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By R. T. Jones

Base metals and platinum group metals can be collected in metallic alloy form, via a wide variety of smelting processes. The recovery, or degree of collection, of the valuable metals is a function of the extent of reduction in the furnace, which, in turn, is indicated by the fraction of iron present in the feed materials that report to the alloy. An equation has been developed that relates the recovery of various metals (such as Ni, Co, Cr, and PGMs) to the recovery of Fe. This recovery equation (for each metal) is characterized by a single parameter (K?) that can either be empirically fitted to the data, or expressed in terms of the equilibrium constant and the ratios of the activity coefficients involved. Data from a number of varied DC arc furnace campaigns are presented to illustrate this behaviour.

Jan 1, 2009

By C. -T. Mutale, A. S. Tuling

Titanium can exist in three different oxidation states. Its oxides are numerous and in presence of iron and oxygen, iron-titanium oxide compounds can also form. Some of the oxides are non-stoichiometric, making the determination of the thermodynamic properties of titanium and its oxides in molten steel and in slag difficult. Therefore, for the assessment of titanium activity in molten steel using the electrochemical measurements of oxygen partial pressure, the identification of oxides in equilibrium with titanium is important. This paper reports on an investigation of solid titanium oxide inclusions, which have been identified by combining different methods of analysis on quenched samples. These samples were taken from a Fe-Ti-melt at 1600°C, quenched in cold water then mounted and polished for optical microscopy. The oxide inclusions were analysed using transmission electron microscopy (TEM) with energy dispersive spectroscopy (EDS). Both single crystal and polycrystalline diffraction patterns were used to identify the oxides by comparing the d spacings with those in the ICDD X-Ray Diffraction (XRD) database. XRD was used to analyse the oxide particles on the top of slow cooled samples. It was found in the TEM study that the similarity of the diffraction patterns of the various phases meant that unique identification was difficult to achieve in some of the diffraction patterns. However, TiO, Ti2O3, Ti3O5, Ti4O7were identified in quenched samples, while TiO2, FeO.TiO2and iron oxides were seen in slow cooled samples. It was also confirmed that the type of oxides is related to titanium content of the samples. Keywords: Titanium, Titanium Oxides, Iron, TEM, XRD, thermodynamic.

Jan 1, 2004

By L. A. Matthews

The embrittlement of the Ti-6Al-4V alloy by hydrogen dosing at elevated temperature has been investigated. Metal coupons were subjected to isothermal treatments in a partial hydrogen atmosphere in the temperature range from 650ºC?950ºC and the degree of embrittlement after treatment was determined by drop-weight impact testing. Embrittlement was found to be inversely related to reaction temperature as a result of the combined effects of greater hydrogen absorption and titanium hydride precipitation at the lower isothermal temperatures. Keywords Titanium, hydrogen embrittlement, impact energy

Jan 1, 2011

By T. Lindstad, V. Myrvågnes

In the production of high silicon alloys, carbonaceous materials like coal, coke, charcoal and woodchips are utilized as reducing agents. Primarily based on historical prices of charcoal compared to fossil reduction materials, the Norwegian Ferroalloy Industry has mostly been using coal and coke (char) as carbon source. The most important role of the carbonaceous material is to react with the SiO gas to produce SiC. The ability of the reduction materials to bind SiO gas can be measured and the value is recognised as the reactivity of the carbon source. This reactivity is one of the most important parameters in the smelting process in order to obtain a high yield of metal. The reactivity of the carbon materials is directly correlated to the material properties. It is known that the rank of the coal influences the SiO reactivity where low rank is beneficial. Coals of the same rank have however proven to have varying reactivity. In order to investigate how the micro-constituents of coal influence the reactivity towards SiO gas, three single seam unwashed coals of different origin which fulfil the requirements of the Norwegian Ferroalloy producers have been chosen. As the structure in the carbonized product is a function of petrographic constitution and carbonization parameters, the coals have been separated into different density fractions. The various density fractions of the same coals proved to have significantly different petrographic composition. The coals were carbonized according to a procedure simulating the conditions the coals experience when charged to an industrial furnace. Chemical-, physical- and petrographical properties of both the coals and the resultant chars have been thoroughly examined and correlated towards the SiO reactivity.

