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By W. S. Steinberg

Keywords: Pyrometallurgy, furnace, open slag bath, Evraz, Highveld In 1963, the full-scale engineering study for the development of an Iron, Steel, and Vanadium plant was initiated. This was the birth of Evraz Highveld and its process flow as it is known today. Highveld started out as a steel works that produced steel and vanadium-bearing slag by using a titaniferous magnetite iron ore mined from its own mine site near Steelpoort. The process utilized co-current rotary kilns for pre-reduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to Open Slag Bath (OSB) operation, in order to enable the maximum production of iron and vanadium while improving the control over operational parameters. The conversion proved to be highly successful and, since 2005, three furnaces have been converted to OSB operation. The fourth furnace will be converted in the first half of 2011. The conversion to OSB furnaces not only yields higher vanadium recovery to the metal at the iron plant, but also improves the overall throughput of the steel plant. This is the result of a higher carbon content of the liquid iron from the OSB furnaces, eliminating the need for anthracite addition to the shaking ladle process. This reduces the blowing time by approximately 60%. The conversion of the furnaces to OSB configuration is seen as an enabling technology change and a prerequisite to the implementation of other plant improvements that are envisaged. The long-term vision of EHSV is to convert five furnaces to OSB mode, and permanently decommission the two remaining submerged-arc furnaces. This will allow EHSV to maintain current steel and vanadium production but at a significantly improved overall efficiency.

Jan 1, 2011

By G. L. Gomes-Sebastiao, W. W. de Graaf

"Gomes Sand is a quarry operation that produces sand and aggregate for the construction industry. The quarry is experiencing inconsistencies in the fragmentation and poor pit conditions as a result of poor drilling and blasting practices. This results in excessive downtime in the load and haul and crushing processes.A benchmarking exercise of the blasting practices was conducted to evaluate the effect of the inconsistency on the mining cycle. After changes in the blasting practices the downtime was reduced, which improved the crushing plant utilization by 4.9%. The improved blasting practices and more consistent fragmentation decreased the average number of loads lost each month due to jaw crusher blockages from 9.2% to 3.9% of plant throughput. The change in blasting practices also improved pit conditions. IntroductionGomes Sand is a quarry operation that has been in operation since 2009, producing sand and stone for the construction industry. The quarry was experiencing unacceptable blasting results. The repercussions included uneven pit floors, large amounts of oversize rock (>500 mm), and inconsistent fragmentation.The blast results affected the load and haul operations as well as the efficiency of the crusher. This resulted in downtime in the daily operations, and consequent production and revenue losses.The crusher product should have a top size of 50 mm. A blast fragmentation of <50 mm would improve the downstream operations and the crusher throughput.An investigation into the blasting practices was carried out to assess whether the downstream delays can be eliminated by improving the blast results. The exercise included:* Assessing if the designed blast layout is adhered to on the bench* Observing the quality and control of drilling* Observing the charging procedure of the blast-holes* Benchmarking the fragmentation consistency of the blasted rock using current blast design and practices* Analysing the throughput of the crushing plant* Investigating the power consumption of the crushing plant and determine if a change in blasting practices will affect this* Evaluating the hours spent by the hydraulic hammer on secondary breaking."

Jan 1, 2017

By S. G. Gendler

One of the ways of trauma and occupational diseases level reduction is noted to be the improvement of the labour protection measures planning. As an indicator for prospective trends determination in the labour protection planning improvement sphere economic risk has been proposed to be used. The trauma and occupational diseases analysis based on the correlative and regressive methods has been carried out for the “Vorgashorskaya” mine of Pechora coal basin. Trauma and occupational diseases occurrences frequency and economic losses value have been estimated. Trauma and occupational diseases economic risk distribution analysis has been presented in respect to the different subdivisions and occupational groups of “Vorgashorskaya” mine.

