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By W. W. de Graaf, M. J. Ntsekhe

Klipspruit Colliery is experiencing coal losses, which leads to a negative impact on coal production and subsequently loss in revenue. This study aimed to identify the possible causes of coal losses in the No. 4 upper and lower seams. The objectives were to identify potential sources of coal losses through a literature survey, to identify areas where the coal losses occurred, to determine factors affecting coal losses, and to identify the most cost-effective methods to reduce coal losses. Highwall losses, top-of-coal losses, and coal edge losses were identified as the major areas of coal loss at Klipspruit. These losses were mostly attributed to the drilling and blasting practises of the pre-split, interburden waste, and the coal seams. Recommendations include re-visiting the current pre-split design and the tolerances adopted for the interburden and coal seam drilling and blasting design. It is furthermore recommended that Klipspruit implement a continuous improvement plan for the drilling and blasting and refresher training for the blasting crew and operators.

Jun 10, 2024

By B. S. Agbenuvor, R. Morrison, V. Jokovic, C. Antonio

Body breakage usually involves breakage of particles by compression between two surfaces or impacted against a rigid surface, with the latter of interest in this current study. This mode of breakage has been identified to be the most elementary size reduction process and the most effective breakage process in comminution devices. It has been found in the literature that the progenies produced from this form of breakage possess a residual velocity at which they move, after the breakage event. In the pursuit of efficiently utilising applied comminution energy, a laboratory-scale breakage device has been developed to deliver precise specific impact breakage using the concept of a fast-moving hammer and a slow-moving particle to effect breakage. The residual velocities of the progenies from the breakage event may be used to generate secondary breakage without further addition of energy if the particle encounters a stiff obstacle such as a steel plate at right angles to its path. To measure the extent of secondary breakage, the steel wall of the device was lined with a rubber material to suppress the second set of breakage events. The performance of the new device is analysed, based on calculated t10 values and measured residual velocities of the moving daughter particles. Testing involving anvils showed a much finer PSD and higher t10 compared to the test involving rubber lining. This finding is corroborated by the measured residual velocities of the progenies. The resulting energies calculated from the measured residual velocities of the progeny were found to be approximately 42-88% of the primary specific impact energy. This retained energy was found to be sufficient for secondary breakage. Keywords: Impact breakage, residual velocity, secondary breakage, energy utilisation

Jan 1, 2020

By G. L. Gomes-Sebastiao, W. W. de Graaf

"Gomes Sand is a quarry operation that produces sand and aggregate for the construction industry. The quarry is experiencing inconsistencies in the fragmentation and poor pit conditions as a result of poor drilling and blasting practices. This results in excessive downtime in the load and haul and crushing processes.A benchmarking exercise of the blasting practices was conducted to evaluate the effect of the inconsistency on the mining cycle. After changes in the blasting practices the downtime was reduced, which improved the crushing plant utilization by 4.9%. The improved blasting practices and more consistent fragmentation decreased the average number of loads lost each month due to jaw crusher blockages from 9.2% to 3.9% of plant throughput. The change in blasting practices also improved pit conditions. IntroductionGomes Sand is a quarry operation that has been in operation since 2009, producing sand and stone for the construction industry. The quarry was experiencing unacceptable blasting results. The repercussions included uneven pit floors, large amounts of oversize rock (>500 mm), and inconsistent fragmentation.The blast results affected the load and haul operations as well as the efficiency of the crusher. This resulted in downtime in the daily operations, and consequent production and revenue losses.The crusher product should have a top size of 50 mm. A blast fragmentation of <50 mm would improve the downstream operations and the crusher throughput.An investigation into the blasting practices was carried out to assess whether the downstream delays can be eliminated by improving the blast results. The exercise included:* Assessing if the designed blast layout is adhered to on the bench* Observing the quality and control of drilling* Observing the charging procedure of the blast-holes* Benchmarking the fragmentation consistency of the blasted rock using current blast design and practices* Analysing the throughput of the crushing plant* Investigating the power consumption of the crushing plant and determine if a change in blasting practices will affect this* Evaluating the hours spent by the hydraulic hammer on secondary breaking."

Jan 1, 2017

By M. J. Nicol, R. P. Colborn

An investigation into the kinetics and mechanism of the oxidation of iron (11) by oxygen in aqueous chloride solutions By R. P. COLBORN Pr. Eng., Ph.D. (Natal) and M. J. NICOLt B.Sc. Hons., Ph.D. (Rand) A reaction mechanism for the oxidation of ferrous chloride by molecular oxygen is developed. and the appropriate constants are evaluated. The effect of a number of cations and anions on the rate of oxidation has been tested.

