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By Z. L. Xue, J. L. Li, X. Y. Wang

"In low-carbon energy-efficient basic oxygen furnace (BOF) steelmaking processes, limestone partly or completely replaces the active lime. The effects of limestone calcination temperature (1200–1500°C) and time (5–15 minutes) on lime reactivity and CaO grain size were investigated. The reactivity was evaluated by titration with hydrochloric acid, and the CaO grain size was analysed using scanning electron microscopy. The results revealed that for calcination temperatures higher than 1300°C, the reactivity reached a maximum and then decreased . The higher the temperature, the earlier the peak of reactivity appears. The CaO grains grow with increasing temperature and time, which leads to the decrease of reactivity. Notably, the effects of temperature on CaO grain size and reactivity are more marked than that of time. To obtain active lime calcined at ultra-high temperature by flash heating, the calcination conditions should be 1300–1400°C for 10–15 minutes, or 1400–1500°C for 8–10 minutes. IntroductionLime is one of the most important slag-making materials for dephosphorization and desulphurization in the basic oxygen furnace (BOF) steelmaking process. The reactivity of lime is a measure of its capability to take part in slag-making. Lime having a reactivity of more than 300.0 mL (4 N HCl), determined by hydrochloric acid titration is generally referred to as active lime (Rusjan et al., 2007; Zeman, 2008). At present, the active lime used for BOF processes comes primarily from a kiln or shaft kiln, where limestone is preheated at 700– 900°C, and then calcined at 1050–1200°C (Drenhaus et al., 2010; Oates, 2007)."

Jan 1, 2016

By G. A. Bezuidenhout, S. Bradshaw, W. Malan

"The purpose of the study was to investigate the feasibility of SiC reduction of low-grade concentrates from Lonmin’s Rowland and Easterns operations with respect to metal fall and PGM recovery. These concentrates are rich in SiO2 and MgO with low concentrations of chalcopyrite and Cr2O3. Pd is the most abundant of the PGMs. SiC reduction of samples was conducted at 1600? with 2.5-3.5 kg SiC per 100 kg concentrate.PGM recoveries for Easterns concentrate were better than for Rowland. More than 85% of the Ir and Pd and almost 60% of the Pt were recovered with 3.5 kg SiC per 100 kg concentrate. SEM of slag samples showed little entrainment of metallic prills compared to Rowland samples. This was attributed to the relatively higher melt viscosities of the Rowland concentrate. In order to decrease slag viscosity and to enhance PGM recovery, the FeO content of the Easterns concentrate was increased with the addition of 10 kg converter slag per 100 kg concentrate. Ir and Pd recoveries were increased to about 95%, while Pt recovery was around 70%. On the basis of these results an optimum feed ratio between Easterns and Rowland concentrates and converter slag is proposed. Carbothermic reduction of the optimum charge was also compared to SiC reduction. Carbothermic reduction yielded a marginally higher metal fall; however, the calculated gas emissions and energy requirements were higher than for SiC reduction."

Jan 1, 2015

By M. Natarajan, C. J. Cutler, E. Mponda

Keywords: Pyrometallurgy, furnace, KCM Nkana, Zambia The Nkana smelter was initially commissioned in 1931, with two reverberatory furnaces, two Peirce-Smith converters, and blister copper casting facilities. Reverberatory furnaces were the mainstay of production up until 1994, when an El Teniente Converter (CT) was installed to upgrade reverberatory furnace matte to white metal, prior to converting in conventional Peirce-Smith (PS) converters. In 2000, a decision was taken to increase the proportion of concentrate smelted in the CT by introduction of bone-dry concentrate injection through the tuyeres. A flash dryer with a nominal capacity of 1 200 metric tons per day of dry product, and associated tuyere injection system was commissioned in March 2004. Based on the projected concentrate arisings from the KCM mines into the future, as seen in 2004, it was decided to develop the CT to be the primary smelting vessel at Nkana, to handle a minimum of 1 250 tons per day of concentrate, and to operate only one reverberatory furnace in slag-cleaning mode pending a full evaluation of alternative slag-cleaning technologies. The anticipated cathode production from Nkana was to be in the range 140 to 150 000 tons per annum. This paper details the outcomes from trials that were carried out in August and September 2004, using two reverberatory furnaces for slag cleaning. The results of these trials, plus further work in October and November, provided confidence to move to one reverberatory furnace for slag cleaning in December 2004. With the advent of Vedanta as the majority shareholder in KCM at the end of 2004, the approach has been to maximize the available smelting capacity. Currently, two reverberatory furnaces and the CT are on-line, with the higher silica concentrates going to the reverberatory furnaces with an appropriate amount of pyrite, and the cleaner concentrates going to the CT. Expansion of the smelter is currently under investigation.

