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By H. J. S. Kriek

Methods are described by which increased production is achieved whilst retaining full availability of equipment and decreased refractory cost. Refractory materials have certain limitations, and when these limitations are known the variables in operating practice having the greatest impact on refractory life can be controlled. The most important factors to be closely controlled are porosity, chemical constitution of refractory materials, slag basicity, slag volume, FeO content of slag and temperature at which the process is operated. Knowledge of the process is invaluable in deciding on the type of refractory to be used. The types of refractories used in and the operating variables of the ironmaking, steel making and steel finishing units are described.

By M. Pierce, E. Karampinos

"One of the main challenges in the numerical modelling of ground support in underground excavations is to reproduce the performance of the sequential installation of the reinforcement while capturing the rock mass behaviour of an advancing face in 3D. The 3D modelling approaches used to simulate the progressive advance of excavations are mostly continuum and often cannot reproduce the rock mass failure mechanisms. The 3D discrete element method (DEM) can better reproduce structurally controlled rock mass failure mechanisms and can explicitly represent the reinforcement elements. This paper builds on previous work that reproduced the structurally controlled squeezing conditions in an underground hard-rock mine using 3D DEM and the in situ behaviour of reinforcement under pull conditions. It addresses important issues on the way reinforcement is explicitly introduced in discrete element models. A pseudo-3D model is employed to overcome the computational restrictions and time limitations of a 3D modelling approach. The work focuses on the scaling of the material properties of the ground support elements when the thickness of the model is not equal to the out-of-plane spacing of reinforcement. It demonstrates the scaling methodology based on the type of the modelled reinforcement elements used and investigates the significance of this approach. The advantages and disadvantages of this approach with respect to 2D and 3D methods are discussed. The results are compared with field data and previous modelling work done at the mine. IntroductionNumerical models can provide significant insight into the anticipated behaviour of underground excavations. The modelling of ground support, however, is not a trivial exercise. An effective representation of ground support in underground excavations should capture the behaviour of both the rock mass and the support elements. When numerical models are used for design purposes, the complexity of the problem requires significant time and expertise (Sweby, Dight, and Potvin, 2016).At a laboratory scale, numerical models have successfully reproduced the results of laboratory tests on rockbolts by explicit modelling of the bolt, the borehole, and the grout. Chen and Li (2015) used a continuum FLAC3D (Itasca Consulting Group Inc., 2012) model to simulate the mechanical behaviour of D-bolts as observed experimentally. Grasselli (2005) used a 3D finite element code to model the behaviour of fully grouted rods and expandable bolts under shear."

Dec 1, 2018

By E. J. Margi

Deep gold exploration such as is used for Witwatersrand gold deposits is both expensive and time-consuming. This paper provides quantitative guidelines as to the economic optimum number of boreholes and deflections within each borehole for a certain reef characterized by its variability pattern and depth below surface in order to maximize the level of confidence for a fixed drilling budget or to minimize the total drilling cost for a given level of confidence. Portions of the Basal, Vaal, and Elsburg Reefs that show a wide range of variability (sample logarithmic variances of 0,63, 1,05, and 2,06 respectively) are examined at depths below surface ranging from 1000 m to 4000 m over a simulated mining property covering 7000 ha (7000 m by 10000 m). It is concluded that four intersections per borehole are optimum in al the cases considered, which cover the majority of current Witwatersrand exploration, with the exception of the highly variable Elsburg Reef at depths of 1000 m and 2000 m, where boreholes with one and two intersections respectively should be preferred.

Jan 1, 1987

By B. J. Pieters

The paper describes the difficulties experienced with inferior coking coals as Iscor began using larger blast furnaces for the production of liquid iron. Research conducted at Iscor from 1977 to 1979 showed that benefits could be gained from the use of partially briqueted charges, and it was decided to install briqueting plants at the Vanderbijlpark and Newcastle Works. Details are given of the later plant, which was supplied by a consortium consisting of Voest Alpine, Didier Engineering, and Sumitomo Metal Industries. Sumitomo also supplied information on the optimization of coke quality along the lines of their Sumicoal System. The results have been a marked improvement in coke quality, much better blast-furnace operation, and increased productivity.

