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Your Council has pleasure in submitting its report for the year ended 30th June, 1970. COUNCIL The following served as Office Bearers during the year under review: Messrs J. K. E. Douglas (President), V. C. Robinson and Prof D. D. Howat (Vice-Presidents), R. C. J. Goode (Immediate Past President) and D. G. Maxwell (Honorary Treasurer). Members of Council: Mr. R. J. Adamson, Dr. M. G. Atmore, Mr M. Barcza, Dr J. M. Bereza, Messrs H. Britten, H. E. Cross, A. R. C. Fowler, G. W. Holl, Dr J. P. Hugo, Messrs N. A. Honnet, P. Lambooy, Prof J. de V. Lambrechts, Mr C. E. Mavrocordatos, Dr J. T. McIntyre, Messrs J. Meintjies, T. C. A. Meyer, J. A. Nixon, Prof R. P. Plewman, Dr R. E. Robinson, Messrs J. F. Reid, H. Simon and P. W. J. van Rensburg. Ten Council meetings were held during the year with an average attendance of seventeen and the standing committees held 45 meetings. FINANCE The annual accounts, which are attached to this report, show an excess of expenditure over income of R4,608 compared with R2,124 last year. This deterioration can be attributed largely to two important factors, namely an increase in secretarial fees of RI, 789 and an increase in the loss on the Journal from R2,343 to R3,508. In addition, our contribution to the expenses of the Federation of Societies of Professional Engineers increased by R607 from R549 to R1,156. The increase in secretarial fees is partly due to our increased demand for services and partly to increased salaries. In order to maintain its essential services it has been necessary for the A.S. & T.S. to increase salaries in order to keep pace with commerce and industry. With regard to the Journal, we did not expect immediate dramatic results from the changes that were effected as from the beginning of last year in the arrangements for publication. However, the improvement has been even slower in materialising than we expected. This situation is being watched carefully and we will not hesitate to make further changes if necessary. It became clear early in the year that the financial position was deteriorating and your Council decided that it was essential to meet the situation by raising subscriptions and entrance fees. At the same time it was decided that there are no grounds for a distinction between Town and Country members and that in future the scale for the compounding of subscriptions should be based on anticipated future membership, rather than past membership. These changes have had only a minor effect on the accounts under consideration. The MacArthur Forrest Memorial Fund shows an excess of income over expenditure of R132 and the total fund was, therefore, increased by this amount to R4,338. The balance sheet shows that the market value of quoted shares and debentures decreased during the year from R13,059 to R6,567, while accumulated funds now amount to R17,959 compared with R22,567 last year. It will also be noted that we are holding R25,844 on behalf of the Symposium on Opencast Mining. MEMBERSHIP Twenty-eight Fellows, twenty-four Members, seventeen Graduates, twenty-five Associates and twenty-seven Students were elected during the year. Four Members were admitted to Life Membership; Five Members were transferred to the grade of Fellow; one Student was transferred to the grade of Member; two Graduates and one Student were transferred to the grade of Member; six Students were transferred to the grade of Graduate; One Associate was transferred to the grade of Fellow; One Associate was transferred to the grade of Graduate. One Fellow, one Member, six Graduates, four Affiliates and ten Students were removed from the Membership Roll in terms of by-law 7.7.1. Your Council records with deep regret the death during the year, of the following: R. A. H. Flugge-de-Smidt, C. S. McLean, Dr H. J. van Eck, (Honorary Life Fellows), J. C. Humphreys, O. Lazar (Life Fellows), D. G. Beadle, J. G. Craig, P. U. Fisher, R. G. McConnell, J. H. Moore, S. Sterling, L. R. Ulyate (Fellows), H. H. Burger, E. A C. Dickson, R. Jack, S. Ring (Members), M. J. Worrall (Graduate). A comparative statement of the membership as at 30th June, 1970, and the end of the previous year is shown in the following tabulation: 30th June 30th June Honorary Life Fellows 10 8 Honorary Fellows 6 6 Life Fellows 189 191 Fellows 514 530 Members 448 465 Graduates 68 80 Associates 155 172 Students 162 161 1,552 1,613 RECLASSIFICATION OF MEMBERSHIP The designations of grades of membership were altered to accord with the practice in professional institutes both here and overseas and members were advised of the new classifications. MEMBERSHIP DRIVE A committee was established to organise a drive for membership as it was felt that there are numbers of persons in our mining and metallurgical industries who are not yet members but who qualify for membership. Members of the committee were allocated responsibility for campaigning in sections of industry and for publicising the aims, objectives and advantages of belonging to the Institute.

