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By P. J. Brereton-Stiles, M. S. Rennie, N. Singh

Ferroalloy producers are large-scale users of electrical energy, which in many countries is in short supply and increasingly expensive. Preheating and/or pre-reduction using natural gas, recycled furnace gas or coal fines have lowered the specific use of electricity, but the high energy concentration necessary for most reduction processes can be achieved only by the use of high electric currents. Most countries have insufficient electricity to supply the demands of industry and the domestic consumer, particularly during certain periods of the day and certain times of the year. The generation and distribution of electricity is a large-scale expensive business, which is financed and managed directly or indirectly by government bodies in most countries. Both economic and political imperatives determine how much electrical energy is made available to whom and at what price. In South Africa demand is set to outstrip supply within the next few years, and the local supplier Eskom has moved from a traditional demand tariff pricing structure to a time-of-use tariff pricing so as to limit peak demand usage. This will mean a substantial increase in electricity cost to those users unable or unwilling to reduce consumption during peak periods. The optimal use of the available electrical energy depends both on the process, the furnace size, the configuration and infrastructure of each plant and its cost structure. As the cost and availability of electricity is set to change dynamically, the management of the situation becomes a real time control and optimisation problem. This paper discusses some the process and operational constraints associated with low- or no-load conditions and how to manage the situation. Electrode management will be one of the key issues.

Jan 1, 2004

By Y. van der Grijp

The applicability of a stochastic approach to the simulation of gold distribution to assess the uncertainty of the associated mineralization is examined. A practical workflow for similar problems is proposed. Two different techniques are explored in this research: a Direct Sampling multi-point simulation algorithm is used for generating realizations of lithologies hosting the gold mineralization, and sequential Gaussian simulation is applied to generate multiple realizations of gold distributions within the host lithologies. A range of parameters in the Direct Sampling algorithm is investigated to arrive at good reproducibility of the patterns found in the training image. These findings are aimed at assisting in the choice of appropriate parameters when undertaking the simulation step. The resulting realizations are analysed in order to assess the combined uncertainty associated with the lithology and gold mineralization.

Jan 1, 2015

By P V. Savage, T Glück, RCA Minnitt, C Bothma

Manganese Metal Operations ?Manganese Metal Company (MMC), a subsidiary of Samancor BHP Billiton, has two production facilities for electrolytic manganese metal in South Africa and produces a range of about 44 Mn metal products. ?The company is accredited with ISO 9000 and uses Six SigmaTM for continuous improvement. ?The control of the process relies on the effective functioning of approximately 250 different control loops at 50% automation.. ?Approximately 50000 samples are analysed every month. ?There are pyro, hydro and physical unit operations for the production of electrolytic manganese metal flake and value added products ? [ ]

Jan 1, 2005

By T. Lindstad, J. Kaczorowski

The Boudouard reactivity of single cokes produced from selected bituminous coals and commercial cokes has been investigated in a thermo gravimetric furnace. The effect of potassium as a catalyst for this reaction was studied, as it is known to accumulate in ferromanganese furnaces. A gaseous impregnation technique using K2CO3 as the potassium source was applied to impregnate the coke samples. The reactivity experiments were designed to simulate conditions occurring in an industrial furnace, as used for production of Mn-alloys. The coke particle size varied from 3.35 to 6.63 mm, while the temperature was maintained between 800- 1100oC with a gas composition from 50 to 75% CO2 in a CO/CO2 mixture. To determine the catalytic effect of potassium, the concentration varied from a fraction of a percent up to 15%wt. The results show that single chars vary significantly in reactivity, depending on the properties of the parent coal, while commercial cokes exhibit similar reaction rates. Temperature and partial pressure of CO2 have the strongest influence on the reactivity, while the influence of gas flow rate and coke particle size were found to be negligible. The catalytic studies revealed that the relative reactivity of non-impregnated samples are preserved after the impregnation, so the least reactive coke is still the least reactive after the impregnation for the whole range of potassium loads. Also, it has been confirmed that the Boudouard reactivity reaches a plateau at potassium concentration of 4%wt.

Jan 1, 2007

By D. G. Krige

Using chip sample data and spatial structure parameters from a large mined-out section of a South African gold mine the advantages to be gained from a regular underground borehole drilling programme have been investigated for short- and medium- to long-term planning based on block valuations. The results have been compared with the current position, which relies invariably on the extrapolation of limited peripheral sampling data from raises, gullies or stope faces. Some preliminary work has also been done regarding the implications of such underground drilling on costs used for the present pay limit calculations. The results of the study, though preliminary, show that the net advantage of advance regular underground drilling could be substantial and that a more intensive follow-up research is warranted.

