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By G. L. Smith

The fundamental challenge facing mineral and metal companies is how to create sustainable value while operating within mandated strategic bounds, identified constraints, and variable market and economic conditions. This can be achieved by allowing the fixed physical nature of the mineral asset to drive definition of the optimal technical solution to mining and processing activities, and developing and resourcing a strategically aligned portfolio of production entities that creates flexibility to near- and longer-term business environment shifts, i.e. a production mix that allows variation of output to respond to short term market variation, within a long term context. The practical achievement of this outcome is enabled by the concept of strategic long term planning. The core elements of strategic long term planning in the metals and minerals industry, and the relationship between them, are expanded. The strategic long term planning framework is a logic construct that enables delivery of an optimized, strategically-aligned business plan from the mineral asset portfolio using a set of tools and techniques with a common language, standards, systems and processes to align decisions and actions on a cyclical basis.

Jan 1, 2012

By A. N. Clay

In recent times, there has been criticism of the minerals industry over the lack of quantifiable boundaries between inferred, indicated, and Measured resources. A recent initiative through the United Nations aims to try to converge the mineral resource classification systems. Since the oil and gas industry uses a probabilistic approach to defining reserve boundaries, it is appropriate to introduce a similar statistical methodology for minerals. The Venmyn Variance Tower has been developed based upon traditional statistics to utilize historical and ongoing information in order to quantify variance of geological and chemical parameters and the boundaries and logic for quantitative mineral resource classification. It is proposed that a less than 50% variance from the mean of all sample parameters is required to achieve the classification threshold to define an inferred Resource whereas between 20-10% is needed for an indicated Resource and less than 10% variance from the mean is needed to declare a Measured Resource. These limits are similar to those used by the oil and gas industry, and it is suggested that these thresholds be adopted as an industry standard to ensure consistent quantitative reporting. While this process is intended to use statistics of an orebody to provide quantifiable and defendable boundaries, it cannot be carried out unless the geology of the mineral deposit is understood and the borehole samples can be categorized into appropriate populations for which the statistics are valid. This means that competent geologists are always required to work with and understand the implications of the Variance Tower results. This paper is intended to form the basis of a series of publications that establish a process to take mineral projects along a quantifiable and logical development path. Hence, no specific field example of the practical application of this process is given here.

Jan 1, 2012

By D. F. Malan

This paper gives an overview of the difficulties associated with determining the strength of hard-rock pillars. Although a number of pillar design tools are available, pillar collapses still occur. Recent examples of large-scale pillar collapses in South Africa suggest that these were caused by weak partings that traversed the pillars. Currently two different methods are used to determine the strength of pillars, namely, empirical equations derived from back analyses of failed and stable cases, and numerical modelling tools using appropriate failure criteria. The paper illustrates that both techniques have their limitations and additional work is required to obtain a better understanding of pillar strength. Empirical methods based on observations of pillar behaviour in a given geotechnical setting are popular and easy to use, but care should be exercised that the results are not inappropriately extrapolated beyond the environment in which they are established. An example is the Hedley and Grant formula (derived for the Canadian uranium mines), which has been used for many years in the South African platinum and chrome mines (albeit with some adaptation of the K-value). Very few collapses have been reported in South Africa for layouts designed using this formula, suggesting that in some cases it might yield estimates of pillar strength that are too conservative. As an alternative, some engineers strongly advocate the use of numerical techniques to determine pillar strength. A close examination unfortunately reveals that these techniques also rely on many assumptions. An area where numerical modelling is invaluable, however, is in determining pillar stresses accurately and for studying specific pillar failure mechanisms, such as the influence of weak partings on pillar strength. In conclusion, it appears that neither empirical techniques nor numerical modelling can be used solely to provide a solid basis for conducting pillar design. It is therefore recommended that both these techniques should be utilized to obtain the best possible insight into a given design problem. Owing to the uncertainties regarding pillar strength and loading stiffness, monitoring in trial mining sections and in established mining areas is also an essential tool to test the stability of pillar layouts in particular geotechnical areas.

Jan 1, 2011

By G. J. de Korte

South Africa’s best-quality coal, located in the central Highveld basin, is becoming depleted and alternative sources of coal, such as the Waterberg coalfield, will have to be developed to supply the country with coal in the future. The quality of the coal being mined in the central basin is gradually becoming poorer. This necessitates that more of the coal be processed to improve the quality to meet customer requirements. The challenge to the coal processing industry is to process low-yielding coals to produce goodquality products and at the same time ensure that coal mining remains economically viable. This requires that more cost-effective coal processing technologies be investigated and implemented.

