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By R. J. Forzatti

The production of sulphuric acid from sulphur generates heat. The majority of this heat is recovered as steam and is often used to generate electricity. Heat not recovered as steam is rejected to cooling water systems. The design of the turbine, condenser, and cooling water systems impacts the overall water, energy, and environmental footprint of the plant. This review considers a conceptual 2000 t/d sulphuric acid plant with several alternative cooling water systems. The review utilizes Hatch?s 4 Quadrant sustainable design tool to compare the alternatives on both an economic and a weighted sustainability scale.

Jan 1, 2014

By P. F. Ledwaba

South Africa?s Northern Cape Province houses a variety of gemstone minerals. Diamonds remain the primary gemstone in the province, but there are also tiger?s eye, sugilite, rose quartz, jasper, amethyst, amazonite, tourmaline, and topaz deposits. This paper gives an overview of the tiger?s eye (TE) mining sector in the Northern Cape, with the objective of assessing the potential of TE to contribute to job creation and poverty alleviation in the province. Mining of TE started in 1803, but gained momentum during the 1960s. Mining is conducted on a small-scale basis, and in most cases without any legal framework. The majority of the residents are not benefiting from TE. It has been reported that an estimated R700 000 to R800 000 worth of TE is leaving the country every week through illegal trading. The potential for TE mining to contribute to socioeconomic development is hindered by illegal operations, lack of technical skills and knowledge, exploitation by dealers, lack of market information, community rivalries, and absence of value addition. A multi-stakeholder approach is needed to formalize the sector and reap the benefits. Mintek is spearheading a TE project in the Prieska area of the Northern Cape, which aims to establish a gemmological centre where TE can be beneficiated into saleable and high-value products..

Jan 1, 2014

By J. Muller

Keywords: Pyrometallurgy, blast furnace, slag viscosity, slag liquidus temperature, phase equilibria The viscosity of molten slag in blast furnace operations is an important process variable, influencing the rate and location of reactions inside the furnace, as well as the ease with which the final slag could be removed from the furnace. To optimize these processes, it is necessary to estimate the slag viscosity and liquidus temperatures as accurately as possible, and know the target values. Models to predict viscosities and liquidus temperatures, incorporating phase equilibrium calculations, have been developed and validated with measured data. Various diagrams have been developed to illustrate how the properties vary with composition and temperature, including pseudo-ternary diagrams of SiO2-MgO-CaO-Al2O3 for viscosity and liquidus temperature. Models were also applied and methodologies developed to analyse historical blast furnace operations and determine target values.

Jan 1, 2011

By H. Immink

Keywords: Kyoto Protocol, carbon credits, global warming, energy, auditing Climate change is nowadays being taken increasingly seriously, and the link between global warming and the carbon dioxide released in the generation of energy is coming under increasing scrutiny. The Kyoto Protocol was signed in 1997, after five years of negotiation. So far, about 84 countries have ratified this agreement, under which terms developed countries have strict targets linked to their 1990 level of emissions. However, ?greenhouse gas? (such as carbon dioxide) emissions continue to rise alarmingly. According to the World Resources Institute, greenhouse gas emissions in the USA increased 13% from 1990-2002, while Australia recorded a 22% increase. In contrast, the European Union, a Kyoto signatory, has seen a small decline in its emissions during the same period. This is led by the UK and Germany, who reduced their emissions by 15% and 19% respectively. The concept of ?carbon credits? provides a funding mechanism for companies in the developed world to compensate for some of their CO2 emissions by paying companies (trading credits) elsewhere in the world to undertake projects to bring about reductions in emissions. In the southern African mining industry, it will be possible to get refunded for undertaking voluntary emission-reduction projects. Concern about the environment is creating business opportunities. A preliminary calculation has shown that various projects in South Africa (those in the pipeline, with quite a high likelihood of coming off) could earn a combined total of about R2.5-billion, under the initial phase of the Kyoto Protocol's carbon-credit scheme, which allows developed-country companies to trade credits with developing countries. A number of local companies are planning projects that could comply with the Clean Development Mechanism (CDM), in which they will implement techniques to achieve certified emission reductions (CERs) of greenhouse gases. In order to prevent abuse of such a system involving vast sums of money, vigorous audits need to be carried out. A company has to prove it has made real changes and is not simply conducting business as usual under a cloak of claimed environmental improvements. PricewaterhouseCoopers has applied to become one of only a few international agencies that will be accredited to conduct validation and verification of the credits, by auditing what is called the ?designated operational entity?. An independent validator needs to confirm that the project meets the strict requirements of the Kyoto Protocol. The company has to demonstrate that it?s not business as usual. So, if you refurbished every five years, the next refurbishment is not a good CDM project, unless you can demonstrate that you will do something beyond the maintenance - that is what can be registered. So, Kyoto intends to get additional projects going, and the money for that is actually quite good - prices of 14 euros per ton of carbon dioxide not emitted have been seen. The price depends on who takes the risk for non-delivery if a project doesn?t deliver the emission reductions on time. The highly energy-intensive South African mining industry is heavily dependent on coal. There should be many opportunities for the pyrometallurgical industry to come up with creative ideas to reduce emissions, and there is now an additional financial incentive to encourage this. Companies can actually get money in return for doing these types of projects, in addition to the contribution to corporate social responsibility.

