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By J. Engelbrecht

Understanding the deportment of minerals in size fractions has already led to improvements in the flow sheets for platinum minerals beneficiation. There are, however, more potential changes in the flow sheets that may improve the recovery of platinum group metals or reduce the costs of beneficiation before refining. Based on known technology of pre-concentration, milling, gravity concentration, flotation, and magnetic separation a number of potential alterations or additions can be considered and motivated based on the mineral deportment in size fractions.

Jan 1, 2012

By I. H. Clark

In some mining situations, backfills are not only required to be free-standing but are also expected to provide hangingwall support. It may therefore be specified that the backfill withstand a certain calculated stress within a given time. Given the materials available, the choice of backfill composition is not always straightforward, and an approach to the evaluation of cemented tailings backfill is therefore proposed. The general use of such a method will greatly assist in both the scientific analysis of the material properties for industry-wide purposes of comparison and decision-making as regards the choice of fill.

Jan 1, 1988

By J. F. Morrison, C. H. Wyndham, N. B. Strydom

INTRODUCTION The shovelling of rock in stopes is still a basic and important operation in many gold mines in the removal of gold-bearing rock from the stopes. There is, however, little factual knowledge of the factors which influence the the rates of energy expenditure and work output, and of the way in which variations in these factors, individually or in combination, affect the mechanical efficiency of the mine workers. What for example is the influence of different rates of shovelling, shovel loads and distances of throw? How does stope width and dip of the stope affect the mechanical efficiency of men shovelling rock? Recently a simple physiological test was introduced into the gold mining industry for classifying Bantu recruits into those capable of hard, moderate and light work. If this test is used to select only those Bantu mine workers who are capable of hard work for the task of shovelling rock in stopes then the rate of energy expenditure which could be expected from these men is 1.5 litres/min for the entire period of the shift. With an adequate knowledge of the influence of the various factors which affect the rate of energy expenditure of men shovelling rock in stopes it would be possible to set work standards for Bantu mine workers in stopes. This should be done in terms of the rate of shovelling, the shovel load and the distance of throw for any combination of width of stope, dip of stope, condition of foot wall and grade of rock in such a way that the resultant energy expenditure would be the 'optimum' that could be expected from the men but would be within their capacities for physical work of an endurance nature (that is, 1. 5 litres/min from the 'average' Bantu mine worker). Work standards could thereby be determined for the different stopes of a mine on a sound and systematic basis. In order to supply the information required a study was carried out by the Human Sciences Laboratory in which the work output and energy expenditures (in terms of oxygen consumption in litres/min) were measured on six highly trained Bantu mine workers under the following conditions: (a) rates of shovelling of 3, 4, 5, 6, and 10 shovels per minute. (b) loads of from 9 to 18 lb on the shovel. (c) distances of throw from 8 to 20 ft. (d) stope width of 28 in., 42 in. and 72 in. (e) dip of stopes of 0°, 15° and 30°. (f) rough and smooth footwalls and various grades of rock size. This paper gives the main results of practical importance of this study. Method The experiments were designed and conducted in conjunction with the Work Study Department of one certain underground conditions such as variable stope widths, stope angle, etc., were made available in a mine Surface Training School and suitable subjects were selected from the large number of labourers being put through the training school. Subjects Bantu recruits who had returned to the mine for a new contract and who had previous underground experience on shovelling were considered to be suitable as subjects for the experiments. The particulars of the subjects are given in Table I. TABLE I PHYSICAL CHARACTERISTICS OF SUBJECTS Weight Height Surface area Max O2 capacity Subject (Kg) (cm) (sq meters) (Litre/minute) A 71.5 167.3 1.80 3.5 B 61.5 162.3 1.65 2.8 C 63.0 164.1 1.69 2.4 D 66.5 167.4 1.75 2.8 E 70.2 164.6 1.77 3.0 F 77.8 173.1 1.92 3.8 Training The method of shovelling, accepted by the Work Study Department, was demonstrated to the subjects who then practised the movements with empty shovels, under the supervision of an instructor. After the technique was mastered, the men started shovelling rock and were trained for at least four hours per day to work at the higher shovelling rates. Training was continued for three weeks to enable the subjects to achieve a reasonable degree of physical training and conditioning. Shovelling method In both the kneeling and standing positions the subjects faced the pile of rock, grasped the shovel in the accepted manner and pushed the blade of the shovel into the base of the pile of rock, sliding the blade between the rock and the concrete floor. In the standing position (72 in. wide stope) the back leg assisted in the movement by pushing the knee against the back of the hand holding the shovel handle. In the kneeling position the elbow was tucked into the side of the body so that the muscles of

By A. Montini

The problems encountered in the design of control systems for milling cir- cuits when the model of the system and the model parameters are uncertain are discussed. Considering these uncertainty factors has led to the development of a technique that gives a quantitative assessment of real system stability, reveals the trade-offs between performance and stability and helps the designer in deciding what level of model complexity to use in the controller design. Furthermore, it allows for on- or off-line optimization of the milling circuit performance as it provides the base for the design of a controller which is stable over the plant operating range.