The aim of this research was to study the absorption characteristics of thermally dried fine coal from South African collieries. After milling to ?150 µm and pressure filtration, the samples were subjected to either air drying or thermal drying at 150°C. The samples were then put into a climate box at 28°C and at three different relative humidity levels, namely 30, 60 and 94 per cent. It was found that the equilibrium moisture content of thermally dried coal at a specific relative humidity was lower than that of air dried coal. The relationship between the equilibrium moisture content and relative humidity is described by 1 ? RH = exp (-KTMen). There was no relationship between the volatile matter content and equilibrium moisture content, but there was an increase in the equilibrium moisture content of the coal with an increase in mineral content. The moisture uptake rate increased with an increase in temperature and a decrease in particle size. A model is discussed that fitted the experimental data and gave a good prediction for changes in the conditions. There was no evidence of greater moisture absorption by thermally dried coal. Keywords: Fine coal, thermal drying, drainage, South Africa, drying

Jan 1, 2002

By M. S. P. Rampedi

The paper reports on a vacation work project conducted at Khuseleka No. 1 Shaft, Anglo Platinum, where there was a need to optimize the transport of personnel to level 15 and below. Approximately 900 men per hour need to travel between the shaft and the start of the current chairlift system. Time studies were used as the major indicator of the extent of the current problem, and it is recommended that a new chairlift system be installed to cover the distance from the vertical shaft station at level 15 to the chairlift decline station on level 15. A capital cost of approximately R10 million is necessary to carry out the proposed recommendation. Khuseleka No. 1 Shaft has the capacity to wind 1070 people per hour, and the current labour complement going to the level 15 shaft station stands at 1570 employees; thus at optimum efficiency the proposed chairlift system could transport the entire shift to the start of the current chairlift system in only 1 hour and 45 minutes. Reducing the distance walked at the start of the shift may also have an impact on productivity.

Jan 1, 2012

By M. C. Bhulose

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree The purpose of this project was to identify constraints that could occur in the current sub-decline shaft at Turffontein Shaft should an increase in production take place. Particular attention was to be paid to the transportation of men and materials and to the broken rock and ventilation capacity of the shaft. This project is an in-depth evaluation of the logistic capacity of the sub-decline system at Turffontein Shaft in order to determine by how much production can be increased in this area to replace tonnages from the vertical shaft area, where ore reserves are rapidly becoming depleted.

Jan 1, 2004

By L. Bbosa

Paper written on project work carried out in partial fulfilment of BSc (Hons) (Eng) (Mechanical) degree Discrete element methods (DEM) are being used to provide detailed impact histories of the particles in comminution devices, such as mills. To match this immense detail of information, far more informative breakage tests than those that are generally conducted are now required. The split Hopkinson pressure bar apparatus is used in this study, as it allows the calculation of breakage forces and absorbed energies. The geometry of rock particles has been identified as significant, so this project undertook to identify the influence of shape on the breakage pattern of blue stone. Comparisons are then made between the breakage pattern of angular rocks and rounded, milled rocks for single impact fracture and consecutive impact loading at low energy. Results of this experiment indicate that although breakage for both geometries occurs over a similar energy range, rounded particles have the greater probability of fracture because they absorb more of the impact energy for a given loading. Size distributions of progeny show that five pebbles or more are sufficient to predict the distribution of most particles in small energy regimes. Cumulative impact testing shows that considerably more energy is required to break a rock through cumulative damage than through a single impact?this is of considerable importance in the light of the indications from DEM simulations that most breakage in a mill will be from cumulative damage rather than single impact breakage.

