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By B. J. Vorster

AngloGold South Africa region currently consists of twelve gold plants. These plants use a combined total of $20 million of cyanide per annum. Of this, the major portion (60%) is consumed at two Ergo dump retreatment plants. Historically the primary motivation for cyanide control at Ergo has been one of leach/cost optimization. However, more recently, with the increased public awareness of cyanide in the environment, a secondary but increasingly important motivation for control has been to ensure that only the minimum amount of cyanide is added to the process whilst not compromising leach performance. Following a brief overview of the Ergo process, the methodology in determining the amount of cyanide to be added is described. The paper then traces the developments in cyanide control from very basic manual systems to the current automated control system. In line with the increasingly sophisticated control systems, developments also took place in regards to the method of cyanide analysis. The development of these analysers is also discussed. Whilst cyanide is one of the major drivers, if not the major driver of gold dissolution, it cannot be viewed in isolation particularly with respect to the relationship between cyanide and oxygen as ascertained from the Elsner?s well-known equation. Consequently, in order to control cyanide addition, knowledge of the relative cyanide/oxygen profiles is necessary. Various means investigated at Ergo for pulp oxygenation have therefore been included for the sake of completeness. Finally a comparison is made of the control achieved from the current system compared to the original manual system. The knowledge and experience gained at Ergo is now being used to draw up guidelines for the installation and optimization work at the other AngloGold plants. The net effect of this will be reduced cyanide consumption for the region, which also, apart from the obvious economic benefit, translates into a reduced environ-mental risk.

Jan 1, 2001

By A. Ahmed, A. Fathy, M. Eissa, K. El-Fawakhry, A. El-Mohammady

Silicomanganese is widely used as a complex reducer and an alloying addition in the production of various grades of steel due to its economic and metallurgical advantages. It is also used as a semi-product in the manufacture of medium- and low-carbon ferromanganese and metallic manganese. Manganese-rich slag, resulting from high carbon ferromanganese production, has the advantages of high manganese content, high Mn/Fe ratio, low excess oxygen, low phosphorus content, low fine content and low cost. Such slag seems to be very attractive to use as raw materials for the production of silicomanganese alloys. In the present study, experimental heats were designed and carried out to optimise the factors affecting the production process of silicomanganese using manganese rich slag in the charge. The results of pilot plant experimental heats showed that the optimum metallic yield and recoveries of manganese and silicon are obtained with initial slag basicity,(CaO + MgO) / (Al2O3), equals 1.8 by using dolomite as fluxing material and charging quartzite and fluorspar in percentage of 25% and 4% of the blend, respectively. The results showed also that an amount of 30% of coke in excess of the stoichiometric amount should be added. These result are relative for the specific high Al2O3 ores used.

Jan 1, 2004

By K. Cybulski

In 2002 a coal dust explosions occurred in the Polish collieries “Jas-Mos” and “Rydultowy” in the Upper Silesia coal basin. In the “Jas-Mos” colliery the coal dust explosion was initiated in the face of gallery by explosives and causing ten death. The stone dust barrier extinguished the flame, stopped the explosion development and saved forty nine miners working in that area. In the “Rydultowy” colliery methane inflammation caused three deaths and seven serious burns and ignited the coal dust explosion. The coal dust explosion was stopped by stone dust barrier and did not cause any victims itself. This paper presents the investigation carried out by the Central Mining Institute Experimental Mine “Barbara” and shows that the stone dust barriers remain still a basic mean for suppression of coal dust explosion in mines. The investigation were aimed at determining the cause of explosion and circumstances that led to their propagation. The evaluation of the state of dust explosion hazard in the areas of accidents have been performed, and the range of flame estimated.

Jan 1, 2003

By J. A. Beukes, M. Marais

TICOR South Africa is a new titanium feed stock producer. In the Ticor South Africa plant the ilmenite feed to the smelter plant is roasted to enhance its magnetic properties. This allows for the magnetic separation of chromite from the ilmenite. The magnetization reaction relies on partial oxidation with both under- and over-oxidation causing insufficient magnetization. To subject the roaster plant feed material to the required physical conditions a circulating fluid bed (CFB) roaster is used. This paper describes the development of a laboratory model that will aid in the control of the CFB roaster.