Jan 1, 2006

By J. Rivoirard

Historically, linear and lognormal krigings were first created to estimate the in situ mineral resources of blocks. Nonlinear geostatistics and indicator kriging were subsequently developed to evaluate also the portion recovered when applying a cut-off on selective mining units (SMUs) within blocks. In practice these methods are generally based either on the Gaussian model with a transformation generalizing the lognormal case or on the indicators above cut-offs. Very often the indicator approach is simplified by kriging separately each indicator, and when starting from a continuous variable, a practical advantage of the discretization into classes lies in the easy treatment of a zero effect and of the high values. However, a number of so-called isofactorial models have also been developed for a discrete or continuous variable, where the full cokriging of indicators (i.e. disjunctive kriging) simplifies to the separate kriging of factors. Moreover, these models are equipped with a change of support, allowing a consistent estimation of recoverable resources on SMUs. Min-Max Autocorrelation Factors (MAF) analysis of the indicators offers a new approach for indicator modelling. In particular the first factor, the one with the highest spatial continuity, can help in choosing the type of model. For example a monotonic experimental first factor can be used directly as the basis of a discrete diffusion model, unless a continuous diffusion model such as the Gaussian model can be used on the original variable. This approach is illustrated on a uranium deposit mined selectively: estimates of recoverable resources by discrete disjunctive kriging and uniform conditioning in a Gaussian model are compared locally to short-term estimates based on two areas densely drilled.

Jan 1, 2014

By M Lipalile, A B. Tunono, A W. Naismith

Konkola No 3 shaft experienced severe mining induced stress and time related deterioration in ground conditions in an area where an over-cut and bench (OCB) mining method was used to extract a shallow dipping wide orebody. This caused an unacceptable risk for safe mining operations to sustain the required levels of production. After a review of the conditions it was decided to change the mining method to CASCADE to recover ore in the affected area and modify the OCB method and use a modified over-cut and bench method (MOCB) for new mining sections. This paper describes the geotechnical criteria included to derive the mining standards for the MOCB. The geotechnical risks are identified and taken into account to develop stope design parameters, stoping sequences and support requirements. A monitoring programme to assess conditions as mining progresses is also discussed.

Jan 1, 2005

Keywords: Pyrometallurgy, Wits University, research Wits Metallurgy celebrated its centenary in 2004. The department has been at the forefront of education and research and has contributed greatly to the metals and minerals industry, both in South Africa and abroad, in terms of human resources and knowledge generation. A significant number of industry and academic leaders worldwide are Wits Metallurgy graduates. Since its early beginnings, pyrometallurgy has always been part of the curricula and research offered by the department. Pyrometallurgical activities started to expand tremendously from the middle of the 1960s, especially by the formation - together with Mintek - of the Pyrometallurgy Research Group, which continues its internationally recognised research activities today. The research efforts have been concentrated on problems associated particularly with ferroalloy, steel, stainless steel production, and PGM/Cu-Ni sulphide smelting. In recent years, research has been further expanded to physical modelling of pyrometallurgical reactors. Almost all of the specific research projects were handled from a fundamental point of view, and hence a large number of MSc(Eng) and PhD degrees were achieved by candidates under the supervision of the Pyrometallurgy Research Leaders. Moreover, a significant portion of the research results were published in internationally recognized journals and conference proceedings. Among these, Infacon and the Molten Slags, Fluxes and Salts Conference series are worth mentioning. The studies from a fundamental point of view include thermodynamics, phase equilibria, transport phenomena, kinetics, and process dynamic aspects of high temperature processes and systems, both in the solid and liquid states.

