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By R. Abela

In over ninety per cent of mineral sand plants, the most commonly used equipment is the spiral concentrator. The tonnage treated over typical spiral plants can range from as low as 200 ton per hour up to 6 000 tons per hour. Due to the limited capacity of each spiral, plants consist of multiple spirals assembled into banks. The mixture of minerals present in the sand feed requires several spiral stages to achieve the desired mineral recovery. Due to the complexity of the spiral circuits, there are always some design and operating problems that present themselves in plants. These range from slurry distribution, spirals operating at incorrect design parameters and feed variations. The material being treated is difficult to maintain in suspension due to its high density, resulting in segregation and preferential flow in pipelines, distributors and sumps. The objective of this paper is to highlight common problems associated with spiral installations to designers and operators of plants. Practical solutions are recommended in order to prevent and minimize these mistakes in the design. These solutions may be used to improve performance on operating plants.

Jan 1, 2003

By E. Harris

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

Jan 1, 2014

By S. O. Bada

Coal samples taken from the No. 2 Seam and No. 4 Seam in a South African colliery were tested in a rotary triboelectrostatic separator. The two-stage triboelectrostatic separation results using the -177 µm size fraction reduced No. 2 Seam coal containing about 30.4 per cent ash to a clean product of 8.9 per cent and 13.1 per cent ash with combustible recoveries of 9.6 per cent and 30.7 per cent respectively. The same separation approach on No. 4 seam feed coal, which contained 36 per cent ash, produced a clean coal product with 10.8 per cent ash at a combustible recovery of 6.0 per cent. Petrographic tests show a significant improvement in the vitrinite content and a reduction in visible minerals encountered when using the triboelectrostatic separator, with about 53 per cent vitrinite reporting to the clean fraction for No. 2 Seam compared to the feed content of 21 per cent, and a 54 per cent vitrinite in the clean No. 4 Seam from a feed content of 21 per cent. Significant sulphur reductions were also observed after separation in both coal samples, with a better separation in the second-stage coal products.

Jan 1, 2012

Physical testing of rock support for rockbursting conditions has been carried out for over 40 years. A review of this testing shows that it has been mostly component?based, rather than actually testing support systems. Further, it is concluded that none of the testing is truly representative of rockburst loading in a similitude sense. Similitude conditions are not achievable, mainly because the real conditions in a rockburst event, such as seismic source location and magnitude, wave frequencies, amplitudes, and interactions, are not all known. Because such information is not available, and because the results of all testing carried out to date have not been able to define, for support design purposes, the capacity of support systems, ongoing physical testing of rockburst support systems is essential. It is essential that the test should simulate, or actually take place in, a supported rock excavation. A rock support system is a combination of individual support components that work together to retain and contain the rock. In doing this, the components are subjected to loading by the rock and to interactive loading between one component and another. It is necessary to prove the capacity of such rockburst support systems by subjecting them to severe loading, as in direct blasting. The direct blasting approach, pioneered more than 40 years ago, probably still provides the greatest validity as a significant test of rockburst support capabilities, even though it does not simulate a rockburst. Direct blast testing of rockburst support systems in a surface environment, such as in a quarry or on exposed rock cutting surfaces, could represent a practical development of the approach, facilitating the execution and monitoring of tests.

Jan 1, 2012

By J. D. Stone

This paper briefly reviews the adequacy of existing management theories and practices and the managerial proficiency or competency in the South African mining industry. The investigation revealed that existing management practices are totally inadequate to enable all employees on all the levels of the mining industry to achieve the results required from them, in all aspects, at all times. As a result, the South African mining industry is gradually losing its long standing reputation as a relative cheap, competitive, and reliable supplier of minerals to the local and global markets. According to some prominent management authors and theorists, an all-inclusive unified management theory does not exist at present. In this paper the authors summarize the main aspects of a newly developed comprehensive, practical, and integrated management method. It is believed that the application of this method would significantly improve the future performance and competitiveness of the South African mining industry

Jan 1, 2010

By W. P. Erasmus

This paper will focus on the use of the ?wet-mix? steel fibre re-in forced shotcrete as a permanent lining in deep shafts, assessing gold bearing reef. It will cover all aspects relating to the choice of this material covering the geological conditions through to the final quality control. All procedures are in line with ISO 9001,as JCI projects who manage the project, are an approved company therof.

Jan 1, 2001

Tunnelling under squeezing ground conditions poses significant challenges. There are fundamental differences in the choice of support for mining as opposed to civil engineering. This paper reviews ground support strategies that have been used to control large deformations in mining excavations based on field data from five different mines in Australia and Canada. Recommendations are made for improved ground control strategies in squeezing rock conditions.