Jan 1, 2003

By J. Engelbrecht

South Africa?s re-entry into the fast moving and competitive global economy calls for some careful strategic planning and a good deal of co-operation between suppliers and end-users. The issues that need addressing are generally well known and include: ?South Africa was ranked 45th out of 46 i.r.o. productivity ?SMMEs contribute 1% to exports compared to 40-60% for the ?tigers? ?High unemployment ?Limited skills of the majority of workers ?Slow growth rate of the economy ?The vast majority of suppliers are not world-class ?The vast majority of suppliers are not export or marketing orientated. In order to survive, all parties, i.e. government, labour and business, will have to play their part.

Jan 1, 1999

By X. B. Zhao, J. G. Cai

The purpose of this paper is to incorporate the dynamic BB model of rock fracture normal behaviour into Universal Distinct Element Code (UDEC), and to conduct UDEC modelling to predict stress wave propagation across rock fractures. With the incorporation of new dynamic model of fractures, the UDEC is improved in the capability of modelling wave propagation across fractures. In this study, the case of normally incident P-wave transmission across a fracture is modelled, and the effect of dynamic normal behaviour of fracture is concentrated on. Wave transmission coefficient for wave transmission across the fracture with the dynamic BB model is obtained for various combinations of fracture dynamic parameters, as well as different wave amplitudes and frequencies.

Jan 1, 2003

By R. Peroni, J. Kopp

Mine planning and scheduling is based on using a geological model for the deposit. Blocks are used to discretize the deposit into mineable volumes where grade values are assigned. Traditional estimation techniques such as kriging or inverse distance weighting are frequently used for this task where an interpolated value is calculated within a discrete volume. This group of block grades is the input for sequence optimizers, which base their decision on the economical value of a given block. Ultimately, the economical value of a block depends on its grade, making mine sequencing sensitive to all estimated values. If one looks to a block not as a single grade but as a set of equally possible grades, its economical value will change as different grades can be assigned to it. Stochastic simulation is known to provide the tools to assess grade variability, which makes it possible to generate equally probable values in a block. Different grade block models can thus be built and multiple sequencing alternatives are observed by running the optimizer for these distinct inputs. The results demonstrate that the methodology is adequate for risk assessment and proves to be useful for mining project sensitivity analyses. Differences in the project net present value showed that there is little difference between the two simulation methodologies (sequential Gaussian simulation and sequential indicator simulation) applied. The process is demonstrated using a Brazilian kaolin deposit. Keywords: geostatistical simulation, mine planning, sequencing, risk assessment, open pit optimization.

Jan 1, 2003

By F. Crundwell, A. J. Lathwood

A number of base-metal operations would like to increase production to take advantage of the higher metals prices. In general, this higher production should not be achieved with major operating changes. In hydrometallurgical facilities, leaching and pressure leaching represents one area where upfront limitations may be a bottleneck to the capacity of the entire plant. An assessment of the capacity of the leaching tanks and autoclaves was performed using a predictive model within the AweSym flowsheet simulator. The model is described, and the results of the application of the model to a number of different leaching reactors are presented. It is argued that the leaching number, which relates the residence time, particle size and the leaching rate, is of prime importance. Finally it is shown that there are some unexpected catastrophic events in increasing production capacity without a thorough understanding of the leaching operation.

Jan 1, 2007

By T. Nishimura, H. Kiyama, K. Wakimoto

Discussion on the load bearing capacity of ground and the stability of tunnel is presented. We derive a simplified solution of a circular lined-tunnel in an elastic ground. The solution results in a better understanding of characteristic curves. Use of DEM allows us to consider effects of possible yield of the overstressed zone around the tunnel and inherent discontinuity of ground on the curves. Diskussion auf der Last Tragfähigkeit Bodens und die Stabilität des Tunnels wird dargestellt. Wir leiten eine vereinfachte Lösung eines kreisförmigen Ausbautunnels in einem elastischen Boden ab. Die Lösung ergibt ein besseres Verständnis der Kennlinien. Um Gebrauch DEM erlaubt uns, zu betrachten Effekte des möglichen Ergebnisses der überbetonten Zone den Tunnel und zugehörige Unstimmigkeit des Bodens auf den Kurven. La discussion sur la portance de charge de la terre et de la stabilité du tunnel est présentée. Nous dérivons une solution simplifiée d'un revêtement-tunnel circulaire dans une terre élastique. La solution a comme conséquence une meilleure compréhension des courbes caractéristiques. L'utilisation de DEM nous permet de considérer des effets du rendement possible de la zone surchargée autour du tunnel et de la discontinuité inhérente de la terre sur les courbes.

