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Ongoing rockpass problems on mines within the South Africa region, prompted AngloGold Ashanti to embark on a risk assessment of major rockpasses. This commenced with the collection of relevant data to identify gaps in the available knowledge and identify existing problems. This was followed by an assessment of rockpass layouts to determine existing and potential interactions with other excavations. An initial risk assessment has been completed and the rockpasses have been ranked in terms of their risk profile. The lack of geological data and an easy and reliable method of surveying rockpasses have been identified as problem areas. Shortcoming is terms of rockpass management procedures have also been identified. Further work is required to quantify the risk in terms of probability of occurrence and consequences.

Jan 1, 2005

Like it or not, CPD is upon us. As from 1 January 2006, all registered engineering professionals, i.e. professional engineers, professional engineering technologists, professional certificated engineers and professional engineering technicians, were required to undertake CPD in order to keep their professional registration current. The rules regarding CPD have been gazetted under Government Gazette No. 28328, Board Notice 131 on 23 December 2005, and they also appear on the ECSA website?www.ecsa.co.za. For the convenience of our members they are reproduced in full in this issue of the SAIMM Journal.

Jan 1, 2006

By C. Dixon

The Abandoned Mine by C.C. Woollacott A heap of rocks marks the abandoned mine. The veld's unpitying silence lies around. Those broken stone?a mute and mournful sign Of human enterprise with failure crowned. Time with the slow hands, shall form the scene anew, Repair the gashes in the wounded soil, And cover up the last remaining clue To a poor useless record of men's toil. And this, the mound they built when hopes were high Shall be a grave, where those hopes buried lie. Outline This paper will consider the implications of the mine closure provisions set out in the new Mineral and Petroleum Resources Development Act and draft regulations. A comparison will be made with the existing provisions in the Minerals Act and the mine closure policy of the Department of Minerals and Energy (DME). The paper will consider whether the new provisions have the potential for improving performance as regards mine closure. It will investigate the financial provisions requirements and the implications of these provisions for mines. It will consider the requirements for a social and labour plan and consider the implications of this for mine closure and its funding. It will analyse the provisions relating to the transfer of environmental liabilities to third parties and consider the implications of this in the case of closing mines and non-closing mines. Finally it will consider the issue of residual legal liability of a mining company once a closure certificate has been issued.

Jan 1, 2003

By G. B. Dukes

Scaling of rockpasses was problematic at Tau Lekoa Mine prior to production commencing in 1991. High horizontal stress levels relative to the host rock mass strength have been instrumental in causing the observed scaling. Scaling has been more pronounced in the deeper rockpasses and these are monitored regularly. Rehabilitation of one of the reef passes and one of the waste passes was required in the period 1999 to 2001. This paper describes the extent of the problems experienced to date as well as the rehabilitation completed.

Jan 1, 2006

The acoustic signals emitted from a laboratory-scale ball mill were used for the estimation of the comminution of two complex sulphide ores, viz. Merensky and UG2 ores from the Bushveld Igneous Complex in South Africa. The digital acoustic signals were transformed to power spectral densities that could be related to particle size distributions (-75 µm to 4000 µm) in the mill by use of continuum regression. This approach is more general than principal component regression methods or Kalman filtering used previously and resulted in significantly more accurate calibration in the case of the Merensky ore, where approximately 93.4% of the variance in the particle size distributions could be explained. With fewer data available, the variance in the particle size distributions in the UG2ore could be explained less accurately (82.4%), but still satisfactorily. In addition, smaller particle sizes (less than 300 µm) could be modelled more accurately in the case of the UG2 ore.

Jan 1, 2000

By H. Saroglou

Anisotropy is a characteristic of intact foliated metamorphic rocks (slates, gneisses, phyllites, schists). Testing was used to establish the anisotropic behaviour of selected gneissic rocks. The effect of anisotropy on various mechanical properties (strength, deformation) and dynamic properties (wave velocity) was examined. The rock samples were also tested at successively higher confining pressures in order to evaluate the effect of anisotropic behaviour at high overburden pressures.

