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By Godofredo F. Barrios

For years urethane screen surfaces have been used in a wide range of wet screening applications where openings from as fine as 100 microns and coarser have been used. The purpose of this paper is to expose the reader to new developments in both screen surface and screening equipment technologies which allow an end user to consider urethane screen surfaces for fine screening applications. These technologies allow an end user to use the inherent advantages of urethane with regards to wear resistance while also realizing the benefits that a high oper area urethane screen surface can bring. These benefits include non blinding characteristics and feed capacities that which rival that of traditional stainless steel surfaces. The paper will highlight the features of this patented urethane screen surface technology and the screening machines they are used in conjunction with. There will also be a presentation of case studies of commercial installations where these technologies are utilized. These case studies are from the base metals industry therefore relevance to the conference is direct and not inferred. Included in the paper will also be constraints which must be taken into account when considering urethane screen surfaces such as temperature and chemical attacks. This paper will expose potential end users to a possibility of using screens to achieve extremely accurate size separations in applications where screens were previously not considered. The paper will explain and demonstrate that prior concerns of screen surface blinding, high screen surface consumption rates and large screen surface area requirements can be eliminated by proper utilization of high open area urethane screen surfaces.

Jan 1, 2007

By C. J. Badenhorst

Oxides of sulphur are corrosive and are produced when sulphur-containing fuels are burned. Sulphur dioxide (SO2) is a colourless gas with a characteristic, irritating, pungent odour. Exposure routes to the human body are mainly through inhalation and skin and/or eye contact. Symptoms of exposure to SO2 may include irritation of the eyes, nose, and throat; rhinorrhea (discharge of thin nasal mucous); choking; cough; and reflex bronchoconstriction. To protect employees against the ill health effects of SO2 exposure, they are often required to make use of respiratory protection whenever entering areas were the SO2 levels exceed the statutory limits. The use of respiratory protective equipment should always be a last resort and should be considered only after other control measures have failed to reduce occupational exposure levels to below the occupational exposure limit or whilst other control measures are being investigated or implemented. Whenever the use of respiratory protection equipment is considered, it should always be used as part of a comprehensive respiratory protection plan. It is also extremely important that all potentially exposed persons are adequately and comprehensively informed and trained.

Jan 1, 2007

By F. Enslin

Heavy metals and sulphates in acid mine drainage (AMD) can beadsorbed onto bentonite clay, leaving clean water and a heavy metal loaded clay precipitate as products. Due to the toxicity of heavy metals, the clay could not be disposed of safely in the past. A method was thus required to remove the heavy metal content from the clay. Acid leaching was proposed to liberate the heavy metals from the loaded clay. Sulphuric, nitric and hydrochloric acid were considered as lixiviants. Loaded clay samples were leached over a range of pH values from 1 to 3.5 to identify an optimum leaching condition. From the results it was found that metals can berecovered from loaded bentonite clay by means of acid leaching and the optimum pH for heavy metal liberation was found to be 2.5, with uranium as an exception, being optimally leached at a pH of 3. This allows for the possibility of selective leaching. Furthermore, X-ray diffraction analyses indicated that the clay structure did not deteriorate significantly during acid leaching, suggesting that the bentonite could be reused. The treatment of AMD with bentonite clay, and subsequent acid leaching of the clay, is a sustainable solution, and current outcomes could possibly lead to industrial implementation of the process during water purifying and metal recovery from waste streams. Keywords: Acid mine drainage, bentonite, heavy metals.

