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By S. E. Olsen, M. Tangstad, G. Tranell, K. Berg, S. Gaal

In this study, the reduction behaviours of MnO and SiO2containing slags by solid carbonaceous materials was investigated in both small and larger-scale laboratory experiments. Five types of carbonaceous material were investigated: 2 graphites, industrial coke, anthracite and eucalyptus charcoal. The effects of the reductant type/properties on the reduction kinetics, metal composition and metal yield, have been quantified. Results show that the reduction rate is highly dependant on the type of carbon used. It was found that the reductant type significantly influenced the SiO2reduction while it did not seem to have a large effect on the MnO reduction. This may be due to the different CO2and SiO reactivities of the materials.

Jan 1, 2004

By I. R. Firth, D. L. Taylor

Metal mining operations, in particular gold mining operations, use intensive ore control procedures in order to manage the extraction of ore zones from benches containing both ore and waste material. Typical grade control procedures rely on blast hole samples to indicate ore grade. Statistical techniques and geological controls are then used to create two-dimensional polygons, which indicate zones of material designated as ore. These ore-polygons are calculated using pre-blast material locations and are generally not corrected for rock movement caused by blasting. This lack of correction appears to exacerbate the material mischaracterization problem of sending ore to the waste dump and/or waste to the mill. One Nevada gold mining company has estimated that this could be a $10 million per year problem for their operations. Using a simplified vector field algorithm, a method of taking point movement data and interpolating post-blast positions for all nodes in a polygon has been developed. Currently working in 2-dimentions (X-Y), this algorithm utilizes the movement vectors calculated from pre-and post-blast positions of targets placed in a blast, to generate a spatial transformation function for any point on the bench. This transformation is then applied to the nodes of the ore-polygons to produce modified dig lines ore polygons reflecting distortion and movement resulting from the blast. The method as implemented uses common mine planning routines and is performed using the Surpac software suite. The method may be adapted to use any pre-and post-blast point movement data available, and most mine planning suites include the simple interpolation algorithms used. Keywords: Blast movement; Ore control; Open pit blasting; Grade control

Jan 1, 2003

Council for 2001/2002 President A.A.B. Douglas President-elect S.J. Ramokgopa Vice-presidents Senior F.M.G. Egerton Junior Prof. T.R. Stacey Immediate Past-president Dr L.A. Cramer Honorary Treasurer J.A. Cruise

Jan 1, 2002

By J. Janssens, B. Coletti, S. Smets, J. Plessers

The oxygen activity of the ladle slag determines the reactivity towards the steel during ladle treatment. Therefore, the in situ measurement of the oxygen activity of slags can be an important tool. The applicability of an electrochemical sensor is examined in this work. The sensor measures the electromotive force (EMF) that is established between a sample of the slag phase that is immersed in the liquid steel bath and a reference system (Cr/Cr2O3). Industrial and laboratory experiments demonstrated the capability of the sensor to detect the influence of the slag components on the measured oxygen potential. Comparison of the measured values with thermodynamically calculated values shows that the measured oxygen activity is systematically too low. This was attributed to a reaction of the steel with the slag sample. To investigate this, further lab tests were performed where the slag oxygen activity was measured after the slag had been equilibrated with the steel. The measured values were dependent on the oxygen activity (aO) of the steel. For industrial applications, it is concluded that the aO of the steel should be known and that this value is necessary for the interpretation of the measured values. Keywords: low carbon steels slags, slag oxygen activity, on-line sensing, thermodynamic evaluation.

