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By L. Jeffrey

The Waterberg Coalfield has vast potential to become a significantmining and industrial centre in South Africa. Its future developmenthinges on a number of critical decisions that must be made jointly by government, power utilities and industry, and on some technical and economic challenges that must initially be overcome. Sufficient water is the primary key to enabling exploitation, together with an adequate market for the large volumes of low-grade coal. As the most likely consumer of this coal will be either a power station or a petrochemical complex, the need for additional energy will be a driving force in the development of this coalfield. Conventional mining methods can exploit the shallow coal resources in both the Grootegeluk and the Vryheid formations, but alternative technologies such as coalbed methane extraction and underground coal gasification are the only currently known technologies that may be able to exploit the deep Grootegeluk Formation resources. However, extensive research is still required into these procedures, particularly with respect to the Waterberg coals. Transport infrastructure to the region is currently not sufficiently well developed to support large-scale exploitation of the region?s coal resources. In particular, the railway line would have to be extensively upgraded to allow the increased export of coal. Alternative transport methods such as pipelines would also have to be pursued to serve a large Sasol-type petrochemical complex or coal gas extraction. The road network would also require improvement, as only the roads between the main commercial centres are currently tarred. Dr Con Fauconnier, Kumba CEO, concluded his presentation to the Investing in African Mining Conference 2004 with the words: Again, it?s all about infrastructure? when it?s there, it enables the development of bulk mining projects which attract the resultant economic benefits for the region and country as a whole. These words aptly sum up one of the stumbling blocks to the future development of the Waterberg Coalfield.

Jan 1, 2005

By W. Stumpf

Mill log analyses and complementary hot deformation studies were carried out on the as-cast structure and on a hot rolled structure of the same low carbon steel (SAE 1006) that had been processed according to the direct or hot charge route in a compact strip plant. The main softening mechanisms during hot rolling were found to be complete dynamic recrystallization during each pass above about 1000°C for the as-cast structure with an austenite grain size of 277µm and, secondly, incomplete static recrystallization after each pass with a finer austenite grain size of about 26 µm and tested below 1000°C. A two-stage hot working mechanism has also been found by others on a similar steel also processed by the hot charge route and this may appear to be a characteristic of this type of material. Constitutive constants determined from hot working studies were combined with other constants from the literature and incorporated into a grain size development model that correctly predicts the final ferrite grain size in the hot rolled strip steel. The predicted incomplete static recrystallization during the last three finishing passes in the plant appears to result in some retained strain in the hot rolled austenite as it transforms to ferrite on the run-out table. Analyses with the model predict relatively little sensitivity of the final ferrite grain size to process and product variables such as temperature and strain per pass for the last three passes and also the starting austenite grain size in the slab. Keywords: Low carbon steel, hot rolling of strip steel, rolling mill log analyses, austenite grain size, ferrite grain size, grain size modelling.

Jan 1, 2003

By L. R. C. Cairncross

In this study, the general case of semi-batch precipitation of nickel hydroxide, Ni(OH)2, is modelled. In practical terms, this precipitation may occur at high ionic strengths, and therefore the model for solution chemistry requires a thermodynamic model that is applicable for these non-ideal systems. The activity coefficient model used is the ELEC-NRTL. The simulation of the solution chemistry is performed using AspenPlusTM, which is a steady-state process simulation program. This allows for rigorous evaluation of the solution speciation, and hence the degree of supersaturation which dictates the precipitation kinetics. The solution chemistry provides the basis for predicting the formation of solids. The model consists of a solution chemistry part and a solids formation part. The inputs to the model include the initial concentrations of the streams entering the reactor, kinetic parameters for the precipitation processes, and a particle size distribution obtained from experiments. The solids formation part of the model employs the method of moments for the evaluation of the population balance. The population balance accounts for total particle number, and the formation and increase in size of particles across the entire particle size range. This balance requires kinetic parameters for the processes of nucleation, growth and agglomeration. Using optimization routines inherent in AspenPlusTM, parameters for the rate of nucleation, growth and agglomeration may be extracted from experimental particle size distributions. These are then used in the model to extrapolate to other conditions. Once an understanding of the kinetics of the precipitation processes is gained, the model provides a predictive tool for optimization of these kinetics, in order to increase the overall particle size and therefore improve solid-liquid separation. The work is deemed to be significant as it sheds some light on solids formation processes involved in precipitation?including nucleation, growth and aggregation?and develops a predictive modelling tool applicable to solutions of high ionic strength. We argue that this dewatering of suspensions is affected significantly by particle size distribution and surface properties of the solids formed by precipitation. This modelling tool should facilitate the design of solids formation processes where downstream dewatering is enhanced.

