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By S. E. Olsen, T. Færden, G. Tranell, T. Lindstad, J. Lubetsky

The authors are lead authors for chapter 4.3 ?Emissions from Ferroalloy Production? in ?2006 IPCC Guide-lines for National Greenhouse Gas Inventories, Volume 3?. The paper discusses the methods to calculate and report emissions from the production of ferrosilicon, silicon-metal, ferromanganese, silicomanganese and ferrochromium alloys, as well as the basis for the methods and choice of emission factors. CO2 is the main greenhouse gas emission from ferroalloy production, accounting for about 95 % of the total CO2-equivalents. The most accurate method of determining emissions is to base the calculations on reported amounts and analyses of reducing agents and carbonate ores used in the process. If analyses are not available, typical CO2 emission factors for the different reducing agents are recommended. If neither reliable amounts nor analyses of all reducing agents are known, default generic CO2 emission factors for the type of ferroalloy multiplied with amount produced, can be used. The CO2 produced from bio-carbon (charcoal and wood chips) should be reported but will not be accounted for in national emissions. If any bio-carbon is used, the default generic CO2 emission factors cannot be applied. CH4 accounts for less than 1 % of the total emission of CO2-equivalents. Default emissions factors for CH4 are given for the production in open or semi-closed furnaces of silicon-metal and ferrosilicon. In the production of FeMn, SiMn and FeCr in closed furnaces the gas containing CO,CO2 and volatiles can be combusted in boilers and N2O may be formed. While reporting is not required, IPCC Guidelines recommend that the N2O-content in the off-gas is measured.

Jan 1, 2007

By M. H. Solomon

After the global financial crisis of 2008, African mining is entering anew phase of development. The rapid withdrawal of emerging market funding from the critical exploration and development industries provided a hiatus in funding, a gap which was quickly filled by Chinese and other Asian investors. While the continent is still economically dependent on its extractive industries, the prevalence of Dutch Disease has undermined Africa?s ability to benefit fully from its mining, oil, and gas industries. While the extractive industries are closely related to many of the more fragile and failed states in Africa, it is equally true that the strongest states in Africa have mining-based economies. This paper explores the possible linkages between mining, strong and weak political economies, and poverty in Africa. It draws the conclusion that neither Dutch Disease nor Resource Course is a given in resource-endowed countries, and that it can be avoided if the mining economies in these countries are actively integrated into their respective broader economies and used to foster economic diversification. The author asserts that given the capacity constraints of many African governments, it is contingent on mining companies to become integrally involved in catalysing diversification around their infrastructure and supply chains.

Jan 1, 2011

By A. Burger Pintér

To be meaningful the sharing of ideas about the National Environmental Management Act (NEMA) and social issues within the context of Mining and Metallurgy (M&M) requires an honest scrutiny of the M&M/social environment relationship, both past and present. It is not a secret that this relationship has been and is fraught with difficulties. Thus from all perspectives (M&M, society and environmental and social consultants) such a dissection, that highlights the realities, both good and bad, is uncomfortable. For this section of the colloquium to have any value, the honest but difficult approach needs to be taken.

Jan 1, 2000

By H. Aykul

The choice of which mining method to use at many large surface coal mines is often dicated by what machinery is available or what experience the mine management can offer. One of the most significant surface coal mines in Turkey is owned and operated by the Turkish National Coal Board, located to the west of the city of Kütahya. The Seyitömer Lignite Enterprise (SLE) extracts low quality coal, the majority of which is supplied to an adjacent power station. The coal seems at SLE contain bands of ash which under normal mining conditions are extracted with the coal. This increases the ash content of the run of mine coal and results in lower efficiency at the power station and financial penalties for SLE. In this paper, therefore, selection of the best possible equipment and production method was identified to achieve high selective mining at SLE. The research found that two different high selective mining methods were suitable for selective excavation of the B3 seam, which were hydraulic excavator and truck and surface miner and truck combinations. It was also found that high selective excavation could provide the desired coal quality at 52% lower costs when the whole process (excavation, transportation, processing, etc.) was considered. Keywords: coal mining, surface mining, selective mining.

