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By D. Yu, Y. Thibault, D. Paktunc

"Prereduction and flux-aided direct reduction of chromite provide significant advantages in reducing energy consumption and greenhouse gas emissions during ferrochrome production. In this investigation, a comparative evaluation of the influences of several alkali fluxes was carried out based on experimental observations supplemented by advanced material characterization and thermodynamic predictions. Direct reduction of a chromite ore with alkali fluxes at 1300°C for 1 hour produced (Cr,Fe)7C3 type alloys with Cr/Fe mass ratios from 0.7 to 2.3. Among the alkali fluxes, reduction aided by NaOH resulted in a high degree (85%) of Cr metallization with the ferrochrome alloy being Cr4.2–4.6Fe2.4–2.8C3. The formation of liquid slag, which facilitated Cr metallization, was limited by the formation of NaAlO2 between 800 and 1300°C. This, in turn, restricted the collection and transport of the charged ionic Cr species (i.e. O2–) to graphite particles. Under the conditions studied, ferrochrome particles were often small and largely unliberated, which would make the physical recovery of ferrochrome challenging. At 1400°C, the amount of liquid slag increased, enabling the growth of alloy particles. Direct reduction of chromite aided by NaOH is promising as an alternative technology to conventional flux-based smelting in electric arc furnaces. IntroductionConventional smelting processes are energyintensive (Riekkola-Vanhanen, 1999) with the energy requirements greater than 4 MWh/t (Naiker and Riley, 2006; Beukes, van Zyl, and Neizel, 2015), and the greenhouse gas emissions can be significant, exceeding 10.5 t CO2 per ton Cr in ferrochrome produced (International Chromium Development Association, 2016). These include emissions occurring on-site (smelter), emissions due to electricity production, and emissions due to upstream processes. Overall energy requirements are influenced by the degree of prereduction and smelter charge temperature. Significant reduction in electricity consumption can be realized if the charge is prereduced before feeding to the submerged arc furnace (Niayesh and Fletcher, 1986). This consideration has led to the development of several prereduction technologies, with the most important example being the Premus process. In comparison to the conventional smelting processes, this prereduction process lowers the overall energy consumption and greenhouse gas emissions by about one-third (Naiker, 2007)."

Dec 1, 2018

By J. R. Heberger

"“Safety Pays in Mining” web application developed by the U.S. National Institute for Occupational Safety and Health Mining Program, helps mines determine the potential costs associated with mining injuries. This web app groups injuries by type, either by the cause of the injury or by the nature of the injury. When the user selects one of more than 30 common types of mining injuries, the app provides information on the distribution of costs of workers’ compensation claims for that type of injury. Based on other user inputs, the app will estimate the total costs of the selected injuries, including an estimate of additional indirect costs, the estimated impact of total injury costs on mining company profits, and provide some examples of other items, such as services or equipment, on which companies could spend the savings that result from the prevention of injuries. This paper reviews the app by discussing its development, how it is used to show the true costs of mining injuries, and how mines can benefit from using it.IntroductionInjuries on the job cause pain and suffering. They can also profoundly affect profits and daily operations. In addition to paying direct costs or increased premiums for workers’ compensation insurance, a company might need to pay overtime for other workers to fill an injured worker’s job role, cover training costs for a replacement worker or divert administrative resources in the wake of an injury. “Safety Pays in Mining” is a web app that estimates the distribution of these injury costs and assesses the impact that occupational injuries have on a company’s profits.The costs of specific types of occupational injuries in mining are not readily available as mining and insurance companies do not usually share this information. As a consequence, companies only have cost information based on previous experience with their own employees. Therefore, if a mine never experienced a finger amputation for one of its miners, for example, it would not be aware of the possible costs associated with this type of injury. In addition, injury costs are unique in that the cost distribution is so wide that just using the average cost of a specific injury type does not provide adequate information. Some injuries involve immensely high costs, and even though the risk of these high-cost injuries occurring is low, mines need to be aware of the potential impact on their company’s financial health."

