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By J. Kortnik

Mining has always been, and still is, an activity which is vital for the development of mankind. This is because a predominant proportion of industrial products and energy is produced from raw materials that are excavated using mining methods. The need for environmental protection and the close proximity of urban settlements and mines in Slovenia have necessitated ever stricter requirements for the excavation of raw materials and introduction of more environmentally-friendly mining methods. This is achieved by implementing a closed eco-technological cycle of raw material excavation within the scope of mining methods. In surface mines, this means prompt reclamation of the degraded surfaces, and in underground mines the use of methods with minimized impact on the surface and on underground water. In underground mines, mining methods with backfilling installed according to the multi-barrier disposal system are the only ones that allow the possibility of implementing a closed eco-technological cycle of excavating raw materials. Various industrial waste materials are also included in the backfilling material in order to improve its strength properties. Backfilling consisting of several different waste materials is produced in the form of a composite. Before backfilling consisting of waste material composites can even begin to be used in mines, an environmental impact assessment of its suitability for mines needs to be made. In order to make such an assessment, a pressure leaching cell and an open diffusion cell were made, i.e. a pressure leachate test and a sorption test were developed. The two cells and the developed tests will enable the study of the influence of backfilling on the environment if installed in an underground mine. The pressure leachate test performed with the use of the pressure leaching cell simulates leaching from a consolidated backfill during the seeping of underground water into the backfilling material under pressure. The sorption test performed in an open diffusion cell simulates the flow of eluate leached from the backfilling material through the rock/geotechnical barrier. The two tests were developed in such a manner that they are performed either in succession immediately after one another, but they can also be performed separately at a certain time interval. The paper presents an assessment of the suitability of backfilling made of different waste material composites. Keywords: environmental impact assessment, multi-barrier disposal system, waste material composites, pressure leachate test, sorption test, pressure leaching cell, open diffusion cell, eco-technological cycle, mining methods with backfilling.

Jan 1, 2003

By Klaus Hasselwander

Fluctuating SO2 gas streams represent a difficult task for designers of SO2 removal systems (with respect to designing the plant), but in spite of the designers great efforts to solve the problems, the operation of such plants requires much care and attention. A fluctuating gas flow usually results from metallurgical smelting processes. Both gas composition and gas flow rate may vary. The first part of this paper outlines some existing technical solutions and presents the Pros and Cons of the different solutions. These solutions outline are: - Sulphuric acid plants operated with a preheater permanent in operation - Sulphuric acid plants with concentration increase of SO2 gas either using regenerative SO2 removal or cryogenic partial condensation of the SO2 - Sulphuric acid plants with additional burning of sulfur to increase SO2 content - Single-stage sulphuric acid plants followed by a tail gas system (which is) designed for periods of low SO2 input In the second part, this paper describes some existing technical solutions for removal of SO2 at low concentrations (i. e. less than 0.1 - 2 %-by volume), which could be used as tail gas treatment system for acid plants. While selecting an appropriate solution, special attention should be given to operating costs, which usually to a large extend depends on the type of absorption agent and the costs for disposal of the sulfur compound produced.

Jan 1, 2009

By L. D. van Dyk

The extraction of iron and lead from their oxides with a volatile organic ligand such as acetylacetone in the gas phase offers potential advantages of lower energy consumption, recycling of the extractant, recovery of pure metals, and a reduced environmental impact compared with conventional extraction processes. The influence of reaction temperature, ligand flow rate, and metal oxide levels on the extraction and rates of reaction of iron and lead from single metal oxide (synthetic haematite (Fe2O3) and synthetic massicot (PbO)) systems in a fluidized bed was studied. It was found that at the investigated acetylacetone flow rates, the influence of mass transfer was limited, but that the reaction suffered from reactant starvation. When the metal load increased the effect of starvation on the rate of reaction also increased. The reaction kinetics increased with an increase in temperature for both systems. At low metal oxide concentrations more that 80 per cent of the iron and lead could be extracted from their respective metal oxides after only four hours.

