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By D. Tesh

The mining industry worldwide is facing a tremendous shortage of minerals engineers in all fields of specialization. For instance, in Australia the skills shortage in the mining industry has been identified as one of the top risks facing the mining industry. In Namibia most minerals engineers employed are expatriates, with some being Namibians who studied abroad. The minerals engineering programmes at the Polytechnic of Namibia are still in their infancy. These programmes were designed to meet the mining industry skills needs. Being young has its advantages in that lessons can be learnt from older minerals education institutions that went through similar challenges. However, this does not imply just copying and implementing their approaches, since the context differs and, to ensure sustainability of the minerals education programmes, curricula have to be customized to the local context. This paper reviews the interventions made by the Polytechnic of Namibia in order to ensure the sustainability of its minerals education programmes. The methodology consisted of an extensive literature review, a status quo analysis of the mining and process engineering department, identifying the gaps between the current state and desired state, and mapping the goals and strategic actions required to progress to the desired state. The following factors were identified as major threats to the sustainability of minerals education at the Polytechnic of Namibia: the quality of students, low student enrolment rates, low pass rates in science and mathematics, shortage of academic staff, dwindling government funding, and limited involvement of the mining industry. The major outcomes of this research comprise the detailed strategic actions employed by the Polytechnic of Namibia to address the threats to sustainability of its minerals education programmes.

Jan 1, 2014

By J. J. Bezuidenhout

The waste-heat boiler is used within the Sulphide flash smelting process as the main dust and energy recovery unit. The large volume of off-gas discharged from the flash smelter is at a very high temperature (1350°C) and contains a significant dust load that subjects the downstream waste-heat boiler to tough and demanding conditions. The boiler cavity is especially prone to dust accretions, fouling, and corrosion caused by accumulation of molten particles and precipitation of sulphuric acid. Computational fluid dynamics (CFD) is applied within a qualitative study to model the flow and heat transfer distribution throughout the waste-heat boiler. The commercial CFD package, Fluent 6.2.16, was applied to a modified waste-heat boiler (23 m ×11 m ×5.4 m) within the Outokumpu flash smelting process. This investigation focuses on the geometric modifications to the typical boiler design, which includes elevation of the ceiling, placement of flow-obstructing baffles and radiation plates parallel within the flow path. Also investigated were various boiler operating conditions such as the circulation of process off-gas, air leakage from the dust discharging hoppers and variation in inlet gas composition. The geometric modifications had the desired effect of increasing the volumetric utilization and therefore enhancing heat transfer between the boiler surface and the gas stream and dust segregation. Introducing circulated off-gas at a rate of 20 m/s and at a 45° angle to the front of the waste boiler further enhanced cooling while reducing the high impact of the furnace-uptake gas-stream on the boiler ceiling. The placement of radiation plates was found to be very effective in enhancing the heat transfer surface and distributing gas flow within the boiler. These results present recommendations towards an improved waste-heat boiler design. Keywords: flash smelting, waste-heat boiler, CFD simulation, off-gas cooling.

Jan 1, 2008

By W. C. Joughin

Problems with the stability and performance of rockpasses in deep-level mines are common. This paper presents the results of an investigation into the recorded performance of rockpasses in deep-level gold mines. Records relevant to the geological environment in which the passes are excavated, their excavation details, and their historical performance are not at all well documented on mines. In general, the quality of data available from mines is poor. The investigation showed that very large spans frequently developed in passes during use, and that rock mass quality, the orientation of the pass with respect to the dip of the strata, and the magnitude of the stress acting normal to the axis of the pass were the main factors of influence. From the historical information obtained, the risks of instability in rockpasses are identified.

Jan 1, 2005

By G. H. Lind

This paper discusses the traditional costing approach currently used in the underground coal mining industry. Activity Based Costing (ABC) is identified as being a potentially more effective manner in which to cost underground coal mining systems. With the use of a costing framework developed by the author incorporating new thinking to eliminate the shortcomings identified in the traditional costing approach, a comparison of two types of underground coal mining systems, viz. continuous miner and longwall, is conducted. It is found that under certain criteria, in all cases, irrespective of the way in which the systems are costed, the continuous miner system is currently the better investment. It is also observed that when a system is costed using ABC that better investment decisions result when compared to costing the same system using traditional costing techniques. It is further seen that traditional costing techniques tend to overestimate the total costs of a mining system. This paper shows one application of ABC that can be incorporated as a management tool.