Jan 1, 1997

By E. R. Davis, R. J. Knott

The paper discusses some of the tools of management in the field of project control, especially in engineering. Project control includes planning and cost engineering, and involves various phases: the conceptual Design and Planning Phase, the Definitive Design and Capital Budgeting Phase, and the Implementation Phase. Each of these phases is discussed in in, together with the use that can be made of data banks, progress reports, and computer systems.

Jan 1, 1982

In ilmenite smelting, the FeO content of the feed material (nominally FeO.TiO2) is decreased by reduction with carbon. In a parallel reaction, a significant amount of the TiO2is reduced to Ti2O3.One of the striking features of these reactions is a consistent relationship between the extents of FeO and TiO2reduction; this relationship is independent of furnace size. It was recently proposed that this relationship follows from the solidification behaviour of the slag, where the final slag composition corresponds to the minimum melting point (?eutectic groove?) in the FeO-TiO2-Ti2O3phase system; the hypothesis is that solidification equilibrium with the freeze lining stabilizes the slag composition. If this is the case, the system of slag and freeze lining must be capable of correcting two types of disturbances: thermal and compositional. Thermal disturbances result from incorrect power input, for the feed rates of ilmenite and reductant. For example, excessive power input will tend to overheat the slag, causing the freeze lining to melt partially, establishing a new steady-state heat loss from the furnace. Compositional disturbances result from an incorrect reductant input for the given power and ilmenite input. In this work, the dynamic response of the slag and freeze lining to different inputs (flow rates of ilmenite and reductant, and power input) is modelled. The model is based on solidification equilibria, and quantified heat loss through the freeze lining. The conclusion is that the solidification equilibrium cannot constrain the composition to the eutectic groove for typical operating conditions. Keywords: ilmenite smelting, freeze lining, solidification, high-titanium slag

Jan 1, 2004

By C. Daly

The Faculty of Engineering at the University of New South Wales (UNSW) offers a core first-year engineering design and innovation course, ENGG1000, undertaken during the first and second semesters. This course is highly regarded in the sense that it provides an introduction to many concepts and activities that students will experience over the four-year minimum for which they are undergraduates at UNSW. Approximately 1400 students enrol in the semester 1 course across the Faculty, typically 80 of which undertake the Mining Engineering stream. Students in teams of between six and eight design and construct a physical model to represent an aspect of their chosen discipline. For example, in 2013 the mining engineers designed and built a model dragline. This paper concentrates a major aspect of the course ? the involvement of team members in group activities and the development of the associated skills of peer assessment and peer review as the course progresses over a period of 12 weeks. The term ?peer assessment? in this paper refers to the requirement for students to assess the design components of their peers. This course has a structured requirement in terms of how a successful design is a result of a sound design process rather than a ?try and see? approach. Each student must describe in detail the process they undertook to achieve their final design ? hence the approach is independent of the discipline and/or project selected. Peer review is a process whereby students review the contribution of their team members to the overall design. This activity encourages team involvement and interaction. The final assessment mark can be moderated by the outcome of this peer review, although it is run twice during the semester. The first ?run? is for feedback only during week six and hence no moderation is undertaken. It was found through consultation with students and from questionnaires that both processes are well accepted and highly regarded by students, as they give them a degree of ownership of the assessment process. In addition, the processes provide rapid and relevant feedback on the progress of individual students. Peer review and peer assessment are also considered to be very valuable tools for use in courses in succeeding years. For instance, many of the courses in mining engineering rely heavily on group assessment tasks.

