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We present a novel hybrid algorithm for quantifying the ore grade variability that has central importance in ore reserve estimation. The proposed algorithm has three stages: (1) fuzzy clustering, (2) similarity measure, and (3) grade estimation. The method first considers data clustering, and then uses the clustering information for quantifying the ore grades by means of a cumulative point semimadogram function. The method provides a measure of similarity and gives an indication of the regional heterogeneity. In addition, grade estimations can be obtained at different levels of similarity using a weighting function, which is the standard regional dependence function (SRDF). Keywords: Grade, fuzzy clustering, similarity measure, point madogram, weighting function.

Jan 1, 2008

By G. Bueno, L. M. Tavares, T. M. Campos

Iron ore pellet feed pressing has been one of the first and most successful applications of High- Pressure Grinding Rolls (HPGR) in the minerals industry. Vale S.A. has been one of the pioneers in this application, currently with six HPGRs in operation in the pelletising plants of the Complexo de Tubarão (Brazil). In spite of the important advances in the technology, risks still exist when scaling-up the process from small-scale information. The present work takes advantage of the recent advances in the mathematical modelling of the HPGR performance, using the population balance model to evaluate the modified Torres and Casali model prediction in iron ore pellet feed pressing for different scales of operation. Results are presented that compare the HPGR performance in different operational scales for iron ore pellet feed pressing, demonstrating the confidence of this model-based approach for scale-up to full-scale HPGRs used in pressing iron ore concentrates. Keywords: Scale-up, HPGR, pellet feed, modelling, simulation

Jan 1, 2020

By T. Watanabe, S. Hayashi, M. Hayashi, K. Nagata, H. Fukuyama

Chemical states of fluorine in CaO-SiO2-CaF2glasses in a composition range of CaO/SiO2=0.5?1.3 and 5?25 mol%CaF2have been investigated by 19F solid-state NMR with and without MAS. The isotropic chemical shifts of the glasses are close to those of cuspidine crystal (59.4 and64.3 ppm with respect to C6F6) and CaF2crystal (58.6 ppm). The fluoride ions are coordinated with four or less than four calcium ions in this composition range. The chemical shifts move to the lower frequency with an increase in the CaF2content, whereas those are not affected by theCaO/SiO2ratio. The ionic distance between calcium and fluoride ions increases with an increase in the CaF2content. The chemical state of fluorine is not disturbed by the degree of polymerization of the silicate network. Comparing the MAS and static NMR spectra, the second moment attributed to 19F-19F dipole-dipole interaction has been estimated. The values of the glasses range over 3.1?7.3107Hz2andthose are larger than the calculated value of cuspidine crystal. This indicates that fluoride ions form Ca-F clusters in the glasses and that the size of clusters increases with increasing the CaF2content. Keywords: chemical state of fluoride ion, CaO-SiO2-CaF2glass, solid state 19F NMR spectroscopy

Jan 1, 2004

By O. I. Ostrovski, D. K. Belashchenko

The aim of this paper is the construction of models of systems with ionic and ionic-covalent bonds (molten salts) using experimental diffraction data and the calculation of their structure and thermodynamic and transport properties. Modelling was performed using algorithm BELION, in which the non-coulomb part of interaction potential between ions in the model was determined by the method of iterative simulation which targeted agreement between calculated and experimental partial pair correlation functions (PPCFs). The ionic charges in salts, which can be fractional, were determined by minimization of internal energy. In this paper, the algorithm BELION is applied for chlorides of alkaline-earth metals. Pair potentials, PPCFs, atomization energies, self-diffusion coefficients and electric conductivity are calculated. The charge of alkaline-earth metals was in the range of 2.0-2.1, slightly increasing from Mg to Ba. Partial pair correlation functions and atomization energies of models agree well with experimental data for MgCl2, SrCl2and BaCl2. Keywords: molten salt, molecular dynamics, partial pair correlation function, ionic charge, atomization energy, diffusion.