Dec 1, 2018

By Matthew Preedy, Brett Campbell, Jim Rush, Alan Howard, Derek Penrice

All Rights Reserved. Printed in the United States of America. Information contained in this work has been obtained by SME, Inc. from sources believed to be reliable. However, neither SME nor its authors guarantee the accuracy or completeness of any information published herein, and neither SME nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that SME and its authors are supplying information but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should be sought. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Any statement or views presented here are those of the authors and are not necessarily those of SME. The mention of trade names for commercial products does not imply the approval or endorsement of SME.

Dec 1, 2018

By H Esterhuizen, W Hartman

Rockfalls or significant deterioration of mine openings can have significant safety and financial impacts for mining operations. The failure of drives in underground mines sometimes highlight deficiencies in the mine risk management systems in detecting geotechnical hazards and to prevent events that can have significant impact. Consequences from these failures includes fatalities, injuries, loss of revenue, additional cost, and potentially a loss in Ore Reserves. Where the impacts are severe, it also affects families and communities linked to the operation. The assessment of underground excavations requires consideration of the full range and spectrum of geotechnical hazards, design aspects, ground support, layouts and sequences. Where the assessment of these are insufficient or incorrect, it can result in drive failures. Care must be taken that meeting production targets and personnel pressures do not result in a situation where production take preference over a proper risk-based assessment of the drives to be mined. The risk management approach is now widely accepted in the mining industry for the control and management of risks in underground mines. Codes of Practices (COP’s), Ground Control Management Plans (GCMP), Principal Hazard Management Plans (PHMP’s) and technical guidance documents has become the norm for describing the mines main hazards, risk levels and intimating controls for safe passage of vehicles and mine personnel. However, where there is a disconnect between these documents and what is actually being done at the mine site, the COP’s and/or Management Plans become ineffective (or vice versa). This disconnect may occur due to the actual content of these documents, a lack of resources, or a lack of understanding about the implementation. There is therefore a need for sites to have a documented and implemented risk-based approach for assessing underground mine development. This approach or system needs to identify all hazards and other factors affecting mine development stability early on in the design process, and outline the risk classification and controls required. This paper presents an amalgamation and modification of previous processes for a Geotechnical Risk Management System for Underground Mine Development. CITATION:Hartman, W and Esterhuizen, H, 2018. A geotechnical risk assessment tool for underground mine drives, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 235–253 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By A Lines

This paper addresses a gap in longwall multi-seam interactions and their predictions, providing a case study for future multi-seam operations for both anticipated conditions and a method for understanding the changes in stress regime. Multiple panels were modelled with the results analysed and compared to panel experiences to validate the parameters and properties. The software chosen (LaModel) is a numerical modelling package designed to model stresses and displacements on thin deposits. It utilises a displacement-discontinuity variation of the boundary-element method and has been used extensively throughout both the United States and Australia in multi-seam operations. Analysis of the results demonstrates a clear correlation with the above workings and regions of significant strata instability. This provides the opportunity going forward to analyse new models and incorporate into mine planning and geotechnical designs. Continuous site-based assessment should be undertaken at multi-seam operations to better understand and quantify likely vertical stress levels within the workings. With a detailed analysis of models prior to extraction and a review of models post extraction. Further research is required as LaModel is limited to vertical stress and it is likely that interactions impact both the horizontal and shear stress regime. 3-dimensional modelling could further assist in this understanding, combined with a thorough stress monitoring regime. CITATION:Lines, A, 2018. Modelling multi-seam interactions for longwall mining, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 185–195 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By H Ramandi, H Masoumi, I Canbulat, B Hebblewhite, J Oh, S Saydam, W Timms, S Mo

This paper reviews the floor heave mechanisms in underground coal mine roadways. Previous studies have reported three main failure mechanisms: bearing capacity failure, buckling and swelling. The buckling failure has been observed where immediate floor strata are relatively strong and thinly bedded. On the contrary, the weak floor strata have been associated with both the bearing capacity failure and swelling mechanisms. The bearing capacity floor failures are likely to induce other types of instability such as pillar punching, tensile failure of pillar, roof fall and subsidence as well as floor heave. Despite a considerable amount of research, predicting the magnitude, location and timing of floor deformation is challenging with current state of knowledge. CITATION:Mo, S, Ramandi, H, Oh, J, Masoumi, H, Timms, W, Canbulat, I, Hebblewhite, B and Saydam, S, 2018. A review of floor heave mechanisms in underground coal mine roadways, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 196–206 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By P Wilson

