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By G. Denton, P. den Hoed, A. Luckos

The potential application of fluidized beds in several sectors of the ferroalloy industry is promising. They can be used in the direct reduction of iron ores to produce a feed for steelmaking, in the reduction of manganese dioxide to produce a lesser oxide for feeding to smelters, in the preheating of chromite for the production of ferrochrome, and in the calcining and pre-reduction of nickel laterites for the production of ferronickel. This paper discusses the potential of fluidized beds in theses processes and highlights the advantages of the technology over other technologies, such as rotary kilns. Two primary advantages?(1) that fluidized beds can treat fine materials and (2) that fluidized beds can be integrated with smelters in a way that allows for more efficient use of energy?may well see the technology gain prominence as more deposits of lower grade are mined and industries strive to use their resources more efficiently. In discussing the potential of the technology in the ferroalloy industry, this paper focuses on the application of fluidized beds in the smelting of chromite, nickel laterites, and manganese ores. Central to the successful operation of this technology is a knowledge of how particle properties influence the behaviour and design of fluidized beds.

Jan 1, 2007

By Q. G. Reynolds

Keywords: Pyrometallurgy, furnace, DC, reverse polarity, dual-electrode The dual-electrode direct current (DC) arc furnace uses two graphite electrodes, one connected as cathode, and one as anode. Such an arrangement avoids some of the design difficulties associated with the anode hearth traditionally used in single electrode and twin-cathode DC furnaces, but can introduce other design and operational difficulties including deflection of the arcs toward the furnace walls. Counter-intuitively, both arc jets in a dual-electrode furnace travel from the electrode down to the bath surface, despite carrying electric current in opposite directions ? this is suggested in the theory of the governing equations of arc formation, and confirmed by experiments using high-speed photography. The dual-electrode arc system at small pilot-plant scale is studied using a transient magneto-hydrodynamic model capable of predicting arc deflection and interaction from first principles, and the results are compared to the behaviour of twin-cathode systems at similar power. Finally, a simple arrangement of the furnace busbars, M configuration, is shown to provide some passive protection against arc deflection.

Jan 1, 2011

By A. K. Haines

The status of the South African research and development programme on continuous ion exchange, which was aimed at the technical and economic assessment of that process for the recovery of uranium, is reviewed. The first phase of this programme, which has now been completed, involved development investigations on various pilot plants and culminated in the successful operation of a large-scale demonstration plant and the incorporation of the system in a number of new South African uranium plants. This account highlights the engineering aspects and the design fo the system, its adaptation to process flowsheets, and plans for future development.

