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By F. Terblanche, M. Holton, A. Kruger

The paper presents an optimal mine planning system designed to simultaneously optimize all the underground mines of large South African gold and platinum mining corporations. The system, code named PlanIT-OPTIM, is a multi-stage solution involving the use of adetailed 3D CAD-based mine planning system (CADSmine™V4). The mine design and scheduling rules defined in CADSmine™ are responsible for simulating mining sequencing, rock mechanics, and ventilation, etcetera. Feasible production ranges generated by CADSmine™ and various high-level mathematical models are used as inputs to a mathematical optimization engine. The optimization engine produces optimal production profiles (i.e. key business indicators such as tonnages, mineral and areas extracted per time period) by maximizing net present value. Other objectives such as profit continuity, production continuity and maintaining available reserves can also be specified as optimization criteria. The final step in the PlanIT-OPTIM process is to convert the optimal production profiles into practical and attainable business plans. This is achieved through the CADSmine™ Detail Optimization Engine that modifies the original CADSmine™ schedule to match the optimal production profiles. With current methods it is an impossible task to find the best business plan for a mining corporation in any reasonable period of time should conditions change (e.g. gold prices, exchangerates, grade estimates, etcetera). The fast turn around time achieved through PlanIT-OPTIM makes it possible to do several ‘what-if’ scenarios in a reasonably short time. PlanIT-OPTIM has already been used in the gold mining industry to find optimal business plans for a mine.

Jan 1, 2003

With the passing of Dr William Bleloch on 20th June 1991, we lost not only a colleague and a good friend but a man who made a very significant contribution to the industrial development of South Africa. He can rightly be called the father of the ekctrochemical and electro-metallurgical industries in this country, since his ideas and dedicated work were directly responsible for the development of these large industries as we know them today.

Jan 1, 1991

By P J. Fourie, J R. Walklate

Gravity separation techniques have been in use in the mineral sands industry for decades; from the Reichert cone to Wilfley tables, Wright sluices and the Kelsey Jig, all attempting that elusive perfect gravity separation. Just as the gravity separation industry evolved, Richards Bay Minerals also evolved in their use and approach to gravity separation. This paper discusses the history of gravity separation at Richards Bay Minerals and briefly comments on future developments. History Primary Concentration Richards Bay Mineral?s (RBM) first mining concentrator and mineral separation plant commenced operation in 1977 to process ilmenite, rutile and zircon bearing dunal deposits along the northern Natal coast. The orebody contained a greater proportion of non-valuable magnetic heavy mineral in the SG range of 3 to 4 compared to West Australian and Florida USA deposits, making mineral separation more difficult(1). The deposit was mined using two dredges feeding a floating 2000 tph concentrator. Concentrator feed was screened and fed to two four-stage circuits consisting of primary, scavenger, cleaner and recleaner Reichert cones [see Figure 1]. The primary units were fed at a rate of 80 tph and a density of 60% solids by weight.

Jan 1, 2006

By J. Alexis, G. Ye, E. Burström

Over the past twenty years the 3 MW DC arc furnace at MEFOS has been frequently used for development of new processes. These processes include recovery of valuable metals from slag, sludge and dust from steel and other metallurgical industry, treatment of ashes from power plant and incinerators, smelting reduction of minerals and zinc recovery from EAF dust. The process characteristics of the DC arc furnace operation in terms of: ? selective reduction, ? total reduction, ? process stability and flexibility, ? dust carry-over, ? thermodynamic conditions provided in the hot spot area, ? precision in composing slag products These are analysed and described in this paper based on technical results from selected test campaigns over the years and thermodynamic considerations. The electromagnetic properties of DC arcs beneath the electrode have been studied by CFD simulation. The calculated result enables us to understand some interesting technical phenomena observed. The heat balance has also been considered based on data obtained from test campaigns and heat balance calculation.