The Mt. Wright Underground Mine is located near the town of Ravenswood in North Queensland and is operated by Carpentaria Gold – a wholly owned subsidiary of Resolute Mining Limited. The establishment of the world’s first Sub Level Shrinkage (SLS) mine from a tradition Sub Level Open Stoping operation has proven to be a geotechnical challenge which has required tailored solutions to overcome unique issues. This paper will be broken into two distinct sections that will outline: a brief overview of the mining method and how the SLS method was chosen; and how the SLS is managed and key geotechnical learnings. The story of the world’s first SLS originated from the need of a bulk mining method to ensure the viability of Mt. Wright into the future. Traditional bulk mining methods such as; Block or Sublevel Caving were originally ruled out due to the low natural ‘cavability’ of the orebody and the proximity of the orebody to existing major infrastructure (Decline, Ventilation Rises and Egresses). The first section of the paper will outline the key geotechnical information that helped decide the SLS method in addition to how continuous backfill influenced the design. The second section is intended to address issues that the geotechnical engineers encountered since the inception of the SLS. The feature topic of this section is mining induced stress. Like most bulk mining methods, Mt. Wright had success when the production front was running parallel to the stress (production front being ‘shadowed’ from the stress). This was until a design change, forced by a splitting ore body resulted in this shadowing effect becoming harder to achieve. As a result, rehabilitation and production hole re-drilling become a regular occurrence, which teamed with a strict set of access controls made the production cycle longer and harder to complete. CITATION:Wilson, P, 2018. Mt Wright – geotechnical learnings from a sub level shrink, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 119–132 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By H Esterhuizen

The Ernest Henry Mine (EHM) in Queensland, Australia is a Sub-level Caving operation that started production below the previously mined open pit at a depth of 535m. Current Production mining has progressed to a depth of 730m, with planned production mining to extend down to at least 1000m below surface. The inclined nature and geometry of the orebody combined with geological structures provides for challenging mining conditions. Over several years, Ernest Henry Mine has introduced measures to improve outcomes based on observations, monitoring and data analysis. As mining progresses deeper, EHM will continue to proactively take steps to ensure future outcomes are anticipated and mining can continue safely and uninterrupted. The focus of this paper is on the changes in seismic- and stress-driven behaviour of the rockmass experienced at EHM, the ground control measures implemented, and the anticipated future conditions and controls required. CITATION:Esterhuizen, H, 2018. The evolution of seismicity and ground control measures at Ernest Henry Mine, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 20–41 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By T R. Stacey

South Africa has a long history of rockbursts, some 100 years. During this time much research and many developments have taken place in the country to limit the occurrence of rockbursts, and to mitigate their effects. In this paper I shall present a personal view of what I consider to be important achievements, and contributions made. Some of these are: planning of stope layouts, and the use of strike barrier pillars; recognition of energy as a key factor, the use of the energy release rate ERR as a layout planning criterion, and development of MINSIM for calculation of ERR and stope planning; sequential grid stope layouts; use of backfill for stope support; and, development yielding support elements, and dynamic testing of stope and tunnel supports. The record shows the establishment of a rock engineering research powerhouse over a 40 to 50 year period and, unfortunately, the complete breakdown of this capability in the subsequent 10 years. CITATION:Stacey, T R, 2018. A personal review of South African rockburst research, experience and lessons learnt, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 5–16 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By B Roache, A Vakili, R Talebi

