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A Colloquium and General Meeting were held on 17th March 1971, the theme being 'Future trends in steel production'. Mr V. C. Robinson (President) was in the Chair. The Colloquium was attended by 121 delegates and was opened by the President at 10 a.m. OBITUARIES THE PRESIDENT: 'It is my sad duty to announce the death of the following: F. O. Read, Fellow, who joined the Institute in 1957 and passed away on 13th January, 1971. P. G. M. May, Member, who joined the Institute in 1969 and passed away on 10th August, 1970. R. J. J. Rademeyer, Life Fellow, who joined the Institute in 1942 and passed away on 23rd September, 1970. As a mark of respect to the memory of the deceased and in sympathy with the bereaved I would ask you all to rise and observe a few moments silence. CONFIRMATION OF MINUTES THE PRESIDENT: 'May we confirm the minutes of the monthly general meeting held on 21st October and 18th November, 1970, as published in the Journal'. Agreed. MEMBERSHIP THE PRESIDENT: 'I have much pleasure in announcing that the names of the undermentioned candidates, having been published in accordance with ByLaw 5.2.2, Council has elected them to membership of the Institute in the following grades: FELLOWS: Romain August Lathioor, Paolo Piga, Renato Ribacchi, Willem Frederick Jacobus Smith, Matthew Churchill, Thomas Anthony James Braithwaite, Hugh Patrick Hart, Eleanor Innocentius Muller, David Alton Smith. MEMBERS: Douglas Adendorff, Petrus Jacob du Plooy, James Valentine Grant Middleton, Karl Anders Ullerstam, Josephus Theodorus Johannes van Wyk, Frank Douglas Abbott. GRADUATES: David Mervyn Gilbart-Smith, John Philip Wilcocks Bennie, Hendrik Theunis Burger, Johann Wilhelm Coetzee, Johannes Stephanus StOols, Leon van Tonder, Brian George Harvey, John Kennedy McLean. ASSOCIATES Richard Cyril Lee Stoyell, Terrence Brian Gouws, Alister Rodney Frederick MacDonald. STUDENTS: Andries Groenewald, Christiaan Johannes Hattingh, William Hendrik Hofmeyr, Stanley Thomas Vincent. I welcome the new members to the Institute and congratulate them on their election. COLLOQUIUM The President welcomed everyone present and mentioned that this was the first of the Colloquia which are to replace the Institute's monthly meetings. He stressed that discussion at Colloquia would be completely informal and would not be recorded unless the contributor requested publication. In conclusion, he thanked the organising committee, the authors and the contributors, and introduced the author of the first paper. The following papers were presented:- 'The future development of the Iron and Steel Industry' by J. P. Coetzee (Published in the Journal March 1971). Among those who contributed to the paper were Dr Bleloch, Dr K. Gebhard, Dr Way and Professor Müller. The main point made by Dr Bleloch related to the reserves of coking coal and of coal for power generation this in country and he deduced that in South Africa we are critically short of coking coal. On the basis that 4 million tons per year of coking coal are consumed for our present steel production, over 16 million tons would be required to meet the anticipated expansion in steel output by A.D. 2000. This must be set against the grim forecast made by the Coal Advisory Board in 1967 that our national reserves of coking coal will be exhausted before A.D. 2000. This gives tremendous significance to the development work presently being carried out by Iscor on alternative methods for coke production. On the other hand the blast furnace may have to be replaced by an alternative process for the reduction of iron ores, e.g., the use of rotary kilns followed by electric arc smelting. Dr Bleloch also expressed grave forebodings about the reserves of bituminous coal, pointing out that with present methods of mining the recoverable coal in any given reserve is in general only 50 per cent of that reserve. He stated that in the past seventy years great quantities of coal have been forever placed beyond the reach of mining by being undermined by extraction of lower seams or lost by being burned. A final point made by Dr Bleloch was the fast rise in the capital investment in a fully integrated steel plant, the figure having risen in the past decade from just over R200 to R350 per ton of finished steel per annum. Dr Gebhard spoke of the direct reduction processes for iron making pointing out the difficulties of securing a high percentage of reduction and the relatively high cost of smelting in electric arc furnaces. As an alternative he suggested briquetting the high carbon sponge iron

By F. M. Ramadhan, M. R. Pratama

Monitoring open-pit mine road conditions has become very critical nowadays. There are several benefits to in conducting research on this field such as opportunity to improve truck’s speed which directly influences truck’s productivity. This research aims to provide a semi real-time, and sensors-based automatic road damage detector that predicts the road quality through road damage exact location tracing, road damages auto-classification, and real-time instruction in the form of work order format to mining road maintenance, and repair authorities through mobile apps and maintenance unit’s in-cabin display. It will also provide the maintenance/repair activity performance evaluation via integrated dashboards. The artificial neural network algorithm is applied during the process of data training regarding classifying road damages and severities which resulted in a valid model. The road damage classification model has a precision level of 80.5% in predicting whether the road is damaged or not. Using this approach, we are expecting to visualise a road quality map of all active roads on mine site.

