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By B. P. Watson, A. Carpede, W. O. Kekana, N. Fernandes, W. Theron, M. P. Mahlangu, G. Betz

The research described in this paper was done to confirm the Upper Group 2 (UG2) PlatMine peak pillar strength formula (Watson et al., 2007), which was determined from a back-analysis of failed and unfailed pillars. Underground measurements were made on a stable pillar that was loaded by firstly reducing it’s length and then by mining the surrounding pillars until pillar failure took place. The pillar was instrumented with suitably positioned strain cells and closure meters, which allowed both the average pillar stress and strain to be determined. The paper describes the methodology applied to identify a suitable position for the instrumentation, as well as the results. A stress/strain curve is presented for a UG2 pillar with a w/h ratio of 2.0, at Booysendal Platinum Mine. The measured pillar strength was similar to the predicted strength using the PlatMine pillar strength formula for UG2 pillars. The PlatMine formula has been successfully implemented on Booysendal Platinum Mine, and about 3 670 pillars have been cut without a single failure. An additional revenue of US$1.3 billion was calculated for the 25-year life of the mine as a direct result of the improved pillar design, given the January 2020 platinum group metals basket price. An extended life of mine and better mining efficiencies will also be realized.

Aug 1, 2021

Mining executives often have a difficult task determining what the strategic objective of the business should be as this can be impacted by the prevailing market conditions. In addition, they have no mechanism to quantitatively 'test' the impact of this strategic decision on the business and understand the underlying dynamics. During the commodities bull run of 2003 to 2008 the strategic objective may have been to grow the long term value of the business (NPV) through increased tonnage, acquisition and finding new reserves, which all came with an increasing fixed cost base. Now with the financial crisis upon us and the collapse of commodity prices and demand, executives have adjusted their strategies as 'cash is king' and short-term cash flow, in some instances at the expense of long terms value, is the order of the day. For many mining companies, mine closures, reductions in production and cost cutting exercisers are now the focus. In many instances, management do not have an ability to rapidly test different strategic alternatives to 'test' the impact on value, unit costs, reserves and profitability at the operational level and optimize the underlying trade-off variables. Economic modelling of the complete business value chain is a means of linking the operational 'reality' and strategic choices, so that the full impact can be assessed. This paper describes some of the challenges facing mining executives and how economic modelling can be applied to make decision making more rigorous.

Jan 1, 2010

By and Z. S. Abisheva, Z. B. Karshigina, Ye. G. Bochevskay, A. S. Sharipova

The production of precipitated silica in the United States is about 145,000 tons of SiO2 and its prices vary significantly (from $ 1 to $ 4.5 per kg) depending on the area of its application. One of the most important parameters is its specific surface characterising dispersion (particle size and shape, presence or absence of pores), at a certain value of which the material acquires new properties and quality. At present, a technology has been developed for processing slag from phosphorus production to produce precipitated silica (‘white soot’) with a high specific surface and the possibility of extracting valuable components such as rare-earth metals (REMs) into a product enriched with them has been shown. However, the content of impurities in the deposited silicon dioxide, such as aluminum and iron, is above acceptable limits and may affect the quality of the final products. Therefore, along with the structure and specific surface, a very important characteristic of ‘white soot’ is the chemical purity of the material. In turn, calcium oxide occupies a significant share in the concentrate of rare-earth metals, which affects the content of ΣREMs oxides, which does not exceed 17.3 %. The low content of a valuable component may affect the feasibility of further processing. For the most complete utilisation of phosphorus slag, the authors propose a method for their acid processing, which allows for minimising the conversion of impurities to finely divided silica and collective concentrate, which will improve the quality of these products. Keywords: Phosphorus slag, precipitated silicon dioxide, rare earth metals, leaching, white soot, specific surface, technology

Jan 1, 2020

By F. Botha

South Africa is amongst the 40 driest counties in the world, with extreme weather conditions and beset by both droughts and floods. Coupled with economic growth is an increased demand on water resources and, as with all other industrial developments, mining requires large volumes of water, which is likely to have an impact on the environment. Further to this, the mining industry also realizes that minerals are a non-renewable resource and the contribution to wealth creation from mineral extraction is not everlasting. It serves as an economic boost and careful planning is required to ensure that the legacy of mining is sustainable, and that some of the returns from mining provide continual economic and social prosperity.