When a highly anisotropic or weak rock mass is subjected to high-stress conditions, it can lead to large ongoing deformations or squeezing ground conditions. Squeezing ground conditions can impose increased support costs, delays associated with rehabilitation, and disruption to production schedules. Ultimately, in more severe cases, it may result in complete drive closure. Several recent case studies investigated the squeezing mechanism and measures to control squeezing ground in underground mines and also to design appropriate ground support systems. Effective management of squeezing ground conditions requires a sound understanding of the failure mechanism and the driving forces. Once the failure mechanism is understood, the appropriate ground support system should be tailored to specifically manage the critical driving forces that control the squeezing mechanism. Support type, support stiffness, reinforcement length, support density, installation times and mining sequence all have important impact on the effectiveness of the support system. This paper provides a case study at the Ballarat Gold Mine in Australia, where drive squeezing was associated with foliated ground conditions located below 700 m depth. Numerical modelling was used to better understand the failure mechanism and the driving forces that lead to squeezing conditions. The effectiveness of various support types was compared to installed ground support performance. This has provided a credible methodology for assessing and optimising the selection of reinforcement in squeezing ground conditions. CITATION:Talebi, R, Roache, B and Vakili, A, 2018. Understanding and modelling squeezing ground conditions at the Ballarat Gold Mine, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 107–118 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By B L. Sainsbury, M F. Lee, A Penney

For most practical rock engineering purposes, stress versus strength conditions around underground openings for which rock masses fail and their various modes of failure, are reasonably well-understood and predictable. Some rock masses and particular rock types fail slowly and relatively quietly. However, others can fail rapidly, violently and maybe with the ejection of significant broken rock. In some countries and in some mines, the latter style of violent fracturing and failure of the rock mass is referred to as ‘strain bursting’. It can be alarming and extremely hazardous to nearby miners and machines. For such situations, the design and installation of appropriate ground support, to provide a safe work place, can be challenging. At any particular mine site, it’s often generally understood which local rock masses (rock types) are prone to strain bursting. Competent and strong siliceous rocks and some massive sulphides are often the main offenders. While some neighbouring, equally-competent and strong rocks might also fail, they do so more quietly and without ejection. To understand this contrast, a better understanding of the fracturing process is required other than simple and standard strength versus stress considerations. Suites of standard intact rock properties from numerous Australian mines have been used to define and help understand different high-stress failure styles for component intact rock; especially those prone to violent fracturing (strain bursting). Simple considerations of micro-fracturing (defects in the intact material), plus the available energy at failure versus the energy consumed during fracturing, distinguishes between over-stressed and competent rock types that fracture violently and those that don’t. CITATION:Lee, M F, Penney, A and Sainsbury, B L, 2018. Proneness of competent over-stressed intact rock to violent fracturing, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 170–184 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By CIM Mineral Resource, Mineral Reserve Committee

The CIM Mineral Exploration Best Practice Guidelines (the Exploration Guidelines) have been prepared to assist professional geoscientists and engineers to conduct consistently high-quality work in order to maintain public confidence. The Exploration Guidelines are meant to assist professional geoscientists and exploration practitioners in planning, supervising, and executing exploration programs. In Canada, there are generally two types of public resource reporting: “Disclosure”, as defined by NI 43-101, is the reporting of technical information to the public and market participants for securities legislation purposes where a Qualified Person (QP) must be involved, and reporting of exploration information for governmental agencies to support obligations under laws including the Mining Acts of each of the Provinces and Territories. The Exploration Guidelines are also relevant where the results will not be publicly reported but are intended for internal company use. While this document is intended as guidance for work conducted or supervised by geoscientists in Canada, many of the practices described herein can be adapted to mineral exploration activities in other countries. The Exploration Guidelines are not intended to inhibit original thinking, or to prevent the application of new approaches that may develop into fundamental components of successful mineral exploration programs. Rather than provide prescriptive solutions to specific issues, they include general guidelines for current professional practice and to demonstrate and defend the merits of new methods. These guidelines do not preclude individuals and companies from developing more detailed guidelines specific to their own requirements. The initial version of the Exploration Guidelines was prepared by the Canadian Institute of Mining and Metallurgy and Petroleum (CIM) Exploration Best Practices Committee and adopted by CIM Council on August 20, 2000. On January 9, 2018, CIM Council formed a new committee, the Mineral Resources and Reserves Committee (CIM MRMR Committee) with a mandate to, among other things, update the Exploration Best Practice Guidelines. The mandate for the committee was accepted by CIM Council on March 2, 2018. The new document was adopted by the CIM Council on November 23, 2018.

