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By Ö. Erdem

The investment decision making process in the insurance and finance industries is affected by new advances such as simulation techniques. These advances have improved the discounted cash flow method (DCF). In DCF, a dynamic and flexible model construction is not possible because it does not consider uncertain conditions. Each project should be evaluated taking into account the related uncertainties because the related uncertainties determine the characterization of the project. Related uncertainties can be processed in dynamic DCF, which is applicable to both financial and non-financial industries with different kind of uncertainties, such as power generation and petroleum projects. The dynamic DCF method can estimate net present value (NPV) while managing related project uncertainties with a simulation method like Monte Carlo Simulation. The simulation method is preferred because its output is unbiased. Therefore, a more realistic financial evaluation of the project can be concluded. In spite of the improvement of dynamic DCF, this project evaluation method is not used frequently in mining industry. However, the mining industry is ideally suited to this concept because it is highly dependent on estimations such as orebody size and ore grade. During the project evaluation stage, these uncertainties can be included with the dynamic DCF method. This study aims to contribute to increasing the usage of this method in mining projects. A copper reserve in Turkey is selected as a case study to apply uncertainty assessment for the evaluation of NPV.

Jan 1, 2012

By A. E. Lewis

The emphasis of this paper is on the characterization and testing of the slag produced by a secondary lead refinery. This work forms part of a broader investigation aimed at reducing loss of valuable product from the process as well as minimizing the environmental impact of the process wastes. It was this work that led to a critical examination of the standard waste classification tests. Characterization of the slag was carried out using a number of complementary techniques. In the broader context, the slag characterization aided in identifying process deficiencies and thus was a critical tool in suggesting potential for process optimization. For this study, the slag characterization provided a relatively comprehensive picture of the composition and properties of the slag, which facilitated understanding the behaviour of the slag under batch test conditions. On the basis of quantity of hazardous components alone, the slag is hazardous according to South African Acceptable Risk Limits (ARL). However, when both the quantity and the leach potential of the hazardous components is taken into account, standard waste tests carried out by three independent agencies indicate that the slag should not be classified as hazardous according to local regulations. Also, according to United States Environmental Protection Agency (US EPA) limits, which are independent of the quantity of the waste, the slag would not be classified as hazardous. The standard waste tests used by the independent agencies was the Toxicity Characteristic Leach Procedure (TCLP), a test which was developed by the US EPA to classify hazardous wastes. One of the requirements of this batch test is that it should be quick, simple to carry out and that the results should be reproducible. Previously, the applicability of the TCLP test to mineral processing and metallurgical wastes has been challenged on a number of points. Additional testing of the slag was carried out using both the TCLP and the Synthetic Precipitation Leach Procedure (SPLP) recommended by the American National Mining Association as being more appropriate for mineral processing wastes. The particular physical and chemical characteristics of the secondary lead slag highlighted additional limitations of both the TCLP and SPLP tests as standard laboratory batch procedures. Keywords: environmental protection, secondary lead processing, slag, leach testing, TCLP, SPLP, ARL, hazardous waste, batch tests

Jan 1, 2000

By W. Abdellah

The purpose of this paper is to establish a qualitative method to estimate the risk level (e.g. rating and ranking) resulting from mining activity. Risk is the product of two factors: probability of failure and cost of consequences. A resultant assessment scale matrix is then used to assign a risk index value which is directly proportional to the potential for excavation instability. A case study, the No. 1 Shear East orebody at Vale?s Garson Mine in Sudbury, Ontario will be examined. A three-dimensional, elastoplastic, finite difference model (FLAC 3D) is presented for a mine development intersection situated 1.5 km below ground surface. The developed assessment scale matrix is used to estimate risk index for intersection (2981) located on 5000 level. The results are presented and categorized with respect to risk-index value, probability of instability, cost of consequence, and mining stage.

Jan 1, 2014

By M. Tangstad

Keywords: Pyrometallurgy, ROMA, Norway, furnace, fines The ROMA project is a competence project on optimizing the usage of raw materials and energy in the ferromanganese, silicon, and aluminium industries. One of the items investigated in this project is the effect of fines on the furnace, and the usage of agglomerates versus lumpy ore. From lab-scale experiments it is shown, that for the charge to agglomerate in the furnace, the charge has to be exposed to a temperature higher than about 1200°C, independent of fines content. The fines less than 1 mm also showed higher agglomeration properties, compared to 2?4 mm, which showed no agglomeration property at all. The properties of agglomerates are very dependent on the pre-treatment of the agglomerate. Sinter and pellets, which have been heated to high temperatures, show a better strength, but also a lower CO reactivity. Sinter also shows a lower melting temperature compared to the ore.

