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By Hunsaker R. D

The description, characteristics, advantages and application of a new bulk explosive for medium to large diameter dry blasthole conditions is described. A brief outline of the delivery system for the product is also included. This explosive has been designed to provide an alternative to ANFO, currently the most common bulk dry hole product available to the mining and quarrying industry. The selection of the optimum explosive for any blasting operation is of prime importance. It is a major factor contributing to the production of the desired results in terms of muckpile fragmentation, shape and diggability. The optimum explosive can be defined as the most cost-effective in producing satisfactory breakage and displacement of the material. ANFO satisfies this prerequisite for a significant proportion of dry hole applications. This unique, low density and low velocity of detonation explosive has been developed to provide the industry with a cost competitive alternative to ANFO. Typical loading or average inhole densities nominally range between 0.40 g/cc to 0.70 g/cc, depending on the application. Characteristics of this explosive allow for specific and common applications in open cut coal and metalliferous operations. These include ore/waste control operations, prestripping and presplitting applications, sites confronting cap rock problems, and large hole diameter quarries.

Jan 1, 1995

By S Coward, S Jackson, S Moayer, J E. Vann

The variability and uncertainty of mineralisation, coupled with subsequent uncertainty in mining and processing, is often paid scant regard or overlooked during the evaluation of mining projects. In many instances, when the project transitions to the operational phase, the reality of feed or product variability and the consequences of unquantified uncertainties throughout the value chain become obvious. The outcome is the familiar picture of frequent ramp-up underperformance and failure to deliver on planned targets and objectives.Both mine and exploration geologists are expected to generate mineral deposit models that are based on an integration of diverse sources of data. These multifaceted deposit models already play a pivotal role in the design, development and optimisation of mining project value, and the trend to a fully digitally engineered future means that this importance is increasing. It is therefore vitally important that tools be made available to the geologist (as well as mining engineers and metallurgists) that enable them to characterise and assess variability and uncertainty via appropriate deposit models and thus articulate their impact on potential project configurations and decisions. Scenario-based project evaluation (SBPE) provides a framework for full and proper analysis of the downstream impacts of inherent deposit variability and uncertainty on project performance.SBPE has been developed by the authors over several years and aims to propagate geological uncertainty and variability through the mining value chain. The outcomes of SBPE can be tested against future external scenarios capturing financial, economic and socio-political factors that also drive project performance. Stochastic representations of the orebody (via conditional simulation (see Chilès and Delfiner, 1999)) that explicitly incorporate variability and represent uncertainty are propagated through the value chain on a block-by-block basis (ie on a much more granular basis than traditional project evaluation approaches).Conventionally, metallurgical processes are modelled with deterministic equations (eg regression models) based on limited data. The SBPE approach allows for the modelling of process performance uncertainty using geometallurgical sampling fully. Multiple outcomes of SBPE are passed through financial modelling, which can also incorporate stochastic components, thus allowing full quantification of the risks and opportunities of a set of project alternatives. The value of the SBPE system is that once a base case has been established, multiple engineered alternatives coupled with external scenarios are easily evaluated and compared in terms of incremental value.A new case study of SBPE is presented that shows how, by analysis of the various aspects of variability and uncertainty, project managers are able to focus on the areas that have the greatest ability to reduce risk and/or add significant value. This can lead to sufficient flexibility being built into operations that allow operators to cope with the real orebody delivered to the plant.CITATION:Jackson, S, Vann, J E, Coward, S and Moayer, S, 2014. Scenario-based project evaluation – full mineral value chain stochastic simulation to evaluate development and operational alternatives, in Proceedings Ninth International Mining Geology Conference 2014 , pp 21–32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 18, 2014

