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By B. Yu, M-H. Cao, C. Zhou, X-Z. Zhang

The transient infiltration and lubrication behaviour of slag during continuous casting of steel is important for billet quality. A two-dimensional coupled mathematical mould model was developed to investigate these phenomena. The accuracy of the model was verified by comparing the calculated slag consumption with measurements by the plant. The results show that the liquid slag is consumed from the middle and late period of positive strip time to the next early period of positive strip time, including the entire negative strip time. The maximum downward infiltration velocity and positive pressure in the slag channel is at the middle of the negative strip time. Increasing the positive pressure of the slag channel is conducive to lubrication. The shear stresses acting on the shell surface and at the mould side were determined by the lubrication slag consumption and total slag consumption, respectively, and gradually decreased with increasing slag consumption. The negative strip time was lengthened to increase the slag consumption and prolong the time near the maximum downward shear stress, so as to be conducive to the demould.

Apr 16, 2024

By G. A. Georgalli

A control philosophy to be applied by Lonmin to maintain constant electrode immersion in their no. 1 circular smelting furnace is put forward. This control philosophy is facilitated though a combination of thermodynamic models used to predict the slag composition and empirical correlations to estimate the furnace geometric factor as well as the slag conductivity. The model can determine the operating resistance set point required in order to maintain a desired electrode immersion as a function of the feeds to the furnace, slag level and temperature. If modifying the resistance set point cannot maintain the desired immersion without moving out of the furnace P-V-I operating envelope, the model can be used to determine the amount of slag modifiers (silica or lime) required to shift the slag chemistry back into a region where the immersion can be controlled though resistance set point manipulation.

Jan 1, 2008

By S. C. Thorley, J. R. Menasce

Trackless mining in low profile (LP) and extra low profile (XLP) platinum stopes has forced equipment designers to re-evaluate their equipment profiles to match the undulating reef. Low profile equipment designed to work in conditions with smooth and flat floors will simply not function with undulating floors and roofs and will become wedged between the floor and roof, beached on undulations due to lack of ground clearance, or suffer excessive mechanical damage. Tyres, too, need special evaluation, as conventional tyres for trackless mining do not work in an extra low profile environment.

Jan 1, 2004

By P. A. P. Fouché

Processing confidence for a bankable feasibility study on a green field heavy mineral deposit is inmost cases achieved only through bulk sample processing. Bulk sample is classified as a large enough concentrate sample that is processed into final products to satisfy market sample demand as well as further processing demands such as smelting. In this case study the demand was to produce 500 tons of heavy mineral concentrate from more than 5 000 tons run-of-mine on are mote location with limited to no infrastructure. The various challenges faced and lessons learned are documented as an outcome of the success of this mission.

Jan 1, 2007

By M. M. Hajdasinski

The internal rate of return (IRR) is one of the most popular project evaluation criteria in the mineral industry, as well as in other industrial sectors. Analysis of its assumptions reveals, however, that this criterion does not function in the way it is supposed to. The search for a new criterion that would reflect the true rate of return (TRR) of an investment project or the true borrowing rate (TBR) of a borrowing project has led to the development of several approaches, yielding, for the same project, generally different values of the interest rate in question. Two of those approaches have been selected as the most representative and practical. Each has been presented in two variants, and subsequently analysed. As a result, it is shown that the various approaches to the TRR/TBR are all consistent with the net present value (NPV) criterion, and that each can serve as an independent project evaluation instrument, provided its assumptions can be regarded in a given situation as realistic enough.

