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The 107th Annual General Meeting of The South African Institute of Mining and Metallurgy was held at The Country Club, Johannesburg, Napier Road, Auckland Park on Wednesday, 11 August, 2004. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations, also to recipients of awards, senior members of industry, Honorary Life Fellows, past-presidents, our members and other guests, among them the following: Ralph Bagirathi, Executive Member, African Mining Association Rudi Rudolph, President, Association of Mine Managers of South Africa Andrew Whibley, President, Association of Mine Resident Engineers of South Africa Dr Con Fauconnier, President, Chamber of Mines of South Africa Nxolisi Diliza, Chief Executive Officer, Chamber of Mines of South Africa

Jan 1, 2004

By H. Tveit, E. H. Myrhaug, J. K. Tuset

Silicon metal as a commodity material is produced by carbothermic reduction of quartz in electric submerged arc furnaces, where CO2 forms as a by-product. Since 1997 the Norwegian Ferroalloy Producers Association have been engaged in research programmes aiming for reduced CO2-emissions associated with fossil carbon in their processes. One important issue has been to study how charcoal and wood chips perform compared to coal and coke in the silicon process. The ability of the carbon-rich reduction materials to react with SiO-gas is commonly assumed to be of large importance to the performance of the process. Based on laboratory experiments with different carbon materials, combined with estimation of parameters in a mathematical model of the reaction between carbon and SiO-gas, a foundation for a theoretical study of the performance of the carbon materials in a silicon furnace is established.

Jan 1, 2004

By L. A. Maseko

"As part of the mining engineering curriculum, students are required to be placed in industry for vacation work or work-integrated learning (WIL). In this paper we review work-based placement as done at the four South African mining schools: the University of Johannesburg, the University of Pretoria, the University of the Witwatersrand, and the University of South Africa.Key aspects of past and current WIL (pre- and post-graduation) practices that may need attention are highlighted for consideration by all universities that provide professional qualifications. Work-directed theoretical learning, problem-based learning, project-based learning, workplace learning, and simulated work experiences are discussed as legitimate approaches to WIL.Regardless of the choice each institution makes, commitments of universities, preparedness of university teachers, and the desire for equity and excellence will play an important role in the provision of WIL.DefinitionsAccredited Qualification: a qualification awarded on successful completion of an accredited programme.Advisory Boards (or Committees): are essential infrastructure for a WIL curriculum that is built on the integration of the workplace and the university. This requires the collaboration of experts from both environments. Workplace advisors are critical to the success of the academy as they embody expert knowledge of the ‘real world’.Assessment: the process of determining the capability or competence of an individual against standards by evaluating performance.Category: a mode of registration defined in or under the ECSA Act which has a distinctive purpose, characteristic competencies, defined principal routes to registration, and educational requirements.Experiential learning: (in South Africa sometimes used synonymously with work placement or cooperative education) is a term used with a great variety of meanings in the international literature. More broadly, it may refer to learning that has meaningful learner involvement. It is the process of generating meaning from direct experience. In the international literature, experiential learning is learning through reflection on doing, which is often contrasted with rote or didactic learning."

Dec 1, 2018

By J. Thompson

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree A study into the stability of strike gullies at TauTona mine was to be carried out. In reaching the conclusions to follow, a three-stage process was followed. ?A literature study as well as discussions with management and workers alike to gain their inputs and perceptions. ?An ESH Department survey into the history of transgression from proper mine standard in TauTona strike gullies. Unfortunately records were found to be scarce and obscure and the importance of better inter-departmental recordings cannot be stressed enough. ?An underground survey of 11 pre-selected gullies distributed in both the UCL and LCL reef horizons. This stage is to carry the greatest weight in the points to be brought forward in this report. The process highlighted and ranked the following areas as the most critical role players in the deterioration of strike gullies: ?Poor blasting practice ?Sub-standard siding depth and lead-lags ?Split sets ?Off line gully development ?Adverse geological features. The following has been suggested to the mine to help reduce strike gully instability. ?Where possible, maintain lead-lags below 7 m?else increase the siding depth to suit. ?Decrease the gully width standard to 1.2 m (especially in ?high risk areas?). ?Discourage drillers from drilling side holes in gully face blast pattern. This will allow for time in which tendon support can be kept up to date. ?Ensure split sets are installed 1 m behind the gully face so as to prevent opening up of fractures. ?Utilize the centre split set in the 1:2:1 pattern to maintain the proper gully line. ?When adverse conditions prevail, it is necessary to apply a special support plan not only to the panel face, but also (just as importantly) to the gully as well. Shotcreting of the gully hanging is a suitable long-term consideration for providing the additional a real coverage needed. List of Abbreviations [CL Carbon Leader M/O Mine Overseer UCL Upper Carbon Leader FOG Fall of Ground LCL Lower Carbon Leader H/W Hanging Wall ERR Energy Release Rate F/W Foot Wall WDL Western Deep Levels ESH Environmental Safety and Health ]

