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By M. Matabane, T. Khati

"Accurate delineation of the contact between a kimberlite pipe and country rock at production level depths is a challenge due to limited geological data. Geological information is obtained from widely spaced diamond core boreholes which are drilled either from surface or from higher mining levels within the pipe. Kimberlite pipe/country rock contacts are notoriously irregular and variable, further reducing the confidence in contact positions defined by the drill-holes. At Finsch Diamond Mine (FDM), the opportunity arose to further improve the confidence in the contact positions relative to the planned slot (end) positions of each sublevel cave tunnel during the development stage of these tunnels. As a result, the accuracy of the 3D geological model has improved.The use of diamond drill core for this purpose is expensive due to site establishment requirements. The lengthy time taken during site establishment also delays the development of tunnels and support cycles, thereby extending the completion dates. FDM has reduced delays during development by adopting percussion drilling, in conjunction with gamma ray logging. The S36 drill rig is mounted on a moveable platform and does not require a costly and lengthy site establishment. The holes are generally drilled (0°/flat) on grade elevation, and these holes could also be drilled from the rim tunnels (developed in waste) into the kimberlite pipe. A single-boom production drill rig is normally used to drill holes about 20 m in length.On completion of the contact delineation drilling, gamma logging of the holes is conducted using the GeoVista geophysical sonde (or probe) to log the natural gamma signature of the dolomite/ kimberlite contact. The advantage of this tool is that the readings are continuous within centimetre intervals, and due to contrasting characteristics between kimberlite (rich in clay minerals) and dolomite, the contact position can be determined accurately. The better definition of contact positions also adds value to tunnel stopping distance in terms of developing the tunnel’s slot at the optimum distance from the contact (easier blasting of longhole rings, avoidance of contact overbreak and premature waste ingress, and other matters relating to extraction of ore from these tunnels). This method is highly successful and has reduced development costs (on-time completion), improved definition of the pipe’s contact position for geological modelling, improved blast design, and mitigated early waste ingress by maintaining the contact’s integrity."

Feb 1, 2019

By R. Zivojinovic, S. Vujic, T. Tanaskovic

The problem of determining the optimum exploitation life of machinery, namely the optimum time for machinery and equipment replacement, represents a complex and highly responsible engineering task. Taking into consideration the situation prevailing at coal pit mines in Yugoslavia, the tasks of this class are very complex and difficult. To make a decision on replacement of capital equipment and machinery, such as bucket wheel excavators within the mentioned systems, understands a management task of utmost responsibility. It requires high professional and analytical knowledge as well as the reliable arguments, based on multidisciplinary professional approach. In this paper, the authors present their views on the problem of establishing the optimum exploitation life of bucket wheel excavators, offering an algorithm, based on dynamic programming, as a solution. Keywords: Bucket wheel excavators, exploitation life of machinery, optimization, operations research, theory of replacement, dynamic programming

Jan 1, 2003

By M. Magnelöv, Du Sichen, U. Sjöström

An experimental study has been performed to investigate the behaviour and separation of inclusions at the interface between steel and slag. The study has been limited to liquid inclusions because they can be a potential problem in transient situations such as ladle changes in continuous casting of steel. Model experiments with water and silicon oils have been carried out to study the kinetics of separation of simulated inclusions at an interface. The properties of the inclusions and the slags have been varied by using different oils with different viscosities, densities and surface tensions. The effect of temperature of the liquids has also been examined. Measurements of the terminal velocity, rest time and the behaviour of the liquid inclusions at the interface have been recorded using a video camera. It has been found that the inclusions reach their terminal velocity early in the vessel and the experimental velocities differ somewhat from the values evaluated using ?intermediate law?. The results from the experiments have shown that the size of the inclusions has no appreciable influence on the rest time. Droplets of AK50 oil have been found to have considerably long rest time. A water film surrounding the droplet has been expected to be the main reason for the long rest time. The present study has also shown that the viscosity of the oil has certain effect on the rest time, but only to some extent, since viscosity has double functions. A higher viscosity provides higher resistance to the droplet entering the oil phase leading to longer rest time and at the same time damps the lateral movement of the droplet along the interface, leading to easier stabilization and shorter rest time. On the other hand, a high viscosity of the oil phase results in slow dissolution process. It has been concluded that a meaningful model of inclusion separation at the metal-slag interface must take the interfacial phenomena into consideration. Keywords: Inclusions, terminal velocity, rest time, dissolution.

