M. Tech. (Department of Metallurgical Engineering, Faculty of Engineering Technology), Vaal University of Technology. / Lonmin mining company located in the Bushveld Complex of South Africa is one of the main platinum group elements (PGEs) producers in the world. Its core operations are made up of 11 shafts and inclines. There are resources of 181 million troy ounces of 3PGE + Au, and there are reserves of 32 million ounces of 3PGE + Au. One of the ore type produced at Lonmin is UG2 ore which is dominated by the high presence of chromite. The UG2 ore is also associated with PGE assemblages divided into sulphides and non-sulphides, and it is beneficiated through the froth flotation technique. Froth flotation is a physico-chemical process that is used for separation of desired valuable minerals from the gangue minerals by utilising the difference in surface properties. The process has been achieving lower recoveries with P4 (shaft name) UG2 ore compared to Eastern Platinum Limited (EPL) UG2 ore when using similar reagents suite, this leads to loss of valuable minerals to the tailings, both ores were from Lonmin. The first step was to conduct the mineralogical analysis conducted using Scanning electron microscopy- energy dispersive spectroscopy (SEM-EDS), X-ray diffraction (XRD), and optical microscopy to study the mineral composition of the two ores, and to identify any differences between them (two ores) considering that EPL UG2 ore is a blend of P1, P2, P3 (shaft names) and P4 UG2 ores while P4 UG2 ore is not blended with any other ores. The mineralogical results showed the presence of chromite, plagioclase, enstatite and sulphide minerals. The PGEs could not be detectable by any of the techniques used due to their small size and rarity. However, X-ray diffraction detected differences in concentrations of minor gangue constituents such as talc, muscovite, chlorite and actinolite and these results suggest that reagent consuming gangue mineralogy may have contributed to the differences in PGE recoveries by flotation. Batch flotation tests were also conducted. The existing reagent suite consisted of CuSO4 as an activator, Sodium n-propyl xanthate (SPNX) as a collector, carboxymethyl cellulose CMC as a depressant, and Senfroth 200 as a frother, and this was a single collector system. Therefore it was imperative to conduct flotation n investigation on alternative collector blends in order to improve the recovery of P4 UG2 ore. SNPX was used as the primary collector and it was blended with the following co-collectors: alkyl dithiocarbamates (DTC), two formulations of S-alkyl-N-butyl thionocarbamates (ABTC C1 & ABTC C2), and two formulations O-isopropyl-N-ethyl thionocarbamate (IPETC 30 & IPETC 31), one co-collector at a time. The first test incorporated the SNPX at dosage of 150 g/t without a blend and this dosage was selected based on the current optimum practice used at Lonmin and to use as a benchmark for the project. Trying to maintain the same dosage of 150 g/t of collectors, SNPX + co-collector were blended at two different dosages of 100 g/t + 50 g/t, and was also due to the fact that the co-collectors were highly concentrated and small dosages were expected to perform very well with SNPX. Lastly, the SNPX + co-collector at dosages 100 g/t + 125 g/t, here the dosage of co-collector was very high compared to 50 g/t and this was to check the effect of high dosages of highly concentrated collectors on the performance of the ore. The flotation results showed that the use of 50 g/t of co-collectors yielded optimum PGEs + Au recoveries and grades, while the dosage of 125 g/t decreased recoveries and grades. The high dosage quantities of collectors do not necessarily mean they will yield improved recoveries and grades. Different chain structures can be used to alter the behaviour of a collector, and these may increase or decrease their capabilities to cause higher recoveries. By using a collector with a longer hydrocarbon chain the flotation limit may be extended without loss of selectivity, consequently bringing about greater water repulsion, instead of increasing the concentration of a shorter chain collector. At 100 g/t of SNPX and 50 g/t of co-collector i.e. SNPX + IPETC 30 yielded improved 3PGE + Au recovery of 85.7 % at 3PGE + Au grades of 60.14 g/t, compared to the unblended SNPX (150 g/t) which yielded 3PGE + Au recovery of 81.1 % but insignificantly higher grade of 60.53 g/t. On the other hand, SNPX + IPETC C1 blend yielded low 3PGE + Au recoveries compared to SNPX + IPETC 30 and SNPX + IPETC 31 blends, but it achieved the highest grade of 76.1 g/t. Evidently, this proves that the relationship between recovery and grade is a trade-off. The results have also shown the synergic effects, especially for SNPX blended with IPETC 30, and SNPX blended with IPETC 31 at dosage of 100 g/t (SNPX) and 50 g/t (IPETCs). It can be concluded that the different interaction obtainable from the thionocarbamate (ROCSNHR), effectively complement that from the xanthate ion (ROCS2–) to achieve more collector interaction at surface sites otherwise interactable for xanthate only. Therefore the collector blends rendered the mineral of interest hydrophobic and as a result the minerals were recovered to the concentrate. On the other hand, too much of collectors may not be beneficial. At the dosage of 100 g/t of SNPX and 125 g/t of collectors, SNPX + DTC attained lower recoveries compared to SNPX, SNPX + IPETC 30, SNPX + IPETC 31, however the grade was higher than achieved SNPX + IPETC 30, SNPX + IPETC 31 and SNPX + ABTC C1. Nevertheless, comparing these results to the dosage of 50 g/t of the co-collectors, the 125 g/t did not perform well at all. The dosage of 125 g/t of co-collectors lead to loss of collecting power and selectivity, especially for SNPX + IPETC 30, SNPX + IPETC 31, and SNPX + ABTC C1 blends. It is therefore wise to conduct an optimisation test to determine the correct dosing rate. In addition, the chromite entrainment was below the smelter limit and is very beneficial since chromite is detrimental to the furnace. Therefore, it is concluded that the blends of SNPX with IPETC 30 and IPETC 31 at a dosage 50 g/t have shown satisfying recoveries and the FeCr2O4 recovery is less than 1 % meaning there will not be any smelter penalties for FeCr2O4 content. Therefore, these are the recommended collector blends. It is recommended that further mineralogical study of the ores be conducted so that it may provide deeper insight into the causes of low recoveries under SNPX only. The system of blended collectors and its optimisation would be beneficial and can be practiced. The Chemisorption studies between the minerals and co-collectors used will provide more specific insight and details into the actual interaction synergy that gave the improved recoveries.