Jan 1, 1978

By Z. Szczepanik, D. Milne, K. Kostakis

Abstract This paper presents the results of a series of creep tests performed on a total of nine samples of Lac du Bonnet granite from the Underground Research Laboratory near Pinawa, Canada. Each of the nine samples were subjected to stresses in excess of 80% of the average uniaxial compressive strength of the granite and were maintained at that level of constant loading for periods of time ranging between a few minutes and several months. Acoustic emission was recorded in order to monitor the development and accumulation of brittle microfracture damage in the samples throughout the long-term loading. According to previously published theoretical predictions and field results, as well as similar experimental results of creep tests in granite, samples should fail when loaded to 70% of their UCS for an extended period of time. Six of the samples did not fail when subjected to stresses in excess of 80% of their UCS over periods of several months and were subsequently subjected to uniaxial compression to failure. The average strength of the samples that had previously been subjected to long-term loading were comparable to the average published strength of this rock. Three of the nine samples had increased end confinement and these three samples failed under long term loading. Résumé Cet article présente les résultats d'une série d'essais de fluage de roche exécutés sur neuf échantillons de granite de Lac du Bonnet, du laboratoire souterrain de recherches près de Pinawa, Canada. Chacun des neuf échantillons a été alors soumis aux charges au-dessus de 80% de la résistance à la UCS moyenne du granit et a été maintenu à ce niveau du chargement constant pendant des périodes s'étendant entre quelques minutes et plusieurs mois. L'émission acoustique a été enregistrée pendant les essais afin d'obtenir des indications des dommages pendant le chargement à long terme. Selon des résultats théoriques précédemment édités et les résultats expérimentaux semblables des essais à long terme en granite, échantillons devrait échouer si chargé à 70% de leur UCS pendant une période prolongée. Six des échantillons n'ont pas cassé quant ils ont été soumis aux charges au-dessus de 80% de leur UCS et ont été plus tard soumis à la compression uniaxiale à la rupture. La force moyenne des échantillons qui avaient été précédemment soumis au chargement à long terme étaient comparable à la force éditée moyenne de cette roche. Trois des neuf échantillons avaient augmenté le confinement de fin et ces trois échantillons ont cassé sous le chargement à long terme. Zusammenfassung Dieser Artikel beschreibt die Resultate von Kriechversuchen, die an neun Proben aus dem Lac du Bonnet Granit des "Underground Research Laboratory" bei Pinawa in Kanada durchgeführt wurden. Jede der neun Proben wurde Drücken unterworfen, die mehr als 80% der einaxialen Druckfestigkeit des Granites entsprechen. Diese Drücke wurden für verschiedene Zeitspannen von wenigen Minuten bis zu einigen Monaten auf einem konstanten Niveau gehalten. Während der gesamten Langzeitbelastung wurden akustische Emissionen aufgezeichnet, um die Entwicklung und gesamthafte Beschädigung der Proben durch Sprödbruch aufzuzeichnen. Entsprechend bisher veröffentlichter theoretischer Vorhersagen, Feldversuchen und auch experimentellen Resultaten von Kriechversuchen an Granitproben wäre ein Versagen der Proben zu erwarten gewesen, wenn sie über längere Zeit einer Last von 70% ihrer einaxialen Druckfestigkeit unterworfen werden. Wider Erwarten trat bei sechs der Proben kein Versagen ein, als sie mit über 80% ihrer einaxialen Druckfestigkeit über mehrere Monate belastet wurden; daher wurden sie im Anschluss bei einaxialer Kompression zum Versagen gebracht. Die mittleren Festigkeiten der im Langzeittest verwendeten Proben sind vergleichbar mit den normalerweise für diesen Gesteinstyp angegebenen Festigkeiten. Drei der neun Proben versagten unter der Langzeitbelastung; diese drei Proben hatten eine erhöhte Endflächenreibung.

Jan 1, 2003

Gold Fields is the world?s fourth largest gold producer with operations in South Africa, Australia, Ghana and South America. All of Gold Fields? South African Operations are located in the Witwatersrand Basin and are intermediate to deep level underground mines exploiting gold bearing, shallow dipping tabular orebodies, which have collectively produced over 50 kt (1,608 Moz) of gold over a period of more than 100 years. Although the use of Monte Carlo as a business tool was introduced in 1964, it has only been in the last 30 years that it has gained increasing acceptance within the mining industry. However, the application thereof has been mostly limited to determination of risk in project areas. This paper however, considers the possibility of using Monte Carlo simulations to asses the underlying ?Root Cause? criteria critical to the operations management of existing mining operations. Currently, working operations have a distinct advantage over project areas as they have a wealth of historical information at hand. This, in turn, can be utilized to model distributions and relationships that can be used in Monte Carlo simulations, the results of which can be analysed to determine areas of concern. Projects can then be set up to ameliorate the effects of these and in turn reduce the risk of not achieving the operational targets. It is here that it must be stated emphatically that it should be the ?root causes? and the associated relationships that need to be emplaced within the model in order to achieve results that reflect the true causal relationship. The paper outlines possible sources of ?root cause? relationships and considers the outcomes of these in a case study on a large South African Gold Mine.

