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By J. P. Gous, M. Tangstad, J. D. Steenkamp

In April of 2013 a 48 MVA submerged arc furnace producing silicomanganese was excavated in South Africa. One of the areas excavated systematically was the furnace taphole. The aim was to obtain a refractory wear profile of the tap-hole area, together with affected hearth and sidewall refractory. Subsequently, thermodynamic modelling was applied to quantify the potential for chemical reaction between refractory and slag and refractory and metal in the tap-hole area.

Jan 1, 2014

By G. T. van Rooyen

The susceptibility of a low-alloy steel that has been hardened and tempered-826 M40 (EN26)-to embrittlement by strain aging during service was simulated by artificial aging of specimens at 100°C. It was found that the brittle transition temperature of both monotonic and cyclically strained material was increased by only about 25°C as a result of strain aging. It is concluded that the susceptibility of low-alloy steels in the hardened, tempered condition is less than that of low-carbon steel, and that such steels qualify for exemption of the periodic 'annealing' required by the Mines and Works Act.

Jan 1, 1986

By P. P. Kim, M. Tangstad, T. A. Larssen

"The kinetics of MnO and SiO2 reduction in SiMn slags based on Assmang/Comilog ore and HCFeMn (highcarbon ferromanganese) slag were investigated between 1500 and 1650°C under a CO atmosphere. The results showed that charges containing HCFeMn slag had relatively faster reduction rates than those without. The difference in the driving force for MnO reduction was insignificant among the SiMn slags at 1500°C, which implies a low contribution of the driving force for reduction rate. The slag viscosities were also rather similar, around 1 poise at 1500°C, which could not explain the different reduction rates. Instead, the different charges containing various sulphur contents are believed to give rise to the varying reduction rates. The estimated activation energies for MnO reduction were around 500–920 kJ/mol for charges containing HCFeMn slag, and between 250–300 kJ/mol for those without. Based on the estimated kinetic parameters, the considered rate models were able to describe the reduction of MnO and SiO2 in SiMn slags between 1500 and 1650°C. IntroductionManganese ferroalloys such as ferromanganese (FeMn) and silicomanganese (SiMn) are important ingredients in steel production due to the beneficial effects of manganese on the physical properties of steel. Mn enhances the strength, toughness, and hardness of steel products, and both Mn and Si are used as deoxidizers to prevent the development of porous structures (International Manganese Institute, 2014; Olsen, Tangstad, and Lindstad, 2007; Subramanyam, Swansiger, and Avery, 1990; Tomota et al., 1987).The thermodynamic background of manganese ferroalloys is well established (Olsen, Tangstad and Lindstad, 2007), but kinetic information is rather scarce, especially for the SiMn process (Tranell et al., 2007; Tore-Andre Skjervheim, 1994). The absence of kinetic information makes it more difficult to understand the reduction mechanisms of MnO and SiO2. It is not clear how different raw materials affect the SiMn process. The main metal-producing reactions in the SiMn process are described by Equations [1] and [2]:"

May 1, 2019

By X. W. Pan

It has been found that the MnO content of a slag decreases sharply when direct current is applied to a 1T1£tal-Slagsystem consisting of liquid Mn-Si-Ccsat metals and MnO-SiO2-CaO-AI203 slag in graphite crucibles. This paper reports a preliminary investigation into the electrochemical effects of direct current on the metal-slag system, the silicon content of the metals, and the MnO content of the slag. The results show that, when a direct current of 7 A is maintained, the MnO content of a metal containing 10 to 11 per cent silicon by weight is reduced rapidly from 26,5 to 17,2 per cent by weight. This reduction seems to proceed further when the process is continued. When the direct current and the voltage are kept constant at TA and 4 V respectively, the MnO content of a metal containing 1 to 2 per cent silicon by weight is reduced to 1 from 25 per cent by weight, which results in a manganese yield of 96 per cent.