Jan 1, 2006

By Jerry Gagnon, Matt Burr, Dave Evans, Timothy Ellis, Davies Kakengela, Abbas Mirza, Larry Webb, François Leclercq, Andrew Johnston

Lead-based alloys are the primary anodes used in electrowinning from sulphate-based aqueous systems. Lead anode technology has evolved over the years, migrating from pure lead and lead-antimonial alloys to the present day lead-calcium-tin alloys for copper electrowinning and lead-silver alloys for zinc electrowinning. It has also migrated from cast to rolled microstructures in search of improved mechanical properties and higher corrosion resistance. Although great strides have been made in the development of new alloys and production processes, the industry still has unresolved issues related to untimely corrosion which limits anode life and may lead to higher contaminant levels in the metal being produced. Lead anodes corrode because of the difference in the chemical/electrochemical potential across the microstructural features of an anode. Given a very high purity material, we find that the grain boundary areas corrode significantly faster than the rest of the grain. The desire to minimize grain boundary corrosion by a balance of alloying element selection and microstructural design allows the grain boundary area to be engineered. However, operational issues can lead to unexpected corrosion behaviours which we will discuss moving forward. The comments in this work, though directed toward copper electrowinning, can be extended to similar phenomena in other metals electrowon from sulphate media (i.e., zinc, nickel, cobalt, manganese). The lifecycle of electrowinning anodes is dependent upon electrowinning tankhouse operating conditions and maintenance of the anodes, including cleaning and straightening. This paper will focus on the operational aspects of maximizing the utilization of lead electrowinning anodes.

Jan 1, 2015

By C. Musingwini, A. S. Nhleko, P. M. Muke

Open-pit mine planning includes the determination of a long-term open-pit mine production scheduling (OMPS) plan. The OMPS plan is generally a three-dimensional (3D) block extraction sequence that seeks to maximise the net present value (NPV) of future cash flows, while complying with technical and operational constraints. The OMPS problem is computationally complex because it involves the analysis of large datasets, while simultaneously incorporating both multiple hard and soft constraints. The OMPS problem has been solved using deterministic or exact approaches, heuristic, and metaheuristic models. When compared to heuristic and metaheuristic models, deterministic approaches tend to take much longer to solve the OMPS problem when the number of constraints increases. Therefore, this paper presents a metaheuristic model which utilises a genetic algorithm (GA) framework to solve the OMPS problem. The GA-based model was applied to the Newman1 and Zuck Small mining instances, which are publicly available from the online MineLib database. The NPVs for the OMPS plan generated using the GA-based model for the two case studies were compared to the best-known published MineLib solutions obtained using the TopoSort heuristic model at the time of this study. For the Newman1 instance the equivalent annual NPVs were approximately US$6.6 million for the GA-based solution and US$5.1 million for the TopoSort solution. For the Zuck Small mining instance, the equivalent annual NPVs were approximately US$99.8 million for the GA-based solution and US$102.5 mil for the TopoSort solution. These results show that the GA-based model produced comparable solutions to some of the best-known solutions, thus, indicating strong potential application of GA-based models to solve OMPS problems.

Sep 1, 2021

By Z. W. Nkosi, M. Sephton, J. H. Potgieter

The exhaust system is a complex assembly of various components performing important tasks in harsh environments. Carbon steels have been used extensively in exhaust systems, but pressure for lower cost, increased fuel efficiency; lower hazardous emissions, weight savings and increased life expectancy have shifted the emphasis to stainless steels. In response to the growing consumption of stainless steels in automotive exhaust systems, the need to properly evaluate their corrosion resistance properties in order to ensure their appropriate use, has increased substantially. This paper evaluated the most common corrosion and oxidation tests developed that are used and applied it to four common stainless steels often employed in hot end exhaust components. In a summary considering the weight loss of an alloy, it general corrosion rate and pitting resistance under all the test conditions for hot end exhaust components, results indicate that 434 was by far the most corrosion resistant alloy, followed by 1.4509 and 321, and lastly 304 was the least corrosion resistant. In general, the ferritic stainless steels, especially 434, outperformed the austenitic ones under all the test conditions.