Jan 1, 1991

By J. A. L. Napier

One of the most important characteristics of tabular mine stress analysis is the need to represent the complex evolution of mining face positions and the accompanying induced stress changes in the rock mass. Integration of seismic activity with numerical modelling requires flexible and efficient solution schemes in which both off-reef damage and large-scale fault slip can be effectively represented. A new approach is investigated in which the stope closure and ride variables can be found using a moving least squares estimator. Some advantages of this approach over traditional element-based tessellation schemes are identified. At the same time, shortcomings of this method are noted when the displacement discontinuity variable is approximated by a polynomial shape function. Difficulties and possible solutions to the shape function formulation near excavation edges are discussed. Une des caractéristiques les plus importantes de l’analyse des contraintes minières tabulaires est la nécessité de représenter la complexe évolution des positions du front de taille et des changements concomitants des contraintes occasionnées dans la masse rocheuse. L’intégration de l’activité sismique avec la modélisation numérique requiert des projets souples et efficaces qui permettent la représentation des dommages hors-filon et des glissements de faille à grande échelle. Une approche nouvelle est étudiée qui permet de trouver la fermeture de la taille et les variables de montage en utilisant un estimateur par les moindres carrés mobile. Certains des avantages de cette approche sur les traditionnels projets basés sur une structure en mosaïque sont identifiés. En même temps, les défauts de cette méthode sont notés lorsqu’on calcule la variable de discontinuité du déplacement approximativement par une fonction de forme polynomiale. Les difficultés et solutions possibles à la formulation de la fonction forme près des bords d’excavation sont discutés. Eine der wichtigsten Charaketeristika der taublaren Grubenspannungsanalayse ist die Notwendigkeit, die komplexe Entwicklung der Abbaupositionen und der damit verbundenen induzierten Spannungsänderungen der Gesteinsmasse neu vorzulegen. Die Integration der seismischen Tätigkeit mit einem numerischen Modell erfordert flexible und effiziente Lösungsschemata, in denen sowohl Schäden ausserhalb des Riffs als auch Verwerfungen großen Ausmaßes effektiv dargestellt werden. Ein neuer Vorstoß wird untersucht in welchem die Strossenschliessung und Schneisenvariablen unter Verwendung des Schätzwertes der kleinsten quadratischen Abweichungen (Gaussscher Schätzwert) gefunden werden. Einige Vorteile dieser Annäherung im Vergleich zu der traditionellen Element-basierenden Tessellation sind identifiziert. Gleichzeitig werden Unzulänglichkeiten dieser Methode vermerkt, wenn die Verschiebungsdiskoniuitätsvariable durch eine polynomische Formfunktion angepaßt wird. Schwierigkeiten und mögliche Lösungen zur Formfunktionsformulierung nahe Exkavationsrändern werden besprochen.

Jan 1, 2003

By P. J. Kinver

This paper deals with the development of the cut-and-fill mining method at the Broken Hill orebody of Black Mountain Mineral Development Company (Pty) Limited, at Aggeneys in the north-western Cape Province of South Africa. Lead, copper, zinc, and silver are produced. Production started in January 1976, being confined to blasthole production methods in the upper, steeply dipping areas of the orebody. This blasthole reserve is 70 per cent depleted, and pillar extraction is in progress. The balance of the production tonnage, 60 kt per month, is produced from three cut-and-fill stopes situated in the flatter-dipping areas of the orebody. The cut-and-fill mining method at Black Mountain is a result of research and planning activities that included the use of modelling, laboratory tests, mathematical analyses, in situ tests, and experience gained from other mining operations. These investigations and the resulting developed methods and designs are summarized in the paper.

Jan 1, 1985

By A. Smith

After the introduction of mechanized bord-and-pillar development at Dumacol in 1958, pillars were being developed at a much faster rate than they could be extracted by hand loading methods. Efforts were therefore made to increase the rate of pillar extraction by mechanization. Following two partially successful mechanized stooping trials in 1964 and 1971, it was decided that mechanized pillar extraction with 1 m3 cable-reel front-end loaders should be introduced. The first section to employ the new equipment started production in May 1979, and the mine now has four mechanized pillarextraction sections in operation. Considerable improvements in production, productivity, safety, and percentage extraction have been achieved.

Jan 1, 1985

The case for national research in mineral processing PRESIDENTIAL ADDRESS given by R. E. Robinson*, Ph.D., B.Sc. (Eng.) (Wits.) Some of you have only raised your eyebrows, some have made tactful comments, and a few of you have been fairly outspoken, but all of you in industry are concerned at the high level of State expenditure by bodies such as the National Institute for Metallurgy. The case for a national research organization in mineral processing is not clear-cut and in fairness I must present both cases - for and against. Competition for student members Each year the South African Institute of Mining and Metallurgy offers a prize (or prizes should the entries warrant it) of up to Rl00 for the best paper or dissertation on a topic appropriate to the interests of the Institute.

