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By B. Andresen, S. T. Johansen, H. Tveit, S. Grådahl, B. Ravary

The Norwegian ferroalloy industry has high ambitions regarding environmental standards. Basic research work has been performed to improve the fundamental understanding of ferroalloy processes and the environ-mental aspects. This paper will present work dealing with the understanding of formation and control of NOx, PAH and dioxins. During this work various techniques and methods have been applied, such as comprehensive industrial measurements, laboratory experiments, model development and application of Computational Fluid Dynamics (CFD). The main goal has been to reduce the environmental impact of ferroalloy plants, by means of improving the combustion processes done by introducing new charging routines and optimized furnace operations, instead of installing expensive gas treatment systems. The Norwegian obligations in accordance with the Gothenburg protocol are to reduce the NOx emissions by 30%, compared with the 1990 level within 2010. Measures developed in this work have resulted in 40-60%reduction in NOx emission, and major reductions in PAH and dioxins for ferrosilicon and silicon metal plants. This has been achieved by introducing semi continuous charging and improved furnace operations. Semi continuous charging and optimized furnace operations are shown to reduce the blowing activity (i.e. emission of large quantity of SiO over the charge by direct channelling from the crater zone). It also reduces variation in off-gas temperature and dust production. To understand the processes and to achieve our results we have used online equipment, with fast sample rates and response times, to measure the off-gas compositions and temperatures. Most of the measuring techniques used are based upon optical principles making use of the absorption- and emission spectrum of the gases. In addition a new prototype instrument is developed for continuous measurement of off-gas characteristics, total dust amount and off-gas temperature. The presented work is a result of a long term co-operation research and development teamwork, between the industry and the research community, and has improved both the process and reduced the emissions. The work has introduced new process design and operation standards, and has resulted in ferroalloy production with better environmental standards.

Jan 1, 2007

By S. Michael, T. E. Moongo

Electrowinning consumes a substantial amount of electrical energy, and owing to the ever-increasing unit cost of electrical power there is a need to improve current efficiency in the process. This research was carried out to design a continuous quality improvement framework for improving electrowinning current efficiency by applying statistical process control (SPC) on an online industrial copper electrowinning operation. A sequential mixed research methodology was applied and a statistical software package utilized for analysing data. It was concluded that metallurgical short-circuits (hotspots) had the most significant effect on current efficiency. Bringing hotspots under statistical control resulted in a 5.40% improvement in current efficiency, which is equivalent to approximately 74 t of 99.999% pure grade A copper cathode production over a period of 1.5 months.

Jan 1, 2021

An extensive laboratory grinding study was carried out on a magnetite ore in order to assess the grinding behaviour of magnetic concentrate and tail from low intensity magnetic separation (LIMS).The test work involved Bond ball mill testing, rod milling, low intensity magnetic separation (LIMS), and batch ball milling down to product sizes of around P80~25 microns. A total of 18 Bond tests and over 150 batch grinding tests and sieve sizing were carried out. Throughout the grinding tests, power draw was continuously monitored. The relationship between the grinding energy and product size was analysed using the conventional energy-size concepts. It was found that the Rittinger equation fits the experimental data well. However, Bond?s equation does not fit the experimental data well, and therefore a modified Bond equation was developed. Differences in grinding properties between the magnetic and non-magnetic component were analysed and compared to the bulk ore. It was found that grinding properties differ significantly and therefore separate grinding test work may be required for each grinding step in the magnetite ore beneficiation flowsheet. Keywords: grinding, iron ores, particle size, modelling.

Jan 1, 2010

By R. M. Franz

This paper considers potential risks to the health of workers in ultra-deep mines, including barotrauma, physiological effects and toxicity of airborne pollutants. Relevant previous research is reviewed, including work by the Chamber of Mines Research Organization and the Deep Mine Cooperative Research Programme, and recommendations are offered for prospectively limiting pressure-related health risks.