Jan 1, 1987

By T. P. Katakwa

The utilization of software is now inherent to virtually every activity along the mining value chain. However, apart from the software survey done by Gibbs in the 1990s and work on the extent of diffusion of information and communication technology (ICT) in the South African platinum sector by Mugodi and Fleming in 2003, the nature and extent of software utilization in the South African mining industry has never been evaluated. The Mine Planning, Optimisation and Valuation (MPOV) Research Group in the School of Mining Engineering, University of Witwatersrand, therefore initiated a project to collate and analyse the current utilization of software in the South African mining industry. This was done through the development of a web-based database of the relevant software. Snowball sampling was used to collect the data because the South African mining industry is diverse and software utilization is fragmented across and within the sectors of the industry. The data was then organized into distinct categories so that the information from a variety of sources could be evaluated on the same basis. A beta version of the database can be accessed online through a user-friendly front-end platform at http://db.mining.wits.ac.za. The database is expected to help at least 13 educational institutions with decisions on facilities and training that are vital to the education of mining and mining-related professionals. Exploration, mining, and consulting companies will also benefit from information in the database relating to availability and useful combinations of software solutions. The database is also strategic to software providers by providing a better understanding of their respective relative market share along the mining value chain. An analysis of the data collated in this research shows that about 77% of the software users are mining companies, 17% are consulting companies, 3% are mineral exploration companies, and the rest are software providers and educational institutions. The software used in the South African mining industry is largely provided by Gemcom Software International, MineRP Solutions, and MRM Mining Services. CAE Mining, who in 2010 acquired the Datamine Group providing Datamine software, is also widely acknowledged as a major software supplier in South Africa, but data from them had not been obtained at the time of producing the beta version of the database due to proprietary constraints. The work reported in this paper is part of an MSc research study in the School of Mining Engineering at the University of the Witwatersrand. Keywords mine planning, mining, value chain, software, database, South African mining industry, utilization.

Jun 1, 2013

By C. Botha

The South African democratically-elected government instituted policies and legislation that are intended to bring about change and transformation in the country and have drastically affected different industries, among others, the mining industry. The Mineral and Petroleum Resources Development Act 28 of 2002 (MPRDA) and the Broad-based Socio-economic Empowerment Charter (Mining Charter) were introduced in order to redress previous inequalities and to promote women's employment in the mining industry. This research evaluates the practical implementation of the MPRDA and the Mining Charter with specific reference to women in underground mining. A quantitative research paradigm was used. Data were collected through a process of a face-to-face interview surveys utilizing a structured questionnaire. The research setting was limited to the platinum-mining industry in the area of Rustenburg in the North West Province. The study population consisted of 195 available women working undergound at the mine. It is clear from the findings that mining companies are facing major challenges in their attempt to incorporate women in underground mining activities. Company policies regarding these issues must be firmly in place; however, the challenge lies in the translation of these policies into practice. In this regard, managers will have to play a leading role in the successful phasing in of women into the underground mining arena.

Jan 1, 2012

A large body of work exists discussing the impact of grinding media on mineral flotation. Generally, the work indicates that a change to a less electrochemically active grinding environment has positive benefits on downstream processing. There is a fear, however, that these benefits may not be realized when treating low sulphide containing ores, typified by UG2 style deposits. A series of experiments was developed to test the flotation response of UG2 ores using the Magotteaux Mill® to determine if measurable differences in the pulp chemistry could be discerned using a range of grinding media types. Further, the flotation responses of the contained sulphides (chalcopyrite, pentlandite and pyrrhotite) were determined. The data collected provided strong evidence that the grinding environment can significantly influence the pulp chemistry and flotation characteristics of all sulphide minerals, even when the ore contains less than 0.5 per cent total sulphide. The results show that the change to an inert media type produced a substantial improvement in the flotation rate of all sulphide minerals, as well as the PGMs.

