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By T. Copland

"The decreasing availability of resources amenable to surface operations has led to increasing numbers of underground mines, with trends indicating this will continue into the future. As a result, there is a need for additional optimization processes and techniques for underground mines, with many analogous methods having already been developed for surface mining. Current methods for design and optimization of stope boundary selection and scheduling mainly involve heuristic methods which focus on a single lever. Individual optimality may be approached, but globally optimal results can be obtained only by an integrated, rigorous approach. In this paper we review previous methodologies for stope boundary selection and medium- to long-term scheduling and highlight the need for an integrated approach. Previous integrated approaches are reviewed and an improved modelling system proposed for shorter solution times and greater applicability to mining situations. Randomly generated data-sets for gold-copper mineralization are used to investigate the model performance, describing solution time as a function of data complexity.IntroductionThe increasing need for mineral resources is driving an increase in underground mines. Lower grade mineralization with larger amounts of overburden is becoming economically viable due to technological advances; however, the software and tools available for strategic underground mine planning are not well developed. Advances in the methods used to determine underground layouts and scheduling must occur to ensure underground mining is as optimized as open pit operations, as underground mining involves many more technical restrictions.The process of determining stope boundaries and scheduling is an example of an aspect of underground mining amenable to optimization (Topal and Sens, 2010). The current industry standard for medium- and long-term planning for sublevel stoping (SLS) is to exclusively determine stope outlines and then determine an appropriate sequence and schedule accordingly. This process violates the concept of optimality as integrating the constraints imposed by pre-determining stope outlines does not allow for considerations in scheduling to influence boundary planning (Ataee-Pour, 2005). An integrated planning process that combines both stope outlines and scheduling would approach the optimal solution and hence generate more value for operations. This investigation specifically deals with the underground sublevel stoping (SLS). Other underground mining methods such as block caving, sublevel caving, and room and pillar mining have unique characteristics and therefore require specific stope boundary/production scheduling considerations."

Jan 1, 2016

By S. Tu, Y. Yuan, H. Wei, Z. Chen, M. Jia

"To reduce production costs and increase efficiency in ageing coal mines, a system that utilizes two shearers in a fully mechanized longwall working face is proposed. Using theoretical and engineering experience, three issues pertaining to the system were determined: (a) the two-shearer mining technique; (b) matching and modifying the equipment; (c) and coal-cutting task allocation for each shearer. Two mining processes are proposed, with the two shearers travelling in either the same or opposing directions. To avoid breakage of chains and pan extrusion of the armoured face conveyor (AFC), the length of the AFC ‘snake’ was controlled. To ensure continuous cutting and transporting of coal, the cross-sectional dimensions of the AFC were checked and the shearer closer to the head drive was modified. Based on the assumption of equal cutting times for each shearer, the meeting position of the two shearers was obtained by using a theoretical model of mining task allocation. Application of this technique at No. 2 Jining Mine, China, has shown remarkable benefits: daily production capacity was increased by 54% and personnel efficiency was improved by 33 t/d per person. IntroductionAll coal mines aim to increase the unit output of the working face to reduce mining costs and improve the economic efficiency of the operation. To achieve this goal, a production model known as one mining face of the mining area has been adopted by most Chinese coal mines (Hu, Meng, and Zhu, 2008; Zhang, Zhang, and Wang, 2000). Under these conditions, the main technical approaches to maximize the output are increasing the width of the working face (Qu, Xu, and Xue, 2009) and accelerating the advancing speed (Robbins, 2000). In coalfields with shallow seams, the width of a fully mechanized face exceeds 300 m (Ju and Zhu, 2015; Fu, Song, and Xing, 2010); in coalfields with deep seams, the width of the face is usually greater than 240 m (Liu et al., 2016; Li et al., 2013). The term ‘super-long working face’ was proposed to describe working faces with a width of over 240 m (Zhao and Song, 2016; Xu et al, 2007) in China. To support these long working faces with rapid advancing speeds, high-powered mining equipment is required (Kulshreshtha and Parikh, 2001, 2002; Tu et al., 2009; Mishra, Sugla,and Singha, 2013). This is easily achieved in newly built mines, but is not a good choice for ageing mines because of the low return on a high investment on account of the limited remaining resources. It is therefore difficult for ageing mines to significantly increase their unit output with the existing mining equipment. This study focused on this problem: two shearers were applied to a longwall fully mechanized working face (LFMWF) to achieve increased unit output."