Sep 1, 2021

By A. D. Pienaar

The aqueous chemistry of niobium and tantalum compounds with hydrofluoric acid is a mature field of investigation. In contrast, very little attention has been paid to reactions of these compounds in non-aqueous environments. Similarly, reactions of elemental fluorine with niobium and tantalum compounds have received little more than cursory attention in literature. This work discusses the isothermal reaction kinetics derived from thermogravimetry, using a less redundant approach than is currently the standard. We also discuss the most likely kinetic models for this reaction.

Jan 1, 2012

By T. Puhakka

Simulation is a way to obtain quickly today future information on how planned systems will most likely behave in various selected situations. This information may then be used to optimize the system and its components and maximize the performance and output. Simulation is a way to fine-tune the layout, match the mobile fleet and optimize the schedule and the way of working to meet the desired production requirements. Simulation provides a glimpse of the upcoming operation, ‘future today’ and helps to predict its restrictions and sensitivity to various aspects. OptiMine™, the Sandvik Tamrock Corp. and CyberCube Oy developed simulation tool is designed to simulate underground rock flow and match suitable technology with various layout options. This tool can be used to view what-if situations and determine what kind of impact mastered changes have to production. The findings of critical points in the layout and working procedures at an early stage of a new mine can help to optimize the layout and material flow. OptiMine™is modular based simulation tool that combines the supplier machine knowledge and traffic guidance with mine operational know-how and mine environment. It is developed to work in a way that an effect of an individual incident, such as the effect of one additional turn in a continuous loading cycle to the daily capacity can be identified. The reported output can be used for economical impact evaluation of selected options. This paper discusses the use of simulation in general and the way the OptiMine™ simulation tool operates and how it may be used for operation, technology and material flow optimization.

Sep 1, 2001

The following comment has been received from Mr A. D. Osche* on the above paper, which was published in the Journal in October 1977 (vol. 78, no. 3, pp. 51-62). Obituary: T. K. Prentice The Institute records with deep regret the death on 30th January of its senior surviving Past President, Mr Thomas Kennedy Prentice, at the age of 83. Book reviews R. A. Rich, H. D. Holland, and U. Petersen. Hydrothermal uranium deposits. (Developments in Economic Geology, vol. 6). Amsterdam, Elsevier Scientific Publishing Co., 264 pp. with 77 illustrations and diagrams, 30 tables. U.S. $34,75. M. David. Geostatistical ore reserve estimation. Amsterdam, Elsevier Publishing Company, 1977. 364 pp. World mineral industry The Australasian Institute of Mining and Metallurgy is celebrating its sesquicentenary in 1979. A conference will be held in Perth from 13th to 18th August, 1979, as part of the celebrations, the theme being 'Australia's Role in the World Mineral Industry'. Engineering teaching staff UNESCO has extended its technical assistance to the Venezuelan government in the training of engineers to suit the rapidly developing economy of the country. UNESCO vacancy Vacancy for a post of expert under the UNDP. (1) Title of post: Expert in metallurgical engineering. (2) Duty station: Instituto Universitario Politecnico of Ciudad Guyana (Venezuela). Shell Design Awards The annual Shell Design Awards, organized by the Design Institute and sponsored by Shell South Africa (Pty) Ltd, focus attention on achievements in South African design.

Jan 1, 1978

To the trustees of The SAIMM Scholarship Fund We have audited the annual financial statements of The SAIMM Scholarship Fund set out on pages 587 to 592 for the year ended 30 June 2005. These financial statements are the responsibility of the trustees. Our responsibility is to express an opinion on these financial statements based on our audit. Scope We have conducted our audit in accordance with International Standards on Auditing. Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes: examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audit provides a reasonable basis for our opinion. Audit opinion In our opinion, the financial statements fairly present, in all material respects, the financial position of the trust at 30 June 2005 and the results of its operations and cash flows for the year then ended in accordance with South African Statements of Generally Accepted Accounting Practice.