Jan 1, 2004

By T. Tamura

It is known that the CaO-FetO-P2O5slag system has a wide liquid miscibility gap at steelmaking temperatures and this two-liquid slag phase has many advantages such as high activities of both FetO and CaO and high amount of P2O5. The phosphorus distribution ratio between the two-liquid slag and molten steel was confirmed to be higher than that between CaOsat.-FetO-P2O5slag and molten steel. The two-liquid slag may be useful for dephosphorization of molten steel and reduction of slag volume. Furthermore, the phase equilibrium of two-liquid CaO-FetO-P2O5slagsaturated with MgO was measured to determine the applicability of the two-liquid slag to dephosphorization in steelmaking process. Keywords: slag, refractories, solid solution, two-liquid phase, dephosphorization, steelmaking, phase equilibrium.

Jan 1, 2004

By Y. Nakata, K. Nagata

Plasma is partially ionized gas composed of ions, electrons and activated elements at high temperature. Some flying ash from incinerated municipal waste is melted to become glass by a transfer-type arc plasma furnace. As the glass is ionic silicate, when an electric current passes through anode to cathode, ions in molten slag electrochemically react with electron in plasma at the surface of molten slag. In case of molten Na2O-SiO2, sodium ions in the molten slag carry electric current and SiO2are reduced to evaporate as SiO gas by electron in plasma. The cases of Ag+in NaNO3-KNO3molten salt and Fe2+in FeO-SiO2slag were examined. The amount of cathodic reaction is larger than that of anodic reaction and not apparently according to the Faraday?s law on the electrochemical reactions.

Jan 1, 2004

By S. Asokan, CVGK Murty, R. Upadhyay

The principal mineral sources of titanium are rutile, anatase (both TiO2), ilmenite (FeTiO3) and leucoxene (a weathered ilmenite of variable concentration of TiO2 but similar to pseudorutile Fe2Ti3O9). These titaniferous minerals along with their value added products like Synthetic Rutile and TiO2 slag constitute ?Titanium Feed-stocks? for TiO2 pigment, Ti metal and welding electrodes industries. Unlike in other industries, the demand driver for titanium minerals is not the metal, but the TiO2 pigment ?a specialty chemical. Of the total titanium feedstocks usage in the world, about 93 % is consumed in TiO2pigment, with only about 3 % is utilized in metal production. India?s heavy mineral sands resources are among the largest and also one of the richest grades in the world. The country?s Ilmenite resource base stands at 348 million tonnes of Ilmenite (18% of the total world reserves)along with 18 million tonnes of Rutile, 21 million tonnes of Zircon, 8 million tonnes of Monazite, 107 million tonnes of Garnet and 107 million tonnes of Sillimanite. Though the grades (Total Heavy Minerals (THM) present in the sand) of Indian deposits are relatively rich, the contained ilmenite are termed as sulphate grade with 50-53% TiO2 (Chavra deposit of Kerala and Ratangiri deposit of Maharastra are an exception with 60% of TiO2). While superior grades with adequate reserves lead to a cost advantage in ilmenite production, the lower TiO2 percentage allows the direct use of Indian ilmenite only in the production of TiO2 pigment through sulphate route and for the chloride pigment production; such ilmenite is required to be upgraded either to Synthetic Rutile (SR) or TiO2 slag. However, in order to produce TiO2 slag in India at a globally competitive cost, the issues like high power tariff, inadequate infrastructure, expensive logistics, less enthusiastic market preferences, supply-demand gaps are to be adequately addressed. This paper deals with some of the above issues and possible solutions thereto in production of TiO2 slag from Indian ilmenite.