Jan 1, 2002

By G. H. Lind

Seven full and partial pillar extraction operations were visited in New South Wales, Australia, in the early parts of 2001. Certain factors unique to these operations have led to the general success of the safe and economic extraction of these coal pillars. Some of these factors attributable to the overall success of these operations are discussed in this paper. In particular, geotechnical mapping, specific legislation pertaining to pillar extraction, mining methods, the role of temporary supports and training are described. It is found that some of these factors have useful attributes which could be used to design a methodology for extraction of underground coal pillars in the Witbank and Highveld coalfields of South Africa.

Jan 1, 2002

By R. P. Mohring

The South African Coal Industry had its beginnings in the Eastern Cape in 1859 when coal was mined to satisfy the fledgling settlements in the Eastern Cape. The growth in the industry was relatively slow up to the early 1970s when, firstly, the export business was expanded coupled with a major increase in the quantity of coal converted to liquid fuels and utilized for power generation. To meet this increased demand the industry developed many new operations employing the latest mining technology and systems. Coal production in South Africa reached 204 million tons in 1996 and revenue from exports reached R8 billion making it the second-largest foreign exchange earner after gold. In his address Rick P. Mohring describes the role coal plays in the international energy scene and outlines South Africa?s position as a producer and consumer of coal, and the challenges facing the industry. A wide range of steam-coals are produced to satisfy both the local market (power generation, coal conversion and the metallurgical industry) and the export steam-coal market. South Africa is in a unique position regarding the export market as it is still a relatively low-cost producer and is geographically well-placed to play in both the European and Far East markets. There are, however, a number of challenges facing the industry. To retain our competitiveness in the international market, ways of minimizing the cost pressures caused by high-cost inflation, increased environmental protection obligations and a decreasing quality resource base need to be sought. Locally the coal mining industry has a major role to play in Eskom?s goal of reducing the real cost of electricity by 15% in the next three years. Safety and health, productivity and the adaptation of the latest technology are issues being addressed by the industry to maintain its dominant position within the South African economy.

Jan 1, 1997

By G. L. Smith

This paper consolidates the key elements of seven contributions, on strategic long-term planning, to two of the three international conferences on Strategic versus Tactical approaches in Mining held over the period 2005?2008. The holistic concept of strategic long-term planning as developed and implemented at Anglo Platinum is described. Consideration is given to the planning cycle, principles supporting the construction of the long-term plan, and aspects of unique best practice as developed in Anglo Platinum. Further description of Anglo Platinum?s approach to corporate governance, including the processes, methodology, systems, unique tools and techniques that are applied to value and select capital investment options is also given.

Jan 1, 2009

By S. L. Chen

Keywords: copper, concentrate drying, steam dryer, dryers By placing additional demands on energy and gas flow, the moisture content of a copper concentrate has an adverse effect on the smelting process. Different drying technologies, such as directly heated rotary dryers, flash dryers, and steam dryers, are available to solve this problem. The energy requirements of and off-gas generated from different dryer types are compared. The performance of the steam dryer was found to be superior to that of the others. In particular, the rotary steam dryer and its benefits are discussed. Structural properties confer an advantage on the rotary steam dryer, for wear on tube elements is eliminated, and drying efficiency is improved. If steam is available, the rotary steam dryer is an excellent choice for drying copper concentrates.

Jan 1, 2006

Keywords: Pyrometallurgy, Pretoria University Substantial research in pyrometallurgy at the University of Pretoria started in 1980 with the appointment of Rian Dippenaar to the Iscor Chair, a position that he held until 1996, when Chris Pistorius became the leader of this pyrometallurgy group. This paper reviews the main research themes over the quarter-century from 1980 to 2005, as well as some of the industrial developments that have shaped the research approach. The main topics have been the use of electrochemical sensors for equilibrium measurements, ilmenite smelting, steel processing, and reduction.