Jan 1, 2009

By C. R. S. Needes, M. J. Nicol, G. T. W. Ormrod, N. P. Finkelstein

The industrial application of a dioxide electrode uranium by C. R. S. NEEDES, Ph.D. (London) (Visitor), M. J. NICOL, Ph.D. (Rand) (Visitor), N. P. FINKELSTEIN M.Sc. (Rhodes), Ph.D. (Liverpool) (Fellow), and G. T. W. ORMROD (Visitor) A correlation between the potential of a U02 electrode and the rate of recovery of uranium has been proved in laboratory and plant trials. When the recovery rates change because of variation in the concentrations of Fe(III), Fe(II), SO4 'and H+, a positive correlation is observed. However, an 2- increase in the concentration of phosphate in solution produces an increase in the U02 electrode potential but a decrease in the rate of leaching of U02. The correlation between the U02 electrode potential and the rate of leaching of U02 is then negative. It is concluded that, as a control device, the electrode cannot compete with the platinum electrode for use on certain plants. Nevertheless, the U02 electrode will act as a useful warning device if the total concentration of iron in solution decreases to below a level concomitant with the economic recovery of uranium. Furthermore, because of the positive correlation between the U02 electrode potential and the phosphte concentration, the electrode will also be of value in the detection of an increase in the phosphate level in solution. When it was incorporated in a suitable industrial probe, the electrode was found to be able to withstand the rigours of the leaching conditions in a large pilot-plant pachuca, and only failed after six weeks' operation.

Jan 11, 1975

By S. Lubbe

South Africa and Australia are the biggest suppliers of zircon sand to the international zirconium industry. However neither South Africa nor Australia is well known for zircon beneficiation. Geratech Zirconium Beneficiation Ltd (GZB) continued with additional research on sodium hydroxide (NaOH) cracking of zircon sand during 2002-2003. In 2003 GZB started extracting zirconium from zircon sand by means of NaOH cracking on a commercial scale. Experience has shown that temperature profile and atmospheric control inside the furnace is crucial for the beneficiation of zircon sand. Silica carryover to zirconium chemicals could result if a high temperature is used. Once the sodium silicate is extracted from the sodium zirconate and dissolved in hydrochloric acid, two distinct routes can be followed to precipitate various zirconium chemicals. The most common route is to precipitate zirconium oxychloride crystals (ZOC), with subsequent purification from all contaminants (crystal route). Less known is the process (liquid route) that involves the direct precipitation of zirconium basic sulphate (ZBS). This route will yield a less pure product, with contaminants such as silica and titanium. An important factor in this route is the prevention of silica gel formation, which could hamper final product filtration. For applications like paint drying (zirconium octoate) or antiperspirants (zirconium hydroxychloride) low levels of contaminants have no effect on the final product. The advantage of the liquid route is fewer production stages compared to the crystal route. The disadvantage of the liquid route is that the market for the products will be significantly smaller. The optimum solution could be a plant design that could cater for both routes. Another example of an application of zirconium chemicals is the use of ammonium zirconium carbonate (AZC) in the paper industry. Zirconium basic carbonate (ZBC) is dissolved in ammonium carbonate to produce AZC solution. AZC is used mainly in European countries in the paper industry. For example, carton boxes were initially produced with formaldehyde as the binder, however, it has now been replaced with AZC since formaldehyde is considered toxic. AZC reacts with the cellulose fibres in the paper to act as the binder. The resulting product is not toxic, and printing ink dries very quickly due to the porous paper structure. Other applications of zirconium chemicals involve the use of acid zirconium sulphate tetrahydrate (AZST), zirconium orthosulphate (ZOS), potassium zirconium carbonate (KZC), and zirconium hydrous oxide (ZHO). Fluoride-based zirconium chemicals like zirconium tetra-fluoride (ZrF4) and hexafluoro-zirconic acid (H2ZrF6) are used in the aluminium industry. Zirconium oxide (Zr02) can be produced from any of the abovementioned precipitated chemicals via a high-temperature decomposition process. The physical properties of such oxides can differ tremendously, depending on the final application. The fired density of sanitaryware is typically 5.8 g/cm3, compared to milling media at >6.1 g/cm3. The required fired density is achieved by controlling the precipitation and decomposition conditions for these two oxides. The same applies to stabilized and mixed oxides, for example where zirconium oxide acts as an oxygen carrier in fuel cells.

Jan 1, 2012

By I. Ashmole

From the point of view of the environmental impact created, dimension stone mining is a relatively benign industry. There are no emissions besides those of the diesel powered earthmoving equipment utilised in its extraction and a small amount of blasting gases. Contamination of water resources is only likely in the event of petrochemical spillages from storage facilities and equipment, and these can largely be either prevented or cleaned up effectively. The major environmental impacts are of a visual nature, while in sensitive areas, habitat destruction and the destruction of archaeological heritage may become significant impacts. The dimension stone industry has grown at an average rate of over 7% per annum since 1986, and is forecast to continue growing at this rate for the foreseeable future. The cumulative environmental impact of the industry will thus become more significant over time. This paper discusses the environmental impacts of dimension stone mining and recommends effective means for dealing with the practical aspects of reclamation and mine closure in dimension stone mining within the context of environmentally responsible business practices. The discussion focuses mainly on the operations of the Finstone Group in Southern Africa, which are considered to be world leaders in the application of environmental management within the dimension stone mining industry, although reference is also made to other situations which the authors have encountered at dimension stone quarries around the world.

