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By R. M. Jara

This work evaluates and characterizes the impact of the support size and mining dilution of a block model in the operation and selection of equipment at an open pit mine. An exploratory analysis and geostatistical modelling of the grades assayed on a set of drill hole samples is performed, which allows constructing a grade model on a dense grid by means of a conditional simulation. The grades are then averaged to greater selective mining unit supports in order to proceed with the study and methodology. First, the metal-tonnage curves are used to analyse the loss of selectivity on the in situ resources caused by a change of support. Concerning the ore reserves and their mining sequence, defined in the pit optimization and analysis process, the same curves prove that the loss of selectivity is more accentuated. Second, the importance of the block boundary dilution produced during mining operations is assessed. Its value depends on the amount of ore in contact with waste, on the loading error of the equipment and on the ore loss/waste dilution criterion assumed by the planner. The dilution percentage and the differences between waste and ore grades become higher when the block size decreases. For these reasons, considering the dilution in the production plans makes mining a small support more constraining. An adequate delimitation of the orebody can improve the mining selectivity, leading to greater income. Finally, a study of the increase in mining cost that provides a zero difference in NPV between the different block size options is carried out, in order to determine the maximum increase in mining costs for which it remains profitable to mine at a smaller block size. Keywords: Mining selectivity, support effect, block boundary dilution, selective mining unit size, block model.

Jan 1, 2006

By B. W. Lee, P. O?Shaughnessy

The practice of manganese ferroalloy smelting has traditionally been based on utilising oxide ores which typically contain a high level of manganese. This preference for oxides has even been extended to the modification of natural carbonates into nodulized oxides. However smelting practices developed over the past 30 years have created a market for natural manganese carbonate ores, driven in part by the unique properties that this type of ore can offer. An understanding of the mineralogy of carbonate ore and its thermal properties has provided important information which enables furnace operators to take full advantage of the chemical differences. However changes to traditional operating practices have been necessary. Once furnace operations using natural and unmodified carbonate ore have been mastered, the unique chemical features of manganese carbonate ore are able to contribute, not only to new product development, but also to cost savings. The use of natural manganese carbonate ore is now a well-established aspect of the industry. The sustained increase in demand for carbonate ore worldwide over the past several years confirms acceptance of its quality. There are effectively few limits to its successful use.

Jan 1, 2004

By C. F. Vos

Small replacements of C12-trithiocarbonate (C12-TTC) for dithiocarbonate (DTC)/dithiophosphate (DTP) in a reagent suite for the flotation of platinum group metals (PGM) have significantly improved the rejection of gangue. Coupled to this is an improvement in kinetics, grade and recovery of PGMs. In a pilot-plant trial, after a 5 mole per cent replacement of the current DTC/DTP collector combination by C12-TTC, large opaque bubbles were replaced by small clear ones. In addition, a similar flotation response was realized with one-third of the current depressant dosage. During a preliminary plant trial on underground UG2 ore, the initial rougher concentrates were characterized by higher PGM concentrate grades and this was in part due to improved chromiter ejection. The concentrate produced from the TTC trial also exhibited a much finer particle size distribution. The overall circuit performance, which included secondary regrind and flotation, showed an increase in concentrate grade of approximately 44% while the tailings grade remained unchanged

Jan 1, 2007

By C. Musingwini

The South African mining industry continues to be a major source of employment at a time when at least 25 per cent of the working age population is unemployed. At the same time the industry faces a skills shortage in many of the disciplines necessary for its future health. The University of the Witwatersrand, University of Pretoria, University of Johannesburg, and University of South Africa have historically produced mining graduates for the South African mining industry with any shortfall being met by the recruitment of overseas graduates. More recently, the global shortage of engineers and other mining industry professionals has seen a reversal of this trend and a very significant emigration of well-educated and highly skilled personnel. The traditional career path for mining graduates is in production and mine management. However, there is the parallel (and possibly more pressing) need for specialized skills in such fields as ventilation, rock engineering, mine planning, mineral resource evaluation, and mineral asset valuation. Chronic shortages in these essential areas continue to hamper the development of the industry and may well frustrate its ambitions to be safe, healthy, and profitable into the future. The permeability of skills across sectorial boundaries within the mining industry requires that skills shortages in the platinum sector are not looked at in isolation, but within the context of the entire industry. This paper reviews the efforts being made by the universities, at both undergraduate and postgraduate levels, to meet the needs of the South African mining industry in terms of the required numbers and the range of specialized skills.

