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By R. G. B. Pickering

Over the last few years Lonmin Platinum and Sandvik have embarked on a unique partnership of collaboration through a systematic approach to developing equipment to mechanize and automate narrow reef platinum mining. After the initial design and manufacture of the equipment the key aspect is the integrating equipment, people and method into a mining system. Another key aspect of mechanization is the optimization of equipment utilization, and this philosophy has ensured continual evolvement of mining methods. This paper describes the trials and development that have resulted in the mining method described as Lonmin mechanized breast.

Jan 1, 2007

Escalating energy and electricity costs have become one of the largest drivers of expenditure in mining operations. Over the last eight years, energy costs have tripled when expressed as a percentage of total expenses in South African mines. In an effort to manage and reduce electricity costs, energy management strategies can be developed, inefficient operating units replaced, and the operation of energy-consuming components of ventilation systems optimized. Power consumption on mines is controlled mainly by three strategies, namely load clipping, by which energy use is reduced for certain parts of the day; load shifting, by which energy use is shifted to other parts of the day; and energy efficiency, by which energy use is reduced permanently. In this paper several projects that were implemented using the first two strategies of load clipping and load shifting are investigated. The actual and potential savings that can be achieved by implementing such energysaving interventions are presented. To reduce the operating costs of ventilating and cooling underground mines permanently, system optimization studies must be completed. Methods that can be used to reduce energy usage by optimizing cooling and ventilation systems are described, and network simulation models that accurately reflect the current and planned ventilation conditions are discussed. These models are then used to examine various options for improving the overall ventilation and cooling strategy. Different optimization scenarios can be simulated, and this assists the design engineer in obtaining the most energy-efficient system that will satisfy design workplace conditions. The final outcome is a reduction in operating costs, which can result in better operating margins and an extension of the life of mine.

Jan 1, 2014

By J. Martinovic

The large proportion of gangue minerals present in platinum bearing ores in South Africa provides challenges to the flotation and downstream processes. In order to take effective measures to reduce their recovery in flotation, an understanding of the mechanisms and factors influencing their behaviour is needed. Typical gangue minerals are pyroxene, feldspar, quartz, chromite and talc. Of these, talc is a naturally hydrophobic mineral and although it is present in relatively small quantities, it has a disproportionate effect as it has a strong froth stabilizing effect, increasing the recovery of other gangue minerals by entrainment. Talc recovery is effectively reduced with the addition of polymeric depressants. Although the other gangue minerals are assumed to be hydrophilic and their recovery by entrainment is expected to follow the water recovery, there is some evidence that they may be activated by the typical reagent suites used. Reagents such as copper sulphate, added as an activator, and collectors are used to selectively induce hydrophobicity on the sulphides. It has been shown that some of these gangue minerals can be activated. This research work investigates whether inadvertent copper activation is mineral specific and evaluates the mechanisms and factors affecting the reversal of activation with the addition of the depressants using electrokinetic measurements, adsorption and microflotation tests. Results are presented that show that the selected minerals do respond differently and that the reversal of activation is dependent on mineral type, depressant type, dosage and ionic strength of the electrolyte.

Jan 1, 2005

A diverse selection of rockbolt designs and resin anchors are available for use in underground mines. Research in recent years at the UNSW Mining Research Centre led to the construction of a rockbolt pull-testing facility. This facility has subsequently been upgraded, commissioned and initial test work has been completed to verify the pull-test process. A test program has been completed with the objective to understand the load transfer mechanism and improve the general performance of rockbolts. This paper describes the results of this research. Une sélection diverse de dessins du rockbolt et ancres de la résine est disponible pour usage dans les mines de métro. Faites des recherches ces dernières années à l'UNSW que le Centre de la Recherche Minier a mené à la construction d'une facilité de l'essai de la traction du rockbolt. Cette facilité a été améliorée par la suite, le travail de l'épreuve en commission et initial a été complété pour vérifier le processus de la traction-épreuve. Un programme de l'épreuve a été complété avec l'objectif comprendre le mécanisme du transfert de la charge et améliorer la performance générale de rockbolts. Ce papier décrit les résultats de cette recherche. Eine verschiedenartige Auswahl an rockbolt-Designs und Harzankern ist dafür verfügbar, benutzen Sie in unterirdischen Bergwerken. Forschung in letzten Jahren beim UNSW-Bergbau Forschung Zentrum führte Ruckerprobung-Einrichtung zur Konstruktion eines rockbolt. Diese Einrichtung ist anschließend befördert worden, ist beauftragt worden und wird abgezeichnet, prüfen Sie, die Arbeit ist vervollständigt worden, um den Ruckprüfung-Prozeß zu verifizieren. Ein Prüfungsprogramm ist mit dem Objektiv vervollständigt worden, den Lastübertragungsmechanismus zu verstehen und die allgemeine Aufführung von rockbolts zu verbessern. Dieses Papier beschreibt die Ergebnisse dieser Forschung.