Jan 1, 2012

By B. Ulrich

The basis of this paper is a compilation of work in the design and construction of copper heap leach facilities, and interviews with various heap leach operations personnel in Chile and Peru. The purpose is not to highlight specific mines and their performance, but rather to discuss geotechnical/civil features of copper heap leach facilities that function well, as well as features that do not. During the 1990s several copper heap leach facilities were brought on-line in South America. Many of these facilities have now been operational for a number of years during which time the operators have been able to monitor the performance of their heaps. This paper serves as a compilation of operators? experiences, and provides a discussion of the lessons learnt over the past decade. Several key geotechnical issues are examined, focusing upon the integrity of the ore, drainage material and pipe network, along with the success of inter-lift liners. This conference provides a timely update of the original paper (Burkhalter et al, 2002).

Jan 1, 2003

By C. L. Reichardt

Mining companies are increasingly looking to the developing world for the next generation of mining projects, often in countries that have little or no previous history of large-scale mining. One of the major challenges for such projects is hiring?and retaining?personnel that have technical skills and experience in mining-related disciplines. Staffing a mine with an expatriate workforce is neither cost-effective nor sustainable, and many countries now insist that mining companies ?transform? the profile of their workforce to more closely mirror the demographic profile of the host population. The need to nurture mining-related skills in emerging mining nations is not solely limited to the workforce: there are also pressing economic and sustainability imperatives to develop capacity within local service providers such as consultants and contractors, as well as to facilitate informed engagement between mining companies, government and civil society. However, few educational institutions in emerging mining nations currently have the ability to offer practical training in mining-related disciplines. Local employees who are sponsored by companies to develop their skills through international study maybe impeded by language and cultural barriers, and may also be taught using course content that is of limited relevance to the specific challenges of their future working environment. This paper addresses the challenge of skills development and retention in emerging mining nations and uses examples from sub-Saharan Africa and the Asia Pacific region to explore practical means of developing capacity in mining-related disciplines. It examines the need for companies to implement strategies to develop local technical capacity in countries where they envisage a long-term operational future and also highlights the need to foster partnerships between academia, developmental institutions, mining companies, governments and civil society to establish the critical mass of mining-related skills required to nurture the development of a sustainable mining industry.

Jan 1, 2009

By P. S. G. Leon

One of the most difficult areas in concession contracts in resource-rich developing countries is achieving an equitable balance between the interests of investors, host states and, increasingly, mine and near mine communities. While some countries in the Andean region have resorted to outright or creeping expropriation of natural resource contracts under the guise of resource nationalism, others such as the Democratic Republic of the Congo (DRC), have claimed international best practice in the review (and setting aside) of important concession contracts.

Jan 1, 2011

By N. F. Mescheriakov

New mechanical and pneumatic-mechanical flotation machines with axial impellers have been developed. Industrial tests show that these machines ensure lower power expenditure (on flotation) by 1.5-2.0 times as compared with reference machines (with the same or improved technological indices). Application of the newly developed axial impeller, with these advantages, is possible in any volume chambers of type OK, Dorr-Oliver, Wemko etc.

Jan 1, 1998

By TvS. von Moltke

Steel is a highly versatile material due to its low cost and good mechanical properties, but typically needs some or other form of corrosion protection due to its tendency to corrode when exposed to atmospheric conditions. In the case of organic coatings, the corrosion protection and functionality of the final product is critically dependent on the adhesion of the coating to the surface of the steel. In this work the effect of contaminants and the nature of the surface layers present on industrial steel products are investigated by means of paint adhesion tests, Auger electron spectroscopy (AES), and X-ray Photoelectron spectroscopy (XPS). It was found that the presence of sodium species on the surface is very detrimental to paint adhesion under wet conditions, while satisfactory adhesion may be obtained even in the presence of silicon and carbon residues. It was also found that the nature of the Fe-O layer, formed under wet conditions is labile and different from that formed in dry air, and that subtle changes in process conditions, such as changing the oxygen content of the quench water, may change the adhesion of paint to the surface of the steel. Lewis acid-base interactions are discussed as a mechanism that may determine the bonding between the steel and polymer coating.