Jan 1, 2014

By C. Daly

"The Faculty of Engineering at the University of New South Wales (UNSW) offers a core first-year engineering design and innovation course,ENGG1000, undertaken during the first and second semesters. This course is highly regarded in the sense that it provides an introduction to many concepts and activities that students will experience over the four-year minimum for which they are undergraduates at UNSW. Approximately 1400 students enrol in the semester 1 course across the Faculty, typically 80 of which undertake the Mining Engineering stream. Students in teams of between six and eight design and construct a physical model to represent an aspect of their chosen discipline. For example, in 2013 the mining engineers designed and built a model dragline. This paper concentrates a major aspect of the course - the involvement of team members in group activities and the development of the associated skills of peer assessment and peer review as the course progresses over a period of 12 weeks.The term ‘peer assessment’ in this paper refers to the requirement for students to assess the design components of their peers. This course has a structured requirement in terms of how a successful design is a result of a sound design process rather than a ‘try and see’ approach. Each student must describe in detail the process they undertook to achieve their final design - hence the approach is independent of the discipline and/or project selected.Peer review is a process whereby students review the contribution of their team members to the overall design. This activity encourages team involvement and interaction. The final assessment mark can be moderated by the outcome of this peer review, although it is run twice during the semester. The first ‘run’ is for feedback only during week six and hence no moderation is undertaken.It was found through consultation with students and from questionnaires that both processes are well accepted and highly regarded by students, as they give them a degree of ownership of the assessment process. In addition, the processes provide rapid and relevant feedback on the progress of individual students.Peer review and peer assessment are also considered to be very valuable tools for use in courses in succeeding years. For instance, many of the courses in mining engineering rely heavily on group assessment tasks."

Jan 1, 2014

The acoustic signals emitted from a laboratory-scale ball mill were used for the estimation of the comminution of two complex sulphide ores, viz. Merensky and UG2 ores from the Bushveld Igneous Complex in South Africa. The digital acoustic signals were transformed to power spectral densities that could be related to particle size distributions (-75 µm to 4000 µm) in the mill by use of continuum regression. This approach is more general than principal component regression methods or Kalman filtering used previously and resulted in significantly more accurate calibration in the case of the Merensky ore, where approximately 93.4% of the variance in the particle size distributions could be explained. With fewer data available, the variance in the particle size distributions in the UG2ore could be explained less accurately (82.4%), but still satisfactorily. In addition, smaller particle sizes (less than 300 µm) could be modelled more accurately in the case of the UG2 ore.

Jan 1, 2000

By R. Altindag

In rock cutting mechanics, the effects of the rock and coal brittleness on the efficiency of cutting bits are examined by many researchers. There is no universally accepted brittleness concept as a measure of cutting efficiency. The effect of the brittleness on rock cutting has not been completely explained. The aim of this study is to correlate the relationships between Specific Energy (SE) and brittleness concepts. The applicability of various brittleness measurement methods for rock cutting efficiency has been investigated. In this study, the raw data derived from previous experimental studies were used, and the relationships between SE and brittleness concepts were investigated. The two previously used brittleness concepts, which are named as B1 (the ratio of compressive strength to tensile strength) and B2 (the ratio of compressive strength minus tensile strength to compressive strength plus tensile strength), and a new introduced brittleness concept named B3 (the area under line in relation to compressive strength and tensile strength) were evaluated in this study. The relations among these brittleness concepts for rock cutting efficiency were established using regression analysis. There is no correlation found between the SE values and the brittleness of B1and B2values. But, the SE is strongly correlated with the brittleness of B3. It was seen that the suggested brittleness of B3concept could be used as an indicator in rock cutting efficiency analysis.

Jan 1, 2003

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 357 to 366 for the year ended 30 June 2002. 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 statements of South African Auditing Standards. Those standards require that we plan and perform the audit to obtain reasonable assurance that 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. Audit opinion In our opinion, the financial statements fairly present, in all material respects, the financial position of the Institute at 30 June 2002 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. Auditors 26 July 2002 Council?s approval of the annual financial statements The annual financial statements for the year ended 30 June 2002 set out on page 357 to 366 wereapproved by the Council on 26 July 2002 and are signed on its behalf by:

Jan 1, 2002

By T. Lindstad, S. Gaal, S. Hansen, S. Prytz

The SINTEF SiO-reactivity test, developed by Tuset and Raaness in the 1970?s, is a recognised method of characterising the ?reactivity? of carbonaceous reactants, used in the ferrosilicon and silicon metal industries. Recently, the test has been updated, which has resulted in the development of an extended and improved SINTEF SiO reactivity test. This has included updating the test reactor, control system, data-logging, handling and preparation of carbonaceous materials to be tested and measurement procedure. The scientific basis has been re-assessed, resulting in a new interpretation of the test results. The repeatability of the test has improved significantly, especially through system automation. In the ?old? test, the kinetics of the reaction: SiO(g) + 2C(s) = SiC(s) + CO(g) for a specific carbonaceous material was characterised solely by the ?R10? parameter, the volume of SiO(g) which passes un-reacted through the coke-bed as the concentration of CO in the outlet gas decreases from 18 to 10%. As both the kinetics and obtainable conversion of SiO to SiC for a reductant is of importance to the ferroalloy producer, the new SINTEF SiO reactivity test ranks carbon materials both according to degree of conversion and reaction rate. From research carried out on the test in the past couple of years at SINTEF and NTNU, it has also become clear that some of the reactions taking place in the test reactor are more complex than previously assumed. As an example, it was previously assumed that the condensation reaction of SiO gas in the condensation chamber of the test reactor can be described as: 2 SiO(g) = Si(l,s) + SiO2(s). However, it has been established that the side-reaction: CO(g) + 2Si(l) = SiC(s) + SiO(g) causes approximately 10% of the total volume of CO to react to SiC and SiO2 in the condensation chamber. This means that some back-reaction i.e., the reverse SiO-generator reaction 3SiO(g) + CO(g) = 2SiO2 + SiC also takes place in the condensation chamber. In the new SINTEF test, the %CO versus time curves are therefore corrected in order to describe the effect of the reaction between SiO(g) and C(s) studied i.e., SiO(g) + 2C(s) = SiC(s) + CO(g). A correction-formula for this purpose is presented.

Jan 1, 2007

By J. N. Van der Merwe

The results of over 900 coal strength tests done during the period 1993?1994 for the SIMRAC project COL021A were re-analysed with a view to find a method to delineate areas or seams that can be grouped together for analyses of coal strength and strength decay characteristics. It was confirmed that the strength of a coal specimen increases linearly with increasing diameter-to-length ratio and decreases exponentially with increasing size of specimen. However, by extrapolation of the data, it was shown that beyond a diameter of approximately 2 m, the size effect is insignificant. For larger specimens, the diameter-to-length ratio (referred to as the width-to-height ratio for full scale mine pillars) alone continues to influence the strength. The slope of the linear strength vs. diameter-to-length ratio relationship is independent of the size of the specimen and is not unique for coals from different mines. However, the intercept of that relationship is unique and is a function of specimen size. This offers a previously unknown method to distinguish between the coals from different mining areas and coal seams. Ranked from weakest to strongest, the samples tested from the different mines are in the order shown below, which roughly corresponds to the judgement of practising rock engineers in the field: ?Sigma ?ZAC ?Goedehoop ?Kriel ?Bank ?Blinkpan ?Secunda ?Greenside Arnot ?Khutala ?Delmas

Jan 1, 2003

By M. Sanchez, C. Morales, J. Palacios

The slag produced in the Peirce Smith converters at the Ilo smelter of Southern Peru Copper Corporation has shown a wide range of magnetite content, which introduces an additional problem in the smelting units due to materials? recirculation. However, the operation data analysis and the application of thermodynamic concepts have made it possible to produce slag with magnetite content between 18 and 20%. The results have suggested that matte grade enhances magnetite formation while silica controls its precipitation, and they are also influenced by the increasing temperature of the slag. Thus, in order to obtain the required magnetite content in the slag, matte grade is gradually enriched in equilibrium with slag containing from 25 to 32% silica.

Jan 1, 2004

"For effective steel refining in the ladle (secondary steelmaking) the amount of steelmaking slag that is transferred from primary steelmaking must be limited, because the steelmaking slag contains iron oxide, manganese oxide, and phosphorus oxide. Adverse effects of slag carry-over include increased consumption of deoxidizers, phosphorus pick-up by the steel, and increased ladle refractory wear. Infrared imaging at longer wavelengths is an effective non-contact method to detect slag in the tapping stream. Various devices are used to shut off the tapping stream rapidly. These include slag darts, pneumatic slag stoppers, and slide gates for steelmaking converters, and eccentric bottom tapping for electric arc furnaces. IntroductionOxygen converters and electric arc furnaces are used for primary steelmaking. For both process types, the product (liquid crude steel) has a similar composition: largely liquid iron, with around 800–1000 parts per million (ppm, by mass) dissolved oxygen and low but significant concentrations of carbon, nitrogen, and phosphorus. The steel is tapped into a ladle, which serves as the refining vessel to adjust the final steel composition and temperature before casting.Some steelmaking slag is inevitably tapped with the liquid steel. The mass of steelmaking slag tapped with the steel is termed ‘slag carry-over’. Controlling and limiting slag carry-over from steelmaking is a primary requirement for clean steel production (Fandrich, Lüngen, and Wuppermann, 2008). Steel cleanliness refers to limiting the concentrations of dissolved impurities (such as nitrogen, oxygen, phosphorus, and sulphur) and of nonmetallic inclusions (oxides, sulphides, and nitrides) in liquid steel and in the final solid steel product. Of these, the strongest effect of slag carry-over is on the content of dissolved phosphorus in the liquid steel"