Jan 1, 1995

By M. Splaine, W. Davison, D. C. Atkinson

"Since 1964, Nchanga Consolidated Copper Mines, Ltd., has been developing and using production scheduling methods for optimizing its metallurgical operations in the short term (up to one year). Medium-range metallurgical planning has been possible only by successive evaluations of a single-year L.P. A modified version of Rosenbrock's direct search technique has now been developed to allow multi-year optimization of both mining and metallurgy for medium-range planning. The modifications to the search technique have produced a marked increase in computational efffciency for this heavily constrained problem in many variables and the system is a usable planning tool, given a reasonably powerful computer. The plans are 'optimum' in the sense that they yield the maximum present value of the operations.Each of the resulting five-yearly mine plans forms the basis for further detailed metallurgical evaluation by the established production scheduling system."

Jan 1, 2014

By A. F. van der Merwe, R-D. Taylor, M. Jacobs, F. H. Conradie

Total bound moisture (TBM) is a typical quality indicator of industrial-grade gypsum. This gypsum is comprised of three distinct phases, namely anhydrite, dihydrate, and hemihydrate, of which only the latter is of much industrial use. TBM analysis is a lengthy laboratory procedure, and an artificial neural network (ANN) TBM inference measurement is proposed as a fast and online alternative. An ANN inference model for gypsum TBM based on plant data was developed. The inputs to the network were primarily focused on the plant's calciner, and different network topologies, data divisions, and transfer functions were investigated. Furthermore, the applicability of the TBM value as a quality indicator was investigated based on a gypsum phase analysis. A strong correlation between TBM and the gypsum hemihydrate and anhydrite content was found, validating the plant target TBM of 5.8% as a quality indicator. A network topology consisting of one hidden layer with logarithmic-sigmoid (logsig) and pure linear (purelin) transfer functions showed the best performance (R > 90%).

Oct 3, 2023

By J. W. van der Merwe

Technology is advancing at a rate that makes it extremely difficult for the mining Industry to keep pace. Many advances occur within a given piece of technology and often this is missed by the disciplines that could have gained advantage by its implementation. Often this may have been simply an aspect of cost exceeding benefit. However, there are some technologies that potentially have such a far-reaching impact on the mining industry that the benefits simply outweigh the cost. The application of 3D laser scanning in the mining industry has the potential of taking the concept of ?Google maps?? underground. This presents an opportunity where the virtual world of underground can be traversed with relative ease and many aspects of measurements could be obtained without having to visit the working place again, potentially saving countless man-hours and still delivering precision work with significant savings in downtime, stoppages, and exposure to safety incidents. Anglo American Platinum maintains its competitive advantage though the review and application of appropriate technology. This paper describes the 3D laser scanning trial at one of Anglo American Platinum?s new shafts, and goes on to show the benefits encountered through the application and the involvement of the various MRM disciplines.

Jan 1, 2012

By M. J. Makhula, R. M. S. Falcon, S. O. Bada, L. M. Falcon

"SynopsisThe combustion and co-combustion behaviour of macadamia nut shell, high-ash coal, and anthracite, along with their blends was studied using thermogravimetry. The reactivities of all samples were analysed in air, oxygen, and CO2 atmospheres and at different heating rates from 10 to 40°C/min. Macadamia shell was found to have a lower ash content, 0.36%, than coal with 27.49% ash. The calorific values were similar, 19.64 MJ/kg and 19.44 MJ/kg respectively. The differential thermogravimetric results indicate that as the heating rates increase the ignition, peak, and burnout temperatures increase significantly, leading to high combustion rates. The interaction between the fuels was evaluated using the weighted average model, and the results indicated that there is more synergetic interaction between 20% macadamia plus 80% coal under oxygen than in air and CO2 atmospheres. The results of the investigation provide the combustion and co-combustion characteristics of various samples and their blends and indicate their combustion compatibilities. IntroductionThe global macadamia nut industry is developing at a very rapid rate. South Africa is currently the world’s third largest producer, with a production of about 35 000 t as of 2012 (Department of Agriculture, Forestry and Fisheries, 2013), compared to 840 t produced in 1996. The greatest numbers of the macadamia nut farms in South Africa can be found in Mpumalanga, Limpopo, and KwaZulu-Natal provinces, with Mpumalanga as the largest producing area. There are many factors influencing the increased demand for macadamia nuts, the most important factor perhaps being their nutritional value (California Dried Fruit and Nuts, 2011; MPC, 2014) and their suitability as a feedstock for manufacturing cosmetics, bakery products, nut paste, chocolates, sauces, and ice-cream. As a fuel, macadamia shell has a high heating value ‘as-fired’ of about 20.71 MJ/kg (Vhathvarothai et al., 2013), which could in turn be used in drying the nust, and the shell could also be milled and applied as a fertilizer."