Jan 1, 2001

By M. D. Dolan

In this study, the development of a new method for investigating the diffusion of metal cations in multi-component slag systems, using microprobe analysis is discussed. This method allows the analysis of the diffusion of multiple species within a single system. This project has focused on the diffusion characteristics of manganese, iron, calcium and silicon in silicate slags, in order to simulate industrial steel and ferromanganese production. The diffusion behaviour of transition metals is of particular interest because of the effects of their variable valence. This study identified the variation in diffusivity of slag components with changes in composition and temperature of multi-component slag systems. The molecular structure of the experimental calcium-aluminosilicate slags was investigated to determine the chemical and physical properties that influence diffusion behaviour. This experimental data was used to develop predictive models for diffusivity. These models enable the estimation of the diffusivity of many slag components in complex slags, over a range of compositions.

Jan 1, 2004

By Sergio Burelli, Darren C. Megaw

"Operational challenges associated with solvent extraction (SX) plants include the effective on-line management of solids introduced from a variety of process streams. Solids are carried over from leaching circuits due to incomplete solid–liquid separation, may be formed as a result of chemical precipitation within the SX circuits, or introduced from downstream electrowinning operations. Solids in SX settlers result in operational challenges that impact plant availability and reduce optimized name-plate design capacity operation. Most available SX crud and bottom solids removal systems are limited in their effectiveness to handle high total suspended solids in SX circuits. Operations are often forced to take settlers off-line for complete removal of contained solids. These cleaning operations are hazardous, high risk, labour-intensive and costly in terms of production down-time and organic extractant and diluent reagent losses. Production pressure results in operations being reluctant to take SX settler units off-line for solids clean-out, resulting in continued operation of the SX, at reduced levels of mass transfer performance. Crud ForxTM is an SX solids removal system, for the on-line removal of interfacial and bottom solids associated with hydrometallurgical SX processes. A case study conducted at Glencore’s Mutanda Mining copper and cobalt operation in the Democratic Republic of Congo demonstrated the effectiveness of the Crud Forx. Benefits identified were an overall improvement in SX fire risk reduction, SX occupational health and safety and an improvement in copper mass transfer. INTRODUCTION Hydrometallurgical copper extraction and purification processes are often associated with ultra-fine solids distribution profiles throughout the process flowsheet (Virnig et al., 1999). The level and impact of the undesired deportment of solids to process streams varies from operation to operation, but the common denominator for all operations that employ solvent extraction (SX) as a copper upgrading and purification step is that, at some stage, they will have to manage solids (crud) within the SX circuit. Available crud removal systems in the industry have had limited success in continuous, effective interfacial crud and bottom solids removal from SX settlers. Most operations use basic removal methodologies which, at best, only result in delaying the requirement for taking the affected SX settler stages off-line for complete clean-out. This operational methodology results in production loss, increased SX organic extractant consumption and adds occupational health and safety risk to SX operations. The integrated Crud ForxTM/Crud FrogzTM SX solids management system assists operations in on-line SX solids management. The system has been proven to significantly reduce the requirement for off-line cleaning of settlers."

Jan 1, 2015

By D. Pohl

The past decade has seen rapid expansion in the West African mineral exploration environment. This expansion has been largely driven by changes in ?Political climate ?Fiscal and legal regimes ?Exploration approaches ?West African geology. Major regional mapping and geochemical surveys by the UNDP, and the BRGM in the late 1970s and early 1980s laid the foundation for the rapid development of mineral exploration and resources during the past decade. An additional driving impetus was the discovery by native artisanal miners of many significant new gold occurrences at Libiri, Essakan, Bouda and Tirahori, during the great droughts of the late seventies and early eighties.

Jan 1, 1998

By V. Coetzee

In 1992, a paper was compiled highlighting a common-sense approach to electric smelting at Impala Platinum. Since then, the smelter complex has undergone considerable changes. Mineral economics, UG2 exploitation, and changing environmental legislation have enforced numerous process upgrades, yet a common-sense approach has always been adopted. This document details the major changes in the smelter complex at Mineral Processes (Minpro) over the past 15 years, and provides the rationale for the changes. Keywords: Pyrometallurgy, furnace, PGM, platinum, nickel, copper, electric smelting, six-in-line, Peirce-Smith, Impala Platinum.

