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By J. Meintjes

The measures taken by Rand Carbide Limited from the 1950s to 1976 to control dust emission from the electric furnaces at its Witbank factory are described. A new design of furnace for calcium carbide followed by a dry-fabric filtration plant for the furnace gases was not successful in arresting the dust. A 131 m chimney commissioned in 1968 effectively dispersed the dust-laden gases from both carbide and ferrosilicon production and so brought considerable alleviation. In 1974 a bag-filter dust-collecting plant was successfully commissioned on a 6 MV.A carbide furnace, and this was followed in 1976 by a bag-filter plant on a 46,5 MV.A ferrosilicon furnace. The company has spent considerable effort and money over two decades in trying to combat dust emission, but eventual success had to await technological development.

Jan 1, 1978

By Northrop. I. N.

Hardmetals possess extremely high hardness and wear resistance, which render them ideal for applications such as metal-cutting tools, rock-drilling tools, and industrial wear-resistant parts like dies, punches, and seals. However, hardmetals are britle, and show poor resistance to impact and shock. They can therefore rarely be used unsupported, and it is common practice to attach hard metal working parts to a more resilient tool holder or support, which is normally made of steel. . . . Owing to the widely differing physical and mechanical properties of steels and hard metals, the Joining of one to the other is problematic, and the method used must be chosen with care. This paper reviews several methods available for the joining of hardmetal to steel, and discusses the advantages and disadvantages of each.

Jan 1, 1987

By B. E. Protheroe, C. Allen, A. Ball

The results of laboratory abrasive and abrasive-corrosive tests carried out on a range of carbon, Iowalloy, and stainless steels are compared with underground tests conducted on similar materials on prototype shaker conveyors carrying gold-bearing quartzitic rock. The dry-abrasion resistance of all the steels was found to be better than that of mild steel. When the added effect of corrosion was tested, the stainless steels proved to be much superior to proprietary abrasion-resistant alloys both in the laboratory and underground. The ferritic stainless grades were shown to be superior on the basis of cost per unit of volume lost. This investigation has shown that laboratory tests on materials can provide valuable information on their possible performance in situ, and can thus be used to replace lengthy experiments on site.

Jan 1, 1981

By R. Meyjes, P. Davies

Keywords: Pyrometallurgy, furnace, smelter, engineering company Metix is a private smelter engineering company wholly owned by its management. Its main lines of business in the ferro-alloy industry being: - turnkey smelter projects (LSTK) - engineering, project, and construction management projects (EPCM) - specialised furnace equipment comprising: ? complete electrode columns, including forged copper pressure rings and contact shoes, as well as fail-safe slipping devices ? water-cooled roofs ? bus-tube systems ? feed systems ? cooling systems ? linings ? off-gas systems ? tap-hole drills & clay guns - furnace power supply systems - ore agglomeration & sinter plants - feasibility studies & due diligence reports - technical consulting for investment banks - project procurement & cost control Metix management experience includes around 130 combined years of contacts and experience in the South African smelter industries. Over 30 furnaces have been built, for processes including FeCr (high, medium, and low carbon), FeSi, FeMn (high and medium carbon), SiMn (ultra low carbon), Si metal, and FeV.

Jan 1, 2006

By M. J. Nicol

An electrochemical investigation of the dissolution of copper, nickel, and copper-nickel alloys in ammonium carbonate solutions by M. J. NICOL, Ph.D., B.Sc. (Hons.) (Wits.) (Visitor) The dissolution of copper and nickel in ammonium carbonate solution was studied by techniques involving electrohemical anodic dissolution and ring-disc electrodes. The rate of oxidation of both copper and nickel by copper (11) was shown to be controlled mainly by diffusion to the surface. Variations in rate with changes in copper (11) concentration, agitation, pH, ammonia concentration, temperature, and copper (I) concentration were investigated and rationalized in terms of their effects on the electrochemical half-reactions involved. Evidence was found for the passivation of nickel and nickel-copper alloys of more than 50 per cent nickel.

Jan 6, 1975

By P. C. van Aswegen

Owing to the strategic value of organic solvents, an investigation was conducted on the reduction of solvent losses at the Buffelsfontein solvent-extraction plant. It was established that the major cause of the high solvent losses was the high content of suspended solids in the uranium pregnant solution. To improve the clarification of the pregnant solution, it was decided to replace the conventional sand clarifiers that were being used at that stage. After pilot-plant tests had been conducted, a circulatorclarifier 16 m in diameter was installed to treat 9000 m3 per day of pregnant solution containing approximately 500p.p.m. of suspended solids. The clarifier was commissioned successfully, and yielded an overflow containing approximately 80 p.p.m. of suspended solids compared to the previous value of 250 p.p.m. This reduction in suspended solids immediately resulted in a decreasing trend In losses of organic solvent, finally yielding a reduction in these losses of approximately 50 per cent.

Jan 1, 1983

By G. J. Wright, M. J. Neale

As machines become more complex and vital to our way of life, any disturbance or failure of their proper functioning tends to have serious consequences. To prevent such failures, increasing attention is being paid to techniques for the monitoring of machinery condition or 'health'. Of the many methods available, examination of the lubricant and any particles it contains forms a basis for interpretation of the conditions of operation, and the rate and severity of degradation of the moving parts, in a machine. Many techniques of wear-debris analysis, such as spectrographic oil analysis and ferography, are available indicate the composition, shape, size, and concentration of contaminants in a lubricant. This paper reviews the important aspects of wear-debris analysis as an integral component of machinery condition monitoring, and gives an insight into the selection of appropriate techniques and the information that can be obtained from each.

Jan 1, 1987

By Alan Bauer

SYNOPSIS A discussion is presented of the advances that have been made in rotary drilling in recent years and it is indicated how and why these drills have replaced percussive equipment even in the hardest formations at larger than 7 in. diameter. A method is presented showing how it is possible to estimate drill requirements and how to optimize drilling and blasting costs for a particular situation. To do this it is necessary to have, in addition to drill performance data, a knowledge of comparative explosive performance. Current methods of doing this are therefore critically appraised. As hole diameters have increased for overall drilling and blasting economies the question of fragmentation arises. In North America this has been approached on a try-it-and-see basis giving results that, in general, have been very satisfactory. The current drilling and blasting practices in North America are reviewed and reference made to the factors of importance in slope control.

By L. H. W. Walker

As part of an overall design of a computer based mining managerial system, the geological and mineral estates management disciplines find themselves centrally placed in terms of producing fundamental data both before and during the mining operation. Computerisation of all aspects of these fields of endeavour has come to be seen as essential for complete integration with other mining orientated disciplines. Release 1 .l. of the Anglo American system of mineral estates management has been tested and is in the process of being implemented at several Anglo American Gold Division mines.

Jan 1, 1987

By R. A. H. Lycett, P. R. Jochens, D. D. Howat

The crystallization of rutile from titaniferous slags by R. A. H. LYCETT, M.Se. (Eng.),"A.M.I.M.M. (Visitor), P. R. JOCHENS, Pr. Eng., M.Se. (Eng.) (Rand), Ph.D. (Member), and D. D. HOWAT, B.Se., Ph.D., F.R.I.C., F.I.M. (Fellow) Factors affecting the precipitation of rutile from smelter slags were investigated, with particular reference to the effect of additions of phosphorus pentoxide to the slag. The phases were identified and the phase boundaries determined for slags having phosphorus pentoxide additions of 0 to 50 per cent. The liquidus temperatures of these slags were determined, and a pseudo-binary phase diagram was constructed. Rutile crystallized as the primary phase from melts having a phosphorus pentoxide content of more than IS,S per cent. Prismatic rutile crystals whose TiO. content was more than 97 per cent were grown from melts that had a phosphorus pentoxide addition of 30 per cent. However, the morphology of the precipitated rutile was such as to make subsequent separation impracticable.

