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By A. K. Singh

Between the main fan and the coalface in a mine a lot of air is lost through leakage at stoppings, doors, air-crossing etc. so that a much larger quantity of air has to be circulated by the fan in order that the stipulated quantity of air reaches the face. Stoppings are of vital importance not only for effective ventilation of underground mines but also for isolation of areas affected by fire or susceptible to spontaneous heating. Generally, isolation stoppings are made of brick in cement mortar. If the area is far from the pit or unapproachable, it is very difficult and sometimes impossible to build these stoppings. To overcome these difficulties, particularly near fire affected zones, an alternate successful attempt was made in Indian mines to make a plug underground, from surface through borehole, using cement concrete. In this paper the salient features of the methodology adopted for construction of the plug and the experimental procedure for the measurement of air leakage by SF6 tracer gas is described. Measurements of air leakage through rows of ventilation stoppings in two mines viz. Moira (Jambad and Kajora seams) and Kuardi11/12 (Niga seam) collieries of Eastern Coalfields Ltd. (ECL) have been incorporated. Results of experiments conducted at the Central Mining Research Institute (C.M.R.I) to determine leakage through25 and 38 cm thick brick stoppings are also discussed. Results of all these studies are compared, which show that the efficacy and reliability of the remote filled cement concrete plug in respect of air permeability is satisfactory.

Jan 1, 2004

Often plant performance suffers as a result of poor control. Poor control leads to low mill throughputs, poor classification and less than satisfactory concentrate grades and overall recoveries. By using the appropriate control tools, substantial gains in plant performance can be made. Mintek?s MillStar and FloatStar controllers have been implemented at various sites across the world. The MillStar controller incorporates leading technology that controls process units from the mill feed through to the flotation feed. Typical results show that milling circuit throughput is increased by 6-10 % and the final product grind size is tightly controlled, thereby enhancing flotation performance. The FloatStar controller is aimed at stabilising and optimising flotation circuits. Through improved level control alone, recovery improvements of up to 1 % have been achieved. Furthermore, by using on-line grade analysers, the controller stabilises final concentrate grades, whilst maximising flotation recovery.

Jan 1, 2005

By Valérie Léveillé

As new legislation drives to lower SO2 emissions from metallurgical plants, plant managers face the challenge of keeping their costs under control. The Cansolv® SO2 Scrubbing System has been broadly adopted in the non-ferrous industry as a cost effective solution for smelter operators to meet the new SO2 emissions targets. The Cansolv® SO2 Scrubbing System is an amine-based regenerable process that selectively absorbs SO2 from a variety of gases, including dilute smelter gases, such as furnace and converter gases. The system produces a pure, water-saturated SO2 byproduct stream, which can then be directed to the front end of a sulfuric acid plant for conversion to sulfuric acid. When deployed in a smelter complex, the Cansolv® SO2 Scrubbing System may also be used to process acid plant tail gas, allowing single absorption sulfuric acid plants to achieve emissions an order of magnitude lower than that of a double absorption acid plant with a lower capital investment. Depending on inlet gas temperature SO2 emissions in the treated gas can be controlled to as low as 55 mg/Nm3. This paper will describe some of the applications where customers have or are planning to use the Cansolv® SO2 Scrubbing System and what as well as which features and cost advantages for the treatment of smelter gases were key to the technology choice.

Jan 1, 2009

By F. N. F. le Roux

This paper describes the method used for excavating the upper 33m of emergency access shaft E2 for the underground single track tunnel running between Park and Rosebank station of the Gautrain Rapid Rail System. The soil was decomposed shale and diabase from the Witwatersrand Supergroup. The location was in the car park of The Wilds (a public park) in Johannesburg. The method proved very simple and required less complex plant and equipment than normal when excavating the shallow soil sections in shafts. It involves driving steel sheets ahead of the shaft sump into the soils and then excavating inside the ?tub? created by the sheets whilst supporting the sheets above with regularly spaced circular Steel Rings. It is the intent of this paper to discuss the method and design approach to the method. This will be done at the hand of experiences at E2 shaft..

Jan 1, 2009

By F. N. F. le Roux

This paper describes the method used for excavating the upper 33m of emergency access shaft E2 for the underground single track tunnel running between Park and Rosebank station of the Gautrain Rapid Rail System. The soil was decomposed shale and diabase from the Witwatersrand Supergroup. The location was in the car park of The Wilds (a public park) in Johannesburg. The method proved very simple and required less complex plant and equipment than normal when excavating the shallow soil sections in shafts. It involves driving steel sheets ahead of the shaft sump into the soils and then excavating inside the ?tub? created by the sheets whilst supporting the sheets above with regularly spaced circular Steel Rings. It is the intent of this paper to discuss the method and design approach to the method. This will be done at the hand of experiences at E2 shaft..