Jan 1, 2015

By Y. Rajpal

The Hedley and Grant pillar strength formula is widely used within the South African mining industry to calculate pillar strengths in bord and pillar mining layouts, and is currently being used at Bathopele Mine. Bathopele is an operation of Anglo American Platinum near Rustenburg, mining the UG2 reef at depths ranging from 40 m to 300 m below surface. The formula includes a parameter K, which is a downrated uniaxial compressive strength value of the rock, used to calculate the strength of a pillar. At Bathopele Mine, for the shallower areas Less than 150 m the value was 33 MPa, but this was increased to 44 MPa due to the fact that rock mass conditions improved and there were no incidence of failure in the shallower areas. Underground observations showed pillars to be stable with no signs of failure, and it was questioned whether the design was not still too conservative, resulting in sub-optimal extraction ratios and consequently a loss of revenue to the mine. A trial mining section was started at the mine where the pillars were reduced from 6 m x 6 m to 5 m x 5 m and the pillar behaviour was monitored for the onset of failure. Numerical modelling was conducted using the TEXAN code to back-analyse pillar stresses in order to find a more realistic value for K. Results from the trial section indicated that the pillar design was in fact too conservative, and the value for K was adjusted to 54 MPa for future designs. This paper details the findings from underground monitoring and numerical modelling results, and includes details for further calibration of the K value in order to further optimize the extraction of the orebody.

Jan 1, 2012

"This paper challenges the traditional notion that mine planners need to plan production so as to incur the lowest mining cost. For a given mine configuration, a mine that increases its mining rate will incur increased mining costs. In an environment in which operations are fixated on cost reduction, a proposal that increases costs will not be readily accepted. Such a proposal requires financial justification—the increase in costs might be recuperated by the additional production. This paper evaluates the net present value (NPV) across a range of copper prices for two underground orebodies located at different depths, using a production rate of 300 kt per quarter and a scenario that introduces additional equipment and costs for 450 kt per quarter. The evaluation was based on the changes of NPV for the orebody located at a shallow depth compared with the orebody at a greater depth. Discrete event simulation combined with mixed integer programming was used for analysis. Unlike traditional sensitivity analysis, this study re-optimizes the mine plan for each commodity price at each production rate. The results show that, for the low mining rate at the final copper price, an NPV of A$1530.64 million is achieved, whereas an NPV of A$1537.59 million is achieved at a higher mining rate. Even though pushing mining rates beyond traditional limits may increase mining costs, this option may be beneficial at certain commodity prices, particularly when prices are elevated. IntroductionA traditional notion among mine planners is that mining rates should be planned in such a way as to reduce production costs. This concept generally relates to the mining rate that results in the highest machine utilization for the selected equipment. Although an existing mine may consider increasing its mining rate by adding equipment to a given mine configuration, this typically increases mining costs. In an environment in which operations are fixated on cost reduction, a proposal to increase costs may be very difficult to argue for. The value of the mine plan is well recognized as varying with the mining rate for a given orebody (Smith, 1997)"

Jan 1, 2017

By K. C. Mills

The objective of this work was to provide process engineers with values of the physical properties of various slag systems involved in high-temperature processes. Software that calculates the thermo-physical properties of slags from chemical composition is available on the www.pyrometallurgy.co.za website. This paper outlines the principles underlying the various models available in the program. The software calculates the following properties of crystalline, glassy, and liquid slags (where appropriate) as a function of temperature: heat capacity, enthalpy, density, viscosity, thermal conductivity, electrical conductivity, and surface tension. We hope, in the future, to update the program to (i) add new models as they become available, (ii) remove any ?bugs? discovered in existing programs, and (iii) provide guidance on the limitations of individual programs.