Jan 1, 2015

By A. McGarr

The shear stress t that can be sustained by the rock mass in the environs of a mining-induced earthquake controls the near-fault peak ground velocity v of that event according to v=0.25(ß/G)t, where ß is the shear wave speed and G is the modulus of rigidity. To estimate t at mining depths, I review the results of four studies involving Witwatersrand tremors that relate to the bulk shear strength. The first and most general analysis uses the common assumptions that the seismogenic crust is pervasively faulted, has hydrostatic pore pressure before mining, and an extensional stress state that is close to failure. Mining operations reduce the pore pressure to zero within the mine and redistribute the stresses such that, in localized regions, the state of stress is again at the point of failure. Laboratory friction experiments can be used to estimate t in the zero-pore-pressure regime. Second, model calculations of states of stress in the vicinity of mining at about 3 km depth indicated the shear stress available to cause faulting near the centre of a distribution of induced earthquakes. Third, laboratory experiments combined with microscopic analyses of fault gouge from the rupture zone of a mining-induced event provided an estimate of the average shear stress acting on the fault to cause this earthquake at a depth of 2 km. Fourth, moment tensors determined for mining-induced earthquakes usually show substantial implosive components, from which it is straightforward to estimate t. These four different analyses yield estimates of t that fall in the range 30to 61 MPa which implies that near-fault particle velocities could be as high as about 1.5 m/s. To the extent that the causative fault ruptures previously intact rock, both t and v, in localized regions, could be several times higher than 61 MPa and 1.5 m/s.

Jan 1, 2002

By A. F. S. Schoukens

The Mintek Thermal Magnesium Process (MTMP) was successfully demonstrated in November 2004. The pilot plant was operated continuously for 8 days, during which about 30 tons of magnesium producing recipe was smelted in a DC (direct-current) arc furnace at a feed rate of 525 kg/h. The furnace was operated at power levels of 700 to 850 kW, resulting in slag tapping temperatures of 1600 to 1700°C. Magnesium extraction averaged 77 per cent and was as high as 85 per cent during good extraction periods. The furnace generated 70 to 85 kg/h magnesium vapour that was delivered to the condenser where the temperature was controlled at 680 to 720°C. The novel condenser captured the magnesium in a liquid state, which was tapped periodically as required. In total, 15 magnesium-tapping operations were carried out, proving that online magnesium tapping can be consistently performed without any major difficulty. About 3500 kg of crude magnesium was produced with a quality that was similar to, if not better than, that of the Magnetherm?s crude metal. The condensation efficiency averaged 85 per cent, and peaked at 87 per cent, which exceeded the target of 80 per cent set for the pilot scale. A brief magnesium market study was also carried out. Magnesium demand is expected to keep on growing by 6 to 8 percent over the next 10 years and could reach 2 million tons by the year 2020. The growth will be mainly in the die-casting sector for light-weight automotive applications. China is likely to remain the dominant supplier of primary magnesium but competitively priced non-Chinese magnesium producers will be needed to sustain the anticipated growth of 6 to 8 per cent over the next 10 years. In addition, a prefeasibility study was undertaken for a commercial plant. The study confirmed the relatively low capitalcosts of the MTMP process, as well as the competitiveness of theoperating costs, as compared to the industrial electrolytic process.

Jan 1, 2006

Paper written on project work carried out in partial fulfilment of B.Sc. Eng. (Extractive Metallurgy)degree The concepts behind support vector machines are very interesting both in theory and in practice, as they are based on a universal constructive learning procedure derived from the statistical learning theory developed by Vapnik. In this paper, their application to time series modelling is considered by means of simulated data from an autocatalytic reactor. In particular, reconstruction methods from non-linear dynamics are used to define a state space model for the process. Multivariate embedding techniques are compared to scalar embedding with respect to modelling. Keywords: System identification, Support vector machines, Multilayer perceptrons, Non-linear dynamics