Jan 1, 2007

By J. P. Theron

Paper written on project work carried out in partial fulfilment of Phd.(Process Engineering) degree Process modelling is an essential element in the development of advanced (model-based) process control systems, accounting for up to 80% of the cost of development. Often, models based on historic process data are the only viable option when dealing with processes that cannot be modeled cost-effectively from first principles. Despite major advances that have recently been made in the field of nonlinear process modeling, some basic idea of the dynamic behaviour of a process system is important prior to system identification. While many process systems seem unlikely to be linear, the possible nonlinear aspects of their dynamics are not necessarily supported by the data. This may have significant implications for subsequent system identification or interpretation of the data. For example, it is quite possible that an underlying nonlinear deterministic signal may be obscured by a high degree of measurement or process noise, to the extent that it may be critical in the choice of model to fit to the data. The method of surrogate data analysis has recently been proposed as a means to classify the underlying dynamics of complex systems, and in this paper the use of Fourier transform surrogates to classify process systems is explored. Keywords: modelling, process control, simulation, surrogate data analysis, nonlinear systems.

Jan 1, 2004

By P. J. Brereton-Stiles, M. S. Rennie, N. Singh

Ferroalloy producers are large-scale users of electrical energy, which in many countries is in short supply and increasingly expensive. Preheating and/or pre-reduction using natural gas, recycled furnace gas or coal fines have lowered the specific use of electricity, but the high energy concentration necessary for most reduction processes can be achieved only by the use of high electric currents. Most countries have insufficient electricity to supply the demands of industry and the domestic consumer, particularly during certain periods of the day and certain times of the year. The generation and distribution of electricity is a large-scale expensive business, which is financed and managed directly or indirectly by government bodies in most countries. Both economic and political imperatives determine how much electrical energy is made available to whom and at what price. In South Africa demand is set to outstrip supply within the next few years, and the local supplier Eskom has moved from a traditional demand tariff pricing structure to a time-of-use tariff pricing so as to limit peak demand usage. This will mean a substantial increase in electricity cost to those users unable or unwilling to reduce consumption during peak periods. The optimal use of the available electrical energy depends both on the process, the furnace size, the configuration and infrastructure of each plant and its cost structure. As the cost and availability of electricity is set to change dynamically, the management of the situation becomes a real time control and optimisation problem. This paper discusses some the process and operational constraints associated with low- or no-load conditions and how to manage the situation. Electrode management will be one of the key issues.

Jan 1, 2004

By H. Saroglou

The anisotropic behaviour of Athens Schist has been brought out through the testing of specimens with varying orientation of schistosity with respect to the major principal stress under uniaxial, triaxial and dynamic conditions. A large number of results from tests on intact rock specimens of the Athens Schist were statistically analysed and evaluated.

Jan 1, 2004

By C. Musingwini

In the past ten to fifteen years, many organizations have applied business process re-engineering (BPR) to significantly improve their business competitiveness or stave off closures. The mining industry in Southern Africa is no exception and documented examples can be drawn from South Africa. Although the concept is superficially simple, its application has been marked by a high failure rate of about 70 per cent because it has been generally misunderstood. Shabanie mine, a chrysotile asbestos fibre producer in Zimbabwe took cognisance of this fact by cautiously embarking on a modular BPR programme in October of 2002. A year was used as a complete cycle or module for re-evaluation of the programme. Shabanie mine adopted BPR as part of management efforts to remain competitive amid serious threats to operational viability. These threats included hyper-inflation driven rising production costs, a declining world asbestos market and a possibility that Russia could take over the shrinking world asbestos market by dumping low-priced asbestos fibre. The only competitive advantage that the mine had was the high quality of its long-fibre chrysotile asbestos. The major BPR thrust was therefore to redesign processes for improved productivity and ultimately achieve a lower cost per ton of final asbestos fibre product. In addition, corporate culture change and cost-saving were also factored into the programme. This paper discusses the implementation experience of the BPR programme at the mine. The main BPR beneficial highlights are improved productivity, sizeable cost-savings, positive corporate culture change and identification of secondary projects. One of the lessons learnt from this programme is that mining companies will have to deal with the HIV/AIDS pandemic if they are to sustain high levels of productivity into the future.