Jan 1, 2004

By O. F. Ochonogor

Laser metal deposition (LMD) is an additive manufacturing technique whereby a stream of metal powder is consolidated by a focused laser beam on the surface of a substrate or engineering component. The interaction zone between the laser beam and powder particles is scanned superficially, generating tracks of deposited material. The tracks are overlapped in a deposition strategy in accordance with slices of a CAD model. Successive layers of material are built up to fabricate a near net shape part. In this work, the technique is used to fabricate metal matrix composites (MMCs) by using an elementally blended feedstock combining metal and ceramic powders in the melt pool, which melt and solidify to create the required morphology. Ti6Al4V + TiC MMCs were produced with 10, 20, and 30 vol.% reinforcing ceramic, and Zr + TiC MMCs were fabricated with 10, 20, and 30 vol.% TiC. The deposited thin walls were analysed using optical microscopy, scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS), and indentation testing. In both systems, the analysis revealed the presence of partially melted TiC particles embedded in the metal matrix along with fine dendrites of re-solidified ceramic. The dendritic structures in the Ti-based composites were confirmed as TiC, whereas in the Zr-based composite the Zr metal reacts with theTiC to form ZrC, leaving Ti in solid solution. Both the MMCs show an increase in microhardness with increasing ceramic (carbide)content, reaching a peak HV0.1 value of 500 in the Zr- based MMC and HV0.1 of 550 in the Ti based MMC.

Jan 1, 2012

By P. J. Bhonde, R. D. Angal, R. H. Tupkary

Manganese imparts numerous beneficial mechanical properties. Hence it finds extensive application in iron, steel and non-ferrous sector. Prevalently, it is incorporated in the form of master alloys i.e. 'ferromanganese'. In India, ferromanganese is mainly the inexpensive and paramount source of availability of manganese. Various conventional and non-conventional techniques of ferromanganese production have been adopted in past and present. However, these techniques have demerits viz. high refractory, energy consumption, losses of valuables in slag and fumes. Also geographical co-ordinates of the plant restricted the manufacturer to prefer an appropriate process. Accordingly, the industrially implemented methods had reliance on availability of infrastructure, energy, mineral resources, grade of raw material, outlay of labor, environmental compatibility of technique etc. In view of the liberalized economy and the gap scenario in the supply and demand of ferromanganese, the authors felt it indispensable to explicitly bridge up this vacuum by initially designing a simple energy conserving, eco-friendly, low capital investment technique for decarburization of ferromanganese. Measurement of the data involved studying the impact of rate governing parameters on the process kinetics. This laboratory scale investigation is expected to escalate the Mn/C quotient of high carbon ferromanganese. Key Words: ferromanganese, carbon, carbide, decarburization, rate, kinetic

Jan 1, 2007

By P. K. Hofmeyr

Base Metal (Cu, Ni, Mo, Zn, Co etc.) analysis traditionally has been very slow in conventional analytical laboratories which can lead to additional costs being incurred in waiting time of drill rigs or mining excessively off-reef. Recent developments in the automation of analytical laboratories now allow for very rapid turn-around times for base metal analytical data which can help reduce such costs as well as reduce the unit costs of the analyses themselves. 2.0 CONVENTIONAL ANALYTICAL LABORATORY PRACTICE Conventional analytical laboratories are necessarily are very manual. Sample preparation is slow and laborious, samples are moved from stage to stage manually and, typically, all samples are processed in batches so a sample which is the first to be, say, milled has to wait for the complete milling of the batch before it advances to the next stage eg. mixed with wax prior to pelletising for XRF analysis. Inevitably this results in long sample data turn-around times for laboratories handling large numbers of samples. Manual sample preparation can only be accelerated by increasing staff which increases costs and can lead to additional errors being introduced. Cleaning of sample preparation equipment, eg. crushers and mills, between samples is essential to avoid cross-contamination between samples and this is slow and labour-intensive. In manual sample preparation the correct sample numbers staying with the samples is totally dependent on the efficiency of laboratory operators. It is extremely difficult to detect when errors have occurred due to the switching of sample numbers during the sample preparation stages. Running duplicates and QC samples at best is only partially successful in detecting when sample number switching errors have occurred. Errors of this nature and cross-contamination problems due to incomplete cleaning of sample preparation equipment tend to occur when laboratories are working at pressure due to high sample numbers and when supervisors are not present during 24/7 laboratory operations which is often required on plant process control laboratories. These problems are common to all conventional analytical laboratories and their magnitude is dependent on the level of control and efficiency of QC systems practised by individual laboratories. The disadvantages of conventional manual analytical laboratories can be summarized as follows:- 1. Labour-intensive which is costly especially when multiple shifts have to be used during 24/7 operations.

