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By P. J. D. Lloyd, Jill Urban, M. R. Urban

The adsorption of gold from cyanide solutions onto constituents of the reef, and its role in reducing the efficiency of the gold-recovery process by M. R. URBAN. M.Sc. (Chem. Eng.) Rand (Visitor). JILL URBAN. B.Sc. (Chem. Eng.) Rand (Visitor) and P. J. D. LLOYD. Ph.D. (Cape Town) (Fellow) Evidence for the adsorption or re-precipitation of gold from cyanide solutions onto gangue minerals of the Witwatersrand reefs has been gathered over a number of years by various investigators. The evidence from tests using radioactive tracers is conclusive and indicates thlt adsorption contributes about 0,1 g/t to the total gold loss from conventional reduction works. The loss is a function of the alkalinity and cyanide concentration of the solution, and it appears to be affected by the extent of time between milling and cyanidation. The heavy minerals appear to be the strongest adsorbers, and the clay minerals somewhat less strong adsorbers. A sensitive qualitative test based on thin-layer chromatography permits the extent of adsorption and desorption to be readily determined.

By M. C. Mulligan

Counter current decantation (CCD) thickener circuits are used to recover soluble metal as pregnant liquor solution from ore leach residue. The basis of CCD operation is to concentrate suspended solids thereby minimizing liquor content in underflow slurry that flow in one direction. Then the underflow slurry liquor is diluted with wash liquor that flows in the opposite direction and the suspended solids are concentrated again and again. The amount of liquor in the thickener underflow contributes to determining the number of CCD stages required to recover the desired amount of soluble metal. Furthermore, similar results could be achieved at a lower wash quantity, reducing the size of downstream equipment. High density thickeners (HDT) are designed to use gravity and compression, and minimize the amount of liquor in the underflow thus minimizing the number of CCD stages. This paper reviews the process used to select HDTs rather than high rate thickeners (HRT) for the Ruashi II copper-cobalt hydrometallurgical process in the Democratic Republic of Congo (DRC), using laboratory HDT simulations, to CCD simulations and thickener design details.

Jan 1, 2009

By B. G. Meyburgh

SYNOPSIS As a result of a test programme over a period of approximately ten years and a decision to extend the uranium plant, it was decided to design and erect the first full-scale Purlex Plant in the Republic of South Africa. The plant at Buffelsfontein G.M. Co. Ltd. was commissioned in August, 1968, and to date has produced results superior to those predicted in the original estimates. The capital expenditure was R678 000 for a plant capable of treating 1 600 gallons per minute of pregnant solution. Compared with the conventional resin ion exchange process, it has been found that the saving in production costs is 21 cents per pound U3O8 produced. The amine loss is 10 parts per million, which is equivalent to a total organic loss of 250 parts per million. The uranium loss in the raffinate is less than 0.001 g/l U3O8. The final product is of a high quality and it is probable that it is pure enough to convert to the fluoride directly.

By R. Venter

Uranium in the tetravalent state has very low solubility in acid and alkaline solutions and needs to be oxidized to the hexavalent state to become soluble. In acid leaching of uranium the uranium is oxidized by ferric iron, which in turn is reduced to ferrous iron. The reduced iron needs to be oxidized to the ferric form to allow the uranium dissolution reaction to proceed. This paper considers the known and proven oxidants used in acid leaching of uranium. These include manganese dioxide, sodium chlorate, hydrogen peroxide, ferric iron, oxygen and sulphur dioxide/air (oxygen). The reaction chemistry of each oxidant as well as the practical applications are considered and discussed. All the oxidants discussed work adequately in acid leaching of uranium and it is possible to engineer solutions for the use of the oxidants in acid leaching on plant scale. The availability and supply of the oxidant as well as the cost and environmental impact of the oxidant plays a major role in the selection of a suitable oxidant. The location of the plant will also have an impact on these issues.

Jan 1, 2009

By S. K. Mahata, P. G. Suresh Kumar, B. B. Singh

Improvement of post tap hole practices is achievable by mechanized handling of melt during the production of Ferro Chrome, resulting in higher recovery of chromium. The paper deals with modern practices adopted in the production of ferro-chrome since past two decades. The methods and practices deal with various areas : a) Improved method of operating the tap hole by selection of right quality of refractory to maintain the life of tap hole. b) Collection of melt in different types of receptacles like refractory brick lined mild steel ladles, cast steel ladles, cast iron pans being chosen for cost effective and efficient handling. c) Separation of slag and metal, casting of metal, crushing, sizing and stock piling etc. d) Slag disposal and recovery of entrapped metal. The drive behind the above development is continuous improvement, which results in higher chromium recovery and reduces loss of metal in slag by completely mechanized method so as to be at the same level with producers of ferro-chrome in other advanced countries , in the emerging global economy.