Jan 1, 2004

By K. Ding

The thermodynamic activity of MnO was measured in MnO-CaO-MgO-SiO2slags that are typically encountered in the production of manganese containing stainless steels. Gas equilibration-quenching technique was employed in measuring the activities. Activity of Mn in Pt-Mn alloys were redetermined at 1600°C which reconfirmed earlier results of strong negative deviations. MnO activities were then measured by equilibrating slags of various compositions based on a statistical experimental design procedure with Pt-Mn alloys under controlled partial pressure of oxygen in MnO saturated platinum crucibles at 1600°C. Activities of MnO were found to increase with increasing concentration of MnO, basicity and CaO to MgO ratio. Two multi-coefficient repression models were developed to predict the activities and activity coefficients of MnO in slags at 1600°C. Keywords: activity, MnO, slag.

Jan 1, 2004

By P. Gonzalez, C. Ariyo, L. Holappa

Oxidation state of titanium was determined in CaO-SiO2-TiOxslags in the composition range25–53 per cent CaO, 27–46 per cent SiO2, 10–55 per cent TiOxat 1873K using gas equilibration method. In the experiments, slags with different titanium oxide contents were equilibrated with a known carbon monoxide and carbon dioxide ratio. The results were used to determine the Ti3+and Ti4+contents as well as the activity coefficient ratio of corresponding oxides in the slag. The dependency of the activity coefficient ratio as a function of oxygen partial pressure was determined. Keywords: titanium, titanium oxide, activity, activity coefficient, slag iron, carbon monoxide,carbon doixide, gas, equilibrium.

Jan 1, 2004

By S. Pal, A. K. Lahiri

Most of the compounds present in slag are surface active. This gives rise to foaminess of slag. The foam life and foaming index are normally determined by the draining rate of slag through the plateau border, so the foaming index is directly proportional to slag viscosity and inversely proportional to slag density and bubble diameter. When a small amount of a strong surface active compound like P2O5or Cr2O3is present in slag, however, the foam life increases significantly and the above relationship is not obeyed. The strong surface active compounds reduce the draining rate from the film between the adjacent bubbles so the film draining controls the life of the foam. The thickness of the film, Marangoni force, viscosity of the slag, and diffusion of surface active compounds determine the film draining rate. The interplay of these factors leads to very low or high film draining rates and affects the film and foam stability significantly. Keywords: slag, foam, foaming index, film draining

Jan 1, 2004

By L. Chen, G. A. Brooks, S. A. Nightingale

The dissolution of alumina and magnesia has been investigated using laser scanning confocal microscopy (alumina) and a rotating finger apparatus (magnesia) to assess the effects of temperature, composition and forced convection on the rate of dissolution in CaO-SiO2-Al2O3based slags. The two techniques have differing strengths and limitations, and provide complementary methods for studying dissolution. Alumina dissolution was studied for temperatures from 1477 to 1577°C. Based upon the data, the rate controlling mechanism was thought to be mass transfer control in the slag. The diffusion coefficients for the alumina particles are estimated to be in the range 10-11to 10-10m2.s. MgO degradation for sample rotation speeds of 50 to 800 rpm at 1500 and 1530°C was studied for both congruent and incongruent dissolution. The results show that the rate of dissolution for this is primarily controlled by a diffusion mass transfer mechanism for congruent dissolution except at the highest rotation speed. For incongruent dissolution, the mechanism is much more complex, with the morphology and distribution of the spinel reaction product having a significant effect. At high speeds and prolonged times, mechanical forces played a major role in the degradation process. Keywords; kinetics, corrosion, refractories, dissolution rate, inclusions, mass transfer, slags, steelmaking

Jan 1, 2004

By S. R. Sankaranarayanan, T. Sowmya

Slags and fluxes used in metallurgical processes are typically made up of oxides (especially silicates), with additions of fluoride and carbonaceous matter. Despite the efforts made towards understanding the role of slags in various processes, little information is available on the structure of these slags. Tools such as X-ray diffraction, spectroscopy, and electron microscopy could be used for this purpose. This paper is based on an ongoing spectroscopic and structural investigation of slags and related materials. Spectroscopic studies of various commercial slags (predominantly ferrous), ores, glass and related materials, covering a wide range of compositions, have been carried out to understand the structure. The infrared spectra were recorded, predominantly, using FTIR spectrometer (Bruker IFS 66U) spanning 4000 to 100 cm-1using the KBr pellet method. The resolution was typically 4 cm-1. The spectral outputs have been compiled in terms of bands present (corresponding to different bonds) and then compared with the typical bands expected for such bonds. Efforts are in progress to identify the trends with respect to the chemical composition?for example, the effects of SiO2, Al2O3, and non-bridging oxygens. Data obtained so far indicate some trends such as (i) a shift in the Si-O band (969 to 1099 cm-1) towards a higher wave number with increasing silica content (almost 2 to 92 weight percentage) and (ii) further strong shifts as a function of the alumina content. These are being further investigated structurally and in terms of chemical composition/parameters. Keywords: slags, silicates, structure, spectroscopic analysis, shifting of bands