Oct 1, 2018

By M. Onifade, O. S. Otuogbai, A. F. Mulaba-Bafubiandi, O. D. Eniowo, H. Grobler

Artisanal and small-scale miners in Nigeria struggle to attract formal financing to upgrade their operations to a more sustainable form of small-scale mining operation. Literature shows that for an investment to attract formal sources of financing; the business must be considered creditworthy by potential lenders. This means that the credit risks associated with the investment must be bearable for the potential lender. This study looks at how artisanal and small-scale miners can attract formal funding, which will help them take the leap from artisanal state to a form of sustainable small-scale mining operation. This study evaluates the creditworthiness of artisanal and small-scale mining operators using key credit risk parameters identified in the literature and through primary investigation. A quantitative study is conducted on a sample of 100 artisanal and small-scale miner establishments in Nigeria to evaluate the effect of these identified credit risk parameters on creditworthiness. It is shown in this study that being a member of a mining cooperative society, which is a form of social collateral, best improves the chances of access to formal financing for miners within the sample group. This underpins the role of social collateral, in both the formal and informal economy, and its influence in improving the creditworthiness of a typical artisanal and small-scale miner.

Jul 23, 2025

By P. O. Akinseye, F. T. Cawood

Mineral royalties are one of the oldest forms of mining taxation, and were initially introduced to extract economic rents from mining. Over time, the royalty regime has become more complex as it was identified as an important policy instrument that can achieve more multi-faceted outcomes. Such a multi-tiered approach in the use of the royalty instrument is also the case with South Africa. With South Africa’s new mineral royalty regime now in place for ten years, it is perhaps time to assess its impact and effectiveness. To carry out this assessment, an econometric evaluative study was undertaken using four major commodities in South Africa, namely gold, platinum, iron ore, and coal. The study explored five different policy options for government to consider and tested them to determine the most favourable one that will realize the regime’s policy objectives. After the assessment, two major options stood out. Hence, this paper seeks to highlight which of the two options is the most favourable for consideration by policymakers. Based on that study, we find that the current structure is effective, but also recommend that the factors in the formula for refined minerals be ‘modified’ to reduce the capped profitability ratio from the current 60% to 30% and the maximum royalty rate for refined minerals from 5% to 3%. The minimum rate of 0.5% during times of depressed mineral prices and no or low profitability will not be affected.

Dec 1, 2021

By T. Marin, J. E. Seccatore, M. Cardu

The most energy-intensive process in the mining industry is particle size reduction – comminution. The first phase of this process is blasting to fragment the rock from the initial Boussinesq’s halfspace size. Scientific literature demonstrates that the output of a blast in terms of fragment size distribution can be manipulated by varying the specific charge (powder factor) and charge distribution. This study focuses on the influence of blasting on the internal resistance of the blasted fragments; in particular the influence of the spatial distribution of charges. Small-scale blasts were performed on 14 marble blocks using different powder factors and charge distributions. Three control blocks were fragmented by mechanical means for comparison. The results show the correlations between charge distributions and the specific energy of mechanical comminution. Opportunities for adjusting charge diameter and distribution in opencast blasts to improve the performancet of comminution circuits are discussed.