In occupational settings where rhodium is produced or used, such as the mining industry, refineries and catalytic industries, workers are at risk of being dermally exposed to this metal in either the metallic form or its salt compounds. A considerable amount of contradictory literature has been published with regard to the sensitising abilities of rhodium and no published information is available on the occupational dermal exposure of rhodium as well as its ability to permeate through the skin. Previous studies conducted on the in vitro permeation of metals, such as nickel, cobalt and chromium, have indicated that certain metals undergo oxidation in the presence of sweat and form ions which are able to permeate through skin. For some metals, this ionisation takes place more rapidly in an acidic environment and a decrease in the environmental pH would cause an increase in the release of ions from those metals. Aim: The aim of this study was to determine whether rhodium in the form of rhodium trichloride (RhCl3) would be able to permeate through the skin in vitro, as well as to determine whether any differences exist between the in vitro permeation of rhodium at a pH of 4.5 and a pH of 6.5. Methods: Full thickness abdominal skin was obtained as biological waste after surgery from Caucasian females ranging between 39 and 42 years of age. The Franz diffusion cell method was used in which the experimental cells contained synthetic sweat with RhCl3 and the blanks did not contain any RhCl3 in the donor compartment. All of the cells contained a physiological receptor solution in the receptor compartment. At intervals of 8, 12 and 24 hours, 2 ml of the receptor solution were removed for analysis. The receptor compartment was rinsed with 2 ml receptor solution which was also removed for analysis and 2 ml of fresh receptor solution was added to the compartment. After 24 hours, the receptor and donor solution was removed respectively for analysis and the skin was removed for digestion, prior to analysis. The mass of rhodium in the receptor solutions were determined using Inductively Coupled Plasma Mass Spectrometry. The donor solutions and digested skin solutions were analysed using Inductively Coupled Plasma Optical Emission Spectrometry. Results: At both pH values of 4.5 and 6.5, rhodium was able to permeate through the skin with a cumulative increase in permeation over prolonged exposure time. After 8, 12 and 24 hours, the amount of rhodium that permeated through the skin was higher at pH 4.5 than for pH 6.5. After 12 hours, the permeation of rhodium was statistically significantly higher for pH 4.5 than for pH 6.5 (p = 0.02). At both pH values, the percentage of rhodium that accumulated in the skin was higher than the percentage of rhodium that diffused through the skin and the lag time was less than six hours. Conclusion: At both pH values of 4.5 and 6.5, rhodium was able to permeate through the skin. A decrease in the pH of synthetic sweat led to an increase in the permeation of rhodium and it is recommended that future in vitro permeation studies be conducted at a pH of 4.5, as the skin surface pH of workers are generally considered to be below 5. A higher percentage of rhodium was retained in the skin than the percentage that diffused through, indicating the ability of rhodium to accumulate in the skin, from where it may exert health effects, such as sensitisation. / MSc (Occupational Hygiene), North-West University, Potchefstroom Campus, 2014

In occupational settings where rhodium is produced or used, such as the mining industry, refineries and catalytic industries, workers are at risk of being dermally exposed to this metal in either the metallic form or its salt compounds. A considerable amount of contradictory literature has been published with regard to the sensitising abilities of rhodium and no published information is available on the occupational dermal exposure of rhodium as well as its ability to permeate through the skin. Previous studies conducted on the in vitro permeation of metals, such as nickel, cobalt and chromium, have indicated that certain metals undergo oxidation in the presence of sweat and form ions which are able to permeate through skin. For some metals, this ionisation takes place more rapidly in an acidic environment and a decrease in the environmental pH would cause an increase in the release of ions from those metals. Aim: The aim of this study was to determine whether rhodium in the form of rhodium trichloride (RhCl3) would be able to permeate through the skin in vitro, as well as to determine whether any differences exist between the in vitro permeation of rhodium at a pH of 4.5 and a pH of 6.5. Methods: Full thickness abdominal skin was obtained as biological waste after surgery from Caucasian females ranging between 39 and 42 years of age. The Franz diffusion cell method was used in which the experimental cells contained synthetic sweat with RhCl3 and the blanks did not contain any RhCl3 in the donor compartment. All of the cells contained a physiological receptor solution in the receptor compartment. At intervals of 8, 12 and 24 hours, 2 ml of the receptor solution were removed for analysis. The receptor compartment was rinsed with 2 ml receptor solution which was also removed for analysis and 2 ml of fresh receptor solution was added to the compartment. After 24 hours, the receptor and donor solution was removed respectively for analysis and the skin was removed for digestion, prior to analysis. The mass of rhodium in the receptor solutions were determined using Inductively Coupled Plasma Mass Spectrometry. The donor solutions and digested skin solutions were analysed using Inductively Coupled Plasma Optical Emission Spectrometry. Results: At both pH values of 4.5 and 6.5, rhodium was able to permeate through the skin with a cumulative increase in permeation over prolonged exposure time. After 8, 12 and 24 hours, the amount of rhodium that permeated through the skin was higher at pH 4.5 than for pH 6.5. After 12 hours, the permeation of rhodium was statistically significantly higher for pH 4.5 than for pH 6.5 (p = 0.02). At both pH values, the percentage of rhodium that accumulated in the skin was higher than the percentage of rhodium that diffused through the skin and the lag time was less than six hours. Conclusion: At both pH values of 4.5 and 6.5, rhodium was able to permeate through the skin. A decrease in the pH of synthetic sweat led to an increase in the permeation of rhodium and it is recommended that future in vitro permeation studies be conducted at a pH of 4.5, as the skin surface pH of workers are generally considered to be below 5. A higher percentage of rhodium was retained in the skin than the percentage that diffused through, indicating the ability of rhodium to accumulate in the skin, from where it may exert health effects, such as sensitisation. / MSc (Occupational Hygiene), North-West University, Potchefstroom Campus, 2014

