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By M. Abdellatif

"SynopsisCalcined basic nickel carbonate (BNC) concentrate was smelted in a pilotscale DC arc furnace to produce a nickel metal. The furnace was continuously operated for 12 days (24 hour/day), during which twelve different smelting conditions were investigated, with the major variables being reductant type and feed rate, flux composition and addition, and BNC feed rate.The 200 kW DC arc furnace was operated at power levels between 110 and 165 kW and at a total feed rate of 78 to 96 kg/h, resulting in an average slag and metal tapping temperature of about 1650°C. A total of 7.2 t of BNC were smelted, producing about 5.44 t of nickel metal and 2.94 t of slag. Nickel recoveries of 96.4% and higher were achieved, and the slag nickel content was as low as 0.1%. The major impurities in the metal were iron (mostly from oxygen lancing) and carbon. The calculated feed carry-over was less than 0.85% and the graphite electrode consumption was between 2.8–3.3 kg/MWh.IntroductionOne of the most distinctive advantages of DC open-arc smelting is the ability to process fine raw materials without any major issues with regard to the operability of the furnace, metal recovery, and metal quality. This has been demonstrated in Mintek’s DC arc pilot plant facilities over a period of about three decades (Curr et al., 1983). The materials that have been processed include laterite (Kotze, 2002), chromite fines (Curr et al., 1983), manganese fines (Lagendijk et al., 2010), PGM concentrates (Shaw et al., 2013), electric arc furnace (EAF) dust (Denton et al., 2005; Abdellatif, 2002a) and stainless steel (SS) dust (Denton et al., 2005; Abdellatif, 2002a; Goff and Denton, 2004), and petroleum fly ash (Abdellatif, 2002b). The top particle size of such materials can vary from a few millimetres (e.g. laterite) to micrometres (EAF and SS dust). Dusting, whether due to physical carryover of feed or to the arc side reactions, has been proven to be a non-issue. As such, the applications of DC open-arc furnaces have the potential to be extended to other raw materials such as particulate nickel oxide, which has a particle size much less than 100 µm.Nickel oxide is typically produced from laterite ore by sulphuric acid leaching, purification, and precipitation as basic nickel carbonate (BNC) (Rhamdhani, Jak, and Hayes, 2008) or as mixed hydroxide precipitate (MHP) (Mackenzie, Virnig, and Feather, 2006), and finally calcining at moderate temperatures (800–1200°C). The NiO product is very fine, with an average particle size in the range of 10–20 µm and a NiO content of more than 99%."

Jan 1, 2015

By D. F. Malan

This paper provides an overview of the concepts of citations and journal impact factors, and the implications of these metrics for the Journal of the Southern African Institute of Mining and Metallurgy (JSAIMM). Two key research literature databases publish journal impact factors; namely, Web of Science and Scopus. Different equations are used to calculate journal impact factors and care should be exercised when comparing different journals. The JSAIMM has a low impact factor compared with some of the more prestigious journals. It nevertheless compares well with journals serving other mining sectors, such as the Canadian CIM Journal. The problems associated with journal impact factors are discussed. These include questionable editorial practices, the negative impact of this concept on good research, and the problem of a few highly cited papers distorting the journal impact factor. As a consequence, there is growing resistance to the use of journal impact factors to measure research excellence. The San Francisco Declaration on Research Assessment is a global movement striving for an alternative assessment of research quality. As a recommendation, the Editorial Board of the JSAIMM should adopt a pragmatic approach and not alter good journal policies simply to increase the journal impact factor. The focus should remain on publishing excellent quality papers. Marketing of the Journal, the quality of the published papers, and its open access policy should be used to counter the perception that journals with high impact factors are better options in which to publish good research material.

Sep 1, 2022

By P. E. L. Balestra, A. O. Filmer

The kinetics of the reactions involved in the non-oxidative dissolution of nickel concentrate in hydrochloric acid were studied by electrochemical and powder-leaching methods. It was found that the rate of non-oxidative dissolution increases with a cathodic shift in the mixed potential, which can be achieved by an increase in the nickel-to-sulphur stoichiometric ratio at the reaction surface. An unactivated concentrate with a sulphur content of 36 per cent exhibited a mixed potential of +O,3V (SCE) and could not be leached satisfactorily in 3 M hydrochloric acid at 60°c. When activated material (18 per cent sulphur) was leached, it had a mixed potential of -O,3V, and high iron and nickel extraction rates. Results reported by other workers on the non-oxidative dissolution of sulphides are explained in terms of the mixed potentials at which dissolution occurs.

Jan 1, 1981

By M. A. Reuter, N. J. Bartie

Metals make modern societies function, and increasingly, various high purity precious and special metals endow sustainability-driving technologies with specific functionalities. These metals become heavily intertwined within products, complicating end-of-life treatment. To counteract the resulting downcycling and potential depletion of scarce resources, maximising both the quantities and qualities of materials recovered during primary extraction and recycling, processes should be a priority in the pursuit of sustainable circular economy. Adopting a process simulation approach; a digital twin for the life cycle of cadmium-telluride solar photovoltaic (CdTe PV) modules was created. The system comprises an integrated metallurgical production system that produces, among others, cadmium, tellurium, selenium, zinc, copper, and lead, all of which are required to manufacture PV modules. System-wide resource efficiency and environmental impacts are assessed using exergy analysis and life cycle assessment, respectively. Simulation of this large and complex product life cycle at a high level of detail allows for the evaluation of potential system-wide effects of various production, recycling and residue exchange scenarios aimed at maximising the sustainability of the entire system. It diminishes the need to make arbitrary choices about allocation methods for the distribution of environmental impacts in multipleoutput production systems. Furthermore, it demonstrates the key importance of metallurgy in achieving circular economy. Keywords: Circular economy, sustainability, simulation, metallurgy, CdTe photovoltaics, life cycle assessment

Jan 1, 2020

GENERAL Invitation to attend O.F.S. Branch Meeting: Members of the Witbank/Middelburg Branch were invited to attend a branch meeting of the O.F.S. Branch on the 15th November. The subject of the meeting would be a talk on the Hendrik Verwoerd Dam Project and up to 25 members could be accommodated on the nights of the 14th and 15th November by kind invitation of members of the O.F.S. Branch. A questionnaire would be issued at a later date, to obtain the names of those interested in attending the meeting. PAPER FOR PRESENTATION The Chairman called upon Mr G. H. J. Kitson to present his joint paper, entitled: 'Photoelectric readings; their significance for dust control on collieries.' G. H. J. Kitson (Member) and Y. J. F. Haven (Visitor). After Mr Kitson had presented his paper, both he and Mr Haven answered questions from the floor. The Chairman then thanked Mr G. H. J. Kitson for presenting the paper, and the meeting closed at 6.15 p.m.

By J. H. C. Pretorius, P. Nelwamondo

"Although South Africa possesses more than 80% of the world’s platinum reserves, its reputation for reliability in supplying platinum to global markets is under threat. This is due to the 49% decrease in output per worker (1999–2014), while the domestic costs have risen by more than 10% annually for the past 5 years. In addition, the continued decline in the commodity price by 38.3% (2012–2016) has resulted in a significant portion of the sector producing at a loss in 2015. The Chamber of Mines (now the Minerals Councilof South Africa) has suggested that solutions to improve productivity and reduce cost pressures are required. This research aims to provide operational excellence through the application of event chain project management (ECPM) to improve productivity and reduce operational costs. A case study was used to carry out research in platinum mines, with data collected using a motion-time study to measure the current efficiency of operations in each mining stope through actual activity durations. The results indicate that through the application of the event chain project management methodology, risks affecting the mining stope schedule can be managed, the efficiency of operations was improved by reducing the time spent on each activity, productivity was increased by shortening the project duration, and operational costs were reduced in the process. IntroductionSouth Africa’s total mining industry production was 4.9% lower in 2016 than in 2015; it decreased by 1.9% year-on-year in December 2016, with the main contributor to this negative trend being the platinum group metals (PGMs) with a drop of 15.1% and contributing -3.8% percentage points (Statistics South Africa, 2016). Although South Africa possesses more than 80% of the world’s platinum reserves, the 8% drop in production output since 2008 has put the platinum mining industry under the threat of being seen as an unreliable supplier to global markets. This decline in production is caused by the 49% decrease in output per worker between 1999 and 2014. In addition, the continued decline in the commodity price by 38.3% from 2012 to 2016 and an increase in operational costs during the same period resulted in a significant portion of the sector producing at a loss in 2015. A turnaround strategy is required to overcome these challenges. The Chamber of Mines has suggested, among others, the need for solutions to improve productivity and reduce cost pressures. The implementation of these solutions will ensure that the PGM industry thrives and reaches its potential of growing production to more than 322 t by 2020 (Baxter, 2016)."