Jan 1, 2005

By T. A. Muhlare

The use of electrolyte additives to smoothen cathode deposits during copper deposition is practised worldwide. These additives absorb on the cathode surface and take part in the electrochemical crystallization process. However, these additives also affect the quality of the cathodes when they are inadequately controlled. Electrolyte additives used by Palabora are glue, thiourea, Avitone and chloride. Their effects were determined on cathode quality, the size of the current density region that gives the desired compact morphology, and current efficiency. This was done in a small-scale cell. Small cells have different hydrodynamics from industrial-scale cells, which makes it difficult to simulate the operation of industrial cells in a laboratory. The approach used here was to use a rotating cylinder cathode to attain controlled hydrodynamics. The rotation speed was chosen to give a diffusion layer thickness that is similar to that of an industrial-scale cell. It was shown that even fairly small changes in the additive levels can significantly affect the cathode morphology, and the current density range over which this morphology can be obtained. Keywords Copper, electrorefining, glue, thiourea, avitone and chloride.

Jan 1, 2011

By D. Zhou, T. Hamano, Tsukihashi. F., W. -G. Seo

The thermodynamic properties for the CaO-CaF2and CaO-BaO systems were calculated by molecular dynamics (MD) simulation using Born-Mayer-Huggins type pair potential. The parameters of interatomic potential were obtained by fitting the thermodynamics properties of CaO, CaF2and BaO with the experimental data. The phase diagrams for the CaO-CaF2 and CaO-BaO systems were calculated by the thermodynamic properties obtained by MD simulation. The eutectic composition and temperature of the CaO-CaF2system calculated by MD simulation were about 28 mole per cent CaO and 1575K, respectively. The calculated eutectic point agrees very well with experimental data, which are about 22 mole per cent CaO and 1633K, respectively. Keywords: molecular dynamics simulation, thermodynamics, phase diagram, calcium oxide, calcium fluoride, barium oxide.

Jan 1, 2004

By Gaspard Devos

1. A NEW CONTEXT FOR METAL INDUSTRY Producers and owners of industrial extractive sites are living hard times due to Environmental pressure and liabilities. This is valid whatever the region in the world, it is just a question of time. On one hand, the normative environmental pressure is increasing through more severe regulations and controls on all pollution sources and production materials. [ ] Furthermore, more impurities are extracted and captured, more the volume of the related wastes is increasing. But disposal costs are increasing, disposal areas for wastes are restricted, markets for wastes are limited and technologies for waste treatment are, most of the time, not available. On the other hand, for most of the extractive industries, the costs required to get access to refine primary raw material are killing the profitability of the industry. Definitively, a technological and economical breakthrough is ongoing: extractive industries have to increase their feed from secondary material and to be involved more and more with the recycling business.