Jan 1, 2003

By P. Sharma, J. C. W. Fowler

This paper discusses the wind blast / air blast phenomenon, how it is managed in coal mines and how it might best be managed in other underground mines. L'article qui suit a pour objets de décrire le phénomène de tir a l'air comprimé et les méthodes de modération de celui-ci dans les mines de houille, et d'indiquer de quelle manière il pourrait être surmonté dans d'autres mines souterraines. Dieses Seminararbeit diskutiert die Windexplosion / Luftexplosion Phänomen, wie es in Kohlenberg-werken geleitet wird, und wie es am besten in anderen untertage Bergwerken geleitet werden könnte.

Jan 1, 2003

By Q. X. Yun

This paper provides a new approach to optimize the production planning in underground mines by means of evolutionary algorithms. Firstly, genetic algorithm is used to reach the global optimization in planning. Then, evolutionary programming is employed to obtain the partial optimization for each year. The application proves that the new approach is reasonable and useful. Keywords: Evolutionary algorithm, Genetic algorithm, Evolutionary programming, Optimization, Mining engineering.

Jan 1, 2003

By M. Wong-Kian, L. A. Cornish, A. van Bennekom

Samples of four different satellite materials were prepared by either hot isostatic pressing (HIP) of the powder or tungsten inert-gas welding of rod onto a 316 L stainless-steel substrate. The samples were subjected to a series of comparative erosion corrosion tests, and generally the Hipped samples experienced between 13 and 24 per cent less loss in mass than the equivalent welded alloys. Resistance to erosion corrosion increased with increasing carbon, chromium, and tungsten contents. Metallographic studies indicated the differences in carbide content between the different satellite materials, and the differences in morphology between the Hipped and welded samples. Finer and more homogeneous microstructures were

Jan 1, 1995

Abstract : The computation of reliability index or failure probability of slopes can be transformed into an optimisation problem. In high rock slope engineering, it is usually a multimodal optimization problem. The traditional optimization techniques are difficulty to find out the global optimal solution because of their easily falling into local optimal value. Recently, a new kind of bionic algorithm - ant colony algorithm (ACA) - has been used to solve this problem. In this paper, the structure of ant colony algorithm and the transfer probability of ants are modified to evaluate the failure probability of complicated slopes. A new adaptive ant colony algorithm (AACA) is proposed to determine critical slip surface and its corresponding failure probability of complicated slopes. A case study is given to verify the proposed approach. The results show that the presented method has obvious advantages compared with traditional methods. ZUSAMMENFASSUNG: Die Rechnung des Zuverlaessigkeitindexes oder der Zerstoerungswahrscheinlichkeit kann sich in einer Optimierungsfrage umwandeln, im Bauprojekt an hoehe Gebirgehang, handelt es sich meistens um eine Optimierungsfrage ueber Multi- Spitzenwert. Mit der traditionelle Optimierungsmethode ist es schwer eine umfassende Loesung fuer die Optimierung zu finden wegen des leichte Verfallens in Beschraenkung der Teiloptimierungsloesung. Mit dem neue Bionik- Algorithmus —— Ameisen - Kolonie- Algorithmus wird dieses Problem geloest. In diesem Text hat man eine Strukturverbesserungsloesung fuer das Ameisen- Kolonie -system und die Wahrscheinlichkeit der Ameisenkolonie erwaehnt, und damit wird man die Zerstoerungswahrscheinlichkeit des komplizierte Hangs feststellen. Mit dem neuen Ameisen- Kolonie- Algorithmus kann man die gefaehrlichste Gleitflaeche und die entsprechende Zerstoerungswahrscheinlichkeit herausfinden. Die in diesem Text beschriebene Methode wurde durch Praxis geprueft. Durch die Pruefergebnisse wurde es gezeigt und bestaetigt, dass der neue Bionik- Algorithmus vorteilhafter als der traditionelle Algorithmus ist. Résumé : Le calcul de l’indice la fiabilité ou de la probabilité de ruptures peut être transformé en un problème de l’optimisation. Pour le cas du génie des pentes de haut rocher , le problème se pose en général en l’optimisation de multi-crêtes. Les techniques traditionnelles conduisent facilement à la solution optimal partielle au lieu de celle globale. Récemment un nouveau type de bionique algorithmique a été appliqué pour la solution de ce genre de problèmes, c’est l’Algorithme Colonie de Fourmis. Dans l’article il est proposé de modifier la structure du système de la colonie de fourmis et la probabilité de transfert des fourmis en vue d’évaluer la probabilité de ruptures des pentes de haut rocher complexes, par ailleurs un nouveau algorithme adapté de colonie de fourmis est formulé pour déterminer la surface glissante critique et la probabilité de ruptures correspondante. Les techniques proposées dans l’article sont vérifiées à travers des expérimentations dont les résultats ont prouvé que les techniques présentées dans l’article sont évidemment meilleures que celles traditionnelles.

