Search Documents

By J. L. Havenga, L. J. van der Walt, J. T. Nel, H. Bissett

"SynopsisNew technologies used to manufacture high-quality components, such as direct laser sintering, require spherical powders of a narrow particle size distribution as this affects the packing density and sintering mechanism. The powder also has to be chemically pure as impurities such as H, O, C, N, and S causes brittleness, influence metal properties such as tensile strength, hardness, and ductility, and also increase surface tension during processing.Two new metal powder processes have been developed over the past few years. Necsa produces zirconium powders via a plasma process for use in the nuclear industry, and the CSIR produces titanium particles for use in the aerospace industry.Spheroidization and densification of these metal powders require remelting of irregular shaped particles at high temperature and solidifying the resulting droplets by rapid quenching. Spherical metal powders can be obtained by various energy-intensive methods such as atomization of molten metal at high temperatures or rotating electrode methods. Rapid heating and cooling, which prevents contamination of the powder by impurities, is, however, difficult when using these methods for highmelting- point metals. For this reason plasma methods should be considered.Thermal plasmas, characterized by their extremely high temperatures (3000–10 000 K) and rapid heating and cooling rates (approx. 106 K/s) under oxidizing, reducing, or inert conditions, are suitable for spheroidization of metal powders with relatively high melting points. Thermal plasmas for this purpose can be produced by direct current (DC) plasma arc torches or radio frequency (RF) inductively coupled discharges. In order to obtain chemically pure spheroidized powder, plasma gases such as N2, H2, O2, and CH4 cannot be considered, while Ar, Ne, and He are suitable. Neon is, however, expensive, while helium ionizes easily and it is therefore difficult to obtain a thermal helium plasma at temperatures higher than 3000 K. Therefore argon should be used as plasma gas. Residence times of particles in the plasma region range from 5–20 ms, but this is usually sufficient as 7–8 ms is required for heating and melting of titanium or zirconium metal particles in the 30 µm size range at 3500 K. In this study the melting and spheriodization of titanium powders was investigated by DC non-transferred arc and RF induction plasma methods. The powders were characterized before and after plasma treatment by optical microscopy and scanning electron microscopy (SEM) to observe if any melting or spheroidization had occurred."

Jan 1, 2015

By J. A. Kinnaird, B. J. Youlton, K. L. Youlton

Methods for treating and processing refractory gold ores are well established. However, what is less well understood is how the formation of the gold-bearing deposits affects gold processing and extraction. In order to evaluate the effect of ore genesis on gold extraction a number of South African gold deposits were studied. These included complex Pilgrim’s Rest samples as well as refractory Fairview, Barbrook, and Consolidated Murchison samples. We found the refractory nature of gold ores is controlled by a limited number of well-understood mineralogical factors. Solid solution gold is linked to low temperature and pressure conditions in fine-grained sedimentary lithologies, while reactive pyrrhotite can form from hydrothermal fluids associated with mafic magmatic rocks. These formational controls can be used to identify and avoid complex deposits at a desktop study phase, or address and reduce complications further along the pipeline using early mineralogical studies.

Jun 1, 2021

By L. Xingwana

"The purpose of this study is to understand how ore loss and dilution affect the mine call factor, with the aim of subsequently improving the quality of ore mined and fed to the mill. It was necessary to know the relationship between ore mined and delivered for processing in order for the mine to operate efficiently. A review of the literature suggested the mine-to-mill integration approach as a standard intervention to address declining mine call factors. A case study was undertaken at a gold mine in the Free State on the influence of the fragment size distribution on ‘free gold’, the effect of ore loss and dilution on the mill efficiency, and time tracking of ore movement from source to the plant. The study revealed that fragmentation, underground accumulation of ore, and dilution have a significant influence on the mine call factor and mine output. It was difficult to quantify the total ore loss due to the time lag between mining and milling, which is extremely variable, when estimating the mine process inventory. However, it was possible to estimate the total dilution with some degree of precision by analysing the daily blast and head grades. It is therefore recommended that mines accept that some gold loss and dilution will always occur during blasting and transport of broken ore, and this loss must be minimized.IntroductionThe mining of high gold grades is obviously very beneficial for the economic viability of an operation, but optimum recovery of the product is required to maximize profits (Chapman and Bindoff, 2010, p. 13). Although integrating these two requirements is very difficult, due to the various activities occurring between mining and processing, it is indispensable. The main driver of this integration is the impact that different ore types and characteristics have on head grade. According to Isokangas et al. (2012, p. 871), mining and processing operations involve a series of well-defined sequential stages that are complementary in an efficiently operating mine, with the performance of one operation affecting that of another. An attempt to optimize each function separately without considering the whole extraction process will not result in the optimum efficiency of the entire mine. Several researchers have developed a proven methodology for revealing these inefficiencies (Dance et al., 2006, p. 1)."

