Search Documents

By R. Boom, J. Halder, B. Snoeijer, B. Deo, A. Overbosch

Operational data of BOF and the slag samples for different starting conditions of phosphorus(0.06–0.26 per cent P) and silicon content (0.3–1.2 per cent Si) of hot metal have been analysed. The contribution of parameters that are well known to affect phosphorus distribution at tap, like basicity, temperature, FeO content of slag, slag mass etc., is investigated through the models of ionic theory of slag, optical basicity, regular solution approach and molecular theory of slag. The best overall results are obtained by the model based on molecular theory of slag in which several operational parameters are also incorporated. The investigations of different slag samples, based on optical, SEM, EPMA and X-ray studies, reveal the effect of MgO and Al2O3on slag morphology and phosphorus distribution in different phases. It is important to consider phosphorus distribution ratio in the solid and liquid part of slag. The solid part of slag, which is mostly dicalciumsilicate, can contain up to 5 per cent phosphorus. The phosphorus content of the liquid part of slag may depend upon the phosphorus content of hot metal or phosphorus load of slag. It is found that incorporation of effect of dicalciumsilicate in the model improves the accuracy of prediction. For better process control, the addition of iron ore towards the end of blow must be avoided while treating high phosphorus hot metal or during the production of ultra low phosphorus steels. Keywords: steelmaking, BOF, phosphorus distribution, slag morphology, MgO, Al2O3,dicalciumsilicate, process control, models

Jan 1, 2004

By D. Tsweleng

In the Evraz Highveld production process, iron ore is prereduced in rotary kilns prior to charging into submerged arc furnaces (SAFs). Owing to the highly aggressive slags that are formed within the combustion zones of these kilns, chrome-oxide-containing lowcement castables have been used for some years in the kiln lining. Due to concerns around the potentially harmful effects should Cr(V1) be present in the spent linings, Highveld and its suppliers of kiln castables devoted time to developing alternative chrome-free lining materials. Such materials needed to be cost-effective and ensure good performance and improved kiln availability. This paper discusses all the parameters surrounding this development. Keywords Low-cement castable, chrome-oxide free, chrome (VI), titaniferous magnetite ore, rotary kiln, submerged arc furnace, open slag bath furnace, Evraz Highveld Steel & Vanadium Limited.

Aug 1, 2013

By M. Shamsi, M. Nehring

One of the most challenging aspects in semi-mobile in-pit crushing and conveying (SMIPCC) system design is determining the optimum depth at which to change from a purely truck-based haulage system to a conveyor-based haulage system. We used scenario analysis to determine the optimum transition depth between a truck and shovel (TS) system and a SMIPCC system. Traditional pit-limit algorithms were used to generate the final pit limit on a copper deposit, which was then divided into four pushbacks. The final operating pushbacks (phases) were designed for both TS and SMIPCC. The end depths for each phase are viewed as candidate transition points to switch from the TS to SMIPCC haulage system. Economic calculations were applied for five different scenarios, including adopting SMIPCC from the outset (pure SMIPCC), after the first, second, and third phases, and finally not using the SMIPCC system (pure TS) at all. The analysis indicates that the second scenario, at a depth of 335 m, results in the lowest cumulative discounted cost (CDC). In this case, the CDC is 17.6% lower than that for the pure TS scenario and 10.7% lower than for the pure SMIPCC system scenario.