Jan 1, 2012

By S. O. Bada

Coal is a complex mixture of organic and mineral constituents and is the most abundant resource of fossil energy in the world. In recent years, significant research into dry coal beneficiation has gained much attention, primarily due to the need to improve grades and reduce the environmental contaminants in coal without the use of water, and to achieve this in as cost-effective manner as possible, relative to wet beneficiation processes. This paper seeks to review the application of various electrostatic separators with their process principles, to draw comparisons between different dry beneficiation techniques with specific emphasis on the tribo-electrostatic separation method, and finally to report the results of tribo electrostatic separation conducted on various South African coals. Previous research conducted on Indian, European and American coals has indicated that this technique is likely to lead to significant economic benefit through the reduction of ash content, NOx and more specifically Sox by separating out the liberated Fe-S-bearing minerals prior to utilization. The removal of the latter suite of minerals is also likely to significantly reduce or eliminate the emissions of associated trace elements, including mercury and arsenic. The research results reported in this paper indicate that the rotary tribo-electrostatic process has the potential for significant upgrading of high ash pulverized South African coal. The impact of various operational parameters was investigated and key factors established for the optimum recovery of low ash and low sulphur fine coal.

Jan 1, 2010

By K. C. Mills

The objective of this work was to provide process engineers with values of the physical properties of various slag systems involved in high-temperature processes. Software that calculates the thermo-physical properties of slags from chemical composition is available on the www.pyrometallurgy.co.za website. This paper outlines the principles underlying the various models available in the program. The software calculates the following properties of crystalline, glassy, and liquid slags (where appropriate) as a function of temperature: heat capacity, enthalpy, density, viscosity, thermal conductivity, electrical conductivity, and surface tension. We hope, in the future, to update the program to (i) add new models as they become available, (ii) remove any ?bugs? discovered in existing programs, and (iii) provide guidance on the limitations of individual programs.

Jan 1, 2011

By Y. Fu, C. Aldrich

This study investigates the use of dense convolutional neural networks to estimate bubble size distributions in flotation froths. 20 videographically captured images of froths from an industrial platinum flotation plant in South Africa were labelled semantically with an image annotation tool, LabelMe (https://github.com/wkentaro/labelme). As a result, pixels in the images could be categorized into three classes, namely ‘bubbles’ (class 0), ‘bubble boundaries’ (class 1) and ‘background’ (class 2). A U-net architecture with a ResNet34 backbone was trained to segment the images via classification of the pixels in the images. 5 of the 20 images were used to validate the performance of the neural network. Explicit inclusion of the bubble boundaries as a class proved to be significantly more effective than training the network with two classes only (i.e. bubbles and background). However, the thickness of the boundary layer regions were critical. If too thin, it was difficult to distinguish between some contiguous bubbles and if too thick, some fine bubbles may not be identified. The results were promising, although there is still significant scope for improvement, among other by making use of more images for training and validation. Keywords: Flotation Froths, Convolutional Neural Networks, Deep Learning, Bubble size Analysis

Jan 1, 2020

By Z. Leng

"After detonation of the explosive, the final blast-induced damage area around the blast-hole falls into three categories, namely crushed zone, fractured zone, and elastic deformation zone. This paper presents a modified model to calculate the size of crushed zone around a blast-hole in drill-and-blast, with the hoop compressive stress and cavity expansion effect taken into account. The material in the crushed zone was assumed to be a granular medium without cohesion, but with internal friction. On this basis, the formula for crushing zone radius was derived. The proposed approach was verified with tests reported in the literature and the simulated results from SPH-FEM coupled models. A full statistical analysis was also carried out, and the predicted values were found to be in better agreement with the test results compared with other models. A sensitivity analysis of the modified model showed that the size of the blast-induced damage area is mainly affected by the following factors: rock mass properties, in situ stress, and borehole pressure. In particular, the roles of borehole pressure and in situ stress are discussed. Finally, suggestions are made on how the size of the crushing zones can be decreased. IntroductionOver the past decades, drill-and-blast has become the most commonly used technology in rock excavation. It is well known that in rock mass fragmentation with explosives, the annular rocks around the blast-hole are converted into fines. The formation of these fines consumes a significant part of the energy of the detonation, which in general is ignored in the determination of the efficiency of detonation (Glatolenkov and Ivanov, 1992; Furtney et al., 2012). Many studies show that only 20–30% of the total explosive energy is effectively used in fragmenting the rock, and up to 50% of the energy generated by conventional charges is wasted in overcrushing of the crushed zone and the inner part of the fractured zone (Ouchterlony et al., 2004; Sanchidrian et al., 2007). How to control the crushed zone to enhance the effective utilization of explosive energy, reducing the unit explosive consumption and the engineering cost, is therefore of great significance."