Jan 1, 2006

By F. P. Hassani

Today, mine backfilling has become an integral part of mining operations, both from a local and overall ground control point of view, and as regards mining techniques and environmental considerations. During the past decade, substantial research has been carried out to contribute to the better understanding of the mechanisms involved in mine backfill behaviour. This work involved analytical, experimental and numerical studies at different scales. Accordingly, this work has been aimed at developing backfill design guidelines for actual working conditions. Backfill design for deep mining conditions is complex and requires understanding of various elements. The most important of these elements are: backfill inherent strength parameters, backfill placement method, stope geometry and interaction between backfill and host rock. The mobilization of backfill strength parameters controls the backfill behaviour and thus, its failure mode. It is believed that the governing boundary conditions and backfill-rock interaction influence the backfill strength mobilization significantly. Accordingly, the interaction between backfill and host rock is an influential factor in overall backfill behaviour under applied loads. The focus of this research is to investigate the backfill-rock interaction, considering a nonlinear behaviour for both backfill and rock mass. Assuming typical stope geometry, the FLAC code was used to model the complex boundary condition associated with narrow vein mining conditions and to simulate the backfill behaviour. A comprehensive numerical study was conducted and the results obtained were compared against field observations. The analysis of findings provides qualitative results, which can be used for backfill design. Keywords: Numerical modelling, backfill, deep mining, non-linear behaviour, rock mechanics, backfill behaviour, narrow vein mining.

Jan 1, 2008

By M. A. El-Sayed

"Double oxide films (bifilms) are significant defects in light alloy castings that occur when, during melt handling, the oxidized surface of the melt is folded over onto itself and then entrained into the liquid metal, encapsulating a portion of the local atmosphere. These defects create crevices in the final castings and have been shown to decrease tensile and fatigue properties, and also to increase their scatter, making casting properties unreproducible and unreliable. This paper reports on two different experiments performed to study the behaviour of such defects in Al alloys. In the first experiment and as a proxy for a bifilm, air bubbles were held in an Al-5Mg alloy melt for varying periods of time before the melt was allowed to solidify. The composition of the gas content of the bubbles was subsequently analysed using mass spectrometry to ascertain how it changed with time. In the other experiment the influence of the age of bifilms on the mechanical properties of Al-5Mg castings was assessed by holding castings in the liquid state for different times before solidification, followed by mechanical property testing and SEM and EDX studies of the fracture surfaces of tensile test bars. This research could provide a better understanding of the behaviour of double oxide film defects, and may lead to the development of new techniques by which these defects could be eliminated, or at least deactivated, in light alloy castings. Introduction One of the major structural defects affecting the reproducibility of mechanical properties of aluminium castings is the double oxide film defect (El-Sayed and Essa, 2017; El-Sayed and Ghazy, 2017). This type of defect is usually created as a result of poor filling system design. Owing to the very high reactivity of liquid Al-Mg alloy with oxygen in the air, the surface of the liquid metal can be considered to be permanently coated with an oxide film (Weigel and Fromm, 1990). As a consequence of surface turbulence, the oxidized metal surface can become folded over onto itself, but not fused, and then submerged into the bulk liquid, with a portion of the mould atmosphere being entrapped within it (Campbell, 2003; Al- Sayed, 2016; El-Sayed, Hassanin, and Essa, 2016)."

Nov 1, 2018

By M. Helm

Over the last 40 years, numerous investigations have focussed on the preg-robbing capacity of carbonaceous material during gold ore processing. Various techniques have been applied to characterize the physical and chemical properties of the carbonaceous material in efforts to predict its preg-robbing capacity. The present study, which forms part of an ongoing investigation, is specifically designed to increase the understanding of preg-robbing in ores containing carbonaceous material. In excess of 100 samples from 13 gold mines located in major gold provinces of the world have been incorporated into the present study. These samples were characterized using industry standard metallurgical techniques and were shown to have gold adsorption capacities ranging from a few grams to many hundreds of grams of gold per ton of ore. Further analysis showed that the crystalline nature of the carbonaceous material, which is related to its geological history, is important in determining the preg-robbing capacity of an ore. This finding builds on the common understanding that the preg-robbing behaviour of an ore is related to the amount (or abundance) of carbonaceous material present in that ore. In this study, Raman spectroscopy was used to evaluate the physical nature of carbonaceous material. This is a tool which has been successfully applied by researchers for the characterisation of carbon materials, with respect to crystallite size and lattice defects. Raman analysis of the samples included in this study showed varying degrees of disorder in the carbonaceous materials from the different deposits. Comparison of the Raman spectra with the gold loading capacities of the samples indicated a direct relationship between the structure of the carbonaceous material and its capacity to preg-rob gold. From this, a simple and robust method has been developed based on the Raman spectra of the sample and carbonaceous material content to predict the preg-robbing capacity of an ore. The potential exists to develop a predictive tool using Raman spectroscopy for characterising the preg-robbing capacity of an ore. Such a tool would have potential application in projects ranging from the early stage of exploration through to more detailed feasibility studies and mining operations. The result of applying the predictive method outlined in this paper would be the effective and proactive management of the deleterious influence of carbonaceous material on gold recovery in mining operations.