Jan 1, 2006

By H. W. J. P. Neomagus, R. K. K. Mbaya, J. R. Bunt, N. T. Leokaoke, N. W. Makgobelele

Silicon Smelters consumes more than 80000 t/a of wood-derived charcoal as carbonaceous reductant in the production of silicon metal. More than 10% of this material is discarded as fines (<6 mm) generated due to abrasion during processing. Charcoal fine residues (<650 μm) and polyvinyl alcohol (PVA) binder were used in this study to produce mechanically strong charcoal briquettes for metallurgical application as carbonaceous reductant. The PVA binder was added in mass percentages of 1, 3, and 5 wt% to the charcoal fines. The compressive strength, abrasion resistance index (ARI), drop shatter resistance (SRI), and water resistance index (WRI) were measured as functions of curing for up to 7 days under atmospheric conditions, and the results compared with metallurgical grade coarse charcoal. The ash content of the produced briquettes was found to be high (6.6–8.0%) compared with the coarse charcoal (1–3%). The 3 and 5 wt% PVA-bound briquettes were found to be the strongest, with compressive strengths of 40 and 115 kg/cm2 respectively, with WRI values of 75 and 73% respectively. The produced briquettes were found to have lower ARI and SRI values compared to the coarse charcoal. Future work should include beneficiation of the fine charcoal discards prior to briquetting, and an increase in binder addition to above 6 wt% to improve the ARI and SRIn.

May 1, 2021

By A. Whillier

The decisive action taken by mine managements in recent years has been the main factor in bringing about the present downward trend in mine fires. A better understanding of the fundamental factors that govern the ignition and spread of fires. obtained as a result of investigations into mine fires, has provided useful guidance to production personnel. Similar investigations into fire-fighting techniques have assisted the Rescue Training Service and mines to institute more effective fire-fighting techniques. Some of the more important findings of recent investigations in these areas are outlined.

Jan 1, 1981

By P. Rice, A. Photolo, A. C. Barnard

Introduction -Sampling Tool Project (STP) -History -Results to date -Costs -Questions

Jan 1, 2005

By P. Mokwena

Paper written on project work carried out in partial fulfilment of BSc (Hons) in Chemical Engineering Diamond synthesis has attracted a great deal of interest because of its exceptional properties and various applications. In this study, the chemical catalytic vapour deposition (CCVD) method was used to synthesize diamond films using acetylene as carbon source and hydrogen as carrier gas at a temperature of 1000°C, and their thermodynamic stability was studied. Photographic analysis revealed that these products are diamond films, Ramman spectroscopy confirmed that they are graphitic while confocal laser scanning microscopic image analyses proved that these diamonds films have structural defects due to iron impurity from the catalyst precursor. The quantity of diamonds films produced is also proportional to the acetylene to hydrogen ratio but these films are larger in size at lower acetylene to hydrogen ratio. Thermogravimetric analyses showed that transformation of these materials begins at 25°C but could not be used to determine if a temperature range below 25°C exists. The stability of these CCVD-synthesized diamonds also increases below 25°C when stored at different temperatures.

Jan 1, 2007

At Namdeb, submerged beaches are earmarked for sampling and future mining and various sampling configurations are tested for optimality through the use of spatial simulations. For the creation of these virtual orebodies, basic statistics and variograms are needed, but in this specific instance no data exists from which the necessary parameters can be determined. The best that can be done is to use proxy data from onshore beaches, with adaptations where needed. The reworking of raised beaches during periods of rising and falling sea levels in some cases destroyed the internal beach structures, and it is very difficult to determine the variograms. A method is proposed whereby simulated annealing is used to adjust the sample locations to align the data pertaining to beach crests or cliff lines, thus improving the variogram structure along the shoreline in the direction of the highest geological continuity.

