto a water-refrigerated copper plate is not new for molten metals. In steel, continuous casting machines are normal in every factory. Water granulation casting exists at some ferroalloys plants. However, the majority of plants and production technology still use the technology of lumping, crushing and sizing. This technology is time consuming, produces fines and requires a relatively large work force. In 2001, Ferroatlantica put into operation a new water-cooled copper casting-machine, which seems to be a very convenient solution to solve all these problems. It is in operation at a silicon factory; the same place where the new ELSA electrode was developed for silicon metal production. This paper describes our experiences using it.

Jan 1, 2004

By P. J. Brereton-Stiles, C. J. Hockaday, I. J. Barker, M. S. Rennie

This paper reports on studies that have been done on the electrical conduction in silicon, ferro silicon, and charge chrome furnaces. A system has been developed that can distinguish between normal resistive conduction and arcing, and this was used to quantify in particular the relative amount of arcing that takes place in these furnaces. It was found that silicon and ferro silicon behave similarly and exhibit a relatively large amount of arcing. Charge chrome on the other hand exhibits considerably less arcing, and the extent of this arcing is highly correlated with the tapping of the furnace. The arcing measurements can also be used online in the control of the furnace, both for the electrodes and electrical circuit, and for the raw materials.

Jan 1, 2007

By K. S. Rao, R. P. Tiwari, V. K. Shrivastava

ABSRACT: In this paper numerical simulation of jointed block mass behaviour obtained in an experimental study has been presented. Singh et al. (2002) conducted extensive tests on the jointed model materials with several joint configurations. The results of this experimental study were used to validate the strength behaviour of numerical block mass model developed using professionally available software. This software basically contains different kinds of material models. From the results of numerical simulation the existence of strength anisotropy was observed. The strength anisotropy so obtained has been compared with the experimental values reported by Singh et al. (2002). The anisotropic curves in both cases are U-shaped with flat base. They show good agreement in sliding mode of failure zone in which inclination ß (= 90° - ?) of joint set-I lie between 20° to 40° for all cases of interlocking. ZUSAMMENFASSUNG: In dieser numerischen Papiersimulation des verbundenen Blockmasse Verhaltens, das in einer experimentellen Studie erhalten wird, ist dargestellt worden. Singh et al. (2002) leiteten umfangreiche Tests auf den verbundenen vorbildlichen Materialien mit einigen gemeinsamen Konfigurationen. Die Resultate dieser experimentellen Studie wurden verwendet, um das Stärke Verhalten des numerischen Blockmasse Modells zu validieren, das mit professionell vorhandener Software entwickelt wurde. Diese Software enthält im Allgemeinen unterschiedliche Arten der materiellen Modelle. Von den Resultaten der numerischen Simulation wurde das Bestehen von Stärke Anisotrophie beobachtet. Die Stärke Anisotrophie also erreicht ist mit den experimentellen Werten verglichen worden, die von Singh et al. (2002) berichtet werden. Die anisotropen Kurven in beiden Fällen sind mit flacher Unterseite u-förmig. Sie zeigen gute Vereinbarung in gleitender Erscheinungsform des Ausfalls Zone, in der Neigung ß (= 90° - ?) von der Verbindung stellenSie Lüge zwischen 20° auf 40° für alle Fälle vom Ineinandergreifen ein. RESUME: Dans cette simulation numérique de papier du comportement joint de la masse de bloc obtenu en étude expérimentale a été présenté. Singh et autres (2002) ont effectué les essais étendus sur les matériaux modèles joints avec plusieurs configurations communes. Les résultats de cette étude expérimentale ont été employés pour valider le comportement de résistance du modèle numérique de la masse de bloc développé en utilisant le logiciel professionnellement disponible. Ce logiciel contient fondamentalement différents genres de modèles matériels. Des résultats de la simulation numérique on a observé l'existence de l'anisotropie de force. L'anisotropie de force ainsi obtenu a été comparée aux valeurs expérimentales rapportées par Singh et autres (2002). Les courbes anisotropes dans les deux cas sont en U avec la base plate. Elles montrent la bonne concordance dans le mode coulissant de la zone d'échec en lequel la inclination ß (= 90° - ?) du joint placez-Je le mensonge entre 20° à 40° pour tous les cas d'enclencher.