Jan 1, 2010

By F. Cihangir, A. Kesimal, K. Karaman, B. Ercikdi

Uniaxial compressive strength (UCS) and shear strength parameters(cohesion and angle of internal friction, Cand F) of rocks are important parameters needed for various engineering projects such as tunnelling and slope stability. However, direct determination of these parameters is difficult and requires high-quality core samples for tests. Therefore, this study aimed to explore the applicability of the Brazilian test (BT) - a simple, less sophisticated and inexpensive method for both specimen preparation and testing - to estimate the UCS and shear strength parameters of rocks. Thirty-seven rock types were sampled and tested, 24of which were volcanic, 8 were metamorphic, and 5 were sedimentary. Statistical equations were derived to estimate the UCS and shear strength parameters of rocks using the BT. The validity of the statistically derived equations was confirmed using predictive analytics software (PASW Statistics 18). A strong linear relation was found between BT and UCS values. BT and UCS values exhibited prominent linear correlations withthe cohesion values of rocks. The Mohr envelope was also used to determine the cohesion and friction angle of rocks using BT and UCS values. It is deduced from the current study that the BT values can be used to estimate the UCS and cohesion. However, no relation was observed between the angle of internal friction values and the UCS and BT for all rock types. Therefore, different approaches are suggested for the estimation of the internal angle of friction for application in the preliminary design of projects.

Jan 1, 2015

By G. L. Smith

As the Platinum mining industry expands in the Eastern Limb of the Bushveld Complex it is increasingly evident that a major constraint to development is a lack of appropriate infrastructure. Of critical concern are water resources and spatial development / infrastructure. This paper identifies the context for infrastructure development in the Eastern Limb and two solutions that have evolved in the areas of water supply and spatial development. INTRODUCTION In an economics context, infrastructure is considered to be the structural elements of an economy which allow for the production of goods and services, without themselves being part of the production process. Despite the lack of a specific definition, infrastructure has largely become understood as to comprise road and rail transport systems, public transport systems, airports, public educational facilities, water supply and water resources, wastewater management, solid waste treatment and disposal, electric power generation and transmission, telecommunications and hazardous waste management systems. Critically it is important to understand that infrastructure not only comprises these physical elements but also the operating procedures, management practices and developmental policies that facilitate the effective utilization and development of the infrastructure in response to societal demand.

Jan 1, 2008

By Sverre Olsen, Kai Tang

The composition of ferromanganese slag is very important as it determines the slag/metal equilibrium relations including MnO content of final slag, melting relations and slag viscosity. The slag composition is further expected to influence the process temperature. The properties of ferromanganese slags are suitably described by its basicity and A/S mass ratios. The influence of slag basicity has been discussed in the previous papers. The present paper will discuss the effect of Al2O3 on melting relations, viscosity and MnO-content of final slag. This discussion will be based on assessed thermochemical databases and a recently developed viscosity model.

Jan 1, 2007

By M. G. Wimberger

The Merensky Reef zone, as developed on Impala Platinum?s Rustenburg Operations, displays a gradational mineralized zone, with grades decreasing from the Merensky Pegmatoid Unit into the footwall and hanging wall. A system of identifying a manageable method of defining the mining cut is introduced, termed the grade profile attenuation cut-off grade. Although horizontal grade selectivity is not applied in the mining of the Merensky Reef zone, low extraction of the orebody, due to manageable and non-manageable factors, can contribute to a reduction in revenue, even losses, due to fixed cost contributions in the mining and beneficiation of the ore. A model is proposed that integrates all variables affecting the revenue of the mining operation, including the grade profile attenuation cut-off grade, the extraction factors, commodity prices and exchange rates, utilizing numerical simulation techniques in a PC-based environment. A breakeven extraction factor for a specific cut-off grade is delivered for a range of market conditions. The breakeven extraction factor is a useful guide when designing mining layouts in structurally complex and low metal content areas. Incorporating distribution functions for individual commodity prices and exchange rates into the model provides mineral resource managers with a risk profile for individual mining areas. Shaft areas have varying grade profiles and each area should have individual models run, to prevent generalizations being made about acceptable risk levels on mining areas.