Jan 1, 2004

By D. J. de Beer

South Africa had a late start with rapid prototyping (RP), with the first system being available in 1991. Up to 1994 only three systems were available in SA. Through active research participation from the CSIR and a number of universities, supported by technology transfer programmes and industry awareness workshops, adoption of RP technologies started to grow. Internationally, RP grew to the extent that several country-based member organizations were formed, and an initiation meeting of the Global Alliance of RP Associations (GARPA) took place during the SME Rapid Conference in Dearborn, USA in 1998. South Africa (SA) was invited under the auspices of the Time Compression Technologies Centre (TCTC) launched by the CSIR, and received an invitation to become a member of GARPA through the launch of a national, inclusive organization. The latter gave rise to a RAPDASA planning/launch meeting held at the University of Stellenbosch, which culminated in the first RAPDASA international conference held in November 2000 at the CSIR, and the election of a first RAPDASA management committee, also at the 1st AGM held during the conference. RAPDASA has been a pillar of strength since then, with an annual international conference being presented. As South Africa?s RP awareness grew through the RAPDASA and independent activities, so did the availability of RP platforms in SA.SA also became a benchmark for other countries/late adopters to follow, as slowly a position of following became a position of leading through innovative applications. The paper highlights SA?s development approach and history, together with the discussion of case studies in various fields. Contribution to the light metals industry will also be discussed. Keywords Rapid prototyping, additive manufacturing, product design, rapid tooling, rapid manufacturing, medical product development.

Jan 1, 2011

By A. Kale

A chlorination pilot plant having capacity to produce 5?10 kg/hr of titanium tetrachloride is in operation at the chlorination facility in Mintek. The bubbling fluid bed chlorination plant can be operated in batch and/or continuous process to study the chlorination kinetics of various feedstocks. The chlorination of titaniferrous ores to produce titanium tetrachloride (TiCl4) was carried out during the commissioning of the pilot plant and also as part of the titanium programme carried out at Mintek. TiCl4 is a basic raw material for producing commercial titanium dioxide pigment and titanium metal. This paper discusses the challenges faced during the commissioning and operation of the chlorination pilot plant. It also discusses the effect on the auxiliary facilities and instrumentation as a result of the harsh operating conditions of +1000°C and use of corrosive gases like chlorine and titanium tetrachloride. It discusses the effect of physico-chemical properties of the titanium tetrachloride and iron chlorides. The effect on the chlorinator refractory lining due to heating and cooling of the chlorinator is also discussed. Besides the special provisions made during the design of the chlorinator, this paper also discusses the operational experience and possible solutions to be implemented in future. Keywords Fluid bed chlorination, titanium ore chlorination, titanium tetrachloride (TiCl4) production using fluid bed technology.

Jan 1, 2011

By B. Schoevaerts

The ever-increasing depth of mineral extraction presents a challenging environment for hard-rock underground mines. High in situ stresses and associated seismicity with potential rockburst hazards are the major decisive factors contributing to the choice of a ground support regime. Conventional ground support systems, designed primarily for static loads, are not always capable of providing safe working conditions for underground personnel in seismically active mines. Systems specifically developed to resist dynamic loading and allowing for larger deformations are therefore preferred alternatives. High-tensile chain-link mesh has a proven record of successful use in open cut operations in various rockfall barrier installations due to its high energy absorption capacity. It has also been used in underground operations in various parts of the world. Its application in South African underground mining, however, is limited due to the high labour intensity. This paper describes a method of mechanized installation of a chain-link mesh as evaluation at Gold Fields' South Deep Gold mine situated some 45 km south-west of Johannesburg. A purpose-built mechanized roll mesh handler, developed in Australia, was used in this trial. The handler is compatible with all standard multi-boom underground drill rigs and is operated utilizing the hydraulic circuit normally used for the feed arrangement. A number of key performance indicators have been specified as success criteria by Gold Fields: ? A 30% faster installation compared to the conventional methodology ? The mesh should sustain any blast damage when applied to the blasting face ? No unravelling of the mesh when cut ? No failure of mesh under normal conditions ? Reliability of the MESHA® installation handler (availability >90% ? Compatibility of the MESHA® installation handler with AC 282 boomers. Although the energy-absorbing mesh combined with yielding rockbolts is a ground support system of choice for rockburst-prone conditions, the operational upsides recognized during the trial imply that this product can also be competitively used in less demanding ground conditions where weld mesh or shotcrete are customarily used as a primary surface support.