Jan 1, 2003

By H. von Blottnitz, B. E. Isheloke

Mining is a significant economic activity in most Southern African Development Community (SADC) countries, and mineral beneficiation has been identified, and controversially discussed as one of the possibilities for industrialisation. With many member countries being economically too small to muster the human and financial resources which beneficiation requires, the recently adopted Regional Mining Vision (RMV) envisages interventions at a regional level. An opportunity arose to ask industry role players to what extent the SADC appears to support regional beneficiation policy interventions undertaken by member countries, and what the challenges are in undertaking beneficiation regionally, as a complement to, or substitute for country-specific beneficiation policies. Twenty-five semistructured interviews were conducted with experts from SADC member countries during the 2019 Mining Indaba. Participants were divided on whether beneficiation should be carried out nationally or in the SADC region. While beneficiation could support value-keeping, key challenges were found to be infrastructure development (i.e. energy, water), scarce skills, access to technology and related costs, but also lack of free trade and movement. We submit that a more integrated beneficiation strategy for the SADC region, as is being developed through the RMV, would indeed be relevant in the future. Keywords: Mineral beneficiation, regional integration, beneficiation policy interventions, African mining vision, mining, SADC

Jan 1, 2020

By Ike Madingoana, Stephan van Zyl, Antoine F. Mulaba-Bafubiandi

"The study presents a control strategy implemented at the Nkomati nickel mine flotation plant for process stabilization and improvement. The control strategy involves flotation concentrate volumetric flow rate stabilization and the flotation cell mass pull control. The flotation concentrate volumetric flow rate is operated at a fixed set point. The initial control strategy involved varying the flow rate to maintain the concentrate tank level thereby reducing pump cavitation. The flotation cells mass pull control comprises air rate manipulation into the cells with the exception of the recleaners. The air rate into cells is automated to adjust based on the concentrate tank level variation. The control strategy was implemented on the roughers, cleaners and the recleaner circuit. The recleaner cells air flow rate is adjusted based on the MgO content in the concentrate. The stabilization of the flotation concentrate volumetric flow rate and the mass pull by aerate automation will increase the scope of optimization for further process improvement. The immediate benefit of the control strategy implementation was plant stability. Disturbance to the flotation cells downstream was minimized due to stable flow rate, and the air addition manipulation ensured that the concentrate tank levels are maintained, minimizing pump cavitation. INTRODUCTION Froth flotation is a challenging process because it is influenced by a large number of factors, including the flotation feed characteristics. One of the ore types mined at Nkomati nickel mine is the main mineralized zone (MMZ). The MMZ ore is hosted in the Uikomst complex, a Ni-Cu-PGE-Cr- mineralized, layered basic to ultra-basic intrusion which hosts commercially viable magmatic base-metal sulphides (De Waal et al., 2001). The MMZ ore is a heterogeneous sulphide mineral resource with a varying sulphide mode of occurrence and texture. The beneficiation of the complex sulphide ore is challenging due to the presence of impurities in the ore. The impurities report to the flotation final concentrate and penalties are levied if the impurities are beyond the contractual limits."

