M.Sc. / Bracketing the depositional age of the Gamagara/Mapedi to Lucknow and Olifantshoek succession in Griqualand West is important because it not only represents one of the oldest known red bed successions in the world but also hosts some of the first well preserved lateritic soil profiles and carbonates with heavy 13C values traditionally correlated with the so-called Lomagundi carbonate carbon excursion. In addition the ancient supergene very large high-grade hematite iron ore deposits of the Sishen-Postmasburg area on the Maremane dome are associated with the erosional unconformity at the base of the Gamagara Formation (a lateral equivalent of the Mapedi Formation). However, the depositional age of especially the Gamagara/Mapedi to Lucknow succession is under dispute because it has been considered a) correlative to the lower part of the Waterberg Group in the Transvaal area, with the implication that it is younger than the Bushveld Complex with an age of ~2,054 Ga, and b) correlative to the Dwaalheuwel-Magaliesberg succession of the pre-Bushveld Pretoria Group of the Transvaal Supergroup in the Transvaal area. The upper age limit of the Gamagara/Mapedi to Lucknow succession is defined by 1,92 Ga felsic volcanics in the overlying Neylan-Hartley succession of the Olifantshoek Group. The Hartley Lava Formation is overlain by Volop quartzites. This study involves age determinations of detrital zircon populations extracted from the basal Doornfontein conglomerate member of the Gamagara/Mapedi succession, and quartzites of the Gamagara/Mapedi, Lucknow, Neylan, Hartley and Volop Formations at various localities in Griqualand West. Based on field work, three unconformity-bound sequences are defined, namely the Gamagara/Mapedi-Lucknow, Neylan-Hartley and Volop sequences. Most interestingly quartzites of the Gamagara/Mapedi-Lucknow sequence contain abundant zircons with ages similar to that of the Bushveld Complex at ~2,054-2,06 Ga in addition to zircons as young as ~1,98-2,01 Ga. An exception is results on one sample of the Doornfontein Member analyzed so far (it is from the Rooinekke iron ore mine south of Postmasburg) that contains only zircons that are older than the Bushveld Complex with a rather prominent youngest population bracketed between 2,2 Ga and 2,32 Ga. The youngest detrital zircon populations in the Neylan-Hartley sequence are either slightly older than the Hartley lava or contain zircons with similar age to Hartley felsic lavas at 1,92 Ga. This sequence thus appears to have developed immediately prior to and coeval with Hartley volcanism. The overlying Volop sequence contains abundant zircons as young as ~1,89 Ga. The results clearly illustrate that the Gamagara/Mapedi to Lucknow succession is certainly not a lateral correlative of the pre-Bushveld Dwaalheuwel-Magaliesberg succession of the Pretoria Group. Rather it should be considered time-equivalent lower parts of the Waterberg Group in the Transvaal area. This implies that the heavy carbonate carbon excursion known from the Lucknow Formation is at least 100 my. younger than the one known from the upper part of the Silverton Formation along the contact with the overlying Magaliesberg Quartzite. There are thus at least three heavy carbonate carbon excursions, known from Paleoproterozoic cover successions of the Kaapvaal Craton in southern Africa, namely one in the ~2.35 Ga Duitschland Formation, a second in the ~2,1 Ga Silverton Formation of the Pretoria Group of the Transvaal Supergroup and the third in the ~1,98-1,92 Ga Lucknow Formation. It is further known that carbonates with normal open marine 13C values of close to zero occur in stratigraphic intervals between each of the heavy carbonate carbon excursions. The only unit that may still be correlated with part of the Pretoria Group is the Doornfontein Member at the base of the Gamagara/Mapedi succession. The correlation of this unit with the base of the Dwaalheuwel Formation and the Hekpoort paleosol of the Pretoria Group thus remain possible but analyses of additional samples are needed to make sure that the conglomerate, and by implication the ancient supergene Sishen-type iron ore deposits, does not also postdate the Bushveld Complex.