Jan 1, 2008

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

By D. G. Krige

For the purpose of determining confidence limits for ore grade estimates, an extensive simulated data base was used, which included 1728 ore blocks with ‘actual’ grades and the corresponding estimates based on ordinary and simple kriging. The practical results show that conditional unbiasedness is essential and that acceptable confidence limits can then be set using Normal theory for the simulated error distribution based on the logarithms of the ratios of ‘actuals’/estimates with a variance related to the kriging variance. The mean of the data used to prepare the variogram and the estimated block grade are to be used properly in this approach. A practical analysis was also done of the actual point and block data from a very large mined out Carbon Leader area. The distributions of the actual grades for two levels of block sizes with different levels of variability were fitted using three models, ie. 2-. 3- and compound-lognormal. The trends of tonnages, grades and relative profits for a range of pay limits, as well as the usual tonnage-grade curves, show a practical insensitivity for the choice between the three lognormal models considered.

Jan 1, 2003

By N. Z. Fotoyi

Keywords: MgO-MgR2O3 refractory, SO2-containing gases, chemical attack The reaction mechanisms occurring when MgO-MgR2O3 refractories are exposed to SO2-containing gas atmospheres were examined. The study examined the characteristic structures of magnesite-chrome, chrome-magnesite and magnesite refractories exposed to SO2-O2 gas mixture at temperatures of 700°C to 1350°C. The phase characterization was conducted with scanning electron microscopy (SEM) and powder X-ray diffractometry (XRD). The results show that the physical characteristics of the refractory matrix along the grain boundaries are important refractory features during chemical attack from SO2-containing gas. Upon heating in SO2-containing gas, the changes in phase-chemical compositions and accompanying grain growth causes loosening of the structure and the pore volume promotes gas diffusion. The chemical reactions that occur form stable sulfate compounds identified as MgSO4, CaSO4 and CaMg3(SO4)4, and lead to disintegration of various phase structures and consequently erosion of the refractory. In conclusion, the reaction mechanisms in MgO-MgR2O3 refractories exposed to SO2-containing gases progress through a combination of structural disintegration and chemical attack.

Jan 1, 2011

By O. Leuangthong, M. Nowak

"The impact of high-grade data on resource estimation has been a longstanding topic of interest in the mining industry. Concerns related to possible over-estimation of resources in such cases have led many investigators to develop possible solutions to limit the influence of highgrade data. It is interesting to note that the risk associated with including high-grade data in estimation appears to be one of the most broadly appreciated concepts understood by the general public, and not only professionals in the resource modelling sector. Many consider grade capping or cutting as the primary approach to dealing with high-grade data; however, other methods and potentially better solutions have been proposed for different stages throughout the resource modelling workflow.This paper reviews the various methods that geomodellers have used to mitigate the impact of high-grade data on resource estimation. In particular, the methods are organized into three categories depending on the stage of the estimation workflow when they may be invoked: (1) domain determination; (2) grade capping; and (3) estimation methods and implementation. It will be emphasized in this paper that any treatment of high-grade data should not lead to undue lowering of the estimated grades, and that limiting the influence of high grades by grade capping should be considered as a last resort. A much better approach is related to domain design or invoking a proper estimation methodology. An example data-set from a gold deposit in Ontario, Canada is used to illustrate the impact of controlling high-grade data in each phase of a study. We note that the case study is by no means comprehensive; it is used to illustrate the place of each method and the manner in which it is possible to mitigate the impact of high-grade data at various stages in resource estimation."

Jan 1, 2015

This paper provides a review of the chemical reactions occurring in the submerged arc processing of chromite ores. The excavations of industrial furnaces have shown that the charge, as it descends through the furnace, passes through a number of distinct reaction zones. Each zone is characterised by differing process conditions and reaction products. The phase equilibria, reaction steps and mechanisms occurring as the charge progresses through the furnace are examined, and the potential influences of these factors on the process outcomes are discussed.

Jan 1, 2004

By D. T. G. Emmett

[ ] South Africa, by a wide margin, is blessed with the largest known world reserves of platinum. The optimal use of these resources for the benefit of all South Africa?s peoples is a goal shared by industry, government and all South Africans. The challenge is to grow the industry in accordance with demand growth and thus to manage a long-term stable growth pattern for PGM usage world-wide. Amplats and the South African producers are well able to meet this challenge [ ] South Africa plays a critical role in the provision of Platinum Group Metals for world markets. In fact no other country has the productive capacity nor the geological reserves to supply the world?s platinum needs. The world required some 5 million ounces of Platinum in 1997 and South Africa supplied a full 74% thereof. The second major supplier, Russia provided a further 18% of world demand, primarily as a by-product of nickel production. Amplats satisfied about 37% of total world demand followed by Impala 20% and Lonhro at 12%.

