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By D. D. Howat

In the field of high temperature smelting processes there have been two dramatic changes in the past twenty years. These are, first, the application of tonnage oxygen for direct injection for the refining of molten iron and other metals and to provide the means of enriching air used for the combustion of fuel. Second, the application of electric power for the generation of high temperatures in place of the combustion of fossil fuels. Of these two developments the application of tonnage oxygen for the refining of molten iron has virtually revolutionised the steel industry throughout the world. The magnitude of this development is exemplified by the fact that less than 5 per cent of the world's steel production in 1960 was made by this process or 16 million tons out of a total of 350 million tons of steel produced, while in 1970 over 40 per cent of the world steel production was made by this process, ie, 251 million tons out of 628 million tons total. In the same period the proportion of steel produced by the old-established open-hearth process has shrunk from 75 per cent to 38 per cent. In the whole history of the development of high temperature metallurgical smelting processes there has never been anything remotely approaching this. The other development, the application of electric power for the generation of high temperatures has not had the impact of the oxygen injection process but I believe that what we should call the electric smelting revolution in metallurgical processes has very far-reaching ramifications for steel production and other pyrometallurgical processes. This may seem a bold and brash statement but it must be remembered that the oxygen injection process constitutes a link in the chain critically dependent upon the production of vast tonnages of molten iron from very large modern blast furnaces. The Achilles heel of this chain of processes, upon which such a large percentage of the world's supply of steel depends, is the availability of metallurgical coke in turn dependent on natural resources of coking coal. Without any exception each industrial country in the world faces a shortage of resources of coking coal and in some cases a critical shortage. Certainly within the present century the major iron and steel producing countries of the world will face this critical shortage of coking coal and major modifications to steel making processes will become inevitable. W. F. Cartwright (Deputy Chairman of B.S.C) said recently that there are considerable doubts as to whether the world will be able to provide enough coking coal to meet world steel demands from the late 1970's onwards if the B.F.remains the main means for making iron from ore. This is one of the supreme ironies of the world metallurgical situation to-day when the technology of iron and steel production has reached an extremely high peak of technical efficiency. The newest modern iron blast furnace capable of producing 6 000 to 8 000 tons per day of molten iron represents probably the most efficient piece of high temperature metallurgical plant and operation known to man. The conversion of this molten iron into steel by the oxygen injection process has made available to the engineering industry steel of a quality and at a price which is quite remarkable. Yet this vast metallurgical pyramid rests on the completely insecure and uncertain foundation of inadequate world resources of coking coal. The shortage of reserves of coking coal in this country is acute and it is possible that these resources will be exhausted within the next twenty years. Yet unless some completely unexpected catastrophe occurs the demand for steel in this country will probably rise at a faster rate than in the Western world due to the expansion of the Bantu population and the increased standard of living. To offset the inevitable shortage of coking coal are our much greater resources of bituminous coal which although of low grade provide a suitable fuel for electric power generation. The geographical disposition of the coal fields in relation to the great industrial areas of the Transvaal makes it inevitable that the development of the pyrometallurgical industries must depend heavily on electric power. The position in this country with regard to electrical power generation and consumption is rather anomalous. Per capita consumption of electric power is high - in 1964 almost twice the world average of 870 KWH and twenty-five times the average of 34 KWH for the Continent of Africa. In 1964 fifty-four per cent of the total world electric power was used in industry - the ratio being approximately 1/9 mining to manufacturing uses. As shown in Table I in 1969 67.2 per cent of the total output of electric power from ESCOM was used for mining and other industrial uses but almost in the ratio 6/4 mining to industrial uses. These figures emphasise the enormous importance of the mining industry to the economy of this country and underline the major contribution made by the gold mining industry. What is of very significant importance is that although the mining industry remains by far the largest single consumer of electrical power the consumption of power for industrial uses is rising rapidly as shown in Table II.

By A. Montini, M. H. Moys

A technique for the measurement of slurry consistency inside a grinding mil is described. The rate of slurry drainage from a sensing probe mounted through the mil shell is measured and correlated with the percentage solids of the slurry discharging from the mil. The response time of the measurement(obtained on a pilot bal mil) is compared with the response time of the viscosity of the mill discharge. It is shown that the new measurement should allow much tighter control of the mil behaviour, with concomitant savings in the consumption of power and steel.