Aug 8, 2024

By H. von Blottnitz, B. E. Isheloke

Mining is a significant economic activity in most Southern African Development Community (SADC) countries, and mineral beneficiation has been identified, and controversially discussed as one of the possibilities for industrialisation. With many member countries being economically too small to muster the human and financial resources which beneficiation requires, the recently adopted Regional Mining Vision (RMV) envisages interventions at a regional level. An opportunity arose to ask industry role players to what extent the SADC appears to support regional beneficiation policy interventions undertaken by member countries, and what the challenges are in undertaking beneficiation regionally, as a complement to, or substitute for country-specific beneficiation policies. Twenty-five semistructured interviews were conducted with experts from SADC member countries during the 2019 Mining Indaba. Participants were divided on whether beneficiation should be carried out nationally or in the SADC region. While beneficiation could support value-keeping, key challenges were found to be infrastructure development (i.e. energy, water), scarce skills, access to technology and related costs, but also lack of free trade and movement. We submit that a more integrated beneficiation strategy for the SADC region, as is being developed through the RMV, would indeed be relevant in the future. Keywords: Mineral beneficiation, regional integration, beneficiation policy interventions, African mining vision, mining, SADC

Jan 1, 2020

By K. A. du Preez, P. J. van Staden, M. van Rooyen

Mine-impacted water, including acid mine drainage (AMD), is a global problem. While precipitation of dissolved metals and neutralization of acidity from mine-impacted water is accomplished relatively easily with lime addition, removal of sulphate to permissible discharge limits is challenging. This paper presents a high-level comparison of four sulphate removal technologies, namely reverse osmosis, ettringite precipitation, barium carbonate addition, and biological sulphate reduction. Primarily operating costs, based on reagent and utility consumptions, are compared. Each process is shown to be subject to a unique set of constraints which might favour one over another for a specific combination of location and AMD composition. Access to and cost of reagents would be a key cost component to any of the processes studied. The total cost calculated for each process also depends on the type of effluents that are allowed to be discharged.

Oct 1, 2021

By P. van der Westhuyzen

Gone are the days of stock-standard diamond beneficiation and final recovery circuits that could, with minor modifications, be adapted to treat any diamond-bearing ore source. A new era has dawned, offering the opportunity to streamline existing diamond processing operations or develop simpler, more efficient, and economical diamond processing plants, with the focus on more efficient comminution, beneficiation, and final recovery. This change in scene has been brought about by: ? The introduction, rapid development, and maturation of multiple comminution, sorting, and recovery technologies ? The need to adapt to a new standard of project approach post the commodity super-cycle phase, where optimizing existing operations and developing scalable, ?fit for purpose? new mines are fast becoming the norm in diamond processing plants in both primary and alluvial operations ? The quest for energy efficiency and lower labour costs ? More remote and inaccessible reserves (under lakes, tops of mountains etc.). This paper serves to identify some technology advances and demonstrates how these could be considered as replacements for or in combination with conventional technologies to arrive at an optimum techno-economic solution. To name a few applications/technologies: ? Comminution: conventional cone crusher, modified/specialized cone crusher, and the high-pressure grinding roll (HPGR). Although significant advances have been made in recent years, this paper only briefly covers comminution within the beneficiation circuit design ? Waste sorting: NIR (near-infrared) sorting, optical (colour) sorting, XRF (X-ray fluorescence) ? Primary concentration by combining dense media separation (DMS) with either XRT (X-ray transmissive), pulsed X-ray, jigs, or pan plants depending on the application, scale, and economics ? Final recovery of diamonds with either conventional X-ray technology, pulsed X-ray technology, or XRT. From recent studies, it can be concluded that there is no longer a standard solution, but rather the ?right? or appropriate solution. Through combining a sound knowledge of the ore source (ore dressing studies or onmine data gathering) and leveraging off the advances in technologies, one is able, through trade-off studies, to arrive at the ultimate techno-economic configuration, the ?right? solution. Emphasis is placed on maximizing diamond recoveries through appropriate technology selection and minimizing the associated costs in an effort to de-bottleneck or improve efficiencies of existing diamond processing plants, or to arrive at the ideal new diamond process plant design..