Jan 1, 2015

By K. Yathavan

Fracturing of rock at low stress levels can be a source of unexpected problems in rock engineering: • the resulting instability can be a safety hazard; • in very brittle rocks it may be associated with violent failure of the rock and strainbursting (rockbursting); • it usually leads to an unexpected requirement for rock support, with time and cost implications; • in rock boring projects, it may result in fracture of the rock ahead of the bored face and in the walls of the bore behind the face. This may lead to cutter head vibration, increased cutter wear and consequently decreased performance and increased costs. Examples of situations in which fracturing of rock at very low stress levels has been observed will be described. This will include details or estimates of the in situ stress magnitudes and the rock strengths involved. La brisure de roche sous faibles contraintes peut être l’origine de problèmes inattendus en génie minier : • L’instabilité résultante peut devenir un danger • Elle peut provoquer des éclatements violents des roches fragiles • Elle nécessite souvent une infrastructure de soutien de la roche, ayant des implications sur les coûts et les délais • Les forages de la roche peuvent provoquer une brisure de celle-ci au niveau de la surface forée mais ainsi à l’intérieur de la roche, causant parfois des vibrations et une fatigue de la tête de forage, induisant une baisse de performance et un accroissement des coûts. Nous avons décrit ci-après des exemples de situations de brisure de roche sous faibles contraintes. Cette description comprend des détails ou des estimations des forces et des contraintes impliquées. Cette étude représente la base du travail de recherche effectué sur le phénomène. ißbildung im Gestein unter niedrigen Stressbedingung kann eine mögliche Ursache sein für unerwartet auftretende Probleme in der Felsmechaniklehre: • Die resultierende Instabilität stellt ein mögliches Sicherheitsrisiko dar; • In sehr sprödem Gestein kann es verbunden sein mit einem plötzlichen und gewaltsamen Zerfall des Gesteins; • In den meisten Fällen ist eine nicht eingeplante Gesteinsabstützung erforderlich, und damit ein Zeit- und Kostenaufwand verbunden; • Bei Bohrungsprojekten kann es dazu führen, daß es während des Bohrvorganges zu einer Rißbildung im Gestein hinter und vor der gebohrten Felswand kommt. Dies kann Bohrkopfvibrationen, eine erhöhte Bohrkopfabnutzung und folglich eine Bohrleistungssenkung, sowie Kostenerhöhung zur Folge haben. Das Phenomen von Gesteinsrißbildung unter niedrigen Stressbedingung wird anhand von einigen dokumentierten Beispielen erörtert. Diese beinhalten zudem Details oder Schätzungen bezüglich der Stärke des in situ Stressfeldes, sowie der gegebenen Gesteinsstärken. Die mit diesem Beitrag dokumentierten Ergebnisse formen eine Grundlage zur weiteren Forschung dieses Phenomens.

Jan 1, 2003

By C. Erichsen, J. Werfling

ABSTRACT: A three-dimensional elastic constitutive model for rock salt is proposed. This stress strain law takes into account the three phases of creep (transient, steady state and accelerated creep), dilatancy, as well as the failure and post failure behaviour. The model was implemented into a finite element program and validated on the results of laboratory tests and in situ measurements. A good qualitative and quantitative agreement with the test and measurement results is achieved. A stability analysis for an underground repository in rock salt is presented. ZUSAMMENFASSUNG: Es wird ein dreidimensionales elastisch-viskoplastisches Stoffgesetz für Steinsalz vorgestellt. Mit diesem Stoffgesetz können die drei Kriechphasen (primäres, sekundäres und tertiäres Kriechen), Dilatanz sowie das Bruch- und Nachbruchverhalten erfaßt werden. Dieses Modell wurde in ein Rechenprogramm, das auf der Methode der finiten Elemente basiert, implementiert und an Ergebnissen von Laborversuchen und in-situ-Messungen validiert. Die Versuchs- und Meßergebnisse lassen sich mit diesem Stoffgesetz qualitativ und quantitativ gut nachvollziehen. Als Anwendungsbeispiel wird der Standsicherheitsnachweis für eine Untertagedeponie im Steinsalz erläutert. RÉSUMÉ: Cet article présente un modéle constitutive élastique/viscoplastique à trois dimensions pour sel gemme. Ce modéle comprend les trois stade de fluage (fluage primaire, secondaire et tertiaire), la dilatation, le comportement de défaillance et d'après défaillance. Il est implanté dans un programme de calcul aux éléments finis. À l'aide des essais laboratoire et des mésures in situ, le modéle a été validé. Les résultats des essais et des mesures concordent qualitatifs et quantitatifs aux résultats des calculations.

