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By J. A. Bakken, G. Sævarsdóttir, H. Pálsson, M. Þ. Jónsson

The role of the electric arc in the consumption of electrodes in submerged arc furnaces has long been debated. The hostile environment in the furnace does not make direct measurement feasible, so simulation has been used to evaluate the arcs contribution to the erosion. Magnetofluiddynamic (MFD) electric arc simulations and a cathode / anode sub-model developed in order to provide boundary condition to the arc model have been used for this purpose. The cathode / anode sub-model provides current distributions and cathode / anode fall voltages for the arc and temperature distribution for the electrode surface, which is paramount to the erosion rate which in turn is calculated from the Clausius Clapeyron equation and the Hertz Knudsen formula for the vapour transport. In the case of high-current industrial AC arcs, arc currents are typically ~100 kA, phase voltages ~100 V and total furnace power ~10 ? 60 MW. The results show that although enormous amounts of material is evaporated, much of it recondenses on the surface. Furthermore the results show that the arc erosion increases strongly with the arc current. If a single arc is present its contribution to erosion is close to the actual total erosion in the furnace. Results from this analysis indicate that there are possibly more than one arc present in the crater, in which case less than 40% of the total erosion would be due to the arc, the rest is chemical erosion.

Jan 1, 2007

By I. Jones

Geologists, engineers, technicians and surveyors have successfully utilized technical software in the mining industry for over 30 years. Software for processing survey, geology, mine engineering and planning information make these functions more efficient by automating repetitive tasks and reducing data processing errors. While these systems have been improved incrementally overtime, new systems that represent giant leaps in technology have been introduced to help mining operations increase productivity and reduce costs. However, their widespread use within the industry has left individual companies without a competitive advantage. Additionally, the ability of these applications to provide the productivity improvements required in today’s uncertain market conditions has since peaked. The next wave of technology—integration of independent software applications—is just starting to emerge and will have a significant effect on the productivity of mining operations. To reap the productivity gains required to remain competitive, mining companies must exploit the collective knowledge and experience of every employee in the organization. Integration of independent software application allows companies to leverage information from all activities, enabling staff to make better decisions to improve productivity. This paper outlines the importance of integration as productivity enabler. Key performance indicators, strategic mine planning, resources management and mine-to-mill integration are discussed as processes that enable productivity. The Gemcom Enterprise Mining System (GEMS)is introduced as the industry’s first integrated solution that enables these productive processes. The paper concludes with a comment on the level of change required to realize the benefits of integration.

Jan 1, 2003

By J. du Plooy

Mintek has implemented a training scheme that provides students with the experiential training requirement for the National Diplomas in Chemical Engineering and Extraction Metallurgy. This note describes the main features of the scheme and the course content, and our view of future developments in this area.

Jan 1, 1998

By R. M. Lamya

The kinetics of copper cementation during atmosphere leaching of a Ni-Cu matte in CuSO4-H2SO4 solution was studied as a function of initial copper ion concentration, initial acid concentration, temperature, stirring rate, particle size distribution and pulp density. It was found that all these process variables influenced the rate of cementation. A two-stage rate of reaction was observed inmost of the experiments, with the rate of cementation in the initial stage being slower than that of the subsequent second stage. The increased rate of cementation in the second stage was attributed to the enhancing effect of the surface deposit. The cementation process was found to take place by two different rate-controlling mechanisms. At a temperature range of 50?70°C, an activation energy of 74.6 kJ/mol was obtained, indicating a surface reaction controlled process. At higher temperatures (70?80°C) a lower value of activation energy was observed (18.2 kJ/mol), indicative of a process controlled by diffusion through surface layers. The structural characteristics of the cemented deposit could not be determined in the investigated system where the deposit was mixed with the leach solid residue.