Jan 1, 2007

By J. Gholamnejad

Determination of the optimum cut-off grades is one of the most important aspects of mine production planning. A cut-off is a grade below which we choose not to process material. This material is treated as waste and dumped. Dumping waste is accompanied by the rehabilitation cost which will affect the overall cost of final production and also the optimum cut-off grade. Rehabilitation cost is the cost per ton of rehabilitating material of a particular type of rock after it has been dumped as waste. One of the most popular algorithms for determination of the optimum cut-off grade is Lane?s method. Lane formulated the cut-off grade optimization, but he did not consider rehabilitation cost during the optimization process. This cost item should be evaluated first, and then considered during the cut-off grade optimization process. In this paper the rehabilitation cost is inserted directly into the cut-off grade optimization process using Lane?s theory. The cut-off grades obtained using the suggested method will be more realistic than ones using the original form of Lane?s formulations.

Jan 1, 2009

By P. G. Terrazas Prado

This paper presents the results of research on the development and application of a custom-made truck cycle and delay automated data collection system (TCD-ADCS) in a surface coal mining. Truck cycle and delay field data are locally stored in trucks and then synchronized and replicated through a wireless network into a centralized server containing an already-developed integrated production management system (IPMS). The system relies on motion sensing and distance travelled in order to automatically define the cycle starting/ending points, cycle time, position, and delay time. Connectivity and communication between loading equipment and trucks are also established. Communication between the equipment operators and TCD-ADCS system is via a user-friendly graphic interface. The hardware used for the development of this system consists of a rugged touch-screen personal computer, 2.4 GHz radio transmitter antenna, and a commercial GPS receiver. The system was developed, tested, and deployed at a surface coal mine in the USA. Keywords surface coal mining, truck and shovel, data collection, information systems.

Nov 1, 2013

By B. P. Watson

In South Africa, the Bushveld platinum group metal deposits are unique in that they are the largest platinum group metal deposits in the world. These deposits occur as two distinct stratiform tabular orebodies and strike for many hundreds of kilometres. Mining is extensive, with depths ranging from close-to-surface to 2 000 m. The mining method is a variation of planar open stoping. Pillars are widely used to support the open stopes. Crush pillars are commonly used in this role, where the residual pillar strength provides the required support resistance to stabilize the stoping excavations. This paper describes the direct measurement of stress within these crush pillars, and describes the stress?strain behaviour of these pillars. These findings indicate that the measured pillar failure stress is too high. The implications of these findings are that roof damage and pillar bursting could occur, and some examples of this type of damage are shown. The paper concludes that this problem could be mitigated if the three dimensional pillar geometry were modified and the pillars were cut smaller.

Jan 1, 2007

By J. E. Chilton

No regular monitoring of methane is required in areas of gassy coal mines outby the mining face. Methane ignitions that have occurred in mine outby areas indicate the need to provide better protection to workers. Handheld methane monitors are now used by some miners to make periodic measurements of methane at the working face. The IYONI II gas detector which is incorporated into a miner’s cap lamp and worn on a miner’s helmet can continuously provide an alarm signal whenever methane levels exceed a set level. Tests were conducted to evaluate the performance characteristics of this methane detector by measuring response times with methane gas supplied through a calibration fixture or adaptor. Other response time tests were performed with the detector in an environmental test box. Performance was also evaluated in a full scale test gallery where face methane emission and underground ventilation were simulated. Procedures for calibration by response time measurement of the IYONI II detector have been developed. In limited testing, the IYONI II detector was found to reliably detect the presence of 1 percent by volume methane.