Jan 1, 2018

Council and Standing Committees, 1975-1976 President: Dr R. E. Robinson. Vice-Presidents: Dr M. D. G. Salamon and P. A. von Wielligh. Honorary Treasurer: J. K. E. Douglas. Immediate Past President: Prof. R. P. Plewman. Members of Council: Dr M. G. Atmore, J. D. Austin, C. T. Fenton, J. A. Holmes, P. Holz, Dr P. R. Jochens, Prof. R. P. King, Dr D. G. Krige, Dr D. I. Legge, D. G. Malan, C. T. Shaw, D. A. Viljoen, R. A. von Maltitz, H. M. Wells. Chairman, Witbank-Middelburg Branch: E. J. Jackson. Chairman, Orange Free State Branch : G. J. C. Young. Past Presidents Serving on Council: R. J. Adamson, H. Britten, H. E. Cross, J. K. E. Douglas, R. C. J. Goode, Prof. D. D. Howat, Dr J. P. Hugo, D. M. Jamieson, D. G. Maxwell, Dr J. T. McIntyre, V. C. Robinson, P. W. J. van Rensburg. Seven Council meetings and five Executive Committee meetings were held during the year, and the standing and sub-committees held fifty-five meetings. Standing Committee Chairmen Membership, P. A. von Wielligh ; Technical Programme-Metallurgy, D. A. Viljoen; Technical Programme-Mining, D. G. Malan; Vacation School-Metallurgy, Dr P. R. Jochens ; Vacation School-Mining, H. M. Wells; Awards, Dr R. E. Robinson; Excursions, Dr D. I. Legge; Adjudicating, Dr R. E. Robinson; Constitution, Rules and Policy, Prof. R. P. Plowman; Mines and Works, C. T. Shaw; Education, Prof. R. P. Plewman; Foundry Colloquia, Prof. D. D. Howat. Representatives on Other Bodies Associated Scientific and Technical Societies: Members : Dr R. E. Robinson and Prof. R. P. Plewman. Alternates : P. A. von Wielligh and Dr M. D. G. Salamon. Federation of Societies of Professional Engineers: Members : J. K. E. Douglas and Prof. R. P. Plewman. Alternates: Dr R. E. Robinson and Dr M. D. G. Salamon. FSPE Technicians Committee: Member: D. M. Jamieson. FSPE Rationalziation Committee: Member: Dr M. D. G. Salamon. South African Council for Professional Engineers (Institute Nominees) Member : R. C. J. Goode. Alternate: G. H. Grange. South African National Committee on Tunnelling: Member : D. G. Malan. Alternate: Prof. R. P. Plewman. Engineers' Liaison Committee (Pretoria) Member : Dr J. P. Hugo. Alternate : P. W. J. van Rensburg. Government Certificate of Competency Liaison Committee: Member: Prof. R. P. Plowman. Alternate: D. M. Jamieson. James Moir Memorial Lectures: Member : Prof. D. D. Howat. World Mining Congress-National Committee: Members : Dr M. D. G. Salamon, Prof. R. P. Plewman, and H. M. Wells. I.F.A.C. Symposium: Member: P. W. J. van Rensburg (Chairman-Organising Committee). Alternate : Dr J. P. Hugo. I. U.P.A.C. Symposium: Member: Dr P. R. Jochens. Membership Nine Fellows, twenty Members, six Associate Members, thirteen Graduates, nine Associates, twenty-nine Students, and ten Company Affiliates were elected during the year. One Fellow was elected to Honorary Life Fellowship, eight Members and one Graduate were transferred to Fellows, twelve Graduates and two Students were transferred to Members, three Students were transferred to Graduates, and one Student was transferred to the grade of Associate. Six Fellows, two Members, and two Associates were admitted to retired membership. Nine Fellows, fifteen Members, three Graduates, one Associate, two Students, and one Company Affiliate resigned. A statement of membership as at June 30th, 1976, and the end of the previous year is shown in the following tabulation. 30th June, - 30th June, 1975 1976 Honorary Life Fellows 16 - 17 Honorary Fellows 8 - 8 Life Fellows 171 - 171 Fellows 549 - 547 Members 523 - 517 Associate Members 15 - 21 Graduates 132 - 123 Associates 209 - 205 Students 173 - 179 Company Affiliates 71 - 80 1866 -1878 Obituaries Your Council records with deep regret the death during the year of the following members: P. A. Creewell, Life Fellow; A. S. Davis, J. S. Hay, P. 0. Lange, N.