Jan 9, 1975

By E. J. Magri

This paper describes a geostatistical study of the relative merits of diamond-saw sampling and conventional chip sampling, using results from experimental work carried out on Randfontein Estates Gold Mine and Western Areas Gold Mine. The diamond-saw sampling procedure is described, and it is concluded that this is a very efficient operation and leads to good-quality sampling that is clearly an improvement over conventional chip sampling. The study principally involved the computation of the errors of estimation of the mea gold value of mining panels for the two sampling methods, revealing that, in the normal production environment, the diamond-saw sampling method is a significant improvement over conventional chip sampling, as evidenced by the reduced estimation errors achieved. The question of optimum sample spacing is discussed, and it is concluded that the required spacing for chip sampling needs to be smaller than for the diamond-saw method.

Jan 1, 1986

By L. A. Vermeulen

Electronic circuits were developed and successfully utilized to record, store, and continuously transmit to a remote station physical information relating to the impacts of pebbles on the shell liners of an industrial pebble mill, and of electrical conduction in the mineral pulp. The information was obtained by the instrumentation of some of the bolts that are used to clamp the liner blocks and litter bars to the mill shell. The features associated with the impact and conduction signals have been interpreted, and it is shown that such signals can lead to continuous measurements of the volume of the load in an industrial mill. Information is given regarding the angular distribution of direct impacts of the pebbles onto the shell liners, the power required to promote impacts, the amount of material in flight, the impact velocity, and the average number of direct impacts with the shell liner that any given pebble undergoes in unit time in the given mill.

Jan 1, 1984

By D. G. Krige

Some basic considerations in the application of geostatistics to the valuation of ore in South African gold mines by D. G. KRIGE, Pr. Eng., D.Se. (Eng.) Rand (Fellow) There is much room for improvement in the statistical procedures that have been used by gold mines over the past decade in the valuation of their ore reserves. Improvement depends on the establishment of the extent to which the patterns of frequency distributions and the directional variograms for the gold values vary from area to area within each section of a mine. The application of the lognormal distribution and of the De Wijsian variogram model for routine ore-reserve valuations requires detailed study before some of the reservations still held by mathematical statisticians can be met. This paper provides some preliminary evidence of the extent to which these models can be used with confidence, as well as suggesting how they can be applied to their full potential.

Jan 4, 1976

By D. G. Hulbert, I. K. Craig, S. P. Moult

This paper describes the application of a throughput-optimization strategy to a run-of-mine (ROM) mining circuit that is controlled by a multivariable controller. The objective of the optimization strategy is to maximize the ROM throughput at a specific product size. Results from long-term tests, which indicated how 'steady-state' optimization can be achieved, were used for the throughput optimization. This strategy increased the ROM throughput by 11,4 per cent. A mathematical relationship relating residue to grind can be used to calculate the economic benefits of stabilizing control. It was estimated that the throughput optimizer could result in an increase in gold production worth Rl,4 million per annum when waste rock is treated, and that stabilizing control could increase the treatment plants annual revenue by R150 000. If the extra milling capacity brought about by the optimizer is interpreted as a capital cost saving of 10 per cent on the price of a new mil, then a capital cost saving of RI million could result.

Jan 1, 1992

The comments by Mr Chaston were constructive and much appreciated. Considering firstly the recovery of cassiterite from fine deslimed material. A size distribution analysis shows that 58 per cent of cassiterite in Union Tin flotation concentrate reports in the minus 15 micron (quartz) size range. This is achieved at a recovery of 67 per cent and concentrate grade of 42,6 per cent. It is of interest to note that at Altenberg in East Germany 85 per cent of the tin in deslimed minus 43 micron material is recovered into a 14 to 16 per cent Sn concentrate using para-tolyl arsonic acid as collector. Reconcentration of this material is then carried out using two shaking table stages which recover 53 per cent of the tin in a 50 per cent Sn concentrate. Flotation was resorted to after recovery rates of 35 per cent and concentrate grade of 30 per cent had been achieved in a 275 ton per day plant comprising 130 tables. Tests on tabling of deslimed minus 43 micron material have not been carried out at Union Tin. The cost of equipment actually associated with cassiterite flotation amounts to about R60 000. The

