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By S. Banisi, S. Zare, M. Mahmoudi, M. Maleki-Moghaddam, M. Yahyaei

As the orebodies become more complex and lower grade, there is an increasing demand from crushing circuits for a finer product. When the product from a crushing circuit does not satisfy the requirements of the downstream processes, the cost of production increases. Thus, enhancing the performance of cone crushers through optimisation of their operating factors becomes important. One of the key factors affecting performance of cone crushers is the filling of the crushing chamber during the operation. The effect of varying the filling of the crushing chamber of a cone crusher was investigated. To assess the crusher performance, parameters such as crusher capacity, power utilisation, and reduction ratio were used. Extensive plant trials were conducted to obtain samples and operational data when the crusher chamber was 50% full (half-full) and 100% full, which is 300 mm above the top of the crusher chamber (super-choked condition). The results indicated a 62% difference in the crushing capacity when the crusher was operated in a super-choked condition compared to the half-full chamber level. In the super-choked condition, the size-specific energy at 12.7 mm was 20 % lower than that of the half-full condition. The Bond ball mill work index (BBWI) of crusher product indicated that the BBWI of the product of the super choked condition is 5.6% less than that of the product of half-full condition. This can be attributed to the generation of micro cracks in particles due to increase in the interparticle breakage when the crusher was operated in the super-choked mode. Keywords: Cone crushers, crushing efficiency, crushing chamber filling

Jan 1, 2020

By C. Klutke

This paper outlines a simple methodology for mineral characterization, developed as part of the Australian Mineral Industry Research Association (AMIRA) managed research project P777 ?The Development of Heavy Suspension Techniques for High Density Separations (Replacement of Clerici?s Solution)?. The project was sponsored by De Beers, Rio Tinto and Iluka Resources. Heavy mineral characterization of samples arising from exploration, mining or metallurgical processes is frequently conducted using laboratory heavy liquid analysis. Unfortunately, there are only a limited number of high density (?heavy?) liquids and these tend to be more toxic as their density increases. Low-toxicity inorganic solutions, based on tungsten compounds, have been developed that can be utilized at relative densities (RD) up to 3.0. Beyond this value organic liquids can be used; however, this presents significant health and safety hazards. Diiodomethane (methylene iodide) having a relative density of 3.31 is commonly used. Mixtures of thallium formate and thallium malonate were found in the early 1900s by Clerici to provide liquids having specific gravities between 4.0 and 5.0. For the characterization of the heavy components of mineral sand deposits (e.g. anatase RD 3.9, rutile RD 4.2, ilmenite RD 4.4?4.7 and zircon RD4.6?4.8) there is currently no heavy liquid alternative to Clerici?s solution. Clerici?s solution is highly toxic and testing is now conducted by few laboratories worldwide, with costs reflecting the chemical costs, infrastructure costs and health and safety regimes (e.g. blood testing of exposed staff). A simple laboratory technique of density fractionation has been developed, employing suspensions of fine tungsten carbide particles in lithium heteropolytungstates solutions, that can replace Clerici?s solution in the evaluation of fine mineral sands samples (e.g. -250 +150microns). The developing methodology that can achieve low-cost, low-toxic separations at relative densities above 4.0 is outlined and the comparison of results with Clerici?s solution presented. In addition, preliminary work on density fractionation of zircon samples is presented. Zircon fractionation relates to their inclusion, radionuclide content and metamictization.

Jan 1, 2007

By R. M. Stroh, D. F. H. Grave

In this paper ventilation planning methods are discussed, with particular reference to the application of computer techniques to the solving of the many problems associated with the forecasting of ventilation and refrigeration requirements in mines of high production rates going to depths and rock temperatures higher than previously experienced. The use of the Starfield-Dickson programmes for calculating heat flow into airways and advancing stopes is demonstrated in the case of ventilation planning on a large mine extending to a brief depth of over 3 km below the surface. The possible effects of new mining methods on ventilation requirements in the future is briefly discussed.

By D. G. Krige

The scope and salient features of a general risk-analysis model for the main types of new mining ventures are covered in brief outline. The following special features and their effects on the investment criteria are discussed: - various criteria for viability, - the maximum shortfall of funds, - correlations between the grades of up to five ore constituents and between the corresponding product prices. differential inflation and escalation rates for costs and prices, - the estimation, if relevant, of a pay limit based either on the major product only, or on the two major products jointly, - the likely recovery grades of all the products to be obtained when the ore-body is mined to any such pay limit. - an option to take account of the effect on the pay limit of any negative taxation on marginal ore, - investment analyses in current and real terms for individual groups of investors subscribing for equity and any loan capital on differential terms.

