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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 R. D. Agrawal, M. L. Kapoor

Cementation has been used extensively by chemists and metallurgists as an economical process for the purification and recovery of metals from dilute solutions. The paper deals. firstly. with the thermodynamic aspects of cementation. and. secondly, with the effects of various process variables, such as temperature. stirring speed. initial concentrationof copper ions. pH of the solution, atmosphere, and surface area of the precipitant metal. on the kinetics of the process in the light of the rate expressions.

Jan 1, 1982

By E. Shavartz, N. B. Strydom

The incorporation of individual cooling in a compressed-oxygen closed-circuit breathing apparatus by E. SHVARTZ, M.Sc. (U.C.L.A.), Ph.D. (U.S.C.) (Visitor) and N. B. STRYDOM, M.Sc., Ph.D. (Illinois) (Fellow) A conventional compressed-oxygen breathing apparatus, which did not include provisions for dehumidification of the inspired air at high environmental temperatures, was tested at these temperatures with and without conductive cooling in the form of 2 kg of pre-frozen ice placed inside the breathing bag of the apparatus. The pre-frozen ice provided conductive cooling of the soda lime and of the chest and abdomen of the subject, who performed moderate work at 50,1 "c. Without cooling, the subject was exhausted after 35 minutes because of a wet-bulb temperature of the inspired air of 46"c. With cooling, the subject finished 2 hours of work. This was possible by keeping the soda lime at a relatively Iow temperature, which resulted in a wet-bulb temperature of the inspired air of only 42 °C after 2 hours, and by conductive cooling of the chest, which resulted in the maintenance of a relatively Iow heart rate and rectal temperature.

Jan 7, 1975

By S. Soren, K. Deo Mehta, G. Jha

The paper aims to find a sustainable sintering process through cleaner means, in order to achieve the desired outputs with zero environmental impact. At present, sintering has no control over its environmental impacts. These impacts occur when fossil fuels such as coal and coke are used in metallurgical sintering. These fossil fuels are undoubtedly effective in their assigned reducing task, but simultaneously emit about 220 kg of GHGs (greenhouse gases) per tonne of sinter produced. The current attempt has focused on reducing these emission levels by switching from coke to a renewable fuel source such as biomass. Biomass is a cleaner fuel source with a significantly lower emission footprint compared to coke. In the experimental campaign, sawdust and wood-charcoal were used in substitution for coke. Experiments were designed in a progressing substitution to obtain the maximum substitution ability without compromising the sinter properties. Sawdust as raw biomass source optimally substituted 10% of coke. The substitution levels were remarkably higher (30%) for wood charcoal due to its low moisture and high calorific values. A fuel blend with 30% biomass and remaining coke succeeded in producing a sinter with acceptable quality indices. Sinters prepared with or without biomass contribution shared an identical phase transformation and microstructures. In order to to maintain consistency in the process, every effort was made to maintain all operational and process parameters identically, except for the fuelling framework. Keywords: Sintering, sustainable, biomass, GHGs, fuel substitution