Jan 1, 2006

By F. M. L. Mulaudzi

Metal dusting is a corrosion phenomenon that occurs in strongly carburizing gas atmospheres at elevated temperatures. Reaction kinetics and product characterizations of Alloys 602CA and 800 were examined by scanning electron microscopy with energy dispersive X-ray analysis (SEM-EDX) and X-ray diffraction (XRD).The results showed that Alloy 602CA is more resistant to metal dusting than Alloy 800. Visual examination and SEM surface analysis showed that Alloy 800 suffered metal dusting attack after a relatively short exposure period. The amount of coke deposits increased on Alloy 800 with increased exposure from 96 to 336 hours. X-ray diffraction on the reacted surfaces identified graphite and austenite in both alloys and some iron oxides/spinel for Alloy 800.

Jan 1, 2012

By P. R. Segopolo

"The purpose of the project is to convert current shuttle car utilization on an underground coal mine to best practice by focusing on change-out points and tramming routes, which have a major influence on shuttle car away times. Time studies were an integral part of the project as these enabled the determination of shuttle car away times. An indirect proportional relationship between shuttle car away times and productivity is established. Through the time studies, it is deduced that a third shuttle car will make an insignificant contribution to production when there is only one split open. During this time, maintenance on the third car can be optimized. In order to satisfy the mine’s key performance indicator of keeping shuttle car away times less than 75 seconds, a belt extension must be scheduled after the third split is open. It is established that at any given time, a minimum of two shuttle cars should be used. When cutting on the left-hand-side of the belt road with only two shuttle cars available, the centre and left (left of the feeder breaker) shuttle cars should be used for coal hauling. When cutting on the right-hand-side, the centre and the right-hand-side cars should be used. If only one shuttle car is available, the centre car is the most efficient to use. Alternative anchoring configurations can be employed so as to enable cars (left or right, especially) to reach the opposite extremities of the panel and hence minimize cable length restrictions. Paper written on project work carried out in partial fulfilment of BSc. Eng. (MiningEngineering)"

Jan 1, 2015

By J. A. L. Napier

It has been established that significant time-dependent stope convergence may occur over time periods of hours and days in certain hard-rock gold and platinum mines. The source of this time-dependent behaviour appears to be associated with both pre-existing discontinuities and with mining-induced fractures that form near the stope face. These induced fractures may be associated with blasting processes and may also be formed in response to high stress concentrations in the unmined regions immediately ahead of the stope face. In shallower platinum mining operations, time-dependent behaviour is, however, observed to be much less marked unless some form of specific mining-induced fracturing occurs. One particular case of considerable interest is the time-dependent behaviour that is found to be associated with the formation and deployment of crush pillars. The purpose of the paper is to present a simple limit-equilibrium computational model of this behaviour that is sensitive to both the formation sequence and the size of planned crush pillars in a mine layout. This model provides a useful means to optimize the sizing of crush pillars, and at the same time may be used to identify potentially hazardous circumstances in which pillars may not crush in a stable manner.

Jan 1, 2012

By J. N. Van der Merwe

"A major shortcoming of the statistical back-analysis of coal pillar strength is that it relies on the asmined pillar dimensions, not taking into account time-related pillar scaling with subsequent reduction in pillar width. The paper describes an investigation where the rate of pillar scaling was applied to the pillars in the databases of failed and unfailed pillars. The reduced pillar sizes were then used in the same method of statistical back-analysis that had been used in the past.This resulted in an equation for pillar strength which predicts significantly greater pillar strength than the previous statistical analyses, which is similar to the strength which had been found earlier by direct testing of large specimens underground. It is concluded that the lower strengths found by previous statistical analyses are due to the incorrect pillar width being used and that by adjusting the pillar sizes to compensate for scaling, more credible results that correspond to direct testing are obtained.As the newly derived strength equation is time-dependent, it follows that the safety factors and probabilities of failure are likewise time-dependant. An equation to determine the probability of failure is also developed. This results in the safety factor being close to unity at a probability of failure of 50%, which is aligned to statistical expectation. IntroductionSince the Coalbrook mine disaster, caused by massive pillar collapse, there have been several attempts at analysing and defining the strength of coal pillars. It was realized in the very beginning that performing classical strength tests on coal specimens in a laboratory and then transferring those results to real coal pillars could not be successful. The scatter of results is one problem and, more seriously, there is a size effect (at least for small specimens) that made the transformation of strength results to much larger coal pillars underground all but impossible.Two main schools of thought then emerged. Some researchers preferred to perform direct strength tests on large specimens underground, while others relied on statistical back-analysis of failed and unfailed pillar cases, attempting to determine the differences in size and shape that would allow a satisfactory prediction of failure. The latter school of thought resulted in the method that was widely accepted by the South African coal mining industry, described in the landmark publication by Salamon and Munro (1967)."