The Annual General Meeting of the South African Institute of Mining and Metallurgy was held in Kelvin House on Wednesday, 24th August, 1977. Dr M. D. G. Salamon (President) was in the chair and declared the meeting open at 16h00. Obituaries The President: It is my sad duty to announce the death of the following members of the Institute : C. G. Evans, J. P. Rees, Life Fellows ; S. R. Bryant, H. MacConachie, M. Mrost, and A. W. van Zyl, Fellows; L. T. Campbell-Pitt, F. W. Collins, A. J. Duncan, I. G. Evans, F. W. Kleinschmidt, P. L. Vaughan, R. W. Wallace, and H. Wason, Members. As a mark of respect to the memory of the deceased and in sympathy with the bereaved, I would ask you to rise and observe a few moments' silence. Minutes The President: May we confirm the minutes of the General Meeting held on 23rd March, 1977, as published in the June issue of the Journal? Agreed.

Jan 1, 1978

By M. Magnelöv, Du Sichen, U. Sjöström

An experimental study has been performed to investigate the behaviour and separation of inclusions at the interface between steel and slag. The study has been limited to liquid inclusions because they can be a potential problem in transient situations such as ladle changes in continuous casting of steel. Model experiments with water and silicon oils have been carried out to study the kinetics of separation of simulated inclusions at an interface. The properties of the inclusions and the slags have been varied by using different oils with different viscosities, densities and surface tensions. The effect of temperature of the liquids has also been examined. Measurements of the terminal velocity, rest time and the behaviour of the liquid inclusions at the interface have been recorded using a video camera. It has been found that the inclusions reach their terminal velocity early in the vessel and the experimental velocities differ somewhat from the values evaluated using ?intermediate law?. The results from the experiments have shown that the size of the inclusions has no appreciable influence on the rest time. Droplets of AK50 oil have been found to have considerably long rest time. A water film surrounding the droplet has been expected to be the main reason for the long rest time. The present study has also shown that the viscosity of the oil has certain effect on the rest time, but only to some extent, since viscosity has double functions. A higher viscosity provides higher resistance to the droplet entering the oil phase leading to longer rest time and at the same time damps the lateral movement of the droplet along the interface, leading to easier stabilization and shorter rest time. On the other hand, a high viscosity of the oil phase results in slow dissolution process. It has been concluded that a meaningful model of inclusion separation at the metal-slag interface must take the interfacial phenomena into consideration. Keywords: Inclusions, terminal velocity, rest time, dissolution.