Jan 1, 2003

By J. Petersen, T. Moyo, J. Dinga

The leaching of chalcopyrite in ferric sulfate media is notorious for its slow and inhibited kinetics. Different methods have been proposed to improve the kinetics, including the use of organic compounds as additives to the leaching media. In this study, the enhancing effect of methanol, ethanol, 1-propanol, and 2-propanol on the leaching of chalcopyrite in aerated acid ferric sulfate solutions using different reactor systems was investigated. The results revealed a clear improvement of copper dissolution by methanol and 1-propanol relative to tests with no additives under similar conditions. Operating a continuous-flow mini-column reactor yields surprisingly good results, potentially related to the maintaining of a consistent leaching micro-environment on the mineral surface. Scanning electron microscopy studies showed that the alcohols result in the removal of surface deposits formed during the anodic dissolution, potentially thus facilitating improved cathodic reduction of the ferric ion to drive the anodic dissolution.

Jan 1, 2023

By A. McKenzie

During the late 1990s Anglo American PLC was evaluating the Gamsberg zinc deposit in the Northern Cape Province. As the primary South African metallurgical technology provider, Mintek became involved in the evaluation of a pyrometallurgical process for the recovery of zinc from the Gamsberg deposit. eloping DC arc furnace technology for the metallurgical industry. This includes the patented Enviroplas® process for the treatment of zinc bearing waste materials. As a consequence Mintek has developed extensive expertise in the pyrometallurgical processing of zinc bearing materials. However, Mintek?s technologies stopped with the production of Prime Western Grade (PWG) zinc. Early on in the evaluation of the Gamsberg project, it became evident that the refining of PWG zinc would play an important part in the economic viability of the project. At the time the only pyrometallurgical technology available for the refining of PWG zinc to Special High Grade (SHG) zinc was the New Jersey process. This process represents 50-year-old technology and has not undergone significant refinement since the technology was developed. In order to provide a complete pyrometallurgical flow sheet for possible implementation at Gamsberg, Mintek assessed the New Jersey process with a view to either improving the technology or developing a new technology appropriate to the 21 century. In 1998 Mintek convened a consortium consisting of Mintek, the University of Cape Town, Eskom Enterprises, Bateman Metals and Anglo American PLC. The consortium successfully applied to the Innovation Fund for funding to develop a new process for the pyrometallurgical refining of PWG zinc to SHG zinc. The main aims of the project were to develop a new technology for pyrometallurgical zinc refining that conformed to the following: ?Decrease the production cost of SHG zinc metal to stimulate the development of the Gamsberg deposit. ?Be compatible with the current Enviroplas® process, preferably as an add-on to that process. ?Should use electrical energy to benefit from local price tariffs. The project commenced at the beginning of 2000 and consisted of three phases: ?an initial technology search and assessment of the fundamental aspects of zinc distillation. ?the design of a pilot plant for zinc refining. ?the manufacture, commissioning and operation of the pilot plant. A new technology based on a DC arc boiler feeding a packed distillation column was developed and during 2003 the project culminated in the successful operation of a 200 kg/h pilot plant. Ultimately, all of the aims of the project were met and the main outcome is that an advanced process for the pyrometallurgical refining of zinc (the Zincref process) has been developed. The main innovation of the technology was the switch from an energy transfer limited process to a mass transfer limited process (for which a patent has been registered).

Jan 1, 2004

By M. A. Hermanus

This paper examines the occupational health and safety performance (OHS) of the South African mining sector against the backdrop of changes in the composition of the sector, international trends in OHS performance, and the agreement on OHS milestones and targets by mining stakeholders at the Mine Health and Safety Summit of 2003. Although OHS performance has improved, progress is slow and there is need for significant rather than incremental change if the targets are to be realized. Since 2003, fatalities and injuries are 20?25% short of annual milestones and not all commodities show consistent improvement. Statistics on occupational health impacts are unavailable, but noise and respirable dust levels are known to be high in mines, with much work lying ahead to address exposures at source. Trends in regulating and addressing OHS hazards are discussed with reference to the notion of ?systems-thinking? and the targets. Efforts to improve OHS and to respond to changes in the sector are constrained by a lack of training and consistency in risk management, guidance for junior, small and artisanal miners, and holistic approaches to risk. For example, treating risk holistically would involve taking proper account of contractors and women in the workplace, and attending to human factors and ergonomics.

Jan 1, 2007

By K. H. Berget, V. Andersen, H. Tveit, R. Jensen

This paper presents some of the work carried out in order to improve the tapping process in silicon production, with special focus on the environmental and the safety standards. Some of the modelling work that has been done to improve the understanding of the process is described, together with the resulting implementation to improve tapping standards.