Jan 1, 2003

By B. Nemutudi, X. Zhang, B. McFadzean, P. E. Ngoepe, P. P. Mkhonto, S. Pikinini

The comparison study on adsorption of potassium normal butyl xanthate (PNBX) and sodium (nbutyl) dithiocarbamate (SNBDTC) on sperrylite mineral forms a basis in understanding the floatability improvement and paves a way for the design of collectors that may impact on a wide range of arsenide minerals. This study used a computational density functional theory (DFT) and experimental microcalorimetry approach to determine the adsorption energies of PNBX and SNBDTC collectors onto a sperrylite mineral surface. From a computational aspect, we considered the most stable surface plane of (100) surface, which had been found to give the lowest surface energy, compared to the other surface planes. It was observed that the PNBX and SNBDTC preferred to bridge on the As and Pt atoms through the S atoms. These findings showed that the collector adsorbed on the surface through both Pt and As atoms and indicated that the As atoms were significantly active in the adsorptions. We found that the adsorption energies were in the order: SNBDTC (–278.38 kJ/mol) > PNBX (–270.92 kJ/mol), indicating that the dithiocarbamate had stronger exothermic adsorption than the xanthate. From the microcalorimetry test it was also found that the SNBDTC was more exothermic than the PNBX and the adsorption energies were: SNBDTC (–473.50 kJ/mol) > PNBX (–331.13 kJ/mol). These results showed that the nitrogen atom in the SNBDTC collector had a great influence on the adsorption strength of the collector on the mineral surface. This is due to the electron deposition behaviour of nitrogen atoms compared to the electron withdrawing character of oxygen and as such the SNBDTC showed better collecting ability than the PNBX. These results paved the way for the design of collectors for sperrylite and other arsenide minerals and suggested that nitrogen in a collector may significantly improve the ability of the collector for improved recovery. Keywords: Computational modelling, microcalorimetry, SNBDTC and PNBX collectors, adsorption energies

Jan 1, 2020

Viscosity measurement was carried out over a narrow range of silica content around the fayalite composition. A wide range of temperature and oxygen potential was covered where the slag was completely liquid. In order to keep the slag composition and the Fe3+/Fe2+ratio constant, theCO2/CO ratio was kept constant as the temperature was varied. Increasing the Fe3+content has little effect on viscosity for slags with a silica mole fraction of 0.31. At higher silica contents, increasing the Fe3+content brings about a small decrease in the viscosity.

Jan 1, 2004

The paper provides a brief review of a multivariate uniform conditioning and a localized multivariate uniform conditioning (LMUC) technique, and presents a production reconciliation case study based on a porphyry copper-gold deposit in Peru. The reconciliation study compares the longterm LMUC mineral resources model (typical of new mining projects, which are invariably based on drilling data on a relatively large grid) to the corresponding production blast-hole grade control model, as well as the final plant production.

Jan 1, 2014

By T. Wennberg

An elevated location of a paste thickener on a ridge close to the disposal area is considered at a Swedish iron ore mine. About 0.7 M tonnes of thickened tailings are planned to be layered as paste in the vicinity of the thickener over several years with pipeline lengths of up to 900 m after about 20 years. In order to clarify the pipeline pumping characteristics of the tailings product for volumetric solids concentration from 40 to 50%, experiments in loop systems with pipeline inner diameters from 0.063 to 0.152 m have been carried out with various types of pumps. The results and comparisons carried out here showed that the performance of centrifugal pumps cannot simply be related to the rheology, but factors related to pump design and build-up tendencies of material within the pump and other particle properties may be of equal importance. During the first years of operation only one thickener underflow pump is required. The reliability and performance for various pump configurations are planned to be investigated systematically in order to meet the most effective long-term solution for paste thickener operation, pipeline distribution and placement in the disposal area as the discharge point advances over the life of the project.