Jan 1, 2003

By J. P. Harrison

ABSTRACT: The significant effect of fracture surface morphology on the mechanical behaviour of rock masses is well known and has been studied by many people. For linear profiles taken from fracture surfaces, short- and long-period variation has traditionally been described using the descriptors ‘roughness’ and ‘waviness’, with Fourier series analysis being perhaps the most commonly used technique to distinguish between the two attributes. However, the mathematical procedure is involved and the assumptions that have to be made may not be appropriate for rock fracture surfaces. In this paper, an alternative method is presented that enables us to distinguish between roughness and waviness of a linear profile by performing only one straightforward analysis. In our technique, surface morphology is studied in terms of the distribution of unit normal vectors to the profile. The statistical analysis of the distribution is performed using Riemannian, rather than the customary Euclidean, geometry, and from this the 1D Riemannian dispersion parameter (DR1) is obtained, which quantifies the geometry of the profile. The method is applied at different scales to both synthetic sinusoidal profiles and real rock profiles. The results show how periodic behaviour of the profile is revealed at scales where DR1 is substantially equal to zero. RESUME: L’influence significative de la morphologie des épontes sur le comportement mécanique des massifs rocheux est bien connue et a fait l’objet de nombreuses études. Pour les profils lineraires, les variations de courtes et longues périodes sont traditionnellement décrites par les indicateurs “rugosité” et “ondulation” qui sont le plus couramment distingués à l’aide d’une analyse en series de Fourrier. Cependant, la méthode de calcul utilisée et les hypothèses faites ne sont pas appropriées dans le cas des épontes rocheuses. Cet article présente une méthode alternative qui permet de distinguer la rugosité de l’ondulation d’un profil en réalisant une seule analyse directe. Avec notre technique, la morphologie de l’éponte est étudiée comme une distribution spatiale de vecteurs normaux au profil. L’analyse de cette distribution est réalisée à l’aide de la géométrie Riemannienne plutôt que la géométrie classique Euclidienne et permet d’identifier la dispersion Riemanienne en 1D (DR1) qui quantifie la géométrie du profil. Cette méthode est appliquée à différentes échelles sur des profils artificiels sinusoïdaux et des épontes naturelles. Les résultats montrent que le comportement périodique du profil est révélé à des échelles où DR1 est essentiellement égal à zéro. ZUSAMMENFASSUNG: Der signifikante Effekt von Bruchoberflaechen Morphologien auf das mechanische Verhalten von Gesteinsmassen ist gut bekannt und von vielen Bearbeitern untersucht worden. Traditionel lineare Profile von Bruchflaechen sind mit kurz und lang periodischen Variationen, die auch als “Rauhigkeit” und “Welligkeit” bezeichnet worden sind, beschrieben worden. Hierbei ist wohl die Fourier Serien Analyse das wichtigste Hilfsmittel zur Unterscheidung der beiden Attribute gewesen. Hierfuer wird jedoch ein mathematisches Prozedere verlangt und Vorraussetzungen gemacht, die vielleicht nicht fuer Gesteinsbruchflaechen zutreffend sind. In dieser Publikation wird eine andere Methode vorgestellt, die uns mit Hilfe nur einer einfachen Analyse erlaubt zwischen “Rauigkeit” und “Welligkeit” bei einem linearen Profil zu unterscheiden. In unserer Methode wird die Gesteinsoberflaeche unter zu Hilfenahme der Verteilung von Einheitsnormalvektoren beschrieben. Die statistische Analyse der raeumlichenVerteilung dieser Vektoren wird mit Hilfe der Riemannschen, anstatt der ueblicherweise benutzten Euklidischen, Geometrie durchgefuehrt. Von ihr wird der Riemannsche Dispersions Parameter (DR1) abgeleitet, der die Geometrie des Profils quantifiziert. Diese Methode ist bei verschiedenen Masstaeben sowohl auf rein harmonische (sinusoidale), syntetische Profile als auch auf Gesteinsprofile angewendet worden. Die Ergebnisse zeigen, dass bei Masstaeben bei denen DR1 nahe Null ist periodische Characteristika der Profile hervortreten.

