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By A. P. Squelch

The high incidence of accidents and fatalities in the South African mining industry, in particular those associated with falls of ground, is often attributed to ineffective and/or inappropriate training methods and material. Recently introduced mine health and safety legislation in South Africa also requires that all mine workers receive appropriate and effective training to enable them to operate safely in their given mining environment. There can, therefore, be no doubt that methods to provide effective training, in particular safety related training, are urgently required in the South African mining industry. In the search for alternative and improved training approaches, attention has fallen on virtual reality (VR) technology as a possible solution. VR has found acceptance in a number of industries as an effective method of training for a variety of work place activities, including those of a safety related nature. VR has successfully been applied in a number of industries to improve the effectiveness of safety and hazard awareness training. The CSIR: Division of Mining Technology (CSIR Miningtek), in conjunction with the Safety in Mines Research Advisory Committee (SIMRAC), therefore evaluated the potential of VR to be used as a training medium in the South African gold and platinum mining industry. Aspects of the evaluation included an assessment of the technical capability of VR to represent a typical underground mining environment with sufficient realism and the relevance of the VR training concept for a largely illiterate workforce. For these purposes, a prototype PC-based VR hazard awareness training simulator has been developed by CSIR Miningtek, and a series of evaluation sessions conducted at a typical deep level gold mine. The conclusion from this evaluation work is that virtual reality technology has the potential to provide effective training systems that are relevant to the South African mining industry. Keywords: Virtual reality, mine training, safety training.

Jan 1, 2001

By Jerry Gagnon, Matt Burr, Dave Evans, Timothy Ellis, Davies Kakengela, Abbas Mirza, Larry Webb, François Leclercq, Andrew Johnston

Lead-based alloys are the primary anodes used in electrowinning from sulphate-based aqueous systems. Lead anode technology has evolved over the years, migrating from pure lead and lead-antimonial alloys to the present day lead-calcium-tin alloys for copper electrowinning and lead-silver alloys for zinc electrowinning. It has also migrated from cast to rolled microstructures in search of improved mechanical properties and higher corrosion resistance. Although great strides have been made in the development of new alloys and production processes, the industry still has unresolved issues related to untimely corrosion which limits anode life and may lead to higher contaminant levels in the metal being produced. Lead anodes corrode because of the difference in the chemical/electrochemical potential across the microstructural features of an anode. Given a very high purity material, we find that the grain boundary areas corrode significantly faster than the rest of the grain. The desire to minimize grain boundary corrosion by a balance of alloying element selection and microstructural design allows the grain boundary area to be engineered. However, operational issues can lead to unexpected corrosion behaviours which we will discuss moving forward. The comments in this work, though directed toward copper electrowinning, can be extended to similar phenomena in other metals electrowon from sulphate media (i.e., zinc, nickel, cobalt, manganese). The lifecycle of electrowinning anodes is dependent upon electrowinning tankhouse operating conditions and maintenance of the anodes, including cleaning and straightening. This paper will focus on the operational aspects of maximizing the utilization of lead electrowinning anodes.

Jan 1, 2015

By A. P. Squelch

The question of what stress condition exists in the hangingwall of tabular stopes remains topical and largely unanswered. Limited field data exist to quantify the situation and provide calibration for investigative computer modelling exercises. Work conducted in1989 and 1990 under a Chamber of Mines Research Organization (now the CSIR: Division of Mining Technology) programme of research into the behaviour and benefits of backfill may assist with this situation. The original work was motivated by the premise that the improved hangingwall stability in backfilled panels (identified by rockfall accident analyses) is due to a change in the hangingwall stress regime. Current, largely theoretical, studies into mechanisms of stope hangingwall behaviour and support interaction could benefit from considering these data. Keywords: Backfill, horizontal stress, stope hangingwall, hangingwall stability, support interaction.

Jan 1, 2002

By Merete Tangstad, Kai Tang

The primary aim of the present investigation is to develop a model which permits to calculate/predict the viscosities of ferromanganese slags, typically focus on the MnO-SiO2-Al2O3-CaO-MgO-FeO multicomponent system. The present viscosity model emphasizes the ability of prediction, i.e. using the binary parameters to extrapolate the viscosities in ternary and higher order systems. To this end, a physical sound model is essential. