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By F. T. Cawood, M. N. M. Cudjoe

The ability to conduct real-time material tracking in mines has been a long-standing challenge. Technological innovations such as radio frequency identification technology (RFID) have over the years contributed to the effective tracking of material flow and reporting of metal content. This paper outlines the laboratory procedures and results from testing the suitability of microdot technology as a viable technique for real-time material tracking in mining. The paper clarifies the reasons for conducting the test and presents the material safety data sheet (MSDS) from a South African and Canadian perspective. Microdots from three aerosol systems were immersed in water, heated to 100°C, and crushed into coarse and fine material. These tests were used to ascertain if the technology could withstand mining conditions. A strength, weakness, opportunity, and threat (SWOT) analysis was used to evaluate and compare microdot technology with RFID. It was shown that microdot technology has some potential to track ore parcels because data integrity was retained after exposure to post-blast mining conditions. However, more improvement is required to digitally detect microdots before the technology can be implemented at scale in the mining industry.

Apr 2, 2022

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 P. Muthaphuli

Kumba Iron Ore?s Zandrivierspoort (ZRP) magnetite-haematite project aims to mine and beneficiate a magnetite resource with low contaminant levels to produce from 1 Mt/a to 2.5 Mt/a product, which will be either a concentrate, micro-pellets for direct reduction, or blast furnace pellets. Anglo American Technical Solutions Research conducted a number of piloting campaigns to validate the process design flow sheet, demonstrate process performance, and to generate data for use as a design basis. Secondary to this, the pilot plant was to produce approximately 7 t of magnetite-haematite concentrate with low enough SiO2 to be used as feedstock for pelletizing studies. The pilot plant achieved 34.2% mass yield, at 69.0% Fe, 2.2% SiO2, from an IsaMill grind of 80% -45 µm. This product quality will compare favourably to other leading direct reduction (DR) pelletizing concentrates. However, two-stage comminution to 80% -75 µm and beneficiation of ZRP ore will produce a blast furnace (BF) quality pelletizing concentrate, indicative quality being 67.6% Fe and 4% SiO2, at higher mass yields. An economic evaluation between producing a DR and a BF pelletizing concentrate will have to be conducted prior to finalizing the concentrate production flow sheet..

Jan 1, 2014

By B. G. Meyburgh

SYNOPSIS As a result of a test programme over a period of approximately ten years and a decision to extend the uranium plant, it was decided to design and erect the first full-scale Purlex Plant in the Republic of South Africa. The plant at Buffelsfontein G.M. Co. Ltd. was commissioned in August, 1968, and to date has produced results superior to those predicted in the original estimates. The capital expenditure was R678 000 for a plant capable of treating 1 600 gallons per minute of pregnant solution. Compared with the conventional resin ion exchange process, it has been found that the saving in production costs is 21 cents per pound U3O8 produced. The amine loss is 10 parts per million, which is equivalent to a total organic loss of 250 parts per million. The uranium loss in the raffinate is less than 0.001 g/l U3O8. The final product is of a high quality and it is probable that it is pure enough to convert to the fluoride directly.

By H. J. Swanepoel, N. B. Strydom

Groups of up to twelve new recruits to the industry were subjected to climatic room acclimatization for either five, seven, eight or nine days prior to being tested for the degree to which they had been acclimatized. These tests were done at 32,2 0C (wet bulb) at a wind velocity of about 0,4 m/sec and the men worked for four hours at a rate of 215,6 kg m/min on one day and at a rate of 431,2 kg m/min on the second day. The results indicated that there is no significant difference between the degrees of acclimatization obtained by the eight- and nineday procedures which confirms the conculsions drawn in a previous report1. The eight-day procedure can thus be claimed to be perfectly adequate and safe. Decreasing the period of exposure to five or seven days would however, not be justified because of the significant differences in physiological responses that were observed on both test days between men acclimatized for these periods and those acclimatized for nine days. It is concluded that it would be unsafe to employ these shorter periods of acclimatization when underground environmental temperatures at which the men are to work, exceed 31 0C (wet bulb).