Jan 1, 2005

By Fadeela Saloojee, Frank K. Crundwell

"Pressure leaching is an option for copper recovery from chalcopyrite. Leaching takes place at high temperatures and pressures in the presence of an oxidising agent. This work shows how the performance of pressure leaching circuits may be improved by optimising the configuration of autoclaves and the heat-removal method. The objective was achieved by creating an autoclave model by combining mass balances, energy balances and population balances. A base-case circuit consisting of a single autoclave was chosen, and this base case was compared with options for increasing capacity by adding more autoclaves to the circuit. These capacity–increase options include circuits in which the additional autoclave is added in parallel, in series and in series with thickening between the two autoclaves. The copper extraction, productivity and cooling requirements for these options are compared. The series circuit with inter-stage thickening has the highest extraction and productivity, however, the cooling duty in the first autoclave is high. In addition to comparing circuit options, three options for heat removal were investigated: cooling coils, quench water and flash recycling. The flash-recycle option results in the highest copper extraction, and the quench-water option gives the lowest copper extraction. INTRODUCTION Background Copper sulfide ores and concentrates containing chalcopyrite are typically hard to leach under atmospheric conditions. Smelting of these ores may also be a challenge, due to the inability of smelting processes to handle low-grade ores, as well as impurities such as arsenic and antimony. Alternative hydrometallurgical routes to treating chalcopyrite are therefore required. One option is pressure leaching, which is the focus of this work. In the pressure leaching process, sulfide ores and concentrates are leached in autoclaves at temperatures of 200 to 220°C and a pressure of about 3000 kPa (Schlesinger et al., 2011). An oxidising agent, usually oxygen, is required to oxidise sulfide ions to sulfate ions. The oxidation of sulfur to sulfate is exothermic; consequently, a method of heat removal is necessary in order to maintain the temperature in the autoclave."

Jan 1, 2015

The risk associated with mining induced seismicity is one of the major threats to the safety and sustainability of deep underground mines. This paper describes techniques that allow site practitioners to efficiently control such risks in mines. The proposed approaches rely on ground support to strategically control seismic risk and re-entry time to tactically control this risk. The strategic approach is based on the detailed understanding of past seismicity to as certain the seismic hazard of individual sources throughout the mine. This approach also relies on assessing the potential damage that these sources can induce on nearby excavations using the excavation vulnerability potential (EVP) and rockburst damage potential (RDP) concepts proposed by Heal et al. (2006). It is then possible to investigate how to reduce the risk of experiencing damaging seismicity in mine drives by locally enhancing the ground support system. The tactical approach relies on a proposed methodology to estimate reliable re-entry times or exclusion periods based on the seismic decay following blasting. Some examples of how these techniques have been applied in Australian mines are given.

Jan 1, 2009

By A. D. Storrie

An underground wet shotcrete trial was completed last year to determine the effectiveness of wet shotcrete as an alternative support mechanism to dry shotcrete in the kimberlite environment. The wet shotcrete was manufactured at the underground batch plants, transported to site using an agiecar and transferred to the shotcrete pump. The wet shotcrete is pumped to the nozzle where compressed air at 7 bar and an accelerator, Meyco SA 160, is added and enables the shotcrete to be placed successfully onto the tunnel wall. No tunnel guard was previously placed on the sidewall and hangingwall. Geotechnical testing indicates that the Grace fibre performed extremely well with the energy absorption tests at 7 kg/m3and 8kg/m3where both achieved over the mine requirement of 750joules. The Grace fibre and wet shotcrete mix also achieved a compressive strength in excess of 55 MPa, well above the 45 MPa requirement for Premier Mine. The recommended wet shotcrete mix design is therefore based upon: [Material/ CriteriaQuantity/m3Units ?Lafarge 42.5 Duratech500kg ?Condensed silica fume40kg ?Rayton Sand1.558Ton ?Delvocrete stabilizer 103.6litres ?Glenium 27CH5.4litres ?Meyco TCC 7355litres ?Water230litres ?Meyco SA16025litres ?Fibre8kg ?Cement/Water Ratio2.35? ?Water/Cement Ratio0.43? ?Flow615 mm] If the wet shotcrete system is implemented there is a potential for Premier Mine to make major savings. In South Africa there are two suitable wet shotcrete machines available for the mining industry, the Spreymec, manufactured by Tamrock and the Fermel/Meyco wet shotcrete machine. The Spreymec is a fully imported machine. The Fermel component is manufactured in South Africa and the Meyco shotcrete components are imported and supported by MBT (Master Builder Technologists) in South Africa. The Fermel/Meyco machine is assembled in South Africa. Premier Mine has allocated some R2, 100,000 towards the implementation of the wet shotcrete system. If implementation is successful there should be an internal rate of return gain of 76% with regard to this project.

