Search Documents

By N. R. Shoko, J. Chirasha

Zimbabwe Alloys has been producing Low Carbon Ferrochrome since 1953. A number of operational and technical advances have been made since then. Some of these advances improved production significantly. Process control, however, remained a challenge not only in the production process itself but also in the handling of finished product. In addition the handling of the slag created an environmental problem. Process control issues were addressed by Zimbabwe Alloys Limited and Japan Metal & Chemicals (JMC) entering into a Technical Transfer Agreement. The aim of the technical transfer was to improve production, alloy quality and, thereby, the financial performance of Zimbabwe Alloys. In addition, the Low Carbon Ferrochrome production process was made environmentally friendlier by modifying the final slag handling methodology. The aspects that are covered and discussed in this paper are, ladle refractory lining changes, improved control of the process, changes in the alloy casting methodology and granulation of the final slag. The improved control of the process was enhanced by the conversion from ladle duplexing to argon purging, introduction of on-line sampling and introduction of second stage process. The combined effect of the above was a significant improvement on on-grade material production, production efficiencies, unit cost of production and a cleaner working environment.

Jan 1, 2004

By M. du Plessis

This paper describes the evaluation of a limit equilibrium model to simulate the behaviour of crush pillars in platinum mines. An analytical model was derived to calculate the residual average pillar stress (APS) values of the crush pillars. The values predicted by this model were compared to the numerical values obtained from TEXAN simulations. In general, the limit equilibrium model appears to be very attractive for simulating pillar failure as the gradual crushing of the outside of the pillar and the transfer of stress to the intact core can be replicated. The value of the TEXAN crush pillar model was further demonstrated by simulating an idealized layout with crush pillars between two adjacent panels. The simulations illustrated that oversized pillars will not crush close to the face and this may lead to seismic failure in the back area. An important finding of the study is that closure measurements may prove to be a very valuable diagnostic measure in crush pillars layouts. Distinct differences in magnitudes of closure were simulated for a scenario where the pillars crush as expected, compared to the scenario where an oversized pillar is left. Experimental closure data collected in a crush pillar stope provided further evidence regarding the value of closure measurements in these layouts.

Jan 1, 2011

By S. Uludag

Spontaneous combustion of coal has been studied by laboratory techniques using an apparatus in a small-scale laboratory testing. Coal?s inherent characteristics can be measured using Differential Thermal Analysis (DTA) and Crossing Point Temperature (CPT) methods. The DTA curve obtained after testing is compared with actual inherent moisture and its effect on spontaneous combustion has been investigated. It has been found that the Wits-Ehac Index increases as the inherent moisture of the sample increases. Therefore it can be deduced that liability to spontaneous combustion increases with increased inherent moisture. In addition, volatiles have a catalytic affect on self heating immediately after the inherent moisture is reduced. This is identified as stage two in the thermogram. The inherent moisture has a cooling effect during the initial stages of testing and is visible in the DTA thermogram. In addition, while an increase in carbon content means an increase in Wits-Ehac Index value, an ash content decreases the likelihood of on spontaneous combustion. Keywords: Spontaneous Combustion, Differential Thermal Analysis, Crossing Point Temperature, Moisture, Coal, Laboratory Testing.

Jan 1, 2007

By J. Eriksson

Slag from stainless steelmaking is known to disintegrate, which is an environmental problem and prevents the cooled slag from being utilized. This disintegration is due to the transformation from the ßto the ? polymorph of di-calcium silicate. The transformation is accompanied by an increase in volume of about 11% and a total disintegration of the slag. AOD slag from stainless steelmaking was re-melted in a laboratory induction furnace, together with olivine and calcinated dolomite, to investigate the prevention of disintegration by increased MgO content of the slag with small changes in CaO to SiO2ratio. The modified slag was examined with X-ray diffraction and scanning electron microscopy. The trials showed that an increased MgO content can change the mineral composition towards formation of more Merwinite and Bredigite, which prevents disintegration of the slag. Keywords: slag, disintegration, di-calcium silicate