Jan 1, 2020

By A. Haque

The shear behaviour of infilled joints produced from ordinary gypsum plaster (gyprock) and bentonite was investigated in the laboratory under Constant Normal Stiffness (CNS) conditions. Shear tests were performed on saw-tooth profiles having Joint Roughness Coefficients (JRC) of 4.75 and 9.25 under an initial normal stress (sno) of 0.30 to 1.10 MPa, and at a normal stiffness (kn) of 8.5 kN/mm. Test data under the same sno and infill thickness to asperity height ratio (t/a) were analysed for two different sets of JRC. The peak shear stress plotted against the t/a ratio under constant sno revealed an increase in peak shear stress with the increase in JRC, up to a t/a ratio of about unity. The effect of roughness on the peak shear stress was observed to be minimal when the t/a ratio exceeded 1.40. A mathematical model for the prediction of peak shear stress due to the increased infill thickness has been developed based on a hyperbolic stress-strain relationship and energy balance principles. The model predictions are in good agreement with the laboratory observations. Le comportement de cisaillement des joints remplis produits à partir de plâtre ordinaire et de bentonite a été étudié dans le laboratoire sous des conditions de rigidité normales constantes. Des essais de cisaillement ont été réalisés sur des profils en dents de scie ayant des coefficients de rugosité des joints (CRJ) variant de 4,75 à 9,25 sous un effort normal initial (sno) de 0,30 à 1,10 MPa, et une rigidité normale (kn) de 8,5 kN/mm. Le résultat des essais conduits sous la même contrainte et épaisseur de remplissage au rapport aspérité/hauteur (t/a) ont été analysés pour deux ensembles différents de CRJ. La variation de l'effort de cisaillement maximal contre le rapport t/a sous une contrainte normale constante a indiqué une augmentation de l'effort de cisaillement maximal avec l'augmentation du CRJ, jusqu'à un rapport de t/a proche de l'unité. L'effet de la rugosité sur l'effort de cisaillement maximal a été minimal quand le rapport t/a a excédé 1,40. Un modèle mathématique pour la prévision de l'effort de cisaillement maximal dû à l'épaisseur accrue du remplissage des joints a été développé sur la base de la variation entre contraintes hyperboliques et déformation et sur des principes de bilan énergétique. Les prévisions du modèle sont en bon accord avec les observations de laboratoire. Das Scherverhalten in mit gewöhnlichem Gips und Bentonit gefüllten Klüften wurde im Labor unter Bedingungen konstanter Normalsteifheit (CNS) untersucht. Scherversuche wurden durchgefürt für Sägezahnprofile mit Werten des Fugenrauhigkeitskoeffizienten (JRC) von 4.75 und 9.25 unter Normalspannungs-werten (sno) von 0.30 bis 1.10 MPa, und bei Normalsteifheit (kn) von 8.5 kN/mm. Testresultate für gleiche Werte von sno und Verhältnis Fülldicke zu Rauhigkeit (t/a) wurden untersucht für zwei verschiedene Werte von JRC. Die Beziehung zwischen maximaler Schubspannung und und t/a Verhältnis unter konstantem sno zeigte einen Anstieg der maximalen Schubspannung mit zunehmendem JRC, bis zu einem t/a Verhältnis von etwa 1.0. Der Einfluss der Rauhigkeit auf den Maximalwert der Schubspannung war minimal solange das t/a Verhältnis den Wert von 1.40 überstieg. Ein mathematisches Modell wurde entwickelt für die Vorhersage der Schubspannung die von zusätzlicher Fülldicke erwartet werden kann, ausgehend von einer hyperbolischen Spannungs-Dehnung Beziehung und dem Energiegleichgewichts-prinzip. Die Modellvorhersagen zeigten gute Uebereinstimmung mit den Laborbeobachtungen.

Jan 1, 2003

By D. D. Hawat

The locations of potential reserves of chromite ores throughout the world are discussed. Reference is made to the marked changes in international trade in chromite ores during the past ten to fifteen years, and to the change in locality of the production of ferochromium aloys, which is curently largely carried out in the country of origin of the ores. The influence of these changes has been very profound in South Africa, which has the largest smelting capacity and the largest production of ferochromium aloys in the world. A proportion of South African ore is stil exported to meet the demands for the production of chromium chemicals and refractories, including a large tonnage of foundry sands. Ferochromium smelters in South Africa have a capacity of virtualy 1 Mt of aloy per annum. Nearly al this development has taken place since the introduction of the argon-oxygen decarburization (A.O.D.) process for the smelting of stainless steels. Formerly, expensive Iow-carbon ferochromium aloys were required as raw materials, but the AO.D. process, which is being used world wide, permits the use of high-carbon ferrochromium, the main product of the smelters in this country. The production in South Africa of chromium-containing corrosion- and heat-resistant steels is stil on a relatively smal scale, but serious atention is being paid to the exploitation of low-carbon weldable feritic chromium steel.

Jan 1, 1986

By A. C. Legg

BCL Limited operates a nickel-copper flash smelting operation at Selebi-Phikwe, situated in north-eastern Botswana. The original furnace was commissioned in 1973 and produces a high grade sulphide matte, from its own concentrates plus additional custom feeds, which is shipped to refineries in Zimbabwe and Norway for further processing. In 2004 the company embarked on a study to modernize the flash smelting complex, with an emphasis on extending campaign life, improving the furnace integrity and enhancing throughput and process efficiency. First phase initiatives from this exercise, including the fundamental switch to a single concentrate burner operation of the flash smelting furnace, were implemented in July 2007. This paper summarizes experiences prior to implementation, details the specific improvements made to the flash smelting furnace and associated operations, highlights the improved plant performance after modernization, and outlines second phase expansion plans that are currently under consideration.