Jan 1, 2013

By A. J. Van Der Merwe, N. A. Barcza, M. Boyes, N. R. Clarke

Oriel Resources has with the support of SRK (Cardiff) and DRA and Mintek (South Africa) carried our a Definitive Feasibility Study (DFS) to recover high grade chrome ore from its Voskhod deposit very close to Chromtau that is near to Aktobe in Kazakhstan. Voskhod is a large podiform ore body that contains nearly 20million tons of chromite grading about 48% Cr2O3 and with a Cr/Fe ratio of over 3/1. Selected bore hole core samples were obtained from the confirmation drilling programme during the DFS phase of the project in 2005 for pilot plant test work to design the mineral beneficiation plant. The chrome ore is characterised by four main types, namely high grade lumpy and chip sized ore, high-grade fine ore, lower grade (subordinate) lumpy ore and lower grade fine ore. Gravity separation tests carried out by Mintek showed that the large density difference between the high grade (at over 3.7t/m3) and lower grade ore (at less than 2.97t/m3 ) should ensure very good separation in the DMS drum and DMS cyclone stages resulting in high recoveries of Cr2O3 - rich chromite ore products. Very high chrome ore grades of up to 64% Cr2O3 and Cr/Fe ratios of 4 to 1 were obtained at an 80% mass yield from selected samples of lumpy and chip ore size fractions. The overall predicted recovery from the design work on the mine and plant is expected to be closer to about 70% of the ROM (Run of Mine) feed. DRA has completed the design of the mineral processing plant to recover about 900 kt/a of chrome ore from the 1.3 Mt/a of ROM feed. The plant has been sized to handle up to 1.5 Mt/a and will also be able to address the variability in ore feed as different regions in the deposit are mined. The lumpy high-grade product and the chips size fraction is expected to grade around 48% Cr2O3 and the fine concentrate between 56 and 58%Cr2O3 The ratio of products is expected to be about 70, 15 and 15 percent respectively but will vary to some extent during the expected 20 year life of the mining operation based on including the associated adjacent Karaagash deposit together with the Voskhod deposit. The prediction of the product split from the processing plant depends on many factors such as the geology, mineralogy, mining, handling and metallurgical processing. An overall process flow model has been developed that covers the ROM ore, the various types of chrome ore feed to the mineral beneficiation plant, the projected products and the subsequent smelting of the chromite ores to produce High Carbon Ferrochromium. The model allows the optimisation of the quality of the chrome ore in terms of Cr2O3 content, Cr/Fe ratio and recovery to be studied. This information can also be evaluated in terms of the economic requirements for smelting High Carbon Ferrochromium (HCFeCr) at a given location. Oriel is planning to supply chrome ore to Ferrochrome plants mostly in China and Russia. The use of the model will assist to maximise the value of the Voskhod project to its owners and also assist the users of the chrome ore in selecting the appropriate supply quality to meet their needs for a given smelter operation. The smelting of high grade Voskhod ore requires a limited addition of about 5 to 7% quartz to flux the MgO and Al2O3 and about 25% coke as a reducing agent to produce an alloy containing from about 65 to 74%chromium depending on the Cr/Fe ratio.

Jan 1, 2007

In extracting base metals from orebodies, sulphide as well as oxide, the main environmental concern is sulphur, whether in the form of sulphurous gases or sulphate in liquid form. Generally sulphur is in over supply in developed countries mainly because of strict legislation to capture it. In developing countries, on the other hand there is usually a shortage of sulphur because of less strict environ-mental legislation. Africa falls in this second category and the African continent imports substantial amounts of sulphur, despite the fact that large quantities of sulphur are emitted by smelters, thermal power stations, coalmines, fertilizer manufacturers and others. Other than making acid from gaseous emissions, existing methods to capture sulphur from gaseous and liquid effluents are uneconomical and it ends up in the environment either as ammonium sulphate (from gaseous effluents) or as gypsum (from liquid effluents). The CSIR?s Environmentek and Key Structure Holdings have developed a process whereby gaseous sulphur emissions and sulphates in liquid effluents can be economically captured and converted into elemental sulphur and metal carbonates. The elemental sulphur is of high purity as it is precipitated from a gas stream and is readily marketable. The metal carbonates (barium or calcium) can be recycled back to the process or marketed. The only harmful by-product of the process is carbon dioxide. Should natural gas or methane be available, the carbon dioxide could be reduced by about one third. Should solar, wind or hydro energy be available to generate hydrogen, the carbon dioxide emissions would be zero. Employing this technology could make Africa independent of sulphur imports and furthermore reduce the impact of acid rain and seepage of sulphate from gypsum and other waste dumps into the environment.