Jan 1, 1987

By Z. Duran, M. Genc, B. Erdem, T. Dogan

This study aims to develop a model for particulate matter concentration during the loading process in open pit mining. The researchers conducted simultaneous measurements of particulate matter and meteorological parameters and collected samples to determine the moisture content of the loaded materials. The analysis used 7,895 measurement data points from gypsum and limestone quarries, employing two data analysis programs, SPSS® and Waikato Environment for Knowledge Analysis, to derive equations for predicting particulate matter release. In the modelling, particulate matter measurements were the dependent variables, while meteorological parameters, laboratory measurement results, and loader bucket capacities were the independent variables. The classical regression models did not adequately capture the dependent variable, thus, the researchers explored the decision tree approach for further modelling. The M5P algorithm was used to generate regression equations for the different data sets, and the findings showed that the models had a satisfactory degree of predictive capability. The number of fine particles released during loading is influenced by various weather factors. Temperature, humidity, wind speed, and station pressure can all affect the dispersal of these particles. Additionally, the moisture content of the loaded material and the capacity of the loading equipment contribute to this process. The M5P decision tree algorithm, which is rarely used in particulate matter concentration models, provides an innovative approach to developing local concentration estimates for non-coal surface mining.

May 8, 2026

By K. Kabezya

A study on slag dispersion in a model of bottom-blown bath smelting converter was undertaken at room temperature. The aim was to investigate the behaviour of the dispersed slag phase at various operating conditions with very high gas flow rates in low slag volume (10%) systems. For simulation purposes water, paraffin-oil, and air were used to represent the bulk steel, molten slag, and gases respectively in a one-fifth cold model of the commercial 100 t Creusot-Loire-Uddeholm (CLU) converter used in the manufacture of stainless steel in South Africa. Dimensional analysis was done to correlate mathematically the dispersed phase holdup with the operating conditions and the modified Froude number. The overall expression of the holdup revealed that the dispersed slag phase decreased with the vertical distance from the original interface between the liquid phases. The dispersed phase also decreased with the radial distance in the water plume zone toward the sidewall. The holdup was apparently much higher on the side of the reactor where there were no tuyeres. The modified Froude number ensured the correlation between the model and the prototype.

Jan 1, 2014

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. Arlandi-Rodríguez, and A. García-Berrocal, A. Alonso-Jiménez, C. Lopez-Jimeno

Spain is a major producer of dimension stone, which is one of the most important industrial sectors in the northwest of Spain. This justifies the maintenance of these industries, although the technical and environmental requirements for their continuity are increasingly demanding. The main target of this paper is to present a new methodology in order to obtain k-ratio stress values on the basis of flat jack measurements and finite element numerical back- analysis with Rocscience© RS2 software. Continuous iterations were performed to try to find a relationship between the k₀ and the measured stress in the tunnel roof and sidewalls. It focuses on technical aspects of the method for designing mine chambers in the slate industry that were previously mined by open pit methods. The size of the chambers impacts the operating cost, and the dimensioning of a correct support ensures better efficiency and safety. Correct knowledge of the k₀ therefore is critical for the design of the support. The proposed new method entails a simplification of the classical procedure for estimating the k-ratio.

Sep 1, 2022

By Brian W. Mackenzie

The mineral exploration environment has observable economic characteristics, the assessment of which provides guidelines for exploration planning in the mining company. The long-term survival of the mining company is directly dependent on successful exploration. Exploration planning contributes to successful exploration through the development of exploration strategies. The objective of exploration planning is to select exploration environments which will enable the mining company to realize best possible profit and corporate risk conditions. Thus, the formulation of exploration strategies is based on profit and corporate risk criteria. Strategic considerations include the selection of commodities as exploration targets, geographic concentration of exploration effort, the realization of acceptable survival conditions, and the structuring of an exploration programme to optimize the economic benefits of the exploration investment process.