Jan 1, 2003

By W. Valderrama, D. G. Almond

Operation of large SAG mills requires a change in the conceptual approach to grinding processes. The traditional energy consumption criteria are now enhanced with new criteria derived from the mechanical dynamics of the mill load. This new approach demands instrumentation capable of providing accurate information about the load movement and the ratio of balls and ore inside the mill. This paper discusses two new performance enhancing tools available to meet these needs.

Jan 1, 2004

The Skorpion Zinc Project demonstrated the viability of the production of zinc from non-sulphide (commonly called ?zinc-oxide?) ores, using the leach/solvent extraction/electrowinning process route. The success of Skorpion raised the profile of a number of other zinc oxide deposits, considered to be similar. However, a study of three such deposits demonstrates that the application of whole-ore-leaching may be limited and that the concentration of zinc, or at least the separation from acid-consuming gangue minerals, prior to leaching is essential to the successful recovery of zinc from these deposits. The recovery of zinc is dependent on an understanding of the geology of the deposit, the mineralogical association of zinc minerals with gangue minerals (Boni, 2005) and limitations of mining practice. Flow sheet development and the associated metallurgical test work to derive an economically viable treatment route from two of these deposits are discussed. Key parameters affecting zinc recovery by gravity separation and flotation are presented, demonstrating that even minor differences in mineralogy have a profound impact on zinc recovery and reagent consumption. The study also deals with the determination of appropriate design parameters through metallurgical mapping of the dense media separation process.

