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With the passing of Dr William Bleloch on 20th June 1991, we lost not only a colleague and a good friend but a man who made a very significant contribution to the industrial development of South Africa. He can rightly be called the father of the ekctrochemical and electro-metallurgical industries in this country, since his ideas and dedicated work were directly responsible for the development of these large industries as we know them today.

Jan 1, 1991

A large number of brittleness concepts have been used in very different studies in the literature. One of them is the B1brittleness concept. In this study, the objective is to criticize the B1 brittleness concept on rotary blast hole drills. The B1 brittleness concept, the ratio of uniaxial compressive strength (sc) to tensile strength (sT), are widely used as a rock brittleness concept in the literature (Inyangand Pitt, 1990; Verhoef, P.N.W. 1993; Neil, D.M. et al.1994;Becker, et al.1984; Evans and Pomeroy, 1966; Göktan, R.M.1992; Kahraman, S. 2001; Yamaguchi, U. 1970; Verhoef, P.N.W. et al.1996; Bilgin, 1982; Howarth and Rowlands,1987; Howarth, D.F. et al. 1986). So, it was used as a rock brittleness concept in this article. The value of the B1brittleness concept is equal to the tangent of ß angle in the following graph. It was seen that more meaningful relationships could be obtained with the B2 brittleness, the under ?Area?(= 1/2(scxsT) = B2) under the curve, instead of tangent ß, (=B1), of the curve.

Jan 1, 2003

This paper provides an overview of possible approaches for structuring the ventilation systems for mines that will become operational within the next decade. Features addressed in the paper include: aspects of airway design and layout in the absence of centralized vertical return shafts, the impact of using diesel-powered trackless equipment in conjunction with conveyor belts in the development and production phases of the project, and the need to balance increasing electrical power costs against the requirement for reduced capital expenditure. The paper provides brief descriptions of the strategies employed in real-life situations and presents an overview of various operational parameters affecting the design of ventilation systems that will be used as ?platforms? for much deeper mines in the future.

Jan 1, 2007

By S. R. Dindarloo

Although blasting is one of the most widely used methods for rock fragmentation, it has a major disadvantage in that it causes adjacent ground vibrations. Excessive ground vibrations can cause a wide range of problems, from nearby residents complaining to ecological damage. Prediction of blast-induced ground vibration is essential for evaluating and controlling the many adverse consequences of surface blasting. Since there are several effective variables with highly nonlinear interactions, no comprehensive model of blast-induced vibrations is available. In this study, the support vector machine (SMV) algorithm was employed for prediction of the peak particle velocity (PPV) induced by blasting at a surface mine. Twelve input variables in three categories of rock mass, blast pattern, and explosives were used for prediction of the PPV at different distances from the blast face. The results of 100 experiments were used for model-building, and 20 for testing. A high coefficient of determination with low mean absolute percentage error (MAPE) was achieved, which demonstrates the suitability of the algorithm in this case. The very high accuracy of prediction and fast computation are the two major advantages of the method. Although the case study was for a large surface mining operation, the methodology is applicable to all other surface blasting projects that involve a similar procedure.

Jan 1, 2015

By D. van Heerden

In the mining industry abrasion caused by both sliding and impact have over the years resulted in costly damage to installations such as ore passes and silos. Good geotechnical practices combined with the use of a high quality abrasion resistant concrete can prolong the life of such an installation and minimize problems associated with abrasion. In order to maximize the life of an abrasion resistant concrete, the choice and combination of the correct raw materials (cement, aggregate and fibre) and overall mix design needed to make up such a concrete are important. This paper presents technical data and practical experience showing that concrete formulated with calcium aluminate cement resists severe abrasion conditions better than similar OPC-based concretes.