Jan 1, 2014

By Martin Banda, Gift C. Chisakuta, Moses Chabinga

KCM made a major modification to the Nchanga Tailings Leach Plant (TLP) changing the circuit from feeding post leach thickeners in parallel with leach discharge for solid ?liquid separation to a Counter Current Decantation (CCD) configuration utilising most of the existing equipment. The new circuit is aimed at improving copper recovery from approximately 70% to 79% through enhanced wash efficiency. The re-introduction of CCD circuit at elevated throughput of 46 000-tpd design was made possible due to the EIMCO E-Duc technology design which is an auto-dilution system that enhances solids settling rate. Commissioning (manual operation) which accommodated on-going operational requirements was phased and completed in January 2004. The circuit stabilised in subsequent months and in March alone an all time record copper recovery of 81.8% was achieved which contributed an extra 779 tonnes copper above the plant?s projected production plans. 100% of the project cost was paid back by end of April 2004 This paper discusses the work involved and the challenges faced during the re-commission

Jan 1, 2005

By Gerard de Vries

pipeline industry and are still growing in size. Liquid epoxy and polyurethanes are an excellent choice for whatever the aggressiveness of the substance transported and whatever the harmful outside influences, maximum protection is required. They can be used as coatings on all kind of pipelines varying from the mainline coating to the field joint coating. Compared with traditional systems like dual layer FBE and 3-layer polyolefin there are some benefits to be considered like easiness of repairs, amount of coats, application temperature and film thickness. The interior coating renders the pipe surface so much smoother that considerable savings can be realized in pump stations. Apart from the interior of the pipeline, the industry is faced with new challenges like higher operating temperatures of lines and an emphasis on product benefits in order to save money. Key words: liquid epoxy, liquid polyurethane, phenolic epoxy, pipeline, field joint coating, internal coating, corrosion control

Jan 1, 2006

By E. H. Myrhaug, K. Aasly, T. Malvik

Quartz is one of the main raw materials for the carbothermic production of ferrosilicon and silicon metal. The ideal process is written: SiO2 + 2C = Si + 2CO The real process is much more complicated, depending on the quality of the raw materials. Several research projects have been carried out on quartz for the (Fe)Si process during the last 50-60 years. One of the important properties that have been discussed in this review is the volume expansion that takes place between 850 °C to 1000 ºC and explosive disintegration for some quartz types. No final and definite conclusions have been made but several reasons have been mentioned: The influence of the phase transformation to tridymite, which takes place within the same temperature interval, has been discussed in several papers. Alkali impurities have been mentioned as a critical factor for this transformation to take place. Other researchers have mentioned mica impurities as a critical factor for the behavior of the quartz at these temperatures. Studies of fluid inclusions in quartz was reported in some papers focusing on the volume expansion of these during heating as a source of explosive disintegration, especially along planes of healed micro fractures that often contain vast numbers of such inclusions. Several methods for investigations of the important properties of quartz have been presented and these provide a good basis for the further research on quartz raw materials.

Jan 1, 2007

By S. J. Frank

Ferroalloy furnaces are well known to be extremely difficult to control from a metallurgical perspective. Mostly metallurgical control is still reactive in nature, causing a significant amount of reworking and product blending to achieve a proper product specification. Despite numerous efforts towards the model based control of primary smelting operations, actual metallurgical feed forward control seems to remain elusive. One of the key reasons in the failure to model these metallurgical reactors well, is that fundamentally orientated pyrometallurgists, statisticians, data miners and control engineers very often have diverging ideas how to model these systems. Furthermore, metallurgists have often come to rely on their ability to develop empirical regression models of furnace behaviour, as they have lost their faith in the ability of thermochemical and metallurgical engineering fundamentals to accurately predict the outcomes from furnaces. This paper shows how good thermochemical modelling can be combined with proper technological and systems analysis, as well as a proper inventory model, to predict the alloy and slag chemistry with good accuracy one tap into the future, at a time horizon of typically around 4 to 6 hours. For this modelling approach, a number of tools will be used, such as data reconciliation, thermodynamic modelling using Fact Sage®, inventory and heel estimation, neural networks and statistical data exploration. Furthermore, systems identification theory will be combined with the approaches given above to develop a truly dynamic predictive model. This paper seeks to demonstrate the need for a hybrid approach, which incorporates plant data and readily accessible thermodynamic data to develop a proper dynamic model.