Jan 1, 2011

By M. Mabuza

Two Rivers Platinum Mine (TRP) is a 55:45 joint venture between African Rainbow Minerals and Impala Platinum, respectively. TRP is situated on the farm Dwarsrivier 372KT, in the southern sector of the eastern limb of the Bushveld Complex. Dwarsrivier is underlain by rock formations of the Critical Zone (Winterveld norite-anorthosite) and the Main Zone (Winnarshoek norite- anorthosite). Two economically significant PGE-bearing layers namely the Merensky Reef and the UG2 chromitite are found within the upper Critical Zone. These are approximately 140 m vertically apart, separated by a series of barren norites and anorthosites. At Two Rivers Platinum, only the UG2 chromitite layer is currently being mined for PGEs. The UG2 sub-outcrops north/south along the Klein Dwarsrivier river valley with a very gentle dip to the west of 7º?10º. At Two Rivers the UG2 averages about 120 cm in thickness, overlain by a waste pyroxenite parting about 20 cm thick, above which is a leader seam about 20 cm in thickness. The mineable cut consists of the leader seam, the waste pyroxenite parting, the UG2 chromitite layer including 25 cm of pegmatoidal pyroxenite footwall, below the UG2 reef to a minimum of 185 cm trackless mining cut. The mining method is a mechanized bord and pillar layout, which will yield a total of 185 000 tons at full run of mine production from the underground UG2 mine.

Jan 1, 2007

Sandsloot open pit is situated on the northern limb of the Bushveld Complex, 250 km north east of Johannesburg, South Africa. Sandsloot is currently the largest open pit platinum mine in the world and is one of six potential open pits in the area. The geotechnical strength properties of the Platreef have posed significant mining and processing challenges to the PPRust operation since inception in 1992. In order to optimize the whole business as opposed to isolated cost centres a mine to mill initiative was embarked upon in 1997. Initial work focused on ore characterization and an entire suite of data was collected for each rock type. This included mineralogy, geochemistry, geotechnical, blast ability indices, as well as metallurgical strength data. The second phase involved the clear definition of customer requirements, namely the optimum performance criteria for the plant and mining departments. This involved extensive field trials and data capture to measure the interaction and influence of the mine to mill value chain. Once the design targets were defined, a 3D geotechnical model was constructed to ensure that the targets were consistently achieved. The model is very similar to an ore reserve model; however, it is populated with geotechnical, metallurgical and blast index data. Through software queries the appropriate blast powder factor for each mining block can be obtained, thereby ensuring the correct fragmentation is blasted for the plant and mining operation. The initiative has delivered significant results showing improvements across the mine to mill value chain. These include increased loading rates, reduced electricity and crushing consumables, as well as higher plant throughput. Additionally, the initiative has benefited both brownfield and greenfield projects on the PPRust operation

Jan 1, 2006

By G. Coetzer

During galena flotation of Rosh Pinah milled material, metal ions and salts contents of various water resources (deionized, simulated circulated, lead concentrate thickener, lead tailing thickener and borehole) influenced mineral recoveries, upgrade ratios, selectivities, froth stability and flotation kinetics. The various water resources employed during galena flotation caused activation, depression or selectivity effects on minerals due to the presence of different ions in solution. Metal ions in these water resources were adsorbed by the ore, whilst ions associated with gangue minerals (dolomite and quartz) were released into the flotation pulp. Lead concentrate thickener water caused depression of sphalerite and pyrite, increased fast floating fractions for silver, copper minerals, sphalerite and quartz (unwanted), and improved slow floating rate selectivity against pyrite and sphalerite. Lead tailing thickener water enhanced sphalerite recovery during galena flotation (unwanted), and increased fast floating fractions of pyrite. Western borehole water did not affect galena recovery, but sphalerite and pyrite recoveries were unacceptably too high. Ions from copper, lead, and zinc salts tended to release high amounts of ions, such as calcium, magnesium, silicon, and manganese from gangue minerals (dolomite and quartz) during milling. During galena flotation, lead ions depressed sphalerite, pyrite and dolomite at a lead concentration of 400 ppm, but sphalerite was activated at a concentration of 800 ppm. Sphalerite was activated with copper ions (89% recovery, 2.09 upgrade ratio) and depressed with zinc ions (maximum recovery of 25%). This corresponds with findings in previous investigations. Dolomite and quartz were slightly activated with zinc ions. No evidence was found that lead and copper ions activated any gangue minerals during galena flotation. Keywords: galena, water resources, metal ions, activation, depression, selectivity.