Nov 23, 2018

By K Tungpalan, E Wightman, M Edraki, E Manlapig, L Keeney

The depletion of easily mined high-grade ore bodies resulted in the industry having to exploit lower grade, complex resources (Albanese and McGagh, 2011; Darling, 2011; Randolph, 2011). The trend is now towards mining and processing of low-grade and complex ores (Darling, 2011; Yingling, 1990). Variable geological and mineralogical characteristics, and complex mineralogy and texture can result in large variations in metallurgical response and also cause challenges in processing. (Carson, 1995; Lorenzen and Barnard, 2011; Yingling, 1990). Variability and the complex nature of ores are fundamental sources of risk that often cause the greatest economic impact (Dusci et al., 2007; Williams and Richardson, 2004). Hence it is important to effectively characterise these types of ore bodies and assess their processing performance (ie recovery, grade). To enable this, there is a need for the following: (i) characterisation of geological, mineralogical and metallurgical variability in the ore body; (ii) effective selection of drill core with characteristics that represent the range of ores in the entire ore body. CITATION: Tungpalan, K, Manlapig, E, Keeney, L, Wightman, E and Edraki, M, 2018. A systematic approach of sample selection to predict processing performance of an ore body, in Proceedings Complex Orebodies Conference 2018, pp 67–70 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By M J. Davies, R S. Davies

Despite increased expenditure, the global discovery rate of world-class ore deposits has been in decline for over a decade (Schodde, 2017). Mineral exploration has traditionally followed an empirical approach, searching for evidence of mineralisation upon the surface of the planet, then drilling to define the extent of an ore body beneath the surface. As outcropping deposits in well-defined areas are depleted, there is a need for exploration to extend to less well-explored search spaces. One popular new frontier is exploration at greater depths beneath the Earth's surface. However, exploring for deep deposits with limited surficial evidence requires the implementation of predictive targeting methodologies (Hronsky, 2011; McCuaig & Hronsky, 2014). The Mineral Systems Concept (Hronsky & Groves, 2008; McCuaig et al., 2010) provides a framework for predictive exploration targeting. Ore deposit formation is recognised to be a focused mineralising event. These events represent self-organising critical systems and are underpinned by the interaction of complex, non-linear processes. Through the collection and analysis of datasets that map mineralising processes, it may be possible to predict the size and location of resultant ore bodies. CITATION: Davies, M J and Davies, R S, 2018. Beyond below-ground geological complexity: Developing adaptive expertise in exploration decision-making, in Proceedings Complex Orebodies Conference 2018, pp 95–98 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By M Ziemski

The provision and management of energy in both fuel and electricity forms is an increasingly important consideration for mines. Pressures from communities, governments and markets are increasing towards more transparent and improved energy management. Combined with the energy-water nexus, where water and energy are closely related in the operation of a mine, this emerging business climate means a more thorough and responsible approach is required for the acquisition and use of energy, as well as the release of emissions. Many of the complexities in potential new ore bodies are borne in remote locations, high altitudes, low grades, arid climates and deep deposits. Each of these challenges affects the successful provision of energy. In combination, such challenges can leave an operation seemingly unviable from an energy perspective, especially when approached from a traditional mining energy feasibility lens. This paper discusses some of the energy alternatives currently available and emerging in the mining industry. Both energy supply and demand options are considered, which can provide a very different energy footprint with the flexibility to address, and potentially overcome, major energy challenges for a mine. CITATION: Ziemski, M, 2018. Energy complexities in complex orebodies, in Proceedings Complex Orebodies Conference 2018, pp 106–111 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 21, 2018