By G Marling, A Calderon, J Harris, P Kirsch, M Shi, D Sprott, A Kirsch

Large-scale infrastructure construction needs to comprehensively manage risks that can impact the health and well-being of many people, from workers (temporary, contracted or full time), to families and surrounding communities. This paper starts with an analysis of incidents (injury, fatality, other damage) in tunnel construction between 2000 and 2014 and assesses the distribution of these events by continent, year, and severity of outcomes. These incidents are then analysed and mapped to a framework of hazards derived from RISKGATE (2014). A comparative register of current tunnel construction risk management guidance is derived from current Australian codes of practice and this register is also mapped to the RISKGATE framework of hazards to identify where coal industry knowledge may offer utility to the tunnelling industry.An initiative of the Australian Coal Association Research Program (ACARP), RISKGATE is an interactive online risk management system developed to assist the mining industry in implementing continual improvement in the management of major unwanted events. To date, a comprehensive knowledge base has been captured for risk management of tyres, collisions, fires, isolation, strata underground, ground control open cut, explosions, explosives, outbursts, coal bumps and bursts, human/machine interface, manual tasks, slips/trips/falls, inrush and occupational hygiene. By capturing operational knowledge from industry experts, RISKGATE provides a cumulative corporate memory at a time of high personnel turnover in the coal industry.This paper proposes and outlines how knowledge within the RISKGATE platform could be applied to managing the significant health and safety risks associated with tunnelling. The authors suggest that to varying degrees the knowledge already captured in RISKGATE is likely to be transferable to tunnelling construction operations. Please note that this paper focuses on tunnel construction and does not address risk management of tunnels in operation (eg road transportation or utility networks).CITATION:Kirsch, P, Kirsch, A, Calderon, A, Marling, G, Harris, J, Shi, M and Sprott, D, 2014. Management of health and safety in tunnelling – application of Australian coal mining knowledge, in Proceedings 15th Australasian Tunnelling Conference 2014 , pp 563–572 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 17, 2014

This paper describes operational experience with seam gas and spontaneous combustion management, gained during ten years of production history (1993 to 2003) in the Wynn seam at Dartbrook Coal mine. In addition, comparisons are made with more recent operational experience in the overlying Kayuga seam. Development and retreat longwall operations were undertaken in a 4.0 m thick working section of the Wynn seam, contained within the lower quarter of a circa 24 m thick mega seam, from 1993 until mining operations were relocated to the overlying Kayuga seam in 2004. Production from the first block of the Kayuga seam is currently underway with seam gas and spontaneous combustion management requirements being refined as further operational experience is gained. Seam gas management techniques, including pre-drainage with pressurised fracturing, surface to underground goaf drainage of a carbon dioxide rich seam gas and novel, high capacity ventilation circuits, were employed in the Wynn seam. Ventilation strategies included operating up to carbon dioxide STEL concentrations of 3.0 per cent in segregated return airways rather than being limited to the TWA-TLV concentration of 1.25 per cent. The spontaneous combustion experience at Dartbrook Coal has, to some degree, resulted in a change in the way the risk is managed in Australian coal mines. Values of carbon monoxide make and hydrogen concentrations are profoundly different from previously recommended management plan trigger levels and those used elsewhere in the industry. However, the detection of higher hydrocarbons together with rising oxygen depletion ratios and absolute hydrogen concentrations remain as indicators of advancing spontaneous combustion events. In this respect, experience gained in the Wynn seam was important in the initial management of the shallower Kayuga seam, an essentially greenfield site with no prior operational experience being available.

Jan 1, 2005

By S Grimsey, E Janetzki, J Emery

Floor failure on the longwall face is a complex problem due to the dynamic interaction between the surrounding strata and powered roof supports involving multiple variables. It can also be highly problematic and costly when not well understood as there are significantly less remedies available post event. This was the early experience at the case study mine where significant lost time was incurred due to unplanned delays in the first two panels. To detect and prevent such occurrences is clearly the best approach, hence a tool to predict both floor failure occurrence and magnitude prior to mining was developed. Several parameters were determined as the key drivers for the failure events that had been experienced at this site. These parameters were, in list of influence from highest to lowest, material strength, retreat rate and the presence of water. The parameters were evaluated using a semi quantitative risk rating system ‘Heave Risk’ and given a weighting per their apparent influence. This ‘expert system’ methodology was selected as the use of risk rating systems in underground coal mining is well established. The heave risk model was first applied to previously mined panels. It accurately identified all areas of known major floor heave, with clearly defined areas of low and high risk apparent. The heave risk model was then used prior to mining and evaluated post mining based on observed conditions. It was found to also be highly accurate for prediction. The variability of each parameter and its influence on the overall risk rating is illustrated and discussed.