Jan 1, 2009

By M. Ndabeni, J. H. van Vreden, M. Le Roux, Q. P. Campbell

It is not uncommon for gold slurry ponds or screen oversize dumps to contain several different types of carbon-rich contaminants. These contaminants act as robbers of dissolved gold which has a detrimental effect during the downstream carbon-in-leach (CIL) or carbon-in-pulp (CIP) processes. With a renewed interest in the reprocessing of contaminated gold waste ponds and dumps, preconcentration of the feed to either the CIL or CIP process becomes important to maximise profits from these resources. An added advantage in removing these resources, which were once thought of as being uneconomical, is the availability of land that can further be rehabilitated for community development projects. For gravity separation, an example of suitable technology is the Reflux Classifier (RC), which can be used for the separation of materials of different densities and can be used as a pre-concentration step. In this project, a laboratory-scale Reflux Classifier was used to pre-concentrate a gold-bearing sample obtained from a waste dump situated to the east of Johannesburg, South Africa. The material had an average gold grade of 1.9 g/ton and a carbon content of 10%. This material was first fed to a semi-batch Reflux Classifier that was used to fractionate it into several different density intervals by varying the fluidisation water feed rate, followed by continuous runs at fixed water flow rates. The results showed that a cumulative gold recovery of 60%, carbon recovery of 85%, and mass pull of 41% was possible for a fluidisation water feed rate of 15 L/min, while a rate of 20 L/min resulted in a gold recovery, carbon recovery and mass pull of 83%, 92% and 79% respectively, which translated into a concentrate gold grade above the set target of 3 g/ton. Continuous operation at 20 L/min yielded an underflow stream with 84% gold recovery at a grade of 5.4 g/ton. Keywords: Reflux Classification, gold recovery

Jan 1, 2020

By G. J. C. Young

Opening: On Tuesday, 9th June, The South African Institute of Mining and Metallurgy held a well-attended Colloquium on Milling at Mintek, Randburg. The meeting opened with a short address by Dr H. Wagner, Director General of the Chamber of Mines Research Organization. In his address, he highlighted the cost of the milling process to the industry. The fact that the industry at home and overseas had, at considerable expense, sent some 270 delegates to the Colloquium demonstrated the industry's concern at the high cost of this process. Clearly, this cost could be reduced only by greater understanding and interchange of information, which was the purpose of meetings such as these. Mine water The Third International Mine Water Congress is to be held in Melbourne from 23rd to 28th October, 1988, the year of Australia's bicentenary.

Jan 1, 1987

By J. D. Koch

A 'project' is defined here as a process in which an idea is developed from its inception until either it is discarded or the product of the idea has been accepted by the ultimate user. The phases in a project, particularly the early phases, are examined, and project organization is described and contrasted with a functional line-management type of organization. Emphasis is placed on comprehensive definition, which is vitally important to the achievement of the goals of time, cost, and quality set for a project.

Jan 1, 1981

By Y. -L. Chiang

Paper written on project work carried out in partial fulfilment of BSc (Eng) (Chemical) The generation and control of manganese sulphide particle size distribution using various mixing configurations were investigated. Specifically, this paper discusses how varying mixing intensities on a macro and micro scale affect the resultant manganese sulphide particle size distribution (PSD) at a constant concentration. The mixing variations were achieved using various Y- and T-mixers as premixing devices into a jacketed, agitated vessel. The reagents used to generate the seeds were aqueous manganese sulphate and sodium sulphide solutions. The results showed that the absence of micromixing resulted in very poor control of the particle size distribution, the particle size and the number of particles produced. This was due to the fact that the macromixing time is much greater than the corresponding precipitation time, resulting in different mixing regions existing within the reactor. From the micromixing experiments, the T?mixer was found to be the most effective mixing device at lower concentrations due to the T-mixer providing a faster mixing time than the other mixing configurations, thereby effectively localizing the supersaturation and hence controlling the precipitation. The results obtained from the direct addition without the extension pipe (i.e. short mixing time) indicated a general increase in mean particle size and decrease in total particle number at reagent concentration of 0.007 mol.dm-3as compared to the corresponding micromixing experiments. The phenomenon may be due to incomplete crystallization at the immediate exit of the mixing device. Further experiments need to be conducted before any conclusions can be drawn about the precipitation mechanisms.