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The use of iron ore concentrate has become of interest as the demand for higher grade sinter feed is increasing. The fine nature of the concentrate however raises concerns as it can affect permeability during sintering which could have a drastic impact on sinter productivity. In this study the use of iron ore concentrate and micropellets as sinter feed was evaluated. Five mixtures containing different proportions of iron ore concentrate and micropellets, together with iron ore fines, were prepared. These mixtures were agglomerated through pilot scale sinter pot tests, followed by measuring the sinter strength, reduction disintegration and reducibility. Samples of the produced sinters were also subjected to XRF, XRD and SEM-EDS analyses for mineralogical analysis, and MF-XRT for sinter structure analysis. Granulation results revealed that the mixture containing 0% micropellets – 40% concentrate showed superiority in material transfer efficiency while the mixture containing 30% micropellets – 10% concentrate showed superiority in permeability. X-ray diffraction analysis (XRD) revealed an increase in hematite as micropellet content increased. The analysis also revealed high SFCA content for the 0% micropellet – 40% concentrate which decreased as micropellet content increased. This was mainly associated with a decrease in reactivity. Optical microscopy confirmed a large presence of SFCA and also revealed significant precipitation of magnetite and SFCA in the bonding phase structures of the high concentrate containing sinters. It also revealed a pronounced presence of acicular SFCA in the high micropellet containing mixtures. Scanning electron microscopy (SEM) and energy dispersion spectrometry (EDS) revealed a slight consistency in phase chemistry across the different sinter mixtures. This was mainly associated to similar chemical compositions of the starting mixtures. It also revealed that the micropellets maintained a hematite-silica core surrounded by a Fe-rich sintered matrix. It was further determined that the introduction of iron ore concentrate and micropellets did not significantly impact mechanical properties of sinter as similar tumble indices (TI) were observed. A slight variation in reduction disintegration index (RDI) was however seen with high micropellet sinters showing a larger degree of degradation compared to high concentrate containing sinters. Sinter reducibility (RI) also decreased slightly as micropellets increased and this was associated with the inability of micropellets to assimilate during sintering. It was therefore concluded that although micropellets and concentrate can be used as sinter feed, the optimum amount thereof was not yet determined. / Dissertation (MEng)--University of Pretoria, 2020. / Materials Science and Metallurgical Engineering / MEng / Unrestricted

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The demands for increasing the efficiency and lowering the environmental effects in iron and steelmaking industries have given rise to interests in application of direct reduction (DR) processes for production of iron by different gases. These advancements require comprehensive models for better control of the process conditions and the product properties. In the present thesis fundamental aspects in reduction of iron oxide were investigated. The experimental studies on reduction of iron oxide pellets were performed under well-controlled conditions in a setup designed for thermogravimetric investigations. The results indicated that the reaction rates by the applied procedure are higher compared to the procedure similar to conventional thermogravimetric analysis (TGA). This difference was caused by the time required for replacing the inert gas by the reaction gases. Reduction by H2-CO mixtures was accompanied by deposition of carbon and formation of cementite. The variations of cementite contents in the industrial iron ore pellets reduced isothermally for different durations, showed that cementite formation starts from the initial stages of reduction. The experimental conditions such as reaction temperature, carbon activity in the reaction gas and reaction time have a large impact on carbide content of the reduced samples. The kinetics of reduction of iron ore powder by H2 and CO gas mixtures with different compositions were studied using a commercial TGA setup. The results showed that the apparent rates of reaction vary linearly with the H2 and CO contents of the gas. Larger amount of H2 resulted in higher reaction rates. The data were employed in the developed reduction model for pellets. The model was based on the mechanism observed in the commercial iron ore pellets reduced by pure hydrogen. The microstructure of reacted pellets showed that reduction of the examined industrial samples is controlled by both chemical reaction and gaseous diffusion. The reduction model was developed by combining computations for the flow and mass transfer in the gas phase, diffusion of gases in the solid phase and chemical reaction at the reaction sites. The modelling and experimental results were in reasonably good agreement. The present model provides a good foundation for a dynamic multi-particle process model. The results highlighted the importance of considering the reduction mechanisms in different types of pellets prior to modelling. Experiments were undertaken to investigate the selective reduction of iron oxide in zinc ferrite. It was observed that gaseous reduction by hydrogen at temperatures up to 873 K is a potential method for reduction of iron oxide to metallic iron, while the zinc oxide remains in the product and losses of metallic zinc are negligible. Using this primary step in the hydrometallurgical processing of EAFD can overcome the difficulties for leaching of zinc ferrite. / <p>QC 20160823</p>

The main purpose of this study was to optimise the grain size distribution of the raw material mixture for the production of iron sinter. It well known that the constitution of the sinter mix is based on the knowledge of chemical composition and grain size distribution. Although Mittal Vanderbijlpark has fixed specifications on the physical and chemical properties of the sinter for optimal blast furnace performance, the particle size distribution of the sinter mix has not yet been optimized. This was achieved by using the granulation characteristics of the sinter mix and the green bed permeability tests. The influence of the moisture content of the feed, granulation time, and mean granule diameter on permeability was investigated on Thabazimbi and Sishen iron ore, as well as on their mixture with fluxes and without fluxes. The iron ore results indicated that the mixture containing 20% Thabazimbi iron ore and 80% Sishen iron ore with fluxes where the coke, lime and return fines were sized by removing the – 0.5 mm size fraction of the return fines and coke, and the 1 mm size fraction of lime has the highest permeability of all the studied mixtures. The sintering properties of the mixtures of optimised grain size distributions were also investigated and the results were very similar for all the mixtures and better than the base case mixture, which was not optimised with respect to grain size distribution. / Dissertation (MEng)--University of Pretoria, 2008. / Materials Science and Metallurgical Engineering / unrestricted