Jan 1, 2004

By B. Larsen, S. Z. Nascimento, K. Fidje, J. P. M. Amaro, H. Gran

Safe and good operation of Søderberg electrodes is dependent upon high quality electrode paste coupled with correct electrode operating procedures. Good electrode performance depends further on proper melting and densification of the electrode paste. The melted paste should form a dense and viscous layer that prevents gasses from the baking process to move upwards. Both paste cylinders/blocks and briquettes can be used, but the procedures may differ between the various types of paste products. For briquette columns the formation of the important viscous layer is obtained through melting and densification of the briquettes. By basic rheological studies of electrode paste and by laboratory tests of briquette beds at isothermal conditions we have achieved a better understanding of the melting process. The effects of temperature gradients, pressure and friction between the briquettes and the electrode casing have also been evaluated qualitatively in pilot scale experiment and in industrial scale tests. The paper shows that melting and densification starts at a considerable lower temperature than the pitch softening temperature. It is concluded that the formation of a briquette electrode column depends on parameters as temperature, briquette column pressure and the friction. Operating conditions influencing the above parameters should be defined and established for each specific furnace operation. Such factors are e.g., charging and slipping procedures, column heating and electrical conditions.

Jan 1, 2004

By A. K. Singh, R. Singh, P. K. Mandal

On the basis of in situ study of pillar loading at different sites, an attempt is made in this paper to visualize the development of mining induced stress under varying geo-mining conditions. Field study demonstrated interesting interaction between size of pillar and nature of roof rock mass under the influence of increasing dimension of the excavation. Stiffness of pillars/overburden, extraction ratio and depth cover are observed to be the important parameters for the estimation of mining induced stress over the pillar. These parameters influence, both, the value of ultimate induced stress (vertical) and its range of influence ahead of the face line. Further, it is observed that the change in width/height (w/h) ratio of a pillar has got considerable influence over the nature of mining induced stress over it. Impact of highly dynamic nature of mining induced stress over the natural supports is observed to be the most serious factor for the safety of working under a hard and massive roof rock mass. On the basis of these observations, a conceptual model of interaction between the natural support and overlying strata is discussed in the paper. ZUSAMMENFASSUNG: Aufgrund ist in situ Studium von Säule Beladung an verschiedenen Stellen, ein Versuch in diesem Papier gemacht, die Entwicklung des Bergbaus vostellen sich, Spannung unter Änderung von Geo Bergbau von Bedingungen hat veranlaßt. Feld Studium hat interessante Wechselwirkung zwischen Größe von Säule und Natur von Dach Felsen Masse unter dem Einfluß von Vermehrung Dimension des excavation vorgeführt. Steifheit des Säulen Overburden, Herausziehung Verhältnisses und Tiefe sind beobachtet bedeckt, die wichtigen Parameter für die Schätzung des Bergbaus zu sein, Spannung über der Säule hat veranlaßt. Diese Parameter beeinflussen, beide, der Wert allerletzter veranlaßter Spannung (senkrecht) und sein Bereich des Einflusses voraus von der Gesicht Linie. Weiter ist, es beobachtet, daß die Änderung in Breite Höhe (W H) Verhältnis einer Säule beträchtlichen Einfluß über der Natur des Bergbaus erhalten hat, Spannung hat darüber veranlaßt. Schlag sehr dynamischer Natur des Bergbaus ist Spannung über den natürlichen Stützen beobachtet hat veranlaßt, der ernsteste Faktor für die Sicherheit des Arbeitens unter einer harten und massiven Dach Felsen Masse zu sein. Aufgrund dieser Beobachtungen, ein begriffliches Modell der Wechselwirkung zwischen der natürlichen Stütze und der überlagernde strata ist im Papier diskutiert. RESUME: En se basant sur dans l'étude de situ de chargement de pilier aux sites différents, une tentative est faite dans ce papier pour envisager le développement de creuse la tension persuadée sous varier de conditions de geo creuse. L'étude de champs a démontré l'interaction intéressante entre la taille de pilier et la nature de masse de rocher de toit sous l'influence d'augmenter de dimension de l'excavation. La raideur de piliers overburden, la proportion d'extraction et la couverture de profondeur est observée pour être les paramètres importants pour le jugement de creuse la tension persuadée par-dessus le pilier. Ces paramètres influencent, les deux, la valeur de tension persuadée ultime (vertical) et sa gamme d'influence en avant de la ligne de face. Plus, il est observé que le changement dans la largeur hauteur (le w h) la proportion d'un pilier a reçu l'influence considérable par-dessus la nature de creuse la tension persuadée par-dessus il. L'impact de nature extrêmement dynamique de creuse la tension persuadée par-dessus les soutiens naturels est observé pour être le facteur le plus sérieux pour la sûreté de fonctionnement sous une masse de rocher de toit dure et massive. En se basant sur ces observations, un modèle conceptuel d'interaction entre le soutien naturel et les couches recouvrant est discuté dans le papier.