Jan 1, 2005

By G. Wendel

Uranium is a naturally occurring radioactive material in the earth?s crust. Geological processes have resulted in concentration of uranium into ore mined for its gold content in South Africa. This uranium is present in the form of discrete particles of uranium minerals, generally oxides, which are normally insoluble. Chemical and physical processes during gold mining and extraction, particularly when carried out in conjunction with uranium extraction and sulphuric acid manufacture, act on the uranium minerals and the radioactive decay products of uranium. This may result insignificant accumulations of radioactive materials in certain parts of the process. There are a number of naturally occurring radioactive materials in the earth?s crust, such as Uranium-235, Thorium-232, andPotassium-40. This paper focuses on Uranium-238, together with its decay products, and how they affect the gold mines. Water plays a significant role in the redistribution of radionuclides, both as a physical transport medium, and as a solvent in which chemical reactions take place.

Jan 1, 1998

By V. Brabie, S. Jansson, L. Bohlin

The rate of dissolution of solid MgO-C and doloma into liquid in CaO-Al2O3-SiO2-MgO slag at different temperatures was studied under conditions of forced convection by rotating cylindrical refractory specimens in a stationary crucible containing the molten slag. The corrosion rate was calculated from the change in diameter of the cylindrical specimens. Refractory specimens were 13 mm in diameter and 70 mm long. The specimens were rotated for15 to 120 minutes at speeds of 100 to 400 rpm in the molten slag. The rate of corrosion increased with temperature and with the rotating speed of the rod, and decreased when the slag was nearly saturated with MgO. The experimental results confirm the assumption that the diffusion of magnesium oxide through the slag phase boundary layer controls the corrosion process. The corrosion mechanism seems to be the dissolution of the refractory materials into the slag, followed by penetration of pores and grain boundaries and dispersion of the grains in the slag. Keywords: MgO-C refractory, doloma refractory, molten slag, corrosion rate, corrosion mechanism

Jan 1, 2004

By J. L. Fuentes-Cantillana, Á. Rodríguez, P. Morillo

Evacuation operations from work places in the case of an emergency are the key to minimising the effects of catastrophic type accidents such as fires, explosions, cave-ins, floods, etc. The correct planning of these operations, having the necessary means for sounding alarms and communicating and suitable training of personnel are the key factors for guaranteeing successful evacuation. The article gives an analysis of the problem in the case of subterranean mining and various types of work developed by AITEMIN in this field, including the development of new alarm and communication means specially adapted to the characteristics of mining operations, development of tools for help in the preparation of emergency plans and experiences in the education and training of personnel.

Jan 1, 2003

By A. Drumond, J. F. C. L. Costa, M. G. Lemos, A. L. Rodrigues, F. G. Niquini

The past decade has seen a renewed possibility of using machine learning algorithms to solve a large collection of problems in several fields. Data acquisition for mining operations has increased with the growth in sensor-based technologies, and therefore the amount of information available for mining applications has dramatically increased. Ore sorting equipment is available for separating ore from waste based on differences in physical properties detected by a real-time analyser. The separation efficiency depends on the contrast in these properties. In this study we investigate the application of machine learning models trained using data from the output of a dual-energy X-ray ore sorting apparatus at a gold mine. The particles were first hand-sorted into ore and gangue classes based on their mineralogical composition. Classification models were then used to help decide the balance between the number of true and false positives for ore in the concentrate, with a view to economic parameters, using their receiver operator characteristic (ROC) curves. The results showed AUC (area under the ROC curve) scores of up to 0.85 for the classification models and a maximum reward condition Fpr/Tpr around 0.5/0.9 for a simplified economic model.

Aug 8, 2024

By A. Mainza, I. Govender, Elbasher M. E. Ahmed

A mechanistic description of axial segregation in rotating drum flows remains an open question. Consequently, optimal mixing of grinding balls and rocks for efficient breakage, maximum production of fines, and slurry transport is seldom achieved. Experimental and numerical studies of granular mixtures in rotating drums identify alternating axial bands that eventually coarsen in the long-term limit. Most models of axial segregation are limited to binary mixtures and cannot always predict the logarithmic coarsening effects observed experimentally. A key missing factor is a robust description of the axial free surface profile that is valid across a wide range of flow regimes. We present a practical model of the axial free surface profile by linking it to readily-derived geometric features of the cross-sectional S-shaped free surface profile. A parametric study shows good agreement with experimental measurements reported in the literature and heuristically valid trends.