Jan 1, 2005

By D. S. van Vuuren

Over the last 60 years many different processes were conceived to reduce the cost of titanium produced by the Kroll process. However, success eluded all previous efforts, which were consequently terminated in periods of economic downturn. Recently, the grow thin demand for titanium and the high cost of producing the metal again sparked renewed attempts in various parts of the world to replace the antiquated Kroll process with a more efficient route. The different options to produce titanium are reviewed, classified and evaluated in terms of the fundamentals underlying the technologies, and it is shown that the options considered to be the most likely to replace the Kroll process, are continuous processes to reduce TiCl4 metallo-thermically to titanium powder. Of these, continuous magnesio-thermic reduction of TiCl4 would conceptually result in the lowest-cost and highest-value product. However, when considering by-product salt removal from the titanium product and recycling of the salt as well, sodio-thermic reduction of TiCl4 is better.

Jan 1, 2009

By B. P. Watson

Several large falls of ground occur annually in the narrow, tabular stopes mined in the Bushveld Complex. These falls comprise safety risks and cause substantial production losses and compromise efforts to increase productivity. Underground observations in conjunction with instrumentation sites were used to establish the strategic parameters required to describe the rock mass behaviour of shallow-dipping stopes on the Bushveld platinum mines. Existing rock mass rating systems were evaluated using the observations and instrumentation results. None of the current systems adequately described all the relevant geotechnical conditions. Thus a hybrid of several current systems was developed, and the proposed system is discussed in the paper. The new rock mass rating system is termed the ?New Modified Stability Graph? system and follows the method originally described by Mathews et al.1and revised by Hutchinson and Diederichs2.Changes have been made to some of the tables provided by Barton3and to the stress analysis suggested by Hutchinson and Diederichs2. In addition, the logistical regression analysis has been applied to databases, formed using the suggested analyses, for three support resistances and risk levels established.

Jan 1, 2004

By A. C. du Preez

Mintek has been involved in extensive test work since the early 1990s on the recovery of nickel and cobalt from leach liquors saturated in calcium, using synergistic solvent extraction systems. During this period the Nicksyn? reagent was developed, optimized, commercially manufactured, and tested by Tati Nickel on a demonstration plant for more than 2800 operating hours. Efficient recovery of nickel without the co-extraction of calcium, thus avoiding gypsum formation in the extraction and stripping circuits, was illustrated. This synergistic system was recently evaluated on a laboratory scale for the recovery of nickel and cobalt from synthetic lateritic sulphate leach liquor containing about 3 g/L nickel, 0.5 g/L cobalt, 0.7 g/L manganese, 20 g/L magnesium, and with calcium at saturation. Extraction and stripping parameters were determined for this feed liquor and are discussed in this paper.

Jan 1, 2014

Outsourcing of specialist and non-continuous services is common practice in international mining operations. There is an increasing trend towards this practice in South Africa as a result of the major organisational changes that have taken place in the industry, and as lower revenues and production cost pressures have reduced profit margins. Many specialist functions have been outsourced in the industry for a long time, an example being shaft sinking, which is undertaken by specialist shaft sinking contractors. In the professional services area, some activities have been outsourced, for example the design and construction supervision of tailings dams, but mining related activities such as geology, mine planning and scheduling, engineering, ventilation, and rock engineering, have traditionally been carried out by in-house staff. In this paper some of the industry problems which have led to an increase in outsourcing of professional services are considered. Then the pros and cons of outsourcing are dealt with before outlining the factors which should be taken into account in choosing an outsourcing partner.

Jan 1, 1999

By D. Grabowski, Z. Pokryszka

A study carried out in the iron basin of Lorraine (North-East of France) highlighted the existence of under-oxygenated and noxious gas emissions (carbon dioxide, radon…) in vast built-up areas related to former mine workings. Site investigations showed that the gas flow was mainly due to natural thermal air circulation between old mines and external atmosphere. The main hazards associated with this flow of gas and its potential accumulation in confined volumes in buildings are asphyxiation and intoxication. A further study is in progress in order to better understand the origin of the gas generation within the old iron mine workings. Following the first hypothesis, the carbon dioxide emission is mainly due to the specific hydro-geo-chemical process associating the pyrite oxidation with the acid dissolution of carbonates. KEY-WORDS : gas, emission, iron mine, pyrite.