Jan 1, 2008

By D. M. Meyer, K. Auerswald

The production of electrolytic manganese in South Africa by M. HARRIS, Pr. Eng., B.Se. (Eng.) (Fellow), D. M. MEYER, Pr. Eng., B.Se. (Meeh. Eng.) (Visitor), and K. AUERSWALD (Visitor) The decision to construct the first electrolytic manganese plant in South Africa was important and farreaching. After evaluating the results of the pilot plant operation, the first South African producer, Electrolytic Metal Corporation (Emcor), established a plant in Krugersdorp. Initially, there were many process problems that had to be InvestIgated, and, after these had been solved and many operating parameters had been established, manganese was successfully produced. When the Delta Manganese plant in Nelspruit was planned, cognizance was taken of the fact that, if peak efficiencies were to be maintained, the process must be operated between fairly narrow parameters. Instrumentation was therefore installed to control the process automatically wherever possible. The main features of the Delta Manganese operation are outlined, with a brief description of each stage of the process from ore milling through to electrowinning and packing of the metal. It is concluded that much benefit can be obtained from further research work into process improvements and into the exact effect of certain variables on plant and current efficiency.

Jan 2, 1977

By H. Brüggemann

The exploration of deposits generates geological data which are suitable for creating a preliminary tectonic and stratigraphic model. Linked with the topographical map and analysis data from exploration drillings, this information forms a numeric representation of the deposit. The following example demonstrates an expert system which connects chemical quality requirements and quarrying criteria, and develops a quarrying strategy based on the calculated model. Additional constraining factors like process technology, quarrying methods, landscape protection regulations, etc. are included. The goal is to guarantee a long-term, homogeneous material flow from the quarry at acceptable production costs - even in the case of an extraordinarily inhomogeneous deposit. In order to fulfil this requirement it is necessary to consider a large number of rules, criteria and instructions which can be structured as an expert system and programmed with LISP at a comparably low cost. The chosen strategy is not necessarily final, but can be changed any time by altering or varying the framework of conditions. The output consists of a block-working sequence which best satisfies the set requirements for appropriate points of quarry opening.

Jan 1, 1987

By A. C. Lawrence, B. Econ, D. Com

The importance of human factors in mining productivity by A. C. Lawrence, D. Corn., B. Econ. (Member) The paper outlines some of the views on the relationship between work attitudes and performance, and examines evidence derived from relevant research done in the mining industry. It is suggested that higher productivity within any given system of mining can be attained if attention is paid to the four factors that represent the CORE of human work performance: Competence, Opportunity (or Organisation), Recognition (or Rewards), and Expectations (or Enrichment).

Jan 7, 1974

Changes in reductant and energy inputs which are required to adjust the slag composition in anilmenite smelter to a higher or lower FeO content are calculated. The calculated changes are based on the assumption that solidification equilibrium with the freeze lining constrains the slag composition to follow a eutectic groove in the TiO2-FeO-TiO1.5phase diagram. Calculated equilibrium conditions along the eutectic groove are presented, and form the basis of the calculations. The inputs of energy and carbon need to deviate strongly from the steady-state values to adjust the slag composition. The inputs required at any given time depend on the desired rate of change of the slag composition, and the current slag composition. The steady-state relationship of a change in energy input of 5 kWh corresponding to a 1 kg change in carbon input does also hold for the changed inputs during transient changes in FeO content. Keywords: Ilmenite smelting, freeze lining, solidification, eutectic