Jan 1, 2016

By J. D. T. Steyl, G. B. Grobbelaar

Two examples are presented to show how first-principles – physical-dynamic, here termed behavioural modelling, is used to build digital twins of unit processes or plant sections. A digital twin equips the metallurgist, engineer, or manager with a powerful tool to conduct model-based design, solve process problems and improve operations. It is particularly relevant in the metallurgical industry where plant behaviour is highly integrated, rates respond to particle dynamics in complicated ways and mineral flows across flowsheet boundaries are variable. The two examples used to illustrate the behavioural modelling methodology are 1) a flotation column unit block and 2) a multi-compartment pressure oxidation (POX) autoclave. It simultaneously accounts for the causality of material and heat flow, takes care of mineral particle dynamics, physical and chemical reaction rates, the plant control system behaviour and operating heuristics. The basic modelling building blocks are briefly reviewed to show how the behavioural modelling attributes constrain the mass and heat flow dynamics to physically realistic values. This is the key aspect that allows project value to be created with minimal input data. Behavioural modelling is especially valuable where the process dynamics are poorly understood or controlled, where data-driven models fail to cope with complex and highly integrated plant behaviour, where quality data is lacking or limited funds are available to generate the data required to fill all the knowledge gaps. The paper uses the flotation column example to show how behavioural modelling and simulation can be used to optimise plant performance, while the multi-compartment POX autoclave model shows how it can be used to diagnose process problems. It also provides a solid basis to add a data-driven component – in other words, it makes a strong case for a hybrid first-principle– data-driven approach to solve process problems, especially where microscopic-level understanding is poor. Keywords: Digital twin, behavioural modelling, simulation, flotation column, pressure oxidation

Jan 1, 2020

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 L. A. Cramer

There are a couple of dozen junior platinum mining companies coming into existence in Southern African and most intend to mine, concentrate the PGM?s in a flotation product and sell the concentrate to one of the major producers in South Africa. The price they will receive for their product and hence the return they achieve for their investment will depend upon the large number of factors that influence the market for such a product. Unfortunately the number of buyers is severely limited as it is dominated by the two major local producers, Impala Platinum and Anglo Platinum. Furthermore the current smelting technology has limited capacity for UG2 concentrates and high nickel concentrates will quickly fill any available base metal refining capacity. Few if any overseas buyers can compete for the bulky flotation concentrate produced. This paper will explore those factors such as metal recoveries, metal prices, operating costs, capacity constraints, deleterious elements, transport issues, metal premiums and discounts that are in play, types of flotation concentrates, processing capital costs, PGM grades, etc and their impact up on what smelters and refiners might be prepared to pay for such PGM concentrates. Ultimately simple graphs and equations can be developed for probably payment terms for such concentrates. Those who negotiate well will move to the higher return section of the envelope and those who use the concentrator facilities to produce the most saleable combination of flotation concentrates will enhance their returns. A deep and firm understanding of the issues surrounding this market is necessary in order to negotiate the best possible price for the seller.

Jan 1, 2008

By D. Norval

Keywords: Pyrometallurgy, slag, metal, entrained, granulation, ferromanganese Water granulation of certain slags with high metal entrainment has customarily not been practised, not only due to the belief that such processes are too dangerous and unproven in the pyrometallurgical industry, but also that it might not be economically viable or environmentally acceptable. General slag granulation, on the other hand, is extensively applied, although in some cases crudely, with disastrous effects, as a result of not recognising the high heat capacities prevalent in slags. Thus, purpose-designed granulation and solidification processes are discussed, taking into account specific applications and the individual signatures of alloys and slags, emphasising that no slag, matte, or alloy responds in similar fashion to a granulation practice. This paper addresses three issues, namely: ? Water-granulation of BOF steel slag, without processing it to render it environmentally safe, physically and chemically acceptable for use by the construction industry, and the process economical ? Processing air-cooled BOF steel slag to change its physical and chemical properties to be acceptable for various uses and extracting metallic and bound iron ? Processing air-cooled or molten manganese slag to lower its manganese content to a level that is acceptable from an environmental and health point of view, and extracting FeMn-alloy of acceptable composition. The latter process culminated in a patented process to extract FeMn from air-cooled and molten manganese slag, and, at the same time, produce a hydraulic (cementitious) slag, thus transforming a possible hazardous by-product into virtually 100% saleable products.