Jan 1, 2003

By K. Liddell

Current practice for the recovery of platinum group metals (PGM) from flotation concentrates is by energy-intensive smelting processes followed by separation and refining of the base and precious metals. Energy costs are rapidly increasing in South Africa and this trend is forecast to continue in future years. Moreover, the smelting operations are highly susceptible to deleterious constituents, particularly chromite; and the increasing tonnages of UG2 chromititic ore being mined results in an increasing chromite content of smelter feeds. Hence there is a substantial incentive to assess and implement alternative processes to smelting for the treatment of PGM concentrates. The Kell process is a patented hydrometallurgical alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations (pressure oxidation leaching of base metals and sulfur, roasting and chlorination of precious metals). The Kell process provides the opportunity for existing and new PGM producers to significantly reduce their energy consumption, and in particular their consumption of electricity, by removing the need to smelt PGM concentrates. Energy costs, greenhouse gas emissions and installed power requirements are also much reduced. Compared with smelting and refining these reductions are calculated as: ? Total energy consumption-50% reduction ? Electrical energy consumption-84% reduction ? Energy consumption costs-76% reduction ? C02 emissions-70% reduction ? Installed power requirement 92% reduction. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection and process optimization. The applicability of Kell to treating low-grade 'dirty' concentrates with high UG2 content as well as to polymetallic concentrates containing base metals as the major payable metals with subordinate PGM means that these savings can also be expected when the process is used for treating a range of concentrate types and grades. Keywords PGM,UG2, Merensky, smelting, chromite, electricity, hydrometallurgy, Kell Process, Eskom.

Jan 1, 2011

By R. Dippenaar

The emergence of new steel grades is largely driven by the need to produce high quality steel at a competitive price. The principal aims are to attain ultra-high purity, (especially low interstitial elements) and ultra-cleanliness (by the control of the inclusion content and size). Whereas the steel used to build the Titanic contained 650 ppm sulphur, resulting in MnS stringer-inclusions 25 mm in length, modern quality requirements for arctic pipelines would only allow 10 ppm of sulphur and inclusions in ball-bearing steels must be smaller than 5µm. Most developments are aimed at hot-metal treatment before refining and ladle treatment after decarburisation. Because ferroalloys are added during or after the refining step, it is the secondary (ladle) refining production technologies that are of specific interest to the ferroalloy producer. Through ladle treatment, hydrogen and nitrogen contents are reduced, ultra-low levels of solute impurities are attained and the shapes as well as the composition of inclusions are modified. Steelmakers are concerned about the cost effectiveness of the use of ferroalloys such as consistent product analysis and delivery, improved financing arrangements and technical support. Minimal variation in product sizing is vital because it impacts on handling problems and because particle size determines the rate of particle dissolution. The required ferroalloy product quality depends on the specific use but in general sulphur, phosphorous and nitrogen contents are of concern. Apart from the presence of trace and impurity elements, ferroalloys also contain inclusions. For example, ferromanganese may contain MnO-MnS-SiO2 inclusions while high-carbon ferro-chrome may contain different kinds of Cr-Mn-spinels. The presence of these impurities and inclusions has a significant impact on steel production techniques and cost and hence, on the selection and use of ferroalloys. The interrelationship between ferroalloy quality and steel production technology is plant and product specific and hence, effective communication between ferroalloy suppliers and steel producers is essential.