Kumba Iron Ore, Ltd. is the world‘s fourth largest supplier of sea-borne iron ore and currently operates two mines in South Africa namely: the Sishen mine in the Northern Cape and Thabazimbi mine in Limpopo. The Sishen mine, located at the northern end of the Maremane anticline where the bulk of the hematite ore is buried beneath younger cover lithologies, was our focus area. Here the iron resources are made up by laminated and massive ore bodies that belong to the Asbestos Hills Subgroup. These ore bodies are overlain by conglomerates, shales, flagstone and quartzite. The alkalis, potassium and phosphorous, are common constituents of iron ore, which is known to have a deleterious effect on the manufacturing of iron and steel. Therefore steel making companies charge penalties when purchasing iron ore concentrates with alkali concentrations above predetermined levels. To ensure that the export batches at the Sishen mine stay within set limits, the ores from different batches (with alkali concentration greater and below set limits) are mixed to produce a batch which meet requirements. However this solution will soon become ineffective as the low alkali ore is progressively depleted. Conventional methods used to treat high alkali ores include pyro-and hydrometallurgical methods. These approaches have several limitations such as poor product recovery, involvement of high process and energy cost and an increase in pollution load of water resources. Therefore necessitating research and development of alternative cheap and environment friendly procedures, which could supplement or replace conventional methods to ensure that mining stays economically feasible at the Sishen Iron Ore mine. The application of microorganisms to mining practices is collectively referred to as biohydrometallurgy and includes bioleaching and biooxidation processes. The phrase bioleaching refers to the conversion of an insoluble metal (typically a metal sulfide) into a soluble form (typically a metal sulfate), via microbial activity. When metals are extracted into solution, the process is referred to as bioleaching, whereas if the metal remains in the mineral, it is referred to as biooxidation. The latter term biobeneficiation refers to the selective dissolution of undesired minerals from the ores by direct or indirect action of microbes, thereby enriching the desirable mineral content. Therefore the objective of this study was to determine whether bacteria (naturally occurring on the ore or introduced species) could be used to selectively remove the alkalis from the iron ore mined at Sishen. The species evaluated were able to change the solution pH and/or form biofilms, which is assumed to have affected mineral mobilization. Data obtained during this study suggests that the composition of the ore plays a significant role in its susceptibility to bioleaching. Furthermore we also found that the indigenous cultures were more effective than the introduced species to mobilize the alkalis, which could possibly be ascribed to an adaptation of the microbes present. These preliminary results suggest that bioleaching is an effective alternative cost effective approach to treat iron ore and could possibly be implemented in future into the mining schedule at Sishen. / Dissertation (MSc)--University of Pretoria, 2011. / Microbiology and Plant Pathology / unrestricted

Across industry the majority of raw materials handled are particulate in nature, ranging in size and properties from aggregates to powders. The stress regimes experienced by the granular solids vary and the exhibited bulk behaviours can be complex and unexpected. The prevalence of granular solids makes them an area of interest for industry and researchers alike as many challenges still remain, such as dealing with complex cohesive behaviour in materials, which often gives rise to handling difficulties. Storage and transportation are an important part of the process chain for industries where particulate solids are commonplace. Failure to properly account for the cohesive nature of a particulate solid can be costly as it can easily lead to blockages in a silo such as ratholing or arching near the outlet during discharge. The cohesive strength of a bulk material depends on the consolidation stress it has experienced. As a result, the stress history in the material leading up to a handling scenario needs to be considered when evaluating its handling behaviour. The Discrete Element Method (DEM) has been extensively used to simulate the behaviour of granular materials, however the majority of the focus has been on noncohesive systems. For cohesive solids, it is crucial that the stress history dependent behaviour is adequately captured. Many of the contact models commonly used in DEM simulations to simulate cohesive granular materials such as the JKR model or liquid bridge models are elastic in nature and may not capture the stress history dependent behaviour observed in cohesive particulate solids. A comprehensive study on the effect of cohesion arising from the addition of moisture on the behaviour of two types of LKAB iron ore fines (KPBO and KPRS) has been carried out. The addition of moisture to the sample has been found to have a significant effect on both kinds of fines. KPRS fines were found to have a much higher unconfined strength and flow function at higher moisture contents, and also show a greater increase in cohesion with the addition of moisture, while at moisture contents of less than 2% the KPBO fines demonstrate higher unconfined yield strength. The KPBO fines were also found to achieve a significantly looser initial packing at much lower moisture content when compared to the KPRS fines. The lateral pressure ratio has also been evaluated. In this study a mesoscopic adhesive contact model that accounts for contact plasticity and stress history dependency in the bulk solid, the Edinburgh Elasto-Plastic Adhesion (EEPA) mode, has been presented and mathematically verified. A parametric study of the DEM contact model parameters was conducted to gain a deeper understating of the effect of input parameters on the simulated cohesive bulk behaviour. The EEPA contact model has been used to predict an experimental flow function of KPRS iron ore fines. The contact model has demonstrated the ability to capture the stress history dependent behaviour that exists in cohesive granular solids. The DEM simulations provide a very close match to the experimental flow functions, with the predicted unconfined strengths found to be within the standard deviations of the experimental results. Investigations into the failure mode predicted by the DEM simulations show that the samples are failing from the development of shear planes similar to those observed experimentally. The effect of increasing levels of adhesion has been explored for a flat bottomed silo where the level of adhesion has been varied. The DEM simulations were found to capture the major phenomena occurring in silo discharge including the various flow zones associated with a flat bottomed silo. Funnel flow, the effective transition and mass flow which are associated with a mixed flow pattern were observed in the model silo. The location of the effective transition height was identified: above this was mass flow. The velocity determined from the discharge rate was found to be in excellent agreement with the velocity profiles found in the zones of mass flow. A high velocity core flow zone was observed above the outlet where velocities were greater than 1.25 times the mass flow velocity, VMF. The level of adhesion in the silo was found to affect the discharge rate - a reduced flow rate was found until the eventual blockage of the silo at a high level of adhesion was found. As the level of adhesion increased the probability of arching also increased, and the formation of intermittent arching behaviour was noted in the cases with higher levels of adhesion in the system. The development of both temporary and permanent cohesive arches over the silo outlet were also observed with stopped flow from the silo.