Jan 1, 2011

By J. P. Gouvea

Back-analysis of two mining-induced tremors in 2011 was used to determine a modelling criterion for the entire Klerksdorp Goldfield (i.e., Vaal Reefs region). At that time, most mining operations in the region were owned by AngloGold Ashanti (AGA) and shared many geotechnical similarities. By 2018 AGA had sold off all its Klerksdorp operations to different mining companies, which continued applying the 2011 modelling criterion. As mining activities became more remote, scattered, and isolated, the extraction of isolated blocks of ground and remnants became increasingly necessary. However, the inherited criterion allowed only minimal or no mining activities at these areas. Keeping in mind that safety is the overriding consideration, an innovative numerical modelling approach, which includes the application of peak particle velocity designs, was developed to provide practitioners in the Klerksdorp Goldfield with a suitable criterion to justifiably and safely mine isolated blocks of ground and remnants. This would not always be possible if a conformist approach was used.

Mar 14, 2024

Professor H.R. Philips was born in South Wales. After graduating with a B.Sc. degree in electrical engineering from the University of Bristol, he joined the National Coal Board's management training programme. Mr B. Moore was born in Coventry, England. He matriculated at Bablake School and then atended Birmingham University, obtaining a B.Sc. Mining Engineering degree in 1953. Professor J .S.J. (J annie) van Deventer matriculated at Swelendam High School. He studied chemical engineering at the University of Stelenbosch, and obtained the degrees of Hons. B. Ing. in 1978 and Ph.D. (Ing.) in 1985. Professor M.D. Brayshaw received most of his education in England but obtained his Ph.D. (Eng.) at the University of Natal. Rock fragmentation by blasting The Third International Symposium of Rock Fragmentation by Blasting will be held in Brisbane, Australia, from 26th to 31st August, 1990. The Third International Symposium of Rock Fragmentation by Blasting is designed to inform delegates on the state of the art in explosives and blasting technology, and to build on the standards of excellence set by the previous symposia in Lulea, Sweden (1983) and Keystone, Colorado (1987). Delegates with an operational, technical, or research focus on blasting will gain from this interactive symposium. Recent journal Mineral resources engineering, edited by C. T. Shaw, T.L. Car, and M. Karmis. London, Taylor & Francis, 1989. Published quarterly. US $107 per year. Risk management The Cost Engineering Association of Southern Africa (CEASA) is to hold its 3rd Biennial Symposium at Indaba, Midrand, on 25th and 26th January 1990. The title of the Symposium is Risk Management in Promotion of Capital Projects. The present political and economic environment in South Africa is characterized by a lack of financial resources, and of technical and management skills, on the part of project owners, designers, and contractors/ vendors.

Jan 1, 1989

By L. Aspola

The platinum group metals (PGMs), i.e. ruthenium, rhodium, palladium, osmium, iridium, and platinum, are typically found in association with each other, but also importantly, with nickel and copper. Typically Platinum and palladium have the greatest economic significance and other PGMs are typically produced as co-products of these. With recent increases in the value of nickel, cobalt, and the PGMs and an ever increasing focus on the sustainable use of metals, interest in the processing of secondary feed material sources and metal-bearing residues has also substantially increased. As an efficient, proven, and environmentally sound technology Outotec Ausmelt Top Submerged Lance (TSL) Technology has gained commercial acceptance in the nickel industry, including PGM recovery. For the processing of nickel- and PGM-bearing feed materials, five Outotec Ausmelt Furnaces at four sites are in operation. Two of these furnaces are located in Rustenburg, South Africa, which is by far the biggest mine-based producer of platinum. Outotec also has hydrometallurgical processes available for further treatment and extraction of PGMs, which are also briefly discussed.

