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By K. R. Koch

Although some of the platinum(II/IV) and rhodium(III) chemistry is considered ?old? and well-known, the application of modern multinuclear NMR spectroscopic methods to this chemistry in solution reveals new details about their rich and relevant solution chemistry. In this paper we will briefly illustrate that the highly-sensitive 195Pt NMR shielding is an excellent probe to explore aspects such as solvation, ion-pairing, and the hydrolysis chemistry of inter alia [PtCl6-n(H2O)n]n-2 (n=0-5). Moreover the novel use of 35Cl/37Cl and 18O isotopes effects as unique NMR ?fingerprints? leading to a new and unambiguous method of chemical speciation of the numerous possible PtII/IV and RhIII complexes present in halide-rich aqueous solutions. In the case of Rh(III) chemistry a new, direct speciation distribution diagram has been established for [RhCln(H2O)6-n]3-n complexes (n = 3-6) in HCl solution at 292 K with these methods.

Jan 1, 2012

By C. Montoya

This paper shows, through a case study, the impact of multivariate grade modelling upon mine design and mine planning. A deposit explored by drill holes is considered, in which the grades of five elements (copper, silver, molybdenum, arsenic, and antimony) are of interest. Forty alternative models of the deposit are constructed by fitting the joint correlation structure of the grade variables and using conditional cosimulation. In addition, a reference model, obtained by averaging the alternative models, is also considered. The study shows that the resulting mine design (final pit characteristics and production schedules) is sensitive to the grade model under consideration, and that the design based on the reference model may not be optimal when compared to the alternative models based on cosimulation. However, when assuming a given long-term plan and extraction sequence, the grades and net present value (NPV) calculated on the reference model are unbiased with respect to those calculated on the alternative models with the same extraction sequence. The latter allow assessing the possible dispersion of the actual grades and NPV around their expected values, and are useful for the planner in order to determine the probability of meeting given production targets and of exceeding or falling short of given threshold grades. Additionally, unlike cosimulation, the separate simulation of each grade variable leads to unrealistic resource models and to biased results in mine design and mine planning. This approach should therefore be avoided, unless the grade variables are spatially uncorrelated.

Jan 1, 2012

By M. Mokgohloa, T. R. Stacey

Boring of tunnels and shafts in hard rock under high stress conditions is becoming more common as mines and tunnels are developed at greater depths. Under the high stress conditions, fracturing of the often-brittle rock occurs in the walls, backs, and ahead of advancing faces of excavations. Fracturing can have a significant impact on boring activities: sidewall spalling, which affects machine gripper capacity, and fractures can also develop in the rock ahead of the face, leading to blocky rock conditions, which may have a significant effect on machine excavation. Fracturing may develop dynamically, leading to rock bursts manifesting in the form of strain bursts, which can be hazardous and destructive. In brittle rock, fracturing is commonly extensional in nature. The focus of this paper is on fracturing in the face of the excavation. Examples of such fracturing behaviour are described briefly in the paper. Numerical analyses were carried out to predict the initiation of extension fractures and their orientations ahead of excavation surfaces, and the resulting formation of rock slabs/plates, and the stability of these plates. The results should be beneficial for the evaluation of the conditions prior to, and during boring operations.

Nov 27, 2024

By L. W. Palmer

Compositing or regularization of drillhole data is common practice in mineral resource estimation and is deemed a necessary step in producing unbiased estimates of mineral resources and reserves. Commonly, data are collected over irregular distances due to the varying relative thicknesses of lithologies drilled or sampling/assaying strategies. This necessitates data transformation to regular lengths of equal size to ensure that all data have the same sample support. However, there have been few detailed publications on the effect of this process on the composited data that are subsequently taken forward for the estimation process. In this paper, three currently available compositing methods are reviewed and the effects of inappropriate compositing methodologies presented. It is shown through a case study that compositing samples to different lengths leads to changes in the average and variance of the grades in the drillcores in the dataset, which will impact the final estimated value. These differences are exacerbated by breaks or gaps in data where, for a variety of reasons, there has been no data collection or data have been lost. The importance of appropriately treating blank and zero data is also presented. Globally, these differences might be minimal, but locally may be substantial, affecting the efficiency of the estimation and subsequent use of the results in, for example, mine planning and reconciliation. Further detailed investigation of compositing practices is required if the full implications of compositing are to be understood and any induced bias effectively defined.