Jan 1, 1988

By A. M. Thyer

Throughout the history of mining, underground fires or explosions have killed many hundreds or thousands of people. Fortunately, the safety record has gradually improved as a result of many people’s work on improving safety standards and work practices. However, fire and explosion still remains a threat in many situations. As a result the UK Mines Inspectorate commissioned a project to study materials used underground and to develop a fire/explosion risk assessment system. Such a system has been developed, following the study of incidents, specified fire resistance criteria, and fire safety practices. The final methodology uses a series of check sheets to identify potential fuels and ignition sources, preventative measures, fire/explosion mitigation systems, and items for inclusion in emergency plans.

Jan 1, 2003

By W. A. Te Riele

The National Institute for Metallurgy was the venue for a one-day colloquium on 'The Chemistry of Processes for the Recovery of Gold on Activated Carbon'. Organized by the South African Chemical Institute (Southern Transvaal Section) in collaboration with the National Institute for Metallurgy (NIM) and the South African Institute of Mining and Metallurgy, the colloquium attracted tremendous interest from the mining industry. Some 300 metallurgists, engineers, and chemists were brought up to date on advances in this technology made by scientists of NIM and the Anglo American Research Laboratories (AARL).

Jan 1, 1980

By F. L. D. Cloete

he above article by E. Barnea, which appeared in the January 1978 issue of the Journal (vol. 78, no. 6, pp. 143-145), calls for comment in view of the author's claims for the novelty of his proof. He states in his article that its main purpose is to give a mathematically acceptable proof by induction of the 'recently proposed' equation

Jan 1, 1978

By F. Q. P. Leiding

SYNOPSIS A technique is described for measuring the change in volume in a borehole drilled in a rock mass subjected to stress and strain. It is shown that the volumetric strain or change in volume provides a practical estimate of the the stress in the rock.

A description is given of a simple, cheap device that enables the intact shear strength of rock to be determined quickly and inexpensively. Thin rock plates, prepared with a diamond saw, are tested in double shear by a linear punching action. By varying the direction of the diamond-saw cut in a number of specimens, the change in shear strength can be measured for different orientations relative to the rock fabric.

Jan 1, 1980

By E. Molobi

"Studs are rods threaded on both ends and are used as mechanical fasteners for two or more components. Stud finds usage in industries such as automotive, construction and aviation. The advantage of studs is that they allow for disassembly of components during maintenance. Studs are continuously subjected to both tensile and shear stresses, depending on the application, therefore they should be manufactured from suitable materials that are capable of withstanding all these external forces. Studs are sometimes manufactured from re-sulphurized steel due to its improved machinability; however, there is a certain limit on the amount of sulphur, above which failure may occur. Premature failure of studs has been a common problem, but failed studs are commonly replaced with new ones without conducting failure investigations. The present work investigates the premature failure of two re-sulphurized steel studs used on a rocker arm assembly and recommends alternative materials. The investigation was carried out by conducting visual examination, microstructural analysis, hardness measurements, chemical analysis and a detailed scanning electron microscopy (SEM) investigation on the fracture surface.IntroductionTwo rocker arm studs used on a 16-cylinder diesel locomotive engine failed prematurely after being in service for less than 5 months. The rocker arm studs had a life-cycle of 5 years. The studs were manufactured from resulphurized steel. The paper aims to establish whether re-sulphurized steel is applicable for the manufacture of studs in the automotive industry.BackgroundLocomotives are classified as either electric or fuel-powered. Diesel locomotives are an example of fuel-powered locomotives. This type of locomotive uses a diesel engine as a means for propulsion. An engine converts chemical energy into mechanical energy required for traction. In an internal combustion engine a rocker arm is an oscillating lever that conveys radial movement from the cam lobe into linear movement to open and close poppet valves of cylinders (Husain and Sheikh, 2013). The rocker arms are secured on to the cylinder head by rocker arm studs."

Jan 1, 2016

By P. A. Laxen, P. J. van Staden

Alternative procedures for the recovery of gold from old sand dumps are discussed, with emphasis on the use of heap leaching. The modification of material to improve its permeability prior to heap leaching is not currently receiving much attention in South Africa. The channeling of solutions through heaps and the high consumption of reagents sometimes ascribed to heap leaching can, as shown by the results described in this paper, be lessened by desliming of the sand prior to heap leaching and the treatment of the resulting slimes fraction by agitation leaching and carbon-in-pulp. This combined procedure results in a higher overal recovery of gold. Alternatively, the sand can be heap-leached as it is after agglomeration with lime and cement, which improves the mixing and neutralization of the material, as well as lessening the probability of channeling.