Thesis (MEng) -- Stellenbosch University, 2014. / ENGLISH ABSTRACT: In this study, SiC reduction of Rowland and Easterns LG (Low Grade) concentrates was investigated. The purpose of the study was to investigate the feasibility of SiC as reductant with respect to metal fall, PGM grade in the alloy, slag composition, Cr solubility and overall PGM recovery. The integration of such process in the current matte-based collection process was also investigated. Currently, the matted-based collection process is most widely used for PGM recovery, but because PGM containing concentrates are becoming more enriched with UG2 (Upper Group 2) LG concentrates, it is expected to be integrated or replaced with an alloy collection process. This kind of process offers greater flexibility to the different types of ore that could be used. The process is chromium tolerant and environmentally friendly. For this purpose Rowland and Easterns UG2 LG Concentrate samples from Lonmin Western Platinum Limited were analysed with XRD, XRF and ICP-MS and it was found that SiO2 and MgO are the most abundant oxides and Pd is the most abundant element from the PGMs. Sulphide bearing minerals such as chalcopyrite were detected in low concentrations (below 1 %) and Cr2O3 concentrations are between 2 – 4 %. The FeO/SiO2 ratio was lower in Rowland LG concentrate. SiC reduction of Rowland and Easterns concentrate was done at 1600℃. Reductant to concentrate ratios for laboratory scale experiments were ranged from 2.5 to 3.5 kg SiC / 100 kg concentrate. SiC reduction of Rowland concentrate had different reduction times. The duration of reduction experiments ranged from 30 - 180 min. PGM recoveries from SiC reduction of Rowland concentrate were very poor (below 10 %) and Fe recoveries were lower than 50 %. A slag viscosity at the end of the melt of more than 4 poise was responsible for poor phase separation. SEM images revealed metal prills entrained in the slag phase instead of settling and combining to the alloy globule at the bottom of the crucible. However, PGM recoveries from SiC reduction of Easterns concentrate was significantly better. More than 85 % of Ir and Pd and almost 60 % of Pt were recovered in a test with a reductant to concentrate ratio of 3.5 kg SiC / 100 kg Easterns concentrate. Fe recovery was also the highest at 66%. Cr and Si concentrations were below 5 % in total. The slag viscosity at the end of melt was calculated to be less than 4 poise and a SEM image of a slag sample revealed few entrained metal prills. After the above findings on the importance of viscosity, it was decided to increase the FeO content in the initial concentrate charge in order to decrease slag viscosity, increase metal fall (PGM collecting phase) and further increase PGM recovery. Peirce-Smith converter slag was used for this purpose. A test was conducted with the addition of 10 kg converter slag / 100 kg Easterns concentrate. The reductant to concentrate ratio was kept at 3.5 kg SiC / 100 kg Easterns concentrate. The results revealed that Ir and Pd recoveries were more than 95%, while Pt recovery was almost 70%. Fe recovery increased to 76 %. On the basis of the results from the test, an optimum feed ratio between Easterns LG concentrate, Rowland concentrate and Peirce-Smith converter slag was calculated. Thermodynamic phase equilibrium calculations predicted that the concentrate charge should consist of 60 - 80% Easterns concentrate with a slag addition of 30 – 40 kg converter slag / 100 kg LG concentrate. SiC reduction of this optimum LG concentrate charge is expected to recover more than 90% of all PGMs. Cr and Si concentrations in the alloy will be below 1 % in total. The amount of converter slag as an addition will be however limited by final PGM grade in the alloy, furnace slag quantities recycled and slag resistivity required in the alloy furnace. The effectiveness of SiC as reductant was also compared to C reduction. C reduction of an optimum concentrate charge had a marginally higher metal fall at the same reductant to concentrate ratio than SiC reduction of an optimum concentrate charge. However, gas emissions are on average 3 times higher for C reduction of a concentrate charge and C reduction requires at least 300 MJ more to smelt 1 ton of LG concentrate than SiC reduction. This is mostly due to C reacting endothermically with FeO to produce Fe(l) and CO(g) in contrast to SiC reacting exothermically with FeO to produce Fe(l), SiO2(l) and CO(g). Integrating SiC reduction of LG concentrates into the existing smelting route at Lonmin was also proposed through a process flow diagram. From an economic point of view, it was found that SiC reduction of 1 ton of LG concentrate charge with a converter slag addition requires almost 700 MJ more than the smelting of a UG2 blended concentrate to produce a matte phase. However it must be taken into account that the sulphide rich layers in the Bushveld complex are being depleted rapidly and alternative processes such as SiC reduction and alloy collection process will be utilized faster than expected. Moreover, gas emissions from reductive smelting is considerably lower, hence it is a more environmentally friendly process. Finally, from the