Jul 10, 2024

By M. Getz, G. Asbjörnsson, M. Evertsson, E. Clausen

The mining and minerals processing industry is gradually being digitalised to improve efficiency and reduce waste. One aspect of this transition is to ensure that relevant process-data in sufficient quality and quantity is given to the operator in the right format and at the right time to improve decision-making. Augmented reality (AR) can serve as a potential ICT-based support tool for human operators to achieve this goal. With AR, virtual information is combined with the real world in real-time. Therefore, AR technology has the potential to fulfil the need for improved data visualisation in Industry 4.0. This article is the result of a collaborative effort of Chalmers University of Technology and RWTH Aachen University to identify selected state-of-the-art applications of AR that are currently being applied in the mining and minerals industry or selected related industries. This paper aims to show opportunities for the application of AR in the mining and mineral processing industry with selected conceptual applications. This paper concludes with several requirements identified as necessary to implement the conceptual applications of AR in the mining and minerals industry. Keywords: Augmented reality, mining, mineral processing

Jan 1, 2020

By M. Cuba

Geostatistical modelling aims at providing unbiased estimates of the grades of elements of economic interest in mining operations, and assessing the associated uncertainty in these resources and reserves. Conventional practice consists of using the data as error-free values and performing the typical steps of data analysis - domaining, semivariogram analysis, and estimation/simulation. However, in many mature deposits, information comes from different drilling campaigns that were sometimes completed decades ago, when little or no quality assurance and quality control (QA/AC) procedures were available. Although this legacy data may have significant sampling errors, it provides valuable information and should be combined with more recent data that has been subject to strict QA/QC procedures. In this paper we show that ignoring the errors associated with sample data considerably underestimates the uncertainty (and consequently the economic risk) associated with a mining project. We also provide a methodology to combine data with different sampling errors, thus preserving the relevant global and local statistics. The method consists of constructing consistent simulated sets of values at the sample locations, in order to reproduce the error of each drilling campaign and the spatial correlation of the grades. It is based on a Gibbs sampler, where at every sample location, the actual sample value (with error) is removed and a conditional distribution is calculated from simulated values at nearby sample locations. A value is drawn from that distribution and kept only if it satisfies some statistical requirements-specifically, the global relative error and local means and variances must be reproduced. All sample locations are visited and simulated sample values are generated iteratively, until the required statistics are satisfactorily attained over all sample locations. This generates one realization of possible sample values, respecting the fact that the actual samples are known to carry an error given by the global relative error. Multiple realizations of simulated sample values can be obtained by repeating the procedure. At the end of this procedure, at every sample location a set of simulated sample values is available that accounts for the imprecision of the information. Furthermore, within each realization, the simulated sample values are consistent with each other, reproducing the spatial continuity and local statistics. These simulated sets of sample values can then be used as input to conventional simulation on a full grid to assess the uncertainty in the final resources over large volumes. The methodology is presented and demonstrated using a synthetic data-set for clarity.

Jan 1, 2012

By R. McGregor

You wouldn't start excavating before testing core samples, so why would you approve a project plan before all factors have been identified, reviewed and addressed? Even a champion sports team made up of the best players can't produce optimal results without a well understood and agreed game plan. Could an F1 racing team produce their outstanding performance without rigorous evaluation and testing of the factors for successful performance? Why would we expect a capital works project team to be able to get it right without an understanding and an involvement in setting and implementing the overall game plan and without an understanding of all stakeholder requirements? For International Power's Hazelwood (IPRH) mine in Victoria, the challenge was development and delivery of a 40 year mine plan, ultimately involving relocation of existing mine operations into an adjacent new coal field, land acquisitions and major environmental and other approvals to allow diversion of three streams, a highway, an Over Dimension route and other infrastructure in a political and environmentally sensitive atmosphere. The lessons from International Power Hazelwood's (IPRH) experience are: ? that the clear set of project principles and guiding values ensured delivery of a robust plan; ? a robust plan can withstand significant change; and ? value management (VM) played an important role in providing assurance, to all, that the plan was sound at both the strategic and micro levels. This Hazelwood mine project included five major VM workshops. The first was a critical review process in addition to design and cost reviews. This VM workshop was used to analyse, at a high level, the preferred coal mining sequence and design concepts, together with the interaction between design elements, risks and costs. In addition to this, the workshop provided an agreed common pathway for all downstream decisions. A second VM study was conducted to ensure that the proposed plan and design for relocation of the conveying systems from the existing mine into the new field were planned for optimum achievement from a whole of life cost, time, operational and maintenance perspective, plus the logistics of continuing operations while relocating assets. A third study followed to review the Conveyor Transfer Alliance and review functional design. A fourth VM study workshop was formed at the start of Phase 2 Alliance to ensure that the best value for money was being achieved through the current design, schedule and project arrangements and that all interfaces between parties had been reviewed and responsibilities were clear and understood. Other studies are outlined later in this paper. This paper details the evaluation criteria and processes used in the project evaluation that led to the WestField Mine Development.