Jan 1, 2003

By deur R. R. Mears

The expected curtailment of activities within the gold-mining industry by the closure of the more marginal mines, and the shortening of the life of the industry as a whole as a result of rising costs and/or an uncertain gold price, are factors that are bound to harm the South African economy in a number of ways. The industry has no option but to regard the gold price, which is determined on the world market, as a given quantity. The remaining ore reserves al tend to be of a lower grade and/or to be found at greater depth. Therefore tighter control of working costs would seem to be almost the only option open to the industry. Working costs can be divided into two broad categories: costs emanating from the environmental characteristics of the orebody, and costs emanating from the general inflationary environment in which the industry has to purchase its inputs. Working costs stemming from the physical environment also fall into two categories: those relating to the grade of the orebody, and those resulting from working at increasing depth and temperature, together with the need to pump increasing quantities of water. The industry is both capital- and labour-intensive in absolute terms, since it requires large inputs of labour as well as of capital. It is limited in its scope to adjust its production function by becoming more labour- or more capital intensive, and is dependent on a large labour force, which cannot easily be replaced by capital inputs. On the other hand, large amounts of capital are required for investment in shafts, development, machinery, and equipment. Since the early seventies, the working costs of the South African gold-mining industry have increased at an annual rate that was significantly higher than the general rate of inflation. This rapid rise in working costs has caused some mines to find themselves in a difficult profit position. At times, the gold-mining industry has even been compelled to restructure its cost/revenue relationship rather fundamentally by revising the grade of ore worked sharply upwards or downwards, as the case may be. The rise in the gold price since 1972 has made it possible for the industry to introduce significant changes in its Black wage policy. The main aim was to increase the permanency of the Black labour force and to encourage local Black workers to join the industry. At the same time, significant increases were also experienced in the cost of machinery and stores, as well as of capital, mainly as a result of inflation. In the study on which this paper is based, the author attempted to measure the influence of environmental factors on working costs, using the physical consumption of electricity as a criterion for measurement. He found that the usefulness of this criterion in relation to factors such as depth, temperature, and water quantities pumped was invariably more than neutralized by the effects of greater productivity and economies of scale. The effects of these environmental factors on the working costs of the industry could therefore not be determined to any degree of accuracy. It seems that good progress is being made with the development of capital-intensive forms of technology aimed at coping with rapidly rising working costs and other effects of increasing depth. Techniques are also being developed to improve rock-cutting procedures and to eliminate the use of explosives in order to introduce a continuous mining process. On the whole, the gold-mining industry seems to be more sensitive to general inflationary pressures than to the cost effects that are associated with depth, temperature, and water quantities pumped. Greater control is possible over physical environmental factors such as the grade of ore mined, temperature, rate and nature of development of a mine, and adaptation of the daily working cycle to a continuous mining process. Wolfe and others hold the view that the industry will lose control over labour costs as a result of the 'sharp increase in wages and the growth of Black trade unions. However, the use of more capital-intensive technology will allow the industry to reduce its labour force, and a smaller, better-trained, and more permanent labour force will enable the industry to cope with the increasingly difficult physical environment and higher wages.

Jan 1, 1987

By H. J. R. Way

Dr H. J. R. Way: In his reply to my queries Mr Bath still adheres to his statement that it may be possible to replace the estimated R200 million reduction in gold revenue in 1980 by exports of ferro-chromium, and apparently based his conclusion on a growth rate in demand for corrosion resistant steels of 10 per cent per annum in the next few years. As I pointed out at the previous discussion at Middelburg this would entail a production of about one million tons of ferro-chromium in 1980. Exact statistics of South African ferro-chromium production are not available, a fact which is very much to be regretted. But statistics of exports of ferro-chromium are available from "Foreign Trade Statistics" of the Customs and Excise. These show that South Africa exported 99,580 short tons in 1967. The quantity of ferro-chromium consumed in South Africa in 1967 was fairly small and we can therefore assume that the production was 99,580 tons. For this amount to grow to 1,000,000 tons in 1980 would require a growth rate of 19.4 per cent per annum. At 10 per cent this would grow to 344,000 tons and at 7 per cent 240,000 tons. The following growth rates in the form of average trends are pertinent: STEEL - Per annum World steel ingot production - 1957-67 – 6.8 per cent Free-world ingot production - 1957-67 – 6.0 per cent Consumptions of crude steel by four major Free-world Consumers - 1957-67 - 5.6 per cent CHROMITE World production - 1952-67 - 2.5 per cent South African total sales - 1948-67 – 5.4 per cent South African exports - 1948-67 – 3.9 per cent United States consumption, very irregular, but - 1962-67 – 6.5 per cent FERRO-CHROMIUM - Per annum United States consumption - 1952-67 - 6.5 per cent South African exports - 1957-62 - 25.2 per cent South African exports - 1962-66 - 41.9 per cent South African exports - 1966-68 - 21.2 per cent These figures show that exports of ferro-chromium have been growing at a very high rate varying from 21.2 per cent to 41.9 per cent since 1957, but in view of the market situation it seems somewhat doubtful if that high rate can be maintained up to 1980. Of our 1966 exports U.S.A. took 63 per cent which was 53 per cent of their total imports. Their average consumption is trending at a growth rate of 6.5 per cent per annum from 1952-67, but the growth from 1964-66 was 5- 2 per cent and 1966-67, -12 per cent!