Jan 1, 2011

By E. S. van Druten, M. C. Bekker

"The complete and successful closure of a mine in the South African environment remains problematic. Closure remains an elusive mining phase due to unclear roles and responsibilities, inaccurate closure management data, and the inability of stakeholders to conceptualize and integrate closure information into business processes. Currently there are no proven methods available to address the complexities encountered during a closure application, and to date no mine has been granted full closure. Many mines are left abandoned and unrehabilitated, resulting in risk to investors, surrounding communities, and regulators. This investigation aimed to determine, categorize, and rank reasons for unsuccessful mine closures. Focus groups consisting of public and private stakeholders were identified and surveyed through a structured, rank-order questionnaire to determine the relative importance of reasons why achieving formal and final mine closure remains elusive. Various requirements and aspects were identified and listed according to four categories: namely, primary, secondary, process drivers, and information sources. These aspects should be considered in the development of an integrated mine closure model.Background and rationalePrior to 1956, mine closures were not subject to legislative requirements, being merely governed by insufficient environmental regulations under the Mines and Works Act 27 (MWA) (Swart, 2003). In 1981 the Chamber of Mines (COM) published a document titled ‘The rehabilitation of land disturbed by surface coal mining’, which constituted the first notable contribution to environmental protection. This guideline was later referenced in the Minerals Act of 1991, which for the first time laid definite environmental burdens on the Mining Right Holder (MRH). The Minerals Act of 1991 was superseded by the current Mineral and Petroleum Resources Development Act (MPRDA) and the Mineral and Petroleum Resources Development Act Regulations (MPRDAR), which specify a regulatory process for mine closure applications and financial provisions."

Jan 1, 2017

By W. Pulles

Mining can adversely affect water quality and poses a significant risk to South Africa?s water resources. Proactive management of environmental impacts is required from the outset of mining activities in order to reduce this risk. Major strides have been made over the last 7 to 8 years, by both the Department of Water Affairs & Forestry (DWAF) and the mining industry, in developing strategies and management plans for the effective management of water within the industry. This has largely been achieved through the development of joint structures where problems have been discussed and addressed through cooperation. This process, which was started around 1991, has continued through to the present time. The mining sector management strategy has been developed at a number of different levels as follows: ?A detailed Management Plan, that sets out strategic objectives, broad strategies and functional and organizational arrangements. ?Operational Guidelines, that define and document specific operational procedures. ?Technical Guidelines, that define and document best practices for pollution prevention and impact minimization from mining operations. The Technical Guidelines consist of Best Practice Guidelines (BPGs) and Regulations.

Jan 1, 1999

By R. S. McDonald

Auburn began operations 40 years ago with an office in Sudbury, Ontario, Canada, to provide services to Inco Limited. Over the next 40 years, operations expanded considerably, with projects being undertaken around the world, servicing the smelting and refining industry. Operating bases have been established in Canada, United States, Mexico, Chile, and Spain, with further growth expected to continue with an operating presence in South Africa. The Auburn Group of companies has serviced the smelting and refining industry for over 35 years. Auburn services a variety of metallurgical plants, and our worldwide experience has gathered considerable knowledge on industry processes and maintenance solutions. Today, the ?Business of Smelting? tackles demanding challenges, and operators search for opportunities and solutions to improve smelter maintenance, reduce operating costs, and decrease downtime. The Auburn Group has developed project teams, technologies, and equipment that provide specialised and innovative solutions to the non-ferrous metal industry to help address these challenges. Our Furnace Services team offers a variety of repair and maintenance services for metallurgical furnaces. Our specialised team has proven methods for completing projects quickly and safely. Our worldwide experience includes turnkey project management, construction, and various scopes of work for demolition and refractory repairs on all types of smelting and refining furnaces. Auburn developed the Results FirstTM programme to provide optimized solutions and results for smelter projects. The programme utilises a proven three-step model for improved results for schedule, budget, safety, and ramp-up to production. Our experienced Project Management teams can handle the planning and construction management of capital projects and plant shutdowns. Our projects have involved smelter/refinery modifications, oxygen plant installations, and sulphuric acid plant audits and maintenance. Our Equipment & Products division supplies specialised equipment and products, which are used in the metals industry for plant maintenance tasks. Our capability to design unique equipment, combined with our ability to source products worldwide, makes us a useful resource to find the best-suited equipment to meet the work-site demands. We specialise in custom remote-control units to handle specific maintenance solutions for smelters and refineries, and custom equipment designs for catalyst handling for Acid Plant maintenance. Our extensive knowledge of and experience with industrial technologies allows us to provide a wide range of Industrial Services. These services include vacuuming, high-pressure water blasting, chemical cleaning, pelletizing, dredging, ore bin clearing, roaster repairs, baghouse/ESP services, and manpower supply for both industrial plants and mines. Auburn?s combined strength of personnel experience, knowledge of industry processes, innovative project methods, and equipment technology make Auburn a unique resource for problem solving on every facet of smelter operations.