Jan 1, 1979

By A. Koursaris, Y. Turan

The object of this study was to investigate the i1Jfluence of nitrogen on the structure and properties of AISI 310S steel. Experimental ingots of the steel with nitrogen contents of up to 0,525 per cent by weight were prepared, hot-rolled, and tested after various treatments. The rollability of the material was adequate. The yield strength, tensile strength, hardness, and fatigue properties of the new alloys improved with increasing nitrogen content. The impact properties improved slightly. Empirical equations were developed for the calculation of the yield and tensile strengths, as well as the difference between these two properties, with increasing nitrogen content.

Jan 1, 1995

By T. Szendrei, S. Tose

The fracturing and movement of rock that occurs in the vicinity of a stemmed borehole charge in open pit mining operations are described by examining the effects of the emitted stress waves – shock and elastic – and the expansion of high-pressure detonation product gases. Three principal modes of momentum transfer to fractured rock are identified, all linked to gas expansion work. This work can be delivered radially (burden), axially (stemming), and in the collar zone (cratering). Flyrock is generated under unusual combinations of blast parameters and rock properties. Although infrequent and seldom predictable, the generation of flyrock can nonetheless be interpreted and modelled in terms of the principal mechanisms of rock projection described in this study. The physical processes underlying these principal mechanisms are identified and will permit the development of predictive models for flyrock velocities.

Dec 13, 2023

Introduction to high temperature oxidation of metals, by N. Birks and G. H. Meier, London, Edward Arnold, 1983. 19S pp. R30,25. Reviewers: M. B. Cortie and G. G. Garrett Seam gas drainage with particular reference to the working seam, edited by A. J. Hargraves. Woollongong, The Australasian Institute of Mining and Metallurgy. 370 pp. $A30. Reviewer: C. J. Fauconnier New books Solvent extraction Part I, by G. M. Ritcey and A. Ashbrook. Amsterdam, Elsevier, 1983. Elektronishche Steuerungen und Mikroprozessoren im Bergbau. Sicherheit und Zuverlassigkeit Environmental impact control. Philosophical and procedural guidelines for the planning professions Mineral processing and extractive metallurgy. Reagents in the minerals industry.

Jan 1, 1984

By D. Brazier, W. Laing, D. Nixon

Keywords: Pyrometallurgy, furnace, smelter, copper, Palabora The Palabora copper smelter has operated for the past 38 years, treating concentrates produced at the mine site. Palabora has reduced captive material by almost 40 per cent with the transition from a large open-cast to a smaller underground mine. The smelter and refinery complex was designed to treat 120 kt contained copper units per annum, with the underground only supplying 70 per cent of the feed. The agreed strategy was to import enough concentrates to maximise production and reduce operational unit costs. This transition has presented the Palabora management with new challenges both in technical and financial aspects.

Jan 1, 2006

The peak in Sulphur price late 2008 caused again intensified investigation into the decomposition of sulphates and spend acid. One option is the recycling of sulphur from spend acid, which already started more than 40 years ago in the field of spend acid from organic processes in refineries and acrylic glass manufacturing. Since this acid couldn't be neutralized and discarded due to high organic contents, another source of SO2 to produce sulfuric acid is the decomposition of metal sulfates. The decomposition of metal sulfates was investigated at the next peak in Sulphur price in the 80?s. The first major scale pilot tests and studies of gypsum decomposition were carried out for clients in Florida. The decomposition of gypsum was quite often mainly influenced by the strategic decision of some countries to get own and independent acid production. In other cases the industry doesn?t have enough space to dump the gypsum. Therefore the company was also forced to convert the gypsum into ?saleable? products to avoid these residues. Other projects were made for the recycling of iron-sulfates from the pigment industry. The motivations for these projects were not only given by acid price. For the German pigment industry it was no longer permitted in the 80?s to dump the iron sulphate residues into the sea. These regulations forced the industry to develop new technology, which allows converting of the FeSO4-residues into iron oxide and acid. Therefore economical and mainly environmental factors influenced the decision of the companies to develop and to build these plants. Beside the above mention iron- and calcium-sulphates many other process exist, which produce metal sulphates as an intermediate product. These cases are not forced by environmental or strategic factors. In cases like Ni, Co or Mn-decomposition the main product of the plant is treated in the decomposition plant and later on used as ferrous-alloys. These final products are higher in price compared to e.g. CaO, which exclude the high-energy consumption for the endothermic chemical decomposition reaction. The reaction of SO2 generation based on acid or sulfate decomposition takes place in the range of 1000°C. The energy demand of the endothermic reaction is considerable and leads due to the high fuel-combustion off-gas stream to a diluted SO2 gas. Energy prices are usually increasing at the same time like sulphur. Sulphuric Acid based on decomposition is therefore more expensive than as acid based on sulphur combustion. The paper describes fluid bed technology and possible process concepts for decomposition plants. Additionally the thermodynamic background of the decomposition process and the main influence factors are provided to receive a better understanding of this technology.