Jan 1, 2003

By J. H. Zietsman, M. W. Erwee, P. J. A. Bezuidenhout, Q. G. Reynolds

"Pyrometallurgical furnaces are tapped through tap-holes that are opened with drills and oxygen lances. The lance is often used on its own or as the last step of opening the tap-hole. Interaction of oxygen with molten material inside the tap-hole can occur, and is a phenomenon that is not well understood. As part of a study that focuses on the effect of lancing on flow inside and around the furnace tap-hole, a cold-model validation was done. The validation study focuses on validating the MULTIPHASEINTERFOAM multiphase flow solver in OpenFOAM® for the problem involved. The sensitivity of the model to different materials properties (viscosity and density in particular) is presented with both cold models and the results from flow simulations in OpenFOAM®. IntroductionMany pyrometallurgical operations are carried out in furnaces where molten material accumulates continuously. Once enough material has accumulated and is ready to be removed from the furnace, material is tapped through one or more tap-holes in the furnace. Tap-holes differ significantly in both geometry and materials of construction, depending on the process involved – examples of different types of tap-hole configurations can be found in, for example, Nelson and Hundermark (2014). Tapholes all share one common feature: they are high, wear areas of the furnace. Molten material at high temperature flows through these areas, after which the tap-hole is sealed, usually using tap-hole clay. The purpose of the tap-hole clay is to harden inside the tap-hole and seal it until the next tap.Once ready to tap, a pneumatic drill and/or oxygen lance is used to open the tap-hole. The extent of lancing a furnace tap-hole depends strongly on the type of furnace. In, for example, many blast furnace operations lancing is limited as much as possible, and done only if drilling was not effective. In other operations, such as on small-scale pilot furnaces with short tap-holes, only lancing is used to open the tap-hole."

Jun 1, 2019

By M. Ng

As part of a long-term study of titanium minerals processing being undertaken by the Julius Kruttschnitt Mineral Research Centre, techniques have been developed to measure the resistivity of ilmenite, rutile, zircon and other associated minerals. The techniques have proven reproducible and have allowed the measurement of resistivity under conditions of varying temperature, surface condition and surface moisture adsorption. The measured values can be linked to the separability of the minerals in the dry plant, and hence are useful as a diagnostic test for existing plants when performance deteriorates, or for greenfield sites to investigate potential problems. One of the major problems in electrical separation of titanium minerals is surface coating on the mineral grains. Coatings can make normally conductive minerals such as ilmenite and leucoxene behave much more like non-conductors. Electrical separation of surface contaminated ilmenite from non-conductors then becomes extremely difficult unless the surface contaminant is first removed. The resistivity measurement technique was used to evaluate the effect of surface cleaning on the resistivity of ilmenite and zircon from a Western Australian deposit which will shortly be in production. Ten different attritioning methods were evaluated, ranging from simple rinsing inwater to chemical attritioning in sulphuric acid combined with ultrasonic leaching. A roasting and quenching step was also investigated. As would be expected, the gentler treatments, such as rinsing in water or Calgon, had only amoderate effect on the ilmenite surface coatings. Ilmenite resistivity decreased by about 1 order of magnitude from 5.6 x108?m to between 2.5 and 4.4 x107?m. More intense treatments had a much more pronounced effect. The most effective, reduced ilmenite resistivity to 6.5 x105?m or three orders of magnitude. Zircon was relatively unaffected by any of the attritioning methods, with only a small increase in resistivity observed from 8.0 x1012?m to 2 x1013 ?m. The results show that measurement of mineral resistivity allows the effect of surface treatments to be easily quantified in a way that has benefits for greenfield site development where only small samples are available for testing. The effect of surface moisture has also been investigated using resistivity measurements. Measurements were made on zircon in an environmental chamber in which both humidity and temperature could be closely controlled. Zircon resistivity at 60 deg C decreased from 6 x1011?m at 5% relative humidity to 8 x108?m at 95% humidity. Moisture content and moisture re-adsorption from dry of zircon and number of other minerals were measured using a Mettler moisture analyser. Zircon adsorbed the least amount of surface moisture (0.05–0.09%) but re-adsorbed moisture from dry the fastest, reaching 98% of the original level in 10 minutes. Leucoxene adsorbed the most moisture (0.67%), but was much slower re-adsorbing this moisture from the dry state, reaching only 63% of the original level in 10 minutes. The difference was attributed to the surface characteristics of the grains, the leucoxene being much more porous than the zircon examined. The resistivities and differing rates of moisture adsorption can be used to quantify the effects of changes in atmospheric conditions of the performance of electrical separation in dry plants.