Jan 1, 2005

By T. R. Roy

A prediction model, developed by Central Mining Research Institute (India) for evaluation of fire risk rating of underground coal mine panels in bord and pillar working in respect of their proneness to spontaneous heating, is presented in this paper. The concept used in this model is innovative and user friendly. This model may be applied to a panel where extraction is carried out using any of the techniques: i) depillaring with formation of small pillars as final operation, ii) extraction by broadening of galleries, iii) depillaring with hydraulic sand stowing, and iv) depillaring with caving. Here, major fire risk parameters are short-listed and divided into three broad groups in accordance with the nature of their contribution to the spontaneous heating of a mine panel. The paper describes the procedure for estimating the fire risk rating of individual groups using separate objective type models developed for this purpose. Then it evaluates the overall fire risk rating of the panel by combining the fire risk ratings of all the three broad groups. The model is tested with the field data collected from different collieries spreading across the country and with the laboratory data for critical assessment of fitness. Keywords : prediction model, fire risk rating of panel, spontaneous heating of coal, underground panel, bord and pillar working.

Jan 1, 2003

The corrosion behaviour of a low carbon steel was investigated in natural seawater and various synthetic seawaters. It was found that the steel corroded nearly four times faster in a 3.5% NaCl solution than in natural seawater for an exposure time of 21 days. The corrosion rate after immersion in synthetic seawaters (ASTM D1141 and Marine Biological Laboratory seawater) is similar to the corrosion rate after immersion in natural seawater. Calcium carbonate (aragonite) deposits were found on the surface of the steel after immersion in natural seawater and the synthetic seawaters. Some magnesium-containing deposits were also found after immersion in the natural seawater. These deposits act as a barrier against oxygen diffusion and thereby lower the corrosion rate. The morphology of the calcium carbonate deposits that formed during immersion in the natural seawater is different from those formed during immersion in the synthetic seawaters. This may explain the slightly lower corrosion rates obtained in the natural seawater. X-ray diffraction also showed that the oxy-hydroxides formed in the 3.5% NaCl solution differed from those formed in the other solutions. Keywords: Corrosion, seawater, low carbon steel, 3.5% NaCl, aragonite

Jan 1, 2006

By S. T. Johansen, C. Colomb, B. Ravary

Combustion and thermal NOx formation have been modelled using the Computational Fluid Dynamics (CFD) commercial code Fluent 6.1. The aim was to predict and give a better understanding of the combustion in electric arc furnaces for the production of ferro-silicon and silicon metal. Another important objective was to assess the impact of a number of operating parameters on the NOx formation. The CFD tools used are de-scribed with a special focus on models for species and turbulence transport. Sensitivity studies have been carried out to study the influence of several parameters: sub-models, process gas composition and distribution at the charge surface and influence of the presence of SiO. The main conclusions are: ?Using the combination of a realistic design, boundary conditions and models, the simulated NOx level is in quantitative agreement with measurements. The presence of water vapor is particularly important because of its influence on the specific heat of the mixture and resulting temperature. ?Release of significant amounts of SiO from the charge surface results in an important increase of NOx, even if we applied a simplified combustion model for SiO gas. However, because of lack of thermal and compositional data for blowing situations (when SiO flows directly from the arc cavity through open channels to the charge surface), no quantitative validation is possible. The way SiO is distributed (uniformly or as a jet) has a limited impact on the result in our computations.

Jan 1, 2007

By N. Ogbonna

A mathematical model for bioleaching at the agglomerate scale is developed. The agglomerate is defined as a unit volume of a heap which contains a solid phase (a size distribution of ore particles), a liquid phase (stagnant and flowing leaching solution) and a gas phase (flowing air and air pockets). Leaching at the level of an ore particle is modelled using a diffusion-reaction equation, and oxidation by attached and detached microbes is treated separately. With the aid of the mathematical model, the effect of particle size distribution on the bioleaching of an ore containing a mixture of chalcocite and pyrite, and a culture of iron oxidizers, is investigated.