Sep 1, 2021

By J. Bakken, M. Th. Jonsson, G. Sævarsdottir

A typical three-phase submerged-arc furnace for production of silicon metal and ferrosilicon has arc currents ~100 kA, phase voltages ~100 V and total furnace power ~10 - 60 MW. The arcs burn in gas filled cavities or "craters", where the main atomic components of the plasma mixture are silicon, oxygen and carbon. Two quite different simulation models for high-current AC arcs have been developed: the simple Channel Arc Model (CAM), and the more sophisticated Magneto-Fluid-Dynamic Model (MFD). These models have been described extensively and results reported at INFACON-8 and INFACON-9, respectively. The coupling between the arcs and the AC power source is described by a complete three-phase Electric Circuit Model. Recent numerical modelling studies of industrial AC arcs show that the boundary conditions at the cathode and anode are critical for the simulation results. A novel Cathode/Anode Sub-Model for high-current AC arcs that treats both cathode and anode indicates a completely different cathode behaviour than previously assumed. A cathode spot which serves a high-current electric arc is shown to be dominated by the energy impact from the arc. This leads to lower cathode fall voltage than obtained from previously developed models. The anode fall voltage is negative, as the main function of the potential barrier is to repel plasma electrons. The cathode spot is diffuse in the sense that the arc in fact contracts away from the cathode. Simulation results are compared to measurements on both industrial furnaces and smaller scale pilot furnaces. An important conclusion, supported by our arc studies, is that the arc length in silicon metal and ferrosilicon furnaces does not exceed 15 cm and the arc may burn anywhere on the electrode, not necessarily beneath the electrode tip.

Jan 1, 2004

By G. E. Blight

Wind erosion can be a major cause of the loss and dispersion of tailings material from a tailings dam into its surrounding environment. Such dust dispersion can be a serious nuisance, as well as a health hazard to inhabitants in nearby settlements, and can also damage the health of animals, degrade crops, making them less marketable, and cause soil and water pollution. The problem of wind erosion can affect tailings dams in all types of climate, but becomes worse as climatic aridity increases. Because clouds of dust are often observed billowing across the top surfaces of tailings dams in dry windy weather, there is a common misconception that the dust arises from wind erosion of the top surface. As a result, much effort and money is vainly spent on treating the tops of tailings dams to prevent dust generation, whereas the slopes of the dams are the true major dust source. This paper briefly reviews what is known of erosion of tailings dams and then proceeds to describe the mechanics of wind erosion in general, and how it affects tailings dams in particular. Finally, recommendations are made for mitigating wind erosion of tailings dams and the resulting blowing dust.

Jan 1, 2007

By T. A. Muhlare

"Large quantities of slag are produced every year and dumped on slag heaps around the world, posing a potential environmental threat due to contained heavy metals content. Slags are waste minerals produced during furnace smelting of minerals. The contained values of base metals may be released into the environment under natural weathering conditions polluting ground and underground water. Copper losses into slag are a continuous problem in pyrometallurgical smelting operations. Due to shortage of ore concentrate, various mining operations have initiated the recovery of copper from dumped slag. The typical process uses crushing, milling and flotation. These operations create excessive liner wear rates during crushing and milling because the bond work index of copper slag is 22 kWh/t and this is considered a very hard slag. The process also has reduced flotation recoveries and requires high flotation reagent consumption. The present work shows that digestion of the milled copper slag slurry with concentrated sulphuric acid at a temperature of 250oC forms a solid cake and leaching of the solid cake with water is a possible option. However, the consumption of sulphuric acid can have a considerable cost on the recovery process. This can be limited by producing a leach residue containing gypsum and silicate materials as amorphous silica which are suitable for use as an additive for Portland cement. Laboratory results show that 90% copper recoveries can be achieved. The leaching is conducted to prevent silica gel formation and iron co-extraction. Leaching is optimum if silica gel-free solutions and good filterable residue are obtained. INTRODUCTION Slag is a waste by-product of smelting and converting operations in metallurgical plants. Both smelting and converting operations are aimed at iron separation from base metal sulphides in non-ferrous metallurgy. The iron sulphide component of the ore or concentrate is oxidized to iron oxide at higher temperatures in the molten form, and then fluxed with silica and other oxide rock minerals to produce fayalite (2FeO•SiO2) slag (Schlesinger et al., 2011). Slags are generally deposited on dumps and considered to be unreactive materials. Smelter copper slag contains significant concentrations of several potentially toxic elements, including arsenic, lead, cadmium, barium, zinc and copper. These elements can be released into the environment under natural weathering conditions and cause pollution of soils, surface waters and groundwater (David, 1998)."