Dr Andrew Cosgarea, Jr, Associate Director of Opera¬tions of the U.S. Mint, and Chairman of the Awards Committee of the International Precious Metals Institute, announced the IPMI award recipients for 1985. The awards were presented at the Institute's Annual Banquet in New York City on 11th June, 1985. The Distinguished Achievement Award was presented posthumously to Dr E.M. Savitsky, of the A.A. Baikow Institute of Metallurgy of the U.S.S.R., for a life-time career devoted to investigations on the properties of the platinum-group metals. Dr Savitsky investigated over 300 phase diagrams, which became the basis for the selection of alloys and the prediction of properties. He published over 300 technical papers during his career. Dr Savitsky died during the summer of 1984 while being considered for the IPMI Award. The Engelhard Henry J. Albert Award was presented to Dr Stephen J. Lippard, Professor of Chemistry, MIT, in recognition of his research contributions in platinum chemistry and its application to nucleic acids. This prize

Jan 1, 1985

By Peter N. Calder, Alan Bauer

The complexity of modem open pit load-haul-dump systems is described, and the need for realistic working models is pointed out. Both standard and probabilistic simulation procedures are discussed, probabilistic simulation being indicated as the more powerful and practical technique. Acquisition of the necessary pit operating data required for simulator construction and general modelling procedures are described. Finally, results from a typical open pit simulator are used to indicate the scope of the technique.

Jan 1, 2014

By A. Navarra, A. Quelopana

The mine production scheduling problem (MPSP) has been studied since the 1960s, and remains an active area of computational research. In extending the concepts of the MPSP, the automated mine may now be regarded as a hierarchical intelligent agent in which the bottom layer consists of distributed robotic equipment, while strategic functionality occupies the higher layers. Here we present a disambiguation of artificial intelligence, machine learning, computational optimization, and automation within the mining context. Specifically, the Q-learning algorithm has been adapted to generate the initial solutions for a high-performing strategic mine planning algorithm, originally developed by Lamghari, Dimitrakopoulos and Ferland, based on the variable neighbourhood descent (VND) metaheuristic. The hierarchical intelligent agent is presented as an integrative conceptual platform, defining the interaction between our new Q-learning adaptation and Lamghari’s VND, and potentially other hierarchically controlled components of an artificially intelligent mine, having various degrees of automation. Sample computations involving Q-learning and VND are presented.

Dec 1, 2021

By M. Keevy, K. Hackney

Centrifugal slurry pump station and deposition sites are a common feature of many mines and mineral processing plants. Yanacocha Mine has completed the design of a pump station consisting of two trains of four pumps each. A number of trade-off studies was conducted to optimize the pump station design. The most significant of these was determining the drive types for the slurry pumps. The pump station duty can vary considerably due to the number of deposition points round the disposal site. The standard solution to this problem on a multi-stage pump train is to install one pump with a variable speed drive to control the pump station output by varying the speed of this pump and stopping and starting other stages. However, there are a number of negative impacts associated with this approach. These include head losses through pumps that are stationary or ?wind-milling?, different wear life on pumps that are running and pumps that are stationary, and slower response to the control system with the possibility of hunting. The use of variable speed drives on all the pumps was considered as an alternative to the standard solution. The factors considered in comparing these options were the control and operational differences, the pump efficiencies and absorbed power, the expected pump wear life, the impact on pump maintenance and the cost of the drive options. For this project the option of using all variable speed drives was selected. The paper presents the following aspects of the study: ?Description of the various options investigated. This includes a discussion on the required duty and the drive options. ?Technical comparison between the options. ?Description of the factors influencing pump performance and life.

Jan 1, 2007

1. Publications of the World Mining Congress Series A: Volume 5 World mining data '90. US$25. Series B: Volume 1 Chromite. US$31. 2. Randol publications The folowing publications are available from Randol International Ltd, P.D. Box 150632, Lakewood, CD80215, U.S.A.). Randol Gold Conference, Sacramento '89. 1990. 400 pp. $80. Randol mining directory 1990-1991. 1990. $100. Randol buyer's guide USA and Canada. 1990. $50. 3. New journal Industrial Metrology, edited by A. Choudry et al. Amsterdam, Elsevier Science Publishers, 1990. Dfl. 266 incl. postage for 4 issues per year. 4. Mintek reports The folowing reports are available from Mintek, Private Bag X3015, Randburg, 2125 South Africa. They are available at R35 (including GST) per copy to SouthAfrican addressees, and US$30 per copy (including airmail postage) to addressees elsewhere. Report M130D The application of a standard leaching procedure to tin-tungsten concentrates from Van Roois Vley deposit: Cross-cut bulk samples, by M.M. Fieberg and C.F.B. Coetzee. First issued 1984, reissued 1990. 11 pp. Report M160D The recovery of graphite from the Messina district, by R.N. Guest. First issued 1984, reissued 1990. 22 pp. Report M305D The beneficiation of nickel-copper ore from Uitkomst, by P.W. Dverbeek. First issued 1987, reissued 1990. 55 pp. Report M320D The flotation of pyrite from Bufe/sfontein Gold Mine, by A.M.R. Botelho de Sousa and V.E. Ross. First issued 1988, reissued 1990. Report M347D A utogenous miling of ore from the UG-2 Reef, by J.K.H. Lichter. First issued 1988, reissued 1990. 13 pp. Report M352D Fly ash as an adsorbent or precipitation agent in the removal of ionic species from solution, by C. Pohlandt-Watson, S.M. Graham, and K.F.G. Brackenbury. First issued 1988, reissued 1990. 9pp. Report M360D Beneficiation of limestone from Pienaars River, by R.N. Guest. First issued 1988, reissued 1990. 23 pp. Report M364D The recovery of gold from deposits in the Pilgrim's Rest area, by R.A. Burger. First issued 1988, reissued 1990. 15 pp. Report M396 Reduction of chromite spinels in iron-chromiumcarbon aloys, by R.H. Eric and E. Uslu. Mar. 1990. 33pp. 5. New review Diverless and deepwater technology. Advances in underwater technology, ocean science and ofshore engineering, edited by the Society for Underwater Technology. London, Graham & Trotman Limited, 1989.224 pp. £55.