Jan 1, 2009

By P. H. Botha

An account is given of the procedures used by the South African Iron and Steel Industrial Corporation (Iscor) for tests on the flotation of coal fines, and some of the beneficiation problems encountered with coal from Durnacol, Grootegeluk, and the Soutpansberg area are discussed. These, and other South African coals differ from overseas coals in that they contain a high percentage of fixed ash, which means that they have to be crushed more finely for liberation and that they then contain more fine material (smaller than 0,84 mm). In addition, the coal from the three areas mentioned occurs in fine layers and seams, and contains many intergrown particles.

Jan 1, 1980

By F. T. Cawood

The new mineral royalty regime for South Africa was signed into law in November 2008, with its main objective being to compensate the State for the depletion of public minerals through a royalty charge payable from 1 March 2010. The aims of this paper are to establish the potential impact of mining royalties on State revenues, industry affordability, and explore whether the dual formula system is likely to encourage miners to become refiners. It also measures the royalty dispensation against economists? tax standards in an attempt to make a judgement on the ?equity? of the new system. This paper argues that most stakeholders should be comfortable with most of the requirements of the Act for most of the time. However, the new regime is unlikely to motivate miners to become refiners, as the benefit of the reduced rate on refined minerals appears to be insufficient to justify the additional costs to refine the mineral resource to the prescribed states of beneficiation.

Jan 1, 2011

By S. Combrink, N. Naude

Hydrocyclones are widely used in wet mineral classification applications and can be notoriously prone to wear. The methods currently used for quantifying hydrocyclone wear profiles are mostly twodimensional. In this paper it was attempted to quantify and monitor wear in three-dimensions, using a micro-CT scanner (Nikon XTH 225 ST). Hydrocyclone wear and, more specifically, spigot wear was investigated on a Multotec HC250 (Dc 250 mm, barrel diameter) hydrocyclone. The hydrocyclone is lined by a vulcanised natural rubber compound within a metal shell, with a thermosetting polyurethane spigot and vortex finder. Tests were conducted on the hydrocyclone in a pilot-scale recirculating test setup. The wear rate of the spigot was quantified by measuring the volume change within the spigot over 122 days in operation, using the micro-CT scanner. After 122 days in operation (recirculating feed materials) the wear in the hydrocyclone led to only a 13.67% loss of spigot volume. The relatively low wear rate could be related to the fact that material recirculation led to particle smoothing and a reduction in size, thereby decreasing the wear rate. This also shows the enormous influence that particle shape and size have on wear. The research was conducted with the support of Multotec, NECSA and the University of Pretoria. Keywords: Wear, hydrocyclone, micro-CT

Jan 1, 2020

By L. Lehasa

The purpose of the project was to investigate the challenges faced by Khutala Colliery pertaining to underground road construction and maintenance. Furthermore the influence of these challenges on productivity and safety requirements were taken into consideration. The operating standards required for the construction and maintenance of the 2 seam road transport infrastructure was investigated, together with reasons why the standards of operating procedure are not met. The Code of Practice put in place by Khutala Colliery was used to view the standard operating procedures. Leading practices on underground road construction were researched. The project aims to discover the gaps that Khutala Colliery must bridge to implement enhanced practices with regards to underground road construction. During the period of study, observations were carried out to determine whether the road construction standards of operating procedure were being adhered to at all times for both road construction and road maintenance. Khutala Colliery has put in place a traffic management plan, which includes safety practices and work policies that must be adhered to while travelling on underground transport roads.

Jan 1, 2012

By E. Adlard

This paper sketches an expert system for use underground in pinpointing problem areas in the operation of machines. The system is typically a software &apos;shell&apos; designed to accommodate a series of &apos;if-then&apos; rules that are intertinked to systematically search for the cause of the problem. During the search, the system asks a series of questions that have to be answered by the operator and then, when necessary, by an artisan. The rules of the system are generated by a knowledge engineer whose function it is to gather the necessary diagnostic information and prepare it in the required format for the expert system. Much still requires to be done in the development of such systems and in the testing of hardware to withstand the mining environment.

