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By M. Grozdanovic, D. Marjanovic, M. Ilic

We present a framework for solving the problem of functional compatibility between process control equipment in control centres at underground mines and operator capabilities. The equipment incorporates displays of current ventilation, gas, and fire hazard data, status of alarm and early warning systems, a voice communication subsystem, and facilities for recording and printing ofdata and reports. The layout of the existing control panel is compared with a recommended design. The basic principles of ergonomic design and arrangement of the controls and indicators, as well as ease of use, type of operations carried out with these controls, and operators’ viewing angles are discussed. The objective is to improve the usability of control panels, display boards, and graphic screens so as to enhance the functioning of control centres and optimize control of technological processes in coal mines.

Jun 10, 2024

By K. Hodgson, Cook. N. G. W.

Most structures are designed so that the possibility of failure is eliminated. However, some degree of failure in the rock around deep mine excavations is inevitable if mining operations are continued. The presence of failed rock constitutes a hazard the magnitude of which can be predicted by computer models from calculations of the energy change per unit area mined in stopes, or the field stress around service excavations. Empirical relationships between these calculable quantities and the incidence of rock failures and delays associated with them have been established. Experiments on the computer using different layouts enable the mining engineer to select the least hazardous of otherwise acceptable alternatives, and to predict the incidence of damage ahead of actual mining, so that appropriate measures to maintain an adequate degree of safety and productivity can be planned in advance.

Jan 1, 2014

By W. A. Smith, M. C. Bekker, C. Marnewick

Projects or project-orientated approaches have become a common form of work in nearly all sectors of economies. This has led to concepts such as ‘projectified’ and ‘project orientated’ organizations. By defining projectification of a company, industry, or economy as the share of project work in total work, one can reasonably determine the impact that project management, and by default projectification, has had on that company, industry, or economy in terms of staff optimization and allocation. This paper presents the results for such a projectification study of the South African mining industry. This sector has long been a significant contributor to the country’s economy from a gross value added (GVA) and employment point of view. Understanding the impact of projectification and the project management way of work on this industry may potentially add significant value to both the mining and project management knowledge areas. We show that although the mining industry is considered by some to operate in archaic ways, the level of projectification has increased over time, and now represents approximately one third of all work conducted.

May 1, 2021

By L. Aspola

The platinum group metals (PGMs), i.e. ruthenium, rhodium, palladium, osmium, iridium, and platinum, are typically found in association with each other, but also importantly, with nickel and copper. Typically Platinum and palladium have the greatest economic significance and other PGMs are typically produced as co-products of these. With recent increases in the value of nickel, cobalt, and the PGMs and an ever increasing focus on the sustainable use of metals, interest in the processing of secondary feed material sources and metal-bearing residues has also substantially increased. As an efficient, proven, and environmentally sound technology Outotec Ausmelt Top Submerged Lance (TSL) Technology has gained commercial acceptance in the nickel industry, including PGM recovery. For the processing of nickel- and PGM-bearing feed materials, five Outotec Ausmelt Furnaces at four sites are in operation. Two of these furnaces are located in Rustenburg, South Africa, which is by far the biggest mine-based producer of platinum. Outotec also has hydrometallurgical processes available for further treatment and extraction of PGMs, which are also briefly discussed.

Jan 1, 2012

By H. Möller, M. Tshibalanganda, C. Taute, A. du Plessis, M. Leary

Additive manufacturing can be used to produce complex and custom geometries, consolidating different parts into one, which in turn reduces the required number of assemblies and allows distributed manufacturing with short lead times. Defects, such as porosity and surface roughness, associated with parts manufactured by laser powder bed fusion, can severely limit industrial application. The effect these defects have on corrosion and hence long-term structural integrity must also be taken into consideration. The aim of this paper is to report on the characterization of porosity in samples produced by laser powder bed fusion, with the differences in porosity induced by changes in the process parameters. The alloy used in this investigation is AlSi10Mg, which is widely used in the aerospace and automotive industries. The sample characteristics, obtained by X-ray tomography, are reported. The design and production of additively manufactured parts can be improved when these defects are better understood.