Jan 1, 2008

By W. Robert, J. Wirth, G. Grasselli

ABSTRACT: Strength, deformability and fluid flow properties of rock joints are to a great extent controlled by the surface roughness. The hydraulic conductivity of a rock fracture depends on the aperture distribution, the surface roughness and the contact area, each of which depend on the stresses that act on the fracture plane. However, despite much recent work, a complete understanding of the relationship between void space geometry, contact areas, applied stress, and hydraulic conductivity has yet to be achieved. Moreover, although in situ rock joints are subjected to both normal and shear loading, few studies have been conducted to investigate the effect of shear displacements on fluid flow through a single rock fracture, and which have addressed the issue of flow anisotropy induced by shearing. Experimental flow tests show that with increasing shear displacement, the fracture becomes heterogeneous and anisotropic, and becomes more permeable in the direction parallel to the displacement (Yeo et al., 1998). On the other hand, dry shear tests show that the surface fails in areas facing the shear direction (Grasselli and Egger, 2003). Moreover, the experimental results confirm that the shear strength of rock joints is direction-dependent. In this paper, a three-dimensional morphological description of several a natural fractures that have undergone shear displacement were generated using the Automated Topographic System at the University of Basel. The data analysis method of Grasselli (Grasselli et al., 2002a) is used to determine the surface parameters that are known to control the shear strength. Simulations of fluid flow through this fracture, in various directions relative to the direction of shear, are conducted using an FEM flow simulator. The results constitute the most detailed analysis yet undertaken of the relationship between shear displacement, shear strength, and fracture transmissivity. RESUME: La rugosité des joints en roche joue un rôle primaire sur la réponse hydromécanique du massif fracturé. En effet, la conductivité hydraulique des discontinuités en roche est influencée par la rugosité, et par la distribution des ouvertures et des zones de contact, dont chacun dépend de l’effort normal et du cisaillement qui agissent sur la surface du joint. Les essais d'écoulement en laboratoire montrent que si cisaillée, la fracture devient anisotrope, et plus perméable dans la direction parallèle au déplacement (Yeo et al., 1998). D'autre part, les essais de cisaillement indiquent que seules les zones de la surface qui font face à la direction de cisaillement sont impliquées dans le cisaillement (Grasselli et Egger, 2003). D'ailleurs, les résultats expérimentaux confirment que la résistance au cisaillement des joints de roche est dépendante de la direction. Dans cet article, plusieurs fractures en roche ont été analysées en utilisant un système de mesure topographique à l'Université de Bâle. La méthode d'analyse de données proposée par Grasselli (Grasselli et al., 2002a) a été employée pour calculer les paramètres de la surface qui déterminent la résistance au cisaillement. Plusieurs simulations du coulage, dans diverses directions relativement à la direction du cisaillement, ont été faites à l’aide d’un programme de calcul à éléments finis. Les résultats constituent une des analyses les plus détaillé sur le rapport entre le déplacement pendant le cisaillement, la résistance au cisaillement, et la transmissivité spécifique de la fracture. ZUSAMMENFASSUMG: Die Festigkeit, Verformbarkeit und Hydromechanik von geklüftetem Fels wird hauptsächlich von der Oberflächenrauhigkeit der Bruchflächen bestimmt. Die hydraulische Leitfähigkeit einer Kluft hängt von der Verteilung der Rissbreiten, der Oberflächenrauhigkeit und den Kontaktflächen ab, die ihrerseits von dem auf die Bruchfläche wirkenden Druck beeinflusst werden. Obgleich in letzter Zeit viel in dieser Richtung geforscht wurde, kann der Zusammenhang zwischen Porenraumgeometrie, Kontaktflächen, wirkendem Druck und hydraulischer Leitfähigkeit noch nicht vollständig erklärt werden. Obwohl Klüfte in situ sowohl Normal- als auch Schubspannungen ausgesetzt sind, wurde der Einfluss von Scherverschiebungen auf den Kluftwasserfluss und die daraus resultierende Fliessanisotropie in einer einzelnen Kluft bisher kaum untersucht. Experimentelle Untersuchungen des Durchflusses zeigen, dass die Kluft für größer werdende Scherverschiebungen heterogen und anisotrop wird wobei die Permeabilität parallel zur Verschiebungsrichtung ansteigt (Yeo et al., 1998). Andererseits zeigen trockene Scherversuche, dass die Oberfläche an Stellen versagt, die gegen die Verschiebungsrichtung anstehen (Grasselli und Egger, 2003). Des weiteren bestätigen die experimentellen Ergebnisse eine Richtungsabhängigkeit der Kluftscherfestigkeit. In diesem Artikel wird eine dreidimensionale morphologische Beschreibung mehrerer natürlicher, durch Scherspannungen verschobener Klüfte vorgestellt, die vom Automated Topographic System der Universität von Basel erstellt wurde. Das von Grasselli (Grasselli et al., 2002a) entwickelte Datenanalyseverfahren wird zur Feststellung der die Scherfestigkeit bestimmenden Oberflächenparameter herangezogen. Mittels einer FEM-Simulation wird der Durchfluss durch eine solche Kluft in verschiedenen Richtungen simuliert. Die Ergebnisse stellen die bisher ausführlichste Analyse des Zusammenhangs zwischen Scherverschiebung, Scherfestigkeit und Durchlässigkeit (Transmissivität) einer Kluft dar.