Jan 1, 2007

Advanced process and equipment analytics have been around for a while. However, with accessible IT infrastructure and site maturity, it is possible to analyse, monitor, and control processing plants and equipment easily. These various disparate systems provide different reports requiring the involvement of various personnel and attention to different reporting platforms. For efficient harnessing of the systems? capabilities, as well as effective improvement and monitoring of process and equipment, a single point of entry is required. A process and equipment optimization solution was required at a concentrator in South Africa, focussing on the product stream of platinum group metal (PGM) concentrate from the UG2 Reef. The investigation of data to identify strategies for optimization was required to allow visibility into plant operations to guide operators, an easier method to identify process loop problems, identification of imminent equipment failures, and advanced process control to optimize throughput and stability. A collaborative effort between the client and General Electric Intelligent Platforms (GEIP) investigated data-driven solutions to each of the problems. With the focus on process optimization and asset monitoring, as well as equipment monitoring, a combination of approaches was utilized to address the various problem areas that were identified. Each was implemented separately in the control layer of the plant IT infrastructure. The integration was done in a centralized web-based reporting tool that integrated the detailed results from the various solutions. On the process control side, monitoring of control loops was included by calculating performance statistics that were reported daily to identify sub-optimally performing control loops and indicating potential problems. The advanced process control solution for this site includes a surge tank controller, stabilizing flow through the flotation banks, and preventing the surge tank from overflowing or running empty. Equipment monitoring was investigated, for preventative maintenance, by making use of statistical data models to indicate imminent equipment failure. These predicted alarm events included the cause for failure, drilling down, and allowing focus on a specific variable for preventative action. The results included a more stable flow through the mill, with fewer stoppages due to surge tank overflows or running empty. The causes for process drift could be identified and operators could react early. Alarms warning of equipment failure 2½ and 4 months in advance were identified in an offline analysis.

Jan 1, 2012

A mineralogical study was conducted on the feed (3.51 g/t Au and ~90 g/t Ag) and four leach residue samples (assaying 0.09 to 0.19 g/t Au and 30.0 to 61.5 g/t Ag) from the Pinos Altos silver-gold deposit in Mexico to determine the cause for gold and silver losses. A comprehensive mineralogical and analytical approach including fire assay, gravity pre-concentration, ore microscopy, mineral liberation analyser (MLA) and electron microprobe was used for the current study. Results showed that gold and silver lost in the leach residues occurred mainly as inclusions in quartz and silicates (accounting for over 80% for Au and 92% for Ag of the head assays, respectively), with a minor amount in iron oxide and other minerals. The amount of liberated gold and silver is negligible. Results also showed that gold and silver particles in leach residues are mainly ranged from 1 µm to 5 µm in size, which implies that ultrafine grinding is required to improve the recoveries of these two metals. Keywords: mineralogy, gold deportment, silver deportment, silver-gold ore, leach residue, recovery improvement.

