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By C. Hutton

"SynopsisThe last commodities supercycle (2003 to 2011) was characterized by a belief in volume at any cost, where absolute output was deliberately prioritized over productivity considerations. This practice fuelled overoptimistic forecasting and planning, which in turn contributed to the economic crisis that followed. The sudden collapse of commodity prices has resulted in mining companies scrambling to find the right balance between optimizing current operations and preserving sufficient flexibility to grasp future opportunities. The runaway costs of building and operating mines have almost squeezed out profit margins, while lower ore grades are inflating production costs. Mining companies therefore need to look at the business with fresh eyes, and develop strategies to attract equity capital as traditional approaches are simply not working anymore. This is especially so in the context of a dwindling investor base that continues to demand greater returns, despite a significantly lower appetite for risk. This paper revisits the micro-economic concepts and demonstrates how pressure from shareholders to prioritize output contributed to spiralling costs and value destruction. Practical techniques are described to model cost curves to optimize a Mineral Resource endowment and address the need to rightbalance a business and preserve agility.IntroductionHenry Lazenby (2014) for the Mining Weekly writes, ‘Bruised and battered, the global mining industry today is undergoing a sea change. Practices and policies that might have worked wonders in the past are not as relevant today, and new approaches to running profitable mining operations need to be found.’ One significant practice the mining industry had during the last commodities supercycle (2003 to 2011) was chasing volume at any cost; absolute output was deliberately prioritized over productivity considerations (Goldsmith, 2013). Lazenby contends that in the face of falling and volatile commodity prices, many mining majors ‘across all commodity groups are currently grappling with sagging profits and low company valuations. This is often regarded as the result of the were in pursuit of growing their output at all costs in a high commodity price environment.’ Lee Hodgkinson, KPMG’s Canadian mining industry leader and quoted by Lazenby, says that ‘mining companies are now trying to find the right balance between optimizing current operations and preserving their agility to grasp future opportunities. The runaway costs of building and operating mines have almost squeezed out profit margins [whilst] lower grades of ore are inflating production costs. Mining companies need to look at the business with fresh eyes, and develop strategies to attract equity capital as it seems clear that some of the traditional approaches to the mining business are simply not working anymore."

Jan 1, 2015

By H. Yilmaz

A testing method for assessing the shear-bond strength of thin spray-on liner (TSL) on rock substrate was developed at Wits University Rock Mechanics Laboratories. The gap between a 20 mm thick steel ring and a rock core is filled with TSL along the depth of the ring. After the curing of the TSL for a predetermined period, the sample is placed on a base, which offers support to the steel ring and the TSL but not to the rock core. A compressive load is applied on the rock core displacing the core on TSL contact and punching it towards the void in the support base. Shear-bond strengths for different TSL products as well as shotcrete were measured. This paper describes the test set-up and points out the important aspects and procedures during sample preparation and test execution. The test results are also presented and discussed.

Jan 1, 2007

By T. J. Goff

Keywords: accurate control, matte level, smelting operations, process control, tapping, sounding bar, electromagnetic measurement [ ] Accurate control of matte levels during primary matte smelting operations is desirable in order to improve process decision-making. High matte levels in the vessel could have to disastrous consequences, particularly in the new generation of intensive smelting furnace with deep-cooled copper coolers. Knowing when to commence tapping and a better understanding of melt times can only be improved if the furnace levels are monitored correctly. At Lonmin Marikana Smelter Division it has long been understood that the matte level information being provided by the manual sounding bar is only as good as the operators? following of measurement procedure, their skill in assessing what the sounding bar is displaying, and their individual interpretation of what they are looking at. This paper sets out to show how this problem was identified as an area of major concern to the plant, how a solution was sought and how an electromagnetic measurement system was installed as an alternative measurement to the matte sounding bar system. Other areas discussed in the paper are the difficulties to be overcome when first installing new equipment and how these teething problems were solved by close co-operation between Lonmin and equipment suppliers, which led to some design modifications to the delivery system. In conclusion the paper discusses the results between the electromagnetic measurement and the manual sounding measurement and how best to integrate the generated data into the plant?s process control system for improved decision making.