Jan 1, 2007

By J. de Villiers

Through the application of the Rietveld method, X-ray diffraction analysis has developed into a fully quantitative method for phase analysis. The Rietveld method itself has progressed from an unstable method that required constant operator intervention to a stable and robust method suited even for routine analysis. The method, however, requires a good initial calibration and periodic checks on its precision and accuracy. Several examples from minerals processing, pyrometallurgy, and materials science show the strengths and applicability of the method. The limitations and sources of error are also discussed.

Jan 1, 2007

By K. M. Godiwalla, S. Ranganathan

The thermal state in submerged-arc furnaces (S.A.F.) producing ferro alloys is important for the conditions of both the grade of alloy produced as well as specific energy consumption. The temperature profile in the S.A.F. is affected by the endothermic chemical reactions and the rate of gas evolution. The gas evolution commences at about 900 C due to the reduction of iron in the ore. A first-principle-based 2-D model has been developed to predict the temperature profile in the furnace. In this study, four ores of different grades have been considered in order to simulate the thermal profile in the S.A.F. The influence of the composition of the ore on the thermal profile and its significance in rationalisation of charge distribution to optimise the process are discussed.

Jan 1, 2007

By P. F. Ledwaba

South Africa?s Northern Cape Province houses a variety of gemstone minerals. Diamonds remain the primary gemstone in the province, but there are also tiger?s eye, sugilite, rose quartz, jasper, amethyst, amazonite, tourmaline, and topaz deposits. This paper gives an overview of the tiger?s eye (TE) mining sector in the Northern Cape, with the objective of assessing the potential of TE to contribute to job creation and poverty alleviation in the province. Mining of TE started in 1803, but gained momentum during the 1960s. Mining is conducted on a small-scale basis, and in most cases without any legal framework. The majority of the residents are not benefiting from TE. It has been reported that an estimated R700 000 to R800 000 worth of TE is leaving the country every week through illegal trading. The potential for TE mining to contribute to socioeconomic development is hindered by illegal operations, lack of technical skills and knowledge, exploitation by dealers, lack of market information, community rivalries, and absence of value addition. A multi-stakeholder approach is needed to formalize the sector and reap the benefits. Mintek is spearheading a TE project in the Prieska area of the Northern Cape, which aims to establish a gemmological centre where TE can be beneficiated into saleable and high-value products..

Jan 1, 2014

By M. Olalde, I. Watson

"The consequences of ineffective mine closure in South Africa are evident from the number of abandoned mines and operations on extended care-and-maintenance, the on-selling of mines to less well-resourced companies to close, and increasing illegal mining activities. However, the data to substantiate these observations and provide insight into the underlying issues has not been available. Through the Promotion of Access to Information Act, a list of mine closure certificates applied for between 2011 and 2016 and a list of certificates granted over the same period for all nine regions of South Africa was obtained. From the analysis of this data, we show that the mine closure system as implemented in South Africa is largely ineffective. Although closure certificates are being granted, these are for prospecting sites and small-scale mines, which have a relatively small environmental impact. No large mines of any environmental significance were relinquished over the period under review, with very few applying for closure certificates. Furthermore, the issuing of closure certificates varies significantly between regional offices, with the success rate for applications being generally low and issuing of certificates taking an extended period. IntroductionThere are a number of concerns with the mine closure process as practiced in South Africa, and these have largely been laid at the door of government. Alberts et al. (2017) stress that the legislation generally conforms to international best practice. However, the system is ‘complex and unwieldy’, involving various pieces of legislation and different government departments with overlapping requirements and different interpretations of the law. A further area of concern is the capacity and competence of government to implement legislation. The ‘shortage of relevant mine closure skills and knowledge within the regulator’ was identified by van Druten and Bekker (2017) as a key contributor to unsuccessful closure. Lack of capacity and resources within the regulator has also been highlighted by Botham, Kelso, and Annegarn (2011) and Milaras, McKay, and Ahmed (2014). A recent study of the mineral application process by Corruption Watch (2017) indicates that positions in the regulator have been frozen for many years, leading to a shortage of staff, and that unqualified individuals have been appointed. There is also the perceived reluctance of government to grant closure in order to limit transfer of the liability to the state and delay the inevitable job losses."