Jan 1, 2001

By M. van Schoor

Coal remains South Africa?s most abundant and cheapest source of energy, and there is an ever-increasing necessity for optimal and safe extraction of the remaining reserves. Increasing focus on cost-effective mining and zero harm to the environment and miners has resulted in a shift in attitude towards the application of geophysics in local coal mining and exploration. Furthermore, technological advances have contributed to geophysics being embraced more readily by the coal mining industry, compared to a decade or two ago. Predictably, the growing interest in geophysical technologies has also created a need for education and training in the basic principles and application of geophysical methods, as local coal mining companies generally do not have in-house geophysicists. Consequently, the Coaltech Research Organisation?s Geology and Geophysics working group forum compiled a textbook aimed at addressing this need: to produce a guide for applying geophysics to coal mining problems in South Africa. The target audience for such a book would be coal geologists, mine surveyors, mine planners, and other mining staff with limited or no geophysics background. This paper provides a very brief overview of the book by summarizing key sections and selected examples. In doing so, the value of geophysics to solving a range of coal mining and exploration problems is highlighted.

Jan 1, 2014

By S. Luyckx

This paper reports hardness and abrasive wear resistance test results from a wide range of WC-Co alloys, varying in cobalt content as well as WC grain size. The results show that the abrasive wear resistance increases with increasing hardness and that the rate of increase is higher for larger WC grain sizes. The increase in abrasive wear resistance was found to be parabolic up to a critical hardness value and exponential above that value. The transition from parabolic to exponential behaviour was found to occur at the same contiguity value for all grain sizes, which suggests that at that contiguity value the WC skeleton becomes continuous in all WC-Co alloys.

Jan 1, 2004

By Y. Nakata, K. Nagata

Plasma is partially ionized gas composed of ions, electrons and activated elements at high temperature. Some flying ash from incinerated municipal waste is melted to become glass by a transfer-type arc plasma furnace. As the glass is ionic silicate, when an electric current passes through anode to cathode, ions in molten slag electrochemically react with electron in plasma at the surface of molten slag. In case of molten Na2O-SiO2, sodium ions in the molten slag carry electric current and SiO2are reduced to evaporate as SiO gas by electron in plasma. The cases of Ag+in NaNO3-KNO3molten salt and Fe2+in FeO-SiO2slag were examined. The amount of cathodic reaction is larger than that of anodic reaction and not apparently according to the Faraday?s law on the electrochemical reactions.

Jan 1, 2004

By M. S. Raseroka

An experimental rig has been constructed to produce chloride stress corrosion cracks in Type 304L stainless steel tube samples. The samples are to be used to test possible in situ repair methods in future work. The factor which influences the time to failure most strongly is the sample temperature; the distribution of cracks within the sample is affected by local temperature variations and by the position of the water line. Low-frequency oscillations in stress, caused by the on-off temperature controller, did not appear to influence cracking in these tests.

Jan 1, 2009

By T. Celik, B. Genc, C. Musingwini

"This paper discusses a new methodology for defining and measuring mine planning software utilization in the South African gold mining sector within an evolving data-set framework. An initial data-set showing the mine planning software providers, their corresponding software solutions, as well as the software capabilities and information on the number of licences was collected and compiled in 2012 in an online database for software utilized in the South African mining industry. Details of the database development and implementation were published in the Journal of the Southern African Institute of Mining and Metallurgyin 2013. In 2014 the data-set was updated with additional and new information. Using the 2012 and 2014 timestamps, a methodology for estimating the software utilization was developed. In this methodology, the three variables of commodity, functionality, and time factor were used to define and measure the software utilization in order to ultimately inform decision-making strategies for optimal software utilization. Using six different functionalities, namely Geological Data Management, Geological Modelling and Resource Estimation, Design and Layout, Scheduling, Financial Valuation, and Optimization, utilization in the gold sector was measured. This paper presents the methodology employed for measuring the mine planning software utilization. The methodology is useful for stakeholders reviewing existing software combinations or intending to purchase new software in the near future and who want to estimate the comparative attractiveness of a certain software package. These stakeholders include mining companies, consulting companies, educational institutions, and software providers. The work presented in this paper is part of a PhD research study in the School of Mining Engineering at the University of the Witwatersrand."