Jan 1, 2007

By N. K. Singo, J. D. Kramers

The reprocessing of tailings resources to extract gold on an industrial scale has become common practice. While these projects are common in the Witwatersrand basin, similar low-technology processes are not operational in smaller goldfields. This study explores the possibility of reclaiming the tailings dump of the Louis Moore Mine in the Giyani Greenstone Belt, investigates potential hazards to communities in the vicinity, and identifies mitigation strategies. Auger samples were taken from the Louis Moore tailings at depths of up to 5 m. Aqua regia leach analyses show Au concentrations of up to 1 g/t. Inferred estimations based on ordinary kriging (OK) and inverse distance weighted (IDW) methods put the residual Au resource in the Louis Moore tailings dump at 0.20 t. Reworking the tailings is viable, although a potential environmental risk exists in the form of elevated arsenic concentrations. Further exploration is required to determine the mineralogical associations of Au and As. Tailings reworking would assist in raising funds for mine rehabilitation. The secondary tailings could potentially be repurposed, which would provide employment and facilitate community development, as well as deliver environmental benefits.

Jul 1, 2021

By A. F. van der Merwe, R-D. Taylor, M. Jacobs, F. H. Conradie

Total bound moisture (TBM) is a typical quality indicator of industrial-grade gypsum. This gypsum is comprised of three distinct phases, namely anhydrite, dihydrate, and hemihydrate, of which only the latter is of much industrial use. TBM analysis is a lengthy laboratory procedure, and an artificial neural network (ANN) TBM inference measurement is proposed as a fast and online alternative. An ANN inference model for gypsum TBM based on plant data was developed. The inputs to the network were primarily focused on the plant's calciner, and different network topologies, data divisions, and transfer functions were investigated. Furthermore, the applicability of the TBM value as a quality indicator was investigated based on a gypsum phase analysis. A strong correlation between TBM and the gypsum hemihydrate and anhydrite content was found, validating the plant target TBM of 5.8% as a quality indicator. A network topology consisting of one hidden layer with logarithmic-sigmoid (logsig) and pure linear (purelin) transfer functions showed the best performance (R > 90%).

Oct 3, 2023

By J A. Rabe, PAP Fouche, K O?Neill

Two of the most important issues mines have to deal with are tracking the ore mined from pit to plant and to test the efficiency of beneficiation equipment. Kumba Resources and Saco Systems are working together at moment to develop a RFID tracer system to help address these issues. This paper will focus on the tracking of ore from pit to plant. The main advantages for ore tracking is to ensure plant feed blending and dilution according to plan. The RFID tracer system works on the basis of a tracer that physically simulates the ore properties and radio frequency technology that facilitates communication with the tracer and allowing information to be stored on the tracer. This paper tends to indicate the progress on the application of RFID tracer technology in the minerals processing environment as tested at Kumba Resources so far. It is concluded that the system has great potential, but some important problems remain

Jan 1, 2005

By J. W. S. Koel, T. R. Twidle, P. C. Engelbrecht

The process flows of the three flotation circuits at the concentrator of the Black Mountain Mineral Development Company (Pty) Ltd are described. Because of the complexity of the circuits and the associated reagent regime, the plant is equipped with a comprehensive range of control equipment. The different process-control strategies are discussed, and the modifications that have been necessary to the stabilizing control loops in the copper, lead, and zinc flotation circuits are shown in detail. It is concluded that the control strategies have continued to bring about benefits and improvements to the process.