Jan 1, 2005

By L. Forbes, G. Forbes, J. Wang

Bubble size measurement is a vital part of flotation system analysis and diagnostics. Over the years, a great many different bubble size analysis tools have been developed. However, all of them rely on ex-situ measurement and in-pulp sampling techniques. This paper evaluates the Mettler Toledo ParticleView™ Measurement probe as a novel method for in-situ bubble size measurement. This device is then compared to the conventional Anglo Platinum Bubble Sizer (StoneThree). It was found that the in-situ bubble size analysis technology appears to be a more user-friendly and reliable option for determining bubble size in flotation. However, the current instrument design is not suited to industrial applications. Keywords: Bubble size measurement, bubble coalescence, PVM probe

Jan 1, 2020

By J. Rowe

The attrition of activated carbon, and the loss of gold associated with it, is of significant economic importance to the operation of a CIP/CIL circuit The focus of this study was on activated carbon recovered from an elution circuit which was deemed too fine for reuse. Results of cyclosizer and laser particle size analysis identified that most of the carbon was contained in the larger size fraction suggesting formation by abrasion. Digestion and AAS analysis of the individual size fractions identified a disproportionate concentration of gold in the finer size fractions which was identified by scanning electron microscopy to be due to the presence of fine metallic gold formed as a result of the acid washing process. Attempts to strip the remaining gold using sodium hydroxide or sodium sulphide based solutions proved unsuccessful due to poor elution efficiencies and re adsorption of gold. Upgrading of the material by froth flotation was also investigated using various conventional flotation reagents which had some success in concentrating the free metallic gold, however, grade and/or recoveries were considered less than desirable. Greater success was ultimately found in the transfer of gold from the fine carbon material onto coarser virgin activated carbon using a caustic cyanide solution. Sodium sulphide, sodium chloride and ammonium chloride based solutions were also trialled but proved less successful owing to their inability to mobilise metallic gold or gold cyanide species. Repetition of the transfer process proved capable of stripping 97% of the gold contained on the carbon fines for abed volume ratio of 6:1.

Jan 1, 2009

By T. Flitton, R. Peattie

"The extreme depths and consequent expense of drilling and sampling the gold-bearing reefs of the Witwatersrand Basin have resulted in limited data being available for estimation of grade ahead of the mining face. There is, however, a wealth of information from mined-out areas of these deposits. This estimation challenge resulted in the development of a unique method of Mineral Resource estimation.AngloGold Ashanti (AGA) utilizes a technique termed macro cokriging (MCK), which allows for the integration of the limited advanced borehole data with the large chip sample data-sets from the previously mined-out areas by adopting a Bayesian geostatistical approach. The MCK process, in short, is the estimation of mixed support size data together with the application of four-parameter distribution models.The gold value estimation for the Carbon Leader Reef (CLR) on the AGA TauTona Mine is used in this paper as a case study of the process and to demonstrate the effectiveness of this technique through production reconciliation. The current method has been proven over the last 20 years and is now an established part of the Mineral Resource evaluation process within AGA.IntroductionOwing to the extreme depths of the goldbearing reefs at the AngloGold Ashanti (AGA) Witwatersrand operations and the prohibitive expense and time involved in drilling boreholes to the required depth, only limited drilling and sampling data is available ahead of the mining face. Whereas traditional estimation techniques are interpolative, within the Witwatersrand the estimation is primarily extrapolative, with the majority of the data being sourced from the mined-out areas. This significant challenge to estimation resulted in the development of a unique method of Mineral Resource estimation and evaluation."

Jan 1, 2016

By I. M. MacGregor

This paper discusses the possible use of petrological data and proximate analyses in the prediction of cutting forces for coal. It is restricted to the development of univariate predictors based on data from thirteen collieries in five major Transvaal and Orange Free State coalfields and three coal provinces. The aim of the work was the identification and development of the best predictors of mean peak cutting force and Hardgrove grindability index from among the independent variables evaluated. The data, which were obtained by use of the penetrometer developed by the Chamber of Mines Research Organization, were processed according to the SPSS computer package. The analysis revealed reasonable correlations between the Hardgrove grindability index and (1) the volatiles and vitrinite content in the Vereeniging-Sasolburg and South Rand Coalfields, (2) the contents of vitrinite, vitrinite plus exinite, and minerals plus inertinite in the Eastern Transvaal Coalfield.