Jan 1, 2006

CSIRO Mineral has recently developed a new electron microprobe based system for characterizing zircon grains from heavy minerals sand deposits. The system acquires cathodoluminescence (CL) spectra, X-ray and backscattered electron (BSE) signals in parallel. By scanning over a specified target area, CL wavelength and X-ray element distribution maps of polished zircon grains can be acquired. Post-inspection of the combined dataset using in-house developed software enables correlations between chemistry and structure to be investigated. The new method offers significant benefits over traditional CL and BSE techniques in that direct comparison with the elemental concentrations over the same region is now achievable. By combining the electron microprobe results with data for the same mapped region obtained via a nuclear microprobe, significantly better detection limits (~ 1ppb) for elements with atomic numbers greater than iron are possible. The ability to measure spatially related analytical data and then investigate the correlation of the CL spectra with chemical data is an important advancement in the characterization of zircons. Key words: zircon, characterization, cathodoluminescence, backscattered electron, electron microprobe, nuclear microprobe, chimage, proton induced x-ray emission.

Jan 1, 2003

By R. G. Cawthorn

The earliest authenticated scientific report of the occurrence of platinum in rocks from the Bushveld Complex appears to be by William Bettel on 10 November 1906. Thereafter, prospecting of the chromite-rich rocks for platinum proved frustrating. I suggest that the resurgence of interest shown by Dr Hans Merensky in 1924 resulted from his realization that newly panned platinum had a different grain size from that in the chromite layers and indicated a different source rock, which he located, and it became known as the Merensky Reef.

Jan 1, 2007

Leinster Nickel Operations, located in Western Australia, consists of an underground and three open pit mines in relatively adverse ground conditions. This paper reviews our ground control practices in the open pits, covering aspects of ground support, wall control and monitoring. These methods have been effective in allowing mining operations to continue beneath unstable slopes. In particular, the use of Ground probe?s slope stability radar has enabled the Harmony open pit to safely operate for months following indication of failure from traditional methods. This case study highlights the benefits of investing in appropriate slope stability monitoring systems.

Jan 1, 2006

By T. F. J. Hälbich

Namakwa Sands aims to conserve environmental resources and prevent or minimize environmental impacts from its operations. The challenge faced by Namakwa Sands is the rehabilitation of the arid winter rainfall Strandveld and lowland Succulent Karoo vegetation zones affected by its mining activities. Extensive experimentation with different rehabilitation methods resulted in the development of an effective rehabilitation programme. The use of topsoil as a seed bank and shade-cloth as windbreaks have significantly aided the rehabilitation process. The aim of the programme is to stabilize the soil environment so as to allow the germination and development of the local plant species. The ability to control wind erosion is critical to the success of the rehabilitation effort. A programme of biodiversity audits has been started to measure the recovery of plant species in the rehabilitated area. The principle of continuous improvement, coupled to site-specific rehabilitation studies, is applied to enhance the rehabilitation programme.

Jan 1, 2003

By J. C. Jansen

The platinum mining industry has experienced a significant increase in fatal accidents. Mine accidents are in principle preventable, and there is enormous pressure on employers to reverse this trend. This paper reviews safety management systems (SMS) as well as behaviour-based safety (BBS). Based on the review, SWOT analyses are performed on the SMS and BBS processes and a model of an integrated safety management system (ISMS) is introduced. A number of fatal accidents is analysed to identify factors that contributed to accidents in the mining industry. Thereafter the potential weaknesses of an SMS of a platinum mine are exposed and the potential benefits of implementing the ISMS for this case study are demonstrated.

Jan 1, 2005

By F. T. Cawood

The new South African Mineral Policy has major implications on the way mineral rent will be collected and shared between the stakeholders in future. Although the policy does not supply details on how this will be done, drastic departures from practices under the previous dispensation require a new approach. For example, there introduction of the ?right to mine? principle implies that the repealed lease consideration concept will be expanded to all minerals. The new policy also makes provision for predetermined standard terms and conditions for all prospecting and mining permissions. It also states that, regardless of whether the mineral rights are state or privately-owned, all prospecting fees and mineral royalties will be determined by state officials after consultation with the registered holder of the mineral rights. This paper proposes a standard mineral royalty formula that complies with the principles mentioned in the White Paper and has been shown to be internationally competitive.

Jan 1, 2001

By G. Kang

The ferroalloys industry has generated historically substantial solid waste. The accumulated waste causes serious problems to the environment. However, it is possible to transform the solid waste into an environment-friendly resource to serve the human being. Consequently, the construction of plants that are ?environment-friendly? and that accommodate ?recycling? has become a target of most ferroalloy producers in the world to ensure sustainable development. This paper introduces the practice of Shanxi Jiaocheng Yiwang Ferroalloys Works, the biggest manganese metal producer in China, in the development of an ?environment-friendly and recycling? process. The process includes power generation using coal gangue, waste from local coal mines; hollow bricks manufacture using slag and fly ash from the power station; cement production using slag from ferroalloy smelting; recovery of ferrous and non-ferrous elements in the dust from the furnace gas cleaning system; application of silica dust in construction and so on. The final objective of the plant is to realize zero discharge of solid waste. The profit of the ?environment-friendly and recycling? process compensates in part for the operational expense of the environment facilities.