Jan 1, 2009

By A. M. Venter

"SynopsisThe availability of advanced characterization techniques is integral to the development of advanced materials, not only during development phases, but in the manufactured components as well. At Necsa, two modern neutron diffractometers equipped with in-situ sample environments, as well as complementary X-ray diffraction instruments, are now available as User Facilities within the National System of Innovation in support of the South African research and industrial communities. Neutrons and X-rays, owing to their different interaction mechanisms with matter, offer complementary techniques for probing crystalline materials. Both techniques enable nondestructive investigation of phenomena such as chemical phase composition, residual stress, and texture (preferred crystallite orientation). More specifically, the superior penetration capabilities of thermal neutrons into most materials allows for the analysis of bulk or localized depth-resolved properties in a wide variety of materials and components. Materials that can be investigated include metals, alloys, composites, ceramics, and coated systems. In particular, depth-resolved analyses using neutron diffraction complements surface investigations using laboratory X-rays in many scientific and engineering topics. The diffraction techniques can add significant downstream value to the anticipated nuclear industry development activities.IntroductionMaterials characterization is central in understanding the relationship between the structure, properties, and performance in order to engineer materials that fit the performance criteria for specific applications. This is conveniently represented in the form of a tetrahedron, generally known as the material science paradigm (Figure 1).The availability of advanced characterization techniques is integral to the development of advanced metals, not only during development phases, but in the form of manufactured components. At Necsa (South African Nuclear Energy Corporation), modern X-ray and neutron diffraction instruments are now accessible to the South African research and industrial communities. These facilities enable nondestructive investigations of materials and components that could add significant downstream value to the anticipated nuclear industry development activities."

Jan 1, 2015

By K. A. Annan

The last seven hot rolling passes of the ferritic stainless steel AISI430 were simulated on a Gleeble-1500D® thermo-mechanical simulator to investigate the effect of temperature, strain rate, and interpass time on the texture. The compression tests were carried out over a wide range of strain rates (0.1 s-1 to 5 s-1) and temperatures (1100°C to 820°C) with different interpass times (2, 10, 20, and 30 seconds). The dynamic recrystallization to dynamic recovery transition temperature was determined from examining the relationship between the mean flow stress and the inverse of the deformation temperature in multi-pass tests. It was found that the texture in the central layer of the compressed sample is a strong recrystallization-type. The through-thickness textural and microstructural banding, to a large extent, were found to be weakened by hot deformation in the two-phase (a+ ?) region, as opposed to the single-phase (a) region.

Jan 1, 2013

By B. Geelhoed

A generalization of Gy?s 1979 model for the variance of the fundamental sampling error has been proposed at WCSB2?2005 by Geelhoed. This generalized model can potentially lead to a better correspondence with actual sampling processes. However, a new parameter is required by the new model: ?the parameter for the dependent selection of particles?(Cij). It is important that this new parameter, which is at the basis of the new theory, is well understood in the sampling and blending community. In order to clarify the meaning of Cijand to prevent potential misinterpretation of Cij, we discuss the difference between Cij and an intuitively associated, but different, parameter: ?the parameter for the dependent selection of particle types?(Mij). In this contribution, the theoretical difference between both parameters is clarified. Simulations demonstrate that, numerically, the difference between Cij and Mij can be large. Some additional advantages of the approach which uses Cij are discussed: (i) the approach based on Cijis more general; (ii) in all cases where Mij is known, Cij can be determined as well, while the reverse is not true; (iii) an equation already exists that relates the sample variance to the value of Cij.

Jan 1, 2009

By Y. -L. Chiang

Paper written on project work carried out in partial fulfilment of BSc (Eng) (Chemical) The generation and control of manganese sulphide particle size distribution using various mixing configurations were investigated. Specifically, this paper discusses how varying mixing intensities on a macro and micro scale affect the resultant manganese sulphide particle size distribution (PSD) at a constant concentration. The mixing variations were achieved using various Y- and T-mixers as premixing devices into a jacketed, agitated vessel. The reagents used to generate the seeds were aqueous manganese sulphate and sodium sulphide solutions. The results showed that the absence of micromixing resulted in very poor control of the particle size distribution, the particle size and the number of particles produced. This was due to the fact that the macromixing time is much greater than the corresponding precipitation time, resulting in different mixing regions existing within the reactor. From the micromixing experiments, the T?mixer was found to be the most effective mixing device at lower concentrations due to the T-mixer providing a faster mixing time than the other mixing configurations, thereby effectively localizing the supersaturation and hence controlling the precipitation. The results obtained from the direct addition without the extension pipe (i.e. short mixing time) indicated a general increase in mean particle size and decrease in total particle number at reagent concentration of 0.007 mol.dm-3as compared to the corresponding micromixing experiments. The phenomenon may be due to incomplete crystallization at the immediate exit of the mixing device. Further experiments need to be conducted before any conclusions can be drawn about the precipitation mechanisms.