Jan 1, 2014

By Z. Khan

Iron, in the form of steel and stainless steel, is the most commonly used metal in the world. Plain steels corrode and oxidize easily, while stainless steels exhibit improved corrosion and oxidation resistance. It has been found that rare earth metal (REM) additions, such as cerium and erbium, result in the improvement of the abovementioned properties in iron-containing compounds. Gadolinium is a REM, however, there is very little information available on the influence of gadolinium on the microstructure and mechanical properties of iron-containing compounds. Thus, the purpose of this research project was to determine the influence of gadolinium additions on the microstructure and mechanical properties of mild steel and 316 stainless steel. Ten alloys were produced for the purposes of this research. Five of the alloys had a base composition of mild steel while the remaining five had base composition of 316 stainless steel. The alloys for each of the base composition contained gadolinium additions of 0.1, 0.5, 1.2, and 5 weight per cent. The as-cast and the cold-rolled alloys were analysed. The alloys responded well to the cold-rolling with the exception of the 5 weight per cent gadolinium mild steel and stainless steel alloys. These alloys were extremely brittle and underwent a significant amount of cracking during the cold rolling process. A microstructural analysis of the alloys was conducted using a light optical microscope, while the chemical analysis of the alloys was conducted using energy dispersive x-ray spectroscopy (EDS). The resulting microstructures and EDS analyses revealed that the gadolinium displayed minimal solubility in the ferrite matrix of the mild steel alloys and minimal solubility in the austenite matrix of the stainless steel alloys. Instead the gadolinium formed as an interdendritic secondary phase in both alloys. EDS analysis revealed that the secondary phase in both alloys was gadolinium-rich. Vickers microhardness tests conducted on both alloys revealed that the alloys were composite-like, with a hard, brittle gadolinium-containing compound dispersed throughout a softer, more ductile matrix. The corrosion resistance of the alloys was determined through potentiodynamic anodic polarization tests. Two solutions were used for the corrosion rate tests: a 0.5 weight per cent NaC1 solution and a 0.5 M H2SO4 solution. The results from the mild steel alloys revealed that in both the solutions, the corrosion potentials and the corrosion resistance of the alloys increased with increasing gadolinium concentration up to 1 weight per cent. The corrosion rate test results from the stainless steel alloys revealed that the passivation current density and corrosion resistance of the alloys increased with increasing gadolinium concentration in both solutions. The oxidation resistances of the mild steel and stainless steel alloys were determined through the use of a Netzstch Simultaneous Thermal Analyser. For both the mild steel and the stainless steel alloys, it was found that the oxidation resistance of the alloys increased as the concentration of gadolinium increased when compared to the as-received mild steel and stainless steel samples. This could be due to a strongly adhering gadolinium oxide scale that formed on the surface of the alloys and resulted in the protection of the mild steel and the stainless steel.

Jan 1, 2012

By J. N. Van der Merwe

The South African coal-mining industry uses a uniform safety-factor formula for non-squat pillars, incorporating a coal-strength constant that was derived empirically by Salamon and Munro in the 1960s. The constant is 7,2 MPa. Since that time, collapses of pillars at relatively high safety factors have occurred in the Vaal Basin. Analysis of the post-1960s&apos; collapses indicated that the strength constant for the Vaal Basin is 4,5 MPa. A crude method for the prediction of the minimum life span of pillars in the Vaal Basin is presented.

Jan 1, 1993

By S. Dey, C. Bhar, S. K. Mandal

Loading and hauling of ore and waste are the key operations of an opencast coal mine and entail a high operational cost. The productivity of a mine can be increased by reducing the cycle time of loading equipment as well as utilizing dumpers optimally. In this paper we discuss the impact of rock type, bucket fill factor, rock fragmentation, the height of the cut, and angle of swing of the bucket on shovel performance. A time study is conducted on shovels in an opencast coal mine with experimental blasts of rocks to assess the impact of different factors on the performance of the shovel. Based on the data, the authors applied multiple regression (MR) and artificial neural network (ANN) techniques to develop different models for the prediction of the shovel cycle time. Developed models are validated by comparing the predicted data with actual field data. With the help of the best model, the plausible fleet size is determined in order to utilize the shovel and dumper optimally and to improve the performance of shovel–dumper operation.