Jan 1, 2003

By C. Atilla Öztürk

Determining the cutability and mechanical properties of rocks is vital for the feasibility studies of a mine or tunnel projects. Many scientists have investigated the correlation between these parameters in order to predict specific energy (SE) and other important rock cutability properties for many years. On the other hand, textural properties of rocks have been quantified in detail by Howarth and Rowlands (1987). Hence, it was possible to correlate mechanical and textural properties of rocks by using a parameter known as the texture coefficient (TC). The main objective of this study was to use the test results taken from a research project carried out by Bilgin and Shahrair1tocorrelate the mechanical and cutability properties of rocks with textural properties of rocks. For this purpose, uniaxial compressive strength (UCS), uniaxial tensile strength (UTS), cone indent or (CI),point load index (PLI), unit volume weight (?), porosity, SE, and normal and cutting force values, were correlated with textural properties of rocks. Hence it was possible to make illuminating interpretations about the relationships between the mechanical and cutability with the textural properties of rocks. Keywords: Cutting properties, mechanical properties, specific energy, texture coefficient.

Jan 1, 2004

By L. du Preez, J. D. Steenkamp

This paper introduces the concept of clean steel production from a pyrometallurgist’s perspective to the broader metallurgical community. A simplistic overview of the steelmaking process from iron ore to car body manufacturing is followed by an introduction to the South African steel industry and the technologies that it utilizes. The process is illustrated by an overview of the flow sheet and technologies for the production of clean steel at Saldanha Steel, South Africa.

Jan 1, 2015

By L. Bircumshaw

Paper written on project work carried out in partial fulfilment of BSc (Eng) (Chemical) degree This paper details the formulation of a mathematical model for the simulation of a primary bioleach reactor, with specific reference to the leaching of pyrite. The model is based on the direct reaction mechanism, where the leaching of pyrite is said to occur via a two-step process. The process involves the formation of ferrous?iron through the chemical leaching of pyrite and subsequent bacterial oxidation of ferrous-iron back into ferric-iron. At steady state the rate of chemical leaching and bacterial oxidation are linked by the ratio of ferrous-iron to ferric-iron in solution. The extent of conversion of pyrite in the reactor system is described using the segregated flow model, with the exit age distribution of the solid phase being described by the Tanks-in-Series model. The final phase in model formulation involves the inclusion of steady state material balances on the bacteria and fluid phase components. The model is compared to pilot plant data and laboratory data for two different types of pyrite concentrates, with simulation results showing that the model is in good agreement with the data. Author key words: Bioleaching; pyrite; primary reactor; modeling; segregated-flow model; tanks-in series model.

Jan 1, 2006

By G. J. van Tonder

The use of Molecular Recognition Technology (MRT), a highly selective separation technology using specifically designed ligands (such as macrocycles), has been demonstrated to be an effective treatment process for removal of several ions that are commonly found in many hydrometallurgical circuits as well as in environ-mental treatment operations. Ions removed by MRT include base, heavy and transition metals, precious metals, halides, and alkali/alkaline earths. A MRT pilot plant run was conducted at Zincor to demonstrate the cobalt/nickel purification of zinc electrolyte, and to recover saleable pure cobalt/nickel sulphate solution. The MRT process holds various advantages, which include the elimination of a catalyst such as arsenic trioxide, conventionally used in cobalt and nickel cementation. SuperLig® 138 can be used to remove cobalt and nickel from120?170 g/l Zn-solutions at pH 1?2. The Zincor MRT application demonstrated its capability of concentrating large volumes o copper barren impure solution at low cobalt and nickel concentration levels in the feed, to small solution volumes at high cobalt and nickel concentrations. Around 99.5% of the cobalt was removed from solution with cobalt impurity levels in feed varying between 10 mg/l and 26 mg/l.