Nov 29, 2022

By Barber C, Buselli G

Detailed monitoring of point sources of groundwater pollution is expensive due to the high cost of drilling monitoring boreholes. Whether groundwater pollution is due to mining, industrial or domestic waste disposal, a universal difficulty when monitoring groundwater contamination is the placement of boreholes to adequately define the extent of the pollution plume. This paper reports groundwater 'resistivity variations determined from transient electromagnetic soundings at a domestic waste disposal site north of Perth in Western Australia. Together with available hydrogeological and water quality data, the geophysics provides a broad "plume scale" picture of groundwater contamination. A simple three dimensional model of plume development, which takes account of the dimensions of the wastes, has also been developed and shows good agreement with the spread of contamination indicated by the geophysics for relatively small values of the dispersivities. Better estimates of these parameters are still required. The work indicates that a combination of geophysics and modelling with ground-truth data from groundwater quality monitoring of boreholes is required to avoid difficulties in interpretation of data and to better define the extent and migration of pollution in Groundwater.

Jan 1, 1988

By M Tsai

Tube bundle gas monitoring systems have been used in the mining industry for over 50 years. The initial design was based on four individual gas analysers along with a series of solenoid valves, gas sample conditioning and flow control mechanisms to ensure the correct gas flow stream volume to the analyser. Simtars staff have identified flow control issues when providing operational support to coalmines on numerous occasions. The accuracy of the oxygen analysis is dependent on control of the gas flow to the analyser. Oxygen is one of the parameters used in calculating Graham’s ratio which is used for the detection of spontaneous combustion activity in coalmines. This paper will provide data which identifies the flow control issues by comparing mine site records for the two surface sample lines in the analyser room and the gas cage. Mine sites will be deidentified within the paper. The paper will discuss some of the changes that have been made in modern tube bundle systems and compare the change to the initial design specification developed by the UK National Coal Board, investigate possible operational impacts and provide a technical fix to solve the current flow issues being experienced at some mines.

Oct 12, 2022

By L Clarke, R N. Campbell, F Bourke, J Anderson

Lithological units have been classified geotechnically with mechanical tests and discontinuity measurements from the GRD Macraes Limited, Macraes Gold Project and Rotowaro coal mine open pits, New Zealand. Using these measurements slope stability probability classifications (SSPC) have been quantified based on an adaption of Hack's (1998) SSPC system which places less influence on rock quality designation and unconfined compressive strength than previous slope/rock mass rating systems. The Hack weathering susceptibility rating has been modified by using the chemical index of alteration values from XRF major element analysis. Slaking and weathering is an important parameter in slope stability in the Waikato Coal Measures and Otago schist lithologies and hence a non-subjective method of assessing slaking/weathering in relation to the chemical index of alteration has been introduced. Other major components of this adapted SSPC system are the inclusion of rock moisture content and rock strength anisotropy effects on slope stability. This paper explains the systematic approach of using the adapted SSPC system to classify slope stability probability. The main modifications of Hack's SSPC system are the introduction of rock intact strength derived from Mohr-Coulomb failure criteria which has been adapted for varying moisture content, weathering state and confining pressure. It is suggested that the subjectivity in assessing intact rock strength within broad bands in the initial SSPC system is a major weakness of the initial system. Initial comparison of rock mass friction angles, cohesion and strengths derived from the adapted SSPC are compared with results derived from modified Hoek-Brown criteria, MRMR and SMR classification systems. The advantage of the modified SSPC system is that slope stability probability, maximum batter and overall slope height and overall slope angle for open pit walls can be predicted in addition to orientation dependent and orientation independent stability. Examples are provided, using the modified SSPC system to predict initial optimum pit slope designs in proposed greenfield mine sites.