Jan 1, 2009

By T. Khumalo, L. Musenwa, S. Masemola, M. Kgaphola

"In 2017, Petra Diamonds completed the construction and commissioning of a modern, fit-for-purpose diamond processing plant at Cullinan Diamond Mine (CDM). The design of CDM’s milling circuit is unconventional in that it comprises an autogenous (AG) mill with a grate discharge with large ports, low-revolution jaw crushers, and high-pressure grinding roll crushers with large operating gaps. In this paper we review the design to provide guidance on what is expected from the milling circuit and to demonstrate how the design aims to address challenges experienced in the old plant, which was based on staged crushing technology. We assessed the performance of the CDM AG milling circuit from commissioning and early production stages to examine its impact along multiple dimensions. In the assessment we sought to understand the lessons from our milling circuit regarding diamond liberation, energy consumption, and the future of diamond processing as a whole. IntroductionCullinan Diamond Mine (CDM), previously known as Premier Mine, is an underground diamond mine owned by Petra Diamonds. Petra Diamonds is a leading independent diamond mining group and a growing supplier of rough diamonds to the international market. Petra Diamonds is listed on the Main Market of the London Stock Exchange under the ticker ‘PDL’. Petra’s total resource of 305 million carats ranks third by size after De Beers and ALROSA (Petra Diamonds, 2018).CDM was established in 1902. The mine rose to prominence in 1905, when the 3106 carat Cullinan Diamond — the largest rough diamond of gem quality ever found — was discovered there. The mine has produced over 750 stones that are larger than 100 carats and more than a quarter of all the world's diamonds that are larger than 400 carats. Cullinan is renowned as a source of large, high-quality gem diamonds, including Type II stones, as well as being the world’s most important source of very rare blue diamonds (Petra Diamonds, 2018)."

Feb 1, 2019

By M. B. Shongwe, G. Freemantle, M. Botha, S. Brill, J. D. Steenkamp

During steelmaking, one important factor for production efficiency is the free opening of the ladle nozzle during continuous casting. Free opening occurs when the well filler sand and the steel flow freely when the slide gate is opened. Well filler sands are used for the slide gate of a ladle to separate the slide gate refractory and the molten steel. The well filler sand is partially sintered by the heat of the molten metal, which can result in the ladle nozzle failing to open if the sand is not sintered to an appropriate extent. It is therefore of great importance that the sintering behaviour of well filler sand is understood. We studied the effect of the well filler sand chemistry on its sintering properties. Samples of well filler sand with various chemical compositions were sintered in a high-temperature chamber furnace. Quantitative X-ray diffraction (XRD), inductively coupled plasma optical emission spectrometry (ICPOES), and wavelength dispersive spectrometry (WDS) by electron microprobe analysis (EMPA) were used to analyse the various well filler sand mixes. Points of analysis were indicated on backscattered electron (BSE) micrographs. Quantitative element mapping was undertaken by energy dispersive spectrometry (EDS). Thermodynamic calculations in FactSage predicted the percentage liquid phase present for the various well filler sand compositions at equilibrium conditions. The results of this work show that the degree of sintering of chromite-silica well filler sand depends strongly on the silica content. The amount of liquid phase formed increases with increasing silica content.

Feb 2, 2022

By C. G. Goncalves

The Gautrain rapid rail link project is currently Africa?s largest infrastructure project connecting South Africa?s major airport (OR Tambo), Johannesburg and Pretoria. Phase one is planned for completion in time for the 2010 FIFA Soccer World Cup and involves 80 km of track and 15 km of underground tunnels. The key shaft sinking blasting issues revolve around maximising advance and improving blasting cycles to meet the tight deadlines as well as environmental control which, in some cases takes place only 15m from the city infrastructure. To achieve success, DetNet South Africa supplied a range of electronic detonator systems to cater for the different blasting applications involved (tunnels, portals, shafts and viaduct foundations). One such product, QuickShot, was used for the first time in a major civil engineering project and has been used in most of the shaft sinking blasts to date. The QuickShot system combines pre-programmed electronic detonators with special on-bench components that enable the user to quickly and easily design the firing sequence solely by using the order of connections. This precludes the user from having to deal in absolute delay times. The connecting system enables benches to be hooked-up speedily by multiple users who have differing levels of experience. This paper provides details of how, after 33 months, the system has been embraced by the project by aiding in maximised advances, improved cycle times and meeting the required environmental constraints.