Jan 1, 2009

A shortage of technical skills in all areas of the mining industry is being experienced worldwide. This has significant consequences for design, operations, productivity and safety and, therefore, needs to be seriously addressed, both in the short and longer term. It is therefore both a strategic and a tactical issue. Importantly, however, since mining is a long-term business, the shortage of skills must be dealt with from a strategic point of view to ensure the supply of the necessary skills for future mining. This paper will deal specifically with the provision of high level technical skills, that is, university graduates in mining engineering, and the outlook for the institutions that are currently producing such graduates.

Jan 1, 2008

By P. C. Schutte

Ergonomics is the scientific discipline concerned with the understanding of interactions among humans and other elements of a system, and the profession that applies theory, principles, data and methods to design in order to optimize human well-being and overall system performance. Despite the fact that the application of ergonomics principles can make a major contribution to the management of significant occupational safety and health risks, ergonomics is currently applied on a limited scale in the South African mining industry. The objective of this paper is to provide a perspective of ergonomics, the main aim being to create a point of departure for the development of strategic objectives to enhance existing health and safety initiatives through the application of sound ergonomics principles. Two of the major consequences of poor ergonomics, namely work-related musculoskeletal disorders and worker fatigue, and possible means of introducing ergonomics into the South African mining industry, are discussed.

Jan 1, 2005

By H. Gumede

The occurrence of fracturing due to high stress levels is a major factor in hangingwall stability in deep level gold mine stopes. However, rock falls cannot be the result of these fractures alone. Rock falls can result only from the occurrence of unstable rock blocks defined by the interaction of the stress induced fractures and naturally occurring geological planes of weakness. These planes include bedding planes and joint set planes. However, there is a general lack of information on the characteristics of these planes (orientations, spacings and lengths)?it does not appear that any such systematic and quantified information, if collected, has been published. To remedy this situation to some extent, joint mapping exercises have been carried out in several geological environments in two gold mines. The data collected on joint geometry included orientation, spacing and length, and this information is included in the paper. In addition, the paper describes the use of the data collected to evaluate the potential for rock falls and the probability of failure of stope support

Jan 1, 2007

By C. Ware, R. Uken, G. Whitmore

The coastal dune cordon of northern KwaZulu-Natal is among the highest in the world reaching heights in excess of 180 m and up to 2 km in width. It comprises a complex system of Quaternary stacked dunes of various geomorphologies, types and ages (Sudan, 1999; Maud and Botha, 2002;Ware et al., 2001; Ware, 2003). The dunes contain economic heavy minerals that have been exploited for the last two and a half decades. Dune units have recently been defined based on sand composition and texture(Sudan, 1999; Ware, 2003). Despite this, little work has been undertaken on the clay-fraction (< 2 um). This work documents the weathering of dunes to form clays. From the documented clay assemblages and relative abundances, a simplified weathering sequence with increasing maturity can be summarized as follows: primary minerals ? illite + vermiculite ?illite +interstratifications ?illite + montmorillonite ?halloysite + interstratifications + kaolinite ?kaolinite. The dominant controlling factors in determining clay assemblages is pH and leaching conditions. The presence of carbonates results in an alkaline pH and high concentrations of Ca2+and Mg2+which favours the formation of montmorillonite and vermiculite. However, vermiculite tends to form under slightly acidic conditions and is indicative of palaeosols where organic acids produce localized acidic pH’s. In contrast to this, kaolinite will only form and concentrate when carbonates have been leached. Kaolinite dominated samples are considered very mature under current climatic conditions(Chamley, 1989). Halloysite represents a transitional phase between montmorillonite and kaolinite (Herbillon et al., 1981). Ion mobility and evacuation is also critical in determining clay assemblages. Past work and field studies indicate that the dune cordon acts as an open system, resulting in carbonates and mobile ions being readily leached and lost from the system. However, when prolonged weathering has caused an accumulation of fine-grained material, the permeability decreases substantially whereby mobile cations and silica cannot be readily evacuated. This results in the formation of montmorillonite rather than kaolinite, even when carbonates have been leached. Illite (sericite) is considered to alter directly from feldspars. However, dune stacking and geometries, vegetation, water fluxes, reworking and erosion complicates this sequence.