Jan 1, 2005

By G. Hangone

Paper written on project work carried out in partial fulfilment of MSc thesis This paper investigates the effects of thiol collectors: xanthates, dithiophosphates, dithiocarbamates and mixtures of these on the froth flotation performance obtained with a bornite-rich copper sulphide ore from Okiep Copper Mine with a feed grade of 1.8%copper. Batch flotation tests were used to assess the performance in terms of mass-water recovery, sulphur grade-recovery and copper grade-recovery relationships and the Klimpel rate constant for copper recovery. The results showed that the di-ethyl-dithiocar-bamate (di C2-DTC) was the weakest collector of copper sulphide minerals. Highest copper recoveries were obtained with the di-ethyl-dithiophosphate (di C2-DTP), which were accompanied with more watery froths and lower copper grades demonstrating frothing properties in addition to collector action. Superior copper recoveries were obtained with the 90% ethyl xanthate (C2-X):10% di-ethyl-dithiophosphate (di C2-DTP) and 90% ethyl xanthate (C2-X):10%di-ethyl-dithiocarbamate (di C2-DTC) collector mixtures compared to that obtained with ethyl xanthate at an equivalent collector dosage of 0.139 mol/ton ore (a dosage equivalent to 20 g sodium ethyl xanthate per ton ore). A superior copper grade was obtained with the 90% ethyl xanthate: 10% di-ethyl-dithiocarbamate collector mixture at a dosage of 0.0695 mol/ton ore compared to that obtained with ethyl xanthate at the same equivalent dosage. Keywords: flotation, collector mixtures, copper sulphide ore

Jan 1, 2005

By F. T. Cawood

The new South African Mineral Policy has major implications on the way mineral rent will be collected and shared between the stakeholders in future. Although the policy does not supply details on how this will be done, drastic departures from practices under the previous dispensation require a new approach. For example, there introduction of the ?right to mine? principle implies that the repealed lease consideration concept will be expanded to all minerals. The new policy also makes provision for predetermined standard terms and conditions for all prospecting and mining permissions. It also states that, regardless of whether the mineral rights are state or privately-owned, all prospecting fees and mineral royalties will be determined by state officials after consultation with the registered holder of the mineral rights. This paper proposes a standard mineral royalty formula that complies with the principles mentioned in the White Paper and has been shown to be internationally competitive.

Jan 1, 2001

By S. V. Rungan

Since 1994, South Africa has been the subject of international attention, especially in regard to its transformation initiatives, which aim to redress the post-apartheid imbalances. Mining, as a major employer and one of the major industries in South Africa, has been the focus of the government?s Black Economic Empowerment initiative with the introduction of the Minerals and Petroleum Resources Development Act and the Broad?Based Socio?Economic Empowerment Charter for the South African Mining Industry. The historical background to South Africa?s transformation and the role of the mining industry are pivotal to an appreciation of certain aspects of the Minerals and Petroleum Resources Development Act and the Broad?Based Socio?Economic Empowerment Charter for the South African Mining Industry. The issues around Black Economic Empowerment and the enabling of a smooth transition to the South African mining industry of the future are explored in this paper.

Jan 1, 2005

By M. A. Amarante

Beneficiation studies were conducted on a Portuguese feldspar ore, in order to obtain final products capable of being used in the ceramic industry. A simple scrubbing operation is enough to break the lumps in the feed. The ore deposit contains ca 35 x 106tonnesfrom which, by screening, three main products could be obtained. This paper focuses on the beneficiation of the 500/74 µm fraction, which constitutes about 27% of the ore, assaying 9.42% Al2O3,equivalent to approximately ca 46% feldspar, with a mean iron content of 0.29% iron oxides. Magnetic separation and froth flotation testwork was carried out, in order to decrease the iron contamination and increase the feldspar content. Magnetic separation alone decreased the iron content of the feed to values between 0.04 and 0.08% iron oxides with an average yield greater than 90%. Flotation with HF, provided a feldspar recovery of 45?46% with a concentrate assaying 17.6% Al2O3. The use of H2SO4, gave a recovery of 35?36% of feldspar concentrate, assaying 16.1% Al2O3. However, economic and environmental advantages of using sulphuric acid may compensate for the lower mass recovery. The iron content of0.12% iron oxides in these concentrates, could be reduced to 0.04?0.05%, by further magnetic separation.