Jan 1, 2004

By Janet M. Epps

The international climate regulating environmental management in mining is rapidly evolving through the combined influences of the development of international guidelines, resolutions, protocols, treaties and conventions; the influences of the international lending and aid institutions who seek a consistent but constantly evolving standard of environmental performance from their clients; the legal precedents being developed in courts al over the world; and the activities of multinational countries who tend to rapidly upgrade technological performance through their international activities (particularly influencing developing countries). In this rapidly evolving regulatory environment, the more 'models' available to this international pool of resource materials that demonstrate practical. cost-effective and (most desirably) incentive based regulatory mechanisms, the better will be the eventual body of 'international standards' we will al have to work with. Australia can make a significant contribution to this process, however, it has only been on the margin of this dynamic, North American and European led process, up to this time. It is in the Australian minerals and energy industry's best interest to take an active part in the evolution and direction of this process.

Jan 1, 1996

By T. Tamenti

The purpose of the project was to conduct a feasibility study to determine if the current operating bottom dump trucks that haul coal should be replaced with rear dump trucks. The engineering availability of the bottom dump trucks was lower than targeted while the operating costs are the highest of all coal haulers within the Anglo Coal opencasts. To determine if it is feasible to replace the current bottom dump trucks with rear dump trucks, a production profile simulation was conducted to determine the number of rear dump trucks that would be required to meet the annual coal hauling requirements. The total capital and operating costs of these rear dump trucks were also determined using a total cost of ownership model. These were compared with the current costs of the bottom dump trucks to determine if it is financially feasible to replace the bottom dump trucks with rear dump trucks. Having considered the capital outlay that would be required to replace the bottom dump trucks with rear dump trucks as well as their respective operating costs, it was concluded that the current bottom dump trucks should be replaced with rear dump trucks. Other factors were considered in coming to this conclusion.

Jan 1, 2007

By E. R. Davis, R. J. Knott

The paper discusses some of the tools of management in the field of project control, especially in engineering. Project control includes planning and cost engineering, and involves various phases: the conceptual Design and Planning Phase, the Definitive Design and Capital Budgeting Phase, and the Implementation Phase. Each of these phases is discussed in in, together with the use that can be made of data banks, progress reports, and computer systems.

Jan 1, 1982

By A. J. Van Der Merwe, J. F. Erasmus

One of the valuation approaches applied to Advanced Exploration Areas and Pre-Development Projects is the so-called ?in situ Mineralization Method? or the ?Yardstick Method?. This method is based on the concept of a known undeveloped Mineral Resource being worth a certain fraction (the ?Yardstick?) of the contained commodity value (?metal in ground?), using commodity prices ruling at the date of valuation. The Yardstick value is derived usually from an average market-based figure obtained from an analysis of recent transactions and is expressed as a monetary value per ounce or per tonne. It maybe modified to accommodate the quality (e.g. grade) and category (e.g. confidence level) of the Mineral Resource/Reserve involved and the time, effort and expenditure expected to be involved in bringing the project to fruition. Some eighteen recent and relevant transactions were analysed, allowing the following general conclusions to be reached: ? a Yardstick with which to value undeveloped PGE mineral resources is likely to range between 0.5% and 2.5% of the in-ground contained metal value ? the expected method of mining (especially with regard to mining costs) and the grade of the mineralization both have a strong influence on the Yardstick ? the status (classification) of the Mineral Resource has some influence on the Yardstick and ? the ruling price of platinum and the regional location of the deposit appear to have insignificant influences on the Yardstick.