Jan 1, 2004

By Z. Lin, M. Isac, R. I. L. Guthrie

The kinetic and thermodynamic efficiencies of chromium recovery from the slag in an AOD process during the slag de-oxidation period with ferrosilicon is a complex process affected by slag basicity, temperature, the dissolution kinetics of the reducing agents, and intermixing of the slag/metal/alloy addition phases within the vessel. The present work focused on a study and simulation of the fluid dynamics and mixing behaviour of ferrosilicon additions in the AOD process for the production of stainless steel. In order to visualize the mixing behaviour, a two dimensional slice model of an AOD vessel was first built and filled with ZnCl2solution and then covered with silicone oil in order to represent the bulk liquid steel and slag phases, respectively. The injection of argon/oxygen process gases was simulated using air or helium. Particle trajectories and intermixing of the phases was monitored with a high-speed camera. To simulate the 75FeSi additions, glass spheres were used. A three-dimensional version of the AOD model was then constructed in order to confirm the adequacy of the slice model. Similar particle mixing behaviour was observed. Both models demonstrated that the ascending gas/liquid plume created two asymmetric mixing zones: a smaller rapidly re-circulating mixing zone adjacent to the side-wall locating the tuyere(s), and a larger mixing zone in the main part of the vessel. The process efficiency during the reduction period is governed by the thermal behaviour of ferroalloy as well as the mixing efficiency in the main large mixing zone. To enhance the recovery efficiency for chromium, small Fe-Si particles are suggested, given their wide distribution within the slag phase, and their large interfacial areas and rapid melting times for Cr2O3reduction from the slag. Keywords; modelling, ferrosilicon, chromium oxidation, AOD steelmaking.

Jan 1, 2004

By H. Kotzé

Ticor SA began with a detailed feasibility study in 1995. The Hillendale mine (situated between Richards Bay and Empangeni) and mineral separation plant were approved in 2000. The smelter, just outside Empangeni, consists of two 36 MW DC arc furnaces that were commissioned in 2003. Experiences gained during the initial commissioning of the furnaces proved valuable in later commissioning work, as shown by the increase in ramp-up rates. The capacity of the plant is 250 kt/a TiO2slag and 145 kt/a of pig iron.

Jan 1, 2006

By Du Sichen, K. Mukai, S. Seetharaman

Viscosities of slags constitute an important physical property needed for an understanding of the mass transfer phenomena in metallurgical processes. Viscosity is also the key that leads to a better understanding of the structure of slags. It is well known that the viscosities of silicate slags decrease with the addition of basic oxides due to the breaking of the silicate network. The measurements of slag viscosities often pose experimental challenges, especially to the choice of materials. The keynote lecture takes up the experimental problems and the various techniques adopted. Dynamic viscosity measurement, as a powerful tool towards an understanding of the kinetics of some high temperature reactions, is brought out. A number of semi-empirical models have been developed to estimate the slag viscosities in the case of multi component slags. A critical survey of these models is presented in the lecture. Earlier models by Riboud et al., Urbain et al. and Mills et al. have been developed further into a new generation of models. Some of the current important models are (1) Model by Iida et al. (2)CSIRO model (3) Pyro research Model (4) Model by Tanaka et al. (5) Model approach by Reddy et al. and (6) KTH-model. The predictions and capabilities of the various models are compared. Estimations of viscosities from thermodynamic data and prediction of liquidus temperatures from viscosities are presented. The concept of surface viscosities with reference to slags and viscosities of two-phase mixtures are also taken up in the presentation.

Jan 1, 2004

By S. -H. Chang, C. -I. Lee, Y. -K. Lee

Based on results from triaxial compressive tests, an experimental damage model to simulate post-peak behaviours as well as nonlinear behaviours before peak strength was developed. In order to consider pre-peak behaviours, variations of elastic constants at each damage level were regressed by functions of confining pressure. In addition, post-peak behaviours were simulated successfully by using Hoek-Brown constants. As results, the experimental model could predict nonlinear behaviours, peak strengths and stiffness changes observed in experiments. Basé sur des résultats des essais compressifs à trois axes, un modèle expérimental de dommages pour simuler des comportements de poteau-crête aussi bien que des comportements non-linéaires avant la force maximale a été développé. Afin de considérer des comportements de pré-crête, des variations des constantes élastiques à chaque niveau de dommages ont été régressées par des fonctions de pression d'emprisonnement. En outre, des comportements de poteau-crête ont été simulés avec succès en employant des constantes de Hoek-Brunes. Comme résultat, le modèle expérimental a pu prévoir des comportements non-linéaires, des forces maximales et des changements de riidité observés dans les expériences. Auf Basis der Ergebnisse des dreiaxialen Drucktests wurde das experimentelle Schadensmodell, das sowohl das nicht-lineare Verhalten vor der maximalen Stärke als auch das Verhalten nach der maximalen Stärke simulieren kann, entwickelt. Um das Verhalten vor der maximalen Stärke zu berücksichtigen, wurden die Veränderungen der elastischen Konstante bei dem jeweiligen Schadensniveau durch die Funktionen des begrenzten Drucks zurückgegangen. Außerdem wurde das Verhalten nach der maximalen Stärke unter Benutzung von Hoek-Brown Konstanten erfolgreich simuliert. Schließlich konnte das experimentelle Modell das nicht-lineare Verhalten, die maximale Stärke und die Veränderungen bezüglich der Steifigkeit während der Experimente voraussehen.