Jan 1, 1986

By M. Stephton, L. A. Cornish, R. Süss, N. B. Maledi, J. H. Potgieter, L. Chown

In today?s gas turbines, the emphasis is on saving energy and reducing the amounts of pollutants emitted. This can be attained only by designing alloys with higher melting points and the capability to retain mechanical integrity at increased temperatures. The development of nickel-based superalloys (NBSAs) has reached its limit, as the alloys are operating at critical temperatures close to their melting points. Further increase in the operating temperatures will result in dissolution of the strengthening phases and even melting. Recent trends are towards developing materials that are adequately strong but have much higher melting points and corrosion resistance than the NBSAs that are currently in use. Studies conducted on Pt alloys with similar structure to the NBSAs have presented mechanical results that are promising. This has led to further development of these alloys as a replacement for NBSAs. The operations of gas turbines are usually limited by hot corrosion, which could lead to catastrophic failures. Increased temperatures have an adverse effect on the corrosion of the alloys by making the environment more aggressive. Hence, during a material selection process, the corrosion behaviour of any selected material for a highly specialized application such as gas turbines needs to be assessed. Generally, coatings are applied to combat degradation by salt deposits, hence coated and uncoated NBSAs were selected as benchmark alloys. Corrosion mechanisms and kinetic studies of the Pt alloys were conducted. High temperature hot corrosion (HTHC) tests were conducted at 950°C for540 hours. Analysis of the corrosion products was conducted using a Raman spectrometer, scanning electron microscope with energy dispersive X-ray spectroscopy (EDS) optical microscopy, and X-ray diffraction study of the phases that formed. Both coated and uncoated NBSAs failed under the test conditions. Samples were covered with a porous non-adherent greenish layer which is characteristic of NiO. Pt alloys displayed superior corrosion properties compared with the benchmark alloys.

Jan 1, 2006

By A. Nkolele

Paper written on project work carried out in partial fulfilment of B. Tech (Metallurgical Engineering) degree Fine coal of the Goedehoop Colliery is dewatered by centrifuging before being sold. Full-scale plant tests were carried out to reduce residual cake moisture by the addition of surfactants. It is believed that by modifying the interface between the coal surface and the adherent surface water, as well as the water occluded in the cake voids, drainage is improved. Two anionic surfactants at concentrations up to 150 g/t were tested on coal of <0.5 mm size. The results demonstrate that quite high additions of surfactant (80 g/t)were needed to reduce moisture from 20 to about 17?18%. It was observed that when increasing surfactant additions at low levels, within a very narrow concentration range, the retained moisture first increased sharply only to decrease sharply immediately thereafter; this effect points to a critical surfactant concentration. Based on the obtained results, the use of surfactants cannot be recommended at this stage; further investigations under more controlled conditions are required.

Jan 1, 2004

By H. Dong

This paper presents a heat conduction model to determine the erosion profile of freeze linings in a ferronickel submerged arc furnace. Kirchhoff transformation was adopted to simplify the nonlinear equation governing heat conduction. The boundary element method (BEM) and Nelder-Mead simplex optimization method were employed to solve an inverse heat conduction problem. Erosion profiles could be obtained when calculated temperatures at sensor locations agreed well with measured temperatures. The model was validated by comparing the heat loss through the linings, which was calculated by BEM and integral operation after erosion profiles were obtained, with the value calculated from industrial data such as actual power consumption, tap-to-tap time, and ferronickel output. The optimal solution for the erosion profile could be acquired when the difference in heat losses calculated by these two methods is at a minimum.