Jan 1, 2006

By C. Wade, A. Swart, M. Dworzanowski

AngloGold Ashanti operate a pyrite flotation plant at their East Gold Plant, Acid Plant and Flotation Plant (EGAF) metallurgical complex within their Vaal River operations in the North West province in South Africa. The flotation plant feed is reclaimed pyrite rich tailings and the concentrate produced is used as the source of sulphur for the EGAF acid plant. The sulphuric acid produced is in turn used for the recovery of uranium at the Vaal River South uranium plant. The original flotation plant built in 1960 was based on the use of many small volume flotation cells and was becoming very expensive to operate and its age severely limited further operation. A decision was taken in 2005 to replace this plant with a new one based on fewer, larger volume flotation cells. This paper describes the benefits of using larger volume flotation cells in this new flotation plant when compared to the smaller volume flotation cells in the old plant. The benefits of the new plant include a smaller plant footprint, fewer flotation cells, fewer pumps, no distribution boxes, simpler piping, a greater flotation volume and a reduction in installed power. The saving in capital cost could not be quantified because of the age of the old plant. The savings in operating cost will arise from fewer operators, less maintenance and reduced power consumption. The new plant has not been in operation long enough to quantify the benefits in operating cost and metallurgical performance. However, recovery improvements can be expected given the greater flotation volume (increased residence time) and the installation of larger, more efficient flotation cells.

Jan 1, 2007

By B. E. Ydstie, B. F. Lund, K. R. Løvåsen, B. A. Foss

The paper presents sensitivity analysis for a dynamic model of submerged arc silicon furnaces. The model we study, called ?Simod?, was developed by Elkem in cooperation with NTNU and Sintef. It is today a much used tool in Elkem for operator training and analysis of the dynamic behaviour of the silicon production process. The aim of our work is to bring the simulator tool closer to industrial practice, and construct a mechanism to adapt the model to the behaviour of a running process, online. The paper presents the results of the sensitivity analysis that has been undertaken for important parameters in the Simod model. The parameters associated with the process inputs are electric power loss, loss of fixed C and reactivity of carbon. The output signals that have been investigated are fed quartz, tapped silicon and silica. The paper also interprets the results of the sensitivity analysis in a process operation context.

Jan 1, 2004

By Y. Zhen, N. Topliffe, G. Shou

The typical service life for a long distance slurry pipeline is15 to 25 years. Determination of wear rate for a pipeline could have a high economic impact on the pipeline project. Wear is a combination of chemical corrosion and mechanical abrasion. The contribution of each factor has to be determined project by project. Normally, chemical corrosion dominates the pipe wear in fine slurry pipelines. These pipelines have been designed with a velocity between 1.5 m/s and 2.5 m/s. Solids are suspended with high homogeneity across the pipeline section. Bottom wear is not much greater than the top wear and not sensitive to velocity. The wear pattern in the pipeline transporting medium coarse solids, such as milled ore and tailings, is different. Wear concentrates on the bottom of pipeline and the outer bends, and is more sensitive to flow velocity. Wear distribution along the pipelines is similar.

Jan 1, 2007

By T. Tamenti

The purpose of the project was to conduct a feasibility study to determine if the current operating bottom dump trucks that haul coal should be replaced with rear dump trucks. The engineering availability of the bottom dump trucks was lower than targeted while the operating costs are the highest of all coal haulers within the Anglo Coal opencasts. To determine if it is feasible to replace the current bottom dump trucks with rear dump trucks, a production profile simulation was conducted to determine the number of rear dump trucks that would be required to meet the annual coal hauling requirements. The total capital and operating costs of these rear dump trucks were also determined using a total cost of ownership model. These were compared with the current costs of the bottom dump trucks to determine if it is financially feasible to replace the bottom dump trucks with rear dump trucks. Having considered the capital outlay that would be required to replace the bottom dump trucks with rear dump trucks as well as their respective operating costs, it was concluded that the current bottom dump trucks should be replaced with rear dump trucks. Other factors were considered in coming to this conclusion.

Jan 1, 2007

By L. Jeffrey

The Waterberg Coalfield has vast potential to become a significantmining and industrial centre in South Africa. Its future developmenthinges on a number of critical decisions that must be made jointly by government, power utilities and industry, and on some technical and economic challenges that must initially be overcome. Sufficient water is the primary key to enabling exploitation, together with an adequate market for the large volumes of low-grade coal. As the most likely consumer of this coal will be either a power station or a petrochemical complex, the need for additional energy will be a driving force in the development of this coalfield. Conventional mining methods can exploit the shallow coal resources in both the Grootegeluk and the Vryheid formations, but alternative technologies such as coalbed methane extraction and underground coal gasification are the only currently known technologies that may be able to exploit the deep Grootegeluk Formation resources. However, extensive research is still required into these procedures, particularly with respect to the Waterberg coals. Transport infrastructure to the region is currently not sufficiently well developed to support large-scale exploitation of the region?s coal resources. In particular, the railway line would have to be extensively upgraded to allow the increased export of coal. Alternative transport methods such as pipelines would also have to be pursued to serve a large Sasol-type petrochemical complex or coal gas extraction. The road network would also require improvement, as only the roads between the main commercial centres are currently tarred. Dr Con Fauconnier, Kumba CEO, concluded his presentation to the Investing in African Mining Conference 2004 with the words: Again, it?s all about infrastructure? when it?s there, it enables the development of bulk mining projects which attract the resultant economic benefits for the region and country as a whole. These words aptly sum up one of the stumbling blocks to the future development of the Waterberg Coalfield.