Jan 1, 2000

Virtual reality (VR) simulators represent a powerful tool for training humans to perform tasks which are otherwise expensive or dangerous to duplicate in the real world. The idea is not new. Flight simulators have been used for decades to train pilots for both commercial and military aviation. These systems have advanced to a point that they are integral to both the design and the operation of modern aircraft (Adams, Klowden and Hannaford, 2001; Mastaglio and Callahan, 1995). This technology has been successfully extended and utilised in the mining industry in a range of successful applications (Bise, 1997; Denby and Schofield, 1999a; Schofield, 2005; Henning et al, 2002; Kaiser, Vasak and Suorineni, 2005). There are a number of lessons that can be learned from other industries that have successfully utilised virtual technology for a number of years. Specific rules of thumb regarding the specification, development, application and operation of these simulators can be garnered from other industrial training systems and examined in a minerals industry context (Tromp and Schofield, 2004; Schofield, 2006). This paper intends to discuss some of these generic rules in the context of a number of recently developed virtual reality mining applications.

Jan 1, 2008

By Jones M

The concept of precise, accurate timing with Electronic Delay Detonators (EDDs) was first seriously addressed in the mid-1980s and much was made of the cheapness and profusion of digital watches in terms of the likelihood of EDDs also being cheap and easy to produce. Ten years later, with every major explosives company and many electronics groups having instituted projects to capitalise on the promise of these devices, production devices are still to come into general use. In South Africa, Expert Explosives units have been used in most applications during proving trials and more recently for production blasting in underground ring stoping and open cast coal. The outcome has been valuable learning both as to the benefits and technical requirements for electronic delay blasting, and especially, safety aspects. Examples are shown of production blasts which utilised the power of EDDs. It is evident that it is not delay accuracy alone which determines the value of these systems, but the whole robustness, flexibility and ease of delay allocation when harnessing blast engineering knowledge. Muckpile movement and shape, fragmentation and vibration frequencies have shown to be greatly influenced by designs which can be implemented no other way. The flexibility of a system and the power of the software controlling it are crucial in capitalising on blasting potential, which lies in integrating control of blast timing with other developing electronic Technologies.

Jan 1, 1995

The 5.6 km Canning Tunnel was constructed to improve water supply from Canning Dam to the Perth metropolitan area. The site area is in the Darling Range which is essentially a laterite-capped plateau-remnant underlain by Archaean granitic rocks, intruded by dolerite. Two arrangements were available. After geotechnical investigations which included geological mapping, seismic refraction geo- physics, diamond drilling and mechanical rock testing, a single tunnel was selected in pre- ference to two short tunnels and a connecting pipeline. The tunnel is hydraulically equivalent to a fully lined tunnel 1.83 m in diameter and 5 580 m long. The alignment diverged from a straight line so that the initial upstream section was almost normal to the contours which allowed for minimal support requirements in a weathered zone. Although steel and con- crete lining was needed at both ends, the main section of the tunnel was unlined except for a concrete floor. A sand and rock trap with a capacity of 46 m3 was constructed near the outlet portal to collect debris and sand down to a size of about 2 mm. Portal excavations were in highly to completely weathered rock which extended 56 m into the tunnel at the upstream end, and 18 m at the downstream end. Conventional drilling and blasting were used for tunnel excavation with survey control by laser. Breakage lEngineering Geologist, Mines Department, Perth, W.A.