Jan 10, 1975

By E. Pothas, P. R. Jochens, L. B. McRae, D. D. Howat

SYNOPSIS The phase equilibria, viscosities and sulphur capacities of titaniferous slags were determined in the composition range of CaO = 30 to 0 per cent, MgO = 0 to 30 per cent, SiO2 = 19.69 per cent, AI.O. = 13.12 per cent and TiO2 = 37.19 per cent. The phase equilibria were determined by high temperature microscopy, the viscosities were measured using a rotating outer cylinder viscometer and the sulphur capacities were evaluated from the results obtained by equilibrating the slag in a gas stream of CO, CO2 and SO2. The behaviour of these titaniferous slags under reducing conditions was examined. Possible use of the slags for aggregate, or slag-cement, and the possibility of extracting the TiO2 are discussed. CONTENTS INTRODUCTION PHASE EQUILIBRIA VISCOSITIES DISCUSSION OF THE PHASE EQUILlBRIA AND THE VISCOSITY VALUES EFFECT OF REDUCING CONDITIONS SULPHUR CAPACITY DISCUSSION OF THE SULPHUR CAPACITY VALUES POSSIBLE USES CONCLUSIONS ACKNOWLEDGEMENTS REFERENCES INTRODUCTION The latest phase in the exploitation of the mineral wealth of the Bushveld Igneous Complex is the erection of a plant by the Highveld Steel and Vanadium Corporation Limited near Witbank to produce steel and vanadium-rich slag from the titaniferous magnetites occurring in this rock formation. These titaniferous magnetites occur as segregations in the gabbro body and the TiO2 is mainly present within the structure of other constituent minerals but also occurs in smaller amounts as ilmenite and ulvospinel. The vanadium is thought to be present in the iron oxide phase due to isomorphous replacement of the iron. Until very recently, it was feared that the high titania content of these titaniferous magnetites would militate against their value as useful iron ores. However, the design of an integrated plant to produce both steel and vanadium-rich slag, and in which the iron-making process is conducted in submerged arc furnaces instead of in

By N. Watson

Historically the insurance industry's involvement in any project has been relatively late in the process. Often it was a case of the last item to be ticked off the checklist has been to ensure that the insurance is in place. However, in more recent times insurers have imposed more restrictions on the cover they are prepared to provide, which has in some cases necessitated a change in the contracting structure to accommodate the insurance policy(ies). In addition, changing contractual practices have changed the allocation of risk between the various parties involved. This calls for a more proactive approach to the design and implementation of an insurance program for both the construction and operational phases of any resource project. This paper explores how a risk managed approach to the design and implementation of an insurance program for a resource project can align itself with current management approaches to project development. From the authors' experience, this approach is best adopted early on in the project (often in conjunction with the bankable feasibility study) and follows AZ/NZS4360 to objectively examine and compare a wide range of risk exposures of the project in a time-effective manner across the following areas: ? personnel; ? environment; ? general management; ? compliance - legislation, systems, protocols; ? asset management; ? change management; ? financial impacts to the organisation; ? products/services; ? service delivery; and ? technology. Having identified and then analysed the risk exposures according to common consequence and likelihood ratings the next step is to develop a risk map of all considered exposures. The true value of this approach lies in the development and implementation of a risk treatment plan for identified exposures where the exposure is unacceptable. The plans will lead to the optimal solution to the appropriate risk prevention, risk mitigation and risk transfer options available. This paper also examines other benefits to the project that may arise from adopting a risk managed approach in addition to the ability to design an insurance program which recognises the exposures and the ability of the organisation (and other project parties) to retain risk.

Jan 1, 2007

By D. Visser, P. D. Toens

The development of a continuous recording scintillation counter mounted on a cyclometer by P. D. Toens (Fellow) and D. Visser (Visitor) In order to facilitate ground radiometric surveys the Atomic Energy Board has developed a continuous recording device attached to a scintillation counter which is mounted on a cyclometer. Details concerning the construction are given.