Jan 1, 2014

By A. Cichowicz

In this study, techniques used to design earthquake-resistant structures are applied to the deep-level mining environment. Earthquake engineers seek to identify the cause of potentially damaging resonance, and design or reinforce structures to reduce these effects. Similar techniques have been used to analyse the dynamic behaviour of the rock mass surrounding a stope in a deep South African gold mine. A three-dimensional seismic array installed in a stope at TauTona Mine (previously Western Deep Levels, East Mine) provided an opportunity to examine the evolution of the wave field close to an underground opening. A set of three-component geophones installed in a borehole above the panel revealed the development of surface waves as wave fronts reached the excavation, and an array of vertical component geophones fixed to the hangingwall provided a two-dimensional map of site effects. While the collected data do not include damaging seismic events, quantitative analysis enabled phenomena which could lead to damage, to be recognized. In the vicinity of the excavation, the energy of the seismic signal is generally transformed from high frequency to low frequency. It was found that seismic events with relatively high corner frequency (150 Hz?200 Hz) usually excite several modes of vibration (30 Hz to 110 Hz), while events with low corner frequency (30 Hz?50 Hz) do not always excite higher modes of vibration in the structure. This implies that the rock mass around the excavation is a complex medium, and should be studied using the multi-degree-of-freedom model. A strong structural effect (due to the excavation shape) was revealed as a low frequency coda wave (at 40 Hz and 60?70 Hz), well developed on the skin of the hangingwall. A strong site effect was revealed by changes in signal properties between hangingwall geophones, exhibiting strong resonances around 160 Hz and in the range 200 Hz to 300 Hz.

Jan 1, 2000

By F. N. F. le Roux

This paper describes the method used for excavating the upper 33m of emergency access shaft E2 for the underground single track tunnel running between Park and Rosebank station of the Gautrain Rapid Rail System. The soil was decomposed shale and diabase from the Witwatersrand Supergroup. The location was in the car park of The Wilds (a public park) in Johannesburg. The method proved very simple and required less complex plant and equipment than normal when excavating the shallow soil sections in shafts. It involves driving steel sheets ahead of the shaft sump into the soils and then excavating inside the ?tub? created by the sheets whilst supporting the sheets above with regularly spaced circular Steel Rings. It is the intent of this paper to discuss the method and design approach to the method. This will be done at the hand of experiences at E2 shaft..

Jan 1, 2009

By B. Tiryaki

Performance prediction models for partial face mechanical excavators, when developed in laboratory conditions, depend on relating the results of a set of rock property tests and indices to specific cutting energy (SE) for various rock types. There exist some studies in the literature aiming to correlate the geotechnical properties of intact rocks with the SE, especially for massive and widely jointed rock environments. However, those including direct and/or indirect measures of rock fracture parameters such as rock brittleness and fracture toughness, along with the other rock parameters expressing different aspects of rock behavior under drag tools (picks), are rather limited. With this study, it was aimed to investigate the relationships between the indirect measures of rock brittleness and fracture toughness and the SE depending on the results of a new and two previous linear rock cutting programmes. Relationships between the SE, rock strength parameters, and the rock index tests have also been investigated in this study. Sandstone samples taken from the different fields around Ankara, Turkey were used in the new testing programme. Detailed mineralogical analyses, petrographic studies, and rock mechanics and rock cutting tests were performed on these selected sandstone specimens. The assessment of rock cuttability was based on the SE. Three different brittleness indices (B1, B2, andB4) were calculated for sandstones samples, whereas a toughness index (Ti), being developed by Atkinson et al.1, was employed to represent the indirect rock fracture toughness. The relationships between the SE and the large amounts of new data obtained from the mineralogical analyses, petrographic studies, rock mechanics, and linear rock cutting tests were evaluated by using bivariate correlation and curve fitting techniques, variance analysis, and Student?s t-test. Rock cutting and rock property testing data that came from well-known studies of McFeat-Smith and Fowell2andRoxborough and Philips3have also been employed in statistical analyses together with the new data. Laboratory tests and subsequent analyses revealed that there were close correlations between the SE and B4 whereas no statistically significant correlation has been found between the SE and Ti. Uniaxial compressive and Brazilian tensile strengths and Shore scleroscope hardness of sandstones also exhibited strong relationships with the SE. NCB cone indenter test had the greatest influence on the SE among the other engineering properties of rocks, confirming the previous studies in rock cutting and mechanical excavation. Therefore, it was recommended to employ easy-to-use index tests of NCB cone indenter and Shore scleroscope in the estimation of laboratory SE of sandstones ranging from very low to high strengths in the absence of a rock cutting rig to measure it until the easy-to-use universal measures of the rock brittleness and especially the rock fracture toughness, being an intrinsic rock property, are developed.