Jan 1, 1985

By I. Zh. Bunin, M. V. Ryazantseva, V. A. Chanturiya

The paper proposes a new method for selective calciferous separation. The effect was achieved through the application of the combination of high-power electromagnetic pulses (HPEMP) and a specific reagent regime of the flotation. The combined application of HPEMP with the special reagent regime allowed for the improvement of the scheelite floatability: the recovery of CaWO4 rises from 41.2 % (untreated sample) to 58.5 (sample treated at 103 pulses). In contrast, the floatability of calcite decreases significantly: the recovery of calcite drops from 74.7% (untreated sample) to 41.1 % (sample treated at 103 pulses). The conditions were found for the selective separation of the minerals with very close flotation properties. Keywords: Calcite, scheelite, flotation, high-power electromagnetic pulses, DRIFT, XPS

Jan 1, 2020

Council and Standing Committees, 1977-1978 President: P. A. von Wielligh. Vice-Presidents: Dr M. G. Atmore and D. A. Viljoen. Honorary Treasurer: J. K. E. Douglas. Immediate Past President, Dr M. D. G. Salamon. Members of Council: J. D. Austin, A. N. Brown, A. A. Hazell, Dr P. R. Jochens, Prof. R. P. King, Dr D. G. Krige, Prof. F. Q. P. Leiding, D. G. Malan, J. C. Mostert, H. G. M. Rose, W. T. Ruhmer, A. A. Sealey, R. A. von Maltitz. Chairman, Witbank-Middelburg Branch: T. S. Wilmot. Chairman, Orange Free State-Klerksdorp Branch: A. N. Shand. Past Presidents Serving on Council: R. J. Adamson, H. Britten, J. K. E. Douglas, Prof. D. D. Howat, Dr J. P. Hugo, D. G. Maxwell, Prof. R. P. Plowman, Dr R. E. Robinson, P. W. J. van Rensburg. Standing Committee Chairmen: Membership, D. A. Vil¬joen; Technical Programme - Metallurgy, Dr P. R. Jochens ; Technical Programme - Mining, Dr D. K. Krige ; Vacation School - Metallurgy, Prof. R. P. King ; Vacation School - Mining, Dr M. D. G. Salamon; Awards, Dr M. D. G. Salamon; Excursions, Dr M. G. Atmore; Adjudication, Dr M. D. G. Salamon; Consti¬tution, Rules, and Policy, Dr M. D. G. Salamon; Mines and Works, P. A. von Wielligh ; Education, Dr M. D. G. Salamon; Monograph Series, Dr R. E. Robinson; Phoenix National Committee, Dr R. E. Robinson ; Pyrometallurgical Discussion Group Convenor, Dr J. B. See/Dr D. I. Ossin.

Jan 1, 1979

By M. Pierce, E. Karampinos

"One of the main challenges in the numerical modelling of ground support in underground excavations is to reproduce the performance of the sequential installation of the reinforcement while capturing the rock mass behaviour of an advancing face in 3D. The 3D modelling approaches used to simulate the progressive advance of excavations are mostly continuum and often cannot reproduce the rock mass failure mechanisms. The 3D discrete element method (DEM) can better reproduce structurally controlled rock mass failure mechanisms and can explicitly represent the reinforcement elements. This paper builds on previous work that reproduced the structurally controlled squeezing conditions in an underground hard-rock mine using 3D DEM and the in situ behaviour of reinforcement under pull conditions. It addresses important issues on the way reinforcement is explicitly introduced in discrete element models. A pseudo-3D model is employed to overcome the computational restrictions and time limitations of a 3D modelling approach. The work focuses on the scaling of the material properties of the ground support elements when the thickness of the model is not equal to the out-of-plane spacing of reinforcement. It demonstrates the scaling methodology based on the type of the modelled reinforcement elements used and investigates the significance of this approach. The advantages and disadvantages of this approach with respect to 2D and 3D methods are discussed. The results are compared with field data and previous modelling work done at the mine. IntroductionNumerical models can provide significant insight into the anticipated behaviour of underground excavations. The modelling of ground support, however, is not a trivial exercise. An effective representation of ground support in underground excavations should capture the behaviour of both the rock mass and the support elements. When numerical models are used for design purposes, the complexity of the problem requires significant time and expertise (Sweby, Dight, and Potvin, 2016).At a laboratory scale, numerical models have successfully reproduced the results of laboratory tests on rockbolts by explicit modelling of the bolt, the borehole, and the grout. Chen and Li (2015) used a continuum FLAC3D (Itasca Consulting Group Inc., 2012) model to simulate the mechanical behaviour of D-bolts as observed experimentally. Grasselli (2005) used a 3D finite element code to model the behaviour of fully grouted rods and expandable bolts under shear."