Jan 1, 2016

By J. W. van der Merwe, K. G. Moloko

Furnace wall tubes from 600 MW subcritical boilers at three coal-fired power stations were sampled and the fireside deposits examined to determine the mechanism of fireside corrosion. This involved an indepth investigation into the morphology and composition of the fireside deposits and the conditions of the furnace that enable this type of attack. SEM-EDS analysis revealed high concentrations of oxygen, iron, and sulphur, QEMSCAN and XRD analyses identified the presence of Fe3O4, Fe2O3, FeS, and FeS2. Differential thermal analysis showed thermal activities at temperatures of 500–600°C, 900–1100°C, and 1100–1250°C, which are associated, respectively, with FeS2 oxidation to FeS and Fe2O3, at 475–525°C, formation of aluminosilicates at 925–1100°C, and melting of FeS around 1190°C. The absence of sodium and potassium eliminates the contribution of molten alkali sulphates to the corrosion. The consistent coexistence of iron sulphide and iron oxide is indicative of the substoichiometric conditions in the furnace, while the detection of pyrite suggests that the coal is not completely combusted, which points to a poor combustion process. These observations were affirmed by gas analysis at one of the stations, where very high levels of carbon monoxide were measured at the furnace wall (≥ 14 000 ppm) and furnace exit (≥ 3500 ppm). The high CO concentrations are indicative of limited combustion caused by limited O2. These reducing conditions promote the formation of FeS-rich deposit, which is the corrosive species responsible for degradation.

Jun 1, 2021

By M. Pawlik, N. Ghaffari Touran

The interactions between apatite and hematite were studied through zeta potential and stability experiments, for this paper. The zeta potential measurements were conducted in both background electrolyte and mineral supernatants. The difference in electrokinetic properties of minerals in the presence and absence of supernatant was explained in terms of the dissolution of minerals and the subsequent readsorption of dissolved species at the mineral-water interface. The stability measurements in individual and mixed mineral systems were also performed to identify the extent of interaction between apatite and hematite upon their direct contact. The results from stability measurements in individual and mixed mineral systems indicate that there is an interaction between apatite and hematite. Based on the results, the implications for the apatite-hematite separation process were discussed. Keywords: Apatite, hematite, dissolved ions, stability, zeta potential

Jan 1, 2020

By Z. Bibak and S. Banisi

Granular systems, i.e. particles with realistic shapes, are commonly encountered in nature and industry. While the discrete element method (DEM) is a tool for the simulation of granular flow, in most of the DEM simulation particles are assumed to be spherical. It is questionable whether results drawn from a spherical particle could be easily transferred to a non-spherical particle. Thus, obtaining a fundamental understanding of the underlying physics of granular flows is not only of academic interest, but is also highly related to industrial applications. An in-house developed DEM software called KMPCDEM ©, which was coded to handle non-spherical particles, was used to simulate the particle behaviour. In this paper, the effect of particle shape on the dynamics of particles of non-spherical and spherical shape, including algorithms for the determination of the particle orientation, the moment of inertia, shape representation, and computation time was described. The assumption of a spherical shape has been justified by the complexity of simulation and significantly higher computation time if a realistic shape for particles was used. Dynamics differences showed that findings obtained from spherical particle systems could not be readily extrapolated to non-spherical particle systems. Consequently, particle shape is an important, if not even the most important parameter to be considered in DEM simulations, and therefore has to be captured accurately if DEM is to be used as a predictive tool. Keywords: Discrete element method (DEM), granular systems, non-spherical particles