findings of this study, it could be said that base metals and PGMs could be recovered in an iron alloy from SiC reduction of LG concentrate with converter slag additions. Therefore integrating such a process into the matte-based collection process could be considered as a future alternative to smelting UG2 LG concentrates. / AFRIKAANSE OPSOMMING: In hierdie studie, word SiC reduksie met Rowland en Oostelikes LG (Lae Graad) konsentrate ondersoek. Die doel van die studie was om die doeltreffendheid van SiC as reduktant te ondersoek met betrekking tot metaalval, PGM graad in die allooi, slaksamestelling (spesifiek word daar gekyk na Cr oplosbaarheid) en algehele PGM herwinning. Die integrasie van die proses in die huidige mat-gebaseerde versamelingproses word ook ondersoek. Tans word die mat-gebaseerde versamelingproses die algemeenste gebruik om PGM'e te kollekteer, maar omdat PGM konsentrate al hoe meer verryk word met UG2 (Upper Group 2) LG konsentrate, word daar verwag dat dit geïntegreer of vervang gaan word met 'n allooi-versamelingproses. Hierdie tipe proses bied groter buigsaamheid om die verskillende reekse van erts wat gebruik kan word. Die proses kan ook chroom hanteer en is omgewingsvriendelik. Vir hierdie doel was Rowland en Oostelikes UG2 LG konsentraatmonsters van Lonmin Western Platinum Limited ontleed met XRD, XRF en ICP -MS en met die ontleding was daar gevind dat SiO2 en MgO die volopste oksides was en dat Pd die volopste elemente van die PGMe was. Sulfiedminerale soos chalkopiriet is in lae konsentrasies opgespoor (minder as 1%) en Cr2O3 konsentrasies is tussen 2-4 %. Die FeO/SiO2 verhouding was laer in Rowland konsentraat. SiC reduksie van Rowland en Oostelikes konsentrate is teen 1600 ℃ uitgevoer. Die reduktant tot konsentraat verhouding vir laboratoriumskaal eksperimente het gewissel van 2.5 – 3.5 kg SiC / 100 kg konsentraat. SiC reduksie van Rowland LG konsentraat het verskillende reduksie tye gehad. Die duur van die reduksie eksperimente het gewissel van 30-180 min. PGM herwinning van SiC reduksie met Rowland konsentreer was baie laag (onder 10 %) en Fe herwinning was minder as 50%. 'n Slakviskositeit aan die einde van die smelt was hoër as 4 poise en was verantwoordelik vir die swak skeiding van fases. SEM beelde het gewys dat fyn metaalstukkies opgehou was in die slakfase in plaas daarvan dat dit vestig en kombineer met die allooibolletjie aan die onderkant van die smeltkroes. In teenstelling was die PGM herwinning van SiC reduksie met Oostelikes konsentraat aansienlik beter. Meer as 85 % van Ir en Pd was herwin en byna 60% van Pt was herwin tydens 'n toets met 'n reduktant tot konsentraat verhouding van 3.5 kg SiC / 100 kg Oostelikes konsentraat. Fe herwinning was 66% en was ook die hoogste van al die eksperimente. Cr en Si konsentrasies was minder as 5 % in totaal. Die slakviskositeit aan die einde van smelt was bereken en is minder as 4 posie. 'n SEM beeld van 'n slakmonster het baie min vasgevangde metaalstukkies getoon. Na afloop van die bogenoemde bevindinge oor die belangrikheid van viskositeit, was daar besluit om die FeO inhoud van die aanvanklike konsentraat te verhoog. Dit was gedoen om die slakviskositeit te verminder, die metaalval (PGM kollektering fase) te verhoog en sodoende die PGM herwinning verder te verbeter. Vir die doel was Peirce -Smith omskakelaarslak gebruik. ʼn Toets was uitgevoer met die toevoeging van 10 kg omskakelaarslak / 100 kg Oostelikes konsentraat. Die reduktant tot konsentraat verhouding was behou by 3.5 kg SiC / 100 kg Oostelikes konsentraat. Die resultate het getoon dat meer as 95 % van Ir en Pd herwin was, terwyl byna 70 % Pt herwin was. Die Fe herwinning het toegeneem tot 76%. Op grond van die resultate van die toets, is 'n optimale verhouding tussen Oostelikes konsentraat, Rowland konsentraat en Peirce -Smith omskakelaarslak bereken. Termodinamiese modellering voorspel dat die begin LG konsentraat voer uit 60 – 80 % Oostelikes konsentraat moet bestaan, met 'n slak toevoeging van 30 – 40 kg omskakelaarslak / 100 kg LG konsentraat. Daar word verwag dat meer as 90 % van PGM'e herwin sal word vanaf SiC reduksie met ʼn optimum LG konsentraat voer. Cr en Si konsentrasies in die allooi sal minder as 1% in totaal wees. Die hoeveelheid slak wat bygevoeg kan word sal egter beperk word deur die finale PGM graad in die allooi, oond-slak hoeveelhede wat herwin kan word en slakweerstand wat benodig word in die allooi-oond. Die effektiwiteit van SiC as reduktant is ook vergelyk met C reduksie. C reduksie van ʼn optimale konsentraatvoer het 'n effens hoër metaalval wanneer dieselde reduktant tot konsentraat verhouding behou was vir SiC reduksie van 'n optimale konsentraatvoer. Gas hoeveelhede van C reduksie is gemiddeld 3 keer meer en vereis te minste 300 MJ meer om 1 ton LG konsentraat te smelt. Dit is hoofsaaklik te wydte aan C wat endotermies reageer met FeO om Fe (l) en CO (g) te produseer, in teenstelling met SiC wat eksotermies reageer met FeO om Fe (l), SiO2(l) en CO (g) te produseer. Integrasie van SiC reduksie met LG konsentrate in die bestaande smeltroete by Lonmin Western Platinum Limited is ook voorgestel deur 'n proses vloeidiagram. Uit 'n ekonomiese oogpunt, is daar gevind dat SiC reduksie van 1 ton LG konsentraatvoer met 'n omskakelaarslak byvoeging ongeveer 700 MJ meer benodig as om 1 ton UG2 gemengde konsentraat te smelt en 'n mat-fase te produseer. Dit moet wel in ag geneem word dat die sulfied ryk lae in die Bosveld-kompleks vinnig uitgeput word en dat hierdie alternatiewe prosesse soos SiC reduksie en ʼn allooiversameling proses vinniger as verwagtend benut sal word. Verder, gas hoeveelhede van SiC reduksie is laer en daarom is dit 'n meer omgewingsvriendelik proses. Ten slotte, vanaf die bevindinge van hierdie studie, kan dit gesê word dat basismetale en PGM'e in 'n ysterallooi herwin kan word deur middel van SiC reduksie met LG konsentrate en die toevoeging van omskakelaarslak. Daarom kan die integrasie van so 'n proses in die huidige mat-gebaseerde versameling proses beskou word as 'n alternatief vir die toekoms om UG2 LG konsentrate te smelt.