Jan 1, 2006

By R. E. Wilmot

This paper is based on the experiences, over many years, on the part of numerous authors in the South African mining industry and that of the hot dip galvanizing process and its application as a corrosion protection system. The paper sets out the extensive development, financial resources and stringent operating requirements of the South African mining industry. After many years of research and operational experiences, hot dip galvanizing and when necessary, duplex systems, have been found to meet the demanding requirements of this particular industry. The paper sets out the requirements from the standpoint of corrosion criteria and is followed with a practical example; ?case history? where the corrosion protection properties of hot dip galvanizing are demonstrated. This case history traces the early investigation of the expected corrosive conditions to be encountered in a new mining operation (now 10 years on) and concludes with two follow up visits to the mine in order to examine actual performance of the corrosion protection system after ten years in service.

Jan 1, 2006

By J. D. de V. Louw

Introduction Zircon is a natural occurring mineral and may exhibit natural low level radioactivity. It contains trace levels (90 to120 pCi/g and 110 to 115 pCi/g respectively or 3.3 to 4.4Bq/g and 4.1 to 4.3 Bq/g) of naturally occurring radioactive uranium and thorium. This mineral is often found in a suiteof minerals (rutile, ilmenite and monazite) Due to the overlap in physical properties of monazite (containing 4–7% thorium) with some of the zircon (slight magnetic susceptibility) it often contaminates the zircon, adding to the levels of thorium in the product. Hazards associated with the products from zircon and its processing is inhalation of respirable dust (generated by milling) containing radioactive uranium and thorium which may cause cancer of the lungs. Legislature regulates the transport, use, workplace environment exposure and storage of radioactive material. In America the general regulation for the unlicensed use of low levels of radioactive materials limits the concentration to 500 ppm (U plus Th). Europe (IAEA) specifies a limit of10 Bg/g (Bequerels per gram) on the parents for transport only which is a higher level of U+Th. Companies selling into these markets need to comply with these regulations and certification is therefore required, not only of the major constituents determining the price, but of the U and Th levels as well. Exceeding the limits for U and Th may result in material being returned to the country of origin. However, for the analyst the requirement is to analyse for these elements throughout the production process as well as the analysis of the ‘tails’ that is returned to the mine area. This requires a wide range of concentration to be analysed. Methods of analysis A wide variety of methods exist for the analysis of U and Th in a range of matrices. (Table I) All these methods have been used with varying degrees of success in terms of accuracy. Overall precision for the different techniques varies from 5 to 25% relative. Time to produce results from these methods vary from a few minutes to several days. The Production Chemist is expected to produce between5 and 10 analyses per hour for process control purposes. A suitable technique that fits this requirement is X-Ray Fluorescence. Both Wavelength Dispersive (WDXRF) and Energy Dispersive X-Ray (EDX) instruments are suitable. X-Ray analysis in general has a few major advantages over competitive techniques. •It is fairly simple to set up and interferences are known and easy to correct •It has multi-element analysis capabilities •Clean spectral lines for U and Th (in zircon specifically) •Uncomplicated and easy to measure background •Low detection limits (3 to 5 ppm) •A very high degree of precision •Sample preparation is uncomplicated and fast (pressed powders and fused beads). In Zircon (ZrSiO4) processed sands the matrix is constant(>99% ZrSiO4) and the background is thus essentially constant. A typical set up for the analysis of U and Th by WDXRFis given below: X-Ray Tube Tungsten (W) Target, 2.5 to 3kW operated at 50mA/50kV Crystal LiF200 (or LIF220 for higher resolution) Analytical Lines (2?)U La1,226.14Th La1,227.47 Detector Scintillation Counter Analysis time, depending on the concentration can vary from as little as 20 seconds up to 5 minutes. Standards As with any other comparative technique XRF analysis relies heavily on the quality of the standards used. Assuming proper set-up and operation of the instrumentation as well as consistent sample preparation, accuracy is determined by the quality of the initial calibration standards. A search for the available zircon certified reference materials (CRMs) shows that there are only a few CRMs