Jan 1, 2003

By M. Andrews, B. J. Göhre, G. Strong, C. Terblanche

Mechanized mining can be experienced as a symphony by substituting the instruments for the different machines that each perform their own function and thus have different sounds. The drill-rig is the soloist around which all the other machines must play their part in harmony. Each machine can function on its own, but productivity is achieved only when all of the machines function in a holistic manner, as the different sounds of instruments form a symphony when playing together. To produce a symphony is to have the ability to put together all the pieces. It is the capacity to synthesize rather than to analyse. Today?s managers have to apply this harmonic way of thinking to make the system of mechanized mining work. In other words each of these people must have the ability of a conductor, whose job involves corralling a diverse group of notes, instruments and performers, and producing a unified and pleasing sound. At Modikwa Mine the introduction of the MAPS (Mine Activity Performance System) has allowed management to obtain a clear view of all the activities associated with the equipment. Through synthesis the issues that hampered productivity were identified and addressed to improve production and reduce costs.

Jan 1, 2006

By C. Scheffer

This paper describes a model that can simulate the behaviour of a pneumatic intensifier that is generally referred to as an ?air pump? (AP). The AP is used in many South African underground mines, and utilizes compressed air with pressures between 0.3?0.6 MPa to pump water up to pressures of 12?18 MPa. The high pressure water is used in numerous underground mines to pressurize props and roof bolts that act as safety and roof support devices. The simulation model reproduces the intensifier's operation under various conditions and therefore can be used to investigate the AP's sensitivity towards environmental conditions, design parameters (such as spring stiffness, plunger diameter, nozzle diameter etc.) and operating conditions. Model validation by comparison with laboratory experiments showed good correlation. The model can subsequently be used to investigate design changes aimed at improving the AP's performance and reliability over a wider range of operating conditions.

Jan 1, 2005

By G. C. Lindeque

"A downward trend in tyre life on haul trucks at an open pit iron ore mine prompted an investigation into the current tyre management strategy in order to improve tyre life. ‘Best practice’ was compared to the current tyre management strategy at the mine to determine aspects that could be improved. Aspects that showed significant room for improvement included employee tyre awareness, tyre pressure maintenance, and road conditions. For each of these aspects a plausible alternative was suggested.A new tyre management strategy was formulated as a step-by-step guide on how to implement the proposed changes. Each step introduces new initiatives but at the same time builds on the previous step’s success. A sensitivity analyses was performed to determine the impact of the proposed changes, with the variables being the reduction in the percentage of premature tyre failure, and the reduction of the site wear rate.The ‘most likely’ scenario showed an increase in tyre life of 41% for the Komatsu 730 trucks and 105% for the CAT 777 trucks if the entire tyre management model is implemented. This would result in a possible annual saving related to tyre usage of R9.2 million. OverviewThe study focused on the tyre life on the main haul fleet at an open pit iron ore mine. The haul fleet consisted of 17 Komatsu 730 (180 t) haul trucks and 12 CAT 777 (90 t) haul trucks.The haulage operation consists entirely of tyre-based haul trucks. Five per cent of the total mining budget is related to tyre costs. Since 2012 there has been a steady decrease in tyre life as measured in operating hours (Figure 1) due to the high percentage of tyres that fail prematurely. In 2014 a total of 41% of all tyres failed prematurely and 61% were classified as ‘worn out’."