Jan 1, 1997

To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements of The South African Institute of Mining and Metallurgy set out on pages 451 to 460 for the year ended 30 June 2002. These financial statements are the responsibility of the Institute?s Council. Our responsibility is to express an opinion on these financial statements based on our audit. Scope We have conducted our audit in accordance with statements of South African Auditing Standards. Those standards require that we plan and perform the audit to obtain reasonable assurance that the financial statements are free of material misstatement. An audit includes: ?examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, ?assessing the accounting principles used and significant estimates made by management, and ?evaluating the overall financial statement presentation. We believe that our audit provides a reasonable basis for our opinion. Audit opinion In our opinion, the financial statements fairly present, in all material respects, the financial position of the Institute at 30 June 2003 and the results of its operations and cash flows for the year then ended in accordance with South African Statements of Generally Accepted Accounting Practice. Auditors 29 July 2003 Council?s approval of the annual financial statements The annual financial statements for the year ended 30 June 2003 set out on page 451 to 460 were approved by the Council on 26 July 2002 and are signed on its behalf by:

Jan 1, 2003

By A. W. Breed

The bioleaching of arsenopyrite, the oxidation of arsenate and the precipitation of ferric arsenate are competing reactions, hence their rates depend on the relative concentrations of the respective species, and the activity of the bacterial culture. Bacterial arsenic resistance may be attributed to the Pst+Pit-mutation and an energy dependent efflux pump. Pst+Pit-mutations result in a reduced uptake of arsenate. This enables the bacteria to survive in solutions in which the arsenate concentration is significantly higher than the arsenite concentration. However, the excretion of arsenate requires energy. Therefore, in the absence of an energy source or during periods of reduced bacterial activity, the inhibitory effect of arsenate may manifest at concentrations to which the culture has been adapted. The chemical ferric leaching rate of pyrite and arsenopyrite decrease with a decrease in the solution redox and may be described using a modified Butler-Volmer equation. The bacterial ferrous-iron oxidation kinetics of L. ferrooxidans also depend on the redox potential, and can be described using a Michaelis-Mententype model modified to account for both temperature and pH. A model developed using the independently determined ferric leaching, and ferrous-iron oxidizing kinetics, has been shown to compare well with the experimental data for the continuous bioleaching of pyrite. Keywords: Leptospirillum ferrooxidans, arsenopyrite, bioleaching, sulphide minerals ferrous-iron oxidation kinetics, ferric leaching kinetics, redox potential

Jan 1, 2000

By M. A. van Nierop

The Discrete Element Method (DEM) is a model that is used to simulate the motion of the media in a grinding mill. The sum of the energy that is lost in inter-media and media-wall collisions represents the power drawn by the mill. The fact that the DEM predicts the power drawn by grinding mills over a large range of diameters has been used to show the validity of the DEM. However, the power drawn by a mill is a function only of the sum of forces of the load on the shell liners. A more accurate and detailed validation of the DEM would be to measure these forces as a function of angular position as the liner moves under the load, and to compare these measurements with predictions generated using the DEM. An experimental mill has been developed to reproduce exactly what the 2-dimensional DEM simulates. The 0,55 m diameter mill has a length of 0,023 m, which is fractionally larger than the diameter of the media used in the mill. One of the lifters in the mill has been instrumented so that the forces on the lifter can be measured as the mill rotates. The DEM simulation will be used to predict these forces. This will give experimental evidence of the validity of the DEM for modelling load behaviour in rotating grinding mills.

