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By A. V. Pavlov, V. A. Grygorian, Kossyrev, A. E. Semin, A. Korostylev

A new way of producing low-silicon ferrosilicon from iron-ore materials in a new type of aggregate-oxygen reactor is presented. The oxygen reactor process is based on using the calorific combustibility and reducibility of carbon materials inside the aggregate. The key to the process is successful post-combustion of carbon monoxide above a layer of a solid coke bed. Initially the possibility of production of grades of ferrosilicon containing 20 to 25% Si (FeSi20-FeSi25) was studied on a laboratory model of the oxygen reactor. Quartz sand and iron ore concentrates (from Russia and India) were used in the laboratory tests. This test work demonstrated that a ferrosilicon grade FeSi15 could be obtained directly from raw iron ore (containing 75.9 % Fe2O3 and a maximum of 23.8 % SiO2) without using rich iron-ore concentrates. The process was successfully tested on a pilot furnace at Serovsky metallurgical plant. Very promising results and efficiency parameters were achieved. The consumption of materials for 1t of ferrosilicon (15 % Si) production was as follows: 1567 kg raw iron ore, 591 kg of coal (in a composition of ore-coal briquettes), 299 kg of coke (for coke bed formation), and 815 m3 of oxygen.

Jan 1, 2004

By A. Hiltunen, R. Hiltunen

The utilization of blast furnace and BOF slags has long traditions and well-known applications in the building and road construction industries and in soil conditioning. The starting point for product development has been the basic physico-chemical properties of slags. This development has led to the almost 100% utilization of blast furnace slags and also considerable amounts of steel slags. While new methods and applications are continuously being looked for and developed in order to recycle and utilize all types of slag, there is at the same time an increasing debate over the exact nature of the slags, whether they are products or waste material, and whether they should be considered substances or preparations. These questions have emerged as a consequence of the environmental effects of the slags and current environmental legislation. The environmental effects of slags can be seen to be both beneficial and less beneficial. There is no doubt about their benefits in the road construction industry, as they allow significant savings in terms of natural materials and in transportation. It is also a known fact that using slags as fertilizers and in the cement industry leads to reduction in CO2emissions. The less favourable effects are the possible harmful emissions into the soil and groundwater. In this paper we describe the properties of slag products and their environmental effects according to investigations carried out in Finland. Keywords: utilization, blast furnace slag, steel slag, properties, solubility, environment

Jan 1, 2004

By J. Ekengård, H. Srinath, M. Andersson, P. Jönsson, D. S. Sarma

The present paper deals with mixing between the metal and slag phase during the ladle refining process, including vacuum degassing. Dispersion of metal drops in ladle slags has been studied. The results show a larger quantity of metal droplets in ladle slag during the alloying and stirring phase than during the subsequent vacuum degassing phase. The thermodynamic and kinetic aspects of the interaction between metal drops and the slag matrix have been considered and probable reasons for the observed distribution discussed.

Jan 1, 2004

By W. W. de Graaf, M. J. Ntsekhe

Klipspruit Colliery is experiencing coal losses, which leads to a negative impact on coal production and subsequently loss in revenue. This study aimed to identify the possible causes of coal losses in the No. 4 upper and lower seams. The objectives were to identify potential sources of coal losses through a literature survey, to identify areas where the coal losses occurred, to determine factors affecting coal losses, and to identify the most cost-effective methods to reduce coal losses. Highwall losses, top-of-coal losses, and coal edge losses were identified as the major areas of coal loss at Klipspruit. These losses were mostly attributed to the drilling and blasting practises of the pre-split, interburden waste, and the coal seams. Recommendations include re-visiting the current pre-split design and the tolerances adopted for the interburden and coal seam drilling and blasting design. It is furthermore recommended that Klipspruit implement a continuous improvement plan for the drilling and blasting and refresher training for the blasting crew and operators.