Jan 1, 2012

The spatial distribution of copper grades at the Mansa Mina project is highly variable due to the presence of high grade copper/silver/arsenic breccia bodies. Copper grades within the breccia bodies tend to average about 4.5% copper while grades in the surrounding stockwork average about 1.0%. The breccia is known to occur in the vicinity of significant controlling structures, however, the outline and therefore the thickness of the bodies are far from regular. Due to the high grade of these bodies a significant proportion of the value of the project is derived from the breccia tonnages. The irregularity in the outlines/thickness translates into an uncertainty in the breccia tonnage and therefore in the value of the project. Acknowledging the economic importance of the breccia bodies and the risk associated with the breccia tonnage uncertainty, significant additional drilling has been proposed to both understand the spatial distribution of the breccias and reduce project risk. The costs associated with this additional drilling are not inconsequential; thus, a reasonable question is ‘what value is derived from this additional drilling’? To obtain an answer to this important question, a simulation approach is applied. First the deposit is simulated using the existing drilling and the uncertainty in the resource is defined. Next the proposed drilling program is simulated and the simulated data are added to the existing data. Using this expanded data set a second simulation of the deposit is created and once again the uncertainty in the resource is defined. Using this approach, the reduction in the uncertainty in the resource can be determined. To convert this reduction in uncertainty (or reduction in risk) in the stated resource into a dollar value, a method of defining the increase in the project rate of return necessary to account for risk is presented. Using the two different rates of return, the difference in project NPV and hence the value of additional drilling is determined.

Jan 1, 2003

By A. M. Bryukhanov, A. G. Mnukhin

The report states accident rates for gassy/dusty coal mines represented as an ergatic system "man – machine - environment" with further analysis by the method of conditional probabilities. A coal mine has been analyzed with allowance for the attending personnel, equipment and environment as a sequence of events and states. Probabilities of operational states have been determined and prediction of mine behavior has been made on the basis of investigation findings for equipment and the personnel states, and analysis of the environment (i.e. mine and mining conditions). Utilization of expert estimation methods has been considered for determining major operational parameters of gassy/dusty mines. The importance of standardized values of permissible occupational risks (permissible probability of accident, PA) is demonstrated. It is also stated that a procedure is essential to determine these values, involving regular check-ups of the integral safety criterion at all mines and further development of customized recommendations for individual mines on efficient improvement of accident situations. Methodology to determine the assessment criteria has been developed and scientifically substantiated for permissible accident rates in hazardous industries.

Jan 1, 2003

By Noel C. Joughin

In making judgements on tolerable levels of risk in industry, and in all spheres of life, it needs to be understood that every action gives rise to risk. Without risk, nothing can be done. Without risk, no economy could be advanced. There is a strong tendency to emphasize the risk at work, but persons who are not working are exposed to a different set of risks. Often persons who are not working face greater risks than persons who are working. Simply, in being alive, one is exposed to the risk of an accident, the risk of contracting a disease, and an extremely diverse variety of other risks. According to the Health and Safety Executive of the UK, it is not possible to have a state of zero risk, because ?a state of zero risk does not exist?. Because zero risk is a physical impossibility, it is not possible to design for a state of zero risk in all engineering design. While the strategic target of achieving zero risk is laudable it does not provide any practical guidance to engineers as to what acceptable limits of risk should be. This causes a significant and real problem in the design for and the management of risk. Without meaningful guidelines, engineers, managers and the authorities often find themselves in disagreement. Thus, it has become essential to establish criteria for tolerable levels of risk and unacceptable levels of risk in order to design and manage engineering systems properly.