Jan 1, 2006

By T. J. Otto, C. Musingwini

"The objective of any mining company is to sustainably maximize the net present value (NPV) throughout the life-of-mine (LOM). The expected NPV over the LOM is calculated based on a mine plan, yet the actual value realized by the mining company depends greatly on the level of intertemporal execution against the mine plan. Consequently, a major key performance indicator (KPI) that is often overlooked in open pit mining, due to a greater focus on temporal KPIs, is the degree of spatial compliance to the mine plan. Such focus sometimes leads to short-term actions being detrimental to long-term plans. In this paper we describe the development and implementation of a spatial mine-to-plan compliance reconciliation approach for an open pit mine. Application to a case study open pit iron ore mine in South Africa indicated a significant improvement in the spatial mine-to-plan compliance, from 69% to 94% over a three-year period from 2014 to 2016. These results indicate that implementation of the proposed spatial mine-to-plan compliance reconciliation approach can contribute positively to improving the level of spatial execution and assists in improving the alignment between short-term, medium-term, and LOM plans.IntroductionThe objective of any mining company is to maximize the net present value (NPV) throughout the life of mine (LOM). However, this objective needs to be fulfilled in a sustainable manner that considers the needs of various stakeholders, including employees, shareholders, and local communities where the mines operate. The expected NPV is calculated using a mine plan as a basis. Mine planning broadly involves identifying a strategy to exploit the mineral resource in a way that maximizes value at an acceptable level of risk throughout the LOM (Tholana and Neingo, 2016).The mine planning process is a well-recognized component in the mining value chain of an open pit mine. Figure 1 reflects the relative position of mine planning within a typical open-pit mining value chain from the mineral resource to the market"

Mar 1, 2019

By S. Moolla, R. Lynch, S. Brijraj

A reliable method to locate microseismic evets is an important objective for routine mine seismic monitoring. We developed an algorithm that can automatically and reliably locate an event from a single uniaxial trace. Signals created by microseismic events are recorded as seismograms that consist of direct P- and S-waves as well as the waves reflected off the underground excavations. We take advantage of the extra complexity these reflections introduce as they make the signal more unique. In our investigation we cross-correlated unaltered synthetic seismograms against trial waveforms created from a linear combination of appropriate waveforms from a library of numerically calculated strain Green’s tensors. We use a single uniaxial synthetic seismogram to invert for the source location, six moment tensor components, and frequency. The resulting cost functions are constructed as maximal correlations at each node in the mine grid through the true source x-planes. This function is maximized by differential evolution to simultaneously yield the source parameters. Sensitivity tests such as shifting the mine plans and altering the background velocities of the media are investigated to test the robustness of the method. We contaminate the data with 40% white noise to test the resolution against simulated real recorded seismograms. The method is demonstrated using synthetic data calculated with a realistic underground 3D velocity model.

Jun 10, 2024

By M. Kumral, Y. A. Sari

Underground mining operations tend to have higher operating costs than surface mines. When metal prices decrease, profitability is jeopardized due to the high costs. Therefore, mining management harnesses new practices that increase operational efficiency. One way to manage this challenge is to invest in new mine planning practices. Stope layout optimization as a part of underground mine planning aims to identify a portion of the orebody in the form of production volumes (stopes) to maximize profit under roadway and stope dimension constraints. In this paper we propose a novel approach based on identifying ore-rich areas of the deposit and prioritizing their extraction through an iterative heuristic clustering approach. The proposed approach is compared with and validated by an exact method through a small mining example. The heuristics produced nearly identical results in a very short time. Finally, a case study was carried out using a larger data-set. The cluster-based iterative approach generated nearoptimal stope layouts in a computationally effective manner.