Jan 1, 2005

By P. van Dorssen

In South African metalliferous mines, stoping operations are largely confined to narrow, tabular orebodies making mechanization extremely difficult. Limited flexibility in terms of stope width has necessitated drilling by means of handheld, pneumatic rock drills at most of our operations. As the largest producer of platinum in the world, we drill in excess of forty million stope blast holes per annum. Cleaning of the broken ore is also done by conventional means?utilizing scrapers and scraper winches. Conventional methods such as these carry high costs in terms of risk exposure as well as labour intensity. The purpose of this paper is to describe the development of a long hole stoping system suitable for the narrow platinum reefs. The new system had to be substantially safer and more cost effective than conventional mining. We selected a site that was conducive to mechanized mining and set out the parameters that we considered would meet our requirements. We then conducted a feasibility study to evaluate the conceptualized long hole stoping system in terms of specific goals. An analysis of the proposed system identified the Key Performance Indicators (KPIs). One of the most critical goals was to be able to create a man-free stope. This would mitigate the safety risk associated with normal stoping operations, as well as the inefficiency cost previously referred to.

Jan 1, 2002

By F. T. Cawood

The definition of mineral rents has historically been somewhat unclear, but a growing understanding of the source and composition of the revenues that comprise these rents mean that they can be more easily identified and quantified. Furthermore the way in which the flow of the rents from mineral developments are captured and then distributed has been a point of contention amongst the various stakeholders. Investors, the host government, the resource owners, environmental interests, indigenous groups and land owners are identified in this paper as the principal participants in mineral development and while each is entitled to a portion of the rent, the size of their portions will differ. A competitive rent-sharing model for southern African countries has been established and indicates how the range of stakeholders could be rewarded for their contribution. Acceptance of the sharing ratios amongst the recipients is a function of their understanding of the size of the rent and their position in the hierarchy of stakeholders. At first glance investors appear to receive the largest share of the rent, but they disburse some of the rent to hidden costs, which when all is said and done, means that investors and host governments retain approximately equal shares of the mineral rent. Both the investor and government are faced with the dilemma of how to equitably distribute the rents they have captured to minority stakeholders. Government captures corporate tax, mineral royalties and a wide range of subordinate taxes, but is required to construct policies that will ensure distributional equity among the various levels of government as well as among the provinces that comprise the country. Investors will have to ensure that a portion of the rents they capture are diverted to other stakeholders namely resource owners, environmental interests, indigenous peoples groups and the landowners. This paper identifies the major recipients of rent and provides some indication of equitable distribution ratios for mineral wealth among them?a first step in ensuring that mineral development is compatible with long-term sustainable development and in the best national interests.

Jan 1, 2002

By P. J. D. Lloyd

At first I read this paper with interest, which grew to fascination, and ended up with horror. Such reactions to a supposedly scientific contribution are rare, and I believe the coal mining community must be warned in the strongest possible terms against the recommendations that this paper makes. The paper purports to have assessed statistically two sets of data on methane concentrations recorded in the return air from Turkish longwalls. The first set of data, from their Table I, is reproduced in Table I below. The data have been rearranged in classes to indicate the underlying distribution. While there is only limited data (N=33), the distribution looks as if it could be the sum of two normal distributions with means around 0.5 and 0.8, or possibly a log-normal distribution. What is quite clear is that it is nota single normal distribution.