Jun 1, 2019

By M. A. Hermanus

This paper examines the occupational health and safety performance (OHS) of the South African mining sector against the backdrop of changes in the composition of the sector, international trends in OHS performance, and the agreement on OHS milestones and targets by mining stakeholders at the Mine Health and Safety Summit of 2003. Although OHS performance has improved, progress is slow and there is need for significant rather than incremental change if the targets are to be realized. Since 2003, fatalities and injuries are 20?25% short of annual milestones and not all commodities show consistent improvement. Statistics on occupational health impacts are unavailable, but noise and respirable dust levels are known to be high in mines, with much work lying ahead to address exposures at source. Trends in regulating and addressing OHS hazards are discussed with reference to the notion of ?systems-thinking? and the targets. Efforts to improve OHS and to respond to changes in the sector are constrained by a lack of training and consistency in risk management, guidance for junior, small and artisanal miners, and holistic approaches to risk. For example, treating risk holistically would involve taking proper account of contractors and women in the workplace, and attending to human factors and ergonomics.

Jan 1, 2007

By K. G. Matshika

"Nickel electroplating from sulphate electrolyte is an efficient process. To achieve good quality cathode, however, parameters such as temperature, nickel concentration, pH, electrode alignment, electrolyte flowrate and additives must be optimised, because these affect cathode morphology and current efficiency. It is also important to control the clarity and contamination of the electrolyte, as these have a considerable effect on the quality of the cathode surface. Delamination, surface roughness and pitting on the cathode surface can be caused by incorporation of solid particles or impurities form the electrolyte. Three types of solid particles were investigated: cuprous selenide, barium/ lead sulphate (co-precipitated) and ferric hydroxide. These particles can be found in industrial electrolytes, especially if there is a problem with the filtration step or contaminants have reacted to form insoluble particles. A rotating cylinder Hull cell was used for this investigation. It is found that the effects on morphology depend on the type of solid, concentration, particle size, current density and electrolyte flowrate. Cuprous selenide is the most detrimental, especially at higher concentrations, higher current densities and low flowrates. Increased rotational speed offers a uniform sheet of fine gas bubbles across the surface of the cathode which reduces the thickness of the diffusion layer of liquid adjacent to the cathode and increases the rate of mass transport to the cathode from the bulk liquid. INTRODUCTION Electrowinning operations are important when recovering associated by-products of nickel production, such as copper, cobalt and zinc, from pressure leach solutions. The base metal mineralization associated with platinum-group metal (PGM) production yields significant quantities of copper and nickel as by-products. The base metal refinery is vital in PGM processing as it increases the PGM concentration from mined ore by a factor of 400, in comparison with concentration by flotation (20 times) and pyrometallurgical processing (20 times) (Crundwell et al., 2011). Anglo American Platinum Ltd produces nickel cathodes by electrowinning and purges sodium from the base metal refinery in the form of sodium sulphate at the Rustenburg Base Metals Refinery (RBMR), as shown in Figure 1. This is the Sherritt acid leach process used in most base metal refineries to ensure no loss of PGMs and shows the subsequent purification steps for copper and nickel. Other refineries in Zimbabwe, such as Bindura and Empress, use the Outokumpu leach process (Pavlides, 2001)."

Jan 1, 2015

By S. Witzke, J. Lehmann, H. Gaye

The modelling work presented here concerns Ni-bearing steels produced by Imphy Ugine Précision. In such grades, the contents of elements such as silicon or titanium must be precisely controlled by slag/metal treatments. The slag phase is described by IRSID slag model that has been slightly revised in order to better fit recent SiO2activity measurements in the low SiO2content domain of the CaO-Al2O3-CaO system. The metallic alloys are described by the unified interaction parameter model (UIPM). In this formalism, the interaction coefficients, giving the effect of nickel on Al, Si, Mn and Ti activities, have been determined by electrochemical measurements and/or extracted from industrial data on slag/metal treatments concerning a wide range of alloy compositions: [ ] Keywords: slag, Ni alloyed steels, activities, interaction coefficient