Jan 1, 1988

By F. Diot, S. K. Tripathy, L. O. Filippov, I. Filippova

Among different pre-treatment methods, a high voltage electric pulse was recently developed and is gaining popularity due to multi-benefits such as pre-weakening along the grain boundaries, as well as size reduction to improve the liberation characteristics. In this paper, the pre-treatment using high voltage electric pulse of lithium-bearing granite ore was studied to understand the morphology through texture, as well as the friability of the particles. To understand the phenomena, SELFRAG, a laboratory facility used for generating high voltage electric pulse and key operating variables were varied. The role of applied voltage (94.5-195.5 kV), number pulse (3-87), and the frequency of pulse (1.3-4.7 Hz) was varied to understand the liberation characteristics as well as energy consumption. Characterisation tools such as optical, and electron microscopy were used to describe the pre-weakening phenomena through textural features. Further, the energy required to break the particle to finer sizes as well as friability were determined and described. Keywords: Pre-treatment, high voltage electric pulse, lithium, liberation, grinding

Jan 1, 2020

By A. J. S. Benade, A. J. A. Heyns, N. B. Strydom

The maximum oxygen intakes of samples of about 30 Bantu, weighing less than 50 kg from different tribal groups (Zulu, Xhosa, Sotho and Shangaan) were measured on a treadmill. The mean maximum oxygen intake of the 164 men was 2,12 litresjmin and only 18 men (11 per cent of the sample) had maximum oxygen intakes of 2,5 litres/min or above (the minimum requirement for such tasks as shovelling rocks and tramming it). The samples of the different tribes differ in age, but when the age effect is taken into account then there were no significant differences between tribes in maximum oxygen intakes. An incidental finding was that both age and body weight correlated significantly with the maximum oxygen intakes of these underweight subjects. Not one of the subjects who weighed less than 45 kg or who was older than 40 years had maximum oxygen intakes high enough to permit their being able to do strenuous work underground. It is clear therefore that Bantu who weigh less than 45 kg or are older than 40 years should not be employed on such strenuous tasks as shovelling rock and tramming it.

By P. S. Turner

After a brief account of the differences between the control of underground fires and those on the surface, the paper describes the analogue detection system used on the mines of the Anglo American Corporation of South Africa Limited. The system comprises Spanair gas analysers, Becon combustion-particle detectors, a telemetering system, a surface signal-recording and-processing system, and an alarm system. The use of the system is described and illustrated.

Jan 1, 1982

By M. M. Hajdasinski

The internal rate of return (IRR) is one of the most popular project evaluation criteria in the mineral industry, as well as in other industrial sectors. Analysis of its assumptions reveals, however, that this criterion does not function in the way it is supposed to. The search for a new criterion that would reflect the true rate of return (TRR) of an investment project or the true borrowing rate (TBR) of a borrowing project has led to the development of several approaches, yielding, for the same project, generally different values of the interest rate in question. Two of those approaches have been selected as the most representative and practical. Each has been presented in two variants, and subsequently analysed. As a result, it is shown that the various approaches to the TRR/TBR are all consistent with the net present value (NPV) criterion, and that each can serve as an independent project evaluation instrument, provided its assumptions can be regarded in a given situation as realistic enough.

Jan 1, 1987

By H. Edinger

China?s engagement with the African continent has increased impressively in the past decade. Even though China is not the African continent?s largest stakeholder, the rapidly increasing engagement is evident in the huge number of Chinese migrants that have come to Africa in the wake of unprecedented trade and investment levels, as well as in increasing diplomatic and political interactions, which has taken most other commercial partners by surprise. All but four countries in Africa have adopted the ?One China?1 policy stance; and in so doing opened the door for new or strengthened commercial dealings with China, including increasing investments into Africa?s extractive industries. This has been particularly evident since the turn of the century, with a clear shift in China?s policy towards Africa elevating the continent in China?s foreign policy objectives. As such, Africa has become a strategic focus2 for Chinese outward bound and internationalizing companies, especially in the extractive industries. This planned shift in focus is based largely on geo-strategic and commercial needs and interests, rather than previous ideological ones.3