Jun 10, 2024

By J. M. Font, R. G. Reddy

Jan 1, 2004

By George J. Karcas, Raimo Kuusisto, Pertti Pekkala

Ongoing Outokumpu development in Solvent Extraction and Electrowinning Technology, involving all aspects of process chemistry, equipment and control, extends over a period of close to 30 years. The development in SX started with molybdenum and rhenium, continued with zinc, manganese, cobalt and nickel and is now focusing on copper. The OutoCompact VSF? SX concept, which has been recently introduced, is a honed version of earlier VSF? technology. The Outokumpu VSF? ("Vertical Smooth Flow") SX package includes the DOP ("Dispersion Overflow Pump") units, the Spirok Mixers, the OutoCompact Settlers including their DDG ("Dispersion Depletor Gate") fences and tank farm equipment such as the LOS ("Loaded Organic Scrubbing") tank as well as the CEP ("Copper Electrolyte Purifying") tank. Although the VSF? SX package can be implemented according to several optional lay-outs, the so-called Track version has lately been introduced to the advantage of new plants. The new OutoCompact SX technology decreases the footprint of future VSF? plants. The lay-out, including plant size flexibility, have further been improved by Outokumpu?s new OutoReverse settler technology. Two of several SX plants currently under construction rely on reverse settlers in order to maximize their performance. The Outokumpu EW technology includes process know-how as well as proprietary equipment. The copper EW package consists of permanent stainless steel cathodes based on wax-less technology and lead anodes utilising polymer concrete cells with the double contact bus bar system and ventilation hoods fitted for efficient mist control. The lifting of cell hoods, as well as cathode washing, is done by the cathode pulling crane. Proper electrolyte flows and matching current density further ensure high productivity of LME grade copper cathodes.

Jan 1, 2005

By I. K. Craig, F. R. Camisani-Calzolari

Defects which occur at the surface of a continuously cast slab impede the throughput of final product, because an extra stage in the process is required to grind the defects away before further processing can take place. Defect prediction and the minimization of the occurrence of defects is required. The use of two models to define the defect propagation is explained. Both models are derived using system identification techniques such as auto-regression with exogenous input(ARX). One model is used to determine the effect of manipulated variables such as casting speed and measured disturbances such as mould level on temperatures within the mould. The other isused to determine or indicate the effect of the mould temperatures on the occurrence of defects such as transversal cracks. The latter model can be used to predict when the defects will occur and the former can be used to control the occurrence of the defects. Keywords: continuous casting, surface defect, control system, predictor, system identification, ARX

Jan 1, 2003

By M. T. G. Davis, J. V. Cleasby, H. J. Wright

Mining practice in the Kimberley Division of De Beers Consolidated Mines Limited by J. V. CLEASBY. B.Sc.. A.R.S.M. (Fellow). H. J. WRIGHT. B.Se.. M.Sc.. (Fellow). And M. T. G. DAVIES. B.Sc. (Visitor) T his paper highlights the changes that are taking place at De Beers Consolidated Mines Limited in mining methods, mechanization, and employment practices. De Beers has four underground mines in Kimberley itself (Dutoitspan, Bultfontein, De Beers, and Wesselton), and two open-cast mines outside Kimberley (Finsch and Koffiefontein). Emphasis is placed on the new method envisaged for Koffiefontein when it becomes an underground mine. The paper also includes notes on chemical drilling and on winding practices.