May 1, 2021

By Y. Jin

Magnesia ramming materials have been widely used in China instead of magnesia bricks as furnace lining materials of ferroalloy refining furnace. The paper introduces the development of the ramming material, recounts its chemical composition, physical property and application characteristics. Because of its high MgO contents and fine sintering property, the ramming furnace bottom has the properties of good refractory, monolithic construction and thermal shock resistance. The changes in mineral composition and furnace tearout characterization show the reasons for the bottom?s long service life. The obvious benefits are widely achieved, the annual saving cost in refractory is about 2 millions US dollars.

Jan 1, 2004

Comminution is a vital part of minerals extraction, and therefore of the South African economy. The high cost and throughput-limiting nature of comminution forms a strong motivation for research directed at improving the efficiency of the process. Building on a ten year background of fundamental charge motion research, a new formal UCT flotation and communication group has been formed. The group is also moving strongly into the field of milling circuit modelling and simulation, based on close links formed with the Julius Kruttschnitt Mineral Research Centre (JKMRC) of Australia, and an international collaborative research programme.

Jan 1, 1998

Experimental results are presented that test the hypothesis that the descaling behaviour of stainless steel slabs following reheating is controlled by interfacial roughening at the scale-steel interface. In this investigation, two stainless steels were considered: type 304 (austenitic, with 18% Cr and 8% Ni) and type 412 (ferritic/martensitic, with 11.6% Cr). It was found that the entanglement that arises at the scale-steel interface was in fact effective in maintaining scale-steel adhesion, under the mechanical descaling conditions used. In the case of type 304, descaling proceeded by fracture along chromite layers, which formed (by internal oxidation) on the austenite grain boundaries; for this steel, the extent of descaling depends most strongly on austenite grain structure, and not primarily on the conditions in the reheating furnace. In contrast, type 412 samples descaled only at the edge of the entangled zone, and showed a greater sensitivity to the reheating conditions; specifically, higher free oxygen in the reheating gas and longer reheating times were found to increase the residual scale thickness. Key words: stainless steel, reheating, scale, entanglement, descaling, fayalite, internal oxidation, grain structure, free oxygen.

Jan 1, 2003

By G. S. Littlejohn

Following study of historical South African practice and a review of recent experience gained during the design, construction and testing of the high pressure plugs at the South Deep Water Barrier Project, this paper makes recommendations to improve practice. Initially, site investigation requirements are described with reference to geological, hydrogeological and seismic considerations, including site preparation and pre-grouting of the surrounding rock mass, if permeable. Structural and hydraulic aspects of plug design address topics such as residual permeability, aggressive mine water, plug materials, mortar strength and bleed. In situ thermocouples and piezometers are recommended to optimize the timing of plug tightening and monitor plug performance during service. Plug construction covers aggregate preparation, mortar quality control, plug tightening grouts, injection pressures, records and the overriding need for a method statement specification to control all aspects of plug construction. On completion of the plug, tests to establish surrounding rock stress regime, plug strength, and residual permeability are described to enable a comparison with original design assumptions. Monitoring and maintenance procedures are proposed to ensure satisfactory long-term performance of the plugs.