Jan 1, 2003

[Ferro Alloys Producers Association The South Africa Institute of Mining and Metallurgy www.saimm.co.za Mintek www.mintek.co.za Eskom www.eskom.co.za ]

Jan 1, 2004

By K. P. Davey

In 1998 an initial objective was given to the author, to process valuable off grade High Carbon Ferro Manganese (FeMn) metal fines profitably. The previous attempts that had been made to re-melt these metal fines through the furnaces had resulted in poor furnace operation, mainly to do with lack of electrode penetration and furnace bed permeability. It was decided that the method to resolve these problems was to agglomerate the metal fines. During the study on the agglomeration of the metal fines, a decision was made to use furnace baghouse dust and stockpiled furnace baghouse dust and sludge (DSF) as a ?filler? in the metal fines. The primary reason for using baghouse dust was to eliminate an environmental hazard, whereas the secondary reason for using the DSF was to utilize manganese units contained in the dust. The off-grade metal fines and dust were compacted using a brick press, with cement and aluminum rich plastic clay as a binder, to obtain agglomerate that was cost effective. Through the re-melting of the agglomerated off-grade metal fines, it was realized that this agglomerate concept could have other uses, that of replacing ores on the furnace, at a lower cost. The agglomerate recipe was changed to create an agglomerate that had a high manganese to iron ratio, this replaced Comilog ore on the furnaces, thereby reducing overall furnace unit costs. Future work concerning agglomeration, is to reduce furnace costs further through agglomerating .0.5mm ultra ore fines and .0.3mm Gloria and Nchwaning sludge. Using this agglomerate replaces a portion of the Gloria and Nchwaning lumpy ore on the furnaces at a lower cost. This would eliminate problematic material that exists at the ASSMANG Manganese mines.

Jan 1, 2004

By J. H. C. Pretorius, P. Nelwamondo

"Although South Africa possesses more than 80% of the world’s platinum reserves, its reputation for reliability in supplying platinum to global markets is under threat. This is due to the 49% decrease in output per worker (1999–2014), while the domestic costs have risen by more than 10% annually for the past 5 years. In addition, the continued decline in the commodity price by 38.3% (2012–2016) has resulted in a significant portion of the sector producing at a loss in 2015. The Chamber of Mines (now the Minerals Councilof South Africa) has suggested that solutions to improve productivity and reduce cost pressures are required. This research aims to provide operational excellence through the application of event chain project management (ECPM) to improve productivity and reduce operational costs. A case study was used to carry out research in platinum mines, with data collected using a motion-time study to measure the current efficiency of operations in each mining stope through actual activity durations. The results indicate that through the application of the event chain project management methodology, risks affecting the mining stope schedule can be managed, the efficiency of operations was improved by reducing the time spent on each activity, productivity was increased by shortening the project duration, and operational costs were reduced in the process. IntroductionSouth Africa’s total mining industry production was 4.9% lower in 2016 than in 2015; it decreased by 1.9% year-on-year in December 2016, with the main contributor to this negative trend being the platinum group metals (PGMs) with a drop of 15.1% and contributing -3.8% percentage points (Statistics South Africa, 2016). Although South Africa possesses more than 80% of the world’s platinum reserves, the 8% drop in production output since 2008 has put the platinum mining industry under the threat of being seen as an unreliable supplier to global markets. This decline in production is caused by the 49% decrease in output per worker between 1999 and 2014. In addition, the continued decline in the commodity price by 38.3% from 2012 to 2016 and an increase in operational costs during the same period resulted in a significant portion of the sector producing at a loss in 2015. A turnaround strategy is required to overcome these challenges. The Chamber of Mines has suggested, among others, the need for solutions to improve productivity and reduce cost pressures. The implementation of these solutions will ensure that the PGM industry thrives and reaches its potential of growing production to more than 322 t by 2020 (Baxter, 2016)."