Jan 1, 2003

By J. W. Klokow, K. L. Riemer, R. I. L. Ferreira

As a result of the increased depth of mining in the South African gold mining industry mining induced seismicity is a severe problem. One of the strategies within the industry to contain the problem is to incorporate a system of regularly spaced stabilising pillars into mine layouts. At the Driefontein Gold Mine a system of closely spaced dip pillars is used to contain seismic energy emissions. Comparisons of seismic data for several mining clusters initially indicated a possible measure of success in the containment and occurrence of larger events. A detailed analysis of data over a 5-year period since the start of mining however, has revealed a delayed seismic response to the increasing strike spans. Significant changes marked by an increase in certain seismic variables have been observed at mining spans of between 100 to 120 meters and could be of significance to pillar spacing in the design of deep level mining layouts. La sismicité occasionnée par l’exploitation minière est un problème grave dans les mines profondes de l’industrie minière aurifère en Afrique du Sud. Une des stratégies utilisées dans l’industrie a été de maîtriser le problème en incorporant un système de piliers de stabilisation régulièrement espacés dans la disposition des mines. A la Driefontein Gold Mine, un système de piliers de pendage proches les uns des autres est utilisé pour contenir les émissions d’énergie sismique. Au début, des comparaisons de donnés sismiques pour plusieurs groupes d’extraction ont indiqué un succès possible dans la limitation et l’occurrence d’évènements sismiques. Cependant, une analyse détaillée des données sur une période de 5 années a révélé un délai entre la progression de l’extraction et une réponse sismique accrue. Des changements considérables dans les variables sismiques ont été observés dans des intervalles d’extraction entre 100 et 120 mètres, ce qui pourrait être significatif pour l’espacement des piliers dans la conception de la disposition des mines de fond. Resultierend aus den zunehmenden Tiefen des Bergbaus in der südafrikanischer Goldbergbauindustrie stellt sich die vom Bergbau hervorgerufene Seismizität als bedrohliches Problem dar. Es war eine der Strategien innerhalb der Industrie, das Problem dadurch einzudämmen, daß regelmäßig plazierte Stabilisierungspfeiler in den Bergbaulayouts inkorporiert wurden. In der Driefontein Gold Mine wird ein System von knapp aneinandergesetzten im Abfallbereich befindliche Pfeiler benutzt, um seismische Energieemissionen einzudämmen. Vergleiche der seismischen Daten für mehrere Bergbaugruppen zeigten anfangs ein mögliches Maß von Erfolg in der Eindämmung und im Auftreten von größeren Fällen an. Eine ausführliche Analyse von Daten über einen 5jährigen Zeitraum hat jedoch ergeben, daß eine Verzögerung zwischen der Progression des Bergbaus und einer erhöhten seismischen Reaktion besteht. Bedeutende Änderungen in den seismischen Variablen wurden an Bergbauspannen von 100 bis 120 Metern beobachtet und könnten für Abstandsbemessung von Pfeilern im Design des Tiefbergbaulayouts von Bedeutung sein.