Jan 1, 2004

By P. J. Lloyd

There are few data on the composition of discard coal in South Africa, and no overall view of the discards for the entire industry. As a result of work on coal qualities in South Africa, a database was established which enabled a good estimate to be made of the composition of the discard from every mine. The data are presented in the form of histograms of ash, volatile matter and fixed carbon content of the 43 million tons of material which were discarded in 1990. The results are discussed in terms of the closeness of the composition of much of the discard material to presently used power station coal. It is concluded that it is mainly developments in equipment, particularly fluidized bed boilers, which inhibit the wider use of discard coal. However, other factors must be noted, including the relatively high sulphur content of the discards, and the fact that even with the most careful storage the material ages and may become unusable after about 15 years.

Jan 1, 2000

By Onuralp Yücel, Süheyla Aydin, Erçin Ersundu

Turkish iron and steel sector, the base of which was established in the 1930?s, plays an important role in the industrialization and development of the country?s economy. In Türkiye this sector is the major consumer of ferroalloys. There had been a great improvement in Turkish Iron and Steel industry, especially after the 1980?sand as a result, 20.9 million tons of yearly crude steel production placed Türkiye 11th in the global steel output and 3rd in Europe. 15 % of steel produced in Türkiye is flat products, while the long products make the rest. The product composition and the general characteristics of steel production process led to an increase in ferroalloy consumption. Domestically consumed ferroalloys are especially ferromanganese, silicomanganese, and ferrosilicon. As of today, ferroalloy production capacity of Türkiye is 173,800 tons/year; 161,500 tons of which is ferrochrome with high and low carbon grades, 7,300 tons of ferrosilicochrome and the rest is ferrosilicon (5,000 tons/year). Türkiye is one of leading ferrochrome producers in the world considering the above mentioned production figures. However, this production is mainly exported since Türkiye?s stainless steel production level is modest requiring low amounts of ferrochrome. The products of iron and steel industry in Türkiye require large quantities of other ferroalloys, which make Türkiye a major importer and exporter of ferroalloys. The aim of this work is to present production, consumption, import and export quantities of: ferrochrome, ferromanganese, ferrosilicon, ferromolybdenum, ferrotungsten, ferrotitanium and ferrovanadium of Türkiye, between 1990 and 2006.

Jan 1, 2007

This paper presents an initial investigation into the viability of co-kriging the grades of multiple mining cuts in a two dimensional, thin reef scenario. Deposits with gradational mineralized zones, in the perpendicular sense, are not as well served by the use of reef accumulation and thickness as deposits characterized by a sharp distinction between ore and waste rock. South African Bushveld Complex platinum deposits and Witwatersrand gold deposits are examples of this distinction. The calculation of an optimal mining cut is of paramount importance in the mining of Bushveld platinum. Two-dimensional kriging of a constant stoping width mining cut is an effective method for resource calculations once a cut is decided, but this begs the question of how to decide on the cut. Comparison of multiple cuts is used as a way of achieving this decision on many of Anglo Platinum’s operations. Although the kriging of each cut is valid in isolation, occasional negative values occur when incremental grades between overlapping cuts are calculated. Negative incremental grades cannot reflect reality. They are thought to be related to the inability of the method to include the strong continuity in the perpendicular direction demonstrated by the relevant variograms. Co-kriging of related variables has been investigated as a potential means tore impose this inherent order relationship. Various co-kriging options have been investigated. The method has been tested on a real data set from an established platinum operation. One of three types of anomaly has been investigated so far. The results show that co-kriging the mining cut grade as the primary variable, with just one secondary variable, the reef thickness, eliminates most occurrences. Severe anomalies remaining are arguably indicative of population mixing and might be more effectively treated by rezoning the data. Aim—To investigate the viability of co-kriging the grades of multiple mining cuts as a method for resolving anomalies in the estimation of such cuts on Bushveld platinum deposits, with applicability to other thin reef type deposits with a gradational not sharp cut-off between ore and waste in the direction perpendicular to the reef. Keywords: co-kriging, cross variograms, ordinary kriging, platinum, two-dimensional, grade profile

Jan 1, 2003