Jan 1, 2003

By A. C. Lawrence, K. F. Mauer

Human factors in stope productivity -a field experiment by K. F. MAUER, M.A. (Visitor), and A. C. LAWRENCE, B.Econ., D.Com. (Member) An experiment in which three human variables were manipulated in eight stopes was conducted in a gold mine over a period of roughly six months. The three variables, which each had two levels, concerned the degree of movement from gangs, the quality of the Bantu production supervisors, and the extent to which gangs were composed of a single ethnic group (Malawians). Time was included as a variable with three levels in the analysis of the findings. On the average, stable gangs produced 12 per cent more than gangs with a high percentage of transfers, gangs with better production supervisors were more successful by nearly 9 per cent than those with poorer production supervisors, and homogeneous gangs were more productive than heterogeneous ones by as much as 15 per cent. In addition, it was found that a number of the variables exercised a joint influence on stope productivity and that the effects of the variables were accentuated by the len gth of time they had been in operation. V

Jan 10, 1973

By deur R. Dippenaar

'n Kort kursus oar die teorie en praktyk van hittebehandeling is vanaf 29 Junie 1981 tot 3 Julie 1981 in die departement Materiaalkunde en Metallurgiese Ingenieurswese aan die Universiteit van Pretoria aangebied. Die kursus is dour dosente van die departement opgestel en in samewerking met 'n aantal gassprekers aDder beskerming van die Suid-Afrikaanse Instituut vir Mynbou en Metallurgie aangebied. Tunnelling The Third International Symposium on Tunnelling is to be held in Brighton from 7th to 11th June, 1982. Professional development seminars The Department of Mining and Metallurgical Engineering of McGill University is to hold the following seminars during 1981-1982.

Jan 1, 1981

By H. A. D. Kirsten

The skills differential between manpower supply and demand is due to deeply rooted socio- and politico-educational misconceptions that can be remedied only by a concerted cooperative effort on the part of the general public, the State, organized industry, organized engineering, and engineering education. This will require the general public to recognize that the reasons for the shortages in engineering manpower should be regarded as critical. Public perceptions of engineering, of the vocational and educational prospects in engineering, and of the skills required are poor. The spectrum of engineering vocations, the corresponding function profiles, the interaction between the vocations and the relative proportions of the vocations in the engineering team are in general not adequately appreciated. The recruitment and training of students and teaching staff, teaching facilities, educational curricula, practical training, qualifications, professional registration, and financing are aspects of engineering education that should be brought to the attention of all concerned. . In addition, the educational curricula for the various vocations need to be specified clearly and definitively if the overall mission of engineering education is to be properly appreciated. The uncertainties between university and technikon education and the pursuant vocations need to be resolved. This can be done only by defining the respective curricula in terms of the mental skills and scientific techniques required. The remedial actions with regard to the rationalization of engineering education comprise informing of the public; establishment of an active political lobby; revision of existing education policy; rationalization of existing educational infrastructure; promotion, development, and guidance of engineering student intake; financing of engineering education; accelerated creation of new employment opportunities; and monitoring of the supply and demand of high-level manpower. The parties required to nitiate these remedial actions are various State departments and corporations involved in engineering and industry, various departments of education, the Directorate of Technology of the Department of Trade and Industry, organized engineering education, organized engineering, organized industry, and the Human Sciences Research Council. Only if these interest groups actively initiate the various actions under the coordinated guidance of organized engineering wil the required results be achieved. The South African Engineering Association has proposed a comprehensive programme as strategy to solving the problem, and has obtained broad consensus from various State departments, organized engineering education and research, and the private sector. A joint venture between the Foundation for Research Development, the South African Engineering Association, and organized industry has been charged by the State President with the task of launching the programme.

Jan 1, 1991

By S. L. Crouch

A. C. Dieringt The procedure described by Professor Crouch for the modelling of mining in faulted ground allows the elastic and inelastic deformation to occur simultaneously, that is, fault slip occurs while an element is being mined. The energy release rates (ERR) shown in Crouch's Fig. 10 are apparently calculated from his equation 9 using the i total deformation Din (see the upper load line of Fig. I) Refractories The institute of 'Gesteinsh iittenkunde' of the technical university at Aachen, the Refractories Research Institute at Bonn, and the Verein Deutscher Eisenshiittenleute (VDEh) at Diisseldorf are to hold the XXII International Refractory Colloquium on 27th and 28th September, 1979, at Aachen.