Jan 1, 2015

By Chandrakala Kari, S. Mohan Rao, Gajanan Kapure, K. S. Raju

High carbon ferrochrome production process is energy intensive, consumes approximately 3300-3400 kWh per ton of metal produced. This amounts to ~ 34% of the total ferrochrome production cost. The power costs in India are almost 4 times greater than the leading ferrochrome producing countries like South Africa. Hence there is a need to look for alternative sources of energy. In ferrochrome making process large volumes of high concentration CO gas (~ 85%V) is developed at ~400-5000C, which if combusted within furnace represents high potential for significant electrical energy savings. In a typical heat in the state-of-the-art submerged arc furnace, about 34 kmol of CO gas is generated per ton of ferrochrome metal, which, if post combusted to CO2, represents 7620 MJ of energy. Post combustion of the evolving CO (and H2) gas to CO2 can be achieved by providing additional oxygen before the generated CO gas leaves the furnace. In this paper, a concept of post combustion in submerged arc furnace as potential source of significant electrical energy saving in ferro-chrome making process has been explored. The prospects and limitations of the same are discussed. The value of this paper lies in its attempt to explore the post combustion application to submerged arc furnace with an objective of significant reduction in electrical energy consumption in ferrochrome production process.

Jan 1, 2007

By L. A. Thompson, A. J. Linington

"Copper–cobalt extraction is a reagent-intensive process resulting in acid consumption greatly contributing towards production costs, which in the current market conditions curtail profitability. Nanofiltration (NF) membranes have become an attractive approach in the mining and minerals industry for product concentration and reagent recovery based on the ability of the membrane to separate monovalent ions from divalent ions. NF membranes can selectively separate acids from metals and salts allowing acid to be recycled as well as the concentration and purification of product streams. Membrane technology in the field of copper–cobalt processing focusses on the concentration of Cu2+ and Co2+ in the pregnant leach solution, recovery of acid from waste streams to neutralization, recovery of valuable metals from waste ponds and process water recovery. This paper aims to provide insight into the potential applications of NF membranes in copper–cobalt processing circuits as well as a brief overview of the effects of process conditions on membrane performance and process development. INTRODUCTION The copper–cobalt industry commonly uses inorganic acids, such as sulfuric acid, in large quantities for primary leaching of copper–cobalt oxide ores and releaching during product purification (Stuurman et al., 2014). This results in numerous acidic intermediate streams containing high metal concentrations and acidic waste streams with low metal concentrations. Acid consumption typically accounts for 10–15% of the operating costs of mines in the Democratic Republic of Congo (DRC) and Zambia (Acid Plant Database, 2015). Due to remote mine locations, poorly maintained roads and cross-border conflict, the cost of sulphuric acid can range between USD 300 and 400 per ton. The pivotal role of acid in the copper–cobalt extraction process has driven many mines to build sulphuric acid plants on site to ensure a reliable acid supply, however elemental sulphur still needs to be imported which faces similar logistical challenges and contributes towards operating costs."