Jan 1, 2004

By R. C. W. Webber

Mining up to depths of 5 000 m would be a world first and, accordingly, no previous experience in the determination of acceptable heat stress limits, criteria or indices is wholly applicable. However, some South African gold mines are already operating at depths beyond 3000 m and much of the knowledge gained in reaching and working at such depths will be helpful in making adequate provision for acceptable environmental control at the greater depths being contemplated. Accordingly, it is necessary to take cognisance of the industry?s experience in deep-level mining and of standards and regulations already established in South Africa and elsewhere in order to ensure acceptable working conditions and control standards, that compare favourably and defensibly with those in other mining industries. The local and international use of heat stress limits, criteria and indices were investigated as it was necessary to determine to what extent any other indices, limits or criteria would be applicable to South African deep mine conditions. In addition, it was necessary to establish whether there was a single heat stress index that could be used for South African ultra deep mining conditions. It was found that an appropriate combination of heat stress indices would be required in planning for and ultimately controlling thermal conditions in ultra-deep mining. The depths being contemplated and the concomitant potential heat hazard present too great a risk for reliance on a single environmental component of heat stress, such as wet-bulb temperature at present in common use locally. The study recommends that a heat stress index, preferably Air Cooling Power (ACP), be used to design an ultra deep mine?s ventilation system and that wet-bulb temperature be used to monitor and control the system once it is implemented.

Jan 1, 2003

By I. Benning

Since the dismal performance of the Rand Mines management was called to account by its shareholders in 1994, the waves of change have continued to ripple across the South African mining industry .The number of listings on the gold board of the Johannesburg Stock Exchange, that once numbered 40 or 50-odd, have now dwindled to no more than a handful as unprecedented restructuring has taken place. The redefining of the industry has not been limited to the gold sector, but across the base metal, coal, diamond, platinum and industrial mineral sectors as well. At the same time the Mining Houses began to reconsider their funding strategies. Originally established in the early part of the century to ensure the long-term sustainability of their group mining operations by providing substantial financial muscle and technical support, the Mining Houses were faced with a rapidly changing political environment, which proved to be a critical catalyst in giving momentum to the change. Furthermore, the significant development costs and increasing risk profile for new projects, coupled with pressure from shareholders demanding respectable returns, opened the door to opportunities for banks to begin providing external debt by the way of project finance. However, the provision of long-term debt to the South African mining industry had generally not been common since mining companies had financed new projects with equity, or with the cash flows from existing operations. Those banks that had the appetite for exposure to the perceived high risks of the mining sector rapidly built up specialist resource banking divisions capable of addressing the increasing demands of the industry. The application of project finance, the principles of which were developed in the 1970s specifically for infrastructure projects and privatization, is now commonly applied in the financing of greenfield and brownfield mining projects. This paper outlines the approach that lending banks would typically adopt when arranging or providing mining project finance, their usual areas of concern and the way in which the finance is structured to mitigate the many inherent risks.

Jan 1, 2000

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 S. P. Pearton

"Pumpable emulsion explosives have been available to surface and underground massive mining operations for decades, and their unique properties offer significant advantages in terms of improved safety, reliability, and performance. However, the benefits of pumpable emulsions have been unavailable to narrow-reef mining operations due to the lack of technology necessary for their successful implementation in this challenging environment. Despite efforts to promote and enhance the safety and performance of bulk emulsions for narrow-reef stoping, little research has been undertaken to advance the pump technologies required for their implementation. This has resulted in a gap in knowledge and technology, and as a consequence the successful implementation of a pumpable emulsion system has consistently eluded the narrow-reef environment.The purpose of the following investigation was to evaluate the viability of pumpable emulsion explosives for use in South African narrow-reef mining operations. By approaching the problem from multiple perspectives, this research aimed firstly to propose a theoretical framework and suite of equipment suitable for the implementation of pumpable emulsions within the narrow-reef environment. Through the development of this suite of pumpable emulsion technology, tests could be undertaken on the proposed narrow-reef emulsion formulation and pumpable emulsion technology to obtain the necessary understanding of the performance of the system under controlled operating conditions prior to its implementation in the broader mining industry."

Jan 1, 2015