Jan 10, 1976

By V. van der Merwe, C. W. Siyasiya

"A petrochemical company experiences premature thermal fatigue failure of the casting moulds used in catalyst production. The aim of the project was to find an alternative alloy that would outperform the current low-alloy cast steel used for the moulds. Based on their thermo-fatigue properties, 3CR12 ferritic stainless steel and H11 tool steel were chosen for testing and comparison with the currently used BS3100 B7 cast steel. Samples of each material were subjected to temperature cycling in a Gleeble 1500TM thermo-mechanical processing simulator, followed by surface analyses. The main parameters derived from the test work were the total true strain, the hot strength of the materials, and the number of cycles to failure. Additionally, the coefficient of thermal expansion for each material was measured using a Bähr dilatometer. H11 tool steel yielded the best performance by way of having the fewest surface cracks, the lowest total true strain per cycle, the most cycles to failure, the highest hot strength, and the lowest coefficient of thermal expansion.IntroductionThe Catalyst Manufacturing Plant (CMP) is a dusty environment with temperatures higher than ambient. Molten mill scale (magnetite, Fe3O4) is tapped from the electric arc furnace into the casting moulds at temperatures close to 1600°C. After 10 seconds the magnetite is quenched with a water spray for 50 seconds to a minimum temperature of 400°C. Sometimes there is residual water in the pans from the cooling fog process (water sprays) in the empty mould. In a typical plant, the factory produces 40–44 batches a day containing between 150–300 moulds, depending on the time required for the specific batch (Buchholz, 2014). The typical batch in the CMP usually weighs about 6 t. The thickness of the tap, speed of the casting belt, and tilting angle all affect the number of moulds per batch.One of the main problems faced during the molten mill scale casting is the premature failure of the casting moulds. Cracks initiate on the surface of the mould, which is in contact with the hot catalyst, and propagate into the interior of the mould. Cracks are generally concentrated in the middle area of the mould where the catalyst makes first contact with the mould, and which experiences the highest temperature fluctuations. This suggests that the cracks are caused by thermal fatigue during the casting process."

Jan 1, 2016

By D. F. Malan, J. A. L. Napier

This paper describes some important aspects associated with historical underground measurements in South African gold and coal mines. Deformation measurements were used to confirm the use of elastic theory to simulate the rock mass behaviour in the Witwatersrand gold mines in the 1960s. Although a prominent time-dependent component of stope closure was measured as early as the 1930s, it was ignored owing to the benefit of adopting elastic theory. Neglecting the time-dependent response of the rock for many decades resulted in important aspects such as the effect of mining rate, the effect of advance per blast, and the need for enhanced design criteria not being explored. Recent work is only now starting to address this gap in knowledge. In-situ measurements of large coal specimens in the 1960s and 1970s indicated that a linear formula may possibly be a better approximation of coal pillar strengths. This alternative formulation was never adopted, however, as the power law strength formula was already deeply entrenched in the industry at that stage. In spite of these apparent failures to continuously generate and adopt new knowledge, a key lesson learnt is that major advances in rock mechanics will not be possible without careful monitoring of the rock mass behaviour in experimental sites. Areas requiring further research, such as pillar strength formulae for the Bushveld Complex and enhanced design criteria for the gold mines, can only be developed using extensive undergroundmonitoring programmes.