Jan 1, 2014

By B. P. Watson

Uniaxial tests performed on core from instrumented sites at Amandelbult 1 shaft, Impala 10 shaft and Union Section Spud shaft showed a nonlinear elastic relationship between applied load and induced deformation. This nonlinear behaviour does not appear to be dependent on borehole orientation but in the case of the Amandelbult and Union sites appears to have been influenced by the stress condition of the rock mass at the time of drilling. Cores drilled at these two sites under destressed conditions, such as over a stope, showed a linear elastic response to the applied load whereas most of the cores drilled under relatively high radial stresses were nonlinear. The Impala 10 shaft tests, however, all showed strong nonlinear behaviour irrespective of the stress condition of the rock mass at the time of drilling, although high stress conditions may have influenced the severity of the nonlinearity. A comparison between underground stress change measurements and an elastic model indicated that the rock mass became nonlinear when the virgin stress condition was relaxed to about 10 MPa. The cores for laboratory testing were retrieved from vertical boreholes drilled up from the centre of a stope and from horizontal boreholes drilled over pillars and stopes at about 600 m, 1 100 m and 1 400 m below surface for the three sites respectively. The k-ratios under virgin conditions were estimated from sockets, modelling and stress measurements to be 1.0, 1.3, and 0.5 for the Amandelbult, Impala and Union sites respectively. Of the three sites, therefore, Impala 10 shaft appears to have had the highest virgin stress state. Tests performed on similar rocks from shallower depths at Impala Platinum essentially showed a linear relationship between stress and strain. From the small Impala Platinum rock test database available to the project, it appears that the nonlinear elastic behaviour initiates at this mine from about 1 000 m below surface and seems to become progressively more nonlinear below this depth. In addition, the nonlinear elastic rocks are weaker, have a lower Young?s modulus and a higher Poisson?s ratio than their linear elastic equivalents. Interestingly the tangential Poisson?s ratios of the nonlinear elastic materials are often greater than 0.5 at 50% of the failure stress, suggesting an early failure initiation. The paper describes the microscope and modelling work done to determine the causes of the nonlinear behaviour and discusses some implications of the behaviour for deep-level mining.

Jan 1, 2009

By B. McFadzean, M. Tadie, T. Dzingai, M. Becker

Ores from a single deposit may exhibit extensive variability in their mineralogy and texture. The ability to quantify this variability and link it to mineral processing performance is one of the primary goals of process mineralogy. This study focuses on the effect of alteration in three platinum group element ore samples from the Great Dyke in Zimbabwe – two of which were more pristine compared to the third, which was locally classified as ‘oxidized’ ore. These ores are known to be characterized by varying degrees of alteration, resulting in numerous challenges in flotation and affecting both grade and recovery. Alteration, by near-surface oxidation, of the valuable base metal sulphides and platinum group minerals resulted in lower flotation recoveries of Cu, Ni, Pt, and Pd. Evidence of incipient oxidation was more readily observed in the base metal sulphide assemblage than the platinum group mineral assemblage, even though the loss in recovery (because of oxidation) was most significant for Pd. Alteration through hydration resulted in a significant increase in mass pull and dilution of concentrate grade through the inadvertent recovery of naturally floating gangue comprising composite orthopyroxene and talc particles. In this study, the amount of naturally floating gangue was more strongly correlated with the talc grain size distribution than the grade of talc in the flotation feed. The oxidation and hydration alteration reactions are not necessarily mutually exclusive, although one may be more dominant than the other, giving rise to ore variability.