Jan 1, 2003

By N September, R Abate

Bateman Modular (previously Van Eck and Lurie) has been building and supplying the mining industry with modular DMS plants for the last 30 years. These DMS modules range in capacity from 1 tph to 200 tph. The most popular unit produced by Bateman Modular over the years has been the 50 tph module. Development In the last 7 years a need has arisen from the industry to provide Modular DMS plants that can treat higher tonnages (150 to 200 tph). The first DMS provided to the mining industry based on the modular concept was a 150 tph DMS Module to MIBA in the DRC. Since then Bateman Modular has provided some 14 Mega DMS modules over the last 7 years with the latest two orders from Debswana (Damtshaa double up project) and Namdeb. Ever since the first Mega Module was supplied Bateman Modular has been improving the Modules. Implementation The modules can be supplied in different configurations so as to improve the overall availability of the plant. Two off 150 tph DMS modules were supplied for a Transhex operation. This allowed the client to still operate one DMS module while maintenance is being performed on the other DMS module. The client also has the option of choosing a single module. Successes The following list of projects provides the base for the success of the Mega Modules.

Jan 1, 2006

By Noel C. Joughin

In making judgements on tolerable levels of risk in industry, and in all spheres of life, it needs to be understood that every action gives rise to risk. Without risk, nothing can be done. Without risk, no economy could be advanced. There is a strong tendency to emphasize the risk at work, but persons who are not working are exposed to a different set of risks. Often persons who are not working face greater risks than persons who are working. Simply, in being alive, one is exposed to the risk of an accident, the risk of contracting a disease, and an extremely diverse variety of other risks. According to the Health and Safety Executive of the UK, it is not possible to have a state of zero risk, because ?a state of zero risk does not exist?. Because zero risk is a physical impossibility, it is not possible to design for a state of zero risk in all engineering design. While the strategic target of achieving zero risk is laudable it does not provide any practical guidance to engineers as to what acceptable limits of risk should be. This causes a significant and real problem in the design for and the management of risk. Without meaningful guidelines, engineers, managers and the authorities often find themselves in disagreement. Thus, it has become essential to establish criteria for tolerable levels of risk and unacceptable levels of risk in order to design and manage engineering systems properly.

Jan 1, 2011

By L. A. Cornish, L. H. Chown, M. Matema, R. Süss, L. Glaner, A. Douglas

Mintek has been developing Pt-based alloys for high temperature applications in aggressive environments, for example, land-based turbine engines, to replace the currently used nickel-based superalloys (NBSAs). The Pt-based alloys have a similar structure to the NBSAs, and since Pt is more chemically inert and has a higher melting point, the Pt-based alloys can potentially be used at higher temperatures. The greater chemical inertness of the Pt-based alloys compared to the NBSAs means that coatings can be simpler, or perhaps not even used at all, depending on the environment. TEM work was done at NIMS, Japan, to investigate the changes in the microstructure o f Pt-Al and Pt-Al-Ir alloys at elevated temperatures using in-situheating up to1100°C. Initial casting trials showed that work needs to be done to optimise casting parameters before commercialisation can take place. Room temperature tensile tests were performed and results were variable mainly due to microstructural differences. The alloy hardnesses were in the order of 300-350HV with ultimate tensile strengths of ~800 MPa and elongations of less than 10%. These results are comparable to other alloys used at high temperatures, which is very encouraging. Keywords: platinum, super alloys, hardness, tensile

Jan 1, 2006

By L. Holappa

Ferroalloys like FeCr and FeMn are mostly produced in submerged electric arc furnaces. Typical of these processes is that the amount of slag is quite high. The role of slag for the process is thus essential and specific chemical, physical and electrical properties are required. Slags in FeCr process are Al2O3-MgO-SiO2 based with minor contents of CaO and CrOx. Slags in the FeMn process are principally similar, originating from silicate minerals but can have quite large composition range depending on the manganese ore and its gangue minerals. Characteristic of the FeMn process is that the slag is rich in manganese oxide up to above 30%. A common feature is that the ?ore oxides?, CrOx and MnOx in slag are not only divalent oxides but also contain some higher valent of Cr3+and Mn3+, respectively. In FeMn production conditions the slag consists mainly of Mn2+. This is a clear difference from CrOx containing slags in which both two and three valent coexist in slags in FeCr process conditions. Oxidation state of the slag depends on the ambient oxygen partial pressure and temperature in the examined process. The thermodynamics of slags in ferroalloys, production are discussed in terms of phase diagrams, activities and oxidation state of chromium and manganese oxides. Further, slag properties influencing reduction kinetics and furnace operation i.e. viscosity and electrical resistivity are discussed. Keywords: review, slags, ferroalloys, ferrochromium, ferromanganese, thermodynamics, physical properties