Jan 1, 1998

By R. Falcon, P. den Hoed, A. Luckos, R. Erasmus, V. du Cann, D. Comins

Carbon as a reductant, additive or filler is an essential element in the processing of metallic ores and the manufacture of iron and steel in the metallurgical industry. In most cases, the element carbon is derived from coal and its carbon derivatives. The properties of carbon required for the different processes in each metallurgical sector vary significantly and, for this reason, matching the correct carbon product for each specific process has become an important if not vital function in all sectors of this industry. This selection process, however, has become increasingly difficult. In many cases, the substitution of new products, despite being similar in all relevant chemical specification characteristics to previous products, has resulted in different performance properties relative to that expected. Under these circumstances, the prediction of performance of unknown carbon products has become fraught with difficulties unprecedented in the past. In order to initiate an investigation into addressing these issues, a test case was selected for indepth study the results of which are reported in this paper. The case concerned the use of a specific carbon feed in a conventional submerged arc furnace which gave rise to an unprecedented amount of unreacted or only partially consumed residue trapped in the frozen slag on the refractory walls of the furnace. During the course of these investigations, different advanced analytical technologies were employed including, inter alia, Raman spectroscopy, surface dimensional tests, organic petrology and various thermal reactivity factors. All results have been integrated into a multidisciplinary assessment presented in summary in this paper. Based on the above, and previous experience, the concept of an all-embracing 3-D coal-carbon ?framework? is briefly introduced. This approach has succeeded in obtaining greater depth of knowledge and a better understanding of the issues at stake with specific reference to the organic composition, structure, texture, internal surface area and consequent reactivity of the carbon materials concerned. In consequence, it would now appear that various properties of relevance to the metallurgical industry may be predicted with greater precision than has hitherto fore been possible.

Jan 1, 2004

Viscosity measurement was carried out over a narrow range of silica content around the fayalite composition. A wide range of temperature and oxygen potential was covered where the slag was completely liquid. In order to keep the slag composition and the Fe3+/Fe2+ratio constant, theCO2/CO ratio was kept constant as the temperature was varied. Increasing the Fe3+content has little effect on viscosity for slags with a silica mole fraction of 0.31. At higher silica contents, increasing the Fe3+content brings about a small decrease in the viscosity.

Jan 1, 2004

By A. V. Roschin, V. E. Roschin

Composite ores are more often used for production of iron in connection with reserve depletion of traditional ore crude in the regions with developed metallurgy. In particular, the majority of perspective ferrum-ore deposits of the Urals are presented by titanferous magnetite ores which contain a significant amount of titanium and vanadium alongside with ferrum. Thus, the deposits of titanferous magnetites of the Southern Urals on the average contain about 20 % of Fe, 8,7 % TiO2 and 0,24 % V2O5. Due to a high content of titanium oxides it is impossible or it is inexpedient to process such ores in blast furnaces. During work just on titanferous magnetite ore refractory titanium-containing slags are formed in a blast furnace, and in case of its dilution by ores of different types the titanium due to the small content in slag is thrown out. It is often impossible to separate such ores into ferriferous and titanferous concentrates because ferrum and titanium are present in the same minerals. This work attempts to selectively reduce ferrum in solid oxide and to separate metallic iron from titanferousslag with fast fusion. Solid-phase reduction of ferrum has been carried out with carbon at temperature of 1000? 1300°?. In products of solid-phase reduction the extremely disperse mix of metal iron and only partially reduced titanium oxides have been achieved. It is impossible to separate such a mix mechanically. However, the fast fusion of the mix allowed separating it into cast iron and slag with the high content of titanium. Thus the cast iron contained less than 0,1 % of titanium, and the slag did not contain practically any ferrum.

Jan 1, 2007

By J. Talja

Keywords: drying, steam drying, concentrates, copper, lead During the past twenty years steam drying has become a prominent technology for drying of non-ferrous metals concentrate. This is mainly because of its low energy consumption and very low emissions. The first applications of significant capacity were stationary steam dryers, which however, faced severe challenges in maintenance costs and availability. That technology was soon replaced by Kumera?s rotary steam drying technology, which has been the dominant technology in new dryer installations world-wide for the past ten years, ever since the first installation in Hamburg in 1999. There are ten Kumera steam dryers in operation today and five more to be commissioned during 2011. Practically every dryer is different owing to continuous development, new innovations and operational experience with continuous feedback from the operators. Most significant improvements relate to capacity increase with the Kumera steam-dryer family, new feeder systems at the wet end, a completely new design of the dry material discharge with increased availability, heating element design and material selection, and control systems. This paper discusses the modifications and improvements introduced which have enabled the Kumera steam dryer to become the global leader in new dryer installations.