Jan 1, 2011

By C. A. Snyders

The research presented in this paper investigated the practical aspects of the recovery of platinum group metals (PGMs) from a dilute cyanide leach solution containing base metals, in a manner similar to that used for gold extraction in a typical CIP process, and focuses on both the adsorption and elution stages. The carrier-phase extraction of precious metals using activated carbon offers significant advantages over other processes in terms of simplicity, the high pre-concentration factor, rapid phase separation, and relatively low capital and operating costs. As a sorbent, activated carbon is still by far the most important material because of its large surface area, high adsorption capacity, porous structure, negligible environmental toxicity, low cost, and high purity standards. Adsorption tests were conducted on a pregnant alkaline leach solution (0.15 ppm Pt, 0.38 ppm Pd, 0.1 ppm Au) resulting from cyanide extraction performed in column leach tests. The initial adsorption rates of Pt, Pd, and Au were very fast and recoveries of these three metals were approximately 90 per cent after 2 hours, and 100 per cent for Pt, 97.4 per cent for Pd, and 99.9 per cent for Au after 72 hours. The parameters that influence the extraction of PGMs and Au were examined to assess their relative importance during the adsorption process in order to provide the basis for process optimization. The concentration of thiocyanate was not identified as significant factor for PGMs adsorption, while Ni concentration was the most significant extraction process parameter. Base metal cyanide complexes adsorb and compete with the PGM complexes for sites on activated carbon, and while copper adsorption can be minimized by adjusting the residence time, Ni adsorbs at approximately the same rate as the PGMs, influencing the loading capacity and adsorption kinetics of the PGMs. The feasibility of eluting platinum and palladium cyanide complexes from activated carbon using an analogue of the AARL process was investigated. Platinum and palladium elute from activated carbon almost to completion in 4 to 5 bed volumes at 80°C, while the elution of gold at this temperature is slow, with a significant amount of gold still to be eluted after 16 bed volumes. The equilibrium loading of gold is exothermic in nature (Fleming and Nicol, 1984) which will result in an increase in gold elution kinetics with an increase in temperature at similar pre-treatment conditions. A similar result was found for the elution of Pt and Pd. Cyanide pre-treatment was found to have a significant influence on PGM elution. Higher cyanide concentration in the pre-treatment step results in more efficient elution up to a point, and results suggest the possibility of an optimum cyanide concentration, beyond which elution efficiency starts decreasing due to increased ionic strength.

Jan 1, 2013

By J. E. Robinson, W. Pilkington, J. L. Taylor, B. J. Bluhm, E. B. Viljoen, P. Le Grange

The Chemwes uranium plant was designed and constructed within fifteen months; commissioning started during. June 1979, and the plant was producing at design capacity four months later. This account highlights the procedures and methods adopted to bring the plant Into production. The description of the various phases includes some details of the early evaluation, and the feasibility and optimization studies; of the financing, project management, design, construction, and commissioning of the plant; and of the training of personnel. Some of the mistakes made and the factors that contributed to the success are also listed.

Jan 1, 1981

By T. Aoki, Y. Maeno, R. Kawano, F. Nakahara, Y. Obara, K. Shibata

The mechanical behaviors of fully-grouted long-embedded cablebolts actually used in situ are very non-linear in pull tests and are different from those of short-embedded cablebolts. We have conducted the pull tests of long-embedded cablebolts installed in mockup rock test blocks, which are 4m in the longitudinal length. In order to investigate the mechanical behaviors inside the test block, the axial load distribution along the cablebolt and locations of acoustic emission events were measured during each pull test. It was found that the axial force distributions were quite linear and that the gradients were interpreted as the grout bond strength by taking into consideration the stress balance at the infinitesimal segment of a cablebolt. Les boulons-câbles longs entièrement cimentés qui sont réellement utilisés sur place présentent, au cours des essais de traction, des comportements mécaniques considérablement non linéaires et différents de ceux des boulons-câbles courts. Nous avons mené des essais de traction des boulons-câbles longs installés dans une maquette de fond rocheux servant d’éprouvette d’une longueur longitudinale de 4 m. Afin d’étudier les comportements mécaniques intérieurs de l’éprouvette, la répartition de la force axiale du boulon-câble et l’émission acoustique ont été mesurées durant chaque essai de traction. Il s’est avéré que les répartitions de la force axiale sont sensiblement linéaires et que leurs gradients représentent la résistance d’adhésion en prenant en compte l’équilibre de contraintes à la partie infinitésimale d’un boulon-câble. Das mechanische Verhalten von ganz eingegossenen, lang eingebetteten Kabelbolzen, die vor Ort eingesetzt werden, ist bei Zugprüfungen sehr nichtlinear und anders als das von kurz eingebetteten Kabelbolzen. Es wurden Zugprüfungen mit lang eingebetteten Kabelbolzen durchgeführt, die in Prüfblöcken (Gesteinsattrappen) mit 4 m Länge eingelassen waren. Zur Untersuchung des mechanischen Verhaltens in den Prüfblöcken wurden die Axiallastverteilung entlang des Kabelbolzens sowie das Auftreten von Schallemission im Verlauf jeder Zugprüfung gemessen. Es ergab sich, dass die axiale Kraftverteilung recht linear ist, und die Gradienten wurden unter Berücksichtigung des Kräftegleichgewichts am infinitesimal kleinen Punkt eines Kabelbolzens als Haftfestigkeit interpretiert.