Jan 1, 2014

By R. B. Khumalo, M. S. Nyarela, R. C. Nemathithi

Palabora Mining Company is one of the largest low-grade copper mines globally. The mine uses block caving for the extraction of the orebody. This paper enumerates the drawpoint loading strategies for the overall head grade improvements, particularly for a block that is nearing depletion. A comprehensive literature review of various considerations relating to improving productivity in block caving is presented to contextualize the draw control in caving. From this study, an optimized draw control strategy is presented, which focuses on three parameters that include grade distribution, loading compliance, and tonnage splits per sector. An empirical method based on the relational study between various parameters is used to outline the key criteria to be used in the optimization of drawpoint loading in block caving.

Nov 30, 2022

By B. T. McKenna, H. Nirschl, P. Morsch, B. Fränkle

Generally, filter media used in filter presses have a limited operational life. Besides mechanical damage, there is a growing deposition of fine particles with increasing filtration cycles, the so-called blinding, inside the filter cloth. The resulting decreasing pore diameters not only affect the efficiency of the filtration process itself by increasing the filter medium resistance, but also make it more difficult to regenerate the filter press between the individual cycles, e.g. leading to an insufficient cake discharge. Since tailings filtration requires handling of large process flows containing a significant fraction of particles in the lower micrometer range, an investigation into media rejuvenation is of interest. Keywords: Tailings filtration, filter fabric resistance, filter media regeneration, filter cleaning, intraweave contamination

Jan 1, 2020

By T. Gibson

It is generally accepted that South African coal mines have gone through the mechanization of most of its underground mines, and while there certainly were a lot of productivity improvements, the lack of visibility on these machines operating underground still leave vast areas for improvement. The average actual cutting time still remains very low, in the 30 per cent area, which leaves significant improvement possible. Currently all analysis is carried out using hand-written reports. Unfortunately this is subjective and often inaccurate because of human interpretation. In addition in order to avoid costly component failure, a monitoring system is required to warn of eminent failures and condition monitoring. The challenge faced was to supply and install a system that was ‘Open’ and could be retrofitted to existing machines in operation because of the current standard of communication links to the underground sections. In addition it was intended to use, existing ‘off the shelf’ software and hardware and adapting this for the harsh underground mining conditions wherever possible in order to reduce costs. As development occurred, as with all technology, doors opened to other opportunities such as, remote access data logging and Internet based reporting. We focused on the Voest Alpine Bergtechnik (VA) range of continuous miners, as need arose to achieve the desired cost improvements because of the strategy of service contracts the subsidiary company, Voest Alpine Mining & Tunnelling (VAMT) offer the mining industry in South Africa. This paper describes a data logging system that has been installed on various continuous miners that provides data in real time, on line, and that could be expanded to any electrically supplied underground mobile or stationary mining machine.

Sep 1, 2001

By W van Drunick, S Naik

To date, Anglo Research has carried out several projects, based on the techniques developed in the AMIRA P9 (AMIRA International Limited), to develop comminution and flotation models for several Anglo Base Metals and, to a lesser degree, Anglo Platinum flotation plants. Plant optimization is thus achieved through steady-state sampling, model-fitting and simulation using the JK SimMet and JK SimFloat software packages. The surveys can vary depending on the needs of the plant/client. The survey can therefore include as little as a single piece of equipment, an entire milling/flotation circuit, or a complete circuit from primary comminution to final flotation concentrate (i.e. the ?integrated survey?). The presence of the AR team on-site usually precipitates in face-value observations that can lead to initial improvements. This stems from the knowledge-sharing on best practice that exists in parallel with the surveys. Numerous (reasonable) changes can then be simulated, thus indicating the optimization step most likely to result in the best efficiency improvements. The simulations can include changes in the flowsheet, ore characteristics, mill loads, grinding media size, change in grind, flotation residence time, air hold-up and several more. Plant surveys can result in process changes that provide the plant with either: higher plant tonnage, improved plant grind, additional flotation recovery and/or improved product grade. The additional benefit of performing an integrated plant survey is that the effects of an optimization change in the comminution circuit can be simulated using the flotation model. This paper describes a number of case studies where individual and integrated plant surveys were conducted by AR for Anglo Base Metals.