Sep 1, 2021

By N. V. Moraka

Calls for transformation in the mining sector are legislated. Whilst the composition of boards in terms of gender diversity and equal representation has improved, little is known on how women directors experience boardrooms. This research investigated the experiences of South African women in male-dominated mining boards. It questions why women remain marginalised in boardrooms, even when they are qualified as the men in their respective fields. The experiences of South African women on male-dominated mining boards were investigated by means of a multiple case study using a qualitative research methodology. Interviews were conducted with 16 women and 12 men serving across six JSE-listed South African mining companies. The findings show that irrespective of their qualification and experience, women,s, contributions are often ignored, and they are assigned to more social roles. Regardless of race, all women experienced gender stereotyping. Strategies are required to ensure that board cultures embrace female talent, where women can effectively contribute to decision-making and maximize their talent. It is argued that gender and identity should be studied in relation to post-colonial history in African countries. Women have multiple, varying identities, and their experiences require a unique investigation that would enable strategies to overcome barriers, through the implementation of an appropriate diversity management programme.

Feb 12, 2024

By J. D. Steenkamp

In a paper presented at the Heavy Minerals Conference 2001 a laboratory scale investigation on the beneficiation of an ilmenite containing waste stream by magnetizing roasting was reported1.This waste stream contained a high concentration of ilmenite, which was contaminated by chromite and other gangue minerals. Interpretation of the results of the investigation was based on the assumption that during magnetizing roasting of an ilmenite concentrate, under the oxidizing conditions, the magnetic properties of the chromite would remain constant. In this article thefollowing hypothesis was tested: The magnetic susceptibility of chromite would remain constant during magnetizing roasting of an ilmenite concentrate under the oxidizing conditions reported by Gouws and Van Dyk1. The results of this study indicated that the hypothesis is not true. The increase in the magnetic susceptibility is not significant though and it is expected that it will not influence the final ilmenite quality to a large extent. Based on the assumptions that the bulk magnetic susceptibility of the waste stream samples represents that of the ilmenite in the waste stream, and the bulk magnetic susceptibility of UG1 chromite that of the of chromite in the waste stream, the results also served to confirm that the waste stream with a high chromite content should be roasted under oxidizing conditions, in a reactor with a well-defined retention time distribution (i.e. a fluidized bed reactor), at a roasting temperature of 750°C (rather than the higher temperature ranges of 800°C and 850°C).

Jan 1, 2003

By K. E. H. K. Ishak, S. R. M. Zan

Cement production requires significant energy, and entails high costs and CO2 emissions. This is because the clinker requires very fine grinding. Grinding aids can improve production and fineness and decrease energy consumption by reducing the agglomeration of particles and protecting the balls and liners in the mill. In this study we compare the effects of three different grinding aids on clinker grinding using a ball mill. A commercial grinding additive, triethanolamine (TEA), and two industrial grinding aids (GAA079 and GAA088) were compared by ball milling tests, with additions of 0.05, 0.25, 0.50 and 1.00 wt%. The industrial grinding aids were characterized using gas chromatography-mass spectrometry (GC-MS). Particle size and morphological analyses were performed using SEM and XRD. The best results were obtained with 0.25% GAA088, which has a higher active component of diethanolamine isopropanolamine (DEIPA) than TEA. The unique combination of TEA and DEIPA in GAA088 enhances grinding efficiency and significantly improves the particle size distribution compared to TEA alone.. The grinding aids produced smooth rounded particles, which have a smaller specific surface area, enhancing the quality of the cement. XRD showed no significant structural distortion with or without grinding aids, and it was also found that the grinding aids helped decrease ball coating during grinding. The use of grinding aids can significantly improve clinker production and fineness while decreasing energy consumption, which can help reduce the costs and CO2 emissions associated with cement production.

