3. Electronic Theses and Dissertations (ETDs) - All submissions

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    Breaching the platinum cost curve: cost curve selection and development, marginal production survival
    (2019) Schmitz, Peter
    The report considers survival mechanisms used by Platinum Group Metal (PGM) producers over the period 2008 to 2017 when mining operations were considered marginal for an extended period. Various methods to build cost curves for the PGM industry were tested, with co-product costing, inclusive of sustaining capital, selected. Industry cost curves were developed for the period, showing that a significant portion of producers were marginal from 2014 to 2017, with Impala lease area, Rustenburg mines and Lonmin marginal for more than two years in that period. Survival was achieved through cross-subsidisation, utilising cash reserves, deferring sustaining capital, re-capitalisation and working capital management, before ultimately restructuring through sale or closure took place. While industry cost curves were effective at indicating operational competitiveness in a particular year, a mechanism to indicate relative financial strength (ability to sustain this position) needs to be sought.
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    Production and evaluation of precipitated calcium carbonate from steelmaking slag
    (2019) Kahlu, Mwengula Gentil
    This dissertation focus on the synergetic use of two of the essential wastes of modern steel manufacturing processes namely the steel slag (solid waste) and carbon dioxide (gaseous waste) in order to produce pure calcium carbonate which may be used for the neutralization of acidic mine waters. In this regards; calcium extraction from steel slag was first conducted using ammonium chloride and ammonium nitrate. Secondly precipitation of calcium carbonate from the calcium-rich leachate was assessed using carbon dioxide, and finally the calcium carbonate precipitated was evaluated for the neutralization of acidic mine waters from the Witwatersrand western basin. Both ammonium solutions selectively extract calcium from the steel slag, but the ammonium nitrate has better calcium extraction efficiency than ammonium chloride. The above was also confirmed by the number of extraction stages required to reach set extraction efficiency as determined using the Mc Cabe and Thiele Diagram method for the two different solvents. The carbonate (CO32-) ions formation being stable in very basic solution, the use of ammonia was required in order to raise the pH of the solution after extraction above 10.3. The calcium carbonate precipitation yield at room temperature evolved as a function of volume and pressure of gaseous carbon dioxide (CO2) injected and reached more than 80% at a pressure of 6.5 bar and a volume of 150 cm3. The scanning electron microscopy analysis of the dry calcium carbonate precipitate obtained revealed that it is comprised mostly of fine particles of rhombohedral shapes. It is our view that the above approach may alleviate environmental management of industrial discharges from steel plants as it allows the reduction of both the solid steel slag and CO2 emissions in the atmosphere via mineral sequestration and may eventually be a significant tool to help combat climate change. Finally, the recycle of the solvent after precipitation and associated losses were considered in order to reduce the cost implication of the overall project.
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    Thermodynamic and parametric modeling in the refining of high carbon ferrochromium alloys using manually operated AODs
    (2017) Mukuku, Kelvin
    This study and the work done involves investigating the effects of different parameters on the decarburization process of high carbon ferrochromium melts to produce medium carbon ferrochrome, and takes into account the manipulation of the different parameters and thermodynamic models based on actual plant data. Process plant data was collected from a typical plant producing medium carbon ferrochrome alloys using AODs. The molten alloy was tapped from the EAF and charged into the AOD for decarburization using oxygen and nitrogen gas mixtures. The gases were blown into the converter through the bottom tuyeres. Metal and slag samples and temperature measurements were taken throughout the duration of each heat. The decarburization process was split into two main intervals namely first stage blow (where carbon content in the metal bath is between 2-8 wt. % C) and second stage blow (carbon mass% below 2 wt. %). The first and second blow stages were differentiated by the gas flow rates whereby the first stage was signified by gas flow ratio of 2:1 (O2:N2), whilst the stage blow had 1:1 ratio of oxygen and nitrogen respectively. The effect of Cr mass% on carbon activity and how it relates to rate of