Jan 1, 2009

By C. G. Goncalves

The Gautrain rapid rail link project is currently Africa?s largest infrastructure project connecting South Africa?s major airport (OR Tambo), Johannesburg and Pretoria. Phase one is planned for completion in time for the 2010 FIFA Soccer World Cup and involves 80 km of track and 15 km of underground tunnels. The key shaft sinking blasting issues revolve around maximising advance and improving blasting cycles to meet the tight deadlines as well as environmental control which, in some cases takes place only 15m from the city infrastructure. To achieve success, DetNet South Africa supplied a range of electronic detonator systems to cater for the different blasting applications involved (tunnels, portals, shafts and viaduct foundations). One such product, QuickShot, was used for the first time in a major civil engineering project and has been used in most of the shaft sinking blasts to date. The QuickShot system combines pre-programmed electronic detonators with special on-bench components that enable the user to quickly and easily design the firing sequence solely by using the order of connections. This precludes the user from having to deal in absolute delay times. The connecting system enables benches to be hooked-up speedily by multiple users who have differing levels of experience. This paper provides details of how, after 33 months, the system has been embraced by the project by aiding in maximised advances, improved cycle times and meeting the required environmental constraints.

Jan 1, 2009

The Annual General Meeting of the Branch was held in the Witbank Golf Club on Thursday, 28th August, 1969 at 5.00 p.m. Mr C. G. Sowry (Chairman) was in the Chair. There were also present: Ten Members: Messrs J. Meintjes (Vice-Chairman), J. E. van Aswegen, A. C. Hofmeyr, I. Botha, B. F. v. d. Merwe, C. H. Coxon, R. Canny, R. C. J. Goode, A. Bain, G. E. Carlyon. Six Associate Members: Messrs B. T. Hosking, R. E. Powell, W. Weber, T. Bulloch, E. J. Jackson, P. J. Muller. Fourteen Visitors. Total Present: 31. The Chairman declared the meeting open and extended a welcome to all visitors including Mr R. C. J. Goode, President of the Institute. MINUTES OF PREVIOUS GENERAL MEETING The Minutes of the General Meeting held on the 26th June, 1969, were read and adopted. CHAIRMAN'S REPORT The Chairman presented a report outlining the activities of the Branch during the past year. Membership of the local Branch had increased from 80 to 99 during the year. DECLARATIONOF OFFICEBEARERS The Chairman announced that owing to his transfer out of the Witbank area, he was unable to accept the nomination as Chairman for a further year of office. The outgoing committee had elected Mr J. Meintjes Chairman and Mr A. Bain Vice-Chairman for the ensuing year. Mr J. Meintjes then took the chair. Mr J. Meintjes thanked Mr C. G. Sowry for his successful steering of the Branch during its period of inauguration. ELECTION OF COMMITTEE MEMBERS The Chairman then read the Scrutineers' Report and declared the following eight members elected as Committee Members for the 1969-1970 year: Messrs I. Botha, A. W. Brereton, G. E. Carlyon, B. T. Hosking, E. J. Jackson, B. D. McNeice, P. J. Muller, B. F. van der Merwe. TALK The Chairman then called upon Mr A. Bain to present his talk and film show on 'Impressions of the mining and metallurgy congress tour to Australasia'. CLOSURE After thanking the speaker for an interesting talk, the Chairman declared the Meeting closed at 8.40 p.m.

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 S. T. L. Harrison, M. Smart, C. J. Edward

Biooxidation, a biohydrometallurgical process, utilizes a mixed microbial consortium to mediate the dissolution of refractory gold-bearing ores to enhance gold recovery during cyanidation. Recognition of water as a critical resource has prompted improved water management strategies within mining and minerals processing. Bioremediated wastewater from the cyanidation tailings provides a potential water source to supplement the water required for the biooxidation circuit, reducing freshwater extraction. Gold biomining operations have typically been reluctant to recycle this wastewater due to the potential inhibitory effects of cyanide and thiocyanate (SCN-) on the microbial population. Historical process upsets suggest that the microorganisms are sensitive to SCN- concentrations as low as 1 mg/L. However, effective bioremediation processes resulting in effluents with low or negligible SCN- concentrations may allow gold biomining plants the opportunity to recycle available water. Microbial activity as well as alteration in community structure were monitored as a function of increasing SCN- concentration over the range of 0 mg/L to 5 mg/L to investigate the response of the biooxidation community to potential SCN- spikes resulting from upsets in the remediation process. Appropriate microbial growth and ferrous iron oxidation activity with a nominal shift in community structure were observed at SCN- concentrations up to 1 mg/L. Thiocyanate concentrations above 1 mg/L resulted in the complete inhibition of ferrous iron oxidation activity. This was attributed to Leptospirillum ferriphilum’s sensitivity to SCN-. Exposure to a SCN- concentration of 5 mg/L resulted in a lower cell concentration and a significant increase in growth lag time, and the absence of L. ferriphilum from the microbial population. At. caldus and Ap. cupricumulans were still present at 5 mg/L SCN-, although Ap. cupricumulans was unable to oxidise ferrous iron at this SCN- concentration. It was concluded that recycling bioremediated cyanidation tailings wastewater within the biooxidation circuit is feasible; however, to retain process performance, SCN- concentrations should not exceed 1 mg/L. Keywords: Biooxidation, thiocyanate, water recycling, community structure