Jan 1, 2006

By J. G. Wiese

Reagents are added to the flotation process of Merensky Reef ores to achieve specific functions that enable the separation of valuable minerals from gangue minerals on the basis of the difference in their surface properties. However, due to the complexity of the process, the various interactions that occur as well as the incomplete liberation of the ore and range of minerals present, it is difficult to quantify the behaviour of each of the reagents. More specifically, changes made to achieve a particular outcome may have secondary effects that can override the desired effect. If all the effects and interactions can be accounted for, it is possible to manipulate reagent suites and obtain better overall metallurgical performance. This paper discusses the effect of the addition of copper sulphate at different operating points of the recovery of the sulphide minerals. Batch flotation tests indicated that the recovery of chalcopyrite was not affected when operating conditions were varied, whereas pentlandite recovery was strongly affected by the point of reagent addition, and pyrrhotite recovery was enhanced by copper sulphate addition, irrespective of the point of addition, with the extent being dependent on the ore source. Floatable gangue was activated by copper sulphate in the presence of the dithiophosphate collector. Froth stability was also affected by copper sulphate addition.

Jan 1, 2007

By R. M. Jara

This work evaluates and characterizes the impact of the support size and mining dilution of a block model in the operation and selection of equipment at an open pit mine. An exploratory analysis and geostatistical modelling of the grades assayed on a set of drill hole samples is performed, which allows constructing a grade model on a dense grid by means of a conditional simulation. The grades are then averaged to greater selective mining unit supports in order to proceed with the study and methodology. First, the metal-tonnage curves are used to analyse the loss of selectivity on the in situ resources caused by a change of support. Concerning the ore reserves and their mining sequence, defined in the pit optimization and analysis process, the same curves prove that the loss of selectivity is more accentuated. Second, the importance of the block boundary dilution produced during mining operations is assessed. Its value depends on the amount of ore in contact with waste, on the loading error of the equipment and on the ore loss/waste dilution criterion assumed by the planner. The dilution percentage and the differences between waste and ore grades become higher when the block size decreases. For these reasons, considering the dilution in the production plans makes mining a small support more constraining. An adequate delimitation of the orebody can improve the mining selectivity, leading to greater income. Finally, a study of the increase in mining cost that provides a zero difference in NPV between the different block size options is carried out, in order to determine the maximum increase in mining costs for which it remains profitable to mine at a smaller block size. Keywords: Mining selectivity, support effect, block boundary dilution, selective mining unit size, block model.

Jan 1, 2006

By M. Wang, Z. Sui, T. Lou

After smelting, the associated mineral ore accompanying Valuable Metal Compounds (VMC),such as titania and borate in BF., most of the VMC were separated from the metal into the molten slag that is an associated slags. Based on several case studies in laboratories and in a practice in a pilot plant on the associated slags , there occur a feasibility to recovery VMC from the slags by anew process- Selective Precipitation Technique (SPT) on which three continuous steps are involved: (1) The selective enriching the dispersed VMC into a designed mineral phase in the molten slag; (2) The selective coarsening the designed mineral phase with large crystal grain size;(3) The selective separating the coarsen phase from tailing by mineral dressing or hydrometallurgical process . Some results on the recovering the VMC from the associated slags by SPT were summarized as examples in present paper. Keywords: selective precipitation technique, associated slag, recovering metals from slag.

Jan 1, 2004

A wide range of materials are used in hydraulic backfilling operations and the pipeline flow behaviour of these mixtures varies considerably. It is shown that despite the large differences in constituent materials and flow behaviour, a common approach can be applied to analysing the flow of all hydraulic backfills. This is extended to include a rational design approach for backfill distribution systems. The use and limitations of pipe loop tests as a design aid is discussed. Backfill quality control is identified as a key area where improvement needs to be made to enhance the reliability of backfill system operation.

Jan 1, 2001

By Q. G. Reynolds

DC arc furnaces are widely used for steel scrap melting, and are increasingly being used for smelting applications as well. The electrical resistivity of slags varies widely, from highly conductive slags in ilmenite smelting, to highly resistive slags in applications such as cobalt recovery from non-ferrous slags, and nickel laterite smelting. Models have been developed to predict the electrical behaviour of the DC open plasma arc and the molten slag bath. These models allow the voltage and current ranges of furnace power supplies to be specified.