Jan 1, 2004

By N. Sahay

Open fire in coal mines is one of the most serious threats to miners, as well as to the mine. Open fire can often be effectively dealt with by prompt local action, otherwise it very quickly becomes uncontrollable. In one incident, none of the available open fire control technologies, viz., water deluge and sprinkler systems, high-expansion foam, high-pressure high-stability nitrogen foam, water misting, and ventilation and pressure control techniques, were effective for saving the mine without sealing from surface, since the fuel-rich environment prohibited underground access due to the methane explosion hazard. The authors have developed a methodology for dealing with advancedstage open fires underground by the application of a modified ventilation control technique. It is based primarily on a better understanding of the behaviour of open fires, proper diagnosis of the problem, application of judicious ventilation control techniques, and selection of suitable fire indices for assessing the status of an open fire. This methodology was used to successfully control an open fire in Surakachhar 3 and 4 incline mine Surakachhar, central India. The fire area was sealed underground and production subsequently resumed in record time. The paper discusses the behaviour of open fires, particulars of the mine, diagnosis of the problem, experimentation methods, and the results obtained.

Jan 1, 2014

By B. Clermont

Ball mills are usually the largest consumers of energy within a mineral concentrator. Comminution is responsible for 50% of the total mineral processing cost. In today?s global markets, expanding mining groups are trying to optimize mill performances. Since comminution is concerned with liberating valuable minerals for recovery in the separation process, it is crucial to run the mills at the best operating conditions which lead to good liberation at competitive throughputs with minimum costs (energy and wear). The high availability of the equipment is also essential to maximize production and profit. To reach this key objective, continuous and reliable information about the mill operation is vital. An innovative tool which can deliver information about in-mill dynamics has been developed by Magotteaux. It can provide online and accurate measurements of the degree of grinding ball fill and pulp position for timely decision making and actions. This tool could be used on its own or linked to an automatic grinding ball loading system named Magoload. Therefore, ball load could be kept constant by using direct measurement. This article describes the Sensomag and presents some of the major improvements that can be achieved with it. Some other promising avenues are still to be explored. Keywords: Comminution, process control, process optimization, process instrumentation, online analysis.

Jan 1, 2010

By J. P. Bergh

The advent of low-quality export coal demand has brought a new range of possibilities to the South African coal industry. Products that traditionally were only of value to the domestic or combustion industry sectors now have the potential to be exported, with only minor amounts of upgrading required through beneficiation. Comparatively high steam-coal export prices can be obtained for lowquality export coal, which enhances the economic feasibility of expanding low-quality thermal coal exports. There are, however, increasing concerns about the feasibility of lower quality thermal coal exports and the broader implications. These concerns relate to the environmental impact of low-quality thermal coal production for export and the inherent threat to the security of domestic thermal coal supply in South Africa. Against this background, this paper serves to explain the extended value chain in the production of export coal. The technical and economic advantages and disadvantages of low-grade exports versus coal production for domestic use are evaluated. The value chain estimation is calculated by the beneficiation modelling and characterization of two coals. Based on the value estimation, the lowgrade export production scenario, and finally the modelling of potential pollutant distribution, are described. Keywords coal beneficiation, techno-economics, thermal coal, dense medium processing, dry processing, fine coal processing, environmental impact.

Nov 1, 2013

By Z. van Zyl

The southern African coal industry is facing the reality that coal reserves are becoming deeper and harder to mine than before. Alternative visions need to be considered to offset the impact of these challenges on productivity, cost, and profitability. One of the main challenges is to maintain current production levels under more difficult conditions, and improve productivity where conditions allow. There is a need to move from the reactive event-based management system towards the more adaptable and flexible process-based management system. This paper focuses on underground coal mining, but the principles are also applicable to other commodities and mining methods. This paper is based on research undertaken by the personnel from Mining Consultancy Services Pty Ltd (MCS) on trends in the underground coal mining sector, as well as practical experience over a period of 16 years in the field of electronic monitoring of mining machinery and productivity optimization.