Jan 1, 2006

By Chris Ringas

The safe operation of gas transmission pipelines is increasingly coming under the spotlight. Increasing environmental pressure is also forcing pipeline owners and operators to ensure the integrity of their pipelines. The integrity of a pipeline is usually determined using intelligent pigging, often referred to as In Line Inspection (ILI). However, in many cases, gas pipelines cannot be pigged for a variety of reasons. The National Association of Corrosion Engineers (NACE) has recently published Recommended Practice (RP) 0502, referred to as the External Corrosion Direct Assessment (ECDA) Methodology to assist pipeline owners with assessing the condition of pipelines that cannot be pigged. 2. External Corrosion Direct Assessment - NACE RP 0502 The ECDA Methodology is conducted in four phases as follows: ? Pre-Assessment ? Indirect Inspection ? Direct Examination ? Post-Assessment In the Pre-Assessment Phase, all the relevant historical and current data relating to the pipeline in question is reviewed. This covers pipeline, construction, soils/environmental, corrosion control and operational data. The aim of the Pre-Assessment Phase is to determine whether ECDA is feasible, and if so, to define the ECDA Regions and finally to select the Indirect Inspection Tools that will be used for each region. Typical overline techniques used for overline surveys include the following: Voltage gradient surveys ? DCVG or ACVG

Jan 1, 2006

By D. M. Walters

To achieve safe and healthy working conditions in shaft sinking operations, ventilation, and where necessary cooling, must be provided. These requirements are considered for sinking vertical, sub-vertical and decline shafts. Regulatory requirements, determining air volumes and amount of cooling required, the various ventilation methods used such as force, exhaust, twin columns, air reversal using four gate systems and the equipment required to achieve this, are discussed. Consideration is also given to the sinking of single and twin declines using diesel equipment, calculating the air volumes required to dilute pollutants and the various methods for achieving this. Also discussed is the importance of having early ventilation design input to the overall design of the mine. In many cases ventilation can be the prime determinant for the size and configuration of the shafts or declines that have to be sunk.

Jan 1, 2009

By B. Schoevaerts

The ever-increasing depth of mineral extraction presents a challenging environment for hard-rock underground mines. High in situ stresses and associated seismicity with potential rockburst hazards are the major decisive factors contributing to the choice of a ground support regime. Conventional ground support systems, designed primarily for static loads, are not always capable of providing safe working conditions for underground personnel in seismically active mines. Systems specifically developed to resist dynamic loading and allowing for larger deformations are therefore preferred alternatives. High-tensile chain-link mesh has a proven record of successful use in open cut operations in various rockfall barrier installations due to its high energy absorption capacity. It has also been used in underground operations in various parts of the world. Its application in South African underground mining, however, is limited due to the high labour intensity. This paper describes a method of mechanized installation of a chain-link mesh as evaluation at Gold Fields' South Deep Gold mine situated some 45 km south-west of Johannesburg. A purpose-built mechanized roll mesh handler, developed in Australia, was used in this trial. The handler is compatible with all standard multi-boom underground drill rigs and is operated utilizing the hydraulic circuit normally used for the feed arrangement. A number of key performance indicators have been specified as success criteria by Gold Fields: ? A 30% faster installation compared to the conventional methodology ? The mesh should sustain any blast damage when applied to the blasting face ? No unravelling of the mesh when cut ? No failure of mesh under normal conditions ? Reliability of the MESHA® installation handler (availability >90% ? Compatibility of the MESHA® installation handler with AC 282 boomers. Although the energy-absorbing mesh combined with yielding rockbolts is a ground support system of choice for rockburst-prone conditions, the operational upsides recognized during the trial imply that this product can also be competitively used in less demanding ground conditions where weld mesh or shotcrete are customarily used as a primary surface support.

Jan 1, 2012

By S. J. Oosthuizen

This article explores the Fray Farthing Chen (FFC) Cambridge process, a novel method for the electrochemical deoxidation of metal oxides in molten salt, discovered at the University of Cambridge in 1997. The process was hailed as a highly promising, potentially low cost, novel method for the production of titanium metal direct from its oxides. The article should inform researchers in the field of some of the challenges in the commercialization of a novel, high profile process involving multiple stakeholders. The author, former senior process engineer at British Titanium Plc, the company originally tasked with commercializing titanium production via the FFC Cambridge process, reviews the latest literature and discusses past and present progress in the pursuit of low cost titanium metal via this process. Topics explored include the history of the process, attempts at commercialization, NASA?s alternative application, and present status of the process. Keywords FFC Cambridge, titanium, molten salt.