Jan 1, 2003

By Jochen Petersen, Thandazile Moyo

"The oxidative leaching of chalcopyrite in ammoniacal solutions has been evaluated using electro-analytical techniques. The anodic dissolution process has been established to be a seven-electron transfer process under nitrogen in ammonia–ammonium sulphate solutions and ammonia–ammonium carbonate solutions. The number of electrons transferred in the carbonate and sulphate salts suggests that the sulphur is oxidised to a thiosulphate intermediate and the copper and iron released as Cu+ and Fe2+. The Cu+ and Fe2+ is subsequently oxidised in solution in non-Faradaic reactions. The deportment of Fe2+ and S2O32- is affected by choice of the ammonium salt used in the leaching process. In the perchlorate salt, only five electrons are transferred, however observations made on the mineral surface after leaching do not support the formation of elemental sulphur. Scanning electron microscopy and energy-dispersive spectroscopy analysis of the mineral surface suggest presence of an iron–sulphur surface layer completely free of copper under the ammonia–ammonium sulphate conditions, an iron-rich surface layer under ammonia–ammonium perchlorate solutions and absence of surface layer build up under ammonia–ammonium carbonate solutions. INTRODUCTION Hydrometallurgical processes for copper extraction provide a viable route to recover the metal from mixed and low-grade ores, as well as overcome the environmental challenges faced by the traditional pyrometallurgical processes. Chalcopyrite is not only the most abundant of the copper sulphides, but also the most stable, making it recalcitrant to hydrometallurgical processes. Hence, hydrometallurgical processing of chalcopyrite continues to be an attractive area of research due to the vaguely understood surface chemistry of the mineral in different aqueous media. Different approaches to hydrometallurgical treatment of chalcopyrite can be carried out. These include thermal treatment prior to leaching, direct leaching and direct electrochemical leaching (Venkatachalam, 1991). Direct leaching of chalcopyrite can be carried out in various solution systems, as reviewed by Roman and Benner (1973) and Venkatachalam (1991). Ammoniacal solutions are attractive and effective lixiviants that form stable amine complexes with some base-metal cations while rejecting iron. Leaching of chalcopyrite in ammoniacal solutions in the presence of an oxidant is possible due to the stabilisation of copper(I) and copper (II) by ammonia at elevated pH levels. In oxygenated ammonia solutions, it has been suggested that chalcopyrite dissolves according to Equation 1 (Beckstead & Miller, 1977a):"

Jan 1, 2015

By Willem C. A. van Niekerk, David A. Baldwin, Nardus Potgieter, Willie A. Gericke

Authorities that regulate environmental issues pertaining to industrial wastes in South Africa regard landfill disposal as the only effective environmental management option for slag and other inorganic by-products from the ferro-alloy industry. Metallurgical slags are widely utilised in civil engineering and construction applications in other countries in the world and in line with the overall philosophy of conserving mineral and other natural resources, these materials should be assessed for the possibility of resource recovery, recycling, reclamation, direct re-use or alternative uses. This presentation describes a risk-based approach for the assessment of by-products from the ferro-alloy industry for alternative use. Once a by-product from an industrial process has been identified for alternative use, its intended use would be defined, but it will not be possible to control its actual use or misuse in society, nor will it be possible to control its fate during the application life cycle. In the interest of protection of human health and the environment, potential risks associated with the handling and uses of a material throughout its life cycle therefore have to be quantified. The assessment has to include both human health and ecological risks and must cover the entire life cycle of a product, from its production up to its end-of-life disposal. The presentation introduces the concept of tiered risk assessment and demonstrates how this applies in the overall assessment of by-products from metallurgical industry sector for safe use in society.

Jan 1, 2007

By T. Nishi, D. Teguri, K. Saitoh

In recent years the requirement for high carbon ferro-manganese (HCFeMn), which is the key product of our company, has increased due to bullish demand for steel products. In our Tokushima works, we have 2 closed types of electric furnaces (1F and 2F), with which we are manufacturing HCFeMn. In order to meet the increase in demand, we made various modifications to these furnaces and we tried to increase the furnace operating loads. Especially for 1F, we deepened the furnace. In this paper, we report the results of this modification. The operational situations of the above-mentioned two furnaces are different because they have different individual profiles. As for 1F prior to modification, the depth of the furnace was one meter shallower than2F, because 1F was designed for the manufacturing of SiMn. On the other hand, our Tokushima works specialized in HCFeMn 14 years ago. However, the profile of 1F was not optimized for HCFeMn. In comparison to 2F, 1F was more difficult to stabilize due to the smaller tolerance for the adjustment of the electrode length, the metal / slag level, and the coke-mixing ratio. We deepened 1F by 770mm by disposing of the furnace rolling mechanism. We consequently achieved a 10% increase in production capacity. This meant the operating load was enhanced from 24.5MW to 27MW, the furnace became more stable and the tapping speed of both metal and slag increased, all which made the tapping easier than before.

Jan 1, 2007

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

Jan 1, 2004