Jan 1, 2004

By J. J. Bezuidenhout

The waste-heat boiler is used within the Sulphide flash smelting process as the main dust and energy recovery unit. The large volume of off-gas discharged from the flash smelter is at a very high temperature (1350°C) and contains a significant dust load that subjects the downstream waste-heat boiler to tough and demanding conditions. The boiler cavity is especially prone to dust accretions, fouling, and corrosion caused by accumulation of molten particles and precipitation of sulphuric acid. Computational fluid dynamics (CFD) is applied within a qualitative study to model the flow and heat transfer distribution throughout the waste-heat boiler. The commercial CFD package, Fluent 6.2.16, was applied to a modified waste-heat boiler (23 m ×11 m ×5.4 m) within the Outokumpu flash smelting process. This investigation focuses on the geometric modifications to the typical boiler design, which includes elevation of the ceiling, placement of flow-obstructing baffles and radiation plates parallel within the flow path. Also investigated were various boiler operating conditions such as the circulation of process off-gas, air leakage from the dust discharging hoppers and variation in inlet gas composition. The geometric modifications had the desired effect of increasing the volumetric utilization and therefore enhancing heat transfer between the boiler surface and the gas stream and dust segregation. Introducing circulated off-gas at a rate of 20 m/s and at a 45° angle to the front of the waste boiler further enhanced cooling while reducing the high impact of the furnace-uptake gas-stream on the boiler ceiling. The placement of radiation plates was found to be very effective in enhancing the heat transfer surface and distributing gas flow within the boiler. These results present recommendations towards an improved waste-heat boiler design. Keywords: flash smelting, waste-heat boiler, CFD simulation, off-gas cooling.

Jan 1, 2008

By Jeremy Bosman, Johan de Korte

Traditionally the feed to coal preparation plants was de-slimed at 0,5 mm. The +0,5 mm size fraction was processed via dense-medium cyclones and the -0,5 mm size fraction was beneficiated with froth flotation, water-only cyclones or spirals. With the introduction of large diameter cyclones, the aperture sizes of de-sliming screens have progressively increased to about 3 mm in the belief that the larger cyclones are not able to effectively beneficiate coal which has a particle size below the ?breakaway? size. The efficiency of separation in the large dense-medium cyclones is improved by presenting a coarser feed to the units. At the same time, the capacity of the de-sliming screens is increased due to the larger screen apertures and in effect, the throughput capacity of the dense-medium section is increased. The 3 x 0,5 mm size fraction, which was previously processed in the dense-medium cyclones, is now added to the fine coal size fraction and processed by water-only methods such as Teetered Bed Separators (TBS) and spirals. Whether this practice is the most economical way to process the 3 x 0,5 mm size fraction requires further thought since the best processing route for the 3 x 0,5 mm size fraction will depend on a number of factors, amongst which are: o The washability of the coal and the amount of near-density material o Processing efficiency o Specification of the required product o The price paid by the customer for the product o The cost of processing the coal Breakaway size The ?breakaway? size is defined as the particle size below which the Epm of the smaller particles starts to decrease significantly. Bosman1 provides an approximate breakaway size versus cyclone diameter (Figure 1). It should be kept in mind though that the Epm of the small particles is a function not only of the cyclone diameter but also of feed pressure, medium density, medium viscosity, particle shape and density, top-size of particles in the feed, etc.

Jan 1, 2006

By J. Drzewiecki, J. Kabiesz

Coal mining using longwall methods of mining can lead to intense disturbances of undermined roof strata. The disturbances may extend beyond the extraction area and the resulted rock mass deformations will appear differentiated. In the case of stiff and undermined roof strata, the energy stored in these rock masses may be frequently dissipated in the form of high-energy seismic tremors. Such events can occur if these strata should fail or „free themselves” either from the constrainment of rock environment or from adjacent strata. It has also been found that the amount of the stored energy closely depends on the size and/or slenderness of these strata. Thus, it would be possible to apply specific preventive measures to reduce the energy of mining – induced seismic tremors. The methods are based on artificial disintegration of the structure of energy – storing strata. One of the most efficient methods is a method of directional hydraulic fracturing, which is regarded as an alternative solution from the traditional blasting and hydraulic methods.