Apr 1, 2021

By N. Tatalias, P. Ilunga, M. Lampi, J. Edwards, K. Valkama, M. Nicolle, D. Samal

"Developing a greenfield mining project is a complex exercise: doing so in an increasingly volatile, uncertain, and ambiguous global economy adds significantly to this complexity. In the context of an elevated cobalt price, this paper outlines the metallurgical and process development of the Mutoshi copper–cobalt project for copper cathode and cobalt hydroxide production in the Democratic Republic of Congo. Chemaf has a long production history on the Copperbelt, a region widely perceived to be tough to operate in. This history stretches back to 2001, during which time the company has developed two copper–cobalt processing facilities. The experience gained in the development and operation of these two facilities has been used extensively in the Mutoshi copper–cobalt project. The metallurgical test work, process design, and project delivery approach are presented. Additionally, the decisions taken to minimize risk and maximize upside to the project are discussed. IntroductionChemaf (Chemicals of Africa), a mining company located in Katanga province of the Democratic Republic of Congo (DRC), has been operating since 2001 with two major copper– cobalt processing facilities: the Usoke and Etoile plants. In 2016, Chemaf acquired the Mutoshi mine, which belonged to Gecamines and had been explored by Anvil Mining since 2004 under a joint venture with Gecamines. Chemaf appointed African Mining Consultants Ltd (AMC) to undertake a preliminary economical assessment, then develop a JORCcompliant Mineral Resource estimate and finally a full life-of mine feasibility study. Both a Mineral Reserve and Mineral Resource were developed and the final life-of-mine feasibility study is to be published shortly. A metallurgical test work programme was initiated and carried out by Chemaf’s research and development laboratory with assistance from the Chemaf process team. After completion of the initial test work, Chemaf developed a process design criteria document for a 20 kt/a copper cathode and 8 kt/a cobalt in hydroxide production plant, followed by a flow sheet and supporting METSIM mass balance. As the drilling progressed, the plant design capacity was revised to 16 kt/a cobalt production. The life of the mine at this production rate is over 40 years."

Nov 1, 2018

By R. L. Setsepu, S. O. Bada, J. Abdulsalam

The utilization of biomass as a solid fuel for co-firing has received great attention from boiler manufacturers as a clean coal technology (CCT) option. This research aimed to produce biocoal pellets, as a clean energy fuel, using hydrochar from trees planted to rehabilitate acid mine drainage (AMD) water and fine coal discards. The hydrochar was synthesized by hydrothermal carbonization of Searsia lancea harvested from AMD-contaminated land at a temperature of 280°C and a residence time of 90 minutes. It was blended with discard coal (–1 mm) at ratios of 25% and 50% hydrochar to produce different forms of solid pelletized biocoal (BC). The physicochemical and mechanical properties of each of the biocoal pellet blends were determined. The 100% hydrochar had the highest calorific value of 29.99 MJ/kg, while the raw discard coal had a calorific value of 16.73 MJ/kg. The ash content decreased from 42% in the discard coal to 25% in the blend of 50% coal and 50% hydrochar biocoal pellets. Biocoal pellets comprising 25% hydrochar and 75% discard coal (BC25 HC/75 COAL) displayed the best mechanical properties (compressive strength 3.06 MPa) of all the fuels, but the physicochemical properties were inferior to the BC50 HC/50 COAL pellets. This research has demonstrated that hydrochar synthesized from a tree species planted for hydraulic control of AMD has the capability to act as a binder for improving the mechanical properties and energy characteristics of fine discard coal.