Jan 1, 2004

By H. Ogasawara

Information on rock stress is important for safe mining in seismically active ground. On a major gold mine, a few tens of crews are continuously conducting geological drilling with small pneumatic machines. However, stress measurements are not often carried out in South African deep-level gold mines. One of the reasons is the drilling diameter that overcoring requires, which is much larger than the diameters used in regular geological drilling, e.g. Boart Longyear Metre Eater, which drills A[O] or B[O] holes. Larger diameter holes result in slower drilling advance, more load in transportation and handling at sites, and higher cost. In order to enable overcoring in BX size (60 mm diameter), we modified the compact conical-ended borehole overcoring (CCBO) technique that has been suggested by International Society for Rock Mechanics (ISRM) and was originally designed for NX drilling (76 mm diameter). With a single overcoring, the 3-D stress tensor can be determined. We tested this modified method at a depth of about 3 km at Moab Khotsong mine in South Africa. We worked with drilling crew who usually work at geological drilling with the Metre Eater. In January 2011, we tried using regular geological drilling tools (a sequence of a normal BX bit, reamer, and rod) without success. In August and September 2011, introducing stabilizers and thin BX bits, we succeeded. We could complete a cycle of procedures necessary for an overcoring, including shaping the borehole-end conically, glueing a 16-element strain cell, and overcoring, within 2.5 hours. Only 10 cm overcoring is needed, which increases the chance of successful overcoring in heavily fractured conditions. This modified method is suitable for up-dip holes to depths of 10-15 m from tunnels, and has the potential to be widely used at the initial stage of geological exploration drilling at many localities.

Jan 1, 2012

By J. P. W. Bennie, A. de Jong, G. M. Denton

Mintek together with Middelburg Steel & Alloys, developed the DC arc furnace process for the production of ferroalloys with the expressed objective of smelting ore fines (<1mm) without the need for agglomeration. In the case of ferrochrome production, the DC arc furnace, being a semi-open bath operation, loses radiant energy directly from the bath to the furnace roof and sidewalls above the melt. This energy loss is reflected in a higher electrical energy usage per ton of alloy than for a submerged-arc operation smelting lumpy ores or sintered pellets. The difference increases still further when pre-heated sintered pellet feed is used in a submerged-arc operation. This shortcoming of the DC arc furnace can however be overcome by preheating the feed to the furnace in a fluidized bed or flash reactor fuelled by cold furnace off-gas. In addition to fluidization and preheating testwork, various preheating flowsheets with associated mass and energy balances have been developed and compared from a techno-economic viewpoint. The three major advantages identified were: a) fluidized beds can preheat ores and fluxes up to 950°C without sticking and defluidizing, b) the open bath DC arc furnace does not require expensive coke or char to maintain the burden porosity and, c) the capital cost associated with the milling, pelletising and sintering plant falls away since ore fines are used directly.

Jan 1, 2004

By Z. Zhang, R. G. Reddy

Experimental and thermodynamic modelling studies on the structure of alkali borate melts and properties are discussed. A thermodynamic structure model for alkali borate melts is developed to describe the distribution of structural groups in the alkali borate melts as a function of composition. A qualitative interpretation for the boron anomaly in viscosity has been proposed, which regards the boron anomaly as a manifestation of the various antithetical effects caused by the introduction of alkali oxide into boric oxide. It has been found that the viscosity of alkali borate melts increases or decreases according to the changes in rigidity and spatial connectivity of the glass network structure, which is the function of temperature and composition. These concepts with some key examples are discussed in relation to their usefulness and practicality in industrial slags. Keywords: alkali borate melts; structural model; activities; structural groups; viscosity;

Jan 1, 2004

By K. Morita, N. Sano

Thermodynamic properties of chromium oxides in molten slags are very important for optimization of stainless steel refining processes as well as reduction processes of chromium ores. The solubility of chromite into molten slags has been found to vary considerably with oxygen partial pressure and slag composition in former studies by the authors. In the present study, activity data and redox equilibria of chromium oxides measured under moderately reducing conditions, PO2= 6.95x10–11atm, at 1873 K are summarized. For the CaO-SiO2-CrOXsystem, the activity coefficient of chromium oxide increased with increasing basicity, and the optimized slag composition for stainless steel refining is assessed as that saturated with CaCr2O4and Cr2O3usingthe phase relations determined. On the other hand, the presence of MgO and Al2O3brings about different behaviour of chromium oxide activity and redox equilibiria and the 44 mass per centCaO-39 mass per cent SiO2-11 mass per cent Al2O3-6 mass per cent MgO slag is recommended toreduce the chromium oxidation loss in the practical stainless steel refining process at 1873 K. Keywords: chromium, activity, stainless steel, AOD, VOD, oxidation loss, redox, CaO-SiO2-Al2O3-MgO slag