Jan 1, 2003

By J. W. van der Merwe

Technology is advancing at a rate that makes it extremely difficult for the mining Industry to keep pace. Many advances occur within a given piece of technology and often this is missed by the disciplines that could have gained advantage by its implementation. Often this may have been simply an aspect of cost exceeding benefit. However, there are some technologies that potentially have such a far-reaching impact on the mining industry that the benefits simply outweigh the cost. The application of 3D laser scanning in the mining industry has the potential of taking the concept of ?Google maps?? underground. This presents an opportunity where the virtual world of underground can be traversed with relative ease and many aspects of measurements could be obtained without having to visit the working place again, potentially saving countless man-hours and still delivering precision work with significant savings in downtime, stoppages, and exposure to safety incidents. Anglo American Platinum maintains its competitive advantage though the review and application of appropriate technology. This paper describes the 3D laser scanning trial at one of Anglo American Platinum?s new shafts, and goes on to show the benefits encountered through the application and the involvement of the various MRM disciplines.

Jan 1, 2012

By K. Ding

The thermodynamic activity of MnO was measured in MnO-CaO-MgO-SiO2 slags that are typically encountered in the production of manganese-containing stainless steels. A gas equilibration-quenching technique was employed in measuring the activities. Activities of Mn in Pt-Mn alloys were redetermined at 1600ºC, which reconfirmed earlier results of strong negative deviations. MnO activities were then measured by equilibrating slags of various compositions based on a statistical experimental design procedure with Pt-Mn alloys under controlled partial pressure of oxygen in MnO saturated platinum crucibles at 1600ºC. Activities of MnO were found to increase with increasing concentration of MnO, basicity and CaO to MgO ratio. Two multi-coefficient regression models were developed to predict the activities and activity coefficients of MnO in slags at 1600ºC. Keywords: activity, MnO, slag

Jan 1, 2005

By W. G. Huang

To recover the coal resources of high-sulphur anthracite in Jincheng Mining Area, underground coal gasification (UCG) of No. 15 seam in Fenghuangshan Coal Mine was proposed. The feasibility of the project was confirmed by investigations of occurrence conditions, coal properties, and roof conditions, as well as experimental studies and theoretical analysis. It was found that UCG technology is appropriate to be adopted in the mining of the No. 15 seam, due to the stable rock conditions, simple geological structure and hydrogeology, the high carbon content of the coal, non-cohesiveness, medium-thermal stability, high ash fusion temperature, and weak reactivity with CO2. Further factors are the characteristics of the immediate roof, which consists of 9.11 m of limestone and mudstone with a compact structure and low permeability, and 4.27 m of dominantly mudstone with low permeability.

Jan 1, 2012

By B. Dias, P. C. Schutte

Work-related musculoskeletal disorders (WMSDs) affect the wellbeing of workers and result in poor quality work, lower work performance and decreased motivation. In contrast to ‘occupational’ diseases where there is a direct cause-and-effect relationship between hazard and disease (e.g., asbestos and asbestosis, lead and lead poisoning), ‘work-related’ diseases are multifactorial, where the work environment and the type of work that is performed contribute significantly to musculoskeletal disorders. WMSD is the term used to describe disorders and diseases of the musculoskeletal system (i.e. muscles, joints, ligaments, tendons and nerves). WMSDs are by definition a work-related phenomenon. The literature shows inarguably that certain jobs and certain work-related factors are associated with a significant risk of contracting a WMSD. It is assumed that repeated movements and postures, static work, continuous loading of the tissue structures or lack of recovery time, trigger or cause a pathological process that then manifests itself as a WMSD. This paper looks at the prevalence of the WMSD condition at three mines in South Africa: a coal, a gold and a platinum mine. Predisposing factors that include work factors, presentation of symptoms and psychological factors will be discussed in the paper.

Jan 1, 2003