Jan 1, 2003

By H. A. D. Kirsten

Shotcrete has become a strategic component of support in underground mines. The ductility of reinforced shotcrete makes it a safe and economic means of surface support under adverse static and dynamic loads. The ability of ductile shotcrete to sustain load at large deflections enables excavations in squeezing conditions to be stabilized and the safety in excavations subject to rock bursting, to be assured. A Shotcrete Working Group was formed to find the configurations of fibre reinforcement that would give shotcrete the same ductility as when reinforced with mesh. Beams and panels reinforced with various types and lengths of fibre were accordingly tested. A single mix design consisting of river sand, ordinary Portland cement, fly ash, condensed silica fume and gunite dust and segregation suppressant was used. Steel and polypropylene fibre varying in length from 25 to 50 mm were used in nominal contents of 5 % and 0.5% by mass respectively. Beams, panels and control specimens were shot into specially made formers. Suitable mixing procedures were developed for the different types of fibre. The test specimens were shot in a semi-dry mix process. The shotcrete was cured until tested 28 days after shooting. The fibre contents and uniaxial compressive and Brazilian tensile strengths of the shotcrete were determined from the control specimens. The beams and panels were tested in bending in specially manufactured test rigs. The beams were examined for simple supports and fixed ends. The panels were fixed in a manner that simulated underground conditions and were loaded statically under uniform pressure. The beams were loaded and the corresponding deflections measured up to failure. The panels were loaded up to mid-span deflections of 150 mm. The results are presented in the form of load-deflection graphs. The peak loads and ultimate deflections for the fixed end beams were considerably larger than for the simply supported beams for the various types of fibre considered. None of the beams tested, however, were able to sustain load at relatively constant value beyond the peak load. The panel tests showed that 40 mm and 50 mm long steel fibre and 30 mm, 40 mm and 50 mm long monofilament polypropylene fibre reinforcement gave shotcrete the same ductility as mesh.

Jan 1, 1998

By Xu H.

In recent years, the mineral applications dealing with more complex data in distributed environment have grown rapidly. Many mineral and mining organizations have to organize internally and globally distributed manufacturing and experiment sites, which share the roles of databases and other multi-services like software programs. Thus, there are commercial and technical pressures pushing the mineral software vendors to move their current service toward Web service. XML has gained wide acceptance for representing, storing and transferring structured data and documents of many kinds, especially in scientific communities. However, so far there is no such a Markup Language in mineral industry. A XML-based uniform encoding, which is called MineML(Mineral Markup Language), is proposed and developed in this project. The framework of the MineML specification is created. MineML will play the role as shared protocols within mineral domain for archiving, transferring the multi-nature data between the software packages on the desktop over the Internet and sharing the services between users at different sites. Inspired by MLA’s (Mineral Liberation Analyser, JKMRC, University of Queensland, Australia) Mineralogical Data Presentation Program, a proof-of-concept prototype of Web Service is developed here to validate and demonstrate the MineML specification. Certain strategies, specific technologies and tools are adopted to create such an environment. To accomplish that, a set of experimental MineML documents including correlated XML, XSD (schemas) and XSL(stylesheets) documents have been elaborated for archiving, presenting and transferring the mineralogical data information, with the persistence on flexibility and extensibility for generic mineral and mining data handling.