Jan 1, 2004

By M. Somerville, S. Sun

The liquidus temperature and viscosity of a range of melter slags produced in South Africa were determined. Drop-quench experiments were carried out on the supplied plant samples to determine the liquidus temperature and phase relations at sub-liquidus temperatures. The temperature measurement range covered 1300°C to 1630°C. Results from these experiments show liquidus temperatures for the melter slags to be in excess of 1500ºC with the chromium containing spinel as the primary crystalline phase. At lower temperatures, an olivine or pyroxene phase co-existed with the spinel phase. The viscosity of the slags was determined over a temperature range of 1350 to 1550°C, under a controlled atmosphere. Results show two orders of magnitude variation in the viscosity (0.2 to 20Pa s) with strong effects of slag chemistry and temperature. Slags with lower SiO2and Cr2O3concentrations were more fluid. Slags with the lowest FeOx and highest SiO2concentrations were the most viscous. These observations are in accord with general behaviour of silicate slags. While the presence of a spinel phase may have an effect on the viscosity of the melter slags, results obtained to date indicate a much stronger effect due to the presence of an olivine or pyroxene phase at lower temperatures. Keywords: phase equilibria, liquidus, viscosity, slags, olivine, spinel, pyroxene

Jan 1, 2004

Work undertaken in the field of cut-off grade optimization has not advanced much beyond the work undertaken by Lane in 1988. His definitive work is based on the calculus of the Net Present Value criterion which is the most widely understood, consistent, and appropriate method by which sequential cash flows arising from the extraction of mineral reserves from an exhaustible resource can be represented. Although the mathematics is not complex Lane’s method is not a widely appreciated or applied approach to maximizing the value of a mining operation through selection and balancing of operational cut-off grades. Three stages in a mining operation namely, mining, processing and marketing were defined by Lane and the economics of each stage are identified and isolated to provide an optimum cut-off for each stage. Points of intersection along the present value curves for each stage of a mining operation are used to identify balancing cut-off grades at points where the capacity of the mining, processing and marketing stages is fully utilized and the Net Present Value of the operation is optimized. Data that simulate a small, deep-level Witwatersrand-type gold mine with an average grade of 6 g/t Au and a logrithmic variance of 1.2,are applied to the model to illustrate the benefits of representing cut-off grades in terms of present value curves for different segments of a mining operation. Keywords: Cut-off grade, Net Present Value, grade-tonnage curve, balancing cut-off grade, mining, processing, marketing.

Jan 1, 2003

By E. R. Davis, R. J. Knott

The paper discusses some of the tools of management in the field of project control, especially in engineering. Project control includes planning and cost engineering, and involves various phases: the conceptual Design and Planning Phase, the Definitive Design and Capital Budgeting Phase, and the Implementation Phase. Each of these phases is discussed in in, together with the use that can be made of data banks, progress reports, and computer systems.

Jan 1, 1982

By B. E. Ydstie, B. F. Lund, K. R. Løvåsen, B. A. Foss

The paper presents sensitivity analysis for a dynamic model of submerged arc silicon furnaces. The model we study, called ?Simod?, was developed by Elkem in cooperation with NTNU and Sintef. It is today a much used tool in Elkem for operator training and analysis of the dynamic behaviour of the silicon production process. The aim of our work is to bring the simulator tool closer to industrial practice, and construct a mechanism to adapt the model to the behaviour of a running process, online. The paper presents the results of the sensitivity analysis that has been undertaken for important parameters in the Simod model. The parameters associated with the process inputs are electric power loss, loss of fixed C and reactivity of carbon. The output signals that have been investigated are fed quartz, tapped silicon and silica. The paper also interprets the results of the sensitivity analysis in a process operation context.