Jan 1, 2003

In the 1980s and?90s the gold mining industry in South Africa came under pressure from the continued poor dollar gold price and escalating Rand based costs, furthermore the external impacts on the industry were changing. Thus, the Chamber of Mines (COM) shifted its focus away from many historical areas of support towards the new industry challenges in safety and health, labour markets, environmental responsibility, mineral rights legislation and social responsibility. During 1997 the lack of funds and the changes facing the tertiary institutions were often subjects of discussion at the various sub-committee meetings. The Metallurgical Sub-committee of the Chamber Education Fund or the Sub-committee of Consulting Metallurgists as it was known identified the need for the funding structure to change with the times. Up to this time the Chamber of Mines operated an Education Fund that supported mining industry academic departments at various South African tertiary institutions; these funds were derived exclusively from the country?s gold and coal mines the basis of Chamber membership. Funds of less than R5 million per annum were available for distribution by the three disciplinary sub-committees of mining, metallurgy and geology.

Jan 1, 2003

By A. Meek

This report compares the compressed air driven rocker shovel to the newly developed Warthog Non-throw development end loader. The two machines were compared on aspects such as safety, loading potential, energy efficiency and costs. The objectives of the comparison were to determine whether or not the replacement of the rocker shovel with the Warthog will be operationally and financially justifiable. The results from this study were obtained from underground observations and time studies on the machines, as well as consultations and data collection at the shaft and suppliers. This paper compares only the Warthog loader to the Trident 215 rocker shovel used at Anglo Platinum?s Brakspruit shaft and does not compare the other models of rocker shovels, which are fundamentally the same but will have different loading potentials and specifications. Cleaning times for the rocker shovel are based on underground observations at Brakspruit shaft. These times can be influenced by factors such as blasting practices, compressed air pressure and operator experience and skill. For this reason the times will most likely vary at different shafts. The Warthog cleaning times are based on manufacturer specifications and results from trial stages and therefore further work is required to confirm cleaning times achieved.

Jan 1, 2009

By J. Daavittila

In the latter part of the 1980s Outokumpu Chrome in Tornio, Finland, was in a situation when its twenty-year-old ferrochrome plant was becoming too inefficient to sustain economically sound production. The company made extensive studies on the then available processing methods to find out the best possible processing route. As a result, the whole plant was practically rebuilt and expanded. When equipment was proven in practical operation, an application for FeMn production was developed. Now as the Tornio FeCr-plant is considering expansion, the same type of exercise is to be performed with today?s challenges, which will be discussed in the paper. These challenges include increasing costs or decreasing quality of raw materials, increasing energy costs, stricter environmental regulations and demand for better working conditions. The possibilities of resolving to these challenges will be discussed in the paper. The future and continuing development with FeCr includes the better utilization of process dusts and a lower consumption of energy. By adapting the latest automation tools to better control the process, even higher efficiencies can be achieved with present technology. New processes are considered for development in the future and some possible technologies will be described.

Jan 1, 2004

By Sverre Olsen, Kai Tang

The composition of ferromanganese slag is very important as it determines the slag/metal equilibrium relations including MnO content of final slag, melting relations and slag viscosity. The slag composition is further expected to influence the process temperature. The properties of ferromanganese slags are suitably described by its basicity and A/S mass ratios. The influence of slag basicity has been discussed in the previous papers. The present paper will discuss the effect of Al2O3 on melting relations, viscosity and MnO-content of final slag. This discussion will be based on assessed thermochemical databases and a recently developed viscosity model.