Jan 1, 2003

By R. L. Castro

Block caving methods, when operated under favourable rock mass conditions, can achieve higher production rates and lower operating costs than other various existing underground mining applications. For this reason, it has been considered the preferred method for the mining of deep and large orebodies in current and future operations around the world. One of the key aspects in the design of block caves is the selection of the production level layout, which, among other parameters, is based on the gravity flow characteristics of the caved rock. This is because gravity flow has a large impact on total ore recovery and the amount of dilution in a caving operation. Today, there are a number of computer based methods which aim to emulate the gravity flow pattern of the caved rock. In this paper, the authors present the development of FlowSiman improved model of gravity flow based on the cellular automaton approach, to estimate dilution entry, mixing and ore recovery. As part of the model development, flow simulations were conducted and subsequently compared to full-scale data collected at two mine sectors operated by Codelco Chile. The results indicate that by using proper calibrated parameters, good correlations between simulated and measured grades as well as dilution entry are obtained. The potential use of the numerical tool to evaluate drawpoint spacing in terms of recovery and dilution for block/panel caving operations is also presented.

Jan 1, 2009

By A. E. Lewis

The emphasis of this paper is on the characterization and testing of the slag produced by a secondary lead refinery. This work forms part of a broader investigation aimed at reducing loss of valuable product from the process as well as minimizing the environmental impact of the process wastes. It was this work that led to a critical examination of the standard waste classification tests. Characterization of the slag was carried out using a number of complementary techniques. In the broader context, the slag characterization aided in identifying process deficiencies and thus was a critical tool in suggesting potential for process optimization. For this study, the slag characterization provided a relatively comprehensive picture of the composition and properties of the slag, which facilitated understanding the behaviour of the slag under batch test conditions. On the basis of quantity of hazardous components alone, the slag is hazardous according to South African Acceptable Risk Limits (ARL). However, when both the quantity and the leach potential of the hazardous components is taken into account, standard waste tests carried out by three independent agencies indicate that the slag should not be classified as hazardous according to local regulations. Also, according to United States Environmental Protection Agency (US EPA) limits, which are independent of the quantity of the waste, the slag would not be classified as hazardous. The standard waste tests used by the independent agencies was the Toxicity Characteristic Leach Procedure (TCLP), a test which was developed by the US EPA to classify hazardous wastes. One of the requirements of this batch test is that it should be quick, simple to carry out and that the results should be reproducible. Previously, the applicability of the TCLP test to mineral processing and metallurgical wastes has been challenged on a number of points. Additional testing of the slag was carried out using both the TCLP and the Synthetic Precipitation Leach Procedure (SPLP) recommended by the American National Mining Association as being more appropriate for mineral processing wastes. The particular physical and chemical characteristics of the secondary lead slag highlighted additional limitations of both the TCLP and SPLP tests as standard laboratory batch procedures. Keywords: environmental protection, secondary lead processing, slag, leach testing, TCLP, SPLP, ARL, hazardous waste, batch tests

Jan 1, 2000

By N. R. Williams

Black Mountain, a polymetallic base metal mine located in the Northern Cape territory of South Africa has been blessed with high grade economic ore for many years. Now that the Broken Hill orebody is nearing the end of its life, a lower grade orebody (Swartberg) is being exploited to supplement production from Broken Hill. In addition, ore from stopes in the upper levels of the Broken Hill orebody is considerably tarnished (oxidized). As a natural result, the remaining ore contains a higher percentage of magnetite, pyrrhotite and pyrite than in earlier years. Bismuth, cadmium and cobalt also occur in the ore in higher quantities. The life of the mine has been lengthened with the discovery of further deeper-lying ore reserves extending from the Broken Hill orebody suitably called the Deeps section. However, to bridge the gap between development of the new reserve and the exhaustion of the old reserve, these lower grade and tarnished (oxidized) ores have to be treated. The mine has had reasonable success in identifying unfavourable or problematic ore types and stockpiling them separately to blend in small quantities with more favourable ore. Bench and plant scale tests have aided identification of the various ore types and significant improvements in flotation metallurgical results have been seen. Copper, lead and zinc metal occur as sulphides in the ore. The mill consists of a differential and sequential flotation process that extracts copper concentrate, lead concentrate and zinc concentrate respectively with silver metal recovered in the copper and lead concentrates. This paper describes the ore blending strategy employed at the mine to maximize the econo-metallurgical efficiency of the operation.