The Malmberget apatite iron ore deposit is one of the most important iron producers within Europe located within an area of world-renowned mines and mining companies. It is becoming increasingly accepted that in order to increase our resources it is essential to gain a better understanding of the formation and evolution of our known mineral deposits. This thesis is part of an ongoing multi-scale 4-dimensional geological modeling project as part of a collaboration between Vinnova, LKAB, Boliden &amp; LTU. The aim of the which is to piece together the series of geological events that are responsible for the entire Gällivare mining district as seen today. This project looks at three smaller old open pits on the outer limbs of the synform fold structure that forms the Malmberget deposit. This thesis aims to gain a better understanding of the structures that have defined this current shape, and relating them to the regional-scale structural evolution. The results show two distinct deformation events, D1and D2, with each event leaving their own signature on the region. D1 deformation resulted in the formation of high strain zones and a gneissic cleavage within the volcanic rocks. D2 deformation subsequently folded the S1 gneissic cleavage and high strain zones but without developing its own fabric. / Multi-scale 4-dimensional geological modeling of the Gällivare area

Este trabalho analisou, comparativamente, os aspectos operacionais entre as configurações de circuito fechado de moagem em moinhos de bolas, quais sejam, os circuitos direto e inverso. Foram realizadas amostragens no circuito industrial de prémoagem e moagem primária do Concentrador I de Germano, da Samarco Mineração, ora operando sob a configuração inversa, ora sob a configuração direta. Os históricos de dados industriais entre os circuitos dos Concentradores I e II de Germano foram também comparados, para complementação desta análise. Por fim, foram realizados ensaios de moagem em escala de laboratório, simulando ambas as condições. As comparações entre diferentes índices de desempenho selecionou o consumo de energia por tonelada de material gerado abaixo da malha de controle como o mais adequado para avaliar o desempenho dos circuitos. A comparação entre os históricos dos dados industriais dos Concentradores I (operando sob circuito inverso) e do Concentrador II (operando sob circuito direto) mostrou um histórico consistente em que o circuito do Concentrador II apresenta menor consumo energético por tonelada de material gerado abaixo da malha de controle do circuito. Estes resultados foram diferentes daqueles obtidos a partir das amostragens realizadas no circuito industrial da Samarco, os quais indicaram melhor desempenho do circuito inverso. A diferença foi atribuída à etapa de classificação, cujo desempenho determina a alteração ou até mesmo anula os benefícios, conforme demonstram os resultados de simulação posteriores. / This work compared the performance associated to both direct and reverse ball mill closed circuit configurations. Survey campaigns were carried out in both Samarco Mineração industrial plants ie. Concentrator I and Concentrator II. The former includes reverse configured ball mill closed grinding circuit, while the latter is equipped with ball mills under a direct closed configuration. The study comprised laboratory jar tests as well as comparisons between historical data obtained for both industrial plants. The energy consumption per ton of generated product was selected as the most adequate parameter to access the circuit performance. Comparisons based on historical data indicated that the Concentrator II, configured in a direct mode, showed a better performance than Concentrator I. Such a conclusion contrasts with the results obtained from the survey campaign which indicated a better performance for the reverse configuration. Such a difference was associated to the performance of the classification, carried out in cyclones, as demonstrated by simulations conducted on the basis of previously calibrated models.