Jan 1, 2003

By O. A. Olaseinde

The 2101 lean duplex stainless steel has wide potential application in storage, heat exchangers, and in the oil and gas industries. This work investigates the electrochemical behaviour of 2101 duplex stainless steel with an addition of 0.15 wt% ruthenium, using potentiodynamic techniques in 1M H2SO4 at 25º, 40º, 60º, and 80ºC. The microstructures of samples were characterized using optical metallography and scanning electron microscopy. The results showed that the ruthenium addition moved the corrosion potential of alloy 2101 to a more positive potential. All samples containing ruthenium displayed longer passive regions at 25°C and 80°C compared to those without ruthenium. Alloys without ruthenium had higher critical current density (icrit) values when compared to the alloys with ruthenium. Ruthenium additions decreased the passive current densities and inhibited anodic dissolution. At room temperature the corrosion rate of alloys with ruthenium was lower than these without ruthenium.

Jan 1, 2012

By G. Denton, P. den Hoed, A. Luckos

The potential application of fluidized beds in several sectors of the ferroalloy industry is promising. They can be used in the direct reduction of iron ores to produce a feed for steelmaking, in the reduction of manganese dioxide to produce a lesser oxide for feeding to smelters, in the preheating of chromite for the production of ferrochrome, and in the calcining and pre-reduction of nickel laterites for the production of ferronickel. This paper discusses the potential of fluidized beds in theses processes and highlights the advantages of the technology over other technologies, such as rotary kilns. Two primary advantages?(1) that fluidized beds can treat fine materials and (2) that fluidized beds can be integrated with smelters in a way that allows for more efficient use of energy?may well see the technology gain prominence as more deposits of lower grade are mined and industries strive to use their resources more efficiently. In discussing the potential of the technology in the ferroalloy industry, this paper focuses on the application of fluidized beds in the smelting of chromite, nickel laterites, and manganese ores. Central to the successful operation of this technology is a knowledge of how particle properties influence the behaviour and design of fluidized beds.

Jan 1, 2007

By L. M. Sekhukhune

The atmospheric leaching of copper-bearing matte by acidic ferric chloride solution was studied at the laboratory scale. The aim was to achieve maximum copper and nickel recovery by investigating the mechanisms of leaching, as well as identifying the effect of temperature, and concentration of ferric chloride and oxygen. Djurleite (Cu1.96S), hazelwoodite (Ni3S2), and Ni alloy were the primary phases detected in the matte. The quantitative composition of the matte was Cu 31%, Ni 50%, S 13%. Fe and Co constituted 2%, with platinum group metals (PGMs) accounting for 0.5%. A maximum nickel extraction of 98% was achieved using two-stage oxidative leaching at 90°C and 11 g/L Fe3+ as compared to 65% under non-oxidative conditions. A copper extraction of 99% was achieved in the first 45 minutes using two-stage non-oxidative leaching, and copper was recovered from solution by cementation. Three processes took place simultaneously throughout the leaching process, namely: dissolution, cementation/ metathesis, and oxidation. The leaching process was found to be diffusioncontrolled.

Jan 1, 2014

By Jo Katembo, Patty Bwando, Patient K. Ilunga, Yves Kalubi, Emman Mulaj

"From 2010, the dolomite concentration in the ore fed to the Usoke Plant increased, resulting in a significant increase in the gangue acid consumption and Mg build-up in the circuit, and thus an increase in the Mg:Co ratio in the plant solutions. This affected the Co salt grade, reagent consumption, filtration and drying capacity. Efforts were put in place to minimise the acid consumption and consequently the Mg dissolution (such as use of pre-diluted acid), but the benefits were negligible. Various efforts were then initiated by CHEMAF to improve the cobalt plant productivity (quantity and quality) by process changes, dual precipitation and seed recycle. The positive results obtained in the laboratory were successfully implemented on plant scale. A change in the process from a single-stage precipitation with Na2CO3 to dual precipitation using a combination of Na2CO3 and NaOH improved the capacity of the Co salt filtration by 30%, the Co salt grade and drying capacity by 50%, and reduced the reagent consumption by 22%. Implementation of precipitate seed recycle increased Mg rejection by 40%, improving the Co salt grade from 20% to 25%, and yielding a further drop in reagent consumption. INTRODUCTION CHEMAF (Chemicals of Africa), a mining company located in Katanga province of Democratic Republic of Congo (DRC), has been operating since 2003. The Usoke hydrometallurgical plant treats the Cu-Co ore from the Etoile pit to produce Cu cathodes via a leach–solvent-extraction (SX)–electrowinning (EW) circuit and Co salt via a selective precipitation process. The plant was designed to treat run-of-mine (ROM) ore grading 6% Cu and 1.5% Co; but, in 2008, due to a decline in grades, a heavy-media separation (HMS) plant was commissioned to enrich the low-grade ROM (3.5% Cu and 0.5% Co) up to 8% Cu and 1% Co before feeding it to the hydrometallurgical plant. Co is recovered by precipitation of Fe and Al with limestone, followed by Co precipitation as Co carbonate using sodium carbonate (Na2CO3), also known as soda ash. 85% of the final effluent from cobalt precipitation is recycled back to the plant as process water; the balance, 15%, is bled out and compensated for by fresh water top up to control and retard the rate of sodium sulfate build up."