May 1, 2021

OFS Branch Minutes of the General Meeting Held at the President Steyn G.M. Ltd Canteen on Wednesday, 13th November, 1974, at 3.55 p.m. Mr D. A. Smith (Chairman of the O.F.S. Branch) was in the Chair. There were also present: Nim reports Report no. 1696 The preparation and certification of a reference sample of a preciousmetalore. Report no. 1705 The effects of various matrix elements on the efficiency of the fire-assay procedure using nickel sulphide as the collector. Report no. 1720 The initial development of processes for the direct leaching of iron-nickelcopper mattes containing platinumgroup metals, and for the production of ferronickel.

Jan 5, 1975

By K. G. Tshilombo

It should be possible to use an oxygen probe to follow iron removal during converting, if local equilibrium is established between iron in the matte and the iron oxides in the fayalitic slag. The oxygen activity is expected to increase strongly as the iron content of the matte decreases (and the iron activity in the matte drops) while the iron oxide activity in the slag remains constant. To test this idea, oxygen activities were measured in synthetic mattes (made up of mixture of Cu2S, FeS and Ni3S2) when in contact with silica saturated SiO2-FeO slags, and silica and (initially) magnetite saturated SiO2-FeO-Fe3O4slags. The measurements were performed on laboratory scale at 1250°C, using an oxygen probe consisting of a stabilized zirconia electrolyte and Fe/FeO reference, and containing the sample in a silica crucible. Electrical contact to the matte was by means of a platinum wire. The measured oxygen activity was sensitive to the iron content of the matte, and insensitive to the composition of the gas atmosphere over the melt. The measured oxygen activity was generally close to that predicted by Fact Sage calculations. This indicates that such oxygen activity measurements could be useful to monitor iron removal during converting of nickel-copper-iron mattes.

Jan 1, 2006

By B. Matsetela, S. Amos, V. Nkuna

"The Kamoa-Kakula copper project—a joint venture between Ivanhoe Mines, Zijin Mining Group Co. Ltd, and the government of the Democratic Republic of Congo—has been independently ranked as the world's largest undeveloped high-grade copper discovery by international mining consultant Wood Mackenzie. It is a very large, near-surface stratiform copper deposit with adjacent prospective exploration areas within the Central African Copperbelt, approximately 25 km west of the town of Kolwezi and about 270 km west of the provincial capital of Lubumbashi. A phased development approach is currently envisaged. The first phase of the project involves the development of a 6 Mt/a underground mine and surface processing complex (dual stream concentrator) at the Kakula deposit, a discovery announced in early 2016. The second phase involves an integrated 12 Mt/a two-stage development, beginning with initial production from the Kakula mine, to be followed by a subsequent, separate underground mining operation at the nearby Kansoko mine, along with the construction of a smelter. Project description and locationThe Kamoa–Kakula project comprises a newly discovered, very large stratiform copper deposit with adjacent prospective exploration areas, located within the Central African Copperbelt in Lualaba Province, Democratic Republic of Congo (DRC). The Kamoa–Kakula project lies approximately 25 km west of the town of Kolwezi and about 270 km west of Lubumbashi. Ivanhoe owns a 49.5% share interest in Kamoa Holding, an Ivanhoe subsidiary that currently owns 80% of the project. Zijin Mining owns a 49.5% share interest in Kamoa Holding, which it acquired from Ivanhoe in December 2015 for an aggregate cash consideration of US$412 million. The remaining 1% interest in Kamoa Holding is held by privately-owned Crystal River.The Kamoa–Kakula project consists of the Kamoa exploitation licences (exploitation permits 12873, 13025, and 13026, which cover an area of 397.4 km2) and one exploration licence (exploration permit 703 covering an area of 12.74 km2). The Kamoa exploitation licences, approved 20 August 2012, grant Kamoa Copper the right to explore for, develop, and exploit copper and other minerals, for an initial 30-year term, expiring on 19 August 2042. The permits can then be extended for 15-year periods until the end of the mine’s life."