Dec 1, 2021

By J. Sjöberg, T. Savilahti, S. B. Umar

"Sublevel caving in Malmberget mine results in mining-induced surface deformation. One of the currently mined orebodies is the Printzsköld orebody. As mining deepens there is need to assess the behaviour of the cave formed in the subsurface above this orebody. Numerical analysis was used to assess the effects of extraction to deeper levels and perform strength parametric studies. Stress redistribution was studied, and the results showed high stress buildups in the hangingwall and the crown pillar. Two failure mechanisms have been identified – shear and tensile. Reducing cohesion by 50% increased the area of the yielded zone by more than 100% in the hangingwall.IntroductionThe Malmberget mine is owned and operated by the Luossavaara-Kiirunavaara AB (LKAB) mining company. Iron ore is extracted by large-scale sublevel caving. The mine comprises a total of 20 orebodies, about 10 of which are in production today (Figure 1). The mine is located in the municipality of Gallivare, about 100 km north of the Arctic Circle (Figure 2).Successful sublevel caving requires progressive caving of the orebody after initial blasting. This results in caving of the hangingwall, sometimes all the way to surface, resulting in surface deformation. As mining progresses to deeper levels a larger area is affected by deformation. Over the years, extraction from the Malmberget orebodies has led to deformation of the ground surface, affecting residential areas and existing infrastructure.Forecasting the caving process is not straightforward as it can be rapid or slow, depending on the rock mass conditions, stress conditions, the failure mechanisms at work, etc. Moreover, several of the orebodies in Malmberget are non-daylighting, which makes reliable caving analysis even more difficult, primarily since there is less available experience from such cases. The present study was designed to improve the understanding of the caving and deformation mechanisms at Malmberget, and in particularly for the Printzskold orebody"

Jan 1, 2017

By von Wielligh. L., D. G. Hattingh, M. N. James, W. Thomas

"SynopsisThe process of joining materials by friction is based on generating the heat necessary to create a solid-state mechanical bond between two faying surfaces to be joined. In simple terms, the components to be joined are subjected to frictional heating between rubbing surfaces, causing an increase in interface temperature and leading to localized softening of interface material, creating what is described as a ’third body’ plasticized layer. This plasticized zone reduces the energy input rate from frictional heating and hence prevents macroscopic melting. The plasticized layer can no longer transmit sufficient stress as it effectively behaves as a lubricant (Boldyrev and Voinov, 1980; Godet, 1984; Singer, 1998; Suery, Blandin, and Dendievel, 1994). The potential for this solid-state frictional joining process to create high-performance joints between, for example, dissimilar materials with limited detrimental metallurgical impact, and reduced defect population and residual stress level, has had a very significant impact on fabrication and repair in industrial sectors such as transport. This paper presents a brief overview of the advances made within the family of friction processing technologies that could potentially be exploited in the nuclear industry as alternative joining and repair techniques to fusion welding.Modern friction processing technologies can be placed into two main categories: those that make use of a consumable tool to achieve the intended repair or joint (friction stud and friction hydro-pillar processing) and those making use of a non-consumable tool (friction stir welding). The most mature friction joining technology is friction rotary welding, where a joint is formed between original parent materials only. A new addition in this category is linear friction welding, which opens the potential for joining complex near-net-shape geometries by friction heating. The continuous innovation in friction processing over the last 25 years has led to the development of a number of unique processes and applications, highlighting the adaptability of friction processes for specialized applications for high-value engineering components.IntroductionAssessing the potential for using alternative joining and repair techniques for specific applications in a given industrial sector is informed by an appreciation of the current size and potential growth in that sector. Power generation by nuclear fission has been out of favour over the past few years, due to several high-profile nuclear incidents, e.g. the Fukushima Daiichi nuclear disaster, as well as concerns over disposal of nuclear waste and spent fuel rods. However, due to rapid increases in the demand for electricity, coupled with many fossil-fuel fired plants reaching end-of-life, there is renewed interest in installing additional nuclear capacity."

Jan 1, 2015

By M. Ye. Scheglov, G. I. Voiloshnikov, S. M. Ryakhovsky, V. E. Dementyev, V. N. Alekseev, N. S. Voiloshnikova