Mar 1, 2021

By B. M. Thethwayo

Graphite blocks are currently used in the concentrate - slag zone in primary PGM smelters, and can possibly be extended to the matte zone. This project evaluates the interaction between synthetic matte and graphite blocks on a laboratory scale. Static crucible tests were performed where graphite crucibles (prepared from standard and high-grade graphite) were filled with synthetic matte (27.7 per cent S ? 46.1 per cent Fe ? 17.0 per cent Ni ? 9.2 per cent Cu) and heated to 1550°C for different time periods (1?5 days). Matte penetration was evaluated using a SEM, while graphite dissolution was evaluated by measuring the carbon content of the matte with a LECO carbon analyser. Matte penetrated into standard grade graphite up to approximately 2 mm, while matte infiltration into the high grade graphite was limited to the immediate hot face. The saturation solubility of graphite in the synthetic matte at 1550°C was 0.43 per cent. Copper, iron, nickel, and sulphur were detected in an accretion that formed in the water-cooled part of the furnace. This accretion consists of mainly Cu-S and Cu-Fe-S based phases.

Jan 1, 2012

By D. C. Panigrahi

Extensive field studies have been carried out to investigate the pillar fire problems in one coal mine in India. A Thermal IR gun and a Thermovision camera have been employed for thermal scanning to assess the state of heating in selected pillars. Special sampling set-ups have been designed to collect gas samples from the holes drilled into the selected pillars and the multigas detector is used to analyse the composition of samples in situ. In order to predict the spontaneous heating in coal pillars, different gas ratios have been calculated and it has been observed that some of the established gas ratios, viz. Graham?s ratio, Young?s ratio etc. have resulted in negative values in samples containing high amounts of methane. The modified gas ratios have been proposed which will be useful for predicting the pillar fires. These ratios may also be used for assessing the condition of fires in sealed-off areas.

Jan 1, 2004

By C. Ntsele

Stirred milling technologies have firmly established themselves in concentrator circuits as energy-efficient alternatives to tumbling ball mills. High and continued increases in electricity costs, coupled with the ever-increasing power consumption by primary grinding circuits due to declining head grades of ore-bodies, provides a compelling case for these technologies. Additionally, the ability to successfully deploy stirred milling in coarse grinding applications extends the range of use in concentrators, thus increasing the opportunity matrix for energy optimization in a flowsheet. This paper therefore details methodologies and strategies that can be applied to evaluate the optimum stirred milling solution for different concentrator applications. These methods and strategies will focus specifically on the two major stirred mill machine types; namely, gravity-induced (VERTIMILL? grinding mill and Nippion-Eirich tower mill) and fluidized (SMD, Isamill?, Knelson-Deswik mill, etc. ). Finally, case studies from circuits across industry and laboratory tests will be used to illustrate the energy benefit from the use of stirred mills.

Jan 1, 2012

By N. F. Dawson

Recovery of a chromite concentrate from UG2 flotation tailings streams, of a grade suitable for further pyrometallurgical treatment for the production of ferrochrome, has certain specific challenges not only by virtue of the decoupled nature of the primary PGM recovery process and secondary gravity based chromite recovery circuits, but also because of intrinsic variations in the nature of the ore and its mineral composition. Variability in the ore, together with upstream process dynamics, creates a challenging environment in which to achieve optimal recovery of a gravity concentrate with accurate grade control. This paper examines certain inter-relational aspects between the ore gangue and chromite mineral types, the influence of the primary PGM extraction circuit and secondary chromite extraction activity as applied specifically to UG2 ore against a background of actual plant experiences and circuit configurations applied in order achieve a suitable quality of chromite concentrate.