Dec 1, 2018

By Y. Fan, D. H. Zhang, J. Y. Xu

The hydrogeological conditions in the Chambishi mine area in Zambia. were investigated. Chambishi is a very wet mine and groundwater discharge costs are high. The research goal was to identify methods to reduce the discharge costs without greatly affecting the mining process. Hydrogeological data was obtained from measurements in drill-holes and from drill cores. The differences in structural deformation in different areas determine whether a layer of rock is an aquifer. In the mine region, the Lower Roan Group ore shale and quartz-sandstone unconformably lie on the basal schist and granite aquifuge. The Upper Roan Group dolomite is continuously distributed over a large area around the orebody. This dolomite is the main target of groundwater control efforts, and its water yield is also influenced by the deformation intensity. Based on the observations, backfilling was gradually adopted to appropriately safeguard the integrity of the aquifuge above the orebody. The overlapping relationship between the aquifer and aquifuge has been utilized to increase mine drainage efficiency. This measure has not only greatly reduced the costs of mine drainage, but also improced protection of the groundwater environment. The old drill-holes that were not sealed after exploration drilling were grouted. Further, possible water-conducting fracture zones were investigated. Cover drilling towards the suspected zone was conducted to prevent the high-pressure groundwater from shallower aquifers from entering stopes in deep areas of the mine.

Jun 10, 2024

By SAIMM SAIMM

To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements of The South African Institute of Mining and Metallurgy set out on pages 575 to 586 for the year ended 30 June 2005. These financial statements are the responsibility of the Institute?s Council. Our responsibility is to express an opinion on these financial statements based on our audit. Scope We have conducted our audit in accordance with International Standards on Auditing. Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes: examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audit provides a reasonable basis for our opinion. Audit opinion In our opinion, the financial statements fairly present, in all material respects, the financial position of the Institute at 30 June 2005 and the results of its operations and cash flows for the year then ended in accordance with South African Statements of Generally Accepted Accounting Practice.

Jan 1, 2005

To the members of The South African Institute of Mining and Metallurgy I have audited the annual financial statements of The South African Institute of Mining and Metallurgy set out on pages 641 to 644 for the year ended 30 June 2006. These annual financial statements are the responsibility of the Institute?s Council members. My responsibility is to express an opinion on these annual financial statements based on my audit. Scope I conducted my audit in accordance with International Standards on Auditing. Those standards require that I plan and perform the audit to obtain reasonable assurance about whether the annual financial statements are free of material misstatement. An audit includes: ?examining, on a test basis, evidence supporting the amounts and disclosures in the annual financial statements, ?assessing the accounting policies used and significant estimates made by management, and ?evaluating the overall financial statement presentation. I believe that my audit provides a reasonable basis for my opinion. Audit opinion In my opinion, the annual financial statements present fairly, in all material respects, the financial position of the Institute at 30 June 2006 and the results of its operations and cash flows for the year then ended in accordance with generally accepted accounting practice appropriate to the Institute. Supplementary information The supplementary schedule does not form part of the annual financial statements and is presented as additional information. I have not audited this schedule and accordingly do not express an opinion on it.

Jan 1, 2006

By C. P. Naudé

Mechel, a large, integrated steel, stainless steel, and ferroalloy producer in Russia is committed to upgrading its facilities to world class pyrometallurgical process and environmental practice. Yuzhural Nickel currently uses shaft furnaces to produce a matte containing iron, nickel and traces of cobalt. This rather old technology is thermally inefficient and is characterized by high operating costs. Mechel has investigated suitable equipment and processes to upgrade the plant, and awarded a contract for the construction of a 12 MW DC smelter, located near the town of Orsk, to Bateman Engineering Projects in June 2008. The selection of DC furnace technology for laterite smelting can be considered as a strategic highlight for the pyrometallurgical treatment of low-grade lateritic ores, and could be the first industrial-scale implementation of this technology. This project has been designed to achieve multiple goals including the demonstration of the process and associated equipment technology at commercial scale, to confirm the scale-up design parameters of the forthcoming 2 x90 MW, twin electrode DC furnaces, and to prove the environmental emission superiority of closed furnaces. It also provides a valuable operator training platform. This paper deals with the process design, key technology building blocks and design features which have been incorporated to produce a pyrometallurgical vessel capable of (i) resisting slag superheat and chemical aggressiveness, (ii) process fine material without pre-agglomeration, (iii) achieve high nickel recoveries and(iv) being tolerant to the variations in chemical composition of laterite ore. The approach to increasing campaign lives between partial and complete rebuilds, through the use of composite furnace module (CFM) technology originally developed and patented by the University of Melbourne, is also followed in more detail. Unfortunately, results from hot commissioning and lessons learned from initial operation are not available because the project completion has been delayed due to the worldwide downturn in demand for commodities. Keywords DC furnace, ferronickel laterite smelting, corrosive slag, coppercooler technology.