Jan 1, 1990

By C. Montoya

This paper shows, through a case study, the impact of multivariate grade modelling upon mine design and mine planning. A deposit explored by drill holes is considered, in which the grades of five elements (copper, silver, molybdenum, arsenic, and antimony) are of interest. Forty alternative models of the deposit are constructed by fitting the joint correlation structure of the grade variables and using conditional cosimulation. In addition, a reference model, obtained by averaging the alternative models, is also considered. The study shows that the resulting mine design (final pit characteristics and production schedules) is sensitive to the grade model under consideration, and that the design based on the reference model may not be optimal when compared to the alternative models based on cosimulation. However, when assuming a given long-term plan and extraction sequence, the grades and net present value (NPV) calculated on the reference model are unbiased with respect to those calculated on the alternative models with the same extraction sequence. The latter allow assessing the possible dispersion of the actual grades and NPV around their expected values, and are useful for the planner in order to determine the probability of meeting given production targets and of exceeding or falling short of given threshold grades. Additionally, unlike cosimulation, the separate simulation of each grade variable leads to unrealistic resource models and to biased results in mine design and mine planning. This approach should therefore be avoided, unless the grade variables are spatially uncorrelated.

Jan 1, 2012

By M. Bester, R. Carey, T. Russell, J. van Heerden

"In order to reach the goal of optimal and safe extraction of the mineral reserve, the mining industry is increasingly focusing on reconciliation across the mining value chain to ensure that the mining process occurs in a progressively more predictable manner. This will consequently improve the understanding of mine plans and their associated implementation risks, ultimately leading to increased investor confidence. In terms of geotechnical engineering, mine to design performance assessment is a critical aspect of mine to plan adherence focusing on the complex aspects influencing slope performance. A mine to design reconciliation process therefore needs to systematically track implementation and geotechnical aspects in order to review or update slope design criteria and pit layouts according to the mine planning cycle as the mine is developed. This paper describes the development and implementation of a standardized mine to design reconciliation system for operations utilizing laser scanning technology, analysis tools, as well as associated key performance indicators. Performance is evaluated on final pit boundaries in terms of geometry achieved as well as blast performance evaluation of face conditions. These aspects as well as the resulting catch berm capacity should be captured in an information system, enabling longer term trend analysis and detailed root cause analysis where unsatisfactory outcomes occur. Adverse outcomes should subsequently be incorporated into the mine’s risk management process informing risk mitigation measures including blast design adjustments, slope design changes, or rockfall protection measures. IntroductionIn order to reach the goal of optimal and safe extraction of the mineral reserve, the mining industry is increasingly focusing on reconciliation across the mining value chain to ensure that the mining process occurs in a progressively more predictable manner. This will consequently improve the understanding of mine plans and their associated implementation risks, ultimately leading to increased investor confidence. In terms of geotechnical engineering, mine to design performance assessment is a critical aspect of mine to plan adherence focusing on the complex aspects influencing slope performance. A mine to design reconciliation process therefore needs to systematically track implementation and geotechnical aspects in order to review or update slope design criteria and pit layouts according to the mine planning cycle as the mine is developed."