Jan 1, 2015

By M .. Hori, H. Onishi, Y. Goda

The split-lining structure was newly developed for the air-tight lining of the underground compressed air storage cavern. This structure consists of separated reinforced concrete (RC) segments and air-tight membrane. It is most important for the Compressed Air Energy Storage Gas Turbine (CAES-G/T) system to develop the economical lining. In order to verify the applicability of split-lining structure, CAES-G/T pilot plant was constructed and operated for 6 months. We confirmed the practical usefulness and safety of this system through the operation. This paper presents the mechanical behaviour of surrounding rock mass and the lining structure observed through the operation of CAES-G/T pilot plant. Nous avons mis au point une structure de revêtement modulaire pour le revêtement des cavernes souterraines hermétiques à pression. Ce revêtement est composé de segments de béton armé et de membranes hermétiques. Il était très important, pour le CAES-G/T (Compressed Air Energy Storage Gas Turbine), de développer un revêtement économique. Afin de vérifier l’aptitude d’application de notre revêtement modulaire, nous avons construit un système pilote CAES-G/T et nous avons effectué des essais de fonctionnement pendant six mois. Ces essais nous ont permis de confirmer l’utilité et la sécurité du système. A travers le présent rapport, nous rendons compte de la structure de ce nouveau type de revêtement et du comportement mécanique de la masse rocheuse environnante que nous avons pu observer au cours desdits essais. Als luftdichter Druckbehälter wurde eine gegliederte Belagsstruktur für tief unterirdisch liegende Felshöhlungen entwickelt. Diese Struktur ist aus Stahlbetonabdeckung und luftdichter Plane aufgebaut. Bei der Entwicklung des Pressluftgasturbinen – Stromerzeugungssystems (CAES-G/T) war es die wichtigste Aufgabe, einen wirtschaftlichen Belag zu entwickeln. Deswegen wurde zum Nachweis der Effektivität der gegliederten Belagsstruktur eine Pilotanlage errichtet und 6 Monate lang betrieben. Durch den Betrieb konnten wir die Praktikabilität und Sicherheit des Systems bestätigen. Dieser Aufsatz ist ein Bericht über das Verhalten der durch Betrieb der CAES-G/T Pilotanlage beobachteten Belagsstruktur und umliegenden Felsmasse.

Jan 1, 2003

By D. J. Fourie

During the production of pure TiO2for the pigment industry, ilmenite, containing 35?60% TiO2, is reduced to high titania slag, containing 70?95% ?TiO2? and pig iron. The high titania slag produced, consists mainly of titanium in different oxidation states and FeO in equilibrium with liquid iron. To predict the phase and chemical reaction equilibria in a furnace, a suitable solution model is required with accurately determined binary interaction parameters, as slag melts tend to behave very non-ideally. This paper investigates two popular slag models, namely, modified quasi-Chemical (MQC) model and the cell model and provides the binary interaction parameters based on recently published data of the ternary system and critically assessed published unary and binary data. Very few modelling results have been published on the ternary Ti-Fe-O system pertaining to high titanium slags. The solution models, with their regressed interaction parameters, can subsequently be implemented in commercial software of the slag-metal phase equilibria to predict how much and which type of solids will precipitate for a given bulk slag chemistry and operating temperature or, alternatively, above which temperature should a furnace be operated to avoid excessive solids precipitation.

Jan 1, 2005

By J J. McEwan

Silver tarnishes readily in common atmospheres and is accelerated in humid atmospheres. Tarnish is the formation of silver sulphide on the surface of silver when it is exposed to a wide range of sulphur-containing atmospheres. Tarnish is unattractive and highly undesirable, and can be removed either with a silver polish or a chemical dip. Dips are generally only recommended when heavy black tarnish cannot be removed with a polish, and care must be taken during cleaning because these can contain aggressive chemicals and give off hazardous and unpleasant smelling fumes. Polishes work best for large areas of plain undecorated silver, and form part of a regular cleaning programme. Some polishes contain chemicals that inhibit tarnishing, but these generally only have a short life. Several methods have been developed to reduce tarnish formation on Silver; these include alloying, surface treatment, and coatings. The authors evaluated a range of self-assembled monolayer (SAM) surface treatments and coatings in earlier research. Four treatments/coatings increased the time to noticeable tarnish by more than ten fold, and the results were reported at the International Corrosion Congress (ICC) in 2005, and at the Mint Directors Conference (MDC) in 2006. SAM treatment using 95% 1-hexadecanethiol (C16H34S) was found to give good anti-tarnish performance and showed potential for the commercial treatment of Sterling silver. Therefore research was performed to optimise the methods of application of this type of coating to provide an easier, faster, and more-user friendly technique to provide an anti-tarnish treatment. Keywords: silver, tarnish resistant coatings.