Sep 6, 2023

By SAIMM Journal

COLLOQUIUM ON COMMINUTION The Institute has arranged a colloquium on the above topic to be held on 13th March, 1973, at Kelvin House. The following papers will be presented: 'Peripheral Discharge Mill', by A. H. Mokken, Union Corporation Limited

Jan 1, 1974

By L. Ntlhakana, K. Khoza-Shangase, G. Nelson, I. Maposa

Occupational noise-induced hearing loss (ONIHL) is associated with various risk factors in South African mines. We investigated the association between standard threshold shifts (STSs) and exposure to noise and platinum mine dust (PMD), using demographic data, five years of annual audiometry screening results, and noise and dust exposure data. Miners’ age, sex, percentage hearing loss (PLH), and dust and noise exposure data were gathered, and a linear mixed effects regression model used to predict STS. Average occupational exposure levels to noise and dust were calculated from recorded measurements. A total of 12 692 records were analysed. Most miners were male (89.6%) and more than 50% were younger than 41 years. More than 70% were exposed to > 85 dBA noise and 58% were exposed to 1.5–2.99 mg/m3 PMD. Changes in hearing levels ranged from 8.3 dBHL at baseline (2014/2015) to 10 dBHL in 2016 (STS), with no changes thereafter. The model showed that the estimated effect on STS for males was 27% and 21% higher than for females, for the left and right ear, respectively The estimated effect of age, PLH, noise exposure and years of exposure on STS was < 10% for each variable. There was no statistically significant association between PMD and STS. The combined effects of age, sex, years of exposure to noise, and noise exposure levels, and strength of associations can be used to predict STS for this group of miners. Our findings may be used to measure the efficacy of the mine’s hearing conservation programme.

Aug 1, 2021

"Investment in diamond exploration has been declining over the past decade, in spite of positive long-term industry fundamentals and a growing interest in diamonds as an investment category. The lack of new significant discoveries in recent years has eroded investor confidence, yet no new discoveries are possible without investment in exploration. Junior ‘mine finders’ have been the hardest hit. Their agility, tenacity, and appetite for risk are not sufficient to attract the funding required, even at the greenfield stage. Developing new discoveries into mineral resources can be crippling without solid financial support. Junior incubators could play a crucial role, especially at the project evaluation stage – but where are they? Alternatives to traditional funding mechanisms have become available, many still untested in the junior diamond exploration space. Valuable lessons can be drawn from the past and used to inform emerging new strategies. IntroductionDiamonds are the ultimate expression of love. Their ancient and timeless allure continues to influence consumer emotions and behaviours across continents, cultures and age groups. Analysts are predicting a sustained supplydemand shortfall in the years ahead which will trend diamond prices generally upwards. With positive long-term industry fundamentals, one cannot help but wonder why funding for diamond exploration and development projects is so scarce.Investment in exploration across commodities – including diamonds – has been declining for a number of years, reaching a historic eleven-year low early in 2017. The lack of major diamond discoveries in recent years has done little to strengthen the case for investing in diamond projects, yet no new discoveries can be made without investment in exploration.Global estimates of known carats in the ground stand currently at 2.5 billion carats, which equates to around 18 years of production at current levels of 140 million carats (mct) per annum. Sustainable replenishment of depleting diamond resources is possible only through the development of new discoveries. This is what junior explorers are best at – but they need investors to fund their evaluation activities from early in the project development continuum."

Feb 1, 2019

By M. Grozdanovic, D. Marjanovic, M. Ilic

We present a framework for solving the problem of functional compatibility between process control equipment in control centres at underground mines and operator capabilities. The equipment incorporates displays of current ventilation, gas, and fire hazard data, status of alarm and early warning systems, a voice communication subsystem, and facilities for recording and printing ofdata and reports. The layout of the existing control panel is compared with a recommended design. The basic principles of ergonomic design and arrangement of the controls and indicators, as well as ease of use, type of operations carried out with these controls, and operators’ viewing angles are discussed. The objective is to improve the usability of control panels, display boards, and graphic screens so as to enhance the functioning of control centres and optimize control of technological processes in coal mines.