Jan 1, 2018

By D. Boldini, R. Lackner, H. A. Mang

ABSTRACT: In this paper, the strong interaction between the hardening shotcrete lining and the surrounding ground in NATM tunneling is investigated by means of axisymmetric analyses, accounting for the three-dimensional nature of the excavation process. The effect of the hydration of shotcrete on strength, stiffness, chemical shrinkage as well as microcracking and creep are accounted for. For the description of the mechanical behavior of the ground, a multi-surface plasticity model is employed. The performed analyses of the excavation process provide insight into the influence of each phenomenon accounted for in the material model for shotcrete on the response of the ground-shotcrete compound structure. ZUSAMMENFASSUNG: In diesem Beitrag soll die Interaktion zwischen dem erhärtenden Spritzbeton und dem Boden auf der Basis axisymmetrischer Berechnungen untersucht werden. Derartige Berechnungen ermöglichen die Berücksichtigung des drei-dimensionalen Charakters des Vortriebprozesses. Die Auswirkung der Hydratation auf die Entwicklung der Festigkeit, Steifigkeit und der chemischen Schwindverzerrungen, sowie das Reißen und das Kriechen des Spritzbetons wurde berücksichtigt. Das mechanische Verhalten des Bodens wurde mittels eines Mehrflächenplastizitätsmodells simuliert. Die durchgeführten Berechnungen des Vortriebprozesses geben Einblicke in die Auswirkungen der Spritzbetoneigenschaften auf das Tragverhalten des Boden-Spritzbeton-Komposits. RÉSUMÉ: La stricte interaction entre le soutènement en béton projeté durcissant et le terrain dans un tunnel creusé avec la NATM est étudiée par des analyses axisymétriques, compte tenu de la nature tridimensionnelle des processus de creusement. Les effets de l’hydratation du béton sur la résistance, la rigidité et la contraction chimique, ainsi que sur la micro-fissuration et le fluage, sont mis en compte. Pour la description du comportement mécanique du terrain on emploie un modèle de plasticité multi-surface. Les analyses conduites mettent en évidence l’influence de chaque phénomène considéré dans le modèle constitutif du béton projeté sur la réponse de la structure composite terrain-béton projeté.

Jan 1, 2003

The heap leaching of base metal ores can be applied within a number of different scenarios, each requiring its own set of parameters to be determined during the metallurgical testwork programme. The occurrence of acid-gangue reactions and its concomitant precipitation reactions is a factor common to all cases, and requires that the optimal irrigation acid strength be found that optimises the combination of extraction kinetics, acid consumption and possible premature blinding of the heap due to precipitation reactions. For the heap bioleaching of base metal sulphide ores the oxygen requirement needs to be determined for the design of the aeration system, and the operating conditions employed need to also facilitate bacterial growth over and above the acid strength optimisation mentioned above. For the heap bioleaching of chalcopyrite, the need to preserve heat in the heap becomes yet a further parameter of critical importance. For the heap leaching of uranium ore a choice is required between either chemical or bacterial oxidation, based on economic and processing factors. Frequently the operating parameters need to be determined for a circuit in which heap leaching is combined with tank leaching and/or pressure leaching. The processing implications and metallurgical testwork approach for each case is discussed.

Jan 1, 2007

By W. Kint

More than 10 years ago, one of MECS?s current partners KVT developed the so called SULFOX process for cleaning waste gases containing sulfuric compounds. In this Wet Acid Process (WAP) compounds such as SO2 and H2S, CS2, COS are oxidized over catalyst bed(s) to SO3 and finally sulfuric acid is formed. The individual plants are designed according the feed gas concentrations and customers requirements to keep the investment and operating costs as low as possible. MECS strongly believes the technology we propose will meet all your expectations. Thanks to our vast experience in the construction of sulfuric acid plants (MECS built over 800 sulfuric acid plants worldwide) we were able to design you a very reliable installation. MECS is offering the metallurgical industry, besides our conventional acid plant technology (for strong SO2) and our DynaWave? scrubbing technology (for very low SO2), a SULFOX wet acid plant (for the mid range SO2 concentrations) including an optional upstream DynaWave gas cleaning plant if required. See the figure below. Besides providing advanced technology, MECS is the only company who designs and manufactures its own key critical equipment. We manufacture our own catalyst, mist eliminators, acid distributors and coolers. Because of our in-depth technology knowledge, we understand the critical aspects necessary for making optimum equipment designs. With this combined supply of technology and key critical equipment, we can make a single overall guarantee second to none other in the world.

Jan 1, 2009

By F. Bonnet, J. Lehmann, H. Gaye

A review of thermodynamic information and models of slags, including associated software when available, is presented. The pertinence and accuracy of these models is discussed by comparison of their predictions for various slag thermodynamic properties with the available experimental data. Practical industrial applications will be illustrated by a literature review of the dephosphorization process of ferromanganese alloys and by the description of Ti behavior during silico-manganese alloys production. This latter example will show how the thermodynamic models have been used to propose a flotation treatment at low temperature to enhance TiC removal.

Jan 1, 2004