Jan 1, 2011

Sishen Iron Ore Mine previously used only A-grade material (>60% Fe in situ value) from the pit for beneficiating in the DMS plant to a final product grade of 66% Fe in lump and 65% Fe fine ore. The B-grade (between 50% and 60% Fe) and C-grade material (between 35% and 50% Fe) were stockpiled separately, owing to the inability of the existing DMS plant to beneficiate material at densities higher than 3600 kg/m3. The ability to beneficiate the B-grade material at densities higher than 3600 kg/m3 was evaluated, and air-pulsed jigs were found to be techno-economically feasible and value maximizing. The beneficiation of B-grade material would add to the existing DMS production of 28 Mt/a, with no additional mining cost and only limited costs for the handling of waste and B-material. The objective of the Sishen Expansion Project (SEP), i.e. the jig plant, was to produce 10 Mt/a of saleable product with six modules to the set physical and chemical specifications by 2009. During the start of construction, it was decided to add another two jig modules to the plant to increase production to 13 Mt/a. During commissioning and ramp-up the shortcomings and advantages of the jigs were fully experienced and understood, resulting in many changes to optimize jigging performance..

Jan 1, 2014

By R. Armstrong

Due to limited available level ground, Nkomati Nickel Mine cut a weathered rock slope at the base of a mountain spur in order to create a platform for construction of the primary crusher plant and run-of-mine stockpiles. As space is limited around the mining area, ore processing at Nkomati is based on a high reliability of flow of material through the crusher plant, with minimal usage of other and larger designed stockpiles. Evidently, any crusher plant shutdown will render the mine as a whole unproductive and put excessive strain on the medium- to long-term large ore stockpiles, the deposition rates for which are restricted by founding material consolidation requirements. At the onset of the 2012 rainy season, movement was identified on the slope monitoring system and cracks developed on the slope. After a minor failure on the crusher slope an assessment of the slope stability was conducted and a slope management plan recommended, which included deployment of real-time monitoring. An evaluation of the conditions leading to instability was conducted and the likely causes for the failure identified. A full evaluation of the slope monitoring, rainfall, and mining conditions was undertaken and movement triggers were determined. This paper describes the events leading to the development of the failure and the evaluation of the monitoring data to determine a management plan for the failure that allowed for minimal shutdowns of the primary crusher.

Jan 1, 2014

Standards And Laboratory Monitoring In Gold Assay Key Components Of Best Practice

Jan 1, 2005

By P Papanastasiou, J Hadjigeorgiou, E Kyriakou

The south west area of Cyprus has a long history of slope instability problems. The location and extent of these landslides has been influenced by ground morphology, geological structure and the presence of weak rocks and cohesive soils. The main triggering mechanisms have been precipitation and/or seismic events. Landslides have contributed to the decision to relocate villages and considerable efforts have been put into maintaining the integrity of the local transportation network. This paper uses a recent case study of road embankment failure near Pentalia in southwest Cyprus to review the available tools for the analysis of slope instability. It further demonstrates how the shear strength reduction technique can be used in a finite element analysis to better visualise the slope instability mechanism of a road embankment and provide a reliable tool in selecting appropriate remedial measures.

Jan 1, 2006

By J. D. Steenkamp

"In July of 2016 and June 2017, major tap-hole repairs were carried out during the annual shutdown of two 63 MVA submerged arc furnaces producing ferrochromium in South Africa. The hot excavations of the tap-holes allowed for a study of the wear profiles. Subsequent thermodynamic calculations allowed for the quantification of the potential for chemical reaction between refractory and slag or alloy contributing to wear in the tap-hole area. Results from both wear profiling and thermodynamic calculations are reported here. IntroductionFerrochrome (FeCr) is an essential alloy in the production of stainless steel (Gasik, 2013). In 2017, 11.7 Mt of FeCr was produced (Pariser et al., 2018.). The main producers were China (39%), South Africa (29%), Kazakstan (12%), and India (8%).A number of grades of FeCr are available to producers of stainless steel, including high-carbon ferrochrome (HCFeCr) (Gasik, 2013). HCFeCr typically contains 60–70% Cr and 4–6% C (Basson and Daavittila, 2013). When the chromium content is lower (50–55% Cr) and the carbon content higher (6–8% C), it is referred to as charge chrome. Charge chrome is typically produced in South Africa due to the grades of ore available.FeCr is produced in submerged arc furnaces (SAFs) and in open arc furnaces (Mc Dougall, 2013) by carbothermic reduction of oxide raw materials. In a SAF the electrode tips are submerged in a porous charge mix. In FeCr production, the electrical energy is mainly liberated by resistive heating of the wet coke bed (Barker et al., 2007; Steenkamp et al., 2017). Thermally conductive lining design philosophies are typically applied in SAFs producing FeCr (Steenkamp, Denton, and Hayman, 2017; Coetzee, Duncanson, and Sylven, 2010; Coetzee et al., 2010).In July of 2016 and June of 2017, major tap-hole repairs were carried out during the annual shutdown of two 63 MVA SAFs producing FeCr in South Africa. The hot excavations of the tap-holes allowed for a study of the wear profiles. Both SAFs were operated on the same site, by two different operating crews, using the same raw materials. The major difference between them was that the SAF excavated in 2016 was an open SAF (referred to as Furnace A) and the one excavated in 2017 was a closed SAF (referred to as Furnace B). In an open SAF, a gap exists between the top of the steel shell and the roof, with the top of the burden being open to the atmosphere and the CO-rich off-gas being combusted as it escapes. In a closed SAF, the roof is attached to the steel shell and the CO-rich off-gas is collected from an offtake on the roof for further treatment and used in downstream processes.The paper presented here reports the macro-scale observations on refractory wear for the two SAFs, and studies the potential for chemical wear of refractory by slag and alloy as a potential contributing factor to the tap-hole wear observed."