Jan 1, 1999

By A. J. Van Der Merwe, N. A. Barcza, M. Boyes, N. R. Clarke

Oriel Resources has with the support of SRK (Cardiff) and DRA and Mintek (South Africa) carried our a Definitive Feasibility Study (DFS) to recover high grade chrome ore from its Voskhod deposit very close to Chromtau that is near to Aktobe in Kazakhstan. Voskhod is a large podiform ore body that contains nearly 20million tons of chromite grading about 48% Cr2O3 and with a Cr/Fe ratio of over 3/1. Selected bore hole core samples were obtained from the confirmation drilling programme during the DFS phase of the project in 2005 for pilot plant test work to design the mineral beneficiation plant. The chrome ore is characterised by four main types, namely high grade lumpy and chip sized ore, high-grade fine ore, lower grade (subordinate) lumpy ore and lower grade fine ore. Gravity separation tests carried out by Mintek showed that the large density difference between the high grade (at over 3.7t/m3) and lower grade ore (at less than 2.97t/m3 ) should ensure very good separation in the DMS drum and DMS cyclone stages resulting in high recoveries of Cr2O3 - rich chromite ore products. Very high chrome ore grades of up to 64% Cr2O3 and Cr/Fe ratios of 4 to 1 were obtained at an 80% mass yield from selected samples of lumpy and chip ore size fractions. The overall predicted recovery from the design work on the mine and plant is expected to be closer to about 70% of the ROM (Run of Mine) feed. DRA has completed the design of the mineral processing plant to recover about 900 kt/a of chrome ore from the 1.3 Mt/a of ROM feed. The plant has been sized to handle up to 1.5 Mt/a and will also be able to address the variability in ore feed as different regions in the deposit are mined. The lumpy high-grade product and the chips size fraction is expected to grade around 48% Cr2O3 and the fine concentrate between 56 and 58%Cr2O3 The ratio of products is expected to be about 70, 15 and 15 percent respectively but will vary to some extent during the expected 20 year life of the mining operation based on including the associated adjacent Karaagash deposit together with the Voskhod deposit. The prediction of the product split from the processing plant depends on many factors such as the geology, mineralogy, mining, handling and metallurgical processing. An overall process flow model has been developed that covers the ROM ore, the various types of chrome ore feed to the mineral beneficiation plant, the projected products and the subsequent smelting of the chromite ores to produce High Carbon Ferrochromium. The model allows the optimisation of the quality of the chrome ore in terms of Cr2O3 content, Cr/Fe ratio and recovery to be studied. This information can also be evaluated in terms of the economic requirements for smelting High Carbon Ferrochromium (HCFeCr) at a given location. Oriel is planning to supply chrome ore to Ferrochrome plants mostly in China and Russia. The use of the model will assist to maximise the value of the Voskhod project to its owners and also assist the users of the chrome ore in selecting the appropriate supply quality to meet their needs for a given smelter operation. The smelting of high grade Voskhod ore requires a limited addition of about 5 to 7% quartz to flux the MgO and Al2O3 and about 25% coke as a reducing agent to produce an alloy containing from about 65 to 74%chromium depending on the Cr/Fe ratio.

Jan 1, 2007

By Y. Poornachandra Rao, P. C. Sudhakar, L. Malakondaiah

NBV commissioned a 27.6 MVA furnace in the year 2005. This paper explains: a)Furnace design features b)Furnace process control, Direct slag granulation c)Continuous casting, Waste heat recovery, Sintering d) Gas cleaning plant, Protection of Environment. Keywords: Furnace Equipment, SiMn Production, Casting, Heat Recovery and Low hood

Jan 1, 2007

By A. Swanson

The Australian coal industry has been subdued in recent years and only a few new plants have been constructed, but the drive for greater efficiency has seen continued technological developments. The paper lists the new plants and major upgrades, plus summarizes technical developments in the areas of dense medium processing, fine coal treatment, froth flotation, dewatering and on-line analysers.

Jan 1, 2001

The 103rd Annual General Meeting of The South African Institute of Mining and Metallurgy was held in the Gold Room, Transvaal Automobile Club, 60 5th Street, Lower Houghton, Johannesburg on Wednesday, 16th August, 2000. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations. Also to recipients of awards, senior members of industry, Honorary Life Fellows, Past Presidents, our Members and other guests, among them the following: Reinie Meyer, President, The Geological Society of South Africa Dr Nielen van der Merwe, Chairman, The South African Institute of Rock Engineering Chris Fourie, President, Institute of Mine Surveyors of South Africa

Jan 1, 2001

By Manoj Kumar, S. Ranganathan, S. N. Sinha

The reducibility of three different manganese ores with coke was studied. The three ores were reduced to different extents under the same experimental conditions. The investigations showed that in the temperature range of 900-1000 ×C, Fe2O3 in the ore was reduced to metallic iron. MnO2 was reduced to Mn3O4 in all cases except one in which it was reduced to Mn2O3. The kinetics of reduction was controlled by different mechanisms in the different ores. Temperature had a significant influence on the reducibility of the ores.