Nov 1, 2018

By V. Ross

"Bench-scale flotation tests play a major role in the geometallurgical process value chain. Despite their apparent simplicity, these tests pose pitfalls in terms of operation, as well as the interpretation and modelling of results. In this paper we highlight key aspects to consider in generating accurate and reproducible experimental results, and critically review some assumptions relating to the estimation of entrainment and froth recovery. We subsequently focus on first-order equations to model kinetics and propose a method that accounts more realistically for the decay in kinetics over the duration of a float, and the contributions of froth stability and hence mass pull. The method was applied to three case studies on platinum group metal (PGM) ores and matched or outperformed first-order, two-component models. Also, it allows for a deeper analysis of the integrity of the bench-scale flotation results. IntroductionGeometallurgy is a structured, multidisciplinary approach that integrates key data from the geological, mining, mineralogical, and metallurgical aspects of the value chain to construct spatial models of an ore deposit such that the overall economic benefit and sustainability of an operation can be optimized. Process geometallurgy is aimed primarily at enhancing metallurgical efficiency and plant throughput by the application of appropriate mining and processing strategies, as well as supporting production planning and operational strategies to reduce the impact of highly variable ores. With flotation being the dominant concentrating process in the mineral value chain, the bench-scale flotation test is an important characterization tool – a relatively cheap, simple, and rapid way to obtain key information about the ore and its amenability to economic extraction of valuable minerals. This includes the evaluation of different ore types and the implications of mineralogical composition and texture for comminution and floatability, the effect of the grinding environment on the liberation of minerals, the electrochemical environment in the pulp (Bradshaw et al., 2006), the screening of reagents to improve floatability (Ekmekci et al., 2003), and the role of hydrodynamics in the recovery of valuables and the entrainment of gangue (Amini et al., 2016; Wang et al., 2016). It is also a critical tool in auditing the performance of a flotation plant by hot floats, paving the way for concept and feasibility studies and providing essential data on kinetics for the purposes of scale-up, optimization, and simulation of flotation circuits."

Mar 1, 2019

By F. Roelofse, D. Grobler, and M. Purchase, C. Gauert, E. Kotze

Scandium is an important industrial metal for which demand is projected to increase in the future. Although many Sc deposits are secondary, Sc is scavenged by clinopyroxene during fractional crystallization of primary, mafic-ultramafic magmas. Sc may thus occur in sub-economic concentrations in mafic-ultramafic intrusions. In this work, we present new data on the concentration of Sc in the Bushveld Complex (BC) of South Africa. The eastern and western limbs of the BC are considered to be largely pristine, primary magmatic deposits, whereas the northern limb shows evidence of largescale, localized crustal contamination. Samples from the primary magmatic cumulates of the eastern limb, from the mineralized Flatreef of the northern limb, and from the crustal-contaminated Footwall Assimilation Zone (FAZ) of the Flatreef were analysed for Sc. Despite the FAZ containing abundant clinopyroxene, interpreted to have recrystallized from the original cumulates in the presence of melted sedimentary rocks, no significant differences are seen in the concentration of Sc compared to other cumulate rocks of the BC containing less-abundant clinopyroxene. The concentration of Sc in the analysed samples is mainly controlled by mineralogy, with anorthosites, chromitites, and harzburgites containing under 20 ppm, and norites and pyroxenites containing 20–40 ppm. The parapyroxenites of the FAZ are less enriched in Sc than expected, suggesting that Sc may have been lost during alteration and recrystallization.

Sep 1, 2022

By J. L. Broadhurst, S. Rumjeet, S. T. L Harrison, T. Chimbganda

Post-mining land use for the production of industrial crops has the potential to mitigate environmental and socio-economic impacts of mine closure and stimulate post-mining economic growth. Fibre-rich plants are of particular interest due to their multi-product potential. In the South African context, where there are many abandoned and end-of-life mines near human settlements, an opportunity presents to assess the feasibility of transforming post-mining land into productive land and building resilient communities through the development of multi-product value chains from fibre-rich plants such as kenaf, hemp or bamboo. This paper provides an overview of the plant selection criteria, phytoremediation potential and the downstream options for the recovery of products and value from bast fibre plants (hemp and kenaf) and bamboo. Based on findings from a comprehensive review of the published literature, as well as interviews with relevant experts within South Africa, it appears that bast fibre plants are the best downstream option for producing ‘green’ textiles and high-end niche products, whereas bamboo is more suitable as a replacement for conventional timber. Although fibre plants have the potential to extract metals from soils, high concentrations may inhibit plant growth and affect the quality of the final fibre product. Further site-specific studies would thus be required to select the best route for both land remediation and optimal product recovery. Keywords: Bioremediation, bamboo, kenaf, hemp, multi-product value chains, sustainable postmining land use