Jul 1, 2019

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 the following 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 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 V. Yahorava

Ion exchange is considered to be an effective technology for the removal of various impurities from cobalt advance electrolytes. With the correct choice of resin, ion exchange can consistently remove the required impurities to the levels for the production of high-grade cobalt metal. Although ion exchange was in the past used primarily for nickel removal, more recently it has been also considered for the removal of copper, zinc, and cadmium. Generally, granular ion exchange products are used, but Mintek is currently evaluating ion exchange fibres for a number of applications, including the removal of copper from cobalt advance electrolytes. Fibrous ion exchangers have major advantages compared to granular resins in that they have significantly higher reaction rates, and wash water volumes could be limited. Granular and fibrous ion exchangers were evaluated and compared for the removal of copper from cobalt advance electrolyte. A synthetic electrolyte containing 50 g/L cobalt and 50 mg/L copper was used for the test work. Equilibrium isotherms, mini-column tests, and split elution tests were done. The results were used to size a full-scale operation to treat 100 m3/h of electrolyte. The potential cobalt losses or recycle requirements were estimated, and data to calculate indicative operating costs for each adsorbent was generated. This information was used for a techno-economic comparison of granular and fibrous ion exchange systems for the removal of copper from cobalt advance electrolyte.

Jan 1, 2014

Outotec?s direct leaching process is an atmospheric leaching process for sulphidic zinc concentrates. The direct leaching process, based on special leaching reactors developed by Outokumpu, is the most economical way to produce electrolytic zinc. The production scale applications of the process realized so far are in use at Boliden?s Kokkola and Odda zinc plants. A new full-scale application of Outotec?s direct leaching process will be started in 2008 in China. The process is integrated to the existing production plant, replacing part of the old production facilities by modern technology. Besides high zinc extraction the plant expansion and modernization offers also indium recovery, iron precipitation and solution purification processes. The process equipment includes tailor-made reactors designed on the basis of the work and experience of Outotec research center. Keywords: zinc, concentrate, atmospheric leaching, technology, indium, iron precipitation, solution purification, Outotec

Jan 1, 2008

By R. M. Tyler

The importance of the heavy mineral sands to southern African economic well-being cannot be over emphasized. The value of the worldwide titanium dioxide industry is estimated at $7 billion. Six out of eight of the world?s proposed new project areas are in southern and eastern Africa, and a seventh at Tamil Nadu in India is partly owned by a South African company, Kumba Resources. The HMS industry can be highly lucrative; its return on capital is the best in the mining industry. There are, however, problems, particularly in the smelting technology. The often considerable affect of mining on environmentally sensitive coastal dunes is also becoming increasingly important. The medium-to long-term demand for Ti-dioxide pigment and ceramic grade zircon appears very healthy. If, as predicted, the costs of producing titanium metal can be reduced, then there is huge potential for the metal. In summary, the HMS industry is an attractive one to be in, with good returns and generally manageable risks. New business opportunities and their economic implications for Africa are discussed.

Jan 1, 2004

Quantitative seismology is an important tool for investigating mineinduced seismicity and the quantification of the seismic rock mass response. The spatio-temporal interpretation of seismic data within an ever-changing three-dimensional mining environment provides some challenges to the interpretation of the rock mass response. A grid-based approach for the interpretation of spatial variation of the rock mass response provides some benefits compared with approaches based on spatial filters. This paper discusses a grid-based interpretation of seismic data. The basic methods employed in the evaluation of the parameter values through space are discussed and examples of applications to different mine sites given.