Jan 1, 2011

By K. S. Liddell

The Kell Process has been developed for the extraction of platinum group metals (PGMs) and base metals from sulphide flotation concentrates. The process has been successfully tested on several different sulphide flotation concentrates, including those from the UG2 chromitite horizon and the Platreef mafic/ultramafic layer. It has been shown to provide high (>95 per cent) and selective extraction efficiencies for the key valuable metals, i.e. Pt, Pd, Rh, Au, Ni, Co, and Cu. The Kell Process consists of several commercially proven unit operations. S, Ni, Co, and Cu are first selectively removed by use of a pressure oxidation step during which the dissolution of PGMs is minimized. The residue from pressure oxidation is subjected to a thermal treatment to ensure efficient PGM recovery by subsequent chlorination. All the core steps are very similar to well-proven conventional unit operations in common use, as are the subsequent metal recovery steps to provide marketable end products. Typical metallurgical responses of flotation concentrates from UG2 and Platreef to the Kell Process are provided, and key outcomes of an energy comparison study with smelting are summarized in this paper. Kell presents a potentially substantial improvement in PGM concentrate processing technology, in terms of economics via much-reduced power costs, ease of processing, and various environmental benefits. It allows for the treatment of high-chromium low-grade 'dirty' concentrates, such as secondary concentrates from the platinum industry's 'mill-float-mill-float' (MF2) flotation circuits and concentrates from retreatment of tailings. It allows greater concentrate mass pulls, has higher tolerance to gangue intergrowths in concentrates, and its use can provide substantial increases in overall PGM recovery. Its adoption would be a step change in the platinum industry, and given the commercially proven unit operations embodied in the Kell Process, at much-reduced risk compared with other more experimental technologies. Since the initial process development work, significant improvements and refinements have been introduced as a result of further compre¬hensive testing and process modelling. Pilot-scale testing and engineering study work is in progress for several selected sites.

Jan 1, 2012

By M. K. Sichone

Anglo Platinum?s Waterval smelting complex based in South Africa operates the Anglo Converting Process (ACP) that produces SO2 offgas. This SO2 offgas is treated in a double-contact, double-absorption acid plant allowing for conversion efficiencies higher than 99.90 %. The catalytic converter used in the acid plant to convert the SO2 to SO3 is a 4-bed reactor loaded with a combination of cesium-promoted and conventional vanadium pentoxide catalysts. In June 2008 there was a shutdown, in which one of the main activities was to screen the catalyst. Before this shutdown, the operator would control the converter pass temperatures manually, via the SCADA, especially during plant start-ups after which some of the automatic temperature controllers were used. After the shutdown, the control philosophy was revisited and all temperature controllers were put on auto mode during plant start up. Furthermore the set points of the pass inlet temperatures were reduced to maximize conversion in the first two passes. The result has been a reduction of SO2 emissions, from a daily average of 50 ? 70 ppm to as low as 20 ppm for similar sulphur dioxide and oxygen concentrations. Further work has been done to maintain high bed temperatures in the third and fourth passes at low SO2 strengths by splitting the gas stream between pass 1 and 2 thus increasing the SO2 content in the gas to pass 2. This increases the temperature of the gas exiting the second pass, which results in higher temperatures in passes 3 and 4. Comparison of the converter performance prior to and after the changes is made. The benefits of partially bypassing the first pass to increase the SO2 content in the gas to the second pass are shown. Conclusions and scope for further work have been drawn from the comparisons.