Oct 1, 2022

By S. M. Bradshaw

In order to assess the requirements for online matching when using a transverse electric field (E-field) applicator to treat mineral ores continuously, the effect of varying load properties on matching has been investigated by simulation. The effective permittivity of the ore to be treated is expected to show variation on both short (< 1 s ) and long (minutes) time scales. By modelling the ore as a series of slices with alternating effective permittivity values, it was shown that permittivity variations on the scale of the expected particle size are attenuated significantly and matching is not required. For variations in permittivity on the length scale of the free-space wavelength, variations in reflected power are at most within ±10% of the mean. This is not considered operationally significant, as extreme permittivity variation over this length scale is unlikely, given the expected distribution of ore particle sizes to be treated. At typical ore transport speeds through the applicator, these variations occur on a time scale an order of magnitude shorter than the response time of typical industrial online matching equipment. This implies that online matching is neither required nor possible for short time scale variation. Long-term variations in dielectric properties can be adequately compensated for by current matching technologies. It is concluded that the transverse E-field applicator is robust to changes in the dielectric properties of crushed ores within the expected range of their variation.

Jan 1, 2012

By F. K. Mulenga, M. Lusambo

"Geometallurgical models are a strategic tool used primarily in planning, diagnosis, and process optimisation. This paper discusses the development of a predictive model for flotation recovery at Kansanshi concentrator in Zambia as a function of key operational parameters. Daily data for milling and flotation from the circuit processing the copper sulphide ore was analysed. This data, recorded over a period of one year of production, was collected from diverse sensors measuring semi-autogenous milling and flotation parameters. Statistical analysis showed that copper head grade, acid-insoluble, and acid-soluble copper, SAG mill throughput, ball mill load, and tonnage of feed material to the SAG mill in the -125 +63 mm size fraction contributed to the prediction power of the proposed empirical model by as much as 90%. Finally, a proposal was made for the development of a simulation model under MODSIM®, a flexible tool for mineral processing applications. This was to test the limitations of the empirical model for future refinement. IntroductionKansanshi is the largest copper mine in Africa and the world’s eighth largest copper producer, with a total of 253 272 t of copper produced in 2016 (Newall, 2017). It is located approximately 10 km north of Solwezi, the capital and administrative headquarters of the North Western Province, Republic of Zambia. The ore deposit consists predominantly of chalcopyrite and malachite with variable amounts of chalcocite, bornite, chrysocolla, and azurite. Because of the varying proportions of sulphide and oxide copper minerals, the ore is classified into three distinct categories: sulphide, mixed, and oxide ores. As such, three separate processing circuits are used to mill the ore down to a standard targeted grind size of 80% passing 150 µm before froth flotation and leaching.A lot of research and development has been done to improve the performance of the sulphide ore circuit at Kansanshi. Despite the research efforts and subsequent operation, the sulphide ore circuit did not attain the target recovery and grade for 2016, primarily because of the complexity of the orebody.The constant drive to achieve the set production target of recovery and concentration grade after froth flotation motivated the development of a tool for the prediction of recovery. The anticipated benefit is not only to enable the plant to apply corrective actions when needed, but also to make a tool available for the quick assessment of the plant performance of the. For that purpose, data spanning June 2016 to May 2017 was analysed, cleaned up and curvefitted to an empirical model. In doing so, key parameters were determined and calibrated to represent the behaviour of the plant."

Nov 1, 2018

By R. J. Hundermark, L. R. Nelson

The critical importance of tap-hole design and management to furnace performance and longevity is explored through examining some of the specific matte, metal and slag tapping requirements of non-ferrous copper blister and matte converting and smelting, ferroalloys smelting and ironmaking systems. Process conditions and productivity requirements and their influence on tapping are reviewed for these different pyrometallurgical systems. Some critical aspects of the evolution of tap-hole design to meet the diverging process and tapping duties are examined. Differences and similarities in tapping practices and tap-hole management are reviewed. Finally core aspects of tap-hole equipment and maintenance are identified that are considered important to securing improved tap-hole performance and life, so pivotal to superior furnace smelting performance.