Jan 1, 2011

By A. McKenzie

During the late 1990s Anglo American PLC was evaluating the Gamsberg zinc deposit in the Northern Cape Province. As the primary South African metallurgical technology provider, Mintek became involved in the evaluation of a pyrometallurgical process for the recovery of zinc from the Gamsberg deposit. eloping DC arc furnace technology for the metallurgical industry. This includes the patented Enviroplas® process for the treatment of zinc bearing waste materials. As a consequence Mintek has developed extensive expertise in the pyrometallurgical processing of zinc bearing materials. However, Mintek?s technologies stopped with the production of Prime Western Grade (PWG) zinc. Early on in the evaluation of the Gamsberg project, it became evident that the refining of PWG zinc would play an important part in the economic viability of the project. At the time the only pyrometallurgical technology available for the refining of PWG zinc to Special High Grade (SHG) zinc was the New Jersey process. This process represents 50-year-old technology and has not undergone significant refinement since the technology was developed. In order to provide a complete pyrometallurgical flow sheet for possible implementation at Gamsberg, Mintek assessed the New Jersey process with a view to either improving the technology or developing a new technology appropriate to the 21 century. In 1998 Mintek convened a consortium consisting of Mintek, the University of Cape Town, Eskom Enterprises, Bateman Metals and Anglo American PLC. The consortium successfully applied to the Innovation Fund for funding to develop a new process for the pyrometallurgical refining of PWG zinc to SHG zinc. The main aims of the project were to develop a new technology for pyrometallurgical zinc refining that conformed to the following: ?Decrease the production cost of SHG zinc metal to stimulate the development of the Gamsberg deposit. ?Be compatible with the current Enviroplas® process, preferably as an add-on to that process. ?Should use electrical energy to benefit from local price tariffs. The project commenced at the beginning of 2000 and consisted of three phases: ?an initial technology search and assessment of the fundamental aspects of zinc distillation. ?the design of a pilot plant for zinc refining. ?the manufacture, commissioning and operation of the pilot plant. A new technology based on a DC arc boiler feeding a packed distillation column was developed and during 2003 the project culminated in the successful operation of a 200 kg/h pilot plant. Ultimately, all of the aims of the project were met and the main outcome is that an advanced process for the pyrometallurgical refining of zinc (the Zincref process) has been developed. The main innovation of the technology was the switch from an energy transfer limited process to a mass transfer limited process (for which a patent has been registered).

Jan 1, 2004

By N. P. Mahumapelo

This paper is based on a study to determine the potential beneficiation opportunities for marble from Griekwastad in the Northern Cape Province. The marble was characterized mineralogically by X-ray diffraction. Major and trace elements were determined using inductively coupled plasma-optical emission spectroscopy. The sample was crushed, and the crushed material beneficiated by tumbling and polishing. The resulting beads were incorporated into a variety of jewellery and other decorative items. It is concluded that the beneficiation of Griekwastad marble presents a good opportunity for value addition and job creation, provided that an effective marketing strategy for the products can be developed..

Jan 1, 2014

It is predicted that vast volumes of affected mine water will be produced by mining activities in the Mpumalanga coalfields of South Africa. The potential environmental impact of this excess water is of great concern in a water-scarce country like South Africa. Research over a period of more than 10 years has shown that this water can be used successfully for the irrigation of a range of crops (Annandale et al., 2002)1. There is, however, continuing concern from the local regulators regarding the long-term impact that large-scale mine water irrigation may have on groundwater quality and quantity. Detailed research has been undertaken over the last three years to supplement the groundwater monitoring programme at five different pilot sites, on both virgin soils (greenfields) and in coalmining spoils. These sites range from sandy soils to very clayey soils. The research has included soil moisture measurements, collection of in situ soil moisture over time, long-term laboratory studies of the leaching and attenuation properties of different soils and the impact of irrigation on acid rock drainage processes, and in depth determination of the hydraulic properties of the subsurface at each of these sites, including falling head tests, pumping tests and point dilution tests. This has been supported by geochemical modelling of these processes to quantify the impacts. The results indicate that many of the soils have considerable attenuation capacities and that in the period of irrigation, a large proportion of the salts have been contained in the upper portions of the unsaturated zones below each irrigation pivot. The volumes and quality of water leaching through to the aquifers have been quantified at each site. From this mixing ratios have been calculated in order to determine the effect of the irrigation water on the underlying aquifers. Keywords: coalmines, irrigation, gypsiferous mine water.

Jan 1, 2009