Jan 1, 2007

By C. P. S. Barnard, D. G. Krige

Objective justification on economic grounds for expenditure aimed at improving the quality of the underground working environment requires a suitable measure of any improvement in productivity that would result under routine working conditions. For this purpose, a composite production criterion is suggested, as well as its correlation under actual operating conditions with various factors directly affecting productivity and the environment. Of the environmental factors, wet-bulb temperature appears to be the major factor affecting productivity. The production data given indicate that a decrease in the wet-bulb temperature of 1OC can be expected to result, on average, in some 3 to 4 per cent increase in productivity; in the higher temperature ranges, this percentage could be much higher.

Jan 1, 1981

By J. O. Claassen

"A study conducted at 22 operating mines in the southern African region indicated that each mine employs about five management and improvement methods with roots in the manufacturing industry. All respondents reported the implementation of cost-saving initiatives, whereas 80% of the mines are affected by restructuring. TQM, Six Sigma, BPM, and TOC were found to be the most prevalent manufacturing management and improvement methods used. A mechanistic vs systemic evaluation of the suitability of these methods to bring about positive change in the industry suggested that complex, ever-changing mining systems are better served by a systemic flow-based approach, which is embedded in methods such as TOC, JIT, TPS, and Lean Production. These methods, however, lack industry presence, possibly because they do not effectively deal with the unique challenges associated with the mining environment. It is argued that successful mining business management and improvement depends on management’s ability to deal effectively with mining industry-specific requirements, the integration of the geologymining- plant system, and the implementation of systemic flow-based principles in all aspects of mining. IntroductionThe study aims to explore the use of manufacturing management and improvement methodologies in the southern African mining industry. Considering the unique challenges associated with mining operations, attention is given to the applicability of the most commonly used manufacturing methodologies in the tactical, operational, and strategic environments. The article endeavours to stimulate more research and debate in an unexplored field of study."

Jan 1, 2016

By deur J. V. D. M. Grimes

Sishen Iron Ore Mine is one of the largest open-pit mines in the world, and loading and hauling constitutes one of the major cost items on the mine. Because high productivity in loading and hauling results in large financial benefits, the following projects to improve productivity were implemented at Sishen: - a computerized truck-allocation system, - an overhead power-supply system for the dieselelectric driven rear-dump trucks, - an in-pit crusher and a belt-conveyor system. This paper concentrates on the truck-allocation system, with special reference to the improved productivity of loading and hauling resulting from the implementation of this system.

Jan 1, 1984

By Anthony K. Anyimadu, Chris M. Rule

Froth flotation is the primary mineral processing separation step employed in the beneficiation of PGM ore bodies. Anglo Platinum operates a significant portion of the total installed flotation capacity in the PGM industry, which is installed at 20 operating plants across the Bushveld. PGM flotation has undergone a considerable evolution in both the capacity of flotation cells employed as well as in the circuit design configuration over the past thirty years. Certain of Anglo Platinum?s flotation circuits have been in operation for a relatively long period of time, (in some operations installed equipment dates from the 1960?s) and this allows comparative operating performance between various equipment types and circuits to be evaluated. This paper summarizes some aspects of this experience. Research trends in flotation are continuously monitored to incorporate appropriate findings into existing and future circuit designs. Continuous evaluation and monitoring of flotation performance is undertaken to identify opportunities for increasing flotation efficiencies. Mineralogical and fractional analyses of plant composites and survey samples are analysed to interrogate speciation and association data. This analysis has enabled a better understanding of priorities and opportunities for improved metallurgical performance. These opportunities are divided into three improvement areas: stability, liberation, and fines flotation. The paper discusses these, as well as the circuit design improvements required to take full advantage of the opportunities identified.

Jan 1, 2007

By Timo Niitti, Sami Grönstrand

n today&apos;s marketplace with high metals prices, many operations are faced with the challenge of improving recovery and at the same time maximizing availability. New operations under feasibility studies have the same requirements, with the additional need for ever higher capacities. Economies of scale have proved a vital competitive advantage in the game of ore dressing. Flotation is the most widely used method for extracting valuable minerals from ore - despite its mature age of 100 years. Customer demand has driven the development to increasing cell sizes, and in most cases, this has brought the advantages of both lower capital expenditure and lower operational and maintenance cost. The challenge of scale up, however, is to meet the metallurgical performance requirements in the larger volumes. The paper outlines recent trends and developments in flotation technology, and presents new solutions designed to address the needs for increased capacities as well as improved performance. Whether the goal is to improve existing operations or to scale up new equipment, computer aided tools are playing a key role in shortening the development cycle and reducing costly trial-and-error tests in full scale. Using the new tools and validation thereof will be outlined, as well as the development principles behind the new solutions. Plant results and experiences with the new developments are presented and discussed in several cases around the world.