Jan 1, 2004

South Africa remains the largest global producer of gold, accounting for 11.3 per cent of total world mine production, which amounted to 2520.2 t in 2005. The benefits and disadvantages associated with hedging practices in general, and among South African gold producers is examined. The wide variety and unique nature of risks faced by the mining industries provide a strong case for hedging. Only the principles of hedging, such as selling ounces of gold in the ground at a pre-agreed price for delivery at a future date as a cost-effective mechanism for price risk management, is discussed. Progressive and cumulative increases in the volume of forward sales in the major producing countries are considered by many to be the cause of the declining gold price over the past decade. In spite of negative publicity, forward selling continued as an industry-wide practice until recently (2002) when the global hedge book contracted by 352 t; contraction amounted to 158.6 t in first quarter of 2006. The objectives and benefits of hedging include continuity and stability of cash flows, stability in price achieved, reduction of frictional costs, and creating an effective management tool. The importance of a defined hedging strategy in reducing uncertainty about the hedging objectives is essential to a successful hedging policy. Historical patterns in hedging revenues at an industry level indicate five distinct periods during which the fortunes of hedgers have fluctuated. Finally, since 2001 the rising gold price and reduced price volatility through the consolidation in the global price means that the need to stabilize revenue flows is less urgent. This has meant that hedging is becoming progressively less important for the mining industry at large.

Jan 1, 2007

By W. H. Van Niekerk

The metal zinc has been around since only about 1400 AD. This may sound like a long time, but when compared to fellow base metals copper and lead, which were discovered in 5000 and 4000 BC respectively, it is evident that zinc is a fairly new kid on the block. This may also be the reason why many new facts and benefits of zinc are still being discovered. For instance, it has been discovered only in the last few decades that virtually no life on earth is possible without zinc. In this address it will be shown that zinc is not only very useful to mankind, but is in fact vitally important for all forms of life. It will be shown that zinc is natural, zinc is essential for life, zinc protects, zinc contributes to the well-being of society and that zinc is fully recyclable. It is therefore hoped, that by the end of this address, zinc will no longer be viewed only as the metal that is responsible for the nice colour of roofing sheets and steel buckets, but may indeed be man?s best friend.

Jan 1, 2005

By F. Dehghani

The influence of different grinding methods on the shape characteristics of magnetite particles was investigated. Also, the effect of particle shape on the flotation of the magnetite, both alone and in the presence of quartz particles, was investigated. The shape characteristics of the magnetite particles were measured and calculated from images obtained by scanning electron microscopy via an image analysis system. The flotation tests were performed using a laboratory flotation cell. Results showed that in the -250+212 µm and -106+75 µm size fractions, ball mill products have a higher elongation value than rod mill products, while in the -150+125 µm size fraction, rod mill products have a higher elongation value. Particles with higher elongation values and lower roundness values have a higher flotation kinetic constant. Furthermore, the influence of magnetite particle shape on flotation is greater, and the flotation kinetic constant is higher, in the presence of quartz particles than in the flotation of magnetite alone Keywords shape, elongation value, flotation kinetics, magnetite.

Dec 1, 2013

By S. Ganguly

Slag samples taken from adjacent to the furnace wall of a submerged arc ferromanganese smelting furnace have been found to contain high concentrations of K2O. To characterize the phase equilibria relevant to these slags experimental studies have been carried out to determine pseudo-ternary sections of the form ?MnO?-CaO-(SiO2+Al2O3) with a fixed Al2O3/SiO2 weight ratio of 0.65 and 6.0 wt% K2O for temperatures in the range 1523-1673 K. In the pseudo-ternary section investigated the primary phase fields are found to be mullite, 3Al2O3?2SiO2; corundum, Al2O3; spinel, MnO?Al2O3; manganosite solid solution, (Mn,Ca)O; dicalcium silicate,2CaO?SiO2; gehlenite 2CaO?Al2O3?SiO2; anorthite CaO?Al2O3?2SiO2; kalsilite KAlSiO4 and leuciteKAlSi2O6. It was found that the presence of K2O in the slag decreases liquidus temperature in the anorthite and gehlenite primary phase fields. The manganosite primary phase field is expanded in the direction of increased (Al2O3+SiO2) and the liquidus temperatures in the manganosite primary phase field are increased significantly with the presence of K2O in the slag.