Jan 1, 2020

By C. Mueller

In many automated mines, multi media video and audio funtionality has to be combined with sensor information or steering commands, which is the idea of a new, PC based integrated and multi media capable control system. The new control system (Multimedia Control - MMC) bases entirely on TCP/IP networking and internet technology. For the first time, this enables the ‘intelligent’ use of video and audio information: pictures and voice sequences may be forwarded on request only, they may be stored if particular events occur (e.g. video black boxes) and sensor signals as well as actions from the automation system can directly be assigned with multi media sequences. MultiMedia Control entirely bases on object oriented software. It uses most modern software technology. As user interface, only a standard web browser is required. This makes the handling of different machines easy. By using mobile web pads, dedicated local operator interfaces are not required any longer. The service staff just connects to the automated equipment by – wireless –LAN to make required adjustments. Customization is easy using an open Application Programming Interface. Software modules may be added to the system without touching or recompiling existing components. The system was prototyped in 2000 using a demo-application. The performance tests showed very positive results both regarding the control system behaviour and the speed/latency timing behaviour of the multi-media information processed. The system now is slightly reshaped to completely meet the final product requirements. It is expected to be available by the end of 2001. Key words: Machine Automation; Control System; Multi Media; Remote Control; Teleoperation; Ethernet; TCP/IP; Internet Technology; Streaming Video; Quality Assurance; Service; Control Centre.

Sep 1, 2001

By C. J. Pretorius

More than 30 percent of the global demand for zircon (ZrSi04) is supplied by South Africa. A significant amount of the zircon is exported, and beneficiated products are then imported for industrial applications locally. Beneficiating the zircon locally could have a positive impact on the local market, since zircon is only one of many such cases. Ammonium acid fluoride serves as an alternative anhydrous fluorinating agent for zircon in the synthesis of several metal fluoridesl.2. It provides an effective dry fluorinating method and is easier to handle than hydrogen fluoride or fluorine gas. Zircon exposed to extreme plasma temperatures dissociates and becomes more reactive. The reaction of the plasma-dissociated zircon (Zr02?SiO2) with the ammonium acid fluoride (NH4F?XHF, where x= 1 to 5) forms two main intermediate compounds (NH4)3ZrFr(s) and (NH4) 2SiF6(s), the latter decomposing to form volatile products at relatively low temperatures, providing easy separation of the silicon and zirconium compounds. The ammonium zirconate compound decomposes to form zirconium tetrafluoride (ZrF4), which can be further manufactured into zirconium metal, to name but one product. Data on the kinetics of the reaction of ammonium acid fluoride with zircon and plasma-dissociated zircon, combined with the thermo-dynamic parameters of the reaction, is essential for the development of an industrial process for the production of a precursor for the manufacturing of zirconium metal, namely anhydrous ZrF4. Both the reaction kinetics and reaction parameters will be included in this study, as well as some proof that the reaction proceeds to ZrF4 on a small batch scale. If the exact reaction parameters can be pinned down, a wide spectrum of anhydrous metal fluorides can be synthesized through this fluorination route.

Jan 1, 2012

Slope stability is a fundamental part of a successful mining operation. It impacts directly on the safety of personnel and the economics of the mine. The Jwaneng Mine in Botswana is planning a push back of 644m depth in the south east wall. Mining will commence in 2010 and be completed in 2024. This will put the mine in the deep pit category. The mine has invested in extensive geotechnical data gathering and design programs that started as far back as 2003 for the south east wall. The south east wail of Jwaneng Mine is characterized by foliation that dips adversely into the mining faces. The orienta1ion of the foliation is variable due to intense tectonic movements that have also caused the occurrence of faults that are sub-vertical. A considerable amount of information on the characteristics of structural patterns and the rock mass has been collected. This paper presents an overview of the feasibility level geotechnical design that is about to be concluded.