Irgiredmet has substantial experience on RIP and RIL technology for gold recovery, having started development of ion exchange technology in 1964. Irgiredmet specialists were involved in the majority of RIL and RIP projects in the former Soviet Union and Russia, and took part in commissioning of practically all plants using ion exchange technology. Laboratory and pilot plant tests were conducted to develop process design criteria for designing 15 RIP plants of the former USSR using bifunctional macroporous anionite AM-2B or its analogs. This paper is devoted to the laboratory, pilot plant testing and introduction of RIP technology conducted in cooperation with GC Pertopavlovsk. Medium base resin PuroLite S992 (PuroGold) was used as adsorbent. Some adsorption regularities and the affinity of resin to metal cyanide complexes were studied. Laboratory batch and continuous pilot tests on resin-in-pulp process were held for oxidised ores from Pioneer, Albyn and Malomyr mines (Amur region, Russia) owned by the Petropavlovsk company. A simplified flowsheet for gold elution and resin regeneration was developed. Alkaline cyanide solution was used as gold eluent and gold was recovered from eluates by electrowinning. Process design criteria were developed on the basis of the testwork results, and the plants were designed and constructed by GC Petropavlovsk. The RIP plant at Pioneer was commissioned in May 2008, at Malomyr in August 2010, and at Albyn deposit in December 2011. These plants are currently in operation at design performance at throughputs from 3 to 6.5 Mt/year. The primary gold ores of Pioneer and Malomyr deposits are refractory to cyanidation; Irgiredmet also completed continuous testwork on RIP technology using medium-base resin for pressure oxidation (POX) residues derived from their flotation concentrates. In 2019 a hydrometallurgical plant for the treatment of refractory gold concentrate after POX was commissioned at Pokrovsky mine (Amur region). Keywords: Gold ores, cyanidation, RIP, RIL –processes, ion exchange resin, medium base resin, adsorption, elution, electrowinning

Jan 1, 2020

By K. M. Primrose

Electrical tomography has developed rapidly over the last few years in its sophistication and practical use to enable three-dimensional information on the distribution of phases within flowing mixtures to be observed1. This paper reviews the current state of application from the industrial perspective, drawing on applications case studies based on scaling studies in the laboratory right through to installations on plant. In the laboratory, applications have looked at scale-up of mixing2 processes involving gas-liquid and solid-liquid suspensions3 with a particular interest in verifying computational fluid dynamics simulations or in checking scale-up design4,5. In the processing plant, the circumstances are usually bespoke and may range from simple detection of the degree of homogeneity of a flowing mixture through to the need to measurement a sophisticated batch process such as crystallization, sedimentation, filtering and drying. Examples drawn from the chemical and pharmaceutical industries will be presented and related to the benefits that can be gained through application of the method.

Jan 1, 2008

By M. Lange

The postulation that primary platinum group metal (PGM) matte will chemically react with magnesia-chrome bricks when temperatures exceed 1500°C was tested. Magnesia-chrome brick samples were heated in contact with matte at 1300°C to 1750°C for 30 minutes, after which the refractory samples were analysed using reflected light microscopy and scanning electron microscopy. The samples were all completely penetrated by matte. As the temperature increased the matte also penetrated the fused aggregate grains and disintegrated them. The chromium concentration of the matte inside the refractory samples was found to be slightly higher than that of the bulk matte. At temperatures of 1500°C and higher, MgO, FeO, and magnesium-rich silicate crystals could be identified in the matte directly adjacent to the refractorymatte interface. Phase relations clearly indicated that chemical reactions take place between primary PGM matte and the magnesiachrome refractory material at temperatures above 1500°C, but that these reactions are more complex than expected from FactSAGE® calculations.

Jan 1, 2014

By R. J. Mason

Background to the Transvaal Iron Age-new discoveries at Olifantspoort and Broederstroom R. J. MASON*, Ph.D. (Visitor) The work being done on Iron Age sites in the Transvaal is described, with particular reference to the finds at Olifantspoort and Broederstroom. The material so far found provides evidence for the production of iron and copper, the farming of cattle and sheep, and the construction of large villages by people who were probably ancestral to the present Bantu population. The material dates from as early as A.D. 270, but clear indications occur from AD. 460 onwards.

Jan 1, 1974

By P. C. Pistorius, D. Kruger, Y. Kacar

Because of its superior properties, stainless steel has been widely used for many applications. Nonmetallic inclusions can influence the quality of stainless steel products. A set of samples was used to track the response of inclusion composition during processing of a heat of titanium-bearing 18% chromium steel, from deoxidation after decarburization, to the solidified slab. The oxide inclusions responded as expected to additions of deoxidizers and calcium treatment, changing from silica to alumina and spinels, and then to calcium aluminates. The samples confirmed that titanium nitride can nucleate on liquid calcium aluminate during steel solidification.