Jan 1, 2015

By G. de B. van Niekerk

This paper briefly outlines some mining technology that is used with success in Australia but is not yet fully utilized in South Africa. The following aspects are discussed: improved rotary-drill bit performance, use of trucks and load haul- dump units underground, long-hole raising, blasting techniques, and the use of butterfly roofbolt plates for support.

Jan 1, 1989

By K. Yathavan

Fracturing of rock at low stress levels can be a source of unexpected problems in rock engineering: • the resulting instability can be a safety hazard; • in very brittle rocks it may be associated with violent failure of the rock and strainbursting (rockbursting); • it usually leads to an unexpected requirement for rock support, with time and cost implications; • in rock boring projects, it may result in fracture of the rock ahead of the bored face and in the walls of the bore behind the face. This may lead to cutter head vibration, increased cutter wear and consequently decreased performance and increased costs. Examples of situations in which fracturing of rock at very low stress levels has been observed will be described. This will include details or estimates of the in situ stress magnitudes and the rock strengths involved. La brisure de roche sous faibles contraintes peut être l’origine de problèmes inattendus en génie minier : • L’instabilité résultante peut devenir un danger • Elle peut provoquer des éclatements violents des roches fragiles • Elle nécessite souvent une infrastructure de soutien de la roche, ayant des implications sur les coûts et les délais • Les forages de la roche peuvent provoquer une brisure de celle-ci au niveau de la surface forée mais ainsi à l’intérieur de la roche, causant parfois des vibrations et une fatigue de la tête de forage, induisant une baisse de performance et un accroissement des coûts. Nous avons décrit ci-après des exemples de situations de brisure de roche sous faibles contraintes. Cette description comprend des détails ou des estimations des forces et des contraintes impliquées. Cette étude représente la base du travail de recherche effectué sur le phénomène. ißbildung im Gestein unter niedrigen Stressbedingung kann eine mögliche Ursache sein für unerwartet auftretende Probleme in der Felsmechaniklehre: • Die resultierende Instabilität stellt ein mögliches Sicherheitsrisiko dar; • In sehr sprödem Gestein kann es verbunden sein mit einem plötzlichen und gewaltsamen Zerfall des Gesteins; • In den meisten Fällen ist eine nicht eingeplante Gesteinsabstützung erforderlich, und damit ein Zeit- und Kostenaufwand verbunden; • Bei Bohrungsprojekten kann es dazu führen, daß es während des Bohrvorganges zu einer Rißbildung im Gestein hinter und vor der gebohrten Felswand kommt. Dies kann Bohrkopfvibrationen, eine erhöhte Bohrkopfabnutzung und folglich eine Bohrleistungssenkung, sowie Kostenerhöhung zur Folge haben. Das Phenomen von Gesteinsrißbildung unter niedrigen Stressbedingung wird anhand von einigen dokumentierten Beispielen erörtert. Diese beinhalten zudem Details oder Schätzungen bezüglich der Stärke des in situ Stressfeldes, sowie der gegebenen Gesteinsstärken. Die mit diesem Beitrag dokumentierten Ergebnisse formen eine Grundlage zur weiteren Forschung dieses Phenomens.