Jan 1, 2002

By C. Balci

Specific energy is defined as the amount of work required to break a unit volume of rock and is used to predict the performance of mechanical miners. It is obtained from full-scale rock cutting experiments, which require large block samples, experienced personnel and expensive equipment found in only a few research centres in the world. Estimation of the optimum specific energy, at which a given geological formation is excavated at optimum cutting geometry in the most energy efficient manner, from mechanical rock properties to predict the performance/efficiency of roadheaders is the basic aim of this study. The mechanical rock property tests require only core samples, which are easier to obtain and to test. In this context, full-scale rock cutting tests are performed on 23 different rock, mineral and ore samples including sandstone, claystone, tuffite, chromite, trona and copper collected from some operating mines in Turkey. The optimum specific energy values are obtained for each sample. Physical and mechanical property tests are performed on the core samples obtained from the same samples to determine uniaxial compressive strength, indirect (Brazilian) tensile strength, static and dynamic elasticity moduli, Schmidt hammer rebound values, density, and Cerchar abrasivity index. The relationships between the optimum specific energy and the mechanical rock properties are analysed using statistical methods. The results indicate strong relationships between the optimum specific energy and the mechanical rock properties. The strongest relationships are found by using uniaxial compressive strength and tensile strength. The performance models developed in this study are in good agreement with the empirical models previously developed for roadheaders and can be used reliably for prediction purposes. Keywords: Mechanical excavation, roadheader, performance prediction, rock cutting, optimum specific energy, mechanical properties of rocks.

Jan 1, 2004

Control of flotation processes is mostly managed by plant operators, who assess the performance of the plant based on their own experience and other heuristic rules. These rules tend to be subjective or ill-defined, since most of them are concerned with the structure of the flotation froth, such as colour, bubble size and shape distributions, froth mobility and froth stability. These phenomena are very difficult to quantify objectively, and inexperience on the part of the operators, human error, etc., can lead to significant inefficiencies in plant operation. In this paper the development of a fuzzy system to support the control decisions of plant operators is described, which leads to significantly smoother control action and more stable plant operation than could be obtained with crisp sets of rules or manual control strategies. Keywords: flotation, fuzzy logic, image analysis, genetic algorithms, rule induction

Jan 1, 2000

By C. Siyasiya

One of the problems that is occasionally encountered during the continuous casting of DIN 1.4003 stainless steel (hereafter referred to as 1.4003) is the side bulging effect, a problem that is generally prevalent in ferritic stainless steels. This occurs because the unconstrained narrow sides of the solidification shell are not able to withstand the ferrostatic pressure once the strand has emerged from the mould. Coupled with side bulging, there is strand width variation at high temperatures, i.e. when the steel is in the ferrite-austenite dual phase region. Both of these dimensional changes to the slab profile create some processing problems in subsequent hot rolling operations when unacceptable width variations are encountered. The strength of the solidification shell and its ability to withstand the ferrostatic pressure during continuous casting is dependent on its thickness and phase composition when exiting from the mould up to a few metres downstream. From the study of the high temperature metallurgical behaviour of this steel, it was observed that a thicker solidification shell when exiting from the mould and a higher austenite volume fraction in the steel would be favourable for the reduction of the side bulging effect during continuous casting. It was also found that as long as the d-ferrite to austenite phase ratio keeps fluctuating due to variations in chemical composition and process control in the dual phase region from cast to cast, the strand width variation problem would probably persist. The remedy to this effect lies in more strict chemical composition and process control during continuous casting of this steel. The hot ductility experiments revealed that 1.4003 exhibits good hot ductility in the strand straightening temperature range with a minimum of 75 per cent reduction in area and this was attributed to the high volume fraction of ferrite (0.2 to 0.4) in the steel. This would provide a remedy to side bulging by increasing the secondary cooling rate of the strand in order to form a thicker solidification shell without necessarily risking transverse cracking and other surface defects during unbending. Keywords: side wall bulging, resistance bending moment, applied bending moment, ferrostatic pressure.