Aug 1, 2021

By R. J. Quevedo, Y. A. Sari, S. D. McKinnon

The large scale of cave mines leads to many challenges, including operational logistics and geomechanics design. In current practice, pillar stability assessment relies almost exclusively on stress analysis. However, stability is also affected by other factors including those related to operational aspects of the mining method, the effects of which are difficult to account for during the design stages. In this paper we present a case study of the application of a machine learning approach to evaluate the influence of these operational factors on pillar stability at the Chuquicamata underground cave mine in northern Chile. Due to the likely multi-factorial damage process leading to collapses and considering the different pillar conditions, a tree-based machine learning method was used and analysed to improve the understanding of the relative importance of the various contributing factors. Unlike stress analysis methods, it does not require any a priori knowledge of failure mechanisms, nor the calibration of associated controlling parameters. The proposed random forest model predicted pillar collapses with 80% accuracy despite limited samples to model from. The main contributing factors to collapses were found to be related to available pillar volume, cave front geometry, and time under abutment stress conditions. The effects and interactions of such factors were also studied, showing that careful and improved control over operational conditions can significantly reduce the likelihood of pillar collapses. These conclusions could not have been obtained from stress analysis alone, illustrating the complementary nature of conventional stress analysis and machine learning approaches.

Mar 14, 2024

By K. Eckert, A. E. Sommer, S. Heitkam

One highly relevant challenge in flotation is the recovery of fine particles. Due to their low inertia, these particles are mostly pushed aside by rising bubbles. Consequently, they typically exhibit low probability for bubble-particle collision and thus, a poor recovery rate. In this work, the trajectories of fine particles in the vicinity of rising bubbles were investigated. The measurements considered a chain of millimetric bubbles in a rectangular container filled with deionized water. The flow field near the bubbles was measured by tomographic particle image velocimetry (TPIV), employing fluorescent tracer particles of 33μm diameter. Subsequently, trajectories of larger particles and bubble-particle collision events are recorded with 4D particle tracking velocimetry using a high temporal and spatial resolution. The results reproduce the well-known collision of particles on the leading edge of a rising bubble. Additionally, collisions on the tailing edge were observed in cases with a low Stokes number. The TPIV results demonstrate, that the high turbulent kinetic energy in the bubble wake allows particles to divert from the fluid streamlines and collide with the tailing edge of the bubble. The tailing edge collision probability increases with the bubble Reynolds number and decreased particle inertia. Overall, the investigation shows that the collision of fine particles in the bubble wake should be considered for the development of further collision probability models. Furthermore, the importance of turbulence on the fine particle flotation was demonstrated. Keywords: 4D Particle tracking velocimetry (PTV), tomographic particle image velocimetry (TPIV), fine particle flotation, collision probability, bubble-particle interaction, wake induced collision

Jan 1, 2020

By N. C. Joughlin, D. K. Hallbauer

The size distribution and morphology of gold particles in Witwatersrand reefs and their crushed products by D. K. HALLBAUER, Dr. rer. nat., Dipl. Min. (Visitor) and N. C. JOUGHIN, B.Se. (Eng.), Ph.D. (Rand) (Member) Undistorted gold particles were obtained from samples of a variety of Witwatersrand reefs by dissolution of the quartz in hydrofluoric acid. The size distribution of the gold particles and their shapes and association with thucholite and pyrite are discussed. Gold particles with a natural flat, plate-like appearance occur in varying proportion in all reefs. The effect of a number of different comminution processes on the gold particles was investigated, and the shape of gold particles in mill pulp from a number of mines was examined.

Prof C T O'Connor holds the degrees of BSc, BSc Hons, University of Cape Town (UCT), where he started his academic Lecturer in the Department of Physical Chemistry in 1976. Mr P Smith, educated in England and the former Southern Rhodesia, joined Gold Fields of South Africa in 1966 as a Metallurgical Learner Official. After obtaining a BSc Eng at the University of the Witwatersrand in 1972, he returned to Gold Fields. Mr P D K Robinson was born in Zimbabwe, and was educated at Dale College in Kingwilliamstown, matriculating in 1952. He holds a Mine Surveyor's Certificate obtained in 1961) and a Mine Manager's Certificate (obtained in 1966), as well as an EDP from the University of the Witwatersrand.