Jan 1, 2003

By Mark Coleman

Pnuematic Conveying and Process Injection Technologies have been implimented in the metals markets for the last 40 years and have consideribly improved the productivity and the performance of many processes. There have been many steps forward in handling technology and this paper seeks to consider those now offered by Clyde Materials Handling who as an established customer-driven solutions provider, which has turned its attention to supporting the Metals Market. Clyde seek to utilises its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries. With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets. Operators within the metals market have developed and deployed pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustain-able solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes. Operators, such as Codelco in Chile, Corus Steel in the UK, and many others across the World have seen pneumatic injection solutions transform their process and costs. To inject a consistent, pulseless and accurate flow of material to a copper concentrate bath smelter, or injecting granular or pulverized coal as a coke substitute in to a blast furnace via the Tuyeres helps to increase the operational capacity, availability and productivity and reduce the cost of the operation. This paper will discuss and highlight the ways in which pneumatic conveying and injection technologies, created by Clyde Materials Handling, and applied in partnership with the customer, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Lead and Zinc Industries. With examples from Zinc Fuming in Australia, Zinc Calcine and Powder Handling in Korea, Precision coal injection to QSL and TSL Furnaces, and metered distribution of Zinc Calcine to Reactors.

Jan 1, 2008

By F. Bonnet, J. Lehmann, H. Gaye

A review of thermodynamic information and models of slags, including associated software when available, is presented. The pertinence and accuracy of these models is discussed by comparison of their predictions for various slag thermodynamic properties with the available experimental data. Practical industrial applications will be illustrated by a literature review of the dephosphorization process of ferromanganese alloys and by the description of Ti behavior during silico-manganese alloys production. This latter example will show how the thermodynamic models have been used to propose a flotation treatment at low temperature to enhance TiC removal.

Jan 1, 2004

By E. Dzingayi

Keywords: Pyrometallurgy, furnace, Bindura, nickel The smelter at Bindura Nickel Corporation processes concentrates from its own mines and other external sources. Concentrates are dried, smelted, and converted to a desulphurised matte (leach alloy) for further processing at the refinery. The smelter comprises a drying plant, submerged arc electric furnace, electrostatic precipitator, and three Peirce-Smith type converters capable of treating 150 000 tonnes of concentrates per year. Concentrates are dried in a rotary coal-fired kiln, blended with fluxes, and smelted in a six-in-line submerged-arc 15MW electric furnace. Slag is tapped and granulated for disposal, and matte is tapped at regular intervals for blowing in Peirce-Smith converters. The paper details the 37-year history of the smelter, including furnace rebuilds and operating parameters as they have evolved in response to changing feed compositions. Special challenges, particularly relating to the treatment of high talc concentrates, are also described.

Jan 1, 2006

By S W. Robertson, A Vercuil, P Craven

Mintek is currently developing a design approach for the heap leaching of low-grade primary copper sulphide material. Since the leaching of chalcopyrite requires elevated temperatures, the generation and management of heat within the heap is crucial. Furthermore, the precipitation of iron needs to be managed to prevent premature blinding of the heap, and acid consumption needs to be limited to contain cost and limit the dissolution of gangue impurities. Standard column tests using jacketed 1-m and/or 6-m columns do not allow accurate prediction of temperature changes and heat generation in an actual heap. Mintek therefore utilizes a computer model to calculate the energy balance and heat generation with time, based on the measured sulphide oxidation rates in the column. The temperature in the column is then adjusted to reflect the computer-predicted temperature in an actual heap. Using this approach, an overall copper extraction of 70% was achieved in 120 days, using 1-metre columns, when treating an ore blend containing 1.36% chalcopyrite, 0.23% chalcocite, 0.07% covellite, 3.8% pyrite and silicate gangue (92%). The chalcopyrite contribution to the total copper content in the feed was 75%. This was followed by 6-m columns using a similar approach, and the column results will be validated on a 23,000 tonne test heap. Key Words: heap; bioleach; chalcopyrite

Jan 1, 2005