Jan 1, 2007

"Chairman: Professor C. O. Frush Rapporteur: Mr A. C. SchmidtPapers:Planning of underground copper mining by J. K. Williams, L. Smith and M. P. WellsLinear programming models of copper leach and solvent extraction plants by W. P. C. Duyvesteyn, J. R. Cutland and J. R. L. RusselPlanning and forecasting stope production by D. W. Kappes and P. F. X. Moussett-JonesA proposed method of dynamic ore reserve assessment for a caving system of mining by A. F. Spinks and S. P. NicholsThe initial point made by Mr L. Smith in presenting his paper was that the planning aid outlined in the preprint was neither sophisticated nor complicated. However, it was a system which worked and was a very real way in which the computer was being used to assist miners, in particular, who at the present moment have very little experience in the use of computers.Mr Smith apologised for the fact that the editors of the paper had eliminated all reference to 'time'. This was very unfortunate because the essence of the system was that it saved time, which was one of the main points made in the paper.The operations being planned by this means cover the Rokana orebody which is a stratiform body mined by open stoping.The planner has to decide how much ore to mine from each base in each time period of his plan, that is, from three to four months hence to a year ahead. Normal procedure is for the planner to have discussions with the underground manager on some of the information he requires. The sort of information needed is (i) tramming limits for each face, (ii) extraction and grade factors, (iii) the present status of mining operations so that the planner knows where to start the new plan, and, (iv) details of any other mining consider¬ations that need to be incorporated in the plan.The objective at this point is to produce an initial plan for discussion purposes. All the information required comes from one sheet per stops and shows, inter alia, the stope identifier, the length along strike, the ore tonnage, the copper and cobalt grades and, finally, the extraction and grade factors.The program itself, among many other things, checks the data for validity, compatibility, completeness and credibility and prints error messages accordingly. Output from this system is in the form of a summary of production from each face, as well as giving the figures of ore reserve depletion. This summary indicates which slopes are to be mined in this time period, the original survey grades (copper and cobalt), the estimated production grades, how much is to be mined from each stope and the copper and cobalt production accordingly."

Jan 1, 2014

By F. T. Cawood

The definition of mineral rents has historically been somewhat unclear, but a growing understanding of the source and composition of the revenues that comprise these rents mean that they can be more easily identified and quantified. Furthermore the way in which the flow of the rents from mineral developments are captured and then distributed has been a point of contention amongst the various stakeholders. Investors, the host government, the resource owners, environmental interests, indigenous groups and land owners are identified in this paper as the principal participants in mineral development and while each is entitled to a portion of the rent, the size of their portions will differ. A competitive rent-sharing model for southern African countries has been established and indicates how the range of stakeholders could be rewarded for their contribution. Acceptance of the sharing ratios amongst the recipients is a function of their understanding of the size of the rent and their position in the hierarchy of stakeholders. At first glance investors appear to receive the largest share of the rent, but they disburse some of the rent to hidden costs, which when all is said and done, means that investors and host governments retain approximately equal shares of the mineral rent. Both the investor and government are faced with the dilemma of how to equitably distribute the rents they have captured to minority stakeholders. Government captures corporate tax, mineral royalties and a wide range of subordinate taxes, but is required to construct policies that will ensure distributional equity among the various levels of government as well as among the provinces that comprise the country. Investors will have to ensure that a portion of the rents they capture are diverted to other stakeholders namely resource owners, environmental interests, indigenous peoples groups and the landowners. This paper identifies the major recipients of rent and provides some indication of equitable distribution ratios for mineral wealth among them?a first step in ensuring that mineral development is compatible with long-term sustainable development and in the best national interests.

Jan 1, 2002

By W. Abdellah

The purpose of this paper is to establish a qualitative method to estimate the risk level (e.g. rating and ranking) resulting from mining activity. Risk is the product of two factors: probability of failure and cost of consequences. A resultant assessment scale matrix is then used to assign a risk index value which is directly proportional to the potential for excavation instability. A case study, the No. 1 Shear East orebody at Vale?s Garson Mine in Sudbury, Ontario will be examined. A three-dimensional, elastoplastic, finite difference model (FLAC 3D) is presented for a mine development intersection situated 1.5 km below ground surface. The developed assessment scale matrix is used to estimate risk index for intersection (2981) located on 5000 level. The results are presented and categorized with respect to risk-index value, probability of instability, cost of consequence, and mining stage.