By E. L. Forner, G. M. Miller, J. Scheepers, A. J. du Toit

"The sizing, designing, and costing of copper electrowinning circuits requires an in-depth understanding of the fundamental relationships between circuit parameters and the practical operation requirements. The aim of this investigation was to optimize total copper electrowinning project cost by mapping the operating limits of key mechanical equipment. The model was compiled by mapping various cellhouse layouts in terms of number of cathodes per cell, crane productivity, stripping machine productivity, and rectifier–transformer (rectiformer) sizing using data tables for sensitivity analysis. These parameters were then collated and evaluated on a cost by size basis. The model provides an optimum band of operation for cellhouse productivity and project capital cost for a typical range of production throughputs, from 10 kt/a to 200 kt/a cathode copper. The information may be used as a high-level selection guide to assist with identifying a costeffective copper electrowinning circuit design for a specific production rate. The data was validated and compared with existing copper electrowinning cellhouses around the world that typically install no more than 84 cathodes per cell. IntroductionThe sizing, designing, and costing of copper electrowinning (EW) circuits require an indepth understanding of the fundamental parameters as well as the practical requirements to optimize cellhouse productivity and capital cost. Although a significant amount of work has been done designing new copper electrowinning circuits, an in-depth evaluation of world operating data reveals that the number of cathodes per cell, which affects cellhouse layout and productivity, is not consistent for a specific production rate (Anderson et al., 2009; Robinson et al., 2003, 2013). Based on this premise, Kafumbila (2017) suggested that there are unanswered questions, such as ‘why are the numbers of cathodes per cell different for copper production rates of 20 kt/a and 40 kt/a?’In this paper, data tables are employed to map the operating limits and costs of key Cu EW equipment. An overall Cu EW project cost map is then compiled by collating optimum cellhouse layout (number of cathodes per cell), optimum crane productivity, optimum"

Nov 1, 2018

By F. K. Mulenga, M. Lusambo

"Geometallurgical models are a strategic tool used primarily in planning, diagnosis, and process optimisation. This paper discusses the development of a predictive model for flotation recovery at Kansanshi concentrator in Zambia as a function of key operational parameters. Daily data for milling and flotation from the circuit processing the copper sulphide ore was analysed. This data, recorded over a period of one year of production, was collected from diverse sensors measuring semi-autogenous milling and flotation parameters. Statistical analysis showed that copper head grade, acid-insoluble, and acid-soluble copper, SAG mill throughput, ball mill load, and tonnage of feed material to the SAG mill in the -125 +63 mm size fraction contributed to the prediction power of the proposed empirical model by as much as 90%. Finally, a proposal was made for the development of a simulation model under MODSIM®, a flexible tool for mineral processing applications. This was to test the limitations of the empirical model for future refinement. IntroductionKansanshi is the largest copper mine in Africa and the world’s eighth largest copper producer, with a total of 253 272 t of copper produced in 2016 (Newall, 2017). It is located approximately 10 km north of Solwezi, the capital and administrative headquarters of the North Western Province, Republic of Zambia. The ore deposit consists predominantly of chalcopyrite and malachite with variable amounts of chalcocite, bornite, chrysocolla, and azurite. Because of the varying proportions of sulphide and oxide copper minerals, the ore is classified into three distinct categories: sulphide, mixed, and oxide ores. As such, three separate processing circuits are used to mill the ore down to a standard targeted grind size of 80% passing 150 µm before froth flotation and leaching.A lot of research and development has been done to improve the performance of the sulphide ore circuit at Kansanshi. Despite the research efforts and subsequent operation, the sulphide ore circuit did not attain the target recovery and grade for 2016, primarily because of the complexity of the orebody.The constant drive to achieve the set production target of recovery and concentration grade after froth flotation motivated the development of a tool for the prediction of recovery. The anticipated benefit is not only to enable the plant to apply corrective actions when needed, but also to make a tool available for the quick assessment of the plant performance of the. For that purpose, data spanning June 2016 to May 2017 was analysed, cleaned up and curvefitted to an empirical model. In doing so, key parameters were determined and calibrated to represent the behaviour of the plant."