Jan 1, 2005

By J. M. Lottering

Paper written on project work carried out in partial fulfilment of B Eng (Chem) degree Operational factors influencing the electrostatic separation of mineral sands were investigated in a laboratory separator. Measurements were collected online by means of an optical sensor using diffused reflectance spectroscopy to determine the mineralogical composition. The results have shown that the roll speed and potential were the dominant operating variables, collectively explaining more than 83% and 68% of the product grade and yield, respectively. In contrast, the feed rate, temperature and position of the plate did not affect separation. The effect of the ambient relative humidity, ranging from 10% to 45%, could not be assessed conclusively and at best appeared to have a weakly beneficial effect on the product grade. Keywords: process modelling, high tension roll separator, mineral sands

Jan 1, 2006

By J. van Deventer

Testwork was done with two different adsorbents, Dowex-Minix gold-selective resin and activated carbon, to detemine their relative performances with regard to gold recovery from clarified low-grade solution employing a fixed-bed operation. The mill discharge from the milling-in-cyanide operation at a Witwatersrand gold mine was used as feed to the adsorption columns. A small amount of gold was leached during the milling process, so that this solution simulates, to a certain extent, a low-grade solution representative of a heap-leach operation. A speciation of the feed solution was done to establish which metal complexes were present in the milling-in-cyanide solution. This information was necessary to interpret metal loadings on the resin, as base metal cyanide species and their respective charges have an effect on the final gold loading capacity of the resin. Equilibrium isotherms were established for both adsorbents to estimate the rate of adsorbent flow anticipated for this specific feed solution. Breakthrough profiles were obtained at two different superficial linear velocities for each adsorbent. Mass transfer zone heights determined from the test work and the elution/regeneration time requirements were used to size a 150 m3/h full-scale plant for both adsorbents. A counter current configuration of adsorption columns, using three columns, should be suitable to recover gold effectively and to produce an effluent with a gold concentration below 0.01 mg/l. Based on the results obtained from the breakthrough tests, a preliminary techno-economic comparison was done between the resin-in-solution and carbon-in-solution options for the recovery of gold from low-grade solutions. This study indicated that the capital expenditure for a carbon-in-solution plant would be about 33 percent higher than that of a resin-in-solution plant. The operating expenditure for a resin-in-solution plant is expected to be only 60per cent of that for a carbon-in-solution plant. Keywords: resin-in-solution, carbon-in-solution, heap leach.

Jan 1, 2000

By J. B. Oosthuizen

Mechanical rock breakers are used in block caving operations to reduce the size of ore fragments which are too large to pass through grizzlys at the load-haul-dumper tipping points. Several layouts of grizzly, rock breaker and ore pass are possible. The authors evaluated three different layouts at the Premier Mine Division of De Beers Consolidated Mines. The first layout consisted of a 15m surge bin before the breaker, which was located 15 m below the production level. The second layout had a 43 m longs urge bin, with the breaker located 43 m below the production level. The third layout did not have a surge bin, the breaker was located on the production level and operated at the tip. The ore throughput, availability and utilisation, delays, costs and operational experience with each system are discussed. It was found that the rock breakers did not represent a bottleneck in the ore transfer system and a surge bin did not significantly improve the production capacity. The mine has decided to make use of rock breakers situated on the production level, breaking rocks at the tip.

Jan 1, 1997

By R. G. B. Pickering

Resue mining was practiced extensively in the East Rand in the first half of this century. The obvious benefits were that a higher grade of ore was trammed to the surface. The disadvantages were slow rates of face advance and an extremely labour-intensive method of mining. A collaborative effort by personnel from Avgold?s Target Gold Mine and Sandvik Tamrock has resulted in the design of a method of resue mining which can be totally mechanized. The purpose of this paper is to describe the methodology used and the proposed new mechanized resue mining method.

Jan 1, 2000

By K. I. Afewu

A modified approach to the implementation of Gy?s sampling theory is discussed and used to design a procedure for sampling crushed gold ore feed to metallurgical process plants. The approach involves calibration of certain ore-specific parameters. These parameters were calibrated for two different crushed gold ores en route to grinding mills in process plants. The model predictions were compared with the predictions from Gy?s original model. Far smaller masses of samples are required by the modified model than by Gy?s model at the same relative variance. The representativeness of the sampling procedure if normally distributed errors are assumed was also calculated. These procedures and evaluations lead to significant savings on cost of handling and preparation of the samples and to a quantifiable degree of confidence in the analytical results for the process plant.