Jan 1, 2004

By T. J. Goff, G. M. Denton

Mintek has developed the EnviroplasTM process for the treatment of solid wastes from the metallurgical industry, especially steel plant dusts, without requiring agglomeration to produce inert slag and at the same time recover metal values such as nickel, chromium and zinc. The products that are generated in the plasma-arc process are usually a metal and a non-toxic slag, which are tapped from the furnace in liquid form. The metal is mainly composed of chromium, nickel and manganese. During the production of stainless steel between 30 and 70 kg of dust and fine waste is generated per ton of steel. Mintek has successfully processed around 1000t of AOD/EAF dust on a toll treatment basis in order to recover the contained Cr and Ni. The metal produced contained 18.5 per cent Cr, and 5.5 per cent Ni. All slag samples tested conformed to US EPA regulations for disposal. The chromium and nickel recovery to metal was 90 and 98 per cent respectively, on a once through basis i.e. no baghouse dust recycle. Slag tapping temperatures varied between 1650°C and 1750°C. The average actual energy requirement excluding furnace heatlosses of smelting steel plant dust with anthracite as reductant was 1.36MWh/ ton of dust. The total mass of feed reporting to the off-gas stream was 10 per cent. The average ZnO content of the fume was 35.5 per cent.

Jan 1, 2004

By X. Pan

Slag-metal equilibrium experiments were conducted at 1500ºC and 1580ºC under 0.03 atm, 0.05atm and 0.83 atm CO partial pressures using silica and Cr-oxide crucibles. The complex slags belonged to SiO2-CaO-Al2O3-MgO-FeOx-CrOxand the metal phase to the Cr-Fe-C-Si-(S)systems. The carbon saturation of the metal phase was avoided using oxide crucibles and thus the results are pertinent to ferrochromium refining slags and processes. From equilibrium data and thermodynamic calculations the CrO /(CrO+Cr2O3) ratio in the slag was determined as 0.75, 0.80and 0.86 under 0.83 atm and 0.05 atm of CO pressure at 1500ºC and 0.03 atm and CO pressure at1580ºC respectively. The results clearly demonstrated that a higher chromium content of the metal results in higher Cr in the slag, and chromium in slag decreases with increasing SiO2. The results were also sensitive to the crucibles used as these oxide crucibles saturated the slag either with respect to SiO2or Cr-oxides. It was also demonstrated that the relative amount of CrO in the slag was higher when SiO2crucibles were used in accord with thermodynamic calculations. Iso-concentration curves for carbon and chromium of the metal phase in equilibrium with the slag were drawn on pseudo ternary SiO2–(AI2O3+CaO+MgO)–(Cr2O3+Fe2O3) diagram. The activity coefficients and activities of carbon and chromium of the metal phase were also calculated from the experimental data and available thermodynamics information and were plotted as iso-activity curves in the same pseudo ternary diagram. Keywords: Chromium, slag, equilibrium

Jan 1, 2004

By E. Kapilashrami, S. Seetharaman

Refractory/metal interactions and associated reactions are significant during casting as they can lead to inclusion formation. High-temperature interactions between aluminosilicate refractories and molten steel were studied in the present investigation using the sessile drop method. The changes in the contact angles between molten iron with well-defined oxygen levels and substrates of silica, mullite (3Al2O3?2SiO2) as well as commercial refractories were measured in the dynamic mode. In all cases, the reaction led to slag formation. The experiments were performed under isothermal conditions at 1823 and 1873 K. A known and constant oxygen partial pressure was imposed above the iron drop, through appropriate CO-CO2-Ar mixtures. For all substrates, the contact angles started decreasing due to the lowering of the surface tension of iron, as oxygen was imposed on to the system. When a critical level of oxygen was reached, slag started forming at the drop/substrate interface and at this stage, the contact angle dropped suddenly. Subsequent behaviour of silica and mullite was observed to be different, with SiO2showing a non-wetting behaviour. In the case of SiO2substrate, there were also deep erosions along the periphery of the drops and there was slag accumulation at the sides of the metal drop, probably due to Marangoni flow and/or SiO(g) formation. SEM and EDS analysis of the substrates revealed that the formed slag was fayalite. The thermodynamic criteria for slag formation and possible mechanisms of the reaction are discussed in the light of the experiments. Key words: silica, mullite, fayalite, corundum, slag formation, sessile drop.