Jan 1, 2007

By C. L. Reichardt

Mining companies are increasingly looking to the developing world for the next generation of mining projects, often in countries that have little or no previous history of large-scale mining. One of the major challenges for such projects is hiring?and retaining?personnel that have technical skills and experience in mining-related disciplines. Staffing a mine with an expatriate workforce is neither cost-effective nor sustainable, and many countries now insist that mining companies ?transform? the profile of their workforce to more closely mirror the demographic profile of the host population. The need to nurture mining-related skills in emerging mining nations is not solely limited to the workforce: there are also pressing economic and sustainability imperatives to develop capacity within local service providers such as consultants and contractors, as well as to facilitate informed engagement between mining companies, government and civil society. However, few educational institutions in emerging mining nations currently have the ability to offer practical training in mining-related disciplines. Local employees who are sponsored by companies to develop their skills through international study maybe impeded by language and cultural barriers, and may also be taught using course content that is of limited relevance to the specific challenges of their future working environment. This paper addresses the challenge of skills development and retention in emerging mining nations and uses examples from sub-Saharan Africa and the Asia Pacific region to explore practical means of developing capacity in mining-related disciplines. It examines the need for companies to implement strategies to develop local technical capacity in countries where they envisage a long-term operational future and also highlights the need to foster partnerships between academia, developmental institutions, mining companies, governments and civil society to establish the critical mass of mining-related skills required to nurture the development of a sustainable mining industry.

Jan 1, 2009

By A. A. Angelov

This paper presents a unique method of monitoring the effectiveness of the planning process as well as the execution of mine plans. The method primarily determines the degree of deviation from the original mine plans by comparing actual mined areas to initially planned mining areas. The performance of mining operations is also measured by comparing actual and planned tonnages for a particular period. Once the degree of deviation from mine plans has been established the cause/s of the deviation can be determined through a simple fault tree analysis. Accurate identification of the reasons of deviation can aid the mine in selecting possible methods to correct the deviation. It is, however, beyond the scope of this paper to discuss the methods employed in correcting such deviations, as each mining operation will have unique causes of plan deviation and methods of remedying them. Deviations from the plan greatly affect the yields obtainable, which in turn affects the life of mine, thus having negative economic and financial implications. Accordingly, this paper presents a project management method which aims to reduce risk by improving planning systems to ensure optimum overall extraction of coal reserves.

Jan 1, 2010

By T. Güyagüler, A. Güngör

Labour protection, that is prevention of occupational disease and reduction in the frequency of accident, has always been a matter of major concern of mining industry. Management and the government should promote and maintain high safety standards through some measures to reduce accident frequency and occupational disease. This can be achieved by using the science and technology for improving the working conditions, educating workers and managers about accidents and prevention techniques. The detailed analysis of an accident requires knowledge of many factors such as location, time, type, cost of accident, victim, nature of the injury, personal and environmental factors etc. that can be obtained from the standard coded accident report form. There is a need to prepare safety data in a common format to produce a common safety reporting system and ‘Occupational Health and Safety Management Tool’ is being designed to manage this by using database and Internet technology. Precautions should be taken according to results from database queries by providing comprehensive and accurate national data. To have an accident is unfortunate, however, to have an accident and learn nothing from it is unforgivable. Keywords: Occupational health and safety, Accident report form, Accident database, Occupational diseases and accidents, Safety reporting system.

Jan 1, 2003

By L. A. Cramer

South African platinum mines produce the world?s majority of platinum metal that is used in autocatalysts and jewellery. As the platinum market is forecast to grow at healthy rates into the future, the South African producers, Anglo Platinum, Impala, Lonmin and Northam, are planning to expand in the next decade. Furthermore, a number of smaller producers who are accessing other mineral rights are entering the buoyant market. The South African platinum mines have traditionally exploited the Merensky Reef of the Bushveld Igneous Complex (BIC); however, the mining of this reef is reaching depths that require significant vertical shaft systems and costly refrigeration for access to the orebodies at deeper levels. In the past decade all of the producers have begun to mine the less attractive UG2 reef because of its cheaper mining costs. This UG2 reef contains significant quantities of chromite with typically a chrome-to-iron (Cr/Fe) ratio of 1.35. UG2 ores can contain between 10 and 25% Cr2O3dependingupon the reef width and the selected mining method. It is relatively cheap and easy to extract a portion of the chromite from a platinum concentrator tailings stream at a grade of between 40?42% Cr2O3. However, it is only in recent years that some ferrochrome producers have begun to source some of their chromite from the tailings of platinum producers. South Africa is also the world?s largest single producer of ferrochrome and supplies much of the world?s stainless steel producers and thus the growing market for their product. As the traditional sources of high Cr/Fe ratio ores have been depleted at the shallow economic depths and thus have become more expensive sources of chromite, technical developments have improved the ability to use fine chromite economically to make acceptable grades of ferrochrome. Thus UG2 fines are now becoming possible cheap sources of acceptable feed to the ferrochrome industry. The abundance of feedstock for ferrochrome production and the lessening dependence on mined material will impact upon the structure of the ferrochrome business in South Africa. With continued platinum mining from UG2 reefs, South Africa is set to remain highly competitive in the world?s ferrochrome/stainless steel industry.