Jan 1, 2007

By S. K. Mahata, P. G. Suresh Kumar, B. B. Singh

Improvement of post tap hole practices is achievable by mechanized handling of melt during the production of Ferro Chrome, resulting in higher recovery of chromium. The paper deals with modern practices adopted in the production of ferro-chrome since past two decades. The methods and practices deal with various areas : a) Improved method of operating the tap hole by selection of right quality of refractory to maintain the life of tap hole. b) Collection of melt in different types of receptacles like refractory brick lined mild steel ladles, cast steel ladles, cast iron pans being chosen for cost effective and efficient handling. c) Separation of slag and metal, casting of metal, crushing, sizing and stock piling etc. d) Slag disposal and recovery of entrapped metal. The drive behind the above development is continuous improvement, which results in higher chromium recovery and reduces loss of metal in slag by completely mechanized method so as to be at the same level with producers of ferro-chrome in other advanced countries , in the emerging global economy.

Jan 1, 2007

By S. M. Spottiswoode, A. J. Jager, N. C. Gay, J. A. Ryder

The South African mining industry is at present planning to extract orebodies at depths of up to 4 km. To do this cost effectively and, at the same time, ensure safe working conditions for mining, the personnel will require both the development of new strategies and the implementation of current rock-engineering technological developments on a wide scale. This paper covers most of the technological developments likely to be required for mining at very high stresses, but it is clear that improved regional support systems will need to be developed to ensure defective stability of the rockmass during mining operations. Similarly, it is clear that improved strategies for mining in large-scale geologically disturbed areas, where slip on faults or dykes can result in wide-spread rockburst damage, will have to be addressed

Jan 1, 1995

By B. McFadzean, M. Becker, S Geldenhuys, A. Molifie

Mineral hydration is known to result in low flotation recoveries and grades within primary platinum group element ores worldwide. This is because the phyllosilicate minerals derived from hydration reactions of silicate minerals (i) form electrostatic coatings on valuable minerals that in turn hinder collector adsorption, (ii) alter the viscosity of the slurry leading to poor gas dispersion and (iii) decrease the concentrate grade due to naturally-floating gangue. Sodium silicate was investigated because its dispersant, rheology modifying, and depressant properties could prove promising in combating the problems associated with these ore types. Quantitative evaluation by scanning electron microscopy analysis revealed large quantities of serpentine and talc present within the ore sample used in this study, which led to a poor flotation response as indicated by batch flotation tests. Using sodium silicate improved the recoveries and grades at high dosages (>1000 g/t). The zeta potential experiments indicate that improved recoveries are, in part, as a result of the reversal of serpentine surface charge, creating electrostatic repulsion between serpentine and valuable minerals which prevents the coating of valuable minerals by serpentine slimes. Ore dilution and rheology tests indicated that decreased viscosity at high dosages also improved recoveries. Talc micro-flotation tests revealed that the depression of talc occurred at higher sodium silicate dosages, which improved concentrate grade. The processing of nearsurface altered ores is becoming an increasing problem worldwide and the use of sodium silicate proved valuable in mitigating the problems associated with the altered ore investigated in this study. Keywords: Alteration, phyllosilicate slimes, colloidal chemistry

Jan 1, 2020

By M. U. Ozbay

This paper presents an overview of the research that has been carried out to improve the understanding of the fracture processes occurring in rock under high levels of stress. The onset and growth of fractures are studied by means of laboratory model testing, and the results obtained are used in the calibration and validation of the numerical model DIGS, which is based on displacement discontinuity. The results obtained so far have shown that, while there are overall similarities between the experimental results and the numerical simulations, improvements to the experimental procedures and the DIGS are required for a detailed mechanistic understanding of shear-band orientations and extension fractures.

Jan 1, 1996