Jan 1, 1991

By E. Emami, J. Valencia, J. Sattarvand

The knowledge of the final location of a drillhole is critical in obtaining the expected blasting results. This paper proposes a new methodology to control the drilling accuracy in open-pit mines using aerial images and machine learning. Specifically, it investigates how support vector machines (SVM) and convolutional neural networks (CNN) are useful for automatically detecting blastholes over drone images captured in blasting patterns. Several datasets were obtained from different mines in Nevada (USA) and were used to train and test models. We then processed those images to create orthomosaic and digital elevation representations of the patterns. Thousands of patches were then extracted and augmented to develop SVM and CNN models. The results demonstrate that machine learning is useful for drillhole detection and, in this way, to control the drilling accuracy and use the explosive energy more efficiently.

Sep 1, 2021

By More-O&apos, R. C. Ferrall, J. W. Wilson

Discussion: M. D. G. Salamon* (Fellow): The theoretical principles behind the techniques of calculation used by the authors was formulated and published during the period 1962- 65. These principles, together with their practical implications, were summarized in a review paper in 1966.1 Now, in February, 1970, we have this long and comprehensive paper discussing the practical application of the theory. I think this is good progress. The large number of practical examples treated in the paper clearly demonstrates not only the skill and knowledge of the authors, but also the versatility of the techniques of analysis. I feel that the techniques described by the authors, and their improved versions, will revolutionize mine planning. I suggest that no shaft system or stoping layout should be planned in future without an adequate rock mechanics analysis. It seems that it will be progressively more difficult to white wash mistakes in rock mechanics and attribute their costly outcome to normal mining risk. We should not, however, become complacent. There is still a lot to learn and do in the future. I do not want to discuss tonight the question of further research but instead, I will raise two other problems which may hinder the future progress of practical rock mechanics. To carry out work similar to that described in the paper, mine managements require men who are capable of doing the work and who have the most efficient techniques of analysis at their disposal. As a research engineer I have been associated with the development of techniques of analysis. I can assure you that these have undergone an amazingly rapid development during the last six years. We have seen the change from the use of the electrolytic tank analogue and manual integration to the method described by the authors, that is, to the employment of the automatic network analogue and computer integration. But this is not the end. In a recent paper Prof R. P. Plewman2 and his co-authors described a completely digital technique. Here the process of calculating on- and off-reef quantities is integrated into one computer run. But these sophisticated methods of computation are useless without men to make intelligent use of them. During the last few years a new breed of mining engineers has appeared on the scene - the Rock Mechanics Engineer. I feel it is timely to call the attention of the senior members of this Institute to the fact that this new breed will succeed in carrying out its duties in a valuable manner only if we manage to attract to its ranks young engineers of the right quality. The requirements are high. The top rock mechanics engineers have to be good mine planners and they have to understand the essence of sophisticated theories. Without these attributes they will not succeed in the long term and the industry will not gain the benefit of available knowledge. To attract this quality of engineers the industry will have to ensure that rock mechanics is accepted by all concerned as a career which could lead to the top echelons of our profession. Finally, I would like to make one or two remarks concerning Part I of the paper. In Sections 3.1 and 3.2 the authors describe methods of determining the normal stress on the reef plane and the convergence distribution in the excavations. The description as given applies only to a horizontal reef. When the reef is inclined the situation is more complex since a shear component of stress on the intact reef and a ride component in the excavations must then also be determined. These can be calculated by methods similar to that described in the paper.3 The practical application of the method of calculating the released energy (Section 3.4) is in the comparison of various stoping layouts to establish an order of preference in terms of decreasing rates of energy release. To carry out these comparisons effectively, the calculations must be carried out in a manner by which the values of energy per unit area obtained are comparable. I would like to note in this respect that the method of calculation given in the paper is valid without reservation only if there is no elastic contact between the hanging and foot walls in the mined-out area. If there is contact then the calculated energy values are correct only if the mined out area is increased in small steps during the analysis. My second point in this regard is concerned with the practical method of calculation as described in Sections 3.4 (ii)-(iii). Firstly, I would like to suggest that the energy calculation should be carried out, as far as possible, by using always the same scale on the analogue. Secondly, the reading of current on a pin should be followed by the removal of that pin to obtain the corresponding reading of potential. The product of these two values will be proportional to the energy released during the mining of the small area corresponding to that pin. The method suggested by the authors tends to mask possible danger points in the layouts, since they obtain an average value for a time period, say, for six months.