Jun 10, 2024

By B. O. Odera

The Pt-based alloys have a high potential for replacing some Ni-based superalloys (NBSAs) used in the highest temperature and most aggressive environments, and vanadium would be a beneficial alloying element. Six alloys of average compositions Pt-26.6Al-9.1V, Pt-23.1Al-17.8V, Pt-9.6Al-21.1V, Pt-17.4Al-6.4V, Pt-22.3Al-7.9V, and Pt-6.0Al-10.1V (all in at.%) were manufactured by arc-melting and examined in the as-cast condition using scanning electron microscopy and X-ray diffraction (XRD). Five samples were heat treated at 1 000°C for 1 500 hours and water quenched, then examined. The phases were identified using energy-dispersive X-ray spectroscopy and the identities were confirmed by XRD. In most of the samples, the phases existing in the as-cast condition were different from those at 1 000°C after ~1500 hours heat treatment. A solidification projection, an isothermal section and a liquidus surface projection were determined for the Pt-rich corner.

Jan 1, 2012

By F. Ntengwe

The Konkola Mine, a subsidiary of the Konkola Copper Mines Plc (KCM) which is owned by the Vedanta group of companies of India and Zambia Consolidated Copper Mines Holding limited, is located at Chililabombwe in the northern extension of Zambia&apos;s Copperbelt province. In its operations, the mine has been experiencing problems in ascertaining the optimum degree of fineness and the operating density of the hydrocyclone overflow in order to achieve high flotation performance. It was believed that recovery of sulphide copper minerals from Konkola ore is a function of the fineness of the grind so that it might be an economical justification to modify the grinding plant in order to run at lower cyclone overflow densities than the case is now. In an effort to improve these operations, it was decided to carry out test work on various hydrocyclones of sizes 0.381 m, 0.4575 m and on 0.508 m. The later was found to give satisfactory results and was installed on the plant. Despite giving satisfactory results there was need to investigate further to establish the working densities and size. Increasing the density of cyclone overflow decreases the per cent passing 75 pm at least in the range 1080-1 150 g/l. Furthermore, hydrocyclones give better separation at low densities of feed and hence the efficiency is high at low feed densities. Circulating load increases with an increase in feed densities and an decrease in the grind. The flotation performance in both sulphide and oxide copper minerals rougher stages is enhanced with an increase in the degree of fineness of the grind, with an optimum being obtained at a density of 1 150 g/l and 81.4% passing 75 µm. Keywords Konkola mine, hydrocylone, optimum degree of fineness, sulphide copper minerals.

Jan 1, 2011

By M. B. Shongwe, G. Freemantle, M. Botha, S. Brill, J. D. Steenkamp

During steelmaking, one important factor for production efficiency is the free opening of the ladle nozzle during continuous casting. Free opening occurs when the well filler sand and the steel flow freely when the slide gate is opened. Well filler sands are used for the slide gate of a ladle to separate the slide gate refractory and the molten steel. The well filler sand is partially sintered by the heat of the molten metal, which can result in the ladle nozzle failing to open if the sand is not sintered to an appropriate extent. It is therefore of great importance that the sintering behaviour of well filler sand is understood. We studied the effect of the well filler sand chemistry on its sintering properties. Samples of well filler sand with various chemical compositions were sintered in a high-temperature chamber furnace. Quantitative X-ray diffraction (XRD), inductively coupled plasma optical emission spectrometry (ICPOES), and wavelength dispersive spectrometry (WDS) by electron microprobe analysis (EMPA) were used to analyse the various well filler sand mixes. Points of analysis were indicated on backscattered electron (BSE) micrographs. Quantitative element mapping was undertaken by energy dispersive spectrometry (EDS). Thermodynamic calculations in FactSage predicted the percentage liquid phase present for the various well filler sand compositions at equilibrium conditions. The results of this work show that the degree of sintering of chromite-silica well filler sand depends strongly on the silica content. The amount of liquid phase formed increases with increasing silica content.

Feb 2, 2022