Jan 1, 2014

By J. Härkki, R. Hiltunen

The Akanvaara intrusion (surface area 50-55 km2) in Savukoski, Northern Finland, hosts 23 distinct monocumulate layers of small euhedral chromite crystals enclosed in a silicate matrix. These chromitite layers have been divided into four groups; UC (upper chromitite), ULC (uppermost lower chromitite) LC (lower chromitite) and LLC (lowermost lower chromitite). The driving force for investigating the Akanvaara chromites and their reduction behaviour originated from their very low MgO content and relatively low Al2O3 content, giving them a unique quality which based on thermodynamics should facilitate the reduction. Another interesting feature is the high amount of V2O3 present especially in the upper chromitite. The chromites included in this study are from the UC and ULC layers (24.9 and 22.7 per cent Cr2O3 respectively). To obtain a better understanding of the reduction behaviour of Akanvaara samples in comparison to MgO-bearing chromitites, Kemi chromite from the ferrochrome works in Tornio, Finland, was included in the study as a reference sample. The reduction experiments were isothermal in a temperature range of 1000-1400°C in CO atmosphere. Experiments were also conducted with coke addition in pellets and briquettes in CO/Ar/H2 atmospheres. The results of the reduction experiments complemented with microanalytical research indicate that the Akanvaara chromites do reduce to a higher degree than the Kemi chromite. Although the aim was to characterize the mechanisms of reduction focusing on gas-solid reactions, the nature and amount of the gangue minerals was such that a considerable amount of slag phase was formed, which affected the reduction mechanisms extensively. The structural features together with low MgO and high FeO content in both Akanvaara chromites are important factors resulting in better reducibility than in the Kemi chromite.

Jan 1, 2004

By R. L. Castro

The extraction of ore in panel caving operations also involves the coextraction of non-economic material, known as dilution. Forecasting, avoiding, and understanding the mechanics of dilution is critical to longterm planning. The models of dilution that are currently in use in panel caving operations are those by Laubscher (1994), who postulated that dilution is due to gravitational flow and depends on the height of interaction, the column height, and the draw uniformity. This paper presents a back-analysis of extraction and dilution behaviour at Codelco?s El Salvador and Andina Divisions, which use panel caving as a mining method. This analysis was conducted in order to review the existent dilution entry mechanisms and calculation methods. Three sources of dilution were identified. The first source is ?gravitational dilution?, which is due to gravitational flow and mixing as dilution migrates by gravity from a sector located above the panel under analysis. The second source of dilution is ?caving dilution?, which occurs when an air gap is formed in a large area and a sudden propagation of a hang-up occurs, inducing early ingress of waste into the production level from a level above. The third mode observed is ?lateral dilution?, which occurs when the panel is located next to an exhausted sector and the broken material enters the draw column early during draw. In the last two cases, dilution could migrate large distances horizontally. The mine data indicated that draw and caving strategy are key for long-term planning of large panel caves.

Jan 1, 2014

By TvS. von Moltke

Steel is a highly versatile material due to its low cost and good mechanical properties, but typically needs some or other form of corrosion protection due to its tendency to corrode when exposed to atmospheric conditions. In the case of organic coatings, the corrosion protection and functionality of the final product is critically dependent on the adhesion of the coating to the surface of the steel. In this work the effect of contaminants and the nature of the surface layers present on industrial steel products are investigated by means of paint adhesion tests, Auger electron spectroscopy (AES), and X-ray Photoelectron spectroscopy (XPS). It was found that the presence of sodium species on the surface is very detrimental to paint adhesion under wet conditions, while satisfactory adhesion may be obtained even in the presence of silicon and carbon residues. It was also found that the nature of the Fe-O layer, formed under wet conditions is labile and different from that formed in dry air, and that subtle changes in process conditions, such as changing the oxygen content of the quench water, may change the adhesion of paint to the surface of the steel. Lewis acid-base interactions are discussed as a mechanism that may determine the bonding between the steel and polymer coating.

Jan 1, 2003

By A. W. S. Schumann

SYNOPSIS The most economic exploitation of South African coal resources requires sustained study of the balance between known resources and the predicted rate of consumption, against the background of the development of other sources of energy in South Africa and relevant developments elsewhere in the world. A number of the major issues which would arise in such a study are discussed, including the need for a standardized South African definition for coal resources, the merits of sectoral forecasts of consumption compared with global forecasts, the encouragement of a higher recovery from reserves, and the development of an export market for South African coal.

By G. L. Smith

The fundamental challenge facing mineral and metal companies is how to create sustainable value while operating within mandated strategic bounds, identified constraints, and variable market and economic conditions. This can be achieved by allowing the fixed physical nature of the mineral asset to drive definition of the optimal technical solution to mining and processing activities, and developing and resourcing a strategically aligned portfolio of production entities that creates flexibility to near- and longer-term business environment shifts, i.e. a production mix that allows variation of output to respond to short term market variation, within a long term context. The practical achievement of this outcome is enabled by the concept of strategic long term planning. The core elements of strategic long term planning in the metals and minerals industry, and the relationship between them, are expanded. The strategic long term planning framework is a logic construct that enables delivery of an optimized, strategically-aligned business plan from the mineral asset portfolio using a set of tools and techniques with a common language, standards, systems and processes to align decisions and actions on a cyclical basis.

Jan 1, 2012