Jan 1, 2020

By A. Kotze, D. Messina, E. Nagels, Y. Cryns, S. Arnout

The FlashPhos process aims to recover white phosphorus (P4) from sewage sludge by drying, flash combustion/gasification, and carbothermic refining steps. This study evaluates the material behaviour of sewage sludge ash melting and reduction in a refining furnace for the novel FlashPhos process. Thermodynamic modelling in FactSage 8.2 is combined with experiments from a tube furnace to determine the possible phosphorus recovery and minor element behaviour. For the two studied sludges, a yield of 40% and 75% white phosphorus is achieved after 1 hour at 1600°C, corresponding with a 60% and 25% loss to the metal phase. This is slightly above the calculated equilibrium yield of 28%–73%, which depends mainly on the Fe/P ratio of the sludge. Temperature is found to have a significant influence on the final phosphorus yield when leading to incomplete melting of the ash. A clean slag is produced in the process free of heavy metals making it suitable to be used as a cement-like binder material. The main heavy metals that co-evaporate with the phosphorus are Zn, Pb, As, Sb, and Sn. Additional processing steps will be required to remove these to produce a pure P4 product. The metal alloy consists of mostly Fe and P with smaller amounts of other components such as Mo, Cr, Cu, Mn, Sn, Sb, and V. The final slag consists of CaO, SiO2, MgO, and Al2O3 with virtually complete removal of P and heavy metals.

Oct 2, 2025

By S. Saeed, N. Coulson, P. F. Stewart

"The Mine, Health and Safety Act No. 29 of 1996, as amended, embodies worker self-regulation to advance health and safety in the workplace. An important provision for this is the Right to Refuse Dangerous Work (RRDW). This paper explores worker perspectives about the implementation of RRDW on South African mines against a backdrop of revised guidance in the sector: ‘Guideline for a Mandatory Code of Practice on the Right to Refuse Dangerous Work And Leave Dangerous Working Places’, gazetted in February 2016 by the Department of Mineral Resources (DMR). A mixed methods study conducted at mines (n = 14) included a survey of workers (n = 293), focus groups (n = 6) and in-depth interviews (n = 16). Workers reported a high level of awareness, a positive attitude, and experience of the formal RRDW. However constraints to the formal RRDW meant that informal worker resistance to dangerous work was commonplace. Evidence of informal non-confrontational consultation, cooperation, and collaboration in the event of a dangerous workplace also emerged between workers, and supervisors. The research underscores the importance of the RRDW and worker health and safety representatives to mine health and safety. The revised guidance addresses RRDW implementation gaps, but of concern is the potential partiality towards management interests. IntroductionEnsuring that mineworkers act on their duties and responsibilities for health and safety remains a concern across the globe. Article 13 of the International Labour Organization (ILO) Convention Safety and Health in Mines (176 of 1995) entrenched the Right to Refuse Dangerous Work (RRDW) as an important mechanism through which workers act in the best interests of their own occupational health and safety (OHS) and is considered a cornerstone of worker self-regulation (ILO, 1995). Countries ratifying Convention 176 are under obligation to make this right available to workers through OHS legislation that frames the circumstances, procedure, and protection of workers from discrimination in the event of a formal work refusal. The Convention has been ratified by 31 countries, with South Africa becoming a signatory in June 2000 (ILO, 2000). Worldwide studies show that workers use this right with caution (Hilgert, 2013) and cases associated with work refusal are rarely presented in court (Gunningham, 2007; Cooper, 2013). Rather, in cases of formal notification of a work refusal, issues arising out of this are addressed either in the immediate workplace or through the site OHS system and/or at industrial tribunals or similar mechanisms (Harcourt and Harcourt, 2000)."