Jul 1, 2019

By K. Ford, R. Urquhart, D. Hobbs

CIS countries are home to some of the world's largest producers of chrome, manganese and silicon ferro alloys and leading suppliers to world export markets. The region's ferro alloys production is rising faster than demand from its domestic steel industry - unit alloy consumption in domestic steelmaking is in fact falling as process efficiencies improve - and there is significant spare capacity available to increase production. CIS producers enjoy certain strategic advantages in the production of ferro alloys - for example, captive ore sup-plies, low power and labour costs - but must also meet certain challenges - such as lower labour productivity and greater distance to market than some of their competitors. CIS producers are ambitious but new investment is needed to upgrade some aging plants and overhaul outdated process technologies if they are to be more competitive with the world's leading producers and address the environmental issues that are now moving up the agenda. This paper describes the structure of the region's ferro alloys industry and discusses its advantages and disadvantages by alloy and by country. It considers how the ongoing process of restructuring and new investment in the industry might move forwards, based on its strengths and weaknesses, technical and environmental factors and the strategies of the main players. It asks how the industry might maximise its substantial potential - in particular, for the production of chrome and manganese ferro alloys - and examines the implications this holds for all global ferro alloys players.

Jan 1, 2007

By J. Roodt

Paper written on project work carried out in partial fulfilment of B. Eng (Metallurgical Engineering) degree This work was done to characterize the leaching of a uranium containing pulp processed by a South African producer to identify parameters that could be adjusted to increase the extraction of uranium in the existing circuit. Batch leach tests were used to characterize the leach properties and especially the influence of the oxidant concentration on the leaching achieved. It was found that relatively high extraction could be obtained even at room temperature by using a high liquid-to-solids ratio and that increasing the oxidant concentration significantly improved the leaching of the uranium minerals.

Jan 1, 2003

By K. Saito, Y. Miyauchi, T. Nishi, Y. Kizu

At Tokushima Plant of Nippon Denko Co., Ltd. high-carbon ferromanganese is produced by the electric furnace method using lump manganese ores and sintered manganese ores manufactured from fine manganese ores. However, the distribution of manganese ores is significantly uneven on earth, and their characteristics considerably vary by ore type. It is known from experience that the production of high-carbon ferromanganese by the electric furnace method depends greatly on material ores. Therefore, to maintain stable operation in the electric furnace-smelting field, it is important to identify the characteristics of each type of material ores in advance. Thus, we evaluated the high-temperature electric characteristics of manganese ores using the electrical conductivity measuring system developed by ourselves and provided the standards for determining ores and blending ratio necessary for stable operation of the electric furnace based on the evaluation results. This time we worked for optimisation of the high-temperature electric characteristics of sintered manganese ores through modification of the characteristics because the blending ratio of sintered manganese ores in the electric furnace is high. The electrical conductivity of sintered ores having various chemical components in a high-temperature region (up to 1 550°C) was measured using our electrical conductivity measuring system and high-temperature electric characteristics evaluating method reported at INFACON 9. As the result of the measurement, we revealed that the high-temperature electric characteristics of the sintered ores depend on their chemical contents and the sintered ores can be modified to those having excellent high-temperature electric characteristics by controlling their chemical contents, so that the resources can be effectively used.