Jan 1, 1976

By I Arburthnot, N Lawler, C Loan

The function of a thickener is to optimise and accelerate the process of gravity sedimentation. The desired end product (be that maximised concentrated solids or clarified liquid) determines how the thickener is designed and operated.Significant internal research, together with extensive on-site piloting, by Outotec has resulted in the determination that the application of the appropriate amount and type of shear to hindered settling aggregates can result in a substantial change to the sedimentation process. A new patented technology, called shear enhanced thickening (SET), has been developed. SET results in considerable design implications for full-scale thickeners, including a substantial reduction in required footprint and/or significant increases in underflow density.The development of SET, combined with laboratory and pilot scale verification, will be discussed along with the introduction of this technology to a number of full-scale thickeners. The associated implications and benefits for industrial thickeners are outlined.CITATION:Loan, C, Lawler, N and Arburthnot, I, 2012. Industrial scale results from shear enhanced thickening technology, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 341-346 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By J J. Van Wijk, A R. Penney

Successful management of geotechnical risk at a mining operation is more than just having a good ground control management plan or using advanced numerical modelling and the latest monitoring technologies. The fundamental requirements for effective geotechnical risk management include identification of potential failure modes, identifying and implementing appropriate controls, and demonstrating the effectiveness of those controls. Effective geotechnical risk management requires an integrated approach by confirming that appropriate risk management systems have been identified and implemented (management plans, procedures etc), and that these systems are executed consistently in the field across all working areas. Development of a thorough integrated auditing process executed by an experienced team of technical subject matter experts with substantial operational knowledge, provides a more complete picture of catastrophic hazard management. Following consistent evaluation criteria allows benchmarking of systems and implementation compliance between the sites being audited, and the results can then be ranked against other operations in an industry database.

Nov 29, 2022

South Australia was founded as late as 1836, forty- eight years after New South Wales, yet within five years had announced the first discovery of metals in Australia. Throughout the 1840s the mining of silver-lead, then copper, spread north through the Mount Lofty and Flinders Ranges creating a thriving industry, years before the discovery of gold in the eastern colonies in 1851. The first significant mine was Kapunda (1842), followed by the much bigger Burra (1845) and other copper finds at Tungkillo, Worthing, Cal- lington, and North Rhine.

Jan 1, 1987

By J Player, R de Vries, J F. Carswell, R Hassell

"The feasibility of Dugald River mine was highly sensitive to mining and geotechnical design assumptions, particularly stope dilution and strike length. Following the start of initial mine development in 2012 the project was suspended in 2013 due to concerns over the complex ground conditions and resulting dilution, stope sizes and general mineability. A technical risk mitigation program was undertaken with a key aim to increase the level of confidence in predicting stope dilution.A stope sizing and dilution model was developed that provided a range of stope sizes based on geotechnical conditions and acceptable dilution. The original feasibility used a standard stope size of 25 m height by 25 m span. The new model was used as the foundation for the subsequent updated development plan for Dugald River that reduced much of the previous technical risk through greater confidence in the geotechnical and mining parameters.Several methods to predict stope hanging wall dilution and appropriate stope size have been used at Dugald River that relied on the modified stability graph method. Improvements to the method were identified as more rock mass and mining data became available through the completion of a trial stoping program, increased underground development and a large geotechnical core logging campaign. These improvements not only focused on the technical aspects of the model, but also on creating an easy to use and sustainable process that could be used at multiple stages of mine planning from life-of-mine (LOM) through to final stope design.Several of the main improvements are: understanding stope failure mechanisms and collecting only geological information that is most relevant detailed modelling restricted to the rock mass that could be expected to influence stope behaviour accounting for different stope failure mechanisms with the stability chart method assigning a geotechnical confidence factor to the data making it useful as a mine planning tool with integration into the mine planning process using performance of completed stopes to update and calibrate the model.The model provides recommended hydraulic radius and associated dilution estimates across the ore body. Providing the hydraulic radius allows planning engineers the option to consider single, double and triple lift stoping options suitable to mine scheduling. While the model has been calibrated for conditions at Dugald River the process used to create the model is not site specific and is applicable to other steeply dipping tabular orebodies.CITATION:Hassell, R, de Vries, R, Player, J and Carswell, J F, 2017. Improving the prediction of stope hanging wall dilution – a critical factor to the success of Dugald River, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 71–78 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 16, 2017