Jan 1, 2009

The peak in Sulphur price late 2008 caused again intensified investigation into the decomposition of sulphates and spend acid. One option is the recycling of sulphur from spend acid, which already started more than 40 years ago in the field of spend acid from organic processes in refineries and acrylic glass manufacturing. Since this acid couldn't be neutralized and discarded due to high organic contents, another source of SO2 to produce sulfuric acid is the decomposition of metal sulfates. The decomposition of metal sulfates was investigated at the next peak in Sulphur price in the 80?s. The first major scale pilot tests and studies of gypsum decomposition were carried out for clients in Florida. The decomposition of gypsum was quite often mainly influenced by the strategic decision of some countries to get own and independent acid production. In other cases the industry doesn?t have enough space to dump the gypsum. Therefore the company was also forced to convert the gypsum into ?saleable? products to avoid these residues. Other projects were made for the recycling of iron-sulfates from the pigment industry. The motivations for these projects were not only given by acid price. For the German pigment industry it was no longer permitted in the 80?s to dump the iron sulphate residues into the sea. These regulations forced the industry to develop new technology, which allows converting of the FeSO4-residues into iron oxide and acid. Therefore economical and mainly environmental factors influenced the decision of the companies to develop and to build these plants. Beside the above mention iron- and calcium-sulphates many other process exist, which produce metal sulphates as an intermediate product. These cases are not forced by environmental or strategic factors. In cases like Ni, Co or Mn-decomposition the main product of the plant is treated in the decomposition plant and later on used as ferrous-alloys. These final products are higher in price compared to e.g. CaO, which exclude the high-energy consumption for the endothermic chemical decomposition reaction. The reaction of SO2 generation based on acid or sulfate decomposition takes place in the range of 1000°C. The energy demand of the endothermic reaction is considerable and leads due to the high fuel-combustion off-gas stream to a diluted SO2 gas. Energy prices are usually increasing at the same time like sulphur. Sulphuric Acid based on decomposition is therefore more expensive than as acid based on sulphur combustion. The paper describes fluid bed technology and possible process concepts for decomposition plants. Additionally the thermodynamic background of the decomposition process and the main influence factors are provided to receive a better understanding of this technology.

Jan 1, 2009

By R Linares

For centuries, diamond's superlative properties have earned it a reputation as the 'dream' material for mankind in its search to create advanced applications. Until recently, this dream has been realized only in the use of diamond for gemstones and abrasive applications where several tons of diamonds are now used on an annual basis. The vision of having large, high quality diamond as part of a broad engineering tool-kit for many diverse high tech industries is now becoming a reality however, with the advent of early stage commercial availability of single crystal and poly crystalline CVD diamond.

Jan 1, 2010

Notices Competition for Student Members of the South African Institute of Mining and Metallurgy Each year the Institute offers a prize (or prizes should the entries warrant it) of up to Rl00 for the best paper or dissertation on a topic appropriate to the interests of the Institute. The competition is open to all Student Members of the Institute. NEW PUPLICATION Bougainville-the establishment of a copper mine. St. Kilda (Australia), 'Foundations', 1973. The editors of Foundations, Australia's journal of architecture, engineering, and construction, are preparing the above book for publication late in 1973. The story of Bougainville is told and illustrated NIM REPORTS Report No. 1503 Fast-neutron-activation analysis for the determination of oxygen m rock sam ples. Report No. 1514 The determination by X-ray-fluorescence spectrometry of minor amounts of niobium and tantalum in geological materials. Report No. 1530 AUREOL - an X-ray-absorption analyser for the determination of the uranium on loaded resin in ionexchange plants. Report No. 1534 The determination, by atomicabsorption spectrophotometry, of noble metals in the presence of sodium, barium, or sulphate ions. A comparison of uranium and lanthanum as 'releasing agents.