Jan 1, 2006

By C. J. Badenhorst

The scope of this project was to research, develop and eventually produce a personal occupational hygiene and safety exposure monitor system to assist in recording and analysing various stress factors that could affect the health, wellness and safety of employees, i.e. that could result in injury or ill health of workers, create stress build-up within individual workers that could negatively affect worker alertness and safety, and, may even result in permanent disability or death. Utilized systems at the time were all reactive, whereas the DOHEMS (Proactive Digital Occupational Hygiene and Safety Exposure Monitoring) System enabled the measurement of exposure (and associated risk) in a proactive manner via real-time exposure and digitized recordings. The idea of the development was to create a unit that is so cost effective, small and light that every worker can use a system on a daily basis. The development will eventually replace current, bulky and expensive monitoring equipment. The device must be a portable battery operated device and monitor the immediate working environment by periodic sampling for vibration, noise, toxic gasses (NO/NOX/CO/VOC, etc.), body temperature and heart rate. The samples must be time and date stamped, utilizing a real-time clock (RTC) synchronized with the closest regional secondary time source and related to synchronized real-time video captured samples. These samples are then recorded onto a rugged non volatile storage device with the capacity to store a vast number of samples covering the entire working shift of eight (8) hours plus. The system has been fitted with a clear visual local alarm indication system, indicating any excessive exposures or stresses, for the worker?s supervisor to respond to. This system allows for a pro-active approach. The system is also a wireless system (to the external environment) so as to not affect the mobility of an employee and flameproof to allow for use in explosive environments. Keywords: safety, digital, exposure, monitoring, proactive.

Jan 1, 2010

By N. P. Mabasa, N. Naudé, A. M. Garbers-Craig

An improved methodology is presented for assessing the economic feasibility and effectiveness of recycling MgO-C and Al2O3-MgO-C refractory bricks, which are widely used in the steelmaking industry. Since approximately 28 Mt of refractory bricks are discarded each year, it is logical to recycle them. When furnaces and ladles are relined, the spent refractory bricks become mixed up, and need to be sorted before recycling. This study examined the use of a hand-held X-ray fluorescence analyser (HH-XRF) to distinguish between spent oxide-based and oxide-carbon-based refractory materials, with special emphasis on spent MgO-C (MC) and Al2O3-MgO-C (AMC) bricks. HH-XRF analysis was conducted on 18 oxide-carbon refractory bricks as well as on MgO-chromite and bauxite-based refractories. X-ray diffraction, reflected light optical microscopy, and scanning electron microscopy with energy dispersive spectroscopy were used to characterize the MgO-C and Al2O3-MgO-C bricks to confirm the accuracy of the HH-XRF analyses. This study also underlined the importance of calibrating the HH-XRF analyser for the refractory bricks to be sorted. The HH-XRF was successful in distinguishing between the different oxide-carbon-based refractory bricks both before and after cleaning. This result is important as it proves that HH-XRF provides a method whereby spent MC and AMC bricks can be sorted quickly and reliably.

Jan 26, 2023

By C. Lemmer

The resolution with which the different categories of resources are forecast for Witwatersrand gold reefs should ideally tie in with block sizes that are optimal in terms of the variability structures of the reefs. A tool, called the ?variancegram?, is proposed as a basis for block size choice. A variancegram is intrinsic to the particular reef and mine concerned. A further requirement is the ability to attach global confidence limits to weighted average estimates built up from combinations of local kriged estimates. Approximations to derive global kriging variances based on variables derived from local kriging deliver hugely inflated results if ordinary kriging is used, and markedly better, but not accurate, values if simple kriging is used. These approximations improve as the number of samples used in kriging each block is increased. It is shown that the behaviour of the different components of the global kriging variance with increasing number of samples, all differs, but they all link to the variancegram for the particular reef. The variancegram can thus be used to correct the different components to the values they would have had if all samples were used in kriging each block, and so deliver the ?correct? global kriging variance, even though only a limited number of samples were used in kriging each block. The desirability of having very stable solutions implemented in production systems is taken into account in the proposals. It is anticipated that the same variancegram findings will also hold for other densely sampled deposits, but this remains to be investigated.

Jan 1, 2014

By A. K. Singh

Between the main fan and the coalface in a mine a lot of air is lost through leakage at stoppings, doors, air-crossing etc. so that a much larger quantity of air has to be circulated by the fan in order that the stipulated quantity of air reaches the face. Stoppings are of vital importance not only for effective ventilation of underground mines but also for isolation of areas affected by fire or susceptible to spontaneous heating. Generally, isolation stoppings are made of brick in cement mortar. If the area is far from the pit or unapproachable, it is very difficult and sometimes impossible to build these stoppings. To overcome these difficulties, particularly near fire affected zones, an alternate successful attempt was made in Indian mines to make a plug underground, from surface through borehole, using cement concrete. In this paper the salient features of the methodology adopted for construction of the plug and the experimental procedure for the measurement of air leakage by SF6 tracer gas is described. Measurements of air leakage through rows of ventilation stoppings in two mines viz. Moira (Jambad and Kajora seams) and Kuardi11/12 (Niga seam) collieries of Eastern Coalfields Ltd. (ECL) have been incorporated. Results of experiments conducted at the Central Mining Research Institute (C.M.R.I) to determine leakage through25 and 38 cm thick brick stoppings are also discussed. Results of all these studies are compared, which show that the efficacy and reliability of the remote filled cement concrete plug in respect of air permeability is satisfactory.