By T. K. Roy

INFACON XI has no doubt earned the distinction as the first such Congress in India. This prestigious occasion could become a reality of a long cherished dream of the Indian Ferroalloy Producers, consumers and ex-porters. The International Committee of Ferro Alloys (ICFA), South Africa, the august body for organising INFACON, every three years, could be convinced by the Indian Ferro Alloy Producers? Association (IFAPA) to award INFACON (XI) to India. This Congresss, organized by IFAPA, has opened a window for the Ferroalloy Community of India, the up-coming Asian Tiger, to register their strength and weakness to the world forum with the principal objectives of evolving long and short-term optimum road-maps for development. It is to be reckoned that India is poised to be a steel giant by 2020 when it is envisaged that the steel production may reach a level of 120 million tons of which significant proportion has to be in the categories of alloy and special steels, requiring standard and high grade ferroalloys. Keeping the above objective in view, the theme of this Congress has been rightfully designed as ?Innovations in Ferro Alloy Industry.? This Congress has also earned a distinction of more than eighty papers, finally selected for inclusion in the Proceedings. More than 100 internationally and nationally reputed experts in the field of ferroalloys (technology and manufacturing practices as well as world scenario) have been approached for critical review of abstracts and selection for the proceedings. It needs to be mentioned without the cooperation received from ICFA the high standard of INFACON could not have been assured. The papers are suitably grouped under seventeen heads, starting from world situation to production and operation followed by present and future technologies and finally to modelling and simulation. It is a Herculean task to the Technical Committee to fit these papers in proper sequence. The Commit-tee members kept no stone unturned to ensure the cogency with the subject matters and at the same timekeeping the flexibility of interests of the participant, especially in the context of three parallel sessions. The Proceedings containing only refereed papers of high quality, will serve the entire gamut of ferroalloy industry and will also highlight the present status of concerned countries. The areas of attention to make the industries globally competitive and at the same time laying emphasis on the prevailing practices, will help the industry leaders to formulate an appropriate global approach. Following the break-through step, instilled by INFACON XI, the Proceedings will be available both in bound and in searchable electronic CD-ROM format. I, as the Chairman of the Technical Committee would like to express thanks and high appreciation to all the Committee members for their whole hearted efforts in all respects without which it would not have been possible to complete these proceedings in the scheduled time. Technical Committee desires to place on record their gratitude to Organising Committee for their synergic cooperation all through in successfully executing multifarious tasks, associated with such a grand international technical Congress.

Jan 1, 2007

By C. J. Van Niekerk

When gold plant residues are cycloned for producing a coarse product for backfilling the gold and uranium values are upgraded in the backfill product. Gravity concentration, wet high intensity magnetic separation and froth flotation were investigated as first-stage recovery processes to recover these economic values from backfill prior to placement underground. This paper addresses the recovery of values from flotation concentrates and also details the economic feasibility of a treatment route including flotation, followed by roasting of flotation concentrate to liberate gold entrapped in pyrite and reverse gold leaching of the calcine so produced.

Jan 1, 1988

By R. L. Paul

Although it is often said that South Africa does not have suitable deposits, or the potential to develop mines on a small scale, a recent survey by the Chamber of Mines1 showed that, out of a sample of 641 producers, 41 per cent had between 10 and 19 employees, and a further 29 per cent had between 20 and 29 employees. This goes to show that minerals-related small, medium, and micro-enterprises (SMMEs) do exist, and can play an important role in the development of rural industries in South Africa. Nchaka Moloi of the Department for Mineral and Energy Affairs defined the various categories of SMMEsas shown in Table I2. An enterprise could be placed in a certain category as long as two of the variables, employees, capex or production applied.

Jan 1, 1997

By G. T. van Rooyen

Materials for Winding Plant Components By Prof. G. T. van Rooyen (ScD) (MIT). Materials for critical applications such as winding plant components are reviewed in terms of the basic requirements which have to be complied with. It is shown that tensile testing alone is not sufficient and that impact testing also is necessary if the incidence of brittle fracture is to be avoided. As a criterion it is suggested that the brittle transition temperature (B.T.T.) determined by impact testing should in all cases be well below the lowest anticipated service temperature. A number of steels were evaluated by impact testing and it is shown that a small ferrite grain size, obtained either by chemical means such as by the use of appropriate alloying elements in the steel or by means of a quenching heat treatment, is effective in attaining a Iow B.T.T. The speed of strain aging as well as the influence of strain aging on the B.T.T. was also evaluated. On the basis of the results obtained it is recommended that steels for critical applications must conform to an appropriate grade and class of steel according to BS 4360 specification. It is further recommended that such steels be exempted from the customary six-monthly heat treatment prescribed by the Mines and Work Act, Regulation 16,18.