Jan 1, 2010

By S. Kirkpatrick, J. Mukendwa

"The mining operation at Namdeb’s Southern Coastal Mine (SCM) is unique. It targets gravel layers up to 30 m below sea level, which continue to dip deeper, further west, under the Atlantic Ocean. On this storm-dominated coastline, severe water seepage into mining areas, rugged orebody footwall characteristics, and highly variable resource grades all contribute to a challenging operational environment. Namdeb has a proud history of innovation, and as the mine progresses further westwards and associated technical and economic challenges increase, this innovative culture has become essential to the future of the mine. The Theory of Constraints (ToC) has been widely used at SCM, and across the mining discipline, to focus efforts on improving overall business profitability. Through analysis of the mining processes, opportunities were identified, solutions developed, and initiatives implemented with staggering results across all three mining disciplines, i.e. stripping, load and haul, and bedrock bulking and cleaning. This paper outlines the solutions adopted and the results of the ToC analysis. IntroductionSouthern Coastal Mine (SCM) is one of three Namdeb operations located in the southwestern corner of Namibia, between the Orange River in the south, the Namib Desert to the east and the Atlantic Ocean to the west (Figure 1). These three geographical features set the backdrop for the world’s greatest marine diamond mining placer (Badenhorst, 2003). SCM is situated along the coastline extending from the mouth of the Orange River to Chameis Bay approximately 120 km to the north. The active mining area, called Mining Area 1 (MA1) is, however, limited to very narrow strip, 30 km in length, in the south of the licence area, close to the town of Oranjemund.Namdeb, a wholly owned subsidiary of Namdeb Holdings, is a 50/50 joint venture between De Beers and the Government of Namibia. Diamonds were first discovered along the Namibian coastline in April 1908, close to the town of Luderitz, but mining operations started in the SCM mining area only in February 1929 (Schneider, 2009). Initially all Namdeb mining operations exploited massive land-based deposits, producing nearly 40 million carats from MA1 between 1920 and 1977 (Schneider, 2009) when mining targeted onshore raised beaches west of the high water line. Since 1977 however, SCM and Namdeb have developed a unique mining method to economically extract the resource which extends westward under the Atlantic Ocean."

Feb 1, 2019

The Technical Programme Committee-Metals Technology of The South African Institute of Mining and Metallurgy, in association with its Vaal Triangle Branch, held a one-day colloquium on 18th April, 1989, the theme being 'Ferous Pyrometalurgy: A Challenge for South Africa'. The venue was the Auditorium 100 at the campus of the Vaal Triangle Technikon in Vanderbijlpark. Project and contract management A Project and Contract Management Conference is to be held on 19th and 20th September, 1989, at the C SIR, Pretoria. Powder metallurgy The PM 90 exhibition is to be held in Wembley, London, from 2nd to 6th July, 1990. The wide range of powders, processing machinery, and powder-metallurgy components at the exhibition will reflect the growth in this highly specialist industry. Castings and forgings Exhibition organizers, FMJ International Publications Ltd, are set to build upon the success of Castings & Forgings '88, which was held as a joint event with Pat- Cast '88. Castings & Forgings '89-with Pat-Cast '89- has already generated a high level of interest, which has been reflected in the demand for stands. Furnaces FURNACES '90, the eighth in this series of exhibitions for the thermal-processing industry, will be held in Solihul, West Midlands, England, on 6th and 7th March, 1990.

Jan 1, 1989

By B. Ceki, A. Mabentsela

The BCL furnace is scheduled to restart operations after being placed on care and maintenance in 2016 due to depressed nickel prices. The decision to start operations after such a stoppage ought to be led by a techno-economic evaluation of process options to make operations more resilient. For BCL, the decision lies between using the existing flash-smelting furnace (FSF) or a top-submerged lance (TSL) furnace. Available studies show that the FSF combined with other converting technologies is cheaper to operate; however, such studies are based on flowsheet simulation results of single copper concentrates and therefore do not provide a full scope of practical capabilities based on smelter operator skills. Using a t-test on normalized prior operational data from three Cu FSF and two Cu TSL, it was found that the only statistical differences between the operating costs of the FSF and TSL technologies are in the coal use for heating the feed blow and number of rebuilds: the FSF consumes coal to heat the feed blow and the TSL requires 2.4 rebuilds during a course of a single FSF campaign. A summative operating cost comparison over the existing BCL FSF 11-year life shows that BCL can decrease operational costs by some BWP 55.5 million if the operation were to change to the newer TSL technology. The savings derive from reduced coal use, which is normally associated with heating the blow when using the FSF. Despite the TSL carrying added costs of 2.4 rebuilds during a life time of one FSF furnace campaign, the cost associated with the TSL rebuilds of approximately BWP 1.3 million is minimal compared with the overall operational expenditure decrease that BCL will incur on using the TSL technology. In terms of the technology, BCL can have higher Ni–Cu recoveries at lower operational costs by elimination of Ni–Cu losses and eliminating the slag-cleaning furnace by converting to a TSL furnace.

Jul 10, 2024