Jan 12, 1975

By D. F. Malan, M. Grave, J. A. L. Napier

Previous fundamental research projects have indicated the value of continuous closure measurements in deep tabular excavations for improved support design, hazard assessment and for quantifying the effect of seismicity on stope closure. This paper describes further measurements in a VCR stope to validate some of the earlier findings. Calculation of the closure ratio showed that it is a good measure to identify different ground conditions and possible hazards. This work was supported by numerical modelling results, which showed that the closure ratio is very useful in discriminating the response of different geotechnical environments. Des projets précédents de recherche fondamentale ont démontré la valeur de mesures continues de fermeture dans le cas de profondes excavations tabulaires pour une conception améliorée du soutien, de l’évaluation du danger et pour quantifier l’effet de la séismicité sur l'affaissement du toit d’un chantier d’abattage. Le présent document décrit d’autres mesures dans un chantier d’abattage VCR afin de valider certaines des conclusions précédemment formulées. Le calcul du degré d'affaissement montre qu’il y va de soi d’identifier différentes conditions de sol ainsi que les dangers possibles. Les présents travaux ont été confirmés par des résultats de modélisation numérique, lesquels ont démontré que le taux d'affaissement est très utile quant à discerner la réponse dans des environnements géotechniques différents. Vorherige Forschungsprojekte haben den Wert von kontinuierlichen Setzungsmessungen im tiefen Sudafrikanischen Strebabbau angedeutet, vor allem fur Ausbaudesign und Risikobewertung, als auch fur die quantitative Bestimmungen der seismizitatsabhangigen Setzung. Dieses Referat beschreibt weitere Messungen in einer VCR Grube um fruhere Bestimmungen zu bewerten. Dass errechnete Konvergenzverhaltniss erweiste sich als eine gute Massnahme zur bestimmung von geotechnischen Zonen und moglichen Risiken. Numerische Analyse unterstutzte die vorliegende Arbeit und deutete darauf, dass das Konvergenzverhaltniss sehr brauchbar ist um Verhaltensunterschiede der geotechnischen Zonen zu erproben

Jan 1, 2003

By Glen Mc Gavigan

The roof of the Sishen cave is being mined in order to exploit 6.8Mt of high grade ore. The cavity is filled with quartzite backfill in order to support the roof in the event of collapse. The cave dips at approximately 37o, is 260m along dip and 70m along strike and has a total volume of 261,391m3. GPS and optical monitoring techniques were attempted to detect subsidence but proved to be impractical. The GroundProbe Slope Stability Radar (SSR) uses differential interferometry to measure sub millimetre movement in a rock face. The SSR was applied in a non production situation and detected subsidences of 38mm/day before visual signs of instability were detected. The rate of deformation detected was slowing as a result of the roof coming to rest on underlying backfill. Monitoring during production drilling detected a sudden subsidence of 18.6mm/hour which resulted in the evacuation of personnel from the area. Further inspection of data showed that the rate of deformation was slowing and production was allowed to continue without further incident. The SSR has helped dispel the fears of workers and has proven that subsidence can be accurately measured and delineated with the SSR.