Jan 1, 2010

By P. J. Le Roux

"Mining companies are under constant pressure to reduce their cost structures to sustain profitability. In mines using an open stoping mining method, dilution often has a significant effect on profitability. At Target mine in South Africa, dilution in some open stopes was found to exceed 10%, falls of ground being a major contributor to the problem. This dilution can reduce the recovered grade from 5.5 to 4.5 g/t, resulting in a potential loss of about R21 million per month based on a gold price of R240 000 per kilogram. In addition to the cost of dilution, the cost of damage to, or loss of, trackless equipment as a direct result of falls of ground in open stopes is significant. Other associated costs include transport, hoisting, secondary blasting, milling, and plant treatment of waste material. Stable open stopes are essential in order to reduce falls of ground. Back-analyses of stope instability at Target mine have indicated that conventional rock mass failure criteria are unsuitable for stope design. An alternative strain-based criterion has been developed, and has proved to be very successful, allowing the stability of open stopes to be calculated reliably. Since its implementation in 2010, dilution and equipment damage have decreased markedly, creating value for the mine. IntroductionMines that make use of an open stoping mining method aim to extract only the ore, leaving the waste behind. Many orebodies have well-defined boundaries between the ore and the waste rock. In such orebodies, the introduction of waste into the ore due to overbreak dilutes the grade. In massive disseminated orebodies, dilution is less problematic. Overblasting, falls of ground, or other causes may result in dilution. A study undertaken in Canada (Pakalnis et al., 1995) found that approximately 51% of all underground metal mines utilized open stoping mining methods and, from surveys conducted at these mines, open stoping operations experienced dilutions of up to 20%, and occasionally more. Dilution of this magnitude has a significant economic impact on any mining venture. Research carried out in Australia by Capes (2009) came to the same conclusion."

Jan 1, 2017

By T. Szendrei, S. Tose

The Gurney approach to explosive/inert material interaction was adapted to analyse the face velocity in bench blasting. The model is based on the blasthole diameter, rock and explosive density, burden, spacing, linear charge density, and the Gurney energy constant. It is validated by comparing its predictions with a set of 20 field measurements of face velocities reported by Chiappetta et al. (1983) in an iron ore mine. The Gurney model links the observed large scatter of measured face velocities to the variation of the Gurney energy constant. This in turn is linked to the variability of the gas pressure acting on the burden. These variable pressures are generated when detonation product gases migrate into the extensive and complex fracture network around and between in-row blastholes. The energy efficiency of burden movement can be derived from the model. It is shown that ~7% of the explosive’s chemical energy is available for gas expansion work on the burden; of this quantity, 36% is actually converted to burden kinetic energy. That is, less than 3% of chemical energy is ultimately expended in burden displacement and throw. The model further indicatesnthat the projection of high-velocity (say, 100 m/s) flyrock is possible only when the path of leastnresistance through the burden has an effective density far less than the host rock. An equationnis derived that identifies the combinations of burden and path density that may yield flyrock. These values are specific to a particular baseline blast design.

Jan 30, 2026

By B. P. Watson, D. P. Roberts, R. A. Lamos

The Upper Group 2 (UG2) chromitite reef is a shallow-dipping stratiform tabular orebody in the South African Bushveld Complex, which strikes for hundreds of kilometres. Mining is extensive, with depths ranging from close-to-surface to 2 500 m. Pillars are widely used to support the open stopes and bords. Little work has been done in the past to determine the strength of pillars on the UG2 Reef and design was done using formulae developed for other hard-rock mines. This has led to oversized pillars with consequent sterilization of ore. In this paper we describe a back-analysis of stable and failed UG2 pillars on the Bushveld platinum mines, and provides a strength formula for UG2 pillars. The formula may be used cautiously on all Bushveld platinum mines with similar geotechnical, geometrical, and geomechanical conditions to the pillars in the database.