Jan 1, 2004

By A. Normanton, B. Harris, V. Ludlow, S. Riaz

Why does a continuous casting mould powder, which works successfully on a particular caster with respect to semi quality, fail to perform on a caster of a similar design utilizing liquid steel from a similar route for an identical product without some tuning of its make-up and composition? In casting sequences of the same steel grade, why do some apparent random heats produce poor surface quality with respect to cracking when otherwise good surface quality is realized? The answer to these questions lies in the interaction of the mould powder, the casting hardware, and the casting process variables. Using, as examples, data collected from within Corus UK and during collaborative work on the assessment of mould powder performance and its effects on surface quality, the interaction of the mould powder, the casting hardware and the casting process variables is explored. The steelmaking route and its associated alumina load, unexpected changes to slag chemistry, infiltration of the slag into the mould strand gap, and the nature of the slag film are all shown to affect powder performance. Keywords: continuous casting, mould powders, alumina, slag films

Jan 1, 2004

By J. Eriksson

Slag from stainless steelmaking is known to disintegrate, which is an environmental problem and prevents the cooled slag from being utilized. This disintegration is due to the transformation from the ßto the ? polymorph of di-calcium silicate. The transformation is accompanied by an increase in volume of about 11% and a total disintegration of the slag. AOD slag from stainless steelmaking was re-melted in a laboratory induction furnace, together with olivine and calcinated dolomite, to investigate the prevention of disintegration by increased MgO content of the slag with small changes in CaO to SiO2ratio. The modified slag was examined with X-ray diffraction and scanning electron microscopy. The trials showed that an increased MgO content can change the mineral composition towards formation of more Merwinite and Bredigite, which prevents disintegration of the slag. Keywords: slag, disintegration, di-calcium silicate

Jan 1, 2004

By D. H. Diering

Definition of mineral resources and reserves forms the basis for effective mine planning and reliable public reporting of mineral assets. Historically the mineral resource and reserves declaration process has been the domain of the geology and surveying disciplines, with the declaration of the reserves by the surveyor being based on the application of modifying factors to the declared resources available for mining. As part of an ongoing process to improve efficiency, reliability, and reproducibility of results, this approach has been revised and enhanced through the introduction of a revised process and reconciliation tools. The revised approach to reserve definition is based on the definition of scheduled resources, at an appropriate confidence estimate in the context of an approved business plan, over the anticipated life of the mineral asset being applied to define reserves. This planning and scheduling is developed, during the annual business planning process, by the mine planning department using tools such as CADSMine?. The scheduled area together with the application of revised modifying factors is tabulated in the BME (basic mine equation) and reflects the mine production plan over time. Simplification of the modifying factors to dilution and losses underpins the simple yet robust approach to improved definition of reserves in this process and in the basic resource to reserve equation (BR2RE). Dilution intrinsically affects grade but not metal content, whereas the losses reflect both the efficiency of mining and planning and are reflected in metal losses, area losses, or both. Reconciliation of the derived ?resource converted to reserve? area, (which is based on the business plan from CADSMine?), versus the ?resource available for mining?, (which is derived from Datamine?), underpins the robustness and auditability of the reserves declaration. This R&R accounting and reconciliation approach is transparent and facilitates interrogation of the logic and rationale of long-term business planning and project strategy. These numbers are processed and reported in the logic of the basic resource equation (BRE), which also addresses aspects such as white areas (future and historic), tail management, and partial extraction (non-scheduled pillars, etc.) in compliance with SAMREC definitions. Areas that do not have the necessary confidence and data support to be declared as resources find their space as pre-resource (outside the domain of public reporting), outlining existing potential for future extraction and reporting. Use of the BRE leads ultimately to a complete, refined accounting and reconciliation-oriented approach for all production entities. The revised resource and reserve process includes the discipline of mine planning as intrinsic to the definition and declaration of resources and reserves. Subsequent to the change in process, the resources and reserves have truly become the domain of the mineral resource management discipline. This paper defines the logic of the basic resource equations and outlines their application in the definition and reconciliation of mineral resources and reserves at Anglo American Platinum Limited.