Jan 1, 2007

1. Book review The geology of some northern Nigerian anorogenic ring complexes, by J.N. Bennet, D.C. Turner, E.C. Ike, and P. Bowden. The British Geological Survey: Overseas Geology and Mineral Resources, no. 61. London, HMSO, 1984. 66 pp. Reviewer: R.H. Ingram 2. Mintek reports Report M226 The separation of tungsten and molybdenum by the formation of sulphide complexes and extraction into a weak-base resin. Report M228 The solvent extraction of zinc, iron, and indium from chloride solutions by neutral organophosphorus compounds. Report M230 Shear flocculation of fines for improved flotation. Report M239 A mineralogical study of residue from the column leaching of a low-grade nickel-copper sulphide ore.3. Recent publication Driger Review, special edition, act. 1985. 48 pp. (Copies obtainable from Roly Nyman, HAMPO PMIE Division, P.O. Box 170, Joham1esburg 2000.) Black Mountain's achievement The 13 689 t consignment of metal concentrate that was loaded aboard the bulk carrier 'George' and shipped out of Saldanha Bay early in December brought the number of tons exported from Black Mountain via the Sishen-Saldanha railway and harbour system to one million.

Jan 1, 1986

By P. Wiesner, H. –M. Stonner

A brief account is given of the influence of sulphuric acid and chloride ions during the recovery of uranium by solvent extraction, followed by a discussion of the settling behaviour of dispersions and models to represent that behaviour. The paper ends with a description of various methods for the recovery of solvent, which is lost in the solvent-extraction process by entrainment and adsorption on solids and by dissolution.

Jan 1, 1982

By L. G. Austin

The paper summarizes the current state of development of simulation models for SAG and FAG mills, and gives the results of recent investigations of the physical processes occurring in autogenous grinding. The breakage process is treated as the sum of three regions of breakage actions: normal breakage caused by nipping of particles between media (steel balls or pebbles); abnormal breakage caused by media when the particle or lump is too big in relation to the media to be readily nipped; and self-breakage resulting from the chip¬ping fracture and abrasion of the tumbling action of rock lumps. Each region of breakage action has associated specific rates of breakage and primary progeny fragment distributions. A simplified form of the model was used to predict the performance of an 8 m diameter SAG mill with L/D = 0.5 grinding a copper ore, and predicted maximum capacity and minimum kWh/ton at about 6% ball load at 25% total filling. Two FAG mills of L/D = 2 were necessary to give the same capacity, and the simulations indicated a lower kWh/ton for these mills. For this ore, both systems were technically feasible.

Jan 1, 1987

By G. R. Drennan, N. J. Wagner, M. J. T. Sebola

The Soutpansberg Coalfield hosts South Africa's hard coking coal reserves. However, coals in this region are understudied compared to other coalfields in the country. This study characterizes the properties of fine-float fraction samples extracted from a wide diameter borehole core in the Makhado Project, Tshipise sub-basin, Soutpansberg coalfield. Conventional analyses were used to determine the coal quality, petrographic composition, mineralogy, geochemistry (including trace element and rare earth element composition), and free swelling index of samples from six coal horizons and three partings from the economic No.6 Seam. The coal samples are classified as medium rank bituminous C coals (0.88 %RoVmr, 0.92 %Rmax) and are highly vitrinitic in composition (97 vol% mineral matter free (mmf)). The samples show strong caking potential (FSI of 9). The total rare earth concentrations range between 570 and 3193 ppm in the ash samples. Preliminary analysis show all but two samples are promising sources of rare earth elements as the total concentrations exceeded the 1000 ppm cut-off grade. Further research is required to confirm these preliminary findings.