Mar 1, 1968

By K. Kabezya

A study on slag dispersion in a model of bottom-blown bath smelting converter was undertaken at room temperature. The aim was to investigate the behaviour of the dispersed slag phase at various operating conditions with very high gas flow rates in low slag volume (10%) systems. For simulation purposes water, paraffin-oil, and air were used to represent the bulk steel, molten slag, and gases respectively in a one-fifth cold model of the commercial 100 t Creusot-Loire-Uddeholm (CLU) converter used in the manufacture of stainless steel in South Africa. Dimensional analysis was done to correlate mathematically the dispersed phase holdup with the operating conditions and the modified Froude number. The overall expression of the holdup revealed that the dispersed slag phase decreased with the vertical distance from the original interface between the liquid phases. The dispersed phase also decreased with the radial distance in the water plume zone toward the sidewall. The holdup was apparently much higher on the side of the reactor where there were no tuyeres. The modified Froude number ensured the correlation between the model and the prototype.

Jan 1, 2014

To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements set out on pages 272 to 277. These financial statements are the responsibility of the Institute's Council. Our responsibility is to report on these financial statements. We have conducted our audit in accordance with generally accepted auditing standards. These standards require that we plan and perform the audit to obtain reasonable assurance that, in all material respects, fair presentation is achieved in the financial statements. The audit included an evaluation of the appropriateness of the accounting policies, an examination, on a test basis, of evidence that supports the amounts and disclosures included in the financial statements, an assessment of the reasonableness of significant estimates, and a consideration of the appropri¬ateness of the overall financial statement presentation. We consider that our auditing procedures were appropriate in the circumstances to enable us to express our opinion presented here. In our opinion these financial statements fairly present the financial position of the Institute at 30th June, 1996, and the results of its operations for the year then ended in conformity with generally accepted accounting practice.

Jan 1, 1996

Report of the independent auditors To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements set out on pages 251 to 257. These financial statements are the responsibility of the institute's Council. Our responsibility is to report on these financial statements. We have conducted our audit in accordance with generally accepted auditing standards. These standards require that we plan and perform the audit to obtain reasonable assurance that, in all material respects, fair presentation is achieved in the financial statements. The audit included an evaluation of the appropriateness of the accounting policies, an examination, on a test basis, of evidence that supports the amounts and disclosures included in the financial statements, an assessment of the reasonableness of significant estimates, and a consideration of the appropri¬ateness of the overall financial statement presentation. We consider that our auditing procedures were appropriate in the circumstances to enable us to express our opinion presented here. In our opinion these financial statements fairly present the financial position of the institute at 30th June, 1998, and the results of its operations for the year then ended in conformity with generally accepted accounting practice.

Jan 1, 1985

By A. G. Ramsay, P. G. Kahles, L. E. Kun

A method for the clarification of uranium pregnant solutions using a high-rate floc blanket was developed from laboratory scale through pilot-plant testing to full-scale production by the Anglo American Research laboratories. A two-stage clarification process (hopper plus leaf) was commissioned at the Western Deep levels uranium plant in October 1980. The high efficiency of the hopper clarification permitted its use on its own. The leaf clarifiers were therefore taken out of service in September 1981, since when the secondary clarification is achieved by further unaided gravity settling in the semi-clarified and clarified pregnant-solution storage tanks. As a result, a daily 12000 to 17000 t of countercurrent-decantation overflow with a suspended-solids concentration of 500 to 600 mg/I is continuously clarified to a suspended-solids concentration of less than 30 mg/I. Secondary gravity settling reduces the suspendedsolids concentration to under 20 mg/I. The cost of the single-stage hopper-clarification process is RO,O020per ton of liquid treated. The removal of the leaf clarifiers from the circuit resulted in an approximate visible saving of RI00000 per annum.