Jan 1, 2015

By D. Hoffmann, S. Plumb

IRUP is an iron-rich ultramafic pegmatite rock that formed due to hot ironrich fluids and gases replacing local stratigraphic zones of the Bushveld Complex. This study focuses on the estimation of the probability of IRUP occurrence on the Merensky Reef at the Marikana Karee Mine. A 2.15 million centare IRUP-rich domain at the Karee Mine was initially defined from the interpretation of a surface aeromagnetic anomaly, and exposures in the mine workings. Surface boreholes (spaced 250-500 m apart) within this IRUP domain contain approximately equal numbers of IRUP-replaced and IRUP-free intersections. Owing to the uncertainty in the continuity of the IRUP alteration (a result of the wide borehole spacing), the risk associated with the development of mining infrastructure within this domain is unquantifiable. Semi-quantitative data comprising visual estimates of IRUP replacement from reef development mapping data and surface borehole reef intersections was interpolated into blocks using indicator kriging estimation. Comparative analyses of the estimate of IRUP occurrences were made by changing the block size and declustering the data systematically. Reconciliations of the probability of IRUP predicted from the block models derived from the different data-sets and sequential indicator simulation models were analysed for four mining study blocks. A quantitative approach to modelling the occurrence of IRUP can be an additional tool for refining the estimate of the geological losses that inform the mine plan in such high-risk zones.

Jan 1, 2015

A new system for granting access to mineral rights is proposed in the recently released White Paper, ?A Minerals and Mining Policy for South Africa?. Official policy states that ?Government?s long-term objective is for all mineral rights to vest in the State for the benefit of and on behalf of all the people of South Africa?. In order to achieve this objective, government is presently investigating the feasibility of imposing a financial or tax-related disincentive to holding mineral rights. The paper aims to present the pros and cons and to examine the alternatives which will cause minimal disruption to the minerals industry in the period during which mineral rights are transferred to the State. South Africa is a country whose economic and political history is embedded in the development of its mineral resources and has inherited a system which cannot simply be wished away. Hasty or radical decisions will compound the problem, rather than provide a lasting and widely acceptable solution. Mineral rights ownership and its impact on access to mineral deposits are discussed. Taxation as a possible economic disincentive is also evaluated. Finally, the value of mineral resource related information as a prerequisite to mineral policy decisions and as an alternative to mineral rights taxation is emphasized.

Jan 1, 1999

By H. Thomas, I. N. M. Nday

"*Paper written on project work carried out in partial fulfilment of BSc.Eng (Mining Engineering) degreeThe optimization of the cycle time to increase productivity at Ruashi Mining was an on-site project investigation conducted from December 2017 to January 2018. The main objective of the investigation was to determine the actual cycle time components. These comprise the queuing time, loading time, hauling time, and dumping time of ADTs (articulated dump trucks). Data was also collected on two hydraulic shovels to identify where these could be optimized. The actual cycle time obtained was compared to the theoretical cycle time to ascertain the constraints, which affect productivity. By applying Systems Thinking to the cycle time, man-made constraints of the actual cycle time were identified and recommendations to mitigate them suggested to optimize the cycle time. However, rainfall is a natural constraint that adversely affects the actual cycle time, and which cannot be mitigated.In addition, both the theoretical and actual cycle time were analysed, as well as the theoretical and actual productivity for the year 2017. Based on the findings, conclusions and recommendations were made to optimize the cycle time. IntroductionThe aim of the project was to increase Ruashi Mining’s productivity by 39%, from about 7.537 Mt of broken material mined to 12..367 Mt targeted in 2017.BackgroundRuashi Mining is a copper (main commodity), cobalt (by-product), and acid producer located in the Democratic Republic of Congo (DRC), 10 km from the city of Lubumbashi. Figure 1 shows the location of the Ruashi Mining open pit.Ruashi Mining started production in 1911 and in 2005 the mine was registered as a DRC company owned by Metorex Group Limited. In November 2013, the Chinese company Jinchua Group International Resources Co. Ltd. bought a majority stake in the business. Ruashi Mining currently produces 38 000 t of copper and 4400 t of cobalt per annum. The company has contracted NB Mining (a contract mining company) to transport its ore. To optimize the productivity of the mine, considering ore flow delivery at Ruashi Mining, the cycle time is the indicator used in this project. The cycle time components were recorded on site using a stopwatch."

Jul 1, 2019