Jan 1, 2014

By P. F. Dicks, N. J. Shackleton, E. H. W. Theron, V. Malysiak

Flotation is a complex physical chemical process in which flotation reagents play a vital role in valuable minerals recovery and concentrate grades. This study examines the performance of new generation AECI Mining Chemicals (previously named Senmin) collectors. They were developed to enhance the valuable minerals recovery and flotation selectivity by tailoring the collectors to target specific valuable mineral species present in an ore and thus create added value for concentrators treating PGM ores. The case study was conducted on a Platreef ore, where batch flotation tests were performed and the concentrates were mineralogically characterised for PGE and BMS using QEMSCAN. Further batch flotation testwork was conducted on Merensky and UG2 ores from various localities in South Africa to confirm the trends observed for Platreef ore. The results have shown that there is a strong correlation between PGE mineral type and AECI Mining Chemicals collector type - clearly demonstrating that one reagent type does not fit all flotation applications. Keywords: Batch flotation, QEMSCAN, collectors, PGE and BMS

Jan 1, 2020

By I. B. Fernandes, M. A. Reuter, A. Abadias Llamas

Metallurgical simulation and evaluation of the resource efficiency of whole production processes are of key importance for impact assessment, in terms of environment and resources. Exergy is a measure of resource consumption, taking into account energy, raw materials, water, and chemicals; which allows for the evaluation of different technologies to find the most resource efficient and environmentally friendly process. This paper compares the sustainability for production of rare earth magnets from primary and secondary resources through an exergetic evaluation of the production process, in addition to traditional life cycle assessment (LCA). The methodology makes use of simulation tools for tracking material flow and resources used, based on thermodynamic laws, from ore exploitation to magnet production and recycling. It highlights areas with the greatest potential for improvements in terms of resource consumption and environmental impact generation, having a thermodynamic-validated flowsheet for primary and secondary production of NdFeB magnets, present in several low-carbon technologies, such as wind turbines, electric vehicles, and cooling systems. It demonstrates the minimum exergy destruction for magnet production, through an irreversibility breakdown chart, showing where irreversible material and energy losses occur. Results show that CO2-equivalent emissions for producing NdFeB permanent magnets from primary resources could be twice as high when compared to magnets produced from recycling technologies. The theoretical maximum exergetic efficiency for primary production is 57.61%, whereas for permanent magnets produced from secondary resources, the exergetic efficiency reaches up to 82.89%. Two magnet recycling technologies were evaluated, i.e. in acidic medium and via hydrogen decrepitation, and it was observed that their exergetic efficiency and environmental impact performed better than production from primary resources. Keywords: Resource efficiency, exergy analysis, permanent magnet recycling, process simulation, system design

Jan 1, 2020

A high volume of slimes which are separated out during the mining of heavy mineral sands has a high environmental impact and results in great capital as well as operational expenses. The presence of clay minerals drastically increases the slimes volume that needs to be catered for due to its low settling capability as well as swelling characteristics. By adding coagulants in the form of cations and organics, one can improve the settling rate of the minerals as well as the degree of solid bed compaction. The addition of flocculant, which is currently used in industry to improve settling rate, is detrimental to solid bed compaction. By combining the cations and flocculant one can dramatically improve the solid bed compaction. This combination is, however, detrimental to the settling rate of kaolinite-rich slimes but improves the settling rate of smectite-rich slimes. Organics can also be used to produce a clear supernatant and improve the settling rate.

Jan 1, 2010

By P. W. J. van Rensburg

Our mineral heritage - PRESIDENTIAL ADDRESS given by P. W. J. van Rensburg, Pr. Eng.. B.Sc. (Eng.)(Rand) INTRODUCTION Stone Age people were living in various parts of South Africa as recent,ly as a thousand years ago, when they were displaced by Iron Age people with a culture developed in the far north. These invaders brought farming, building, and the earliest mining developments to the Transvaal, thus ushering in the beginning of our great mineral heritage. It is of particular interest to record that, up to comparatively recent times, some of these people were excavating iron-bearing shale rocks for their smelting furnaces on the Melville Koppies in J ohannesburg. Although the most recent the iron-smelting furnaces discovered on these koppies is estimated to be some five-hundred years old, it believed that these Iron Age people were driven out, and their settlements destroyed, by Zulu impis only one-hundred-and-fifty years ago.

Jan 10, 1973

By R. Yi

The determination of the optimum cutoff grade for a surface mine may be very different from that of an underground mine because a selectable mining method may be used in the latter case. A review of research into the theory of cutoff grade is made and then a new method, based on Optimal Control Theory, is presented. This method uses a Hamiltonian function to assist in obtaining the solution. It is shown that the life of a mine can be divided into three parts: a beginning period bf planning before mining; an intermediate period when both an average price and market information are used continually to adjust the cutoff grade; and, a final period when the main consideration is the current market situation.

Jan 1, 1987