Jan 1, 1979

The sixth University of Stelenbosch (US)/University of Cape Town (UCT) Minerals Processing Symposium was held at the University of Cape Town on Friday, 7th August, 1987, and was sponsored by The South African Institute of Mining and Metallurgy (SAIMM). Once again the Symposium attracted a large number of delegates from the mining, metallurgical, and chemical industries. Uranium and electricity A symposium on 'Uranium and Electricity- The Complete Nuclear Fuel Cycle' will be held in Saskatoon, Canada, during 18th to 20th September, 1988. The Symposium is sponsored by the Canadian Nuclear Society. Electric steel The Institute of Metals, organizers of the 3rd European Electric Steel Congress, have announced that this important international event will take place in October 1989 at the Bournemouth International Centre.

Jan 1, 1987

By F. T. Wang, Y. Yuan, S. H. Tu, X. G. Zhang

Hydraulic support instability (HSI) is one of the most common causes of disasters in underground coal mining, posing a threat to the safety of mine workers and normal operation of the equipment. It is prone to occur in fully-mechanized mining faces with a large mining height (FMMLMH), especially when the dip angle of the coal seam is large. The key to controlling HSI is to deduce its mechanism and employ effective control techniques. This paper focuses on the analysis of HSI types, the key parameters and techniques to control HSI in FMMLMH, the establishment of a model of HSI in FMMLMH, and a multi-parameter sensitivity mechanical model of different HSI forms in the no. 7219 longwall face in Xutuan Coal Mine, Huaibei Mining Group, by using sensitivity analysis . The results show that HSI mainly presents in three forms: hydraulic support gliding (HSG), hydraulic support tilting (HST), and hydraulic support tail twisting (HSTT). The occurrence of the above three forms depends mainly on support anti-instability capability. In the no. 7219 longwall face, HSG and HST are the main two forms of HSI. The dip angle of the working face and the friction coefficient between floor and hydraulic support are the sensitive parameters for HSG, while HST is strongly dependent on the dip angle of the working face and the friction coefficient between roof and hydraulic support. By the applications of measures such as the oblique layout of the working face, cutting the floor into a step pattern, moving the support under pressure, and raising the setting load, the support stability was controlled effectively.

Jan 1, 2015

Mining executives often have a difficult task determining what the strategic objective of the business should be as this can be impacted by the prevailing market conditions. In addition, they have no mechanism to quantitatively 'test' the impact of this strategic decision on the business and understand the underlying dynamics. During the commodities bull run of 2003 to 2008 the strategic objective may have been to grow the long term value of the business (NPV) through increased tonnage, acquisition and finding new reserves, which all came with an increasing fixed cost base. Now with the financial crisis upon us and the collapse of commodity prices and demand, executives have adjusted their strategies as 'cash is king' and short-term cash flow, in some instances at the expense of long terms value, is the order of the day. For many mining companies, mine closures, reductions in production and cost cutting exercisers are now the focus. In many instances, management do not have an ability to rapidly test different strategic alternatives to 'test' the impact on value, unit costs, reserves and profitability at the operational level and optimize the underlying trade-off variables. Economic modelling of the complete business value chain is a means of linking the operational 'reality' and strategic choices, so that the full impact can be assessed. This paper describes some of the challenges facing mining executives and how economic modelling can be applied to make decision making more rigorous.

Jan 1, 2010

By J. A. Maritz

Since the dawn of mining, pillars have been used as primary support to ensure stable workings. Early designs were based on trial and error, after which more scientific means developed over time. A vast amount of progress has been made, especially in soft-rock room-and-pillar design methodologies, from which hard-rock design theories developed with minor changes to constant parameter values. The commonly used Hedley and Grant method for hard rock and Salamon and Munro methodology for soft rock draw on the tributary area associated with the pillar, the width-toheight ratio of the pillar, and a back-analysed strength reduction factor. In these methods, only the vertical stress, or stress normal to the pillar influences the load applied to the pillar. This investigation considers the possible influence of shear stresses on pillars in a room-and-pillar layout in single reef planes and multi-reef environments, based on elastic numerical modelling methods. The possible shear stress poses a safety and financial risk to the design process, whereby an undersized pillar would lead to unstable working conditions, whereas oversized pillars could lead to an under-utilized ore resource.

Jan 1, 2014