Jan 1, 2006

By R. J. Pine, J. M. Rance, J. S. Coggan

ABSTRACT: The safe design of excavations created in a fractured rock mass is of paramount importance in rock engineering. Depending on the nature of the stress regime acting on an excavation, and the associated deformational behaviour of the rock mass surrounding the excavation, a number of potential failure mechanisms exist. These involve a combination of shear failure on existing joints, extension of critically oriented joints and propagation of new fractures through previously intact rock. Conventional numerical codes usually adopt either a continuum or discontinuum approach; this often results in significant over simplification and kinematic limitations particularly when modelling complex rock mass behaviour in the close vicinity of excavations. This paper describes the results from several case examples using a combined finite element-discrete element code, ELFEN that incorporates a crack propagation mode. Through the use of selected rock engineering examples, the authors demonstrate the potential of the code in the realistic simulation of complex rock failure both in underground and surface excavation applications. RÉSUMÉ: La conception sûre des excavations créées dans une masse de roche fracturée est d'importance primordiale dans la géotechnique. Selon la nature du régime d'effort autour d’une excavation, et le déformation associé de la masse de roche autour de l'excavation, il exsite un certain nombre de mécanismes potentiels d'échec. Ceux-ci comportent une combinaison d'échec de cisaillement sur les joints existants, la prolongation des joints d’orientation critique et la propagation de nouvelles ruptures dans la roche précédemment intacte. Les codes numériques conventionnels adoptent habituellement l’approche, soit d’un continuum, soit de discontinuum; ceci a souvent comme conséquence une sursimplification significative et les limitations cinématiques en particulier en modelant le comportement complexe de la masse de roche très proche des excavations. Cet article décrit les résultats de plusieurs exemples de cas en utilisant un code qui s’agit d’une combination d’élément discret et d'élément fini, ELFEN qui incorpore un mode de propagation de fissure. Par l'utilisation des exemples choisis géotechniques, les auteurs démontrent le potentiel du code dans la simulation réaliste de l'échec complexe de roche pour les applications aux excavations soit au fond soit à l’extérieure. ZUSAMMENFASSUNG: Das sichere Design der Aushöhlungen, die in einer zerbrochenen Felsenmasse verursacht werden, ist vom paramount Wert in der Felsentechnik. Abhängig von der Natur des Druckregimes, das auf einer Aushöhlung und dem dazugehörigen deformationalen Verhalten der Felsenmasse umgibt die Aushöhlung fungiert, bestehen eine Anzahl von möglichen Ausfalleinheiten. Diese beziehen eine Kombination des Scherausfalls auf vorhandenen Verbindungen, Verlängerung der kritisch orientierten Verbindungen und Ausbreitung der neuen Brüche durch vorher intakten Felsen. Herkömmliche numerische Codes nehmen normalerweise entweder ein kontinuum oder discontinuum Annäherung an; dieses ergibt häufig bedeutende Übervereinfachung und kinematische Beschränkungen, besonders wenn es kompliziertes Felsenmasseverhalten in der Nähe der Aushöhlungen modelliert. Dieses Papier beschreibt die Resultate von einigen Fallbeispielen mit einem kombinierten begrenzten Element - getrennten Elementcode, ELFEN, das einen Sprungausbreitungmodus enthält. Durch den Gebrauch von vorgewählten Felsentechnikbeispielen, demonstrieren die Autoren das Potential des Codes in der realistischen Simulation des komplizierten Felsenausfalls bei Anwendungen für beide Tagebaue und Untergrundsaushöhlungen.

Jan 1, 2003

By F. W. Petersen

The Conference Minerals & Materials '96 was held in Somerset West, South Africa, from 31st July to 2nd August, 1996. It was organized by the Universities of Stellenbosch and Cape Town, the Cape Technikon, and the Western Cape Branch of The South African institute of Mining and Metallurgy (SAIMM). The three-day Conference was attended by 180 delegates, representing countries such as Australia, South Africa, United Kingdom, Finland, Sweden, Germany, Poland, Zambia, and Zimbabwe. The programme and associated exhibition were well organized, and each of the delegates received two volumes of proceedings containing the 77 papers presented at the Conference.

Jan 1, 1996

By G. E. Blight

Wind erosion can be a major cause of the loss and dispersion of tailings material from a tailings dam into its surrounding environment. Such dust dispersion can be a serious nuisance, as well as a health hazard to inhabitants in nearby settlements, and can also damage the health of animals, degrade crops, making them less marketable, and cause soil and water pollution. The problem of wind erosion can affect tailings dams in all types of climate, but becomes worse as climatic aridity increases. Because clouds of dust are often observed billowing across the top surfaces of tailings dams in dry windy weather, there is a common misconception that the dust arises from wind erosion of the top surface. As a result, much effort and money is vainly spent on treating the tops of tailings dams to prevent dust generation, whereas the slopes of the dams are the true major dust source. This paper briefly reviews what is known of erosion of tailings dams and then proceeds to describe the mechanics of wind erosion in general, and how it affects tailings dams in particular. Finally, recommendations are made for mitigating wind erosion of tailings dams and the resulting blowing dust.

Jan 1, 2007

By A. L. Hinde, A. A. Bradley, K. H. Stanton, P. J. D. Lloyd, G. K. Schymura

As part of its programme to develop methods for concentrating minerals underground, the Chamber of Mines of South Africa in conjunction with Lurgi evolved and tested a I MW centrifugal mill. The machine is capable, in the autogenous mode, of grinding more than 25 t/h of minus 75 plus 44 mm hard quartzite to a minus 3 mm product containing over 50 per cent minus 75 µm material, and as a ball mill of grinding more than 60 t/h of minus 19 mm quartzite to a minus 3 mm product containing over 35 per cent minus 75 µm material. Extrapolation of computer models of the process suggests that these limits can be comfortably exceeded. Long-term continuous testing is in hand, aimed at proving that this I m in diameter by I m long mill is in every respect the equivalent of a conventional 4 m by 6 m ball mill.