Thesis (PhD) -- Stellenbosch University, 2014. / ENGLISH ABSTRACT: The process route for the production of base and platinum-group metals from natural sulfide ores commonly requires the conversion of high-iron furnace matte into an iron-lean converter matte. This is followed by pre-treatment through cooling of the iron-lean molten matte, physical processing of the solidified matte and hydrometallurgical metal extraction. Lonmin is the third largest producer of platinum-group metals in the world and utilizes Peirce-Smith converters for blowing high-iron furnace matte with air to a final iron concentration or endpoint. The molten matte is water granulated and solidification occurs via fast-cooling. The solidified matte is ground in a closed circuit ball mill with hydrocyclone classification and subjected to first stage atmospheric leaching. The specification of an ideal or desirable converter iron endpoint requires careful consideration. Most importantly, it must ensure the crystallization of converter matte with mineralogical qualities that are within the setpoints of the downstream unit processes and techniques. An additional consideration is for the final blown converter matte to achieve an optimum bulk concentration of the base metals Ni and Cu and platinum-group metals Pt, Pd, Rh, Ru and Ir. Mattes characteristic of variable iron endpoints were regularly produced at the Lonmin converter plant section. Uncertainty by plant metallurgists in knowing the desirable iron endpoint, particularly within the context of the Lonmin base metal refinery, and poor control has had detrimental effects on the mineralogical quality of the final matte and hence on the processing characteristics of the solidified matte particles downstream. A desirable iron endpoint required investigation, selection and implementation at Lonmin. The primary focus of this study was therefore to quantify the effect of a specific iron endpoint on the mineralogy and mineral chemistry of solidified converter matte. A fundamental examination of the solidification process upon cooling was regarded as critical to an in-depth understanding of the attained mineralogy and mineral chemistry as a function of a specific iron endpoint. It became equally important to quantify the effect of the resultant mineralogy, and hence iron endpoint, on the physical property of mineral structures in relation to downstream grinding, liberation and leaching characteristics. Despite considerable industry context, limited in-depth and coherent studies on the effect of a specific iron endpoint on fast-cooled converter matte systems were found in both industrial and scholarly literature. Previous findings in literature offered a limited quantitative understanding of the effect on mineralogy and mineral chemistry. Phase and cooling equilibria of multi-component, iron endpoint specific Ni-Cu-S matte systems were also not fully available. These would have been particularly useful in understanding the complexities of converter matte solidification as a function of iron endpoint. Physical property knowledge of converter matte mineral structures was hardly available and even less so in relation to grinding, liberation and leaching processes. A comprehensive investigation was therefore required to address these extensive knowledge gaps with respect to fastcooled converter matte systems in an industrial framework. Three Peirce-Smith converter production samples, representative of the extent in variability of iron endpoints attained at the converter plant, were used in a systematic investigation coupled to a novel combination of modern analytical techniques, computational thermochemistry and metallurgical testwork. The modern analytical techniques included the application of high resolution transmission electron microscopy and focused ion beam scanning electron microscopy tomography. Computational thermochemistry was applied through the use of MTDATA phase diagram software. Metallurgical testwork involved laboratory batch grinding at various specific energies. Closely associated leach experiments were also considered relevant to this wide-ranging investigation. The Peirce-Smith converter samples investigated were indicative of mattes that attained specific endpoints of 5.17%, 0.99% and 0.15 weight% Fe. The highest combined bulk concentration of the important base and platinum-group metals was achieved in the matte which attained a specific iron endpoint of 0.99%. The mineralogy of all three converter mattes was dominated by nickel sulfide mineral structures matched to the natural mineral of heazlewoodite. Mineral structures of copper sulfide, NiCu-alloy, spinel and OsRu-alloy were also constituents of the different converter mattes. The attainment of a specific iron endpoint was found to result in measurable mineralogical differences with respect to relative mineral abundances, external morphological characteristics and mineral chemistry. The mineralogical differences were particularly distinct between mineral structures of the high (5.17%) and low (0.99% and 0.15%) iron mattes. Subtle mineralogical differences were evident between mineral structures of the low iron mattes. The 0.99% Fe matte was characteristic of a significantly higher NiCu-alloy relative abundance, compared to the 5.17% Fe matte. The NiCu-alloy structures were found to act as the primary collectors of the economically significant platinum-group metals. Mineralogical observations were used to develop an understanding of the underlying mineralization mechanism of NiCu-alloy structures. High-fidelity color and grayscale 3D reconstructions were produced of the resultant mineralized structures. It was shown theoretically that variations in iron endpoint specific starting compositions of oxygen-free liquid matte systems alter the solidification pathway towards the eutectic. Moreover, a quantitative understanding of liquid phase solidification of the high and low iron matte systems, including oxygen, was developed to within ±2.5 oC. Most of the specific energy available for grinding was expended breaking the nickel sulfide matrix, particularly of the high iron matte. The breakage rates of copper sulfide mineral structures in the 5.17% Fe matte were calculated to be higher than in the 0.15% Fe matte at 25kWh/t specific energy. The degree of copper sulfide liberation was shown to be higher for the 5.17% Fe matte than for the 0.15% Fe matte at the same specific energy of grinding. A higher degree of Ni extraction and Cu cementation could be achieved when leaching low iron matte particles. The production of converter matte attaining a specific iron endpoint of 0.99% was found to be the most suitable with respect to endpoint selection criteria. A practical iron endpoint range of 1.6% to 1.0% was recommended for the production of converter matte with a resultant mineralogical quality within the constraints of the Lonmin base metal refinery. This study offers an integrated understanding of base and platinum-group metals production as a function of a desirable iron endpoint at Lonmin. This was not previously available in metal production literature. New technology for the monitoring and consistent control of such a practical iron endpoint range can subsequently be implemented. / AFRIKAANSE OPSOMMING: Die prosesroete vir die produksie