Jan 1, 2016

By Ö. Erdem

The investment decision making process in the insurance and finance industries is affected by new advances such as simulation techniques. These advances have improved the discounted cash flow method (DCF). In DCF, a dynamic and flexible model construction is not possible because it does not consider uncertain conditions. Each project should be evaluated taking into account the related uncertainties because the related uncertainties determine the characterization of the project. Related uncertainties can be processed in dynamic DCF, which is applicable to both financial and non-financial industries with different kind of uncertainties, such as power generation and petroleum projects. The dynamic DCF method can estimate net present value (NPV) while managing related project uncertainties with a simulation method like Monte Carlo Simulation. The simulation method is preferred because its output is unbiased. Therefore, a more realistic financial evaluation of the project can be concluded. In spite of the improvement of dynamic DCF, this project evaluation method is not used frequently in mining industry. However, the mining industry is ideally suited to this concept because it is highly dependent on estimations such as orebody size and ore grade. During the project evaluation stage, these uncertainties can be included with the dynamic DCF method. This study aims to contribute to increasing the usage of this method in mining projects. A copper reserve in Turkey is selected as a case study to apply uncertainty assessment for the evaluation of NPV.

Jan 1, 2012

By L. Andrews

Mineralogy, traditionally associated with concentrator studies, is being increasingly applied to problems in pyrometallurgy. Such investigations commonly make use of a number of techniques, and the results are combined for a meaningful interpretation, which can lead to a successful solution for the problem. Mineralogical techniques are described for various pyrometallurgical operations. Examples are given of studies and investigations involving mineralogy in chemical-looping combustion, feed monitoring to platinum-smelting furnaces, and losses to slag in base metal and platinum smelting.

Jan 1, 2011

By N. Ragoonanthun

Paper written on project work carried out in partial fulfilment of B.Sc. (Mining Engineering) degree This report investigates the optimization of a raiseline in order to open up the ore reserve quicker. The project was carried out at Mponeng Mine (an Anglogold shaft formerly known as Western Deep Levels 1 Shaft and South Mine, in Carletonville). The project was divided into two focus areas namely: ?To design an optimum layout of a raiseline, which includes the scheduling of all activities for the establishment of the infrastructure. Consideration was given to the blasting practice, mining cycle, orepass placement and slusher positioning. Two designs were carried out on the above basis. ?The design of a ledging operation/practice to match the optimized layout of the raiseline. The ledging cycle design involved a thorough investigation into the possible use of drill rigs, Electronic Delay Detonators (EDD) blasting technology, longer drilled holes, Threshold Blasting (THROB),and water jet cleaning.

Jan 1, 2003

By S. M. Spottiswoode

Much as one hopes to predict whether damaging seismicity might occur somewhere in the next shift, this is not possible at present. Recently, an analysis of seismicity at two mines has shown that a small increase in seismicity occasionally occurs before both large and small events. This analysis is extended here to five mines, with the same results. Earthquake seismologists forecast hazard in terms of the average incidence of earthquakes over the last 50 years, adjusted on an hourly basis according to the possibility of aftershocks of events that have happened. The rate of seismicity in any area remains approximately constant when expressed as seismicity per area mined, or better still, per unit of elastic strain energy released. It is suggested that seismic hazard in mines be estimated using historical seismicity and forward modelling, adjusted according to the possibility of aftershocks. In summary, medium-term forecasting of seismicity is viable; short-term prediction of large events is not.

Jan 1, 2010

By K Kongolo, M K. Kalenga

It is well known that the electrochemical precipitation of metals from aqueous solutions is conducted by the electrochemical standard potential scale. This scale indicates the order of nobility of different metals. Consequently, the standard potential scale shows the nocivity of metals when they are present as impurities in aqueous solutions containing metals. In the hydrometallurgy of cobalt, nickel and zinc are co-deposited during cobalt electrodeposition. Nickel has almost the same chemical, physical and electrochemical properties as cobalt. Furthermore, the electrochemical potential of nickel is relatively higher than that of cobalt. For this reason nickel is preferentially reduced at the cathode in the presence of cobalt. The presence of small amounts of zinc in solution leads to contamination of cobalt electro won. In spite of its lower electrochemical potential in comparison to cobalt, zinc is reduced on the cathode because of its higher hydrogen-overvoltage. But, in the hydrometallurgy of zinc, small amounts of cobalt present into solution will contaminates the zinc reduced at the cathode. This is easily explained by the fact that cobalt is more electropositive than zinc. The co-deposition mechanism of sulphur at the cathode is not yet well understood. Great attention has to be paid to the mechanism of co-deposition of sulphur during cobalt electrolysis..This work aimed to investigate the influence of some parameters on the co-deposition of nickel, zinc and sulphur during cobalt electrowinning. The following parameters have been investigated : Co2+ concentration in the electrolyte, current density and ammonium sulphate (NH4)2SO4 additions. It has been established that important nickel, zinc and sulphur co-deposition takes place at relatively low Co2+ concentration in solution. The behaviour of these elements with regard to the cathodic phenomena has been established.