Jan 1, 2003

By B. Friedrich

In a German governmental funded three-year research project, a closed loop recycling process for Nickel-Metalhydride-Batteries (NiMH) is under development. Today the discarded batteries are used in the steel industry as a cheap nickel source. Cobalt and rare earth (RE) are slagged and lost for reuse. The entire value of the metals in discarded Ni-MH is estimated to be 4?-4.5 ?/kg. Spent NiMH-batteries containing 36?42 per cent Ni, 3?4 per cent Co and 8?10 per cent rare rarth (Ce,La, Pr, Nd). The dismantled and processed NiMH-batteries are melted in a DC electric arc furnace producing a nickel-cobalt alloy and a slag phase highly enriched with RE-oxides. The key to success in this process is to find a suitable slag system, which ensures best separation of NiCo-alloy from the rare earth oxides and high concentration of RE in the slag. Different oxidic and halogenic slag systems are investigated in the melting process. So far a slag system based on 65per cent CaF2 and 35 per cent CaO delivers the best separation of the two phases and metal yields. A slag with a composition of 20?25 per cent La, 13-16 per cent Ce, 1.5?2.5 Pr, 4.5?6.5 per cent Nd is obtained and further treated to misch metal hydro-/electrometallurgically. The first results of the influence of rare earth oxides on the density of CaO-CaF2slag system are shown at 1600°C. Keywords: battery recycling, CaF2, CaO, rare earth oxides, slag characterization, density measurement

Jan 1, 2004

By J. M. Font, R. G. Reddy

Jan 1, 2004

By A. du Plessis

The study summarized in this paper focused on expanding existing South African mine closure cost calculation models to provide a new model that incorporates risks, which could have an effect on the closure costs during the life cycle of the mine. This research is important because currently there are a number of mines that do not have sufficient financial provision to close and rehabilitate the mines. The magnitude of the lack of funds could be reduced or eliminated if the closure cost calculation is done in a more risk-orientated manner. The model consists of an expansion of existing closure cost calculation models, by applying the Monte Carlo risk simulation technique to model influences of external and internal changes affecting closure costs. It is shown that the proposed risk-based model provides a way to understand better the implications of uncertainty on the closure costs.

Jan 1, 2006

By J. Ekengård, H. Srinath, M. Andersson, P. Jönsson, D. S. Sarma

The present paper deals with mixing between the metal and slag phase during the ladle refining process, including vacuum degassing. Dispersion of metal drops in ladle slags has been studied. The results show a larger quantity of metal droplets in ladle slag during the alloying and stirring phase than during the subsequent vacuum degassing phase. The thermodynamic and kinetic aspects of the interaction between metal drops and the slag matrix have been considered and probable reasons for the observed distribution discussed.

Jan 1, 2004

By E. T. Boshoff

Paper written on project work carried out in partial fulfilment of B. Eng. (Metallurgical Engineering) The weathering of kimberlite can be accelerated with cations in solution if swelling of the kimberlite occurs in contact with the weathering medium. The type and amount of swelling clays present, along with the surface charge and cation valence, determine the degree of swelling that can occur. Crystalline swelling occurs by the incorporation of cations in the interlayer spacing of the silica sheets. Kimberlite exposed to cupric cations showed very strong weathering, indicating that this type of weathering may be considered a viable process option. Kimberlite fines generated after weathering with monovalent cations showed poor settling behaviour compared to kimberlite weathered with di-, and trivalent cations.

Jan 1, 2005

By E. Chen, M. Barati, K. Coley

The reaction between carbon and slags is of significant importance in direct smelting of iron ores, EAF slag foaming and copper slag cleaning processes. This reaction is known to occur via gaseous intermediates and it is important to have fundamental data to understand the relative importance of each reaction step. In this study, the rate of CO2dissociation on different slag surfaces is measured using an isotope exchange technique. It was found that increasing iron oxide content up to 30 wt per cent does not have a significant effect on the rate constant while increasing from this limit, increases the rate constant dramatically. Activation energy of CO2dissociation on slags of unit basicity and different iron oxide contents is in the range of 180±40 kJ/mol. It is found that rate constant dependence on oxygen potential in the slag phase is increasing with iron oxide concentration. In the case of copper making slags, the influence of copper oxide is found to increase the magnitude of apparent rate constant, while decreasing the activation energy considerably. Key words: Gas-slag reaction, CO2dissociation, copper slag, kinetics, isotope exchange