Jan 1, 1998

By E. L. Thyse

Keywords: Pyrometallurgy, converter, nickel, matte, distribution Metallic elements occupy a wide range in granulated nickel converter matte phases. The distribution of these metallic elements, particularly during crystallization path events, appears to be poorly understood. The present study serves to investigate the distribution of Fe, Co, Ni, Cu, and Pb between nickel-sulphide, copper-sulphide, and alloy phases. A novel combination of thermo-chemical modelling, electron microscopy, and electron probe microanalysis was applied to understand crystallization path events and the associated metallic element distribution. This study has demonstrated that major Ni incorporated during copper-sulphide crystallization would serve to mobilize minor Co towards distribution in copper-sulphide phases. In addition, solid solution substitution of Cu by Ni is manifested by compositional zoning of copper-sulphide phases. The role played by Ni during alloy crystallization suggests that minor Co was also mobilized, along with an increase in principal Ni. Fe, by contrast, seems to be incompatible with principal Ni. In addition, solid solution substitution of Ni with PGEs and Cu is manifested by compositional zoning of NiCu-alloy phases.

Jan 1, 2011

By D. Fenn, A. du Kanda, D. Dukhan

"SynopsisGibb Consulting Services was contracted by Eskom Line Engineering Services to conduct an investigation to determine the absolute displacement to date and infer the current rate of displacement of unsurveyed colliery backfill.At the test site, where a 400 kV power line is to be constructed, neither the surface nor the backfill material had been monitored and it was not possible to state whether the surface will be subject to future settlement that may compromise surface infrastructure. Therefore indirect methods of estimating current and future displacements needed to be found to act as a proxy for a comprehensive long-term settlement monitoring exercise and provide a reasonable estimate for the settlement that has occurred in the decades of mining.The innovative solution was to recover essentially undisturbed core from backfill using a sonic drill rig and use the measured dry density values from the samples as a proxy for the rate and absolute displacement in the backfill.The success in obtaining an essentially undisturbed backfill core and the clear relationship of the backfill density with age and depth allowed the conclusion to be issued that the power line infrastructure can be constructed over the backfill; with a warning that once the water table recovers after mining ceases some collapse settlement may occur.With this method, the amount of settlement can be predicted and, if proven conclusively, provides a way to confidently release huge areas of currently waste ground for future surface infrastructural development.IntroductionIn coal mining, it is normal mining practice to backfill the newly mined-out voids with the excavated waste rock and soils. As there is no requirement for the mining companies to uniformly compact the spoil or accurately monitor surface or inter-backfill displacement, these backfilled voids are prone to differential compaction and consolidation settlement. They are therefore avoided as sites for future surface infrastructure work, especially for linear structures such as roads, railways, and power lines."

Jan 1, 2015

The modelling of lithological domains is a critical step in mineral resource and reserve evaluation. Deterministic models rely on an interpretation of the available drill hole data and expert knowledge, but do not account for the uncertainty in the spatial extent of the lithological domains. Instead, probabilistic models based on conditional simulation can be used to map the probabilities of occurrence of the domains within the deposit, which reflect the uncertainty in their presence or absence at unsampled locations. The mineral grade model is then obtained by weighting the predicted grades associated with each lithological domain by the probability of occurrence of this domain. Such an approach accounts for the continuity of the grades proper to each lithological domain and for the uncertainty in the spatial extent of these domains within the deposit. An application to a porphyry copper deposit is presented. Keywords: spatial uncertainty; plurigaussian simulation; geological control; kriging; geostatistics.

Jan 1, 2007

By J. Golamnejad

This paper attempts to model long-term production scheduling problems by chance constrained binary integer programming in a stochastic environment. This stochastic model is set up to account for ore block grade uncertainty. The probability distribution function of grade in each block is used as a stochastic input to the optimization model. This distribution function in each block should be determined using a Geostatistical Simulation approach. The deterministic equivalents of these chance constraints are then achieved, which are in the form of nonlinear in binary variables. A confidence level at which it is desired that the uncertain constraints holds, is specified in each scheduling period. Rather than the previous risk-based model, this formulation will yield schedules with a high chance of achieving planned production targets while maximizes the expectation of net present value and minimizing the variance function simultaneously. Using this method, the grade uncertainty is integrated explicitly into the optimization process.

Jan 1, 2006