Jan 1, 2009

By M. Arlandi, J. C. Monge

In this paper, the finite element method is used to obtain deformations of a rock tunnel. More than 3,000 numerical simulations and calculations were carried out. The analysis of this results has allowed to achieve mathematical formulations and graphs, to obtain in advance support monitored displacements in tunnelling construction, so they can be predicted before excavation and supporting woks. The application of the presented formulations and charts will aid engineers to control tunnel monitoring, reducing decision time when problems occur. The analysis is limited to cases involving elastic behaviour of the terrain for tunnels of average to good quality in rock, and to excavation sections of average or smaller dimensions for road tunnels. The results show that, in all cases, mathematical expressions to obtain induced displacements around tunnel excavations, have similar pattern than Kirsch (1898) expressions for circular excavations. As corollary of the achieved results, a method to estimate in situ natural geostress ratio K0=sh/sv , by means of convergence measurements, is presented. In diesem Beitrag wurden die Verschiebungen eines Tunnels durch die Methode de Finiten Elemente berechnet. Mehr als 3000 numerische Simulationen und Berechnungen wurden ausgeführt. Die Analyse dieser Resultate hat es ermöglicht, mathematische Formeln und Grafiken zu entwickeln, die zur Voraussage der Verschiebungen in Tunnel dienen, auch unter Betrachtung der verschiedenartigen Abstützungen. So können die Verschiebungen vor den Erdarbeiten und dem Bau der Abstützung abgeschätzt werden. Die abgeleiteten Formeln und Grafiken werden vor allem einen grossen Dienst für Ingenieure bei der Mithilfe zu zeitsparenden Entscheidungen im Tunnelbau und bei der Tunnelkontrolle leisten. Die analysierten Fälle sind auf eine elastische Modellierung des Baugrunds beschränkt, sowie auf eine mittlere bis gute Qualität des Felsens und auf die Aushebung von Abtragungsabschnitten mittlerer oder geringer Grösse für den Strassenverkehr. Die Resultate zeigen, dass in allen Fällen die hergeleiteten Formeln zur Berechnung der durch den Tunnelbau verursachten Verschiebungen um den Tunnel die gleiche mathematische Struktur haben wie diejenigen von Kirsch (1898) für kreisförmigen Bodenaushub. Als Korollarium der ausgeführten Berechnungen wird eine Methode zur Abschätzung der vorherrschenden in situ Geospannungs-Verhälniss K0=sh/sv angegeben, die von den Messungen der Verschiebungen im Tunnel ausgeht. Dans cet article, la méthode des éléments finis est utilisée pour obtenir les déformations d’un tunnel creusé dans la roche. Plus de 3000 simulations numériques et calculs ont été effectuées. L’analyse de ces résultats a permis de définir des modèles mathématiques et des abaques afin de prédire, avant l’excavation et les travaux de soutènement, les déplacements auscultés pendant la construction du tunnel. L’application de ces modèles et abaques permettra donc aux ingénieurs de contrôler les déplacements durant l’auscultation du tunnel et de réduire le temps de décision lorsque des problèmes surviennent. L’analyse est limitée au cas du comportement élastique du terrain pour des tunnels creusés dans de la roche de moyenne a bonne qualité, et à de sections d’excavation de petites à moyennes dimensions pour des tunnels routiers. Les résultats montrent que, dans tous les cas, les expressions mathématiques permettant d’obtenir les déplacements induits autour des excavations de tunnel, présentent des similitudes avec celles de Kirsch (1898) pour des excavations circulaires. Comme corollaire aux résultats obtenus, une méthode pour estimer le rapport des

Jan 1, 2003

Rock mass classification systems are extensively used in rock engineering design work, and mine design is no exception. Among the systems most widely used for mining-related design work are the NGI 0-system (Barton et al., 1974), the RMR system (Bieniawski, 1976), the MRMR system (Laubscher and Taylor, 1976) and, more recently, the GSI system (Hoek et al., 1998). Classifying the rock mass is widely seen as being the fieldwork required to characterize the rock mass and enable the application of empirical design methods associated with the different classification systems. This paper argues that it is fundamentally important to recognize the distinction between rock mass characterization and rock mass classification. These two processes should, in most cases, be separated from each other. Rock mass characterization should be used to determine the intrinsic properties of the rock mass independently of the application; i.e. independent from the infrastructure to be designed, the size, shape, and orientation of the excavation(s) or pillar(s), etc. Rock mass characterization should also be compatible with most classification systems and empirical design methods to be used. Rock mass characterization is the background fieldwork required to perform rock mass classification and/or engineering design work. Rock mass classification is the subsequent step to the characterization, and an integral part of the design process. Parameters that vary according to the design, such as the relative orientation of geological structures compared to the opening or the mine-induced stresses, should be calculated as part of the rock mass classification and design process, rather than during the rock mass characterization process. The failure to distinguish between rock mass characterization and rock mass classification can lead to major design errors and poor results.