Jan 1, 2016

By N. Sinclair

"In open pit dozer bulk push operations, the material left resting against the highwall after blasting poses an issue. This is because dozers cannot physically get in behind the waste to begin the bulk pushing process. Instead, an excavator can be used to side-cast this waste for the dozers to access. An alternative technique is to have the dozers ‘side-cut’ the material, which involves the dozers running parallel to the wall, digging out the material, and eventually rotating their blades to begin bulk pushing. Industry practices suggest the latter technique is less productive and economical than using an excavator. However, such excavator sidecasting ‘economic viability’ assumes that smaller/ancillary type excavators are used (i.e. less than 23 m3 bucket capacity). So, what happens if some mine sites are restricted to using relatively larger excavators (> 23 m3 bucket) that are preferred for higher priority digging tasks? When can they avoid using their excavator? This paper explores multiple scenarios that have been designed and developed to simulate data results, which identify conditions in which the dozer side-cutting technique becomes more economically viable than excavator side-casting in terms of decreased unit cost per loose cubic metre. IntroductionOptimizing the cost of waste removal operations is important for the profitability of opencast coal mines. In the past decade, dozer bulk pushing has emerged and taken over from traditional waste removal operations such as dragline and truck-and-shovel methods at various sites around the world (Beatty, 1994). In a typical bulk push operation, once the bench has been blasted, waste is left resting against the highwall, which can either be cleared using a loading unit or by having the dozers ‘side-cut’ the highwall.Dozers perform most effectively when slot dozing side-by-side, perpendicular to the highwall. However, when dozers are required to remove material off the highwall, they must push parallel to the highwall, rather than perpendicular, hence ‘side-cutting’ the material to ensure a clean face. While dozer sidecutting is possible, it has been found that the majority of mine sites use a loading unit in this situation to avoid dozer inefficiency. Other perceived issues with dozer side-cutting include higher maintenance requirements and safety risks to dozer operators working in close proximity to the highwall."

Jan 1, 2019

By G. C. Lindeque

"A downward trend in tyre life on haul trucks at an open pit iron ore mine prompted an investigation into the current tyre management strategy in order to improve tyre life. ‘Best practice’ was compared to the current tyre management strategy at the mine to determine aspects that could be improved. Aspects that showed significant room for improvement included employee tyre awareness, tyre pressure maintenance, and road conditions. For each of these aspects a plausible alternative was suggested.A new tyre management strategy was formulated as a step-by-step guide on how to implement the proposed changes. Each step introduces new initiatives but at the same time builds on the previous step’s success. A sensitivity analyses was performed to determine the impact of the proposed changes, with the variables being the reduction in the percentage of premature tyre failure, and the reduction of the site wear rate.The ‘most likely’ scenario showed an increase in tyre life of 41% for the Komatsu 730 trucks and 105% for the CAT 777 trucks if the entire tyre management model is implemented. This would result in a possible annual saving related to tyre usage of R9.2 million. OverviewThe study focused on the tyre life on the main haul fleet at an open pit iron ore mine. The haul fleet consisted of 17 Komatsu 730 (180 t) haul trucks and 12 CAT 777 (90 t) haul trucks.The haulage operation consists entirely of tyre-based haul trucks. Five per cent of the total mining budget is related to tyre costs. Since 2012 there has been a steady decrease in tyre life as measured in operating hours (Figure 1) due to the high percentage of tyres that fail prematurely. In 2014 a total of 41% of all tyres failed prematurely and 61% were classified as ‘worn out’."

Jan 1, 2016

By F. M. Ramadhan, M. R. Pratama

Monitoring open-pit mine road conditions has become very critical nowadays. There are several benefits to in conducting research on this field such as opportunity to improve truck’s speed which directly influences truck’s productivity. This research aims to provide a semi real-time, and sensors-based automatic road damage detector that predicts the road quality through road damage exact location tracing, road damages auto-classification, and real-time instruction in the form of work order format to mining road maintenance, and repair authorities through mobile apps and maintenance unit’s in-cabin display. It will also provide the maintenance/repair activity performance evaluation via integrated dashboards. The artificial neural network algorithm is applied during the process of data training regarding classifying road damages and severities which resulted in a valid model. The road damage classification model has a precision level of 80.5% in predicting whether the road is damaged or not. Using this approach, we are expecting to visualise a road quality map of all active roads on mine site.

Sep 1, 2021

By Z. Halifa, P. G. Geyer

Tapping a blast furnace is necessary not only to deliver the product, but is also essential for the safety of the furnace and workers in the cast-house. This paper will highlight the practices at ArcelorMittal’s blast furnaces in the Vanderbijlpark Works, with specific focus on tap-hole design and monitoring as well as casting practice. Extension of the tap-hole life and hearth campaign will be illustrated with reference to the methods of maintenance of the tap-holes, troughs, runners, and cast-house equipment. The importance of proper cooling, good thermocouple installation, and temperature monitoring will be explained.