Jan 1, 2012

By M. B. Shongwe, G. Freemantle, M. Botha, S. Brill, J. D. Steenkamp

During steelmaking, one important factor for production efficiency is the free opening of the ladle nozzle during continuous casting. Free opening occurs when the well filler sand and the steel flow freely when the slide gate is opened. Well filler sands are used for the slide gate of a ladle to separate the slide gate refractory and the molten steel. The well filler sand is partially sintered by the heat of the molten metal, which can result in the ladle nozzle failing to open if the sand is not sintered to an appropriate extent. It is therefore of great importance that the sintering behaviour of well filler sand is understood. We studied the effect of the well filler sand chemistry on its sintering properties. Samples of well filler sand with various chemical compositions were sintered in a high-temperature chamber furnace. Quantitative X-ray diffraction (XRD), inductively coupled plasma optical emission spectrometry (ICPOES), and wavelength dispersive spectrometry (WDS) by electron microprobe analysis (EMPA) were used to analyse the various well filler sand mixes. Points of analysis were indicated on backscattered electron (BSE) micrographs. Quantitative element mapping was undertaken by energy dispersive spectrometry (EDS). Thermodynamic calculations in FactSage predicted the percentage liquid phase present for the various well filler sand compositions at equilibrium conditions. The results of this work show that the degree of sintering of chromite-silica well filler sand depends strongly on the silica content. The amount of liquid phase formed increases with increasing silica content.

Feb 2, 2022

By L. Roux

The initial evaluation of a coal deposit often raises uncertainty with regard to the accuracy of the reported Resources and Reserves. Reconciliation of results from mining and beneficiation with the original raw field data highlights deficiencies in original estimations. Credible Resource and Reserve estimation forms the basis on which an entire mining enterprise is motivated, initiated, funded, and established as a commercially viable proposition. This is required for sustainable extraction purposes and to support vital downstream industries such as power generation. Accurate determination of the density of the matrix of the material being evaluated is the key to credible values being obtained for Resources and Reserves. Losses between 15% and 20% of the Resource/Reserve can be realized if incorrect densities are applied to the tonnage derivation. Coal plies and particles have different relative densities, determined by the maceral composition, rank, and mineral and moisture content. These factors in turn contribute to the moisture, volatile matter, ash and carbon contents of a coal, which affect the overall density of the raw coal. More specifically, the relationship of ash to density and the effective matrix porosity were found to be critical in solving the greater majority of the problems in predictive calculations. A major deficiency identified is the inability to determine effective porosity, allowing absorption of adventitious moisture and altering the mass of the core sample. Although the volume of the raw material is altered through crushing, the change in mass after controlled air-drying, used with the original geometrical volume of the raw material, provides a credible air-dry density and allows the determination of the volumetric change related to effective porosity. This parameter can be validated through the evaluation of proximate ash using the ash-adjusted algorithm and a correction for the inherent moisture applied to also give a credible relative density value for an air-dried sample. A combination of theoretical, empirical, and reconciliatory evaluations of the available data, taken from the exploration phase through the mining process to final production, has shown that an integrated approach using the ash-adjusted density (AAD) methodology, in conjunction with other evaluative techniques, provides credible results with a considerably higher degree of accuracy than is currently possible.