Jan 1, 2012

By Van Sint JanM., M. Prudencio

ABSTRACT We report the results of a model-testing program to evaluate the strength characteristics of non-persistent joints. We describe the conditions under which new tensile cracks generate and propagate to connect existing joints so that the rock mass becomes fractured into several blocks, leading to a low strength. The strength of some models was equal to that along a single joint through the full sample length. In models with two joint sets, failure took place along a composite plane, partly sliding along a discontinuous joint and shearing through the intervening intact block of rock, or else by rotation and sliding of the blocks. This last failure mode could also lead to very low model strength. ZUSAMMENFASSUNG Dieser Bericht beschreibt die Ergebnisse von Versuchen mit Modellfelsmassen um den Einfluâ von unterbrochenen Rissen in ihrer Widerstandsfähigkeit zu untersuchen. Es werden die Umstände beschrieben unter denen neue Zugrisse entstehen, sich verbreiten, sich mit bestehenden Rissen verbinden und die Felsmasse in mehrere Felsblöcke zerlegen und zu einer kleinen Widerstandsfestigkeit führen. Der Widerstand einiger Versuchskörper entsprach der Festigkeit eines Risses der die ganze Länge des Versuchskörpers überquert.Versuchkörper mit zwei Rißfamilien versagten unter einer zusammegesetzten Ebene, zum Teil mit Verschiebungen nach unterbrochenen Rißebenen die sich durch Schnittversagen intakter Felsblöcke verbinden, und zum Teil durch Drehungen und Verschiebungen einzelner Felsblöcke. Die letzte Versagunsart kann zu einer stark verminderten Widerstansfähigkeit führen. RÉSUMÉ Nous présentons les résultats de quelques essais fait sur des modèles évaluant les caractéristiques de résistance des fractures discontinues. Nous décrivons les conditions sous lesquelles des nouvelles fissures de traction peuvent s’engendrer et se propager pour faire la connection avec des fractures existantes, de façon que le rocher se fracture en plusieurs blocs, menant à une résistance réduite. La résistance de quelques modèles fut égale a celle d’une fracture traversant toute la longueur du modèle. Pour les modèles ayant deux ensembles de fractures, la rupture a eu lieu sur une surface mixte, causée d’une part, par le glissement sur une fracture discontinue et d’autre part, par la rupture à travers le pont de matériel intact; ou bien par rotation et glissement des blocs. Cette dernière façon de rupture peut aussi aboutir à une très faible résistance des modèles.

Jan 1, 2003

By N. N. Malila, N. R. Shoko

The ever-increasing pressure on the profit margins of ferro-chrome producers and the gradual depletion of deposits of rich hard lumpy chrome ores calls for the ferrochrome industry to maximise the use of fine fractions of concentrates and friable chromite ores. Zimbabwe is endowed with huge deposits of refractory and friable ores that occur on and off the Great Dyke complex. The conventional metallurgical process of smelting of chromite ores in submerged arc furnaces is favoured by the use of refractory hard lumpy ores. The requirement to use all lumpy ore has been circumvented to a large extent at Zimbabwe Alloys. The use of briquetted chrome ore fines in the production of Ferrosilicon Chrome and High Carbon Ferrochrome has yielded positive results over a period in excess of twenty-five years. Of the three industrially used methods of agglomeration of chromite ores; sintering, pelletisation and briquetting, briquetting is preferred because the other two are associated with higher capital and operational cost. Zimbabwe Alloys has developed operational and technical expertise on the briquetting and utilisation of chromite ore fines and concentrates. Variations in the quality of available chromite ore fines imply that their amenability to briquetting is a dynamic problem. Appropriate briquetting parameters to guarantee quality briquettes are essential to the successful use of briquetted chromite ore fines. In developing a technology for briquetting of chromite ores, it is important not only to study the mineralogical and grain-size characteristics of the chromite ore fines but also to make an informed choice of the type and quantity of the binder and the conditions for producing a physically and chemically competent green and cured briquette. This paper discusses Zimbabwe Alloys' experience on the briquetting process and the advantages derived in the smelting of the briquetted chromite ore fines in comparison to the use of conventional lumpy chromite ore with respect to improvements in chromium recovery and as a consequence related efficiencies and unit cost of production.

Jan 1, 2004

By C. Musingwini, G. Njowa, M. Burnett, C. C. Birch

From 2022 to 2040, the global demand for mineral commodities is projected to increase by fourfold to six-fold, largely due to traditional drivers such as population growth and urbanisation compounded by the adoption of decarbonisation technologies that are more mineral intensive than fossil fuel technologies. To meet this projected demand, companies operating in the minerals industry should accelerate the development of mineral projects. Since most of the companies generally operate in multiple geographical, regulatory or legislative jurisdictions, it is critical that the information on Mineral Resources and Mineral Reserves they report on in the public domain should be comparable and consistent across different jurisdictions. The Committee for Mineral Reserves International Reporting Standards fosters alignment of national and regional mineral reporting codes through an internationally accepted template that creates common technical understanding of definitions, classification, estimation processes and the Public Reporting of Exploration Results, Mineral Resources, and Mineral Reserves. The Committee for Mineral Reserves International Reporting Standards Template-based codes guide reporting at respective national and regional levels. Since mine planning is critical in the conversion of mineral resources to mineral reserves, a shared technical understanding should aid comparability of mine planning results. However, differences persist in the way mine planning results are reported. Unlike most previous studies, which have primarily focused on comparing mineral reporting codes, this paper updates and extends such comparisons by exploring how similarities or differences in reporting should influence the mine planning process. It also recommends some principle and process changes to assist mine planning professionals to improve consistency and comparability in reporting mine planning results.