Jan 1, 2007

By M. Hopf

The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However, even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able consistently to identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed).Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa. Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway

Jan 1, 2006

By T. A. Muhlare

The use of electrolyte additives to smoothen cathode deposits during copper deposition is practised worldwide. These additives absorb on the cathode surface and take part in the electrochemical crystallization process. However, these additives also affect the quality of the cathodes when they are inadequately controlled. Electrolyte additives used by Palabora are glue, thiourea, Avitone and chloride. Their effects were determined on cathode quality, the size of the current density region that gives the desired compact morphology, and current efficiency. This was done in a small-scale cell. Small cells have different hydrodynamics from industrial-scale cells, which makes it difficult to simulate the operation of industrial cells in a laboratory. The approach used here was to use a rotating cylinder cathode to attain controlled hydrodynamics. The rotation speed was chosen to give a diffusion layer thickness that is similar to that of an industrial-scale cell. It was shown that even fairly small changes in the additive levels can significantly affect the cathode morphology, and the current density range over which this morphology can be obtained. Keywords Copper, electrorefining, glue, thiourea, avitone and chloride.

Jan 1, 2011

This paper describes a simple finite element (FE) modelling approach which leads to the computation of seismic energy release rate (ERR) and strain energy storage rate (ESR) which result from mining. The concept of critical strain energy is introduced as a means to help evaluate the strainburst potential in mine structures. A new, energy-based, burst potential index (BPI) is proposed. The use of ERR, ESR and BPI is demonstrated by a cut-and-fill stope case study. The merits of using such energy parameters in the interpretation and analysis of strainburst phenomena are discussed. While the study gives promising results, site-specific back analyses would be required to first calibrate the model and fit it with the local mine conditions, before it can be adopted as a routine design tool.

Jan 1, 1999

By R. T. Jones

Technical publications in the field of mining and metallurgy have existed for a long time. Recent developments in electronic publishing on websites make it possible to disseminate information more widely and cost-effectively than before. Professional societies have an opportunity to serve their members and their industry by publishing high-quality peer-reviewed papers on their websites as well as in printed form. Older publications can be scanned, and optical character recognition used to provide searchable text. Various business models exist around this process. This paper outlines the approach used by the Southern African Institute of Mining and Metallurgy (SAIMM) to provide free open access to their journal papers and conference proceedings, as well as the work being done by OneMine.org to collect technical papers from a number of international societies and make them available to subscribers via a large database. An approach is outlined that should be of benefit to authors, readers, and society at large.

Jan 1, 2012

By W. E. Lee

Penetration and dissolution mechanisms are reviewed for predominantly single-phase oxide, two phase oxide and oxide-carbon composite refractories by liquid silicate slags. Theoretical models of these processes, as well as static (sessile drop, dipping and crucible) and dynamic (rotating finger and rotary slag) experimental tests, along with their practical limitations are considered. Direct (congruent or homogeneous) attack is controlled by the reaction rate at the slag-refractory interface or the rate of diffusive transport of species to it through the slag leading to active corrosion. Indirect (incongruent or heterogeneous) attack is controlled by diffusive transport through the slag or through a new solid phase, which forms at the original slag-refractory interface. This may lead to passive corrosion. Examples of direct and indirect attack in a range of refractory/slag systems are described highlighting the critical influence of the composition and hence viscosity of the local liquid slag adjacent the solid refractory. Penetration and corrosion can be controlled either through the local slag composition via the refractory or the bulk slag or by microstructural control of the refractory by e.g. internal generation of dense layers or external deposition/generation of passive coatings, so-called in situ refractories.

Jan 1, 2004

This paper provides a review of the chemical reactions occurring in the submerged arc processing of chromite ores. The excavations of industrial furnaces have shown that the charge, as it descends through the furnace, passes through a number of distinct reaction zones. Each zone is characterised by differing process conditions and reaction products. The phase equilibria, reaction steps and mechanisms occurring as the charge progresses through the furnace are examined, and the potential influences of these factors on the process outcomes are discussed.

Jan 1, 2004