Jan 1, 2005

By A. D. Thomas

Some years ago, the authors developed an analysis of non-Newtonian pipe flow based on enhanced turbulent microscale and associated sublayer thickening. This analysis, which can be used for various rheologic modelling equations, has in the past been applied to smooth-walled pipes. The present paper extends the analysis to rough walls, using the popular Bingham plastic equation as a representative rheological behaviour in order to prepare friction-factor plots for comparison with measured results. The conditions for laminar-turbulent transition for both smooth and rough walls are also considered, and comparisons are made with earlier correlations and with experimental data.

Jan 1, 2007

By H. Krogerus, P. Jokinen, T. Lintumaa

The energy consumption and recovery of chromium are important economic factors in ferrochrome production. Outokumpu has a lot of experience of the reduction behavior of the sintered pellets in industrial-scale furnaces and also on the grounds of numerous laboratory and pilot-scale investigations. Sintered pellets have shown a superiority over lumpy ore and briquettes made of the same chromite grade. The good performance of the pellets has also resulted in investigations on the reasons for such a performance. In this study, the factors affecting pellet behavior in smelting furnace were investigated. This study is divided into two sections, i.e. the investigations were on the factors affecting solid state reduction and on the factors affecting reduction under melting. These tests were performed by means of thermo gravimetry and by smelting tests. The correlation between the pellet characteristics and reduction behavior was shown and its influence on industrial-scale furnaces was discussed. Factors worth of consideration are for instance, the extent of oxidation during sintering, slag formation and chemistry in respect of molten state reduction, and the grain size of the chromite mineral in the raw material in respect of kinetic reasons (retention time in smelting).

Jan 1, 2007

With increasing demand for real-time monitoring of mine parameters, the requirement for appropriate data management in many mining applications is also increasing. This includes atmospheric monitoring in underground coal and metal mines. Although a number of different (real-time) monitoring systems have been installed in underground mines, they all typically share the same systems or sub-systems, where each sub-system may include both custom hardware and / or software components. In addition, monitoring components installed in underground coal mines in the USA should also be intrinsically safe and approved by the US Mine Safety and Health Administration. Real-time analysis adds complexity to the system since data validation and storage should be completed independently of filtering, data reduction operations, or visualization. Real-time processing may include statistical evaluation, trending, cross-correlation, and real-time alarm or warning generation. This paper presents the concept and design of an integrated system under development for atmospheric monitoring in US coal mines.

Jan 1, 2014

By H. Möhle

Premier Mine is a large underground diamond mine, situated at Cullinan in the Gauteng Province of South Africa. The mine hoists over 3 millions tons of diamond bearing kimberlite per year, from a modern, mechanized panel retreat block cave mining operation. Troughs sited at the base of the cave are developed into the overlying caved ore, allowing loading access to the ore through draw points. Trough opening is therefore a vital aspect of the mining operation. Most of the production is dependent on fast, reliable and safe trough opening. Successful trough openings are achieved under difficult mining conditions due to restricted void, long up-holes and the inherent properties of kimberlite?soft, elastic rock with a high swell factor. Early in 1998, Premier Mine undertook a joint development project (with an electronic initiation system supplier) to determine whether the use of a fully programmable electronic detonator system would enhance the mining cycle in the trough opening process. Blasting commenced in February 1998, initially with blasts of a similar size and duration to those that had been previously blasted with shock-tube systems, to confirm the operational capabilities of the blasting system. The accuracy, reliability and flexibility of the electronic delay detonators (EDDs) minimized associated risks for re-engineering of the trough opening process. Further, as blast timing was optimized, larger blasts were successfully initiated. To date over 20 troughs have been opened successfully with the use of EDDs. Not only did it take less time to open troughs, but also drilling and blasting operations have been optimized, as well as an overall improvement in safety. This paper details the benefits that EDDs have delivered to Premier Mine in this area. The logic followed is: ?Review of the original trough opening practices ?Re-engineering of the trough opening process ?Implementation of EDDs ?Evaluation of improvements and conclusions.

Jan 1, 2000