By K. R. Vost

This paper reviews the theoretical methods used in South Africa for the prediction of heat pick-up and air-temperature gradients along main haulages. These methods include those of Starfield, Ramsden, McPherson, and Goch and Patterson. The differences in predictions based on typical airway conditions are explained as being due to differences in the mathematical models on which the predictions are based. The largest discrepancies were found for dry airways and for airways with bulk air coolers. The errors in predictions of the effect of machines and coolers that have been running for only a few months are calculated, and the limitations of various simplified methods are discussed.

Jan 1, 1982

By Z. T. Bieniawski

Estimating the strength of rock materials by Z. T. BIENIAWSKI, Pr.Eng., D.Sc.(Eng.) (Visitor) A practical approach for estimating the strength behaviour of rock materials is presented. The demand for data on rock properties in engineering design is considered, and it is shown that, based on the trends observed in the South African mining industry during the last twenty years, simple and easy-touse methods for the estimation of the uniaxial and triaxial strength of rock materials are needed. It is shown that the uniaxial compressive strength of rock can be conveniently determined from the pointload strength index, which is obtained underground on unprepared rock cores. The triaxial strength of rock can be estimated for most practical purposes from empirical strength criteria. Two such criteria are proposed that allow estimation of the triaxial strength for rock materials to about 10 per cent. The only input required for these criteria is the uniaxial compressive strength. The validity of the practical approach outlined in this paper is confirmed from the experimental tests conducted on some 700 rock specimens representing five rock types. A practical example for the prediction of rock strength is given.

Jan 3, 1974

By R. J. Dippenaar, J. C. van den Berg

This paper describes an investigation into the prereduction of hematite fines in a fluidized-bed reactor as a means by which they can be prepared for direct smelting in a transfered-arc plasma furnace. A single-stage fixed fluidized bed reactor using the in situ gasification of coal was employed. It is shown that the hematite is reduced to magnetite at 1000 QC, the degree of reduction being limited by the inherent shortcomings of a single-stage reactor in which both the gasification and the reduction reactions have to occur. Methods by which the degree of reduction can be increased are suggested. The gasification process was studied in some detail, and three different reducing agents are compared. The dominating effect of the Boudouard reaction on the behaviour of the fluidized bed is clearly illustrated. Non-coking coals of high reactivity are best suited to this process, a finding that would complement the trend away from coke as a metallurgical reducing agent.

Jan 1, 1989

The mining rock-mass rating (MAMA) classification system was introduced in 1974 as a development of the CSIA geomechanics classification system to cater for diverse mining situations. The fundamental difference was the recognition that in situ rock-mass ratings (AMA) had to be adjusted according to the mining environment so that the final ratings (MAMA) could be used for mine design. The adjustment parameters are weathering, mining-induced stresses, joint orientation, and blasting effects. It is also possible to use the ratings (AMA) in the determination of empirical rock-mass strength (AMS) and then in the application of the adjustments to arrive at a design rock-mass strength (DAMS). This classification system is versatile, and the rock-mass rating (AMA), the mining rock-mass rating (MAMA), and the design rock-mass strength (DAMS) provide good guidelines for the purposes of mine design. However, in some cases a more detailed investigation may be required, in which case greater attention is paid to specific parameters of the system. Narrow and weak geological features that are continuous within and beyond the stope or pillar must be identified and rated separately. The paper describes the procedure required to arrive at the ratings, and presents practical examples of the application of the system to mine design.

Jan 1, 1990

By E. J. Magri

This paper describes a geostatistical study of the relative merits of diamond-saw sampling and conventional chip sampling, using results from experimental work carried out on Randfontein Estates Gold Mine and Western Areas Gold Mine. The diamond-saw sampling procedure is described, and it is concluded that this is a very efficient operation and leads to good-quality sampling that is clearly an improvement over conventional chip sampling. The study principally involved the computation of the errors of estimation of the mea gold value of mining panels for the two sampling methods, revealing that, in the normal production environment, the diamond-saw sampling method is a significant improvement over conventional chip sampling, as evidenced by the reduced estimation errors achieved. The question of optimum sample spacing is discussed, and it is concluded that the required spacing for chip sampling needs to be smaller than for the diamond-saw method.

Jan 1, 1986