By A. Hinde, M. H. Moys

Tailings from metallurgical plants, when deslimed with hydrocyclones, provide a valuable source of material for the backfilling of mines. The effectiveness of this material as a support medium is a sensitive function of its particle- size distribution and water content. It is therefore important that the hydrocyclone-classification plants used to prepare the backfill are operated efficiently, and that the effects of feed disturbances on the composition of the backfil are minimized. This paper addresses the problem of the design, control, and optimization of classification plants to satisfy this need. The development of a computer program to simulate the dynamic behaviour of a hydrocyclone circuit of any given configuration is described. The use of the simulator to investigate the relative performance of conventional and innovative control strategies for single-stage and two-stage circuits is discussed in depth. The results of simulation studies are presented that indicate there is considerable scope for improving the performance and cost-effectiveness of backfill-classification plants.

Jan 1, 1991

By Y. G. Che, M. Brown, R. L. Gandhi, M. D. Watson

Slurry pipelines have proven to be an economical method of mineral concentrate transport over long distances. Some of these pipelines are internally lined with high-density polyethylene (HDPE) to avoid internal corrosion. HDPE is an inert and extremely smooth material, and it was believed hat scale deposits would not form on it. However, there have been instances of scaling on HDPE lined pipes. Scale problems have also occurred on bare steel pipes. In this paper experience with scale problems in some of these pipelines will be summarized. Alternatives available for control of scale problems will be discussed, and a success story for the control of scale problems in the 300 km long Century zinc and lead slurry pipeline will be presented.

Jan 1, 2007

By I. D. Wood

Deposition of gold-bearing deposits in the Witwatersrand Basin was controlled by hydraulic processes. These resulted in the formation of independent sedimentological facies areas having different statistics and semivariograms. Consequently, when there are indications that data are a mixture of statistical populations, it is important to decompose them into statistical subpopulations and analyse these independently. However, in the case of actual mining, physical position and extent of sub- populations are important and, as a consequence, any decomposition of data must take space into account if it is to be of use. An algorithm for the spatial decomposition of data into its sub-populations is described and is applied to real data taken from the Witwatersrand. Two distinct areas with completely different geostatistical parameters were revealed.

Jan 1, 1987

By L. Wade

The advent of relatively cheap computing power has precipitated a rapid growth of computer usage in the mining industry. In order to obtain most benefit from this development a need is recognised for the future mining graduate to be trained in computer literacy. This paper outlines the type of training required and describes progress to date with such a programme at the University of the Witwatersrand. Certain challenges concerning the teaching effort are discussed.

Jan 1, 1987

By H. M. Friede, R. H. Steel

Notes on Iron Age copper-smelting technology in the Transvaal by H. M. FRIEDE, Ph.D. and R. H. STEEL (Visitors) Earlier reports on Iron Age copper metallurgy and copper-smelting techniques in the Transvaal are surveyed, and a description and tentative classification of the copper furnaces are given. The analyses of furnace slags and sherds of glazed crucibles from archaeological sites of the Transvaal and the neighbouring Orange Free State pro. vide evidence of copper smelting there in Iron Age times. . An investigation conducted by the Department of Archaeology of the University ofthe Witwatersrand provided information on the details of furnace construction and smelting processes, on the composition of the materials used and produced, and on the making and handling of tools and accessories, such as bellows and tongs, needed by Iron Age smelters. Three models (the KaondejVenda furnace, the Rooiberg crucible furnace, and the Uitkomst furnace) were constructed and operated as a demonstration of Iron Age copper smelting as it was practised in the Transvaal.

Jan 11, 1975