Jan 1, 2014

By A. Modi, C. Li, R. Kabwit, W. Y. Xinchao, R. Joshi

The KIMIN copper project can treat 1.7 million dry t/a copper-cobalt ore. It has three mills in operation, two using conventional milling in water and the third in raffinate. We introduce the project process circuit and the capital and operating costs of using the raffinate process compared with conventional milling in water. There is a capital saving of approximately 11.5% for major equipment by removing the pre-leach thickener. In addition, it also achieves an annual operating cost saving of USD 2.1 million due to an increase in 49% of acidic raffinate recycled and reduction in lime consumption. The features of CITIC’s new duplex stainless-steel ball mill ,as the key equipment of the system, are also introduced

Jan 1, 2023

By G. Nino de Guzman, L. C. Woollacott

The isotherms that are usually taken to represent the force 'driving' the adsorption in carbon-in-pulp processes may change from contactor to contactor. This paper reports on an investigation into the extent to which this Isotherm shift is Influenced by the changes in oxygen and cyanide concentration that occur in operating plants. The impact of the isotherm shift on the reliability of simulation results is examined.

Jan 1, 1993

By B. K. Loveday, N. V. Ramlall

A study was carried out to evaluate various batch flotation models for the recovery of minerals in a UG2 platinum ore. The major minerals in a UG2ore can be grouped as platinum group minerals, chromite, and siliceous gangue. This study also examined the entrainment of minerals during flotation. The models were ranked using statistical methods and an analysis of model-fit residuals. Entrainment parameters obtained from model fitting were evaluated for logic using a simple mineral-to-water ratio versus time plot. The foremost conclusion from the study was the importance of entrainment modelling. The measurement of water recovery increased the size of the data-set, and the inclusion of a simple entrainment model was statistically significant. The overall fit to the data was improved, and the entrainment model provided logical information on the recovery of gangue minerals that were not considered to be floatable.

Jan 1, 2015

By T. D. Mailula

Paper written on project work carried out in partial fulfilment of M.Sc.(Chemical Engineering) degree Chromite and talc are two major gangue minerals in platinum bearing UG2 ore processed from the Bushveld Complex in South Africa. During flotation, talc is effectively depressed by the addition of depressants. Chromite, on the other hand, is considered to be hydrophilic, its recovery is believed to follow water recovery and therefore recovered by entrainment only. In certain cases it has been shown that chromite can be activated by the reagent suite and hence is made amenable to true flotation. The aim of the work was to investigate the effect of the addition of copper sulphate as an activator and the effect of the depressant type and dosage on the recovery of chromite. The results of these experiments showed that copper sulphate, at higher dosages, activated the chromite. Low dosages of copper sulphate resulted in no chromite activation. This was observed at low depressant dosages of both IMP4 (guar gum) and KU5 (carboxymethyl cellulose (CMC)). When the depressant dosages were increased, at higher copper sulphate dosages, it was observed that the activated chromite was depressed by IMP4, but that the activation was still significant with the use of KU5. The activation of the chromite is attributed to the form of the copper species present in the solution and on the mineral surfaces at pH = 9 enhancing collector adsorption and thereby increasing hydrophobicity. These species were not measured directly and it is recommended that this should be further investigated using surface mineral techniques. Keywords: flotation; depressants; chromite; copper sulphate

Jan 1, 2003

By J. -P. Chilès

The discrete Gaussian model is a very popular change-of-support model for estimating block grade distributions. It is designed for a stationary random function Z(x) that is regarded as the transform of a stationary random function Y(x) with Gaussian marginal. It is based on an assumption that is not fully true and thus constitutes an approximation to the exact solution. We examine the effect of this approximation on the modelling of the marginal distribution of block values of a lognormal random function. The initial discrete Gaussian model and a variant of that model are considered.