Jun 1, 2019

By J. West

For many years line-of-sight (LOS) issues for underground mobile equipment is a growing focus of research. This research is a result of the numerous fatalities and injuries which occur in the mining industry and which are related to poor operator LOS. Three assessment methods are currently used to assess operator LOS of underground mobile equipment. The light filament (LF) method is a hands-on assessment method that is performed in the field. This method is not evaluated in this paper. The laser scan (LS) method of assessing equipment is a quick and reliable method that comes from the need to evaluate vehicles already located in the field. The computer simulation (CS) method can assess LOS issues using a computer aided drawing (CAD) model, which is useful for assessing current or prototype models. The purpose of the current research is to compare and validate different operator LOS assessment methods. Comparison of the results of the LS and CS visibility plots yielded similar quantifiable results. A visual comparison of the results further illustrate that the LS and CS methods are acceptable assessment tools for mobile equipment operator LOS evaluation. The visibility assessment methods are now being prepared as guidelines for the mining industry to assess current and potential designs.

Jan 1, 2007

By A. Kapito

The formation of bainite in steel is dependent on the size of the casting, the heat treatment, and the alloying elements. It is difficult to obtain a fully bainitic microstructure in steels during heat treatment because of its close proximity to the martensite (a?) reaction. The ferrite (a) and pearlite reactions in steels are also rapid and shield the bainite reaction. Alloying elements therefore need to be added to separate the bainite reaction. Boron (B) and molybdenum (Mo) are key elements added to bainitic steels because of their ability to retard the a reaction. Other elements used in the production of bainitic steels are silicon (Si), chromium (Cr), manganese (Mn), and titanium (Ti). In this paper we investigate the effect of alloying elements on the bainite reaction through the use of dilatometry. Dilatometry is a technique that determines phase transformations in the steel and through which continuous cooling transformation (CCT) curves can then be developed. Some initial results are presented of an ongoing study on the development of bainitic steels for railway wheel applications.

Jan 1, 2013

By J. West

For many years line-of-sight (LOS) issues for underground mobile equipment is a growing focus of research. This research is a result of the numerous fatalities and injuries which occur in the mining industry and which are related to poor operator LOS. Three assessment methods are currently used to assess operator LOS of underground mobile equipment. The light filament (LF) method is a hands-on assessment method that is performed in the field. This method is not evaluated in this paper. The laser scan (LS) method of assessing equipment is a quick and reliable method that comes from the need to evaluate vehicles already located in the field. The computer simulation (CS) method can assess LOS issues using a computer aided drawing (CAD) model, which is useful for assessing current or prototype models. The purpose of the current research is to compare and validate different operator LOS assessment methods. Comparison of the results of the LS and CS visibility plots yielded similar quantifiable results. A visual comparison of the results further illustrate that the LS and CS methods are acceptable assessment tools for mobile equipment operator LOS evaluation. The visibility assessment methods are now being prepared as guidelines for the mining industry to assess current and potential designs.