Jan 1, 2004

The Annual General Meeting of the South African Institute of Mining and Metallurgy was held in Kelvin House on Wednesday, 24th August, 1977. Dr M. D. G. Salamon (President) was in the chair and declared the meeting open at 16h00. Obituaries The President: It is my sad duty to announce the death of the following members of the Institute : C. G. Evans, J. P. Rees, Life Fellows ; S. R. Bryant, H. MacConachie, M. Mrost, and A. W. van Zyl, Fellows; L. T. Campbell-Pitt, F. W. Collins, A. J. Duncan, I. G. Evans, F. W. Kleinschmidt, P. L. Vaughan, R. W. Wallace, and H. Wason, Members. As a mark of respect to the memory of the deceased and in sympathy with the bereaved, I would ask you to rise and observe a few moments' silence. Minutes The President: May we confirm the minutes of the General Meeting held on 23rd March, 1977, as published in the June issue of the Journal? Agreed.

Jan 1, 1978

By D. M. MacHunter, T. Lawson, D. K. Henderson

The development and commercialization of new generation high tension electrostatic separators has provided a basis for simplifying mineral separation plant circuitry. The inclusion of new design features including insulated plate electrodes that have resulted insignificantly improved separation efficiencies in electrostatic separators are described. The increase in separation efficiency has resulted in a reduction in the number of treatment stages required to produce final high grade mineral products. Comparative performance data on different feed types are presented. A comparison between mineral separation plant flowsheets using both conventional and new generation high tension electrostatic separation technology is presented. A 55% reduction in the number of installed electrostatic separators and a 36% reduction in plant area was achieved through the use of this new electrostatic separation technology.

Jan 1, 2003

By T. J. Goff, G. M. Denton

Mintek has developed the EnviroplasTM process for the treatment of solid wastes from the metallurgical industry, especially steel plant dusts, without requiring agglomeration to produce inert slag and at the same time recover metal values such as nickel, chromium and zinc. The products that are generated in the plasma-arc process are usually a metal and a non-toxic slag, which are tapped from the furnace in liquid form. The metal is mainly composed of chromium, nickel and manganese. During the production of stainless steel between 30 and 70 kg of dust and fine waste is generated per ton of steel. Mintek has successfully processed around 1000t of AOD/EAF dust on a toll treatment basis in order to recover the contained Cr and Ni. The metal produced contained 18.5 per cent Cr, and 5.5 per cent Ni. All slag samples tested conformed to US EPA regulations for disposal. The chromium and nickel recovery to metal was 90 and 98 per cent respectively, on a once through basis i.e. no baghouse dust recycle. Slag tapping temperatures varied between 1650°C and 1750°C. The average actual energy requirement excluding furnace heatlosses of smelting steel plant dust with anthracite as reductant was 1.36MWh/ ton of dust. The total mass of feed reporting to the off-gas stream was 10 per cent. The average ZnO content of the fume was 35.5 per cent.