Jan 1, 2007

By R. J. Cocks

Water auditing and water efficient practices are evolving as the quantitative tools for water balance reporting in the mining and minerals processing sector. This paper was written to describe the process of water auditing in a gold mining environment. It will contribute towards building an appropriate water management framework for The Cooperative Research Centre (CRC) for sustainable resource processing (CSRP). The research assists with the assessment of water balances in mining and hydrometallurgical processes and provides, on the ground, steady-state data for ongoing probabilistic modeling underway at most of Newmont?s gold mine operations. Five Newmont case study mine sites including the Tanami Granites Goldmine are central to this PhD water project study. The function of the Tanami-Granites water audit exercise was to measure a controlled flow of various water quality types and set a framework to establish further research for water efficiencies and water conservation in mining.

Jan 1, 2009

By J. E. Dickinson, J. L. Sutherland, J. Zhou, M. J. Cole, K. P. Galvin

Interest in early gangue rejection has grown substantially in the minerals industry to reduce energy and water consumption arising from excessive comminution. Recent developments in coarse-particle flotation have proven successful by promoting a quiescent hydrodynamic environment to limit particlebubble detachment and by helping to convey more buoyant particles to the overflow. Current approaches also benefit from upstream classification to remove the finer particles ahead of the coarse-particle flotation. In this study, coarse-particle flotation was investigated experimentally using a novel hybrid gravity-flotation system called CoarseAIR™ that exploits the hydrodynamic advantages of the Reflux® Classifier. The system consists of a lower fluidised bed housing, with a system of inclined channels above. The inclined channels enhance the segregation and hence rejection of intermediate through to relatively coarse particles containing little or no surface liberation. This approach overcomes the need for pre-classification, while offering strong transport of coarse particles made buoyant through their attachment to air bubbles. The paper explores the strong relationship between the solids transport to the overflow and the input gas flux, showing firstly the potential for significant mass rejection at the relatively low gas fluxes, and robust performance in terms of recovery across the full range of gas fluxes. Keywords: Flotation, inclined channels, coarse particle flotation, Reflux Classifier

Jan 1, 2020

By L. Morin, S. Mortazavi, K. Volchek, A. Demers, A. Di Feo

The objective of this paper was to investigate the possibility of reducing process (fresh) water and increasing recycled water (thickener tank overflow water). As part of the investigation, rougher flotation tests were done with the two water types and a mixture of the two (50%/50%). The effect of recycled water on the grade-recovery response and rougher recoveries was investigated. When thickener tank overflow was used (50% and 100%), the nickel+copper grade versus nickel recovery decreased. The decrease in the grade-recovery was due to higher pyrrhotite recovery. Also, there were no effects on nickel and copper recoveries, which was confirmed using multivariate statistical analysis at the 95% significance level. Keywords: Flotation, nickel, copper, water recycling, multivariate statistical analysis, MANOVA, reverse osmosis

Jan 1, 2020

By P. R. Mothemela

The objective of the investigation is to optimize the truck and shovel operations for pre-stripping at New Vaal Colliery by introducing campaign mining. The aim of campaign mining is to improve the efficiency of the loading, hauling, dumping, and maintenance operations which are critical to the success of truck and shovel operations. The current loading (single-sided loading method), hauling, and dumping operations at New Vaal Colliery were found to be inefficient. Time studies were used as a major indicator to highlight the inefficiency of the truck and shovel operations, and it is recommended that an improved loading configuration, hauling, and dumping operations be implemented by using campaign mining. It is also recommended that a service truck be used to maintain the pre-stripping fleet in order to reduce travelling times to the main workshop. As expected, the improved operating conditions will lead to an increase in pre-stripping production.