Jan 1, 2015

By A. J. Geldenhuys

This paper will focus on two topics, namely (1) an innovative process for the neutralization and partial sulphate removal of acid streams produced during coal mining and processing and (2)optimization of this integrated neutralization process by adding small amounts of synthetic organic polymers. The integrated lime and limestone process has been developed to neutralize acid mine water and to remove sulphate (to less than1 200 mg/l), magnesium and metals. Limestone and lime treatment is the most cost-effective technology for neutralization and partial sulphate removal of acidic/sulphate-rich water to sulphate levels of less than 1 500 mg/l due to precipitation of magnesium and removal of the associated sulphate fraction (through gypsum crystallization). Neutralized mine water of this quality may be suitable for irrigation. The process consists of the following stages: 1. Limestone (CaCO3) neutralization to raise the pH to 7 and CO2-production. 2. Lime (Ca(OH)2) treatment to pH 12 for Mg(OH)2precipi-tation and gypsum (CaSO4.2H2O) crystallization. 3. pH adjustment with CO2recovered from stage 1 and CaCO3 precipitation. Retention times of 1 hour, 4 hours and 1/2an hour were required by stages 1, 2, and 3 respectively. The sulphate level was reduced to 1 094 mg/l, which is less than the original aim of 1 200mg/l. Chemical costs associated with neutralization, using limestone instead of lime, are reduced by 69% in the integrated limestone/lime process. The overflow water from the clarifier of each of the above stages generally contains a wide variety of colloidal impurities that may cause the water to appear turbid or may impart colour. This results in very slow sludge settling rates that cause overflow water with a high degree of turbidity and colour. There are a number of successive or simultaneous stages involved in the agglomeration of particles. To get optimum neutralisation of the acid water and partial sulphate removal to below the saturation level of gypsum (i.e. 1 500mg/l), maximum sludge recovery is needed. The higher the concentration of seed crystals, the larger the surface area. Therefore, effective removal of suspended and colloidal matter from the overflow of each stage is required and can be achieved by coagulation and flocculation. The polymers PAC6 and 3095 were effectively used as coagulant and flocculant respectively. The addition of these polymers resulted in a clear overflow in each of the above stages with a very low turbidity.

Jan 1, 2003

By D. D. Munro

Finsch Mine is a kimberlite diamond mine located at Lime Acres in the Northern Cape Province of South Africa. The mine was founded in 1961 and started surface mining in 1964. Underground production commenced in 1990 using a modified blast-hole open stoping method for the mining of Blocks 1, 2 and 3. Block 4 is currently being mined as a block cave. The process of identifying and optimizing a method to mine the Block 5 orebody started in 1991, and in 2006 incline caving was identified as being technically feasible. This paper aims to document the process employed in developing this method by the Block 5 prefeasibility team as well as discuss the technical challenges encountered during this process. The paper commences with a history of Finsch Mine and highlights the complex geology and threat of sidewall failure that prompted the decision to use block caving as the mining method for Block 4. A literature study of mines that implemented mining methods upon which the incline cave was conceptualized is then presented. These practices were then used to form the basis for the designs on which the initial geotechnical modelling was done and built upon through an iterative process of modelling and design changes. The ventilation of the mining area, initial productivity simulation results, and the applicability of automation and comminution processes in the incline cave are also presented. The paper concludes with an investigation into some of the challenges of the mining method, and shows that that incline caving is a technical option available for further investigation in determining the optimal mining method to be employed at Block 5, Finsch Diamond Mine. Keywords massive mining, incline caving, geotechnical modelling.

Jul 1, 2013