Jan 1, 1990

By D. G. Hulbert, D. J. Oosthuizen, D. de V. van der Spuy

Expert Online, as a software system, is aimed at providing plant operators in the minerals industry with effective training and on-the-job assistance. It incorporates a number of features to achieve this goal, of which the most important is its ability to explain the dynamics of the plant and control system in simple language, mimicking an informed plant expert who has online access to the inner workings of the plant and control system. This is made possible by a novel form of Artificial Intelligence, called the Interpreting Expert System. Previous implementations of the IES were only capable of explaining controller actions. Expert Online will extend this capability to also perform the more difficult task of explaining process behaviour. Expert Online will implement three main processes, namely the accumulation of data from the controllers and plant models, the interpretation, processing and filtering of that data and lastly communicating the relevant information to the user, both as written messages and in other audio-visual forms. Although Expert Online is aimed at the operator, other plant personnel, like supervisors and plant managers, will also benefit from it. This paper focuses on the structural and functional design of Expert Online for implementation on the latest version of Mintek’s open control platform, PlantStar, highlighting advances and additions since the previous implementations of the Interpreting Expert System and concluding with an example illustrating some of the principles.

Jan 1, 2003

By N. B. Prenn, R. H. Robinson

"The model described is a design and economic planning tool for analyzing surface mineral deposits. Mineralization, topography, costs and significant geologic features are input to the model. The results are:(i) final pit limits yielding the maximum total profit,(ii) annual cut-off grades and plant sizing yielding the maximum present value, and(iii) annual maps of the pit and annual production statistics for the mine, concentrator and smelter.Additionally, summaries are printed of the block mining sequence and cash flow. A special feature is an option to include dump-leaching operations. Stockpiling of material can also be simulated by the model. The model is built around theories of dynamic cut-off grades and a pit design algorithm. The dynamic cut-off grades maximize present value by examination of all economic and physical constraints for the optimum combination. The pit design algorithm is a set of rules formulated to find the maximum value from a special graph. The graph is different from graphs of analytical geometry, being made up of points and arrows connecting some of the points. These graph elements describe the relationship between any point in the deposit and the material which must be mined to get at that point. The model was designed to bring together the interdependent theories of economics, pit design and production scheduling."

Jan 1, 2014

By M. Weir, J. R. Cutland, L A. J. Pronk van Hoogeveen

"A computer system for the design of open pits to mine stratiform orebodies has been developed for use at Nchanga Consolidated Copper Mines, Ltd. The particular requirements of such a system, for example, the accuracy of representation of geological detail and the ability to follow footwalls, arc described in this paper, together with the methods that have been adopted to satisfy them.A modified version of the Open Pit Design Program of Rio Tinto Zinc Consultants, Ltd. is incorporated in the system and the geological data are converted into a form usable by the computer by means of a pencil follower. Some of the uses which have been made of the system are described, with reference to the long- and medium-term planning of the Nchanga Open Pit, the major producing pit at Chingola Division."

Jan 1, 2014

By M. Frenzel, K. Bachmann, M. Rudolph, R. Tolosana-Delgado, E. Schach, M. Buchmann, L. Pereiraa, K. G. van den Boogaart, N. Kupka

Geometallurgy - the science of predicting the behaviour of ores along the value chain based on their geological and mineralogical characteristics - has barely moved beyond process minerology studies. These studies typically link process behaviour to the mineralogical and microstructural characteristics of pristine or processed ores in a qualitative or semi-quantitative manner. Eventually, a trial-and-error optimisation of the operation is achieved. However, to deliver on its promise, geometallurgy should progress beyond this current approach to a fully quantitative understanding of process behaviour, including the various uncertainties involved, namely predictive geometallurgy. One of the barriers currently hindering this development is the neglect of most ore characterisation data obtained in geometallurgical studies. This is mostly due to the large extent of this information exceeding the capacity of conventional software. To address this challenge, we developed a data mining platform consisting of an SQL database, an R front-end in-house package, and back-ends to interpret data from several analytical instruments. This platform enables the use of the statistical and data mining power of the R open-source environment for any geometallurgical study. Potential applications range from ore characterisation to process understanding and forecasting, and from geostatistical prediction to operational control and optimisation. The scripting abilities of R allow for the: 1) processing of many streams in loops, thus freeing the user from repeating tedious click-and-drop tasks; 2) computation of virtually any derivate or aggregate quantity from the data; 3) distribution of the work among several processor clusters; and 4) keeping of a log file for the calculations done. This contribution presents the building blocks of this platform, and illustrates with several examples its potential to enable predictive geometallurgy. Keywords: Data mining, entropy, kernel methods, LASSO regression, predictive geometallurgy

Jan 1, 2020