Jan 1, 2020

The development of short- and medium-term mine production schedules in isolation from each other has meant that only a local optimum can be achieved when each scheduling phase is carried out. The globally optimal solution, however, can be achieved when integrating scheduling phases and accounting for the interaction between short-term and medium-term activities simultaneously. This paper addresses the task of integrating short- and medium-term production plans by combining the short-term objective of minimizing deviation from targeted mill feed grade with the medium-term objective of maximizing net present value (NPV) into a single mathematical optimization model. A conceptual sublevel stoping operation comprising 30 stopes is used for trialling segregated and integrated scheduling approaches. Segregated medium- and short-term scheduling using separate models achieved an NPV of $42 654 456. The final scheduling approach involved integrating the two scheduling horizons using the newly-developed globally optimal integrated production scheduling model to achieve an NPV of $42 823 657 with smoother mill feed grade. The larger the stope data set, the larger the difference between the two scheduling approaches is likely to be. At the very least, an integrated approach ensures feasibility across the two scheduling horizons, which cannot always be assumed when using a segregated approach.

Jan 1, 2012

By Mark Dangerfield

[Power-Point Presentation]

Jan 1, 2005

By Tian Yingzhong, Guo XIN, Wei Peihe

The intention is to solve a series of problems in the flotation and desiliconisation of complex bauxite; aiming to achieve monomer dissociation of target minerals based on process mineralogy. According to the mineral surface, there are differences in physical and chemical properties and the molecular design theory of flotation agents. Designing the polar and non-polar groups of the bauxite flotation collector to make the reagent group easily combine with the mineral to form a cyclic chelate, will enhance the collection performance, and strengthen the drug selection performance. Developing a new type of positive flotation collector for bauxite with small dosage, strong selectivity and low foam volume. Keywords: Process mineralogy, monomer dissociation, molecular design, new positive flotation collector

Jan 1, 2020

By A. M. Garbers-Craig, T. Coetsee, T. M. Nemavhola

Accretions often form in furnaces when slag and charge materials attach to the refractory wall and build up over time. Accretion formation is usually unwanted because it reduces the working volume of the reactor and hinders material flow through the reactor. However, in some instances a thin, stable accretion layer may be desirable to protect the underlying refractory material. In order to prevent and/or manage accretion formation, it is important to understand the underlying principles of this phenomenon in the particular reactor. Excessive accretion formation hampered production at the Exxaro FerroAlloys ferrosilicon melting and atomization plant. This plant uses induction furnaces in which a 15% silicon-iron alloy is produced by batch smelting a mixture of ferrosilicon of 75%Si grade and low-carbon steel. The molten ferrosilicon alloy is then gas-atomized to a powdered product for use as a dense medium in mineral processing plants. The objective of this study was to investigate the effect of different impurity levels in the ferrosilicon feed material on the extent of accretion formation as well as the effect on the accretion properties, which influence the ease of accretion removal upon furnace shut-down. Refractory and accretion samples were collected after a furnace shut-down and characterized using X-ray diffraction and scanning electron microscopy–energy dispersive spectroscopy. It was concluded that the trace elements in the FeSi-75 feed material (Al, Ca, Mn) were mostly responsible for accretion formation, but that rust on the low-carbon steel and oxidation of the steel contributed to accretion attachment to the lining. The total contaminant content, calcium to aluminium ratio in the FeSi-75 feed material, and thereby the liquid to solids ratio in the accretion at temperature determine the strength of attachment as well as growth of the accretion.

Feb 2, 2021