Jan 1, 1982

By C. Wade, A. Swart, M. Dworzanowski

AngloGold Ashanti operate a pyrite flotation plant at their East Gold Plant, Acid Plant and Flotation Plant (EGAF) metallurgical complex within their Vaal River operations in the North West province in South Africa. The flotation plant feed is reclaimed pyrite rich tailings and the concentrate produced is used as the source of sulphur for the EGAF acid plant. The sulphuric acid produced is in turn used for the recovery of uranium at the Vaal River South uranium plant. The original flotation plant built in 1960 was based on the use of many small volume flotation cells and was becoming very expensive to operate and its age severely limited further operation. A decision was taken in 2005 to replace this plant with a new one based on fewer, larger volume flotation cells. This paper describes the benefits of using larger volume flotation cells in this new flotation plant when compared to the smaller volume flotation cells in the old plant. The benefits of the new plant include a smaller plant footprint, fewer flotation cells, fewer pumps, no distribution boxes, simpler piping, a greater flotation volume and a reduction in installed power. The saving in capital cost could not be quantified because of the age of the old plant. The savings in operating cost will arise from fewer operators, less maintenance and reduced power consumption. The new plant has not been in operation long enough to quantify the benefits in operating cost and metallurgical performance. However, recovery improvements can be expected given the greater flotation volume (increased residence time) and the installation of larger, more efficient flotation cells.

Jan 1, 2007

By G. Tranell, L. Kolbeinsen, S. Gaal, J. Safarian

The effect of carbon material properties on the rate of MnO reduction from ferromanganese slag by solid graphite was investigated. A sessile drop technique was used to study the reduction rate of a synthetic slag containing 45 wt% MnO at 1500 and 1600 ºC. Different types of graphite substrates were used and the con-tact angle between slag droplets and substrate were measured in-situ. Moreover, the slag droplet volume during the interaction with the graphite substrates was calculated and normalised. The mathematical relationship between the slag density during the reduction and the normalised slag droplet volumes during the reduction were derived and the MnO reduction curves were then calculated. A method for measuring the slag reactivity of solid carbon was defined and used to qualify the propensity of the different graphites to react with the liquid slag. Some supplementary studies such as manganese evaporation measurement and EPMA analysis for determining the extent of MnO reduction were also carried out. It was observed that there is nota significant difference in the wetting angle of the graphite substrates by the slag, and the wetting is not changed within the temperature range of 1500-1600ºC. However, the changes in the contact angle during the slag reduction at 1600ºC are more than at 1500ºC. The kinetics of MnO reduction is dependent on the type of graphite and it is more dependent on the graphite properties at lower temperatures. On the other hand, the dominant properties of graphite on the reduction rate vary with temperature. A multivariate analysis on the graphite properties and the parameters related to the slag reactivity indicated that the kinetics of MnO reduction is mainly dependent on the temperature, and then on the graphite properties. It was also found that at1500 ºC the surface area and the CO2 reactivity are the most important graphite properties for the slag reduction, suggesting that the reactivity of carbon is rate controlling at 1500 ºC. However, the porosity related parameters are the most important graphite properties at 1600 ºC, suggesting that CO gas desorption is rate controlling at high temperatures.