Jan 1, 2004

By M. Shapiro, L. A. le Grange, B. Henning

Effective pyrometallurgical process vessel design requires accurate assessment of the heat fluxes through the walls of the furnace. This is particularly important for freeze lining operation which is designed to protect refractory materials exposed to chemically corrosive molten contents, or facilitate high temperature operation when the refractory materials are used at conditions close to their service limits. Numerical modelling of fluid flow and heat transfer in process vessels is often used to aid in the design of process vessels. Sophisticated models are used to analyse the three dimensional flow and heat transfer predicting the effects of electrical heating, magnetic stirring, buoyancy, shear forces, various cooling effects and ultimately heat fluxes at the walls of the furnace and refractory. Traditionally these models are applied to the separate single fluid systems in a vessel such as the freeboard region including the arc, the slag region and the metal bath. Boundary conditions such as shear forces and heat fluxes between connecting regions such as the slag and metal bath are either estimated or carried over from separate solutions. Shortcomings in these traditional approaches include the estimation of sometimes critical boundary conditions leading to unreliable heat flux calculations. Also when boundary conditions are carried over between solutions, the process is difficult to set up, time-consuming and finally not fully coupled. In this paper the definition and results of a fully integrated numerical model of a complete arc furnace are presented. The most important mechanisms acting in an arc furnace were considered, including the fields of electrical potential, current, magnetism, momentum, heat transfer and radiation. Temperature dependant properties included electrical conductivity, density, viscosity, and thermal conductivity. The geometry consists of the freeboard, the arc, slag, metal baths and different refractory regions. Although the combined model of air, slag and metal would be defined as a multi-phase problem it is not solved as such. Instead the different fluids are separated by sets of special solid baffles. These baffles allow the implicit transfer of current, magnetism, heat transfer and shear forces between the different fluids and disallow mixing of the separate fluids. The strengths of the integrated model are threefold: Firstly, it provides robustness in defining the geometry and boundary conditions for the overall model. Secondly, it provides the capability to switch on and off individual mechanisms such as buoyancy, magnetic stirring and shear forces in order to observe their individual importance. Finally, it provides a useful tool in the design process through its ability to obtain results of parameter changes in short time scales.

Jan 1, 2004

Records over the past ten years indicate that there is potential for serious multiple accidents due to engulfing associated with rockpasses. Significant attention is not usually given to the design of rockpasses, with the implication that mistakes leading to poor performance of the passes are often repeated. This paper outlines general guidelines for the design, support, operation and rehabilitation of rockpasses based on information obtained from the limited amount of literature on the subject.

Jan 1, 2005

By N. Ragoonanthun

Paper written on project work carried out in partial fulfilment of B.Sc. (Mining Engineering) degree This report investigates the optimization of a raiseline in order to open up the ore reserve quicker. The project was carried out at Mponeng Mine (an Anglogold shaft formerly known as Western Deep Levels 1 Shaft and South Mine, in Carletonville). The project was divided into two focus areas namely: ?To design an optimum layout of a raiseline, which includes the scheduling of all activities for the establishment of the infrastructure. Consideration was given to the blasting practice, mining cycle, orepass placement and slusher positioning. Two designs were carried out on the above basis. ?The design of a ledging operation/practice to match the optimized layout of the raiseline. The ledging cycle design involved a thorough investigation into the possible use of drill rigs, Electronic Delay Detonators (EDD) blasting technology, longer drilled holes, Threshold Blasting (THROB),and water jet cleaning.