Jan 1, 2003

By Vinay Kumar Agrawal, Rama Nath Praharaj

IMFA Group is the largest producer of Charge chrome not only in India but also in Asia. This Group has plants situated at Therubali and at Choudwar. They also have a Thermal power plant at Choudwar which not only caters to the power requirement of Choudwar plant but also supplies power to Therubali. The plants are fed for Chromite ore through the captive mines namely Nuasahi Chromite mines (40.47 Ha) , Bangur Chromite mines(37.34Ha), Sukinda chromite mines (116.76 Ha), Mahagiri Chromite Mine(73.777 Ha) and Chingudipal Chromite mines (26.62 Ha). Nuasahi Chromite Mine, which is situated in Keonjhar district, is an underground mine and is based upon best technological advancements in the industry. The underground mining operation is certified under ISO-9002, ISO-14001and OHSAS 18001. This not only shows the concern for the quality, environment but also for the health of the employees. The Nuashahi is the first chromite mine to backfill the opencast excavations created during the last 50 years and carry out the production from underground area below the opencast workings. This paper deals with the state of art technology of sub-level open stopping in thin ore bodies. The under-ground mine openings was started in the year 1997. In next four years the production of chromite from underground was started.(2001). At present the mine is in a good shape with several running stopes. Today it is producing around 10,000 Mt per month of chromite. The development of the mine is carried out with an average of 200 mtr per month of tunneling. The mine is having a mechanical ventilator having a capacity of24000 M3 per hour at 50mm water gauge, thus feeding sufficient air for the persons working in underground. The mine is being dewatered through a most modern positive suction sump, having a capacity of 500 cum and operated with 120 HP pumps. After commissioning of this sump in the year 2003, the mine has taken a quantum jump in production with remarkable saving in power consumption.

Jan 1, 2007

By J. Engels

CODELCO is considering the implementation of high-density tailings management at the Chuquicamata mine in northern Chile for its long term disposal plan. To achieve this, CODELCO commissioned the design, construction, and operation of a 70 t/d pilot plant, fed by existing tailings. The testing programme was completed in May 2011, and consisted of laboratory rheological and characterization assessments, pipe loop testing, beaching trials, and analyses of deposition behaviour for solid contents ranging from 57?68% (w/w). This paper describes the characteristics of the pilot plant, the testing programme, the beach trial analyses, and the resulting beach profile predictions based on the stream power theory. CODELCO also used other predictive beach slope methods, such as the equilibrium slope concept, which are not discussed in this paper. The final beach profile for design will be selected after an expert analysis of all methods has been completed.

Jan 1, 2012

By P. R. Segopolo

"The purpose of the project is to convert current shuttle car utilization on an underground coal mine to best practice by focusing on change-out points and tramming routes, which have a major influence on shuttle car away times. Time studies were an integral part of the project as these enabled the determination of shuttle car away times. An indirect proportional relationship between shuttle car away times and productivity is established. Through the time studies, it is deduced that a third shuttle car will make an insignificant contribution to production when there is only one split open. During this time, maintenance on the third car can be optimized. In order to satisfy the mine’s key performance indicator of keeping shuttle car away times less than 75 seconds, a belt extension must be scheduled after the third split is open. It is established that at any given time, a minimum of two shuttle cars should be used. When cutting on the left-hand-side of the belt road with only two shuttle cars available, the centre and left (left of the feeder breaker) shuttle cars should be used for coal hauling. When cutting on the right-hand-side, the centre and the right-hand-side cars should be used. If only one shuttle car is available, the centre car is the most efficient to use. Alternative anchoring configurations can be employed so as to enable cars (left or right, especially) to reach the opposite extremities of the panel and hence minimize cable length restrictions. Paper written on project work carried out in partial fulfilment of BSc. Eng. (MiningEngineering)"

Jan 1, 2015

By C. Musingwini

An often overlooked factor in the analysis of mine layouts and schedules is technical operating flexibility (or tactical flexibility), mainly due to its nebulous nature. By glossing over technical operating flexibility the resultant mine layouts and schedules maybe suboptimal. The need to incorporate technical operating flexibility into the analysis and comparison of mine layouts and schedules is increasing in importance. The nature of technical operating flexibility is illustrated, previous work on valuing of operating flexibility reviewed, and a proposal made on how technical operating flexibility can be quantified for tabular reef mines by using a platinum reef deposit as a case study. Once technical operating flexibility has been quantified it becomes possible to explore its incorporation into the analysis of mine layouts and schedules and subsequent optimization processes. This paper is a revised version of a paper presented in the Proceedings of the Second International Platinum Conference, ?Platinum Surges Ahead? in 2006. The work described in this paper is part of a current PhD study at the University of the Witwatersrand. Keywords: mine plans, layouts, schedules, technical operating flexibility/tactical flexibility, ore availability.