van onedel en platinumgroepmetale uit natuurlike swawelertse vereis gewoonlik die omsetting van ’n ysterryke hoogoondmat in ’n ysterarm omsettermat. Hierna volg voorbehandeling deur die afkoeling van die ysterarm gesmelte mat, fisiese verwerking van die soliede mat, en hidrometallurgiese metaalekstraksie. Lonmin is die derde grootste produsent van platinumgroepmetale ter wêreld en gebruik Peirce-Smith-omsetters om ysterryke hoogoondmat met lug te blaas totdat dit ’n finale ysterkonsentrasie- of ystereindpunt bereik. Die gesmelte mat word met water granuleer, en solidifikasie vind deur middel van snelafkoeling plaas. Die soliede mat word in ’n geslotekringbalmeul met hidrosikloonklassifikasie gemaal en aan eerstestadium- atmosferiese loging onderwerp. Die spesifikasie van ’n ideale of gewenste ystereindpunt verg deeglike oorweging. Bowenal moet dit verseker dat die omsettermat kristalliseer met mineralogiese eienskappe wat binne die setpunte van die eenheidsprosesse en - tegnieke verder af in die prosesstroom val. ’n Bykomende oorweging is dat die uiteindelike geblaasde omsettermat ’n optimale massakonsentrasie van die onedel metale Ni en Cu en die platinumgroepmetale Pt, Pd, Rh, Ru en Ir moet bevat. Matte met die kenmerke van wisselende ystereindpunte is gereeld by die Lonminomsetteraanleg geproduseer. Die onsekerheid van metallurge by die aanleg oor die gewenste ystereindpunt – veral binne die konteks van die Lonmin-raffinadery vir onedel metale – sowel as swak beheer het ’n nadelige uitwerking gehad op die mineralogiese gehalte van die uiteindelike mat, en dus ook op die verwerkingskenmerke van die soliede matdeeltjies verder af in die prosesstroom. Die bepaling van die gewenste ystereindpunt het sorgvuldige ondersoek, seleksie en toepassing deur Lonmin vereis. Hierdie studie is dus hoofsaaklik uitgevoer om die uitwerking van ’n spesifieke ystereindpunt op die mineralogie en minerale chemie van soliede omsettermat te kwantifiseer. ’n Grondliggende ondersoek na die solidifikasieproses by afkoeling is as noodsaaklik beskou vir ’n diepgaande begrip van die verworwe mineralogie en minerale chemie as ’n funksie van ’n spesifieke ystereindpunt. Mettertyd het dit egter ewe belangrik geword om die uitwerking van die gevolglike mineralogie, en dus die ystereindpunt, op die fisiese eienskappe van minerale strukture met betrekking tot maling-, vrystellings- en loogprosesse verder af in die prosesstroom te kwantifiseer. Ondanks heelwat bedryfskonteks, het nóg bedryfs- nóg vakkundige literatuur veel diepte- en samehangende studies oor die uitwerking van ’n spesifieke ystereindpunt op snelafgekoelde omsettermatstelsels opgelewer. Vorige bevindinge in die literatuur het boonop ’n beperkte kwantitatiewe begrip van die uitwerking op mineralogie en minerale chemie getoon. Die fase- en afkoelingsekwilibriums van ystereindpuntspesifieke Ni-Cu-S-matstelsels met veelvuldige komponente was ook nie ten volle beskikbaar nie. Dít sou veral goed te pas gekom het om die kompleksiteite van omsettermatsolidifikasie as ’n funksie van ystereindpunt te verstaan. Kennis van die fisiese eienskappe van die minerale strukture van omsettermat was kwalik beskikbaar, terwyl selfs minder inligting oor maling-, vrystellings- en loogprosesse opgespoor kon word. Daarom was ’n omvattende ondersoek nodig om hierdie beduidende kennisleemtes met betrekking tot snelafgekoelde omsettermatstelsels in ’n nywerheidsraamwerk aan te vul. Drie Peirce-Smith-omsetterproduksiemonsters wat die wisselende bestek van ystereindpunte by die omsetteraanleg verteenwoordig, is in ’n stelselmatige ondersoek gebruik, tesame met ’n vernuwende kombinasie van moderne ontledingstegnieke, gerekenariseerde termochemiese bewerkings en metallurgiese toetswerk. Die moderne ontledingstegnieke sluit onder andere in hoëresolusie-transmissie-elektronmikroskopie (HRTEM) en gefokusdeioonstraalskandering-elektron-mikroskopie (FIB SEM) tomografie. Die gerekenariseerde termochemiese bewerkings is met behulp van MTDATAfasediagramsagteware uitgevoer. Metallurgiese toetswerk het die maling van laboratoriumlotte teen verskillende spesifieke energieë behels. Nou verwante loogproefnemings is ook as relevant vir hierdie omvattende studie beskou. Die bestudeerde Peirce-Smith-omsettermonsters het op matte met spesifieke eindpunte van 5.17%, 0.99% en 0.15 gewig% Fe gedui. Die hoogste gekombineerde massakonsentrasie van die belangrike onedel en platinumgroepmetale is in die mat met ’n spesifieke ystereindpunt van 0.99% gevind. Die mineralogie van ál drie omsettermatte is oorheers deur die minerale strukture van nikkelsulfied, wat met die natuurlike mineraal heazlewoodiet ooreenstem. Die verskillende omsettermatte het ook die minerale strukture van kopersulfied, NiCu-allooi, spinel en OsRu-allooi bevat. Daar is bevind dat die verkryging van ’n spesifieke ystereindpunt tot meetbare mineralogiese verskille in die relatiewe volopheid van minerale, die eksterne morfologiese kenmerke sowel as minerale chemie lei. Die mineralogiese verskille was veral duidelik te sien tussen die minerale strukture van die ysterryke (5.17% Fe) en ysterarm (0.99% en 0.15% Fe) matte. Fyn mineralogiese verskille is ook tussen die minerale strukture van die ysterarm matte bespeur. Die 0.99% Fe-mat het tipies beduidend meer NiCu-allooi as die 5.17% Fe-mat bevat. Die NiCu-allooistrukture tree oënskynlik op as die hoofversamelaars van die ekonomies belangrike platinumgroepmetale. Mineralogiese waarnemings is gebruik om ’n begrip te ontwikkel van die onderliggende mineralisasiemeganisme van NiCuallooistrukture. Die gevolglike gemineraliseerde strukture is met behulp van driedimensionele rekonstruksies met hoë kleurgetrouheid sowel as in grysskaal voorgestel. Daar is teoreties aangetoon dat variasies in ystereindpuntspesifieke beginsamestellings van suurstofvrye vloeibare matstelsels die solidifikasieroete na die eutetikum wysig. Daarbenewens is die vloeifasesolidifikasie van die ysterryke en ysterarm matstelsels, wat suurstof insluit, op sowat ±2.5 oC gekwantifiseer. Die meeste van die spesifieke energie wat vir maling beskikbaar was, is gebruik om die nikkelsulfiedmatriks te breek, veral vir die ysterryke mat. Berekeninge toon dat die breektempo’s van die minerale strukture van kopersulfied by die 5.17% Fe-mat hoër was as by die 0.15% Fe-mat teen ’n spesifieke energie van 25 kWh/t. Die mate van kopersulfiedvrystelling was hoër by die 5.17% Fe-mat as by die 0.15% Fe-mat by dieselfde spesifieke energie vir maling. ’n Hoër mate van Ni-ekstraksie en Cu-sementasie is verkry toe ysterarm matdeeltjies geloog is. Wat eindpuntseleksiemaatstawwe betref, is die produksie van ’n omsettermat met ’n spesifieke ystereindpunt van 0,99% as die mees geskikte aangewys. ’n Praktiese ystereindpuntbestek van 1.6% tot 1.0% word aanbeveel vir die produksie van ’n omsettermat met ’n gevolglike mineralogiese gehalte wat binne die perke van die Lonmin-raffinadery vir onedel metale val. Hierdie studie bied ’n geïntegreerde begrip van die produksie van onedel en platinumgroepmetale as ’n funksie van ’n gewenste ystereindpunt by Lonmin. Hierdie inligting was nie voorheen in literatuur oor metaalproduksie beskikbaar nie. Nuwe tegnologie vir die monitering en konsekwente beheer van so ’n praktiese ystereindpuntbestek kan dus op grond hiervan in werking gestel word.