Jan 1, 2018

By G. Jandieri

An improved methodology is presented for assessing the economic feasibility and effectiveness of recycling industrial waste. The methodology is based on the break-even control mechanism, but at the same time provides for the introduction of new evaluation criteria such as the threshold of conditionality and the degree of ore substitution. Based on an improved analysis, it becomes possible to more precisely predict recycling efficiency. A more refined determination of the lower limit of concentration of recoverable metals, at which technogenic waste can be assigned the status of secondary raw materials and processed profitably, leads to a significant expansion of the secondary raw material base suitable for recycling. The potential for recycling manganese-containing dust from the production of ferrosilicomanganese, dehydrated sludge from the hydro separation of slags, and cake from the production of electrolytic manganese dioxide at the Chiatura mining enterprise is used as an example. It is shown that with a threshold of –24% Mn content, the highest recycling efficiency can be achieved by the production of low-phosphorus manganese slag and conversion to ferrosilicomanganese using the above waste to replace 40-60% grade III and IV manganese concentrates in the feed.

Jan 26, 2023

By C. Birch, J. Perold

"Due to the challenging geological environment of the Postmasburg Manganese Field (PMF), a study was conducted to determine if any benefits would derive from the inclusion of resistivity data during threedimensional (3D) modelling of the manganese resource. This was achieved by estimating manganese resources from 2011/2012 drilling data and comparing them with manganese resources estimated from the same drilling data and resistivity data collected during 2013 and 2017.Both models were adjusted to limit their extent to the same 3D modelling space. Significant volume and tonnage differences were observed for all lithological units. The greatest differences were noted in the manganiferous zones of alteration – 7.200 Mt for the geological model versus 3.700 Mt for the geoelectric model.This study showed that the inclusion of resistivity data can reduce exploration costs significantly, as a direct consequence of the resistivity data allowing more accurate siting of boreholes. This decreases the number of boreholes, samples, and analyses required due to the 3D electrical delineation of mineralized areas prior to drilling.An additional benefit is the ability to more correctly forecast the net present value of an operation due to more accurate estimation of manganese resources and stripping ratios. This is clearly demonstrated by the estimated gross profit estimation of R409 million for the geological resource model versus R264 million for the geoelectric resource model.The addition of resistivity data can, therefore, reduce exploration costs and can increase confidence in geological and financial modelling. It would be reasonable to conclude that this approach could also be used for karsthosted massive sulphide deposits. IntroductionAccording to Corathers (2014) and Gajigo, Mutambatsere. and Adjei (2011), South Africa holds between 75–80% of global manganese reserves, followed by Ukraine (10%), Australia (3%), India (3%), and Gabon (2%). The known, land-based, manganese resources located elsewhere are estimated at 2%.The majority of economically important sedimentary manganese ore deposits in South Africa are situated in the Northern Cape Province (Gutzmer, 1996). Manganese ores of the Postmasburg Manganese Field (PMF) were discovered in 1922, and the Kalahari Manganese Field (KMF) in 1940. According to Astrup and Tsikos (1998) and Gutzmer (1996), mining of manganese ore from the PMF ceased during 1989 in favour of the superior quality of manganese ore from the KMF."

Mar 1, 2019

By S. J. van Wyk, A. S. H. Haagner, A. Abraha

Opencast coal mining is responsible for the greatest area of land disturbance across all of the commodity types in South Africa. Many thousands of hectares have been rehabilitated to date and, although rehabilitation performance is not always measured or reported, a significant database, spanning 24 years, has now been analysed to identify the main shortcomings holding back rehabilitation sustainability across the industry. Data from 48 different collieries with rehabilitation performance scores measured from 2000-2024 were analysed. A standardised assessment framework was implemented at all 48 collieries, focusing on aspects of land capability, soil fertility, landscape form and drainage, vegetation species composition and basal cover, implementation of maintenance programmes, and prevalence of invasive alien plants. The findings show that, although invasive species management, plant species composition, and plant basal cover are often adequate, the implementation of aftercare and maintenance programmes (influencing soil fertility) and deficiencies in overall landform design and drainage systems are most significant in preventing overall rehabilitation progression and self-sustainability. Integrating these during design and rehabilitation execution, followed by intensive maintenance (especially in the first five years post-topsoiling and seeding) will be key for the overall industry performance to improve to acceptable levels. The database is biased towards collieries that actually do undertake rehabilitation and that do measure it, hence the actual industry performance is likely worse than what is presented. Due to the substantial hectarages involved and the main post-mining land uses being grazing and crop production, the industry cannot afford to keep perpetuating deficiencies in achieving the foundational aspects of rehabilitation that would pave the way for sustained economic future use.

Apr 25, 2025