Jan 1, 2004

By Z. Lin, M. Isac, R. I. L. Guthrie

The kinetic and thermodynamic efficiencies of chromium recovery from the slag in an AOD process during the slag de-oxidation period with ferrosilicon is a complex process affected by slag basicity, temperature, the dissolution kinetics of the reducing agents, and intermixing of the slag/metal/alloy addition phases within the vessel. The present work focused on a study and simulation of the fluid dynamics and mixing behaviour of ferrosilicon additions in the AOD process for the production of stainless steel. In order to visualize the mixing behaviour, a two dimensional slice model of an AOD vessel was first built and filled with ZnCl2solution and then covered with silicone oil in order to represent the bulk liquid steel and slag phases, respectively. The injection of argon/oxygen process gases was simulated using air or helium. Particle trajectories and intermixing of the phases was monitored with a high-speed camera. To simulate the 75FeSi additions, glass spheres were used. A three-dimensional version of the AOD model was then constructed in order to confirm the adequacy of the slice model. Similar particle mixing behaviour was observed. Both models demonstrated that the ascending gas/liquid plume created two asymmetric mixing zones: a smaller rapidly re-circulating mixing zone adjacent to the side-wall locating the tuyere(s), and a larger mixing zone in the main part of the vessel. The process efficiency during the reduction period is governed by the thermal behaviour of ferroalloy as well as the mixing efficiency in the main large mixing zone. To enhance the recovery efficiency for chromium, small Fe-Si particles are suggested, given their wide distribution within the slag phase, and their large interfacial areas and rapid melting times for Cr2O3reduction from the slag. Keywords; modelling, ferrosilicon, chromium oxidation, AOD steelmaking.

Jan 1, 2004

By N. R. Williams

Black Mountain, a polymetallic base metal mine located in the Northern Cape territory of South Africa has been blessed with high grade economic ore for many years. Now that the Broken Hill orebody is nearing the end of its life, a lower grade orebody (Swartberg) is being exploited to supplement production from Broken Hill. In addition, ore from stopes in the upper levels of the Broken Hill orebody is considerably tarnished (oxidized). As a natural result, the remaining ore contains a higher percentage of magnetite, pyrrhotite and pyrite than in earlier years. Bismuth, cadmium and cobalt also occur in the ore in higher quantities. The life of the mine has been lengthened with the discovery of further deeper-lying ore reserves extending from the Broken Hill orebody suitably called the Deeps section. However, to bridge the gap between development of the new reserve and the exhaustion of the old reserve, these lower grade and tarnished (oxidized) ores have to be treated. The mine has had reasonable success in identifying unfavourable or problematic ore types and stockpiling them separately to blend in small quantities with more favourable ore. Bench and plant scale tests have aided identification of the various ore types and significant improvements in flotation metallurgical results have been seen. Copper, lead and zinc metal occur as sulphides in the ore. The mill consists of a differential and sequential flotation process that extracts copper concentrate, lead concentrate and zinc concentrate respectively with silver metal recovered in the copper and lead concentrates. This paper describes the ore blending strategy employed at the mine to maximize the econo-metallurgical efficiency of the operation.

Jan 1, 2001

By C. J. Cutler

Metallurgical accounting for toll treatment smelters pose a number of challenges. Multiple feed stockpiles have to be accounted for as part of the monthly recovery estimation. Moreover, multiple metallurgical intermediates make up part of the in-process inventory, which also influence the monthly recovery calculation. Errors propagate from the measurements of volumes, assays, moisture fractions and bulk densities in the various material types through multiple steps up to the point where the final recovery is calculated. These errors contribute non-linearly to the variance in the final recovery estimate. This paper develops the mathematical formulation for variance propagation in toll smelting operations, including the effect of in-process inventory, assuming measurement biases have been eliminated beforehand. Operational data from a Southern African copper smelter is used for a case study. The method of propagation of variance showed that uncertainties in stockpile assays were the main contributors to variance in the recovery estimate. Variance in the volume and bulk density uncertainties contributed a secondary, yet significant, proportion to the overall recovery variance. It was determined, for the given case study, that the recovery variance depended on the calculation method used and that variance propagation via the two-product formula was smaller than recovery variances calculated via the standard recovery formula. However, the probability that the two product formula will give inaccurate (versus imprecise) results is significantly more due to the practical difficulty of equiprobable sampling of tailings streams from smelter plants (which includes materials such as slags and flue dust). Recommendations are made on how to achieve a reduction in overall uncertainty for toll treatment smelters. Keywords: metallurgical accounting, copper smelters, pyrometallurgy, variance propagation, errors, precision, sampling

Jan 1, 2006