Jan 1, 2004

By W. J. Theron

The purpose of the paper is to give an introduction to the concept of fatigue and its causes in the mining industry. By knowing the fundamental role it plays, together with its dynamics, can positively contribute to a mine?s safety management system. The difference between physical and psychological fatigue will be addressed with a possible range of causes that could trigger fatigue. There are two main sources of fatigue: firstly, work-related fatigue which is associated with activities at the workplace; and secondly non-work-related fatigue. The shared responsibility between the employer and employee is also discussed as it involves factors that occur both in and outside the workplace. Employers have the responsibility to manage fatigue through using a risk management approach. Employees have the responsibility to ensure they get enough sleep, take sufficient and regular nutrition, are healthy and physically fit and come to work fresh and alert. The impact of the implementation of a fatigue management plan and procedures has the potential to eliminate employee fatigue or its causes, reduce the likelihood of fatigue occurring in the workplace, and counteract the effects of fatigue when it occurs. Factors considered when implementing a fatigue management system include: extended hours of work, shift work, time of day and work design. Fatigue is one of the major role players (either causal or contributory) when it comes to causes of fatalities in the mining industry. Our main challenge in identifying whether fatigue played a role is the fact that it cannot be tested in post-mortems like drug or alcohol abuse. It is an aspect worth understanding and getting an organization sensitive to managing it properly to benefit both organizational as well as employee needs. Keywords Signs of fatigue: Causes of fatigue, circadian rhythms, the fatigue equation, fatigue management, fatigue affecting safety, fatigue fighting tips, lifestyle suggestions.

Jan 1, 2011

By D. K. Chibwe, P. Taskinen

"This investigation consists of a numerical and physical modelling exercise on flow patterns, mixing, solid-liquid mass transfer, and slag-matte phase distribution in a 0.2-scale cold model of an industrial Peirce-Smith converter (PSC). Water, kerosene, air, and sintered benzoic acid compacts were used to simulate matte, slag, injected gas, and solid additions into the PSC. The 2D and 3D numerical simulations were carried out using volume of fluid (VOF) and realizable k-e (RKE) turbulence models to account for the multiphase and turbulence nature of the flow respectively. These models were implemented using the commercial computational fluid dynamics numerical code FLUENT.Numerical and physical simulations were able to predict, in agreement, the mixing and dispersion characteristics of the system in relation to various blowing conditions. Measurement of mass transfer indicated that fluid flow in the PSC is stratified. Blowing configurations and slag volume both had significant effects on mixing propagation, wave formation, and splashing.As a potential process alternative to increase conversion efficiency, we propose a combined blowing configuration using top lance and lateral nozzles. The numerical simulations were conducted on combined as well as lateral blowing conditions, and the results of the combined concept are encouraging."

Jan 1, 2015

By Luthie Els, Chris Coetzee, Roedolf Koekemoer, Casper Els, Olof Vorster, Frank Fereday

Three electric arc furnaces (EAFs) were constructed by Union Carbide at Tubatse Ferrochrome (TFC) in1975. This plant was expanded to four furnaces at the East Plant in 1985 and the gas cleaning system was enlarged without taking flow dynamics into consideration. In order to improve competitiveness, TFC has increased furnace capacity, partially substituted coal for coke, and changed the charge mix. These changes increase the heat and dust load into the air pollution control (APC) system. TFC embarked on a project to improve the APC capacity by: ?Quantifying the required off-gas capacity ?Optimising the aerodynamic flow through the system by means of Computational Fluid Dynamics (CFD) ?Converting the old Brandt Koyo top entry baghouses to bottom entry ?Upgrading the cleaning system ?Installing Gore-tex® ePTFE membrane filter bags The estimation of required off-gas capacity is traditionally done by rule-of-thumb methods such as specific extraction. A more elegant evaluation method was developed for simulating the effects of changes in charge mix on the furnace reaction gas volume and the APC system. Reaction gases are calculated by modelling the reactions taking place in the furnace and off-gas volumes are compared to both fan and baghouse capacity. This enables identification of bottle-necks in the off-gas system. CFD techniques were utilized to evaluate geometric imbalances and propose solutions to ensure optimal use of off-gas capacity. The system modifications were completed over several months and the modified equipment went into service in May2006.

Jan 1, 2007

By V. Coetzee

In 1992, a paper was compiled highlighting a common-sense approach to electric smelting at Impala Platinum. Since then, the smelter complex has undergone considerable changes. Mineral economics, UG2 exploitation, and changing environmental legislation have enforced numerous process upgrades, yet a common-sense approach has always been adopted. This document details the major changes in the smelter complex at Mineral Processes (Minpro) over the past 15 years, and provides the rationale for the changes. Keywords: Pyrometallurgy, furnace, PGM, platinum, nickel, copper, electric smelting, six-in-line, Peirce-Smith, Impala Platinum.