decarburization was investigated, and the results indicated that an increase in Cr 66.54 – 70.5 wt. % reduced carbon activity in the metal bath from 0.336 – 0.511 for the first blowing stage. For the second blowing stage, the increase in Cr mass % of 67.22 – 71.65 wt. % resulted in an increase in C activity from 0.336 – 0.57. The trend showed that an increase in chromium composition resulted in a decrease in carbon activity and the same increase in Cr mass% resulted in reduced carbon solubility. Based on the plant data, it was observed that the rate of decarburization was time dependent, that is, the longer the decarburization time interval, the better the carbon removal from the metal bath. An interesting observation was that the change in carbon mass percent from the initial composition to the final (Δ%C) decreased from 10.18 – 8.37 wt. % with the increase in Cr/C ratio from 8.37 – 10.18. This effect was attributed to the chromium affinity for carbon and the fact that an increase in chromium content in the bath was seen to reduce activity of carbon. It was also observed that the effect of the Cr/C ratio was more significant in the first stage of the blowing process compared to the second blowing stage. A mass and energy balance model was constructed for the process under study to predict composition of the metal bath at any time interval under specified plant conditions and parameters. The model was used to predict the outcome of the process by manipulating certain parameters to achieve a set target. By keeping the gas flow rates, blowing times, gas ratios and initial metal bath temperature unchanged, the effect of initial temperature on decarburization in the converter was investigated. The results showed that the carbon end point with these parameters fixed decreased with increasing initial temperature, and this was supported by literature. The partial pressure of oxygen was observed to increase with decrease in C mass % between the first and second blow stages. For the second stage blow the partial pressure changed from 5.52*10-12 – 2.1*10-10 and carbon mass % increased from 0.754 – 2.99 wt. %. A carbon mass % of 7.87 had an oxygen partial pressure of 4.51*10-13 whilst a lower carbon content of 1.53 wt. % had an oxygen partial pressure of 8.06*10-11. The CO partial pressure however increased with increase in carbon composition in the metal bath. When the oxygen flow rate increased, a corresponding increase in the carbon removed (Δ%C) was observed. For the first stage of the blowing process, an increase in oxygen flow rate from 388.67 – 666.5Nm3 resulted in an increase in carbon removed from 5.06 – 7.28 wt. %. The second blowing stage had lower oxygen flow rates because of the carbon levels remaining in the metal bath were around +/- 2 wt. %. In this stage oxygen flow rates increased from 125 – 286.67 Nm3 and carbon removed (Δ%C) from 0.16 – 2.093 wt. %. The slag showed that an increase in basicity resulted in an increase in Cr2O3 in the slag. As the basicity increased from 0.478 – 1.281, this resulted in an increase in Cr2O3 increase from 0.26 – 0.68. Nitrogen solubility in the metal bath was investigated and it was observed that it increased with increasing Cr mass %. The increase in nitrogen solubility with increasing Cr mass % was independent of the nitrogen partial pressures.
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    Investigation of the leaching of the platinum group metal concentrate in hydrochloric acid solution by chlorine
    (2016) Asamoah- Bekoe, Yaw
    The dissolution of platinum-group metals (PGMs) requires a high chloride ion concentration in an acidic solution and a suitable oxidant. At Impala Platinum Refinery, the concentrate is leached in a hydrochloric acid solution using chlorine gas as the oxidant. The goal of this leaching step is a total dissolution of the PGMs and gold. The silver precipitates as silver chloride. The efficiency of this stage is crucial for the performance of the precious metals refinery. The aim of this project is to investigate the factors that influence the efficiency of the PGM leaching operation and to model for the results obtained. In order to investigate and evaluate the total dissolution of the PGt;~; in HClICl2 leach system, it is necessary to establish the effective conditions for the dissolution of chlorine gas in hydrochloric acid solution. The results showed that the solubility of chlorine gas increases with an increase in the acid concentration and chlorine gas concentration but decreases as the temperature increases. The HCI solution is almost saturated with chlorine after about 50 minutes. The chlorine mass' msfer coefficient is dependent on the temperature, the stirrer speed, the concentration of the HCI solution and that of the chlorine. [Abbreviated abstract. Open document to view full version]
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