Jan 1, 2006

By Ishwinder Grewal, Michael Fullam

Many factors affect the overall performance of a gravity circuit beyond that of the primary gravity recovery device. It is critical to examine the gravity circuit in its entirety in order to determine the dominant operating variables that affect overall performance. Knelson has developed a mathematical model which has been used to assist in the design of gravity circuits, and in particular, in making accurate predictions of plant scale gravity recovery. More recently, inclusion of recovery by particle size class and additional data from various mine sites and research studies has made the model more robust. The model is now able to predict GRG (gravity-recoverable-gold) recoveries using various devices such as centrifugal concentrators, shaking tables, jigs and flash-flotation within the grinding circuit. The benefits derived by these recent advancements in modeling capability are two-fold; the first is as a tool to assist in circuit design and correct equipment selection and the second is as an analytical tool to help to evaluate and enhance the performance of existing gravity circuits.

Jan 1, 2006

By A. Nel

The gold mining industry in South Africa stands to benefit much from the implementation of the self-directed work team concept. Its introduction implies flatter hierarchical structures, empowerment of the workforce and increased participation. Research indicates that half of the initiatives to implement self-directed work teams, however, fail, and it is therefore imperative for companies to be aware of the factors impacting on the effectiveness of self-directed work teams in order to focus on these early in the implementation phase. The objective of the study was to qualitatively determine these factors. Semi-structured interviews based on the phenomenological method were carried out. The sample included members of, and individuals involved with, self-directed work teams (N= 26) from a large gold mining company in South Africa. Results show that most respondents rated the availability of resources to do their work as the most important factor affecting their effectiveness.

Jan 1, 2006

By D. P. Roberts

This paper reviews the use of crush pillars on mines in the Bushveld Complex and the Witwatersrand Supergroup. Stress measurements were undertaken in order to determine the residual strength of these crush pillars. The results from these stress measurements are compared with previous attempts to determine the residual strength of crush pillars using back analysis. It is concluded that the residual strength of such crush pillars lies in a band between 13 MPa and 25MPa. Using the data from the stress measurements, as well as published and unpublished data, a stress-strain curve for a crush pillar with a width-to-height ratio of 2:1 is proposed. Where further work is required, this is indicated in the text.

Jan 1, 2005

By J. Alexis, G. Ye, E. Burström

Over the past twenty years the 3 MW DC arc furnace at MEFOS has been frequently used for development of new processes. These processes include recovery of valuable metals from slag, sludge and dust from steel and other metallurgical industry, treatment of ashes from power plant and incinerators, smelting reduction of minerals and zinc recovery from EAF dust. The process characteristics of the DC arc furnace operation in terms of: ? selective reduction, ? total reduction, ? process stability and flexibility, ? dust carry-over, ? thermodynamic conditions provided in the hot spot area, ? precision in composing slag products These are analysed and described in this paper based on technical results from selected test campaigns over the years and thermodynamic considerations. The electromagnetic properties of DC arcs beneath the electrode have been studied by CFD simulation. The calculated result enables us to understand some interesting technical phenomena observed. The heat balance has also been considered based on data obtained from test campaigns and heat balance calculation.

Jan 1, 2004

By R. J. Hundermark

Keywords: Anglo American, Anglo Platinum Ltd, Waterval, Mortimer, Polokwane, ACP, pyrometallurgy, platinum, PGMs Anglo Platinum Ltd is the largest primary platinum producer in the world and operates three smelters in South Africa: Waterval, Mortimer and Polokwane. The operational details of the smelters are covered in previous reviews, thus only unit operations that have been upgraded are discussed. The most significant of the upgrades include the installation of a second ACP converter at Waterval Smelter in 2006 and the anticipated upgrade of Mortimer Smelter to 38MW in 2011. Several advances have been made in the smelting operations to improve the furnace stability and longevity. Control of the chromium input to each of the smelters has substantially allowed continued operations at levels below the spinel saturation point in slag, which results in lowered matte and slag temperatures. Mogalakwena concentrate, arising from the Platreef ore, is used to dilute high chromium-containing concentrates. In addition, furnace controls have improved in terms of crucible temperature and condition monitoring, improved feeding control, management of alarms and trips and having the quality of instrumentation and operational rigour required to support this. Advances have been made on the ACP converter in terms of good converter matte quality, and increased intensity and efficiency of operation. Combined with improvements to both the conventional and tower sulfuric acid plants, the emissions from Waterval Smelter have been reduced substantially since the introduction of the ACP. This is in spite of increasing metal throughput. The Anglo Platinum Ltd smelting operations have made significant progress since 2006 and further advances are envisaged to further improve on safety, reduce costs, increase efficiencies and throughput, while reducing emissions.