Jan 1, 2006

By J. Engelbrecht

South Africa?s re-entry into the fast moving and competitive global economy calls for some careful strategic planning and a good deal of co-operation between suppliers and end-users. The issues that need addressing are generally well known and include: ?South Africa was ranked 45th out of 46 i.r.o. productivity ?SMMEs contribute 1% to exports compared to 40-60% for the ?tigers? ?High unemployment ?Limited skills of the majority of workers ?Slow growth rate of the economy ?The vast majority of suppliers are not world-class ?The vast majority of suppliers are not export or marketing orientated. In order to survive, all parties, i.e. government, labour and business, will have to play their part.

Jan 1, 1999

By A. Mboma

Keywords: Furnace, decommissioning, care and maintenance, re-start, funding, nickel Bindura Nickel Corporation (BNC) operates two nickel mines, and treats concentrates from these mines as well as toll concentrates from the region around its Bindura Smelter and Refinery (BSR) complex. At the smelter, concentrates of at least 5% nickel content are blended and dried to 4% moisture in a coal-fired rotary kiln. Matte smelting of concentrate is carried out in a six-in-line electric arc furnace, where the furnace slag is granulated and discarded. Furnace matte is transferred via ladles into Peirce-Smith converters, where, after granulation, a leach alloy containing 68%Ni, 20%Cu, and 6%S is produced. Converter slag is recycled via the matte-smelting furnace. The onset of the global economic recession towards the end of 2008 resulted in a collapse of metal prices, worsening the local situation that was already marred by unfavourable macro-economic conditions in Zimbabwe. As a result, BNC mines were put on care and maintenance in November 2008, followed by Bindura Smelter and Refinery in February and March 2009 respectively. The business environment has since changed, and BNC is getting ready to re-start the plant. This paper describes the decommissioning of the Bindura furnace, asset preservation during the care and maintenance programme in the past two years, and preparation for starting up of the Bindura smelter in the near future.

Jan 1, 2011

By Merete Tangstad, Kai Tang

The primary aim of the present investigation is to develop a model which permits to calculate/predict the viscosities of ferromanganese slags, typically focus on the MnO-SiO2-Al2O3-CaO-MgO-FeO multicomponent system. The present viscosity model emphasizes the ability of prediction, i.e. using the binary parameters to extrapolate the viscosities in ternary and higher order systems. To this end, a physical sound model is essential. Temperature dependence of viscosity is described by the Eyring?s formalism. The well-known cell model is used to define the SiO44- tetrahedra in the silicate melts. Composition dependence is expressed in term of viscous activation energy, which is characterized by the binary structural units. The viscosities in ternary and higher order systems are hence predicted using the binary activation parameters. The model has been used to calculate the viscosities in the whole liquid composition range of ferromanganese slag.

Jan 1, 2007

By R. Dekkers, J. Plessers

The feasibility of using hydrogen to obtain clean steels is investigated. High hydrogen contents are generally considered as detrimental due to the risk of flakes, bubbles and breakouts during casting. Hydrogen can nonetheless be removed by degassing of the steel. The results of industrial campaigns, where total oxygen content and hydrogen content were monitored, are presented. High resolution microscopy of inclusions and laboratory experiments on the rate of inclusion removal by CaO-Al2O3 slags at different partial hydrogen have been carried out. So far, evidence that hydrogen may influence inclusions or the steel cleanliness is not clear. Keywords: hydrogen, cleanliness, inclusions.

Jan 1, 2004

By Q. G. Reynolds

DC arc furnaces are widely used for steel scrap melting, and are increasingly being used for smelting applications as well. The electrical resistivity of slags varies widely, from highly conductive slags in ilmenite smelting, to highly resistive slags in applications such as cobalt recovery from non-ferrous slags, and nickel laterite smelting. Models have been developed to predict the electrical behaviour of the DC open plasma arc and the molten slag bath. These models allow the voltage and current ranges of furnace power supplies to be specified.

Jan 1, 2004