Jan 1, 2003

By N Morales, G Nelis

Short-term plans must meet the long-term goals while accounting for shovel selectivity, operational space, and scheduling restrictions. There are several approaches that deal with these issues to deliver a feasible short-term schedule. This paper compares two approaches based on mathematical programming to address the short-term mining cut definition and scheduling in an integrated way. They work by scheduling extraction to comply with long-term production goals, but they differ in how mining cuts are modelled. The first approach schedules Selective Mining Units (SMUs) but aggregates them around predefined locations. The second approach does not work on SMUs; it decides directly what mining cuts are to be used from a pre-defined set of shapes. It assigns a destination and schedules the extraction for the selected mining cuts. We applied both approaches in a real case study to compare their results in terms of profit, mining cut design, expertise needed, profit, and optimisation performance.

Sep 1, 2021

By A. Karadogan

Decision making can be defined as the selection process of the best routes from the alternatives in order to achieve a goal, and mostly involves uncertainty. Additionally, mostly qualitative variables (weak rock, massive ore deposit, etc.) are in question. Mine planning engineers often use their intuition and experience indecision making. As fuzzy set theory has been used since 1970, these uncertainties are easily evaluated in the decision-making process. Real world study is decision making under vague constraints of different importance, involving uncertain data (qualitative variables), where compromises between antagonistic criteria are allowed. This paper presents a new approach in the selection of an underground mining method based on fuzzy set theory for the Ciftalan Lignite Site located close to Istanbul in Turkey. The physical parameters such as geology and the geotechnical properties of ore, hanging and foot wall, economic effects, environmental effects, are established with field and laboratory tests together with the determination of other qualitative variables. Meanwhile, some qualitative variables dealing with the matter was described according to the view of a number of experts. Then fuzzy set theory is applied to these parameters, considering the available underground methods in order to choose the proper method. At the end of the evaluations, the room and pillar method with filling was determined as the most suitable method for the test site. Keywords: Decision making, fuzzy set theory, underground, mining, method selection

Jan 1, 2008

By H. F. Fuls

Skorpion Zinc, an integrated zinc mine and refinery located in the south of Namibia, has a production capacity of 150 000 t/a of special high grade (SHG) zinc. The Skorpion zinc oxide resource will be depleted by 2017. Extensive exploration drilling for additional zinc oxides was conducted without success. With the abundant availability of zinc sulphide concentrates regionally (Black Mountain and Gamsberg in the Northern Cape or Rosh Pinah Zinc and new deposits in the Rosh Pinah region) the life of the operation can be extended by processing of zinc sulphide concentrates. The leach kinetics of zinc sulphides is vastly slower than for oxides, preventing the processing of zinc sulphides in the existing process under current conditions, and Skorpion Zinc faces the challenge to identify a suitable zinc sulphide treatment process that can be integrated with the existing plant. Various zinc sulphide processing options were identified through an extensive literature search and non-viable options were eliminated. Mass and energy balances were established for potential options and an economic evaluation (including capital and operating cost estimation) was conducted to identify a suitable process. It is concluded that ferric leaching of sphalerite in a sulphate medium under atmospheric or pressure leach conditions are suitable processes for Skorpion Zinc. These processes present advantages over all other zinc processing options when elemental sulphur is preferred as the final deportment for sulphide sulphur. Both these processes can be integrated into the existing refinery and will be able to process concentrates with a wide composition range.

Jan 1, 2013