Jan 1, 2004

By M. Verri

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Jan 1, 2009

By J. W. Latilla, J. J. van Wijk

In late 1997 a request was received to assist with determining the powered support unit (shield) load capacities for the planned 2 seam short wall. This project had a number of aspects which made it attractive to utilize numerical modelling in conjunction with other more conventional design tools in the design of the shields. Amongst these were: The 2 seam panels were to be laid out about 25 m below the previously short walled 4 seam, the 4 seam had in turn been over-mined by the 5 seam long wall, the proposed face height of the 2 seam short wall was 5.5 m while the 4 seam had been mined at 4 m. The top seam in the area (5 seam) had been mined at between 1.5 and 2.2 m high, the face conditions with about 95 m of broken material applying dead weight loading to the 2 to 4 seam inter-burden septum were hard to predict and cyclical loading due to the presence of strong sandstone bands in the 2 to 4 seam inter-burden. The basic thrust of the study was to take the known, and successful, situation (4 seam short wall) and carry out comparative modelling to enable prediction of likely 2 seam conditions. Some two dimensional aspects studied were: 5 m goaf hanging up behind shields, stresses in beams to determine likely first goaf roof span, stresses in cantilever beams to asses cyclical loading due to sandstone bands in the interburden being loaded by the overlying goaf and stresses on chain and crush pillars adjacent to the goaf edge. Three dimensional aspects that were investigated included: Load distribution along face for close goafing and 5 m goaf hang-up and load in a 1 m wide rib modelled in the position of the powered support units. From the modelling it was possible to determine the optimal shield leg capacity of the new 2 seam equipment. These outputs were used when drawing up the technical specifications for manufacture of the new equipment. The face was successfully commissioned in August 2002. Fin 1997, requête fut faite pour aider à la détermination des capacités de charge pour l’unité de soutènement mécanisée (bouclier) pour la couche 2 courte taille en projet. Certains aspects de ce projet le rendaient intéressant pour utiliser la modélisation numérique en même temps que d’autres méthodes conventionnelles pour la conception des boucliers. Parmi ces aspects se trouvaient : Les panneaux de la couche 2 devaient être placés environ 25 m au dessous de la couche 4 courte taille ; la couche 4 avait été remplacée par la couche 5 longue taille ; la hauteur de taille proposée pour la couche 2 courte taille était 5.5 m, tandis que la couche 4 avait été exploitée à 4 m. La couche supérieure de la région (couche 5) avait été exploitée entre 1.5 et 2.2 m de hauteur ; il était difficile de prédire les conditions de taille, avec environ 95m de matériaux cassés ajoutant une charge morte à la plaque de séparation entre les couches 2 et 4 et un chargement cyclique causé par des bandes de grès dans l’entre-fardeau 2-4. L’idée principale de l’étude fut de prendre la situation connue et réussie (couche 4 courte taille) et de faire une modélisation comparative pour prédire les conditions probables de la couche 2. Certains des aspects à double dimension qui furent étudiés étaient : Un accrochage de remblai de 5m derrière les boucliers ; contraintes dans les poutres pour déterminer le premier intervalle probable entre remblai et toit ; contraintes dans les poutres en porte-à-faux pour évaluer le chargement cyclique causé par les bandes de grès dans l’entre-fardeau qui est accablé par le remblai et les contraintes sur les piliers par chaîne et d’écrasement adjacents au bord du remblai. Aspects à trois dimensions qui furent étudiés : Distribution de la charge le long de la taille pour les remblais proches et l’accrochage de remblai de 5 m et la charge dans une nervure de 1 m de large modelée dans la position des unités de soutènement mécanisées. La modélisation a permis de déterminer la capacité de portée optimale du bouclier du dispositif nouveau pour la couche 2. Ces résultats furent utilisés pour dresser les spécifications techniques pour la fabrication de l’équipement nouveau. La taille fut commissionnée avec succès en août

Jan 1, 2003

In recent years several mine researchers have studied the optimization of cutoff grade with the purpose of maximizing Net Present Value (NPV). The best and most popular one is the Lane algorithm. Based upon the Lane algorithm it is possible to calculate the optimum cutoff grade for mine, mill, and refinery capacities for single metal deposits with variable grades. The Lane algorithm cannot be used in multiple metal deposits. The reason is that, while in single metal deposits six points are possible candidates for the optimum cutoff grade, in multiple metal deposits an infinite number points are possible candidates for the optimum cutoff grades and objective function evaluation of these infinite points is impossible. In this study the Golden Section search method was used to calculate optimum cutoff grades of multiple metal deposits for the same conditions as Lane assumed in single metal deposits. Based on this method, grade-tonnage distribution uncertainty space of problem is guessed. In the next step, by selecting test points in uncertainty space and evaluating the objective function at these points, a part of uncertainty space will be eliminated. The procedure is then repeated until the uncertainty space has been sufficiently reduced to ensure that the optimum cutoff grades have been located to the required accuracy. Key words: Optimum cutoff grades, Optimization, Net Present Value (NPV), Golden Section search method

Jan 1, 2003

By Li-ming Qi

During mining, the stress in the coal face varies, and, at the same time, the gas flows from the coal body into the excavation, which will cause the gas pressure to change continuously. Assuming the coal gas content of the coal to be constant, and applying the law of energy conservation, the influence of stress concentration on the gas pressure was analysed. It was found that the stress is proportional to the gas pressure. Finally, as a result of analysis and the law of gas flow, the gas pressure dynamic distribution ahead of tunnelling was modelled, and the mechanism by which blasting induces outburst was explained by making use of the model. Keywords: gas pressure, stress concentration, excavation, tunnel.

Jan 1, 2007