Jan 1, 2011

By D. J. Steynfaard

Sishen Iron Ore Mine is situated 280 km north-west of Kimberley in the Northern Cape Province of South Africa. The mine produces and sells high quality iron ore of various specifications to various national and international clients. The saleable product is derived from the blending and beneficiation of different types and qualities of hematite iron ore. This paper documents the new developments which were implemented (or are in the process of being implemented) on the mine in the long-term planning, medium-term planning, grade control and material tracking in the beneficiation plant with special attention being paid to the quality of the final, saleable product. The process starts with the long-term planning where the pit shell and pit optimization is determined by Whittle 4X. New developments include the introduction of a linear programming based scheduling system to enhance the long-term schedule generated by Whittle 4X. The LP route was decided on in order to take into account all the constraining factors of the final product that could not be configured in Whittle. To complement this the XPAC Auto Scheduler scheduling package was introduced to do the medium-term mine scheduling. This 18-month rolling plan includes cost parameters to enable the planner to extract a detailed operational budget from the scheduling while ensuring that production standards are maintained and grade constraints are met. The existing grade control system was enhanced with GPS capabilities and a computer system to do material tracking. The high precision GPS system introduced on the shovels allows for the accurate control of the loading procedures at the mining face. Because of the complicated geology and grade composition of blasting blocks it is imperative to accurately differentiate between different materials in the same blasting block and being able to excavate that with the loading equipment. The GPS system on the trucks allows for accurate location monitoring of dumping in order to keep track of specific material types. The state-of-the-art material tracking system developed for Sishen will enable the grade control officer to keep track and record various parameters of the material from its in situ position in the blasting blocks, through the crusher and onto different stockpiles, in various stages of the beneficiation process and onto the blending beds, into the dispatching trains and eventually into the ships for international distribution. These developments elevate the Sishen planning and grade control systems to a new level of service excellence from which management can obtain accurate and timely information on product status. It also enables Sishen to maximize resource utilization while still complying with the tough market constraints.

Jan 1, 2003

By D. M. Walters

To achieve safe and healthy working conditions in shaft sinking operations, ventilation, and where necessary cooling, must be provided. These requirements are considered for sinking vertical, sub-vertical and decline shafts. Regulatory requirements, determining air volumes and amount of cooling required, the various ventilation methods used such as force, exhaust, twin columns, air reversal using four gate systems and the equipment required to achieve this, are discussed. Consideration is also given to the sinking of single and twin declines using diesel equipment, calculating the air volumes required to dilute pollutants and the various methods for achieving this. Also discussed is the importance of having early ventilation design input to the overall design of the mine. In many cases ventilation can be the prime determinant for the size and configuration of the shafts or declines that have to be sunk.

Jan 1, 2009

By S. C. Gouws

"SynopsisSustainable infrastructure development has long been identified as a key enabler for socio-economic growth and poverty reduction in societies globally. Twenty-one years into the young South African democracy, economic prospects are fragile and unemployment statistics are high. According to Trading Economics (2015) the GDP growth rate in South Africa averaged 3.07% from 1993 until 2015.Through the National Development Plan 2030, the government has responded by instituting the Presidential Infrastructure Coordinating Commission (PICC) to direct national growth and drive job creation by effecting a long-term infrastructure investment programme. The Commission is mandated by Cabinet to coordinate, integrate, and accelerate implementation of more than 150 individual social and economic infrastructure plans.In the civil infrastructure development sector, increased urbanization is compelling governments and the public sector to expand safe and reliable public amenities, but the availability of real estate for construction in congested cities is a challenge. Within the mining infrastructure construction industry safe, rapid, and efficient mine extraction strategies are imperative to realize increased production, business hurdle rates, and stakeholder expectations.Asset owners and stakeholders are obliged to consider advanced mechanized underground excavation and support technologies in order to present feasible solutions timeously. From an engineering design, procurement, and construction management (EPCM) perspective tunnelling technology and boring applications have a distinct advantage over conventional excavation techniques. These solutions may enhance commerce and transportation by expanding infrastructure in concentrations of national economic activity, providing crucial linkages with rural areas, between cities, and across international borders.This paper explores the contribution by mechanized tunnelling technology and boring applications applied in conjunction with digital and automation technologies compared with conventional methodologies. The technological expertise, combined with a paradigm shift in delivery of project objectives, will promote economic growth, aid recovery from the economic downturn, and improve social development."