Jan 1, 1983

In the investigation described here, it was found that the main effect of temperature is on the rate of flotation, and that adsorption of the reagent is not rate controlling. Above 10°C, the flotation rate of pyrite and gangue increases almost exponentially with a rise in temperature. Below that temperature, the flotation rate of pyrite shows a sudden marked decrease, that of gangue increases, and the sulphur grades are significantly poorer. In the flotation of pyrite, the mass transfer of the pyrite from the pulp to the troth is thought to be the ratecontrolling step, whereas the flotation of gangue is controlled by the combined effect of the stability and velocity of the froth and the viscosity of the elutriating medium. The latter is probably the controlling effect at temperatures below 10°C. Little difference was noted in the recoveries (provided no time limit was set) with changes in temperature; hence adequate recoveries can be obtained at Iow temperatures by the introduction of longer residence times for the pulp. The adverse effects of Iow temperatures on grades can be overcome only by additional cleaning or by heating of the pulp.

Jan 1, 1984

To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements set out on pages 251 to 257. These financial statements are the responsibility of the institute's Council. Our responsibility is to report on these financial statements. We have conducted our audit in accordance with generally accepted auditing standards. These standards require that we plan and perform the audit to obtain reasonable assurance that, in all material respects, fair presentation is achieved in the financial statements. The audit included an evaluation of the appropriateness of the accounting policies, an examination, on a test basis, of evidence that supports the amounts and disclosures included in the financial statements, an assessment of the reasonableness of significant estimates, and a consideration of the appropri¬ateness of the overall financial statement presentation. We consider that our auditing procedures were appropriate in the circumstances to enable us to express our opinion presented here. In our opinion these financial statements fairly present the financial position of the institute at 30th June, 1998, and the results of its operations for the year then ended in conformity with generally accepted accounting practice.

Jan 1, 1998

By J. T. Collins, C. J. Cloete

Secunda Collieries forms part of Sasol Coal, the coal division of the Sasol Group of companies, and already produces 29 Mt of coal per annum from its four collieries: Twistdraai, Brandspruit, Bosjesspruit, and Middelbult. The successful establishment of this mining complex was achieved only through a unique team spirit in which the central services and the decentralized teams under the leadership of the mine management of each of the four mines played an important role. The Secunda mining complex has now reached the optimization phase, during which the mining cost, productivity, safety, and quality of work become as important as production. The setting of priorities and problem solving over the long, medium, and short term are essential for improving the performance of the four collieries. Management had to adapt to the fast-changing environment during the enormously fast build-up of production. The major challenges in the environment were posed by the frequent dolerite intrusions, the extremely hard cutting conditions caused by carbonated nodules and thin sandstone intrusions in the coal seam, and excessive roof and face pressure in some areas due to semi-massive sandstone formations in the rock strata.

Jan 1, 1986

By M. Cortie, L. Iorio

The amount of nitrogen contained in an austenitic stainless steel affects its properties significantly. The maximum content of nitrogen feasible in a range of experimental low-nickel austenitic stainless steels containing significant additions of copper is evaluated The nitrogen content is calculated based on published interaction coefficients, and by use of the FACT thermodynamic computer program and database. The differences between the two methods of prediction can be attributed to inaccuracies in the published interaction coefficients. The calculated nitrogen contents of some experimental alloys are compared with the actual nitrogen contents obtained when the alloys were produced in an induction furnace. The actual nitrogen contents obtained were higher than those predicted by either method, and this is believed to be due to a super saturation of nitrogen occurring in the melt, which was not relieved during the short period in which the charge was molten. It was evident that the experimental alloys can contain between 0,25 and 0,40 per cent nitrogen (depending on temperature, composition, and nitrogen pressure) when melted in a sealed induction furnace, and this is more than adequate for the purpose of forming and stabilizing the austenite phase.

Jan 1, 1994

Contribution by G. Narsimhan It was with much pleasure that I went through D.F. Malan's excellent paper. The following explanatory and critical note has been the result of my deep study of the paper. Although by qualifications and experience I have been a chemical engineer, involved over four decades with problems in the modeling and simulation of transport-limited (heat and mass) chemical reactions in multi-phase systems, I have of and on interested myself in challenging problems in extractive metallurgy. This is the first time I have veered of to continuum mechanics, at the age of 71! Author's reply. I thank Professor Narsimhan for his extensive contribution to the paper. It provided me with the stimulus to derive an extended model. However, there are some inaccuracies in his arguments that need further discussion. Professor Narsimhan's main concern is that there is not a good enough fit between the derived viscoelastic Kelvin model and the experimental data supplied by Güler1 (see Figure l1 on page 218 of my paper). I will therefore explain the choice of a viscoelastic model in more detail and also make specific comments on the arguments given in his contribution.

Jan 1, 1996