Jan 1, 2014

By Lesley Andrews

"Electron microbeam analysis of metallurgical samples covers a broad field and has applications in the areas of minerals processing, hydrometallurgy, pyrometallurgy, physical metallurgy and corrosion.Some idea of the possibilities of microbeam techniques can be illustrated by examining the following example of a run of mine gold ore sample. Milling and bulk chemical analysis of the ore will provide major and minor element analysis as well as the gold grade. More detailed chemistlY can also reveal the presence of trace elements that may be advantageous or deleterious to downstream processing. Electron microbeam analysis can provide additional information in the form of - size, liberation, association and composition of the gold, the percentage of refractory gold, the size, liberation, association and composition of enclosing sulphide or arsenide phases and the levels and association of the trace elements that may affect processing. In most cases electron microbeam analysis compliments bulk chemistry, and does not replace it. Both techniques should be used in parallel for maximum effect.This paper touches on the origin and history of electron microbeam techniques, as well as the theory behind microbeam analysis and processing. The more common types of instruments and their applications will also be dealt with briefly - more details on, and examples of, the applications and choice of technique will be covered in the presentation.Mosely first discovered, in 1913, that the frequency of emitted X-radiation excited by an electron beam is a function of the atomic number of the analysed element. This discovery led to the development of spectrochemical analysis. The forerunners of the electron microanalysers of today, however, were only invented during the nineteen fifties. The electron microprobe was developed in parallel by Castaing and Guinier in France and by Borovski in Russia, but Castaing's design was the basis of modern microanalysers. The initial area of analysis was brought down from over 1 mm2 to less than 2 µm, as it is today. In 1956 Cosslett and Duncumb invented the scanning electron microprobe, where a beam of electrons could be scanned across an area of a sample. This, in turn, led to the development of the electron microprobe with both scanning and point analysis capabilities that we know today.Essentially, all electron microbeam instruments operate by the production of a beam of electrons from a filament in a vacuum (i.e. an electron gun). The electron beam leaves the gun and is accelerated and focused by a series of electromagnetic lenses while passing down an evacuated column. The electrons eventually strike the surface of the sample to be analysed and may travel through a thin sample (transmitted electron microscopy) or react with a thicker sample to produce several reflected kinds of radiation."

Jan 1, 2014

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 N. Naude, W. P. Roux, O. Kaba

Ceramic filtration plates are used for dewatering slurries with high solid concentrations and particles in the size range of 30 μm to 150 μm. After extensive operating times, the ceramic filter plates at Minas Rio in Brazil begin to blind due to the precipitation of barium sulphate on the surface of the ceramic filter plate, which reduces the overall efficiency of the filtration process. Further research is needed to identify the barium precipitate phases on the blocked filter plates and its thermodynamic and kinetic behaviour in the system. A crystallography analysis was performed on the sample and the results showed that there are two different sets of precipitates formed on the filter plate: grey crystals which were large and scatted on the filter plate and red micro crystals that covered the entire surface of the filter plate. The red microcrystals on the sample were identified with XRD, which indicated that the sample contained barium sulphate in the mineral form barite. Experiments were conducted to determine the optimum conditions under which barium precipitation will occur. The conditions tested as a possible driving force for barium sulphate precipitation were the effect of temperature, pH and concentration. The pH and temperature ranges were pushed to both the lower and higher boundaries. The effect of temperatures as low as 15oC was studied and pH levels of 7 and upwards. The first nuclei started appearing at a pH of 7 but significant growth is promoted at higher pH levels. The X-Ray diffraction analysis confirmed the phase of the precipitates formed, and the orthorhombic crystallographic structure formed is a characteristic of barium sulphate. Keywords: Iron ore, barium sulphate, temperature, pH, concentration, morphology, and ceramic filter plate

Jan 1, 2020

By D. M. Poulter, J. N. Brooke, P. H. Williams

"The complexity of the mining and metallurgical operations of Nchanga Consolidated Copper Mines, Limited, has made it necessary to use computer-assisted planning techniques in order to maximize copper production and marginal contribution to profit. The most successful of the Group Production Scheduling systems utilized linear programming to optimize the concentrate routing only. This third-generation system was commissioned in March, 1968.It bad become necessary by March, 1970, to expand the long-term planning activities and to take into account new mines and new concentrate treatment schemes. Technical difficulties and manpower limitations made it impossible to expand the third-generation system, and it was decided to construct a new Group Production Scheduling system using only linear programming.The plant models in the new fourth-generation system are based on data available from the monthly reports of the metallurgical plants. The models consist of mass balances and empirical relationships. Matrix coefficient assignment and management reports are produced using a Report Generator Language designed for linear programming data files. The development of this system is an example of a user application of a system package."

Jan 1, 2014