Jan 10, 1973

By C. Tokoro, T. Kato

The objective of this study is to improve the shrinking core model for particles with a particle size distribution and clarify the activation mechanism of rare earth elements dissolution by mechanochemical activation. To achieve this objective, the method, called the doubly integrated micromodel, was applied for a shrinking core model in this study. This method consists of integrating the batch leaching rate of a single particle over the distribution of both feed particle size and reactor residence time to arrive at the fraction unleached. The usefulness of the shrinking core model improved by doubly integrated micromodel was confirmed by comparing it with a shrinking core model. To apply the shrinking core model improved by doubly integrated micromodel to rare earth elements dissolution from weathered residual rare earth ores by mechanochemical activation, leaching experiments were performed for grinding samples by planetary ball milling. The reaction equation of mechanochemical reaction by planetary ball milling for weathered residual rare earth ores was investigated by x-ray absorption fine structure analysis. As a result of a kinetics study, the rate-determining process of leaching changed from reaction to diffusion reaction control by planetary ball milling. Based on these results, it was revealed that the main mechanism of activated rare earth elements dissolution from weathered residual rare earth ores was a mechanochemical reaction by planetary ball milling. Keywords: Mechanochemical reaction, particle size distribution, shrinking core model

Jan 1, 2020

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

By A. Kapito

The ferrite-pearlite microstructure is the most popular microstructure for alloys used in structural applications, including railway wagon wheels. These alloys have been designed through alloying and thermo-mechanical processing to have a refined microstructure. Ferrite-pearlite alloys are low cost, weldable, have good fabricability, and are reliable under extreme conditions. Given these performance attributes, it seems unlikely then that their dominant position as structural steels would ever be challenged by alternative microstructures. One major achievement in the development of ferrite-pearlite steels has been in the refinement of their interlamellar spacing to very fine distances of the order of < 0.3 µm. A refined microstructure increases the hardness of the alloy, thus increasing its life under wear conditions. The interlamellar spacing in pearlitic steels has, however, been refined almost to its theoretical limit. The increasing demand for speed and increased axle loading on railway wagons requires the use of stronger, tougher, and more durable materials. This has opened the window for the development of novel bainitic steels. Bainitic alloys have a higher level of microstructural refinement than pearlitic ones. They have shown to have good wear resistance and rolling-contact fatigue resistance, and high toughness. This paper will discuss the progress to date on the development of bainitic railway wheel alloys. Four alloy chemistries have been chosen for possible further development.

Jan 1, 2012

By G. R. Lane

A large opencast gold mining company in Africa had just completed a feasibility study for the expansion of the operations. A traditional net present value project valuation methodology had been used that showed a very positive net present value (NPV). The project team had conducted a qualitative risk assessment that identified and logged all potential project risks and had subjectively incorporated ?risk? via the discount rate and other assumption contingencies around gold price expectations, operating parameters etc. Management requested that an independent quantitative risk modelling approach be adopted to obtain a better understanding of the impact of risk on the overall project valuation and confidence level in the final valuation. A detailed project valuation model was configured in the Carbon Modelling Technology and the stochastic modelling module used to perform the Monte Carlo simulations. Analysis of historical operational performance data relating to actual achievements versus planned and budget determined the historical variability of the underlying parameters as well as variance to budget. This was done at a detailed level for mining rates and costs, processing rate, costs and recovery, and other operational efficiency measures. External market assumptions relating to gold price, exchange rate, and inflation were modelled and the dependency between them modelled using a copula. This case study will demonstrate the approach taken to building and populating the quantitative risk model and the overall results of the Monte Carlo simulation. The final valuation demonstrated that the project had a 44 percent probability of an NPV less than zero i.e. 44 percent chance of project finance loss.