The continuous casting of zinc alloys has been of fundamental importance for many years in the production of a number of products, including sheet for architectural applications, battery cans for dry cells and wire for metallising. The intrinsic benefits of continuous casting, including efficiency and high tonnage capability, uniformity of metallurgical structure and properties, and absence of voids and other defects, have contributed to the success of these products. Less well known, but of growing importance, is the more recent application of continuous casting technology to the production of zinc alloy bar stock products, including bearing stock, machining bar stock, forging stock and cathodic protection anodes. A wide range of zinc alloys are now continuously cast in a variety of cross sectional shapes and sizes to suit the diverse characteristics of these products. Of particular significance are the introduction of hollow zinc-aluminum bearing stock, and the availability of zinc alloy machining bar stock for hydraulic applications and for producing prototypes of zinc alloy pressure die castings. In addition to the traditional benefits, continuous casting provides special properties which are important in the application of these bar stock products. The list of successful applications of continuously cast zinc alloy bar stock is growing rapidly, and the market potential for resultant new zinc applications appears to be significant.

Jan 1, 1993

Brand se Baai, on the North-Western Cape Coastline of Southern Africa, is the site of the Namakwa Sands Limited Heavy Mineral Sands Mining Operation. The mine is a 14 000 000 tonnes per annum open-cast strip-style mining operation using truck and excavators to mine the sand. The orebody consists of relatively unconsolidated sands reworked by fluvial, marine and aeolian mechanisms. The total orebody includes three primary ore types, namely the Red Aeolian Sands, the Dorbank (a hardcap layer) and the Orange Feldspathic Sands, which forms the bulk of the resource. Mine planning and scheduling is done using a 50 m + 50 m variable bench height system with three primary bench heights. The Aeolian and Dorbank each have a bench that varies with their thickness of up to a maximum eight metres and the Orange feldspathic sand, a standard bench height of eight metres. For a number of years Namakwa Sands used a complex 2D, Datamine Based, macro system to perform the resource evaluation and mine design. As the mining operations expanded it became clear that a complete system redesign was required to cope with the increasing operational pressures coming to bear on the old system. The biggest challenges facing any replacement system are the sheer scale of the mining operation (16 km long and 7 km wide resulting in a minimum of 30 000 individual 50 m + 50 m mining blocks), the size of the geological data files (up to one gigabyte) and representing the benching system accurately (as the benches follow the topography and are not horizontal). In addition to these large-scale issues, the ability to run multiple mine design scenarios was required, an aspect which the old system was unable to perform adequately. Based upon these primary difficulties, a new business process was developed which required a complete rethink of the mine design methodology as well as the creation of a new system to deplete the resource model, produce monthly reconciliation evaluations and create a ultimate pit limit based on the operations mining cost model. Using a system based on the Earthworks Mine2-4D Mine Design and Scheduling System (with its mine design and scheduling specific tools), as well as a small, customised program, massive time-savings have been made. It is now possible to run several life of mine scenarios in the same timeframe that a single life of mine run took under the old system. This paper will present the methodology and business decisions behind the new Namakwa Sands system, and detail the restructuring and development used to deal with the large data set sizes and long processing times inherent in the old system. Future enhancements to the system that will make it more generically applicable to open-cast mining scenarios will also be dealt with.

Jan 1, 2003

By W A. Peck

Raise boring is the preferred option for constructing ventilation shafts in Australia. The trend has been towards larger diameters and longer single-pass shafts, and if at all possible, reaming through to the surface. The risk of raise failures, due to missed, unforseen or latent ground conditions has therefore been increasing, along with the need for better, more confident stability assessments.While the stability of specific weak zones and structures must be assessed individually, empirical rock mass classification schemes have been successfully used for about the last 20 years to assess general raise stability; eg the McCracken and Stacey method (M&S).Unfortunately M&S, as originally documented in McCracken and Stacey (1989), did not include a database of raise diameter and rock mass conditions versus actual performance. Nor was there a procedure for assessing the risk of failure due to adverse ground conditions. Peck and Lee (2008) published an Australian database of raise bore performance. Raise diameter and ground conditions, in terms of a lower bound Qr value, were presented for 50 cases versus raise performance. This paper updates the 2008 raise performance plot with more and SRF-corrected data. McCracken and Stacey (1989) had previously recommended that additional geotechnical data should be acquired and analysed when the proposed raise plotted on the unstable side of raisebore stability ratio (RSR) = 1.3, but the Australian data used in this study also suggests that all sites with Qr Contributions and sensitivities of various rock mass parameters (RQD, Jn, Ja, Jr, Jw, SRF, time-dependent weathering/deterioration) to raise stability and risk of failure are discussed. Numerous case studies are used to illustrate issues with stability assessments.As raises can now be remotely supported using sprayed fibrecrete, questions of time-dependency are also discussed. In recent times, contiguous piles, ‘mini-piles’ and grouting have also been successfully used to presupport or otherwise improve the stability of near-surface sections of weathered, or poor quality rock masses.