Jan 1, 2012

By E. Chen, M. Barati, K. Coley

The reaction between carbon and slags is of significant importance in direct smelting of iron ores, EAF slag foaming and copper slag cleaning processes. This reaction is known to occur via gaseous intermediates and it is important to have fundamental data to understand the relative importance of each reaction step. In this study, the rate of CO2dissociation on different slag surfaces is measured using an isotope exchange technique. It was found that increasing iron oxide content up to 30 wt per cent does not have a significant effect on the rate constant while increasing from this limit, increases the rate constant dramatically. Activation energy of CO2dissociation on slags of unit basicity and different iron oxide contents is in the range of 180±40 kJ/mol. It is found that rate constant dependence on oxygen potential in the slag phase is increasing with iron oxide concentration. In the case of copper making slags, the influence of copper oxide is found to increase the magnitude of apparent rate constant, while decreasing the activation energy considerably. Key words: Gas-slag reaction, CO2dissociation, copper slag, kinetics, isotope exchange

Jan 1, 2004

By K. M. Godiwalla, S. Ranganathan

The thermal state in submerged-arc furnaces (S.A.F.) producing ferro alloys is important for the conditions of both the grade of alloy produced as well as specific energy consumption. The temperature profile in the S.A.F. is affected by the endothermic chemical reactions and the rate of gas evolution. The gas evolution commences at about 900 C due to the reduction of iron in the ore. A first-principle-based 2-D model has been developed to predict the temperature profile in the furnace. In this study, four ores of different grades have been considered in order to simulate the thermal profile in the S.A.F. The influence of the composition of the ore on the thermal profile and its significance in rationalisation of charge distribution to optimise the process are discussed.

Jan 1, 2007

By B. Friedrich

In a German governmental funded three-year research project, a closed loop recycling process for Nickel-Metalhydride-Batteries (NiMH) is under development. Today the discarded batteries are used in the steel industry as a cheap nickel source. Cobalt and rare earth (RE) are slagged and lost for reuse. The entire value of the metals in discarded Ni-MH is estimated to be 4?-4.5 ?/kg. Spent NiMH-batteries containing 36?42 per cent Ni, 3?4 per cent Co and 8?10 per cent rare rarth (Ce,La, Pr, Nd). The dismantled and processed NiMH-batteries are melted in a DC electric arc furnace producing a nickel-cobalt alloy and a slag phase highly enriched with RE-oxides. The key to success in this process is to find a suitable slag system, which ensures best separation of NiCo-alloy from the rare earth oxides and high concentration of RE in the slag. Different oxidic and halogenic slag systems are investigated in the melting process. So far a slag system based on 65per cent CaF2 and 35 per cent CaO delivers the best separation of the two phases and metal yields. A slag with a composition of 20?25 per cent La, 13-16 per cent Ce, 1.5?2.5 Pr, 4.5?6.5 per cent Nd is obtained and further treated to misch metal hydro-/electrometallurgically. The first results of the influence of rare earth oxides on the density of CaO-CaF2slag system are shown at 1600°C. Keywords: battery recycling, CaF2, CaO, rare earth oxides, slag characterization, density measurement

Jan 1, 2004