Thesis (MSc)--University of Stellenbosch, 2004 / ENGLISH ABSTRACT: A variety of computational techniques are used to calculate structural, thermodynamic and transport properties of two specific Platinum Group Metal (PGM) complex systems. The first system consists of a PGM complex ([PdCl4]2-; [PtCl4]2-; [PtCl6]2- or [RhCl6]3-) with sodium counter-ions in a water solution at 30ºC and at a concentration of 0.106 mol/dm3. The second system under consideration is that of a PGM complex ([PdCl4]2-; [PtCl4]2-; [PtCl6]2- or [RhCl6]3-) with sodium counter-ions in a water solution in the presence of four poly (ethylene oxide) (PEO) chains at 30ºC and at a concentration of 0.013 mol/dm3. A conformational study of the two types of dihedral angles in a PEO chain (-C-O-C-Cand -O-C-C-O-) is performed and the extreme flexibility of the polymer is confirmed. Dihedral angle distributions of the two dihedral angles are calculated and explained in terms of the potential energy surface obtained from the conformational study. The solvation geometries of the PGM complexes are confirmed and the results are contrasted with those in the system where the polymer (PEO) is present. It is concluded that the effect of the polymer on the structure and degree of solvation is negligible. The free energy of solvation values of the PGM complexes are calculated to provide insight into their structural characteristics such as solvation shell volume and geometry. The structural and thermodynamic properties of the PGM complexes in solution are also used to explain the trends observed in the calculated diffusion coefficients. Comments are made on the accuracy of the calculated diffusion coefficients as well as the legitimacy of the mechanistic speculations which results from them. Suggestions regarding possible future improvements to the computational methods are made. / AFRIKAANSE OPSOMMING: Verskeie berekenings tegnieke is aangewend om die strukturele, termodinamiese en verplasings eienskappe van twee spesifieke Platinumgroep Metaal (PGM)-kompleks sisteme te bereken. Die eerste sisteem bestaan uit die PGM-kompleks ([PdCl4]2-; [PtCl4]2-; [PtCl6]2- of [RhCl6]3-) met natrium teenione in water by 30ºC en met ‘n konsentrasie van 0.106 mol/dm3. Die tweede sisteem bestaan uit die PGM-kompleks ([PdCl4]2-; [PtCl4]2-; [PtCl6]2- of [RhCl6]3-) met natrium teen-ione in water in die teenwoordigheid van vier poli-etileenoksied (PEO) kettings by 30ºC en met ‘n konsentrasie van 0.013 mol/dm3. ‘n Studie is gemaak van die konformasies van die twee soorte dihedrale-hoeke in ‘n PEOketting (-C-O-C-C- en -O-C-C-O-) en die insense buigbaarheid van die polimeer is hiermee bevestig. Die dihedrale-hoek-verspreidings van die twee tipes dihedrale hoeke is bereken en word verduidelik in terme van die potensiёle energie kromvlakke soos bereken tydens die konformasie analiese. Die geometrie van die solvasie van die PGM-komplekse is bereken en vergelyk met die sisteme waar die polimeer (PEO) teenwoordig is. Hieruit word afgelei dat die effek van die polimeer op die struktuur en graad van solvasie van die komplekse minimal is. Die vrye energie van solvasie van die PGMkomplekse is bereken met die doel om insig in te win oor die stukturele eienskappe soos byvoorbeeld die volume van die solvasie sfeer en die geometrie daarvan. Die strukturele en termodinamiese eienskappe van die PGM-komplekse in oplossing word ook gebruik om die neigings in die berekende diffusie koёffisiente te verduidelik. Opmerkings word gemaak aangaande die akkuraatheid van die berekende diffusie koeffisiente asook die geldigheid van die meganistiese spekulasies wat daaruit gemaak word. Voorstelle word ook gemaak rakende toekomsige verbeterings aan die reken tegnieke.

Thesis (MSc)--Stellenbosch University, 2003. / ENGLISH ABSTRACT: The determination of the platinum group metals (PGMs), platinum, palladium, rhodium, iridium, ruthenium and osmium, remains a problem for the low-grade ore samples, and the analysis of these samples in a routine laboratory relies entirely on the fire assay technique. The use of large sample masses to overcome sub-sampling errors has been the greatest advantage of this technique. The increased economic value of PGMs and recent developments in instrumentation such as inductively coupled plasma-mass spectrometry (ICP-MS) which is capable of trace element detection as low as part per billion (Ppb) levels, have led to a search for complementary methods to ensure the accuracy of fire assay results. This work investigates the feasibility of direct dissolution of ore samples using microwave-assisted dissolution followed by ICP-MS as the measurement technique. Due to the limited sample mass that can be used, a thorough consideration had to be given to sampling errors and analytical errors to assess the overall precision achievable. Most PGM-bearing minerals occur as sulphides and these are highly resistant to acid dissolution. It was found that roasting the Merensky type samples in air, prior to dissolution gives quantitative recoveries for platinum. Recoveries up to 100% were obtained for platinum, palladium, rhodium and gold for a Merensky flotation concentrate with excellent precision (about 4%) except for gold which had poorer precision (16%). However, ore samples presented a problem due to their lower PGM content and smaller sample masses being used. Precision for all elements improved significantly (from about 20% to about 8%), with the use of l g-sample aliquot compared to that ofO.25 g-sample. Acid dissolution, even after roasting proved to be insufficient for the UG-2 chromitite samples. When roasting was followed with reduction under hydrogen flame the solubility of the UG-2 flotation concentrate improved remarkably. The recoveries obtained were approximately 95 ± 5% for platinum, 99 ± 5% palladium, 104 ± 12% gold and 102 ± 5% for rhodium with good precision (comparable to that of Merensky concentrate). The accuracy and precision of the results depended very much on the sample mass and air-flow in the furnace during the roasting procedure. For this method to be used successfully, the air flow is very critical, and should lead to a better furnace design which can rotate the crucibles to enable an even flow of air over all the samples during roasting. / AFRIKAANSE OPSOMMING: Die bepaling van platinumgroep metale (PGM'e), platinum, palladium, rhodium, iridium, ruthenium en osmium is 'n voortdurende probleem vir die lae-graad erts monsters. Die analise van hierdie monsters