Aug 2, 2022

By M. Borowski, N. Szlazak, D. Obracaj

Methods of research and control of the intensity of gas inflow to undersoil layers, after the mines were abandoned are presented in the paper. Gas migration causes them to penetrate to lower storeys of buildings and earthen structures being a menace to people's health and life. The results of measurements of gas concentration in undersoil layers, gas emission to atmosphere and their accumulation in buildings on the territory of closed down mines are presented.

Jan 1, 2003

By E. E. Almási, G. Mucsi, G. Rákhely, Á. Rácz, B. Csőke, Zs. Pap, K. Bohács, N. Halyag

Wet stirred media milling is a widely applied grinding process in the field of mineral processing to produce <10 μm ground materials. In this paper, the results of wet stirred media milling of different Ti, Fe and Cu-oxide and phosphate minerals are presented. During the experimental work, grinding of ilmenite, vivianite, hematite and cuprite was carried out in a continuous operation wet stirred media mill. During the experiments, the particle size distribution and specific surface area of the ground materials were determined after a certain grinding time, as well as measuring the specific grinding energy, thereby determining the grinding kinetics of the different minerals. The measurement results showed the differences and similarities in the grindability of the individual minerals. Nano particulate vivianite, hematite and ilmenite was successfully manufactured in a stirred media mill; however cuprite was characterised as the coarsest final product for the same grinding circumstances. Keywords: Wet stirred media mill, cuprite, vivianite, ilmenite, hematite

Jan 1, 2020

By G. Nino de Guzman, L. C. Woollacott

The isotherms that are usually taken to represent the force &apos;driving&apos; the adsorption in carbon-in-pulp processes may change from contactor to contactor. This paper reports on an investigation into the extent to which this Isotherm shift is Influenced by the changes in oxygen and cyanide concentration that occur in operating plants. The impact of the isotherm shift on the reliability of simulation results is examined.

Jan 1, 1993

By C. Chapman, M. G. Reading, M. P. Amsden

Computer control of flotation at the Ecstall concentrator By M. P. AMSDEN, C. CHAPMAN, and M. G. READING Ecstall Mining Limited, a subsidiary of Texas Gulf Sulphur Company, operates the Kidd Creek Mine, a 10000 tons per day base metal producer, near Timmins, Ontario. Two different types of ore are mined and milled: copper-zinc and silver-lead-zinc. At the highly automated Ecstall concentrator the ores are processed by selective flotation in three individual circuits. One of the most important metallurgical tools for process control is a sample system incorporating continuous on-stream X-ray analysis. Recently this system was automated further by the addition of computer control of reagents for two copper-zinc flotation circuits. The computer programs, utilizing optimum seeking methods and smelter contract terms, have increased copper recovery by 1,1 per cent, zinc recovery by 1,4 per cent, and have reduced reagent costs by 16 per cent. Although not expected, copper and zinc concentrate grades were improved slightly as well.

By T. Feroze, B. Genc

"The ventilation of underground coal mines plays an important role in minimizing the risk of methane and coal dust explosions. The ability of ventilation, with the use of line brattices (LBs), to remove methane and coal dust in empty headings is dependent on the amount of air leaving the LB and entering the heading. The quantity of this air depends on the associated system variables, namely heading dimensions, settings of the LB, and velocity of air in the last through road (LTR). However, the exact effect of these system variables on the flow rate at the exit of the LB in an empty heading is not known. The installation of LBs in South African coal mines is generally carried out based on experience. This can result in overor under-ventilation and may increase the cost of providing ventilation or cause accidents, respectively. In this paper, using computational fluid dynamics (CFD), the air flow rate at the exit of the LB in an empty heading was estimated using full-scale three-dimensional models. The CFD model used was validated using experimental results Firstly, the settings of these three system variables were varied, the flow rates at the exit of the LB were measured, and finally the results were used to calculate the effect of each system variable. The outcome is a mathematical formula that can be used to estimate air flow rate at the exit of the LB in empty headings for any practical scenario.This paper will help the coal mining sector in South Africa by providing estimation models based on scientific reasoning for the installation of LBs, and will also serve academia as part of the curriculum towards educating future mining engineers."

Jan 1, 2016