Jan 1, 2007

The gold concentration profiles which develop inside the activated carbon particles during the adsorption process were measured, so as to obtain additional direct proof of intra-particle mass transfer rate-control and to determine how individual carbon particles in a population vary in their gold uptake behaviour. The observed gold concentration profiles inside the activated carbon particles were typical of situations where an intra-particle mass transfer mechanism is rate-controlling. Gold di-cyanide penetrated the carbon particles with a wave-like front until it was uniformly distributed throughout the particle. This corresponds with the profiles predicted by the film and surface diffusion model. However, the rate with which gold di-cyanide was transported inside the individual carbon particles varied within the population of carbon particles. This variation was characterized by a lognormal distribution in surface diffusivity. Because the estimated variances of these surface diffusivity distributions were small, the dynamic adsorption behaviour of the carbons used in the present study did not deviate significantly from that predicted by a model based on film mass transfer and a single surface diffusivity. Van Deventer (1984, 1985 and 1986a) reported data that could not be adequately described by a model based on film mass transfer and a single surface diffusivity. In this study a model based on film mass transfer and a wide lognormal distribution of surface diffusivity values was applied to his data. It was shown that a population of carbon particles with a wide distribution in surface diffusivity values could offer an alternative explanation to the mechanism proposed by Van Deventer which was based on film mass transfer, with partitioning of the carbon into micro- and macropores with surface diffusion in the macropores and slow mass transfer into the micropores.

Jan 1, 1997

By L. J. Gardner

Ore pass systems play a critical role in moving broken rock from the workplace to surface, and the integrity of the ore pass excavations is crucial. Over the life of the mine, ore pass integrity deteriorates, which may eventually result in the ore pass no longer being fit for purpose. This paper presents several case studies of successful ore pass rehabilitation exercises.

Jan 1, 2006

By B. A. Day

The traditional view taken of commodity prices is that they are cyclical, with strong demand boosting prices and attracting new suppliers. The resulting increased supply pushes prices down with consequent exit of the higher cost producers. And so the process repeats itself. Little attention is given to shifts in underlying global issues and their effect on the traditional process which is seen as being controlled by ?amorphous? market forces with producers profiting from the good times and trying to survive in the bad.. The questions posed are: does this still apply and will it apply into the future? What new factors are affecting the cycles? Can we expect to find the traditional commodity cycles repeated in the 21stcentury? Are producers powerless within the forces of the cycles? Forces likely to affect future commodity prices will be suggested, using gold, zinc, copper, tin and coal as case studies. The long-term downward trend in the real price of commodities is identified.

Jan 1, 2000

Analysis for pillar extraction potential (A-PEP) is an intelligent tool, which could be used as a preliminary output indicator when considering the secondary extraction of regional support pillars in the Witbank and Highveld coalfields of South Africa. The safe and economic extraction of underground coal pillars is of paramount significance and importance to the South African coalmining industry to ensure continuity of supply of this fossil fuel. Pillar extraction practices in South Africa have been responsible a significant proportion of safety and fatality statistics in relation to its relative output (less than 5 per cent of total South African coal production) and, as a result, research was undertaken in local pillar extraction operations and extended to similar operations in New South Wales, Australia to assess a way forward for pillar extraction in South Africa. It was found that, although little in the way of new technologies has emerged in this field in the recent past, significant contributions could be made in the field of risk analysis to obtain a generic design methodology for pillar extraction in South Africa. The resultant A-PEP tool to assess pillar extraction potential is based on certain physical, risk and economic factors, which combine to indicate operational success in terms of economic, health and safety attributes. At the time of A-PEP?s development there was alack of operating underground coal pillar extraction operations, which made it difficult to validate its applicability. Since then, however, A-PEP has been successfully tested and validated against two unique underground coal pillar operations, which is the discussion of this paper. One operation is situated in the Witbank coalfield and is extracting pillars, which are 20 years old and at a depth of 80 metres below surface, while the other operation is situated in the Highveld coalfield-which is extracting 6 month-old-pillars underneath a massive dolerite sill at a depth of 220 metres. A-PEP has shown that its predictive nature is consistent the workings at both operations, irrespective of their unique conditions, and as such it can be successfully used as a mine planning tool. The A-PEP mine planning tool thus represents a positive step toward an integrated approach to underground coal pillar extraction when considering legal and operational aspects, which could form the basis for legislative guidelines when considering the future of pillar extraction in South Africa.