in 'n roetine laboratorium is geheel afhanklik van die klassieke "fire assay"-tegnieke. Die groot voordeel van hierdie tegniek is die voorkoming van monsternemingsfoute deur die gebruik van groter monster massas. Die ekonomiese waarde van PGM'e saam met die onlangse ontwikkeling van instrumentasie soos die induktief-gekoppelde plasma-massaspektrometrie (IGP-MS) wat in staat is om spoorelemente in konsentrasies so laag soos dele per biljoen (ppb) te meet, het daartoe gelei na soeke vir komplementêre metodes om die akkuraatheid van klassieke "fire assay" -tegnieke te verseker. Hierdie werk ondersoek die waarskynlikheid van direkte oplossing van ertsmonsters deur gebruik te maak van mikrogolf-ondersteunde oplossing gevolg deur IGP-MS as opmetingstegniek. As gevolg van die beperkte monster massa wat gebruik kan word, moes deeglike oorweging gegee word aan monsternemingsfoute en analitiese foute, om die oorkoepelende presiesheid te bepaal. Meeste PGM-draende minerale bestaan in die vorm van sulfiede en bied groot weerstand teen oplossing in 'n suur. Die gloei van Merensky-tipe monsters in lug voor oplossing gee kwantitatiewe herwinning van platinum Herwinning tot 100% is behaal vir platinum, palladium, rhodium en goud vir 'n Merensky-flotasie-konsentraat met uitstekende akkuraatheid (4%) behalwe vir goud met 'n swak (16%) akkuraatheid. Die erts monsters was problematies as gevolg van die laer PGM inhoud en kleiner monstermassas wat gebruik is. Presiesheid vir al die elemente het beduidend verbeter (van 20% tot 8%) met die gebruik van 1 g- monster massas vergelyk met 0.25 g-monsters. Ten spyte van die gloei van die monster is suur oplossing onvoldoende vir die UG-2 chromatiet-houdende monsters. Wanneer die monster gegloei is onder 'n waterstof vlam (reduksie) het die oplossbaarheid van UG-2 flotasie-konsentraat aansienlik verbeter. Die herwinbaarheid wat behaal is, is 95 +/- 5% vir platinum, 99 +/- 5% vir palladium, 104 +/- 12% vir goud en 102 +/- 5% rhodium met goeie relatiewe presiesheid vergeleke met Merensky-konsentrate. Die akkuraatheid en presiesheid van resultate hang meerendeels af van monster massa en lugvloei in die oond gedurende gloei. Die lugvloei is krities vir die sukses van hierdie metode en sal moet lei tot beter oond ontwerp wat kroesies kan roteer en 'n gelyke vloei van lug oor die monsters gedurende verbranding toelaat.

Thesis (MSc)--Stellenbosch University, 2014. / ENGLISH ABSTRACT: See item for full text / AFRIKAANSE OPSOMMING: Sien item vir volteks

Nitrogen oxides (NOx) are atmospheric pollutants that pose a serious threat to both the environment and human health. Although catalytic deNOx technologies for engines working under stoichiometric air-to-fuel ratios (i.e., most gasoline engines) are already available, their performance is unsatisfactory under excess air conditions like those under which diesel engines operate. The selective catalytic reduction of NOx with hydrocarbon reductants (HC-SCR) is a potential deNOxsolution for diesel engines, whose operating temperatures are 150-500 ºC. Given that is unlikely for a single catalyst to show acceptable activity throughout this entire temperature span, the use of two catalysts is proposed in this dissertation. Whereas several catalysts active at high temperatures (>300 ºC) are already available, a catalyst showing an acceptable performance at low temperatures (<300 ºC) is yet to be found. Platinum group metals (PGMs) supported on activated carbon have been identified as promising low temperature HC-SCR catalysts. However, these materials show three main drawbacks: 1) the propensity of the carbon support to undergo combustion in an oxidizing environment, 2) a narrow temperature window of operation; and 3) a high selectivity towards N2O (as opposed to N2). To address the first limitation, the use of multi-walled carbon nanotubes (MWCNTs) as the support has been investigated and found to yield catalysts displaying a higher resistance to oxidation. Further, the acid activation of MWCNTs prior to their use as catalyst support has been explored, following reports than link carrier acidity with improved catalyst performance. In turn, the use of PGM alloys as the active phase has been examined as a means to improve catalyst activity and selectivity. Additionally, kinetic, spectroscopic and mechanistic studies have been performed in an attempt to probe structure-activity relationships in the MWCNTs-based formulations showing the best deNOx performance. The fundamental insights gained through these studies may inform further improvements to HC-SCR catalysts. Finally, the synthesis of the most promising formulations has been scaled-up using commercial metal monoliths as the catalyst substrate and the resulting monolithic catalysts have been tested in a diesel engine for activity in the HC-SCR reaction.

The goal of this research was to devise a new analytical technique, using Accelerator Mass Spectrometry (AMS), to measure Platinum Group Element (PGE) concentrations to the sup-ppb levels in natural, insulating, samples. The challenges were threefold. First, a method of sputtering an insulating sample to successfully produce a stable beam of anions needed to be devised. Second, a suitable standard of known PGE concentrations had to be found and third, spectral analysis of the beam had to verify any claims of PGE abundance. The first challenge was met by employing a modified high intensity negative ion source flooded with neutral caesium that successfully sputtered insulators to produce a beam of negative ions. The second challenge, that of finding a suitable standard, was fraught with difficulties, as no synthesized standards available were found to be appropriate for this work. As a result, direction is provided for future production of standards by ion implantation. The third challenge, successful spectral analysis, was accomplished using a newly designed gas ionization detector which allowed for resolution of the interfering molecular fragment from the PGE ions. Coupled with the use of the SRIM computer programme, positive identification of all peaks in the spectra of the analyzed samples was accomplished. The success of the first and third challenges lead to the qualitative analyses of geological samples for sub-ppb levels of PGE by AMS. Quantitative analyses await only for the appropriate standards and with those will come a whole new range of research possibilities for measuring sub-ppb levels of PGE in insulating samples by AMS.