Jan 1, 2004

By A. M. Bryukhanov, A. G. Mnukhin

The report states accident rates for gassy/dusty coal mines represented as an ergatic system "man – machine - environment" with further analysis by the method of conditional probabilities. A coal mine has been analyzed with allowance for the attending personnel, equipment and environment as a sequence of events and states. Probabilities of operational states have been determined and prediction of mine behavior has been made on the basis of investigation findings for equipment and the personnel states, and analysis of the environment (i.e. mine and mining conditions). Utilization of expert estimation methods has been considered for determining major operational parameters of gassy/dusty mines. The importance of standardized values of permissible occupational risks (permissible probability of accident, PA) is demonstrated. It is also stated that a procedure is essential to determine these values, involving regular check-ups of the integral safety criterion at all mines and further development of customized recommendations for individual mines on efficient improvement of accident situations. Methodology to determine the assessment criteria has been developed and scientifically substantiated for permissible accident rates in hazardous industries.

Jan 1, 2003

By D. W. Dew

Billiton Process Research has carried out extensive research over the past four years to develop new process technology using bioleaching for extraction of copper and nickel from their sulphide concentrates. Continuous pilot scale and laboratory batch testwork has been carried out with adapted mesophile bacterial cultures at40°C?45°C, moderate thermophile cultures at 50°C?55°C and thermophile cultures at 65°C?85°C. Pilot scale work has demonstrated the commercial viability of mesophile cultures for bioleaching of secondary copper sulphide and nickel sulphide concentrates. Moderate thermophiles offer benefits in terms of reduced cooling requirements for commercial reactors and, in the case of bioleaching of nickel concentrates, some selectivity over bioleaching of pyrite. Continuous pilot scale testwork has shown that thermophiles achieve efficient bioleaching of primary copper sulphide and nickel sulphide concentrates, giving much higher recoveries than achieved by bioleaching with a mesophile or moderate thermophile culture.

Jan 1, 2000

By A. McGarr

The shear stress t that can be sustained by the rock mass in the environs of a mining-induced earthquake controls the near-fault peak ground velocity v of that event according to v=0.25(ß/G)t, where ß is the shear wave speed and G is the modulus of rigidity. To estimate t at mining depths, I review the results of four studies involving Witwatersrand tremors that relate to the bulk shear strength. The first and most general analysis uses the common assumptions that the seismogenic crust is pervasively faulted, has hydrostatic pore pressure before mining, and an extensional stress state that is close to failure. Mining operations reduce the pore pressure to zero within the mine and redistribute the stresses such that, in localized regions, the state of stress is again at the point of failure. Laboratory friction experiments can be used to estimate t in the zero-pore-pressure regime. Second, model calculations of states of stress in the vicinity of mining at about 3 km depth indicated the shear stress available to cause faulting near the centre of a distribution of induced earthquakes. Third, laboratory experiments combined with microscopic analyses of fault gouge from the rupture zone of a mining-induced event provided an estimate of the average shear stress acting on the fault to cause this earthquake at a depth of 2 km. Fourth, moment tensors determined for mining-induced earthquakes usually show substantial implosive components, from which it is straightforward to estimate t. These four different analyses yield estimates of t that fall in the range 30to 61 MPa which implies that near-fault particle velocities could be as high as about 1.5 m/s. To the extent that the causative fault ruptures previously intact rock, both t and v, in localized regions, could be several times higher than 61 MPa and 1.5 m/s.

Jan 1, 2002