Jan 1, 2015

By G. M. J. van Heerden, R. C. W. Webber-Youngman

"This article describes the re-engineering principles applied in the design of a personnel transportation system for the Bafokeng Rasimone Platinum Mine in the Rustenburg area of South Africa. It incorporates conveyor belt travelling, chairlift operation, and also includes consideration of proposed changes/modifications to the existing conveyor belt infrastructure.The purpose of the project was to identify, through a process of evaluation, the appropriate option and/or combination of transportation options that would be safe in terms of personnel transportation as well as cost-effective. Alternative measures for transporting personnel (not using belt riding) would have a significant positive spin-off, increasing the availability of the belt and thereby increasing production. This paper explores the feasibility of interventions that would improve safety through eliminating risk associated with personnel transportation as well as contributing towards improving the mine’s position on the cost curve.The design in consideration at the Bafokeng Rasimone Platinum Mine consists of two shaft systems, namely the North Shaft and South Shaft, each comprising twin decline shafts. One of the decline shafts is equipped with a conveyor belt for rock and personnel transportation, and the other with a winder for trackbound material transport. The conveyor belt has been used for personnel transportation since the commissioning of the shafts. The conveyor belt is equipped with platforms for personnel getting off and on the belt and a number of safety devices designed to ensure safety while travelling on the belt. Intensive training in the practical aspects of belt riding is given to every person, and unsupervised riding on the belt is permitted only once belt riding competence is demonstrated. Despite this, the safety results were poor, with 106 injuries between 2006 and May 2013. Fortunately, no fatalities were reported during this period.An investigation of alternative means for personnel transportation or engineered solutions to the current conveyor belt infrastructure in the safest, most effective, and most economical way was therefore needed. There was a major risk of safety-related stoppages being imposed following another belt accident/incident. This would prevent the mine from transporting personnel underground by belt and result in major production losses. From the commissioning of the Phase 2 shaft deepening project on both shafts, dedicated chairlifts have been used for personnel transportation as opposed to the conveyor belt installed in the Phase 1 area. The chairlifts have been in operation since 2004 and no chairlift-related incidents have been recorded thus far. According to safety statistics, it is clear that the chairlift is the safer method for the transportation of people in the shaft.To fulfil the objectives/scope of this study, it was recommended that both primary (new chairlift decline with infrastructure) and secondary options (modifications to the current conveyor belt infrastructure) be considered for implementation on both the North Shaft and South Shaft to reduce or eliminate accidents/incidents as a result of belt transportation. The associated capital expenditure would be approximately R200 million. Considering the future impact on the business as a whole, this would definitely be capital well spent."

Jan 1, 2016

By R. E. Wilmot

This paper is based on the experiences, over many years, of numerous authors in the South African mining industry and of the hot dip galvanizing process and its application as a corrosion protection system. The paper sets out the extensive development, financial resources and stringent operating requirements of the South African mining industry. After many years of research and operational experiences, hot dip galvanizing and, when necessary, duplex systems, have been found to meet the demanding requirements of this particular industry. The paper sets out the requirements from the standpoint of corrosion criteria and is followed with a case where the corrosion protection properties of hot dip galvanizing are demonstrated. This case history traces the early investigation of the expected corrosive conditions in a new mining operation and concludes with two follow-up visits to the mine in order to examine actual performance of the corrosion protection system after ten years in service.

Jan 1, 2007

By R. Thomason

Thank you Dr Barcza, President of the South African Institute of Mining and Metallurgy, for inviting me to share our experiences in Australia as regards the competency movement and my Association?s experience in assisting engineers become managers. This is my second visit to South Africa, and I am struck by the similarities between our countries. This extends to the professional issues associated with engineering and competencies in particular. I propose to outline two exciting stories today. ? Development of competency standards for professional engineers in Australia. ? Development of a management programme which has assisted professional engineers regain positions of leadership in Australian industry and government. First of all I would like to outline the Association of Professional Engineers, Scientists and Managers, Australia(APESMA).

Jan 1, 1997

By B. P. Watson

The Bushveld platinum group metal deposits are two distinct, shallow-dipping stratiform tabular orebodies which strike for many hundreds of kilometres. Mining is extensive, with depths ranging from close-to-surface to 2 300 m. The mining method is a variation of planar open stoping. Pillars are widely employed to support the open stopes. In the deeper levels, in-stope pillars are required to fail in a stable manner soon after being cut, and the residual pillar strength is used to stabilize the hanging wall. These pillars are commonly known as crush pillars. Little work has been done in the past to determine pillar peak and residual strengths, and pillars have been designed using experience and formulae developed for other hard-rock mines. This has led to over and undersize pillars with consequential loss of ore, pillar bursts and potential collapses. This paper describes a crush pillar design methodology, and provides design charts. Three mining environments were incorporated in the investigations, which included underground and laboratory measurements, analytical solutions, numerical model sand back analyses. The results of the study are suitable for the areas where the research was carried out, and may also be applied with caution in other similar environments.

Jan 1, 2010