Aug 1, 2021

By T. Matlou, S. Myendeki, V. Midzi, T. Zulu, H. Mabotja, T. Mulabisana, B. S. Zulu, L. Hlatshwayo, T. Makhateng

The Council for Geoscience (CGS) performed a macroseismic investigation following the occurrence of an earthquake in the Boksburg area on 11 June 2023. The event had a magnitude of ML 4.4 and a focal mechanism that showed the event as having strike-slip motion along a northwest-southeast oriented fault. The event resulted in aftershocks, some of which occurred away from the causative fault in the east in an area without a mapped fault. However, the cluster of past events in that area suggests that there is an active fault. Due to the size of the main earthquake, a macroseismic survey was conducted to determine its impact on the community in the region. Analysis of observed data obtained from questionnaires resulted in the creation of 153 intensity data points. Their distribution showed high intensity values close to the earthquake source area. However, the investigation highlighted a number of anomalies, such as the higher than expected intensity values observed far from the event epicentre. It could be that these anomalies are caused by site conditions, for example, amplification of ground motion due to thick soil layers.

Jan 12, 2025

By H. Han, Z. Gao, Y. Gao, W. Sun, J. Wang

Strategic Ca-bearing minerals like scheelite and fluorite are usually separated by flotation, yet the separation is quite difficult due to their similar surface Ca active sites. Compared with the conventional strong collector sodium oleate (NaOL), lead nitrate-benzohydroxamic acid (Pb-BHA), complex collector shows a better selectivity for scheelite, yet its high cost hinders its wide application. Therefore, a novel collector (Pb-BHA-NaOL complex) was initially developed in this work to overcome the abovementioned dilemma. The flotation results of a single mineral showed that Pb-BHA-NaOL had a better selectivity for scheelite than Pb-BHA. Under the conditions of sequential assembly of Pb, BHA and NaOL at the molar ratio of 240:120:1 and pH 9.0, selective separation of scheelite from fluorite could be achieved without adding any depressants. In addition, for the same preferred scheelite recovery, Pb- BHA-NaOL could also save approximately 20% Pb and BHA compared with Pb-BHA. The analyses of the zeta potential measurement and X-ray photoelectron spectroscopy indicated that Pb-BHA-NaOL showed stronger adsorption on scheelite relative to fluorite. Meanwhile, Pb-BHA-NaOL showed more adsorption modes and higher utilisation of Pb and BHA on scheelite than Pb-BHA, which was due to the accelerator, NaOL. Keywords: Scheelite, fluorite, lead nitrate, benzohydroxamic acid, sodium oleate, flotation

Jan 1, 2020

By R. Xie, J. Liu, Y. Zhu, Y. Li

The surface chemistry features of spodumene and feldspar were investigated by XPS, zeta potential measurements and first principle calculation. The results indicated that the zeta potential of feldspar was more negative than that of spodumene. The most possible active sites on spodumene and feldspar were Al sites and O sites. However, the number, type and activity of these sites were different. The flotation behaviour of five new collectors (cationic collector decyloxy-propyl-amine (DPA), anionic collector α-bromododecanoic acid (α-BDDA), N-Dodecyliminodiacetic acid (DIDA), and mixed collector DPA-BDDA and DPA-DIDA) were investigated through micro flotation experiments and analysed based on the surface chemistry features of spodumene and feldspar. The results revealed that cationic collector DPA processed a high collecting capacity for both minerals. The highest recovery of spodumene and feldspar was 91.60% and 95.30% respectively. The anionic collector α-BDDA and DIDA showed poor flotation behaviour. The recovery of spodumene and feldspar when using α-BDDA as collector was less than 5% and when using DIDA as collector was less than 1%. For the mixed collector DPA-BDDA, the recovery of spodumene and feldspar was 82.27% and 32.61% respectively at pH 4.5. For mixed collector DPA-DIDA, the recovery of spodumene and feldspar was 35.69% and 9.08% respectively at pH 5.8. The results indicated that the cationic collector had high collecting capacity, but low selectivity. The collecting capacity of anionic collector for spodumene and feldspar was poor at the same concentration compared with cationic collectors. Mixed collector DPA-BDDA showed good flotation behaviour and selectivity on spodumene. The ―COO- in mixed collector might improve the selectivity. However, too much ―COO- would increase the electrostatic repulsion, which might cause low selectively and poor recovery. Keywords: Spodumene, feldspar, surface chemistry features, mixed collector, flotation

Jan 1, 2020