Jan 1, 2004

By C. Birch

"A ‘geologically constrained’ orebody model has long been hailed as vital for a Mineral Resource statement that is compliant with the South African Code for Reporting of Exploration Results, Mineral Resources and Mineral Reserves (SAMREC Code). In this paper, the requirements for geological modelling as contained in the outline for the SAMREC Code are considered, and whether the new modelling software available on the market is a ‘black box’ or is better for modelling than traditional methods of wireframe creation.Implicit geological modelling is a technique that uses a radial basis function to establish and update geological models relatively quickly and efficiently from borehole data, outcrop data, manually interpreted vertical or horizontal sections, and structural data. Assays and any coded drill-hole data, such as lithology and alteration, can be interpolated.Leapfrog Geo software is an example of this new approach to geological modelling. A case study of a short training course in geological modelling for non-geologists at the University of Witwatersrand, as part of the Higher Certificate in Mineral Resource Management, is presented. The benefits of this type of geological modelling software are considered for this type of assignment as well as for mining industry applications.The use of geological models in mine planning is reviewed and a case study is presented comparing the variations in mine plan design and financial output of 13 final-year Mine Design projects from the University of the Witwatersrand School of Mining Engineering. These designs were all based on the same geological model created in the traditional way, and yet the resultant mine designs were significantly different, with very different resulting financial outlooks for the project. This raises questions as to how significant a very detailed model in the pre-feasibility and feasibility phases of projects really is, considering the huge costs involved in gathering the required data to build a SAMREC-compliant geological model."

Jan 1, 2014

By R Kroukamp

Horizontal belt filters are typically used for separation of relatively free filtering solids where good post treatment is required. He horizontal belt filter is a continuous filter with an endless cloth supported on a grooved carrier belt. The belt and cloth are driven around two rollers across a series of evacuated suction boxes. The feed suspension is introduced at one end of the filter and deliquored to produce a cake at the other end. The benefits of using horizontal belt filters are good cake washing, continuous and visible processing, fully automatic operation, flexibility, high capacity and relative high speeds of operation. If required, horizontal belt filters enable efficient counter-current washings to minimize the usage of wash liquid. The horizontal belt filter has applications in the following: [? Metal concentrates ? Mineral sands ? Tailings ? Coal ? Iron ore ? Alumina ? Chloride processing ? Nickel and Cobalt refining ? Platinum group metals ? Zinc processing ? Many other applications in the Mining and Metallurgy industries ] 2. Operating Principle of a Horizontal Vacuum Belt Filter 2.1 Cake Forming The slurry to be dewatered is evenly distributed onto the filtering surface. Gravity assists the cake formation and the feed can be introduced in multiple stages. 2.2 Cake Washing Once the cake is formed, wash liquor/water can be introduced onto the top of the cake via a wash launder or sprays. Multiple wash stages, co-current, counter-current or direct washing can be added by increasing the length of the filter.

Jan 1, 2007

By J. Alexis, G. Ye, E. Burström

Over the past twenty years the 3 MW DC arc furnace at MEFOS has been frequently used for development of new processes. These processes include recovery of valuable metals from slag, sludge and dust from steel and other metallurgical industry, treatment of ashes from power plant and incinerators, smelting reduction of minerals and zinc recovery from EAF dust. The process characteristics of the DC arc furnace operation in terms of: ? selective reduction, ? total reduction, ? process stability and flexibility, ? dust carry-over, ? thermodynamic conditions provided in the hot spot area, ? precision in composing slag products These are analysed and described in this paper based on technical results from selected test campaigns over the years and thermodynamic considerations. The electromagnetic properties of DC arcs beneath the electrode have been studied by CFD simulation. The calculated result enables us to understand some interesting technical phenomena observed. The heat balance has also been considered based on data obtained from test campaigns and heat balance calculation.

Jan 1, 2004

By J. Gummer, M. Williams, S. J. Hawksworth

A common problem encountered in British coal mines is bearing failure on conveyor system idler rollers, which on occasions has led to fires. The UK Mines Inspectorate initiated a study of such failures to assess the potential for ignition of explosive atmospheres. As part of this study HSL have developed a system to measure the temperatures generated within the bearings during controlled failure. Temperatures are measured using both infrared thermal imaging and contact thermometry. The work to date has shown that temperatures well in excess of the auto-ignition temperature of methane can occur.

Jan 1, 2003