Jan 1, 2007

Rockbursts continue to be a scourge in the mining industry, being responsible for accidents and damage to mining excavations. Although the problem has been present for more than a century, and although much research has been carried out, a solution is still elusive. Determination of, firstly, the demand on the support system imposed in the rockburst and, secondly, the capacity of the support system, cannot be carried out with any confidence, and therefore rockburst support cannot be designed using a conventional design approach. In contrast with the conventional approach, observations of rockburst damage in a mine have revealed a possible alternative approach to rockburst support ? sacrificial support. It was observed, in rockburst events, that a support system consisting of concrete panels restrained by grouted cables was destroyed, and the concrete panels were ejected. However, the rock behind the panels remained apparently undamaged and in place. This behaviour reignited the concept of sacrificial support, conceived more than 20 years ago, and which is described in this paper. The remedial solution implemented on the mine, involving cables wrapped over the panels and retained by grouting into boreholes, has been subjected to rockburst loading and has confirmed the validity of the sacrificial support concept. The concept of sacrificial support may be controversial, but is deliberately presented here with the aim of generating discussions and contributions, and with the ultimate aim of improving safety and reducing rockburst damage in mines. Keywords rockburst, seismicity, seismic waves, rock support, support design.

Jul 1, 2013

By A. K. Anyimadu

Ongoing development work on ultra-fine grinding for various applications at the Group?s concentrators has been conducted by Anglo Platinum over the last few years. Current potential applications for mainstream grinding and concentrate grinding are the subject of a group-wide research and development programme. The first 10 000-litre 2.6 MW IsaMill was jointly developed by Anglo Platinum, Xstrata Technology and Netszch for installation at the Western Limb Tailings Re-treatment project in Rustenburg, South Africa. The unit was commissioned in late 2003/early 2004,and has operated in an intermediate concentrate regrind application successfully since. This paper describes the operational performance to date, as compared with the original duty specifications and objectives. The first mainstream M10 000 IsaMill with a 3 MW drive will be operational in November 2006 at the Potgietersrus Platinum (PPL) ?Platreef? Sandsloot Concentrator in South Africa?s Limpopo Province. Keywords: Western Limb Tailings Re-treatment Plant, IsaMilling, Platreef, platinum, palladium, PGMs, tailings.

Jan 1, 2007

By A. K. Anyimadu

Ongoing development work on ultra-fine grinding for various applications at the Group?s concentrators has been conducted by Anglo Platinum over the last few years. Current potential applications for mainstream grinding and concentrate grinding are the subject of a group-wide research and development programme. The first 10 000-litre 2.6 MW IsaMill was jointly developed by Anglo Platinum, Xstrata Technology and Netszch for installation at the Western Limb Tailings Re-treatment project in Rustenburg, South Africa. The unit was commissioned in late 2003/early 2004, and has operated in an intermediate concentrate regrind application successfully since. This paper describes the operational performance to date, as compared with the original duty specifications and objectives. The first mainstream M10 000 IsaMill with a 3 MW drive will be operational in November 2006 at the Potgietersrus Platinum (PPL)?Platreef? Sandsloot Concentrator in South Africa?s Limpopo Province. Keywords: Western Limb Tailings Re-treatment Plant, IsaMilling, Platreef, platinum, palladium, PGMs, tailings.

Jan 1, 2007

By R Ratlou

Increased contamination due to sand in spiral feed has had a negative effect on the efficiency of spiral concentrators at Navigation Plant. The no. 1 seam at Kromdraai opencast, which was previously mined by underground bord and pillar methods, is now susceptible to spontaneous combustion because of air ingress into the old workings which are exposed in the opencast high wall. This posed a risk in the loss of reserves to burnt coal. As solutions, buffer blasting of the preceding cut to collapse bords and soft overburden dressing of un-collapsed bords were implemented to prevent air entering the workings. The latter remedy resulted in increased contamination due to addition of sand in Run of Mine. After evaluating alternatives, a low capital option was selected. The 110t/hr Teetered Bed Separator (TBS) has been installed, primarily to desand and upgrade the feed to the spiral concentrators. The unit indicated an upgrade with a yield increase of 0.4% during test work and is currently showing an overall plant yield increase of 0.97%.

Jan 1, 2006

By S. Luyckx

This paper reports hardness and abrasive wear resistance test results from a wide range of WC-Co alloys, varying in cobalt content as well as WC grain size. The results show that the abrasive wear resistance increases with increasing hardness and that the rate of increase is higher for larger WC grain sizes. The increase in abrasive wear resistance was found to be parabolic up to a critical hardness value and exponential above that value. The transition from parabolic to exponential behaviour was found to occur at the same contiguity value for all grain sizes, which suggests that at that contiguity value the WC skeleton becomes continuous in all WC-Co alloys.

Jan 1, 2004

The estimation of the spatial variation of the b-value of the Gutenberg- Richter relationship is important for both the general interpretation of the mechanism of rock mass response and seismic hazard assessment. The interpretation of b-value as a parameter of rock mass response is discussed in this paper. The methods applied to evaluate the spatial variation of b-value and the algorithm for obtaining the magnitude of completeness and b-value for subsets of data are presented with some verification analyses. The algorithms presented enable the automation of a spatial evaluation of b-value.