Mar 21, 2011

By P Pieterse

Kumba Iron Ore Ltd is currently commissioning the Sishen Expansion Project (SEP) û a brownfields project on the Sishen Iron Ore Mine located in the Northern Cape Province, South Africa. SEP is designed to produce 13 Mtpa of product from 21.7 Mtpa of ROM feed. The beneficiation section of SEP employs jigs to process narrow size fractions in the 25 x 0.8 mm size range. The -0.8 mm fraction is screened out ahead of the jig plant and rejected as waste without any prior beneficiation. The processing of this fraction was not included in the early stages of SEP development because no suitable beneficiation or dewatering technologies could be identified within the time-frame required to implement SEP. This paper presents the SEP 1B project, ie the metallurgical and process engineering study that was done to evaluate the techno-economic viability of processing the -0.8 mm material of SEP. To support this evaluation, metallurgical bench scale testwork was done on selected samples characterising the material types used in the SEP for gravity concentration beneficiation. Subsequently, pilot testwork on a 300-ton bulk sample demonstrated that an integrated teeter-bed/spiral circuit could be used to successfully beneficiate the -0.8 mm fraction. The study has established the viability of the proposed process and has concluded that approximately 390 000 tpa could be produced and added to the SEP fine ore product without violating the applicable product specifications. The proposed process has been designed to be implemented in modular units in order to facilitate implementation and ensure future expandability. Based on the recommendations of the study, approval has been granted for the detail design feasibility study. Production is scheduled to commence in the first quarter of 2010.

Jan 1, 2008

By S Maritsa, E K. Chiw, S M. Masuka, ika, T Chisahwira

The challenges facing the iron and steel industry on a global scale include depletion of resources, excessive energy consumption and CO2 emissions. The demand for iron products in Zimbabwe is increasing due to massive infrastructural development like the expansion and improvement of mines, transportation systems and water reticulation systems. In Zimbabwe, cast iron is mainly produced from recycling scrap metals. However, there is currently a shortage of scrap, which has resulted in the vandalism of state-owned properties such as bus terminals and railway wagons and lines. Nevertheless, Zimbabwe is rich in limonite ores, which are idle, and it is the aim of this research that this ore be effectively used to produce feed for the blast furnace. The Blast furnace is still the dominant route for producing cast iron where sintering and coking processes are the main routes for preparing the Blast furnace feed. Sintering limonite ore fines produce a product of poor grade because of the high value of loss on ignition that has a negative impact on Blast furnace efficiency. Furthermore, the sinter plant and the coke making plant are a source of huge environmental pollutants. Since low-grade Zimbabwean coal fines are also available in abundance, they were used in the preparation of the composite materials ensuring maximum utilisation of this resource. Results showed that the limonite ore-carbon composite pellets sample with the binary basicity ratio (CaO/SiO2) of about 0.27 and coal addition of 2.5 wt per cent achieved above the minimum physical quality requirements for pellet of drop number of at least 4, a dry compression strength greater than 2.2 kg/pellet and an indurated compression strength greater than 250 kg/pellet. Limestone was used as the binder avoiding the addition of more impurities from bentonite since the limonite ore has a high SiO2 content of about 8.78 wt per cent.

Sep 18, 2023