Jan 1, 2003

By M. Görnerup, M. Hayashi, S. Seetharaman, C. -Å Däcker

The mould flux plays a crucial role in the continuous casting operation of steel due to its multi-functional assignment as lubricator and heat flux controller. In reality, the commercial fluxes can fall short of the expectations of the operator. In such cases, the performance of the mould flux reduces production throughput in the casting machine. This paper presents the results of a study of two different commercial mould fluxes in continuous casting of steels. The results of online sampling during casting, as well as off-line measurements in the laboratory, are presented. Mould flux powder and slag samples from the caster have been characterized with respect to melting behaviour, interfacial tension and thermal diffusivity, using various measuring techniques. An experimental technique has been developed in order to simulate the melting behaviour of a flux in the mould, which has been found to be useful for qualitative studies. A cross-sectional view of different powders reveals that up to four different material layers may exist in the bed: a loosely packed powder layer, sintered layer, semi-solid layer and liquid slag layer. It is found that the melting rate of the mould flux is dependent on the liquid slag layer thickness. Thus, in a continuous casting operation the melting rate is likely to be non-uniform with position in mould due to the difference in liquid slag layer thickness. Mould slag composition is found to be influenced by the starting powder for as long as 30 min, representing a large part of the first heat casting time. Observations of gas formation indicate that interfacial reactions between the steel and slag take place. Keywords: continuous sacting, mould flux, mould slag, properties

Jan 1, 2004

By K. Sørli, H. Elstad, I. M. Skaar, A. Hildal

Generally, monitoring of refractory furnace linings is of interest to the metallurgical industry. The main issues are to control wear of the furnace lining and break out of molten metal. Penetration of molten metal through the lining can cause considerable damage to equipment in the vicinity of the furnace and endanger operators. Rebuilding of a furnace lining is expensive, mainly because it stops production, but also because the lining materials are expensive. Here, two methods for monitoring the lining of a smelting furnace are presented. The methods are based on monitoring of the temperature distribution in the lining, more specific monitoring an isotherm in the lining. One method is based on the assumption of unidirectional heat flow locally, reducing the problem to a set of one-dimensional heat conduction problems. The other method is based on inverse heat conduction. In this context inverse heat conduction means estimating the wear from temperature measurements using mathematical optimization techniques. The study is based on the ilmenite smelting furnace at Tinfos Titan & Iron KS. Some results from real temperature measurements and real observations from the ilmenite smelting furnaces is presented.

Jan 1, 2003

By S. Sun

The equilibrium distribution of Cu, Fe and Ni between Cu-Ni-Fe mattes and Pt alloy was measured as functions of the sulphur partial pressure (pS2), oxygen partial pressure (pO2),temperature and Fe content of the matte. The distribution ratios of Cu, Fe and Ni between matte and alloy were independent of oxygen pressure when the pS2was fixed at 2.5x10-5atm and pO2was varied between 10-15and 10-12atm. The distribution ratio of Cu, Fe and Ni increased as the sulphur partial pressure increased. The Cu and Ni distribution ratios decreased with increasing temperature and the Fe distribution ratio increased slightly over the temperature range of1350?1500°C. For mattes where the proportions of Cu and Ni were kept constant, the distribution ratio of Cu increased as the Fe content in the matte increased. The Fe and Ni distribution appeared to be independent of the iron content in the matte and had a value of 1.2 and 1.6 respectively. The activity of Cu, Fe, Ni in the matte was calculated using a regular solution model for solid Pt-Fe-Ni-Cu alloy. The activity coefficient of Cu, Fe and Ni decreased as pO2and pS2increased.The activity coefficients also appeared to be independent of the Fe content and temperature over the range of 36 to 54 wt% iron and 1350 to 1500°C respectively. Keywords: activity, alloy, matte, thermodynamics

Jan 1, 2004

By J. H. Potgieter

This paper describes two cases of corrosion that occurred in dry-process, rotary, cement-clinker kilns. In the case of the kiln with five pre-heater stages, the attack occurred primarily from sulphates that probably originated in the raw feed and fuel being used in the plant and that penetrated the refractory lining. The corrosion was similar to ash-deposit corrosion often observed in steam boilers. In the second case the plant consisted of a long dry kiln with a single pre-heater fitted to the feed-end. In this case the corrosion could be ascribed to alkali chloride penetration through the refractory-brick lining and subsequent hot corrosion of the kiln shell.

Jan 1, 2004