Jan 1, 2012

By J. A. L. Napier

One of the most important characteristics of tabular mine stress analysis is the need to represent the complex evolution of mining face positions and the accompanying induced stress changes in the rock mass. Integration of seismic activity with numerical modelling requires flexible and efficient solution schemes in which both off-reef damage and large-scale fault slip can be effectively represented. A new approach is investigated in which the stope closure and ride variables can be found using a moving least squares estimator. Some advantages of this approach over traditional element-based tessellation schemes are identified. At the same time, shortcomings of this method are noted when the displacement discontinuity variable is approximated by a polynomial shape function. Difficulties and possible solutions to the shape function formulation near excavation edges are discussed. Une des caractéristiques les plus importantes de l’analyse des contraintes minières tabulaires est la nécessité de représenter la complexe évolution des positions du front de taille et des changements concomitants des contraintes occasionnées dans la masse rocheuse. L’intégration de l’activité sismique avec la modélisation numérique requiert des projets souples et efficaces qui permettent la représentation des dommages hors-filon et des glissements de faille à grande échelle. Une approche nouvelle est étudiée qui permet de trouver la fermeture de la taille et les variables de montage en utilisant un estimateur par les moindres carrés mobile. Certains des avantages de cette approche sur les traditionnels projets basés sur une structure en mosaïque sont identifiés. En même temps, les défauts de cette méthode sont notés lorsqu’on calcule la variable de discontinuité du déplacement approximativement par une fonction de forme polynomiale. Les difficultés et solutions possibles à la formulation de la fonction forme près des bords d’excavation sont discutés. Eine der wichtigsten Charaketeristika der taublaren Grubenspannungsanalayse ist die Notwendigkeit, die komplexe Entwicklung der Abbaupositionen und der damit verbundenen induzierten Spannungsänderungen der Gesteinsmasse neu vorzulegen. Die Integration der seismischen Tätigkeit mit einem numerischen Modell erfordert flexible und effiziente Lösungsschemata, in denen sowohl Schäden ausserhalb des Riffs als auch Verwerfungen großen Ausmaßes effektiv dargestellt werden. Ein neuer Vorstoß wird untersucht in welchem die Strossenschliessung und Schneisenvariablen unter Verwendung des Schätzwertes der kleinsten quadratischen Abweichungen (Gaussscher Schätzwert) gefunden werden. Einige Vorteile dieser Annäherung im Vergleich zu der traditionellen Element-basierenden Tessellation sind identifiziert. Gleichzeitig werden Unzulänglichkeiten dieser Methode vermerkt, wenn die Verschiebungsdiskoniuitätsvariable durch eine polynomische Formfunktion angepaßt wird. Schwierigkeiten und mögliche Lösungen zur Formfunktionsformulierung nahe Exkavationsrändern werden besprochen.

Jan 1, 2003

By P. R. Beeley

Metal founding - a modern perspective The recent development of metal founding is reviewed in the context of basic requirements for the successful manufacture of cil;5ti,ngs.Progress has been related to the two interdependent fields of process technology and product characteristics. . After a brief review of the growth of the traditional industry. various features of the modern industry are discussed. Reference IS made to current trends in process technology and to the introduction of new techniques affecting production engineering, product quality. and the general nature of the industry. Metallurgical aspects of metal founding are considered, and modern techniques for the control of casting conditions are examined. These aspects are related to the structure and quality of cast metal and to the development of newer types of cast material and product.

Jan 9, 1976

By A. Schippers, S. Hedrich

Chalcopyrite represents the most important copper resource and is currently mainly exploited using pyrometallurgy. Bioleaching is an environmental-friendly and economic alternative to conventional mineral processing technologies. The technical feasibility of stirred tank reactor bioleaching of copper ore concentrates using acidophilic iron-/sulfur-oxidising bacteria is proven, however, often incomplete due to inefficient chalcopyrite dissolution. A decoupling of bacterial growth from bioleaching activity in one bioreactor by adjusting appropriate temperatures for both process steps allows for almost complete chalcopyrite dissolution. Separation of copper and recovery of other metals from the PLS was possible by implementation of different biological and chemical techniques. The Ferredox process has been proposed to treat limonitic laterite ores for cobalt and nickel recovery by means of anaerobic reductive dissolution with autotrophic, acidophilic bacteria. As a modification, aerobic reductive dissolution of laterites with acidophilic bacteria has shown economic and environmental advantages over anaerobic reductive dissolution. The reductive bioleaching technology has the potential to increase metal recovery in existing mines, and transform unexploited ores and limonite stockpiles into valuable resources. Keywords: Biomining, bioleaching, chalcopyrite, laterite, Ferredox process

Jan 1, 2020

By C. O. Esterhuysen, J. P. Deetlefs, C. A. Wessels

The productivity indices of the Republic of South Africa compare poorly with those of its competitors in the rest of the world. The theory of productivity is relatively simple, and various models are available to demonstrate this. The problem is how to apply the theory in practice and to convert it into a practical management system that will guarantee results. The secret lies in a management approach that aims at a continuous improvement in achievement and that involves the entire work force down to the lowest level in the process. Good management systems ensuring the necessary attention to, among others, management by objectives, finance, personnel, maintenance, planning, and control are a prerequisite for continued improvement and staff involvement. The net result of such an approach is described by the term performance management, which encompasses the total integration of al a company&apos;s management systems.

Jan 1, 1989