Mar 30, 2026

By P G. Gaylard

The minerals Industry carries out over US$ 2 billion of R&D annually. The R&D is performed at three levels ? in house research facilities; on a one-on-one basis with a research provider; as syndicated (collaborative) research. The key to a successful R&D programme is project selection. It is suggested that at this time of ?bounty? for the minerals industry the research portfolio should contain some ?blue sky? but potentially long term significantly beneficial projects. This said, the projects should align the technical concepts with the business imperatives. AMIRA has found the ?Road Map? concept has assisted in defining areas for R&D. Examples of this methodology using a Copper Road Map developed by AMIRA for the copper producers operating in South America is presented. The benefits derived from syndicated research are also discussed.

Jan 1, 2007

By F. Lombard

We consider the Grubbs estimation of the precision of an online gauge. Typically, this type of estimation involves independent results from two or more reference instruments (sampling and laboratory analysis operations). The properties of the estimator are then independent of the product variability. However, the use of more than one reference instrument entails significant additional costs. The two-instrument Grubbs estimator, which is based on results from a gauge and a single reference instrument, has the disadvantage that its standard error is heavily dependent on the degree of product variability. We propose a new estimator that has a variance that is more or less independent of product variability. In fact, the variance is typically less than that of the Grubbs estimator based on the use of two reference instruments. In order to function successfully, our methodology requires some prior knowledge of the extent of product variability and of gauge precision. In practice, such prior knowledge is often available and it is a weakness of the traditional two - and three-instrument Grubbs methods that no use is made of such knowledge. The efficacy and robustness of the new method is illustrated by Monte Carlo simulation.

Jan 1, 2012

By T. A. Muhlare

"Large quantities of slag are produced every year and dumped on slag heaps around the world, posing a potential environmental threat due to contained heavy metals content. Slags are waste minerals produced during furnace smelting of minerals. The contained values of base metals may be released into the environment under natural weathering conditions polluting ground and underground water. Copper losses into slag are a continuous problem in pyrometallurgical smelting operations. Due to shortage of ore concentrate, various mining operations have initiated the recovery of copper from dumped slag. The typical process uses crushing, milling and flotation. These operations create excessive liner wear rates during crushing and milling because the bond work index of copper slag is 22 kWh/t and this is considered a very hard slag. The process also has reduced flotation recoveries and requires high flotation reagent consumption. The present work shows that digestion of the milled copper slag slurry with concentrated sulphuric acid at a temperature of 250oC forms a solid cake and leaching of the solid cake with water is a possible option. However, the consumption of sulphuric acid can have a considerable cost on the recovery process. This can be limited by producing a leach residue containing gypsum and silicate materials as amorphous silica which are suitable for use as an additive for Portland cement. Laboratory results show that 90% copper recoveries can be achieved. The leaching is conducted to prevent silica gel formation and iron co-extraction. Leaching is optimum if silica gel-free solutions and good filterable residue are obtained. INTRODUCTION Slag is a waste by-product of smelting and converting operations in metallurgical plants. Both smelting and converting operations are aimed at iron separation from base metal sulphides in non-ferrous metallurgy. The iron sulphide component of the ore or concentrate is oxidized to iron oxide at higher temperatures in the molten form, and then fluxed with silica and other oxide rock minerals to produce fayalite (2FeO•SiO2) slag (Schlesinger et al., 2011). Slags are generally deposited on dumps and considered to be unreactive materials. Smelter copper slag contains significant concentrations of several potentially toxic elements, including arsenic, lead, cadmium, barium, zinc and copper. These elements can be released into the environment under natural weathering conditions and cause pollution of soils, surface waters and groundwater (David, 1998)."

Jan 1, 2015