Jan 1, 2005

By W. S. Steinberg

Keywords: Pyrometallurgy, furnace, open slag bath, Evraz, Highveld In 1963, the full-scale engineering study for the development of an Iron, Steel, and Vanadium plant was initiated. This was the birth of Evraz Highveld and its process flow as it is known today. Highveld started out as a steel works that produced steel and vanadium-bearing slag by using a titaniferous magnetite iron ore mined from its own mine site near Steelpoort. The process utilized co-current rotary kilns for pre-reduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to Open Slag Bath (OSB) operation, in order to enable the maximum production of iron and vanadium while improving the control over operational parameters. The conversion proved to be highly successful and, since 2005, three furnaces have been converted to OSB operation. The fourth furnace will be converted in the first half of 2011. The conversion to OSB furnaces not only yields higher vanadium recovery to the metal at the iron plant, but also improves the overall throughput of the steel plant. This is the result of a higher carbon content of the liquid iron from the OSB furnaces, eliminating the need for anthracite addition to the shaking ladle process. This reduces the blowing time by approximately 60%. The conversion of the furnaces to OSB configuration is seen as an enabling technology change and a prerequisite to the implementation of other plant improvements that are envisaged. The long-term vision of EHSV is to convert five furnaces to OSB mode, and permanently decommission the two remaining submerged-arc furnaces. This will allow EHSV to maintain current steel and vanadium production but at a significantly improved overall efficiency.

Jan 1, 2011

The newly implemented mineral law framework exacerbated the need to clarify the roles and responsibilities of mine and land surveyors in the preparation and registration of plans and diagrams. The main concern is that survey tasks may be performed by persons who are not considered competent under the different laws. The methodology used was to analyse historic and present legislation on the issue in order to formulate a narrow interpretation of the current requirements. The major findings are tabulated to present a summary of who is responsible for which areas of survey.

Jan 1, 2010

By E. Harris

Frithia humilis is an endangered succulent plant species. Its distribution range overlaps with the coal fields of Mpumalanga and it is therefore threatened by opencast mining activities in particular. One of the 11 known populations of F. humilis was translocated from a licensed coal mining site to three suitable receptor sites within the species? distribution range. A longterm monitoring programme was initiated to track the progress of the newly established populations. Temporal trends in population demography, size classes, and fecundity were recorded. Population numbers of size classes fluctuated annually. However, flower frequency increased over time and seedling recruitment contributed significantly to population growth. Receptor sites with similar geological conditions to the donor site had more persistent cohorts, which suggest that such sites should receive priority during the translocation of endangered edaphic specialists. This study not only confirms that a Frithia humilis population can successfully establish after a translocation, but also serves as an important baseline for future comparative purposes to gauge the long-term success of the translocation effort.

Jan 1, 2014

By N. Z. Jovanovic

Irrigation of agricultural crops may be a cost-effective option for the utilization of gypsiferous minewater as it may also create an opportunity to produce crops during the dry winter season on farm sin South Africa, such as in Mpumalanga. In this study, intensive field monitoring systems were developed and implemented to assess the feasibility and sustainability of irrigation with gypsiferous mine water. Soil water and salt balance components, as well as crop yields, were monitored in field trials carried out at Kleinkopjé and New Vaal Collieries (Anglo Coal), and at Syferfontein (Sasol). Field measurements indicated that high crop and pasture yields can be obtained, provided fertilization and irrigation water management are appropriate. Soil water and salt balances indicated that considerable amounts of minewater can be used and considerable masses of salts can be removed through precipitation of gypsum in the soil profile. With appropriate management, water and salt runoff and salt leaching can be intercepted, thereby minimizing the impact on groundwater. The SWB model is being validated through on-going monitoring. This will allow the use of the SWB model at other sites to predict the long-term impact of irrigation with mine water on soil and groundwater, as well as to run scenario simulations in order to recommend sustainable management of irrigation with minewater.

Jan 1, 2004

By J. H. Zietsman

It has previously been observed that industrial high-titania slags display a compositional invariance, remaining close to stoichio-metric M3O5. The present study focuses on this invariance and the phenomena which may cause it. The invariance was studied using thermochemical calculations and a mechanism is proposed for the observed behaviour. The mechanism suggests that a combination of thermochemical equilibrium and transient slag solidification and melting results in the observed compositional invariance. The proposed mechanism provides new insights and prompts questions about other mechanisms in the smelting process.

Jan 1, 2004