Jan 1, 2004

By B. Andresen, S. T. Johansen, H. Tveit, S. Grådahl, B. Ravary

The Norwegian ferroalloy industry has high ambitions regarding environmental standards. Basic research work has been performed to improve the fundamental understanding of ferroalloy processes and the environ-mental aspects. This paper will present work dealing with the understanding of formation and control of NOx, PAH and dioxins. During this work various techniques and methods have been applied, such as comprehensive industrial measurements, laboratory experiments, model development and application of Computational Fluid Dynamics (CFD). The main goal has been to reduce the environmental impact of ferroalloy plants, by means of improving the combustion processes done by introducing new charging routines and optimized furnace operations, instead of installing expensive gas treatment systems. The Norwegian obligations in accordance with the Gothenburg protocol are to reduce the NOx emissions by 30%, compared with the 1990 level within 2010. Measures developed in this work have resulted in 40-60%reduction in NOx emission, and major reductions in PAH and dioxins for ferrosilicon and silicon metal plants. This has been achieved by introducing semi continuous charging and improved furnace operations. Semi continuous charging and optimized furnace operations are shown to reduce the blowing activity (i.e. emission of large quantity of SiO over the charge by direct channelling from the crater zone). It also reduces variation in off-gas temperature and dust production. To understand the processes and to achieve our results we have used online equipment, with fast sample rates and response times, to measure the off-gas compositions and temperatures. Most of the measuring techniques used are based upon optical principles making use of the absorption- and emission spectrum of the gases. In addition a new prototype instrument is developed for continuous measurement of off-gas characteristics, total dust amount and off-gas temperature. The presented work is a result of a long term co-operation research and development teamwork, between the industry and the research community, and has improved both the process and reduced the emissions. The work has introduced new process design and operation standards, and has resulted in ferroalloy production with better environmental standards.

Jan 1, 2007

By G. van Hout, D. Rahal

Caving is a mass mining method that is normally applied to large, low grade orebodies because of its low production cost and high capacity. However, equipment breakdown and poor draw management can cause mining costs to exceed that of all other mining methods. One way to minimize the effect of disruptions in the mining cycle is to use Mixed Integer Linear Programming (MILP) for long-term scheduling. This paper describes a MILP goal program which has the dual objectives of minimizing deviation from the ideal draw profile while achieving a production target. Schedule optimization is performed using a life of mine approach in which all production periods are optimized simultaneously. The underlying assumption being that material mixing in the short-term (between monthly optimization cycles) has a minimal effect on the long-term state of the panel. Schedule optimization is carried out using six general constraint types to model and control production. The constraint types define: deviation from ideal practice, panel state, material flow conservation, production quality, material flow capacity and production control. These constraints define production targets and drive production toward the ideal profile while maintaining correct mining practice. Application of the model using production scheduling data for a De Beers kimberlite mine. It is shown how different production control constraints regulate production from individual drawpoints as well as recovery of the ideal panel profile by implementing an optimised draw schedule.

Jan 1, 2003

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

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

By B. Ulrich

The basis of this paper is a compilation of work in the design and construction of copper heap leach facilities, and interviews with various heap leach operations personnel in Chile and Peru. The purpose is not to highlight specific mines and their performance, but rather to discuss geotechnical/civil features of copper heap leach facilities that function well, as well as features that do not. During the 1990s several copper heap leach facilities were brought on-line in South America. Many of these facilities have now been operational for a number of years during which time the operators have been able to monitor the performance of their heaps. This paper serves as a compilation of operators? experiences, and provides a discussion of the lessons learnt over the past decade. Several key geotechnical issues are examined, focusing upon the integrity of the ore, drainage material and pipe network, along with the success of inter-lift liners. This conference provides a timely update of the original paper (Burkhalter et al, 2002).

Jan 1, 2003