Jan 1, 2005

By P. de A. Barbosa, M. G. Bergerman, E. da Fonseca

Located in the state of Pará, Brazil, the Sossego copper and gold mine consists of a heterogeneous geological deposit. Its complexity derives from the hydrothermal alteration, the ore-forming event, which modified the host rocks, such as granite, and metamorphosed volcanic rocks into several mineral assemblages. Different mineral assemblages have led to differences in abrasiveness. A few Bond abrasion tests conducted during the mine feasibility study did not provide a robust abrasiveness database, thus the variation of physical properties for some mineralisation host rocks was not possible. Although several test methods may be used to determine ore abrasiveness, the Bond method is the one most commonly used in the mining industry. Despite being simple to carry out, this test method has certain limitations as to particle size and the amount of ore sample required, which often makes it difficult or even impossible to apply in the early stages of a project and in geometallurgical studies. The Laboratoire Central des Ponts et Chaussées (LCPC) test may provide an alternative, as it requires a smaller amount of fine-grained material. This study aimed to provide data on wear properties of various ore types from Sossego mine using the LCPC method. It included validation for 40 different ore samples using the Bond test as a benchmark. The results showed good correlation, indicating it may be possible to use the LCPC test as an alternative to the Bond abrasion test. A high abrasiveness index was found for acid metavolcanic rock, confirming the results observed in Sossego mill’s operating database, pointing to a mineralogical drive to amorphous quartz. Keywords: Abrasiveness, geometallurgy, copper ore, Bond abrasion test, LCPC

Jan 1, 2020

By J. Lehmann, H. Gaye

A brief review of Computational Thermodynamics software concerning the modeling and prediction of reactions involving metals, slags and fluxes is presented. Their application for various steelmaking treatments is discussed. Examples concern phosphorus removal in BOF and EAF, ladle steel desulfurization, and specific treatments for inclusions control in semi-killed or Al-killed carbon and stainless steels.

By C. B. Espag de Klerk, J. de Goede, M. Le Roux, Q. P. Campbell

"Excessive amounts of moisture in product coal can influence the efficiency of downstream utilization processes due to a decreased calorific value and handling problems. Stockpiles can be used to decrease the moisture content of coal by means of gravity drainage and evaporation. This paper is focused on the evaporation of moisture from a coal stockpile surface with the aim of investigating the effect of particle size on the rate of evaporation as well as the depth to which evaporation extends.It was observed that moisture initially evaporates at a higher rate from a stockpile consisting of fine particles (-6.7 mm) than from coarser particles (-13.2 mm +6.7 mm). This high rate of evaporation is restricted to the outer shell of the fine coal stockpile. However, for coarse coal, the porous nature increases the depth at which evaporation occurs. Evaporation of moisture was observed up to the fourth day of each experimental run, after which steady state was obtained. It was shown the water can evaporate from the surface into the body of the stockpile, depending on the coal particle size and void spacing. An experimental reclaim depth of 0.4 m was achieved after 4 days. IntroductionCoal stockpiles serve as surge capacity for downstream utilization processes and can also be used for moisture reduction by means of gravity drainage and evaporation. Excessive amounts of moisture in coal can cause handling problems and, most importantly, will decrease the calorific value, leading to inefficient combustion.Research has shown that evaporation by means of wind and solar action is considerably more effective than gravity drainage(Williams, D.J. 2006), but the effect is limited to a restricted depth from the exterior of the stockpile (Boyapati, E. and Oates, A. 1994; CSEM-UAE, 2010). The effectiveness of wind and solar action can be improved by orienting the stockpile perpendicular to the predominant wind direction, maximizing the surface area of the pile, and reclaiming the coal from the pile gradually in shallow cuts over a large area (Williams, D.J. 2006)."

Jan 1, 2016