Nov 1, 2018

By D. A. Hayman, N. Rambuda, N. A. Sithole, C. Hockaday, J. D. Steenkamp

"Mogale Alloys operates two alternating current (AC) submerged arc furnaces (SAFs), and two direct current (DC) open bath furnaces. These furnaces are capable of producing two products, silicomanganese (SiMn) and ferrochrome (FeCr), with a total production capacity of 110 000 t/a. This paper focuses on the silicomanganese process specific to Mogale Alloys, with a two-furnace operation facility that produces 55 000 t of SiMn per annum.IntroductionMogale Alloys is situated in Krugersdorp in the West Rand District Municipality in South Africa’s Gauteng Province. The Krugersdorp facilities were initiated by Palmiet Chrome Corporation in February 1963 to produce charge chrome (Basson, Curr, and Gericke, 2007). Mogale Alloys bought the Palmiet Chrome facilities in 2005 from Samancor Chrome. The Afarak Group currently owns 90% of Mogale Alloys.SiMn is produced in two 20 MVA submerged arc furnaces (SAFs), which were originally built for chromite processing, and ferrochromium (FeCr) in two DC open bath furnaces rated at 40 MVA and 10 MVA. When this paper was compiled, the 10 MVA furnace was not operational due to the high cost of production, and one of the 20 MVA SAFs was recently converted to produce FeCr due to market constraints. Mogale Alloys has 290 permanent employees with four contracting companies on site. The paper presented here focuses on the production of SiMn at Mogale Alloys.The high-level process flow at Mogale Alloys is summarized in Figure 1, which details the raw material input and the products produced by the two 20 MVA furnaces. SiMn is produced by carbothermic reduction of manganese-bearing raw materials from four different sources, namely Wessels, Mamatwan, and UMK ores, and BHP sinter feed. The carbon sources are bituminous coal from Forzando and Msobo, local suppliers in Mpumalanga."

Nov 1, 2018

By J. P. T. Kapusta

"The copper smelting industry faces increasingly stringent environmental regulations and must continue driving innovation to reduce energy usage in its production chain. With the coming of age of ‘bottom-blowing’ copper technologies in China over the last decade, much renewed attention has been brought to tuyere bath smelting for clean copper-making. Since bottom-blowing sonic injection was originally developed and implemented in steelmaking in the 1970s and lead smelting in the 1990s, the time seems appropriate to revisit the sonic injection concepts and dispel some myths. After reviewing the trends in the copper industry and providing a brief historical context of research and development related to sonic injection, the author presents a comparison of the main submerged tuyere bath smelting technologies, namely the Noranda Reactor (NR), the Teniente Converter (TC), and the Chinese Bottom-Blowing Smelting Furnace (SKS/BBS) for copper, and the Queneau-Schuhmann-Lurgi Reactor (QSL) for lead. The core of this article, however, consists of a brief description of the fundamental theories for sonic injection (jetting regime) and ‘sonic flow mapping’ to illustrate the relationship between the minimum tuyere back-pressure required to achieve sonic flow and the tuyere internal diameter. The article also offers a comparison between side- and bottom-blowing in jetting regime before concluding with the author’s vision of the new trend in submerged tuyere bath smelting. IntroductionIn the last decade, developments in the copper smelting industry have been driven by two key concepts: (1) increasing cleaner smelting capacity to meet the world’s growing copper demand, as illustrated in Figure 1, and (2) increasing process off-gas capture to comply with more stringent environmental regulations and abide by a corporate social responsibility ethic of a clean work environment (for smelter employees) and clean air (for families living around smelters). The copper smelting industry has also faced some major challenges in the last few decades, including (1) low treatment and refining charges (TC/RC or processing fees) impacting custom smelters, (2) lower concentrate quality and grades with higher levels of impurities (e.g. As and Hg), (3) higher processing and transportation costs due to the rising cost of energy, (4) restrictions in process intensification (tonnage oxygen usage) due to furnace integrity limits, and (5) scarcity of educated and trained personnel due to fewer metallurgists graduating from pyrometallurgical school programmes combined with a high retirement rate of skilled workers."

Nov 1, 2018

By A Giblett, B Putland

This paper provides a simple guiding framework for grinding circuit optimisation, focussing on common themes in past optimisation success stories, the conditions for success and techniques that can be employed to identify and define opportunities. Many significant grinding circuit improvements have been reported for operating plants, based on recurring themes such as the optimisation of mill feed size, mill liner design, process control, critical size, grinding media and classification. The paper condenses these experiences into a set of simple questions for the operator to ask, and provides guidance towards identifying and achieving the optimisation goals.CITATION:Giblett, A and Putland, B, 2018. The basics of grinding circuit optimisation, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 129–140 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018