Jan 1, 2013

By L. G. Austin

The paper summarizes the current state of development of simulation models for SAG and FAG mills, and gives the results of recent investigations of the physical processes occurring in autogenous grinding. The breakage process is treated as the sum of three regions of breakage actions: normal breakage caused by nipping of particles between media (steel balls or pebbles); abnormal breakage caused by media when the particle or lump is too big in relation to the media to be readily nipped; and self-breakage resulting from the chip¬ping fracture and abrasion of the tumbling action of rock lumps. Each region of breakage action has associated specific rates of breakage and primary progeny fragment distributions. A simplified form of the model was used to predict the performance of an 8 m diameter SAG mill with L/D = 0.5 grinding a copper ore, and predicted maximum capacity and minimum kWh/ton at about 6% ball load at 25% total filling. Two FAG mills of L/D = 2 were necessary to give the same capacity, and the simulations indicated a lower kWh/ton for these mills. For this ore, both systems were technically feasible.

Jan 1, 1987

By M. F. G. Bruce

Two backfill systems have been developed on West Driefontein, namely the centrifuge dewatered tailings system and the cyclone-classified tailings system. Modifications to the two systems since the publication of the original paper (Close and Klokow, 1985) are discussed in addition to the results obtained. Considerable experience has been gained from the operation of the centrifuge dewatering units as well as the placement of dewatered tailings in a difficult mine environment. The centrifuge dewatered tailings method has proved successful in the extraction of a highly stressed block of ground at No. 5A Sub-vertical Shaft. The utilization of backfill support in this area made it possible to dispose of a high-grade barrier pillar. This pillar was considered necessary prior to the introduction of backfill support. The recovery of the gold from this pillar made the use of dewatered tailings backfill cost- effective, despite high labour and maintenance costs. Current experience with the bagfilling method of placing cyclone- classified tailings indicates that it is viable and requires considerably less capital investment. Although expensive at present, it is envisaged that costs will decrease once cheaper bags and other forms of stope support are used. The placement of backfill in small-diameter sausage-type bags requires no change in mining cycle and allows the backfill to be placed close to the stope face. Both backfill systems are being expanded but preference is to be given to the cyclone-classified tailings system.

Jan 1, 1988

By C. -J. Rick

The ferroalloy market is characterized by a very long communication distance between the consumer and the producer. This has created a situation where it has been difficult to change ferroalloy properties. In this paper different FeNi and FeCr-compositions are discussed and their merits for stainless steel-makers in different situations are compared using the process models applied at Outokumpus Avesta works and Acerinox's Columbus operation Keywords Ferroalloy design, ferrochrome, ferronickel, stainless steel making, UTCAS software.

Jan 1, 2010

As part of a broad program to optimise the performance of their grinding circuit, BHP Billiton Cannington have installed an OCS© Expert system together with three VisioRockTM online particle size analysis cameras. The main purpose of the system is to stabilise grind size and feed to the flotation circuit. This particular application of OCS© is the first installation to incorporate Metso Minerals Process Technology-Asia Pacific's (MMPT AP) Dynamic SAG/AG Mill Model, which is able to predict numerous mill parameters that were previously unable to be measured with the existing plant instrumentation. Integrated into the logic of the control algorithm are online vision based, particle size measurements of the AG mill feed and recycle crusher product. This paper will describe the history of the project from initiation to date, the model and OCS© logic configuration, and demonstrate the significant benefits realised at Cannington mine.

Jan 1, 2007