Jan 1, 2014

By G. Coetzer

"Prior to operating a non-recovery coke pilot plant oven, it was essential to ascertain coal cake stability during the loading of a 1 m3 (1 m × 1 m × 1 m) coal cake into the cold pilot-plant oven by a pusher mechanism. Previously established laboratory-scale compaction parameters, to obtain coal cakes with sufficient stability, were employed during the loading tests of the coal cakes. Two different coals were evaluated, namely Waterberg semi-soft coking coal (sscc) and Oaky North hard coking coal.It was demonstrated that lower applied compaction forces (14%) can be utilized during 1 m3 compaction, in comparison to laboratory-scale tests, to obtain similar wet cake densities, owing to differences in the effect of frictional forces. Wet cake densities for Waterberg sscc improved slightly (3%) to 1.13 t/m3 when utilizing 79 t/m2 applied force for a 1 m3 coal cake, in comparison to laboratory-scale tests. Similar results were obtained for Oaky North hard coking coal, with a 6% density increase to 1.27 t/m3 at a similar applied force. Porosities decreased by 13% and 32% for Waterberg sscc and Oaky North coal, respectively, when 1 m3 compaction was compared to laboratory-scale tests. An opportunity exists to further decrease the porosities of Waterberg sscc during compaction, whereas acceptable compaction parameters were achieved for Oaky North hard coking coal. Most major vertical cracks and the partial collapse of coal cakes were mitigated, and high-stability coal cakes were obtained that could be successfully loaded into the pilot-plant coke oven by a pusher mechanism.Factors contributing to the instability of the coal cake during loading into the oven, such as vertical cracks, are (i) the cubic geometry (1 m3) of the coal cake, (ii) friction exerted by the oven floor, and (iii) mechanical problems, such as a misalignment between the pusher machine feeder plate and the oven floor. IntroductionOperation of the stamp-charging horizontal 1 t electrically heated coke pilot-plant oven at Exxaro Resources requires coal cake stability during the loading of a 1 m3 compacted coal cake into the oven. In this case, a pusher plate is utilized to push the coal cake into the oven over the oven floor. This is in contrast to a ‘spoon’ or bottom plate feeding mechanism as found in industrial horizontal coke ovens. The pusher plate loading mechanism dictates that the coal cake should possess high stability and inherent strength owing to frictional forces exerted by the oven floor. In order to obtain a coal cake of acceptable stability for the 1 t coke oven, various compaction parameters need to be verified and established."

Apr 1, 2019

By X. Yang, G. D. Zhai

The prop is the most important part to ensure the proper functioning of hydraulic support. When the hydraulic support is impacted by the roof, the prop is prone to extrusion deformation, expansion, and even bursting. In order to study the stress on a doubly-telescopic hydraulic support prop under impact load, an impact simulation was carried out based on the drop weight method. First, the impact model of the hydraulic system of the prop was established in AMESim software and the dynamic response curves of the bottom and middle cylinder of the prop obtained. Then, according to the conservation of energy, the pressure formulaes in the hydraulic cylinder of the prop under impact load were derived and verified by the AMESim simulation results, and the maximum pressure on the inner surface of the hydraulic cylinder of the prop obtained. Lastly, the transient dynamic simulation of a hydraulic support prop was carried out in ANSYS Workbench software, and cloud diagrams of stress and deformation of the prop obtained using Workbench simulation. The AMESim simulation process describes the change in fluid pressure in the prop, and the pressure formulae can be used to estimate the internal pressure of the prop under impact load. The finite element analysis results show that the stress of the middle hydraulic cylinder is much greater than that on the bottom hydraulic cylinder under impact load, which can provide a reference for prop design.

Jul 2, 2022

By J. Trckova, P. Prochazka

Physical models from equivalent materials satisfying geometrical and physical similarity have been constructed. A special technology of simulating the excavation of an opening at the front part of a tunnel and of measuring the deformation at the tunnel face was applied. The results yielded by the physical models were used to formulate constitution relations in the numerical solution. This coupled modelling enables us to predict the behaviour of tunnel structures more accurately. On a construit des modèles physiques, réalisés en matériaux équivalents et répondant aux conditions de ressemblance géométrique et physique. Sur ces modèles, on a utilisé une technologie intéressante de simulation du forage du tunnel et de la mesure de déformation du front de taille pendant le forage en progression. Les résultats donnés par les modèles physiques ont été utilisés pour formuler les relations de constitution dans la solution numérique. Une telle construction de modèles combinés permet de prévoir plus précisément le comportement de la structure du tunnel. Es wurden physikalische Simulierungsmodelle aus äquivalenten Werkstoffen konstruiert, welche die Bedingungen der geometrischen und physikalischen Ähnlichkeiten erfüllen. Bei diesen Modellen hat man die interessante Simulationstechnologie des Tunnelvortriebs sowie die Verformungsmessung beim Tunnelabbaustoß während des Vortriebsvorgangs eingesetzt. Die Ergebnisse der physikalischen Simulation wurden zur Formulierung von Konstitutionsrelationen in der numerischen Lösung genützt. So eine kombinierte Simulation erlaubt eine genauere Prognose des Benehmens der Tunnelstruktur.

Jan 1, 2003