Jan 1, 2010

By D. D. Marsden, L. E. Kun

Although a regulation is in force that all water used underground shall be free of bacterial contamination, in practice it is often very difficult to accomplish this. The standard method of disinfection m South African mines IS treatment with calcium hypochlorite, although liquid sodium hypochlorite is used at a few sites. Primarily because the process depends on human control for the addition of the hypochlorite and the regulation of its now, it is frequently found difficult to disinfect mine water adequately and continuously. In many marine environments, chlorine generated by the electrolysis of seawater in its passage through an electric cell is used for disinfection. The generation procedure is continuous and needs no human control except for occasional checking of the equipment. This paper describes the successful implementation of the process, suitably .modified, .at four underground sites. After severe scaling problems had been overcome, a procedure resulted that chlorinates considerably more effectively than the previous system (dosing with calcium hypochlorite), and that has a lower amortized operating cost.

Jan 1, 1981

By M. Nicolle

The Tati Activox® Project will be the first full-scale implementation of the patented Activox® process (The Tati Activox® project was deferred in 2008. Please refer to the Norilsk Nickel press issue on the topic for more info). The process was developed by Norilsk Process Technology and has been tested on Tati mine sulphide concentrates in laboratory, pilot and demonstration plant scales and demonstrated its viability. There are inherent risks to the final scale-up of the process from the demo plant and one of them will be investigated in this paper. Compartment 1 is designed to leach approximately 77% of the total nickel leached. For this reason agitation requirements in the first compartment of the autoclave are reviewed. An attempt is made to minimize the process and mechanical risks associated in achieving oxygen mass transfer into the slurry solution. The agitator powers for oxygen mass transfer are calculated using empirical correlations and compared to demonstration plant testwork. The resulting gassed power per unit volume (P/V) is higher than most commercial autoclaves and raises uncertainty on the viability of using such high unit power inputs. Additionally, there is concern about the ability of the autoclave shell to withstand and support the higher loading of large agitators. An alternative solution to designing for the increased P/V is assessed in which the number of compartments within the autoclave is reduced from 5 to 4 by removing the compartment wall separating compartments 1 and 2. This results in an enlarged first compartment containing 3 agitators instead of 2. Therefore the compartment 1 oxygen demand is supplied through 3 agitators, which lowers the P/V per agitator. The reduction in the number of autoclave compartments raises the potential for short-circuiting the mean flow pattern by slurry particles. Short-circuiting and low velocity zones could result in a lower recovery of metal and localized hot spots, respectively. A computational fluid dynamic (CFD) analysis was conducted to quantify these concerns and also to evaluate further design considerations. The results indicate that the proposed design change to 4 compartments affects short-circuiting. The impact of increased short-circuiting on the overall autoclave recoveries is not quantified, however; it is expected to be negligible based on testwork done in the Tati Demonstration Plant and similar modifications made to another operating autoclave. The CFD analysis also suggests that there will be no low velocity zones within the compartment.

Jan 1, 2009

By Lene Hansen

Sulphuric acid plants now and then see unexpected increases in SO2 emissions. Our experience is that it is not always easy for the acid plants to pin point the exact reason for the SO2 increase. Sometimes a catalyst bed is sacrificed even though reliable emperature readings and gas analyses could have verified satisfactory activity, hence the leaking heat exchanger is never discovered and after the shutdown the SO2 emissions are still too high. This paper will look into some basic catalyst management tools: Good record keeping is a necessity for collection of representative catalyst samples, reliable operating data is an inevitable starting point for all analysis and trending of operating data is a must for plant optimisation and troubleshooting. In addition these catalyst management tools will give a continuous updated knowledge of the catalyst status in each bed providing the basis for a more effective replacement strategy. The most typical reasons for increasing SO2 emissions will be presented together with easy guidelines for cross-checking of operating data, temperature optimisation and good record keeping.

Jan 1, 2009