Jan 1, 2007

Council for 1999/2000 President M.H. Rogers President Elect Dr L.A. Cramer Vice Presidents Senior A.A.B. Douglas Junior S.J. Ramokgopa Immediate Past President J.R. Dixon Honorary Treasurer J.A. Cruise [ ] Annual report In accordance with the current management policy, this report on the activities of the Institute is presented under eight main headings: 1. Interests of Individual Members 2. Technical Meetings 3. Publications 4. Regional Development 5. Engineering Science and Technology in South Africa 6. International Liaison 7. State Liaison 8. Management and Administration.

Jan 1, 2001

By J. Glazewski

The mining industry in South Africa has developed its own environmental guidelines in the form of an Aide-Mémoire1,which is an extension of the previous rehabilitation provisions to include all aspects of the environment and all phases of a mining operation. This development, at the time, recognized an international trend towards the formalization of environmental management in mining practice, which resulted from the realization of the large environmental liabilities that mines could face, particularly on closure. Over the past decade the international environmental focus in the mining industry has moved from operational management, to the reduction of liability on mine closure. Mine closure guidelines are being developed internationally by nations (for example, SRK, 19982) and by large mining groups (for example, Rio Tinto, 19983). In South Africa the Department of Minerals and Energy (DME) is presently reviewing the Aide-Mémoire to bring it in line with international and local developments and a separate mine closure plan is being considered.

Jan 1, 2000

By P. S. Paul

Mine accidents/injuries are complex and generally characterized by several factors, from technical to social characteristics. In this paper, a sociotechnical model for work injury in mines was developed and tested through structural equation modelling with application to case study mines in India. In total 14 variables were considered in this study. Most of the variables are not directly quantifiable. Instruments were developed to quantify them through a questionnaire survey. Underground mineworkers were randomly selected for the survey. Responses of 300 participants were used for the analysis. The analysis was conducted in three parts. Firstly, high-low plots were constructed to explore the variations in responses to the questionnaires by the accident involved (AG) and non-involved (NAG) workers. Secondly, a t-test was conducted to see whether the responses were significantly different for the two groups or not. The chi-square results showed significant differences of responses among the two groups. Finally, how these difference scan cause accidents/injuries in mines was hypothesized and evaluated using structural equation modelling. The measurement model of the Linear Structural Relations (LISREL) program was used to identify the latent constructs of the sociotechnical model. The structural model of LISREL was used to estimate the interrelationships among the constructs. The case study results showed that there is a sequential interaction among the sociotechnical factors leading to accidents/injuries in mines. Work hazards induce more job stress in the workers while social support mitigates the same. Job stress and safety environment predict the workers? job involvement. A worker who is more job-involved exhibits better safety performance, which in turn reduces work injury. The safety environment is shown to have a direct mitigating effect on work-related injury. The findings of this study clearly revealed that job stress and safety environment are the two key factors influencing work-related injuries in mines that need to be addressed properly through effective safety programmes.

Jan 1, 2005

By M. J. Nicol

Mr Vegter has analysed, in some depth, the approximations made in the treatment of the kinetic data presented in the original by ourselves (ref.1) and has come to the conclusion that ?under the experimental conditions used by Adams and Nicol (1986) the steady-state assumption was inaccurate?. We are acutely aware of the fact that the experimental method adopted does not permit the attainment of a true steady-state in the elution reactor. However, this does not eliminate the attainment of a pseudo steady-state by a suitable choice of the experimental parameters with the accompanying simplification of the analysis of the data with the aim of drawing the reader?s attention to the most important objective of the paper viz. the effect of various operating parameters on the rate of elution of gold.

Jan 1, 1997