Jan 1, 2011

By H. Yilmaz

A testing method for assessing the shear-bond strength of thin spray-on liner (TSL) on rock substrate was developed at Wits University Rock Mechanics Laboratories. The gap between a 20 mm thick steel ring and a rock core is filled with TSL along the depth of the ring. After the curing of the TSL for a predetermined period, the sample is placed on a base, which offers support to the steel ring and the TSL but not to the rock core. A compressive load is applied on the rock core displacing the core on TSL contact and punching it towards the void in the support base. Shear-bond strengths for different TSL products as well as shotcrete were measured. This paper describes the test set-up and points out the important aspects and procedures during sample preparation and test execution. The test results are also presented and discussed.

Jan 1, 2007

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 L. Rademeyer, P. Mazzoni, C. Kubank, F. Brown

The Corridor Sands deposits of heavy mineral sands represent the largest known economic resource of titanium dioxide minerals. The West Block of Deposit 1 alone contains Measured and Indicated Mineral Resources of 1.7 billion tonnes containing 4.14 per cent ilmenite, estimated in accordance with the JORC standard, sufficient for at least the first 20 years of mining. Total mineral resources are estimated to be approximately 17 billion tonnes at 5 per cent Total Heavy Minerals (THM). Test work was undertaken on the West Block of Deposit 1 over a period of two years in order to develop the process flow sheet to bankable standards. Geological, mineralogical and metallurgical test work was integrated from a pre-feasibility stage to the full bankable stage. The process flowsheet was developed with the central objective of the production of saleable products, of consistent quality and acceptable to the respective end-markets. The aim of this paper is to describe the way in which the various challenges for the project have been addressed by using integrated geological and mineralogical information, which has resulted in the development of a complete flow sheet. The process confirmed that material within customer specifications could be produced, once various metallurgical parameters were understood. This flow sheet development progressed from laboratory test work through to full field trials at pilot plant scale on large consignments of mineralized material. The flow sheet was developed to such a standard as to be used with confidence for both engineering design and cost estimates, and to determine the recovery factors to be used in financial evaluations. Keywords: Corridor sands, Flow sheet, Pilot plant Titanium dioxide

Jan 1, 2003

By S. Ndlovu, M. Malatse

"The Witwatersrand Basin is the heart of South Africa’a gold mining industry. The cluster of gold mines located in the Witwatersrand Basin generates a significant amount of mine tailings, which have adverse effects on the environment and ecological systems. In addition, disposal costs are very high. The exponential population growth in the Witwatersrand area has resulted in pressure on the reserves of traditional building materials. Quarrying for natural construction material is very expensive and damages the landscape. This work therefore examines the use of gold mine tailings in the production of bricks.Different mixing ratios of gold tailings, cement, and water were used. The resulting bricks were then cured in three different environments - sun dried, oven dried at 360°C, and cured in water for 24 hours. The bricks were then tested for unconfined compressive strength, water absorption, and weight loss. The results showed that the mixture with more cement than tailings had a compressive strength of approximately 530 kN/m2. It was also found that the best brick curing system was in a water environment. Bricks made from tailings cost more than conventional bricks because of the higher quantity of cement used, but the manufacturing process consumes less water. Overall, the results indicated that gold mine tailings have a high potential to substitute for the natural materials currently used in brickmaking.Paper written on project work carried out in partial fulfilment of BSc. Eng. (Metallurgyand Materials Sciences)"

Jan 1, 2015