Jan 1, 2001

By Marco Barla, Mariacristina Bonini, Giovanni Barla

ABSTRACT: The paper describes the characterisation studies of Tectonised Clay Shales at laboratory and in situ scale. The interest relates to tunnelling under squeezing and swelling conditions, in Italy, along the Apennines. The results of monitoring during full face excavation are presented in conjunction with numerical modelling. RESUME: Cet article présente la caractérisation, à l'échelle du laboratoire et in situ, des Argiles Chaotiques. L'attention est portée sur le creusement, dans ces milieux gonflants, des tunnels, dans les zones montagneuses des Appennini, en Italie. Enfin, on présentera les résultats de la modélisation numérique et la comparaison de ces derniers avec les mesures effectuées in situ. KURZFASSUNG: Die Arbeit beschreibt die Charakterisierungsstudien von tektonisierten Schiefertonen, sowohl im Labor als auch vor Ort. Das Interesse gilt dem Tunnelbau unter Quetsch- und Schwellbedingungen in Italien entlang der Apenninen. Die Überwachungsergebnisse des ganzflächigen Ausbruchs werden mit numerischen Modellen präsentiert.

Jan 1, 2003

In order to deliver a quality shotcrete and concrete product underground for the extensions to the Cullinan Diamond Mine operations it was decided to develop a new, simpler concrete product to meet underground support requirements. The aim was to develop a concrete product that not only reduced costs but also met the performance criteria of the current range of concrete products used on Cullinan Diamond Mine, a 25, 45 and 60 MPa concrete and a fibre reinforced wet shotcrete. The concrete product batching and delivery system was to be from surface as opposed to the current underground batching systems. The operational principle was to include an automated surface batching plant with delivery of the concrete product to a borehole containing suspended pipelines delivering to an underground storage facility from where the product is delivered to the working area by further pumping or agicars. Keywords: concrete, shotcrete, full flow, frictional loss, pipeline transport, positive displacment pump

Jan 1, 2006

By J. Gunaselvam

This article deals with an investigation into the specification and use of appropriate seating systems to reduce whole-body vibration (WBV) exposure in typical vehicles used in the SA mining industry. The EU Directive EU/44/2002 to be legislated in 2005 in European countries, provides legal and economic motivation for this project. The criteria for seat selection can be condensed to the requirements in the directive, which mandates an action level of 0.5 m/s2and a vibration exposure limit of 1.15 m/s2 for an equivalent 8-hour daily exposure period. As part of this study six suspension seats, which the manufacturers claim satisfy the requirements in ISO 70966, were tested to determine the most suitable seat for an articulated dump truck. Six test subjects, three ?light? and three ?heavy? as specified in ISO 70966, were used to estimate the seat transmissibility functions in the vertical direction of the six different suspension seats. Transmissibility functions were measured in the laboratory with two excitation levels of 1 m/s2 and 2 m/s2 r.m.s. in the 0.5?30 Hz frequency range, as well as one spectrum approximating the EM5 spectral class. SEAT values were calculated for road vibration data measured on a typical articulated dump truck. A set of seat selection guidelines that can be followed by vehicle manufacturers and suppliers, procurement officers and and the technical staff on a mine is proposed in this article. It is recommended that additional studies of the use and operating conditions of seating systems in the SA industry, as well as an epidemiological survey be commissioned to gather additional information on this subject. Nomenclature ADT Articulated dump truck DSTF Dynamic seat testing facility EM1 Frequency spectra associated with earth moving equipment (?articulated or rigid frame dumper?) according to ISO 7096 EU European Union ISO International Standards Organisation PSD Power spectral density r.m.s .Root mean square SEAT Seat effective amplitude transmissibility WBV Whole-body vibration

Jan 1, 2005