Jan 1, 2014

The simple act of taking a sample implies that someone will use the information contained in the analytical result to make a decision about a course of action. In the mining industry, the decisions may involve huge capital commitments for opening or closing a mine, or marginal tactical costs that involve deciding if a truckload of mineralized rock should be sent to the mill for processing, or the waste dump. Sampling is among the most fundamental activities in a mining operation, and this paper aims to examine some of the technical issues that can assist in ensuring that samples are representative and correct. Insights into the scale of variability require that we disaggregate sampling variance into its component parts and evaluate each one individually. The work of Pierre Gy in understanding the different sampling errors is the first step in establishing an optimal protocol. This must be followed by the appropriate measures to ensure the protocol is implemented such that minimal bias is introduced in the sampling process. Even with these insights the possibility exists for large unseen and hidden costs can accumulate in a mineral development because of sampling errors. These hidden costs arise due to misunderstanding of the principle factors that affect the size of sampling errors, such as the mass of the sample, the effects of splitting a sample to reduce the mass, and the influence of the nominal particle size. The handling of sample material without due regard to the sampling characteristics of the material being sampled is also a major source of sampling errors. The most significant problem is due to the influence of the so-called volume-variance effect. This effect is a consequence of the support effect and the information effect both of which relate to the difference in size at which samples are collected and mining blocks are extracted. The information effect is a function of the availability of data at the time that decisions are made about the destinations of mineralized rock, namely the mill or the waste dump. Implementation of appropriate sampling protocols in the mineral value chain remains a challenge throughout the industry. The growing understanding and deepening appreciation of sampling theory and methods means we stand on the threshold of a new era for implementing and understanding appropriate sampling procedures and protocols. In the interests of optimal development of the national patrimony it is suggested that standardization through the identification of structural problems and continuous improvement of mining processes be instituted at a national level.

Jan 1, 2007

By T. G. Carter

Support system design for tunnels and underground excavations has for many years relied heavily on the use of rock mass classification systems and the Hoek-Brown failure criterion as a means for characterizing rock mass behaviour. Because of their development, both the GSI system and the Hoek-Brown criterion admirably characterize most ?normal? rockmasses from the viewpoint of their behaviour for rock excavations. They, however, run into difficulties when applied at the two ends of the rock competence scale. This is largely because block size and incipient strength are such that rockmass behaviour in these domains tends not to be controlled by interblock shear strength but rather by material strength. At the low end of the rock competence scale (UCSi <<15 MPa and GSI generally <30) discontinuities play less of a role and rock mass strength tends to matrix strength. Similarly, at the high end of the scale (GSI >>65, mi>>15), because discontinuities are now widely spaced, block size becomes so significant that again, intact material behaviour rather than the fracturing becomes the dominant factor controlling rock mass strength. In this paper several case examples are presented to illustrate the application of the high-end (spalling) and low-end (weak ground) transition Hoek-Brown relationships proposed by Carter, Diederichs and Carvalho (2007) as a basis for better defining rockmass behaviour at the extreme ends of the rock competence scale.

Jan 1, 2008

By A. T. van Zyl, M. Mthenjane, M. J. Cole

Growing global concern over the impacts of climate change, attributable largely to fossil fuel energy sources, has led to the widely shared goal for a ‘just transition’ to cleaner energy and reduced dependence on carbon-based fuels. As the world’s 14th biggest CO2 emitter and being particularly vulnerable to the impacts of climate change, South Africa must embark on a just transition pathway. This paper reviews expected coal mine closures and associated community vulnerabilities and local governance challenges in South Africa. Decommissioning schedules for all coal-fired power stations and operating coal mines are plotted, and 69 mining host communities and 21 municipalities are mapped, classified, and described. Community socio-economic profiles are measured using a set of SDG indicators and census data and municipalities assessed through financial audits. Our research shows that five coal-fired power plants (8.9 GW) and 15 coal mines (29.5 Mt/a) will probably close by 2030, and a further four plants (14 GW) and 23 mines (106 Mt/a) by 2040. Thus, the shift to cleaner energy will likely occur without the premature closures implied by the just transition. The impact of mine closure on the 2.5 million residents of host communities will be significant, particularly as levels of income, employment, and education are already very low and many municipalities are in financial distress. The South African approach to the just transition needs to take local realities into account and the narrative must support an effective transition that does not undermine energy security and economic growth.

Jun 5, 2023