May 1, 2021

By C. W. P. Finn

INFACON is of special significance to people in South Africa who are interested in ferro-alloys, because it was in South Africa that the idea of regular international congresses on ferro-alloys was conceived and developed. INFACON 74, the first-ever such congress, was held in Johannesburg from 22nd to 26th April, 1974, being organized by the South African Institute of Mining and Metallurgy, the National Institute for Metallurgy, and the Ferro Alloy Producers' Association of South Africa. Design Awards The Design Institute is inviting entries for the 1981 Shell Design Awards. Any product that falls into the three categories shown below, and that was designed in South Africa and is in production, is eligible for an award. Since their inception in 1970, the Shell Design Awards

Jan 1, 1981

By O. Barron, C. Felix

In 2023, polymer electrolyte membrane fuel cell membrane electrode assemblies accounted for about 62% of the global fuel cell market share and this demand is expected to grow. Commercialisation requires technologies capable of cost-effective, high-volume manufacturing. The membrane electrode assembly is crucial and represents a significant cost to polymer electrolyte membrane fuel cell manufacturing. Manufacturing the electrode components for membrane electrode assemblies at high volumes can reduce production costs while delivering on the forecasted industry demands. Roll-to-roll is a mature coating technology applied in various manufacturing industries such as batteries, printed electronics, microelectronics, photovoltaics, printing, paper consumables, etc., with significant potential for polymer electrolyte membrane fuel cell manufacturing. While the high-volume production process for membrane electrode assembly manufacturing differs from laboratory-scale, the membrane electrode assembly structure remains unchanged. Roll-to-roll is a continuous coating process with speeds of 10 m/min being achieved. In this work, MicrogravureTM and slot-die coating methods have been adopted and have shown promising outcomes for producing gas diffusion electrodes for membrane electrode assemblies. An overview of the MicrogravureTM and slotdie coating methodologies is provided, and a discussion on preliminary results and challenges are presented. Work on MicrogravureTM gas diffusion electrode manufacturing has already achieved comparable performance with spray-coated gas diffusion electrodes. The influence of coating parameters and drying on the coated catalyst layer quality is discussed.

May 27, 2025

The response was good-one of the best the SAIMM has had to its various questionnaires. 231 replies were received from 2768 members representing a response of 8,35%. For fellows and Members together, the response was 13,7%. The spread of responses based on respondents' work situation appeared to be well balanced with some bias from those in consulting organizations. Members' perceptions of their employers' positions withrespect to environmental management looked somewhat optimistic, but it is encouraging to note that they reported that more than half were developing environmental management systems. Training of varying degree was taking place at al levels in their organizations. Members saw their Institute as an important agent inlifting environmental awareness, literacy and responsibility not only through the journal and symposia, but also by liaison with government departments and educational institutions. Most respondents saw environmental legislation both from local and overseas sources as affecting their organizations, their products and services with the emphasis on corporate image, core business and sales.

Jan 1, 1995

By T. G. Pedro, Q. Gonzalo, R. E. Roberto

Anionic surfactants, such as oleic acid and sodium oleate (OLE), and cationic surfactants, such as dodecyl amine-hydrochloride (DDA), are used as flotation collectors of spodumene. However, recovery is poor even if activating ions are used because gangue minerals are also activated. Some reports demonstrate that OLE/DDA mixtures act as a selective collector to enhance spodumene recovery. From mostly macroscopic tests, it has been argued that anionic OLE and cationic DDA form electroneutral complexes, which are adsorbed on the mineral surface through chemisorption; however, no molecular evidence has been presented. Therefore, the adsorption mechanisms of the collector mixtures remain mostly unknown. It seems necessary to first study the behaviour of these surfactants confined in salt solutions, to determine auto-associations when they are pure and cross-associations when mixed, the transition from monomers to micelles, and the structure of the micelles and the effects of pH, temperature and concentration. In this paper, ab initio calculations are first used to determine the surface charge distribution of OLE and DDA separately. Then molecular dynamics simulations are used to determine the conformation, aggregation, and diffusion of these pure and mixed surfactants in freshwater and saltwater with the ionic strength of seawater in a pH range. In particular, it is interesting to determine the various associations that result in mixtures of both surfactants and the impact of alkali and alkaline earth metal cations on the structures formedp. Cations influence the order of the structure and orientation of water dipoles, reducing the mobility of water, ions, and surfactant molecules. This knowledge is critical to improve the molecular understanding of the adsorption mechanisms on minerals. Keywords: Computer simulation, molecular dynamics, flotation, collectors, saltwater

Jan 1, 2020