Jan 1, 2007

By R. T. Jones

Slags have been produced as by-products from pyrometallurgical processes for thousands of years, and have generally been regarded as waste. Many of these slags are no longer seen as residues merely to be discarded, but as potential economic sources of metals, or as useful by-products in their own right. Slag cleaning can enhance the recovery of valuable metals in existing pyrometallurgical processes, or can produce economic value from recycling old slag dumps. For example, a process has been developed and implemented industrially for recovering cobalt from copper smelting slag in a DC arc furnace. The relatively non-leachable behaviour of glassy slags allows them to be used as a very safe means of disposal of metallurgical waste streams, including many that are classified as hazardous. The high temperatures, reducing conditions, and good mixing that can be achieved in a DC arc furnace enable the effective functioning of this environmentally beneficial means of disposal. Lead blast furnace slag can be rendered safe for disposal by treating it using the Enviroplas process, which strips most of the hazardous lead from the slag (and traps the rest in an insoluble glassy slag) and recovers economic quantities of zinc by absorbing (in a lead splash condenser)the zinc vapour that is fumed off in the furnace. Another example can be seen in the recovery of a chromium- and nickel-containing alloy from stainless steel plant dust, while producing a disposable residual slag. The examples presented here illustrate that it is possible to develop processes that are both economic and environmentally beneficial. Keywords: DC arc furnace, plasma, slag cleaning, cobalt recovery, zinc fuming, Enviroplas, jigging, re-melting fines, environmental, economic

Jan 1, 2004

By G B. Gnoinski

The Skorpion Zinc Mine and Refinery is situated approximately 25 km north of Rosh Pinah, south-western Namibia. The supergene zinc oxide deposit at Skorpion is hosted in a volcano-sedimentary succession within the para-autochthonous Port Nolloth Zone of the Gariep Belt. Rock types hosting the ore deposit include altered and metamorphosed volcaniclastic and clastic sediments, limestone and rhyolite. At Skorpion, the metallurgical process is unique and the plant design requires minimal fluctuations within a selected feed grade. In addition, the presence of limestone inter-fingered with ore in some areas of the deposit results in dilution problems which may increase gangue acid consumption and therefore processing costs. Hence, selective mining is necessary to ensure the delivery of suitable ore to the processing plant, in order to keep the overall operating costs at a minimum. A complex control system is in place and is capable of a high degree of selectivity. The paper describes the grade control system in place at Skorpion Mine which ensures that the qualities of the blocks planned for mining and the material being mined meet the stringent process requirements of the refinery, i.e zinc grade, gangue acid consumption and deleterious elements that may impact on the efficiency and costs of the metallurgical process. Keywords: Skorpion zinc, zinc oxide, supergene, volcano-sedimentary, grade control

Jan 1, 2007

By P J. Fourie, J R. Walklate

Gravity separation techniques have been in use in the mineral sands industry for decades; from the Reichert cone to Wilfley tables, Wright sluices and the Kelsey Jig, all attempting that elusive perfect gravity separation. Just as the gravity separation industry evolved, Richards Bay Minerals also evolved in their use and approach to gravity separation. This paper discusses the history of gravity separation at Richards Bay Minerals and briefly comments on future developments. History Primary Concentration Richards Bay Mineral?s (RBM) first mining concentrator and mineral separation plant commenced operation in 1977 to process ilmenite, rutile and zircon bearing dunal deposits along the northern Natal coast. The orebody contained a greater proportion of non-valuable magnetic heavy mineral in the SG range of 3 to 4 compared to West Australian and Florida USA deposits, making mineral separation more difficult(1). The deposit was mined using two dredges feeding a floating 2000 tph concentrator. Concentrator feed was screened and fed to two four-stage circuits consisting of primary, scavenger, cleaner and recleaner Reichert cones [see Figure 1]. The primary units were fed at a rate of 80 tph and a density of 60% solids by weight.

Jan 1, 2006

By Dziurzyn&apos, W. ski

This article outlines the results of a computer simulation reproducing the transport of a mixture of air and methane following the outburst on 25 November, 2005 in transport gallery D-6, bed 409/4, at the ?Zofiówka? hard coal mine. Based on a mathematical model, numerical method and boundary conditions from the disturbance caused by the outburst, the Ventgraph system of computer simulation programs was adopted for the study. We performed a computer simulation of the influence exerted by the outburst on the propagation of the air and methane mixture, and compared the results of this simulation with those of the actual event as registered by sensors of the mine monitoring system. A validation of the model allowed us to present temporal changes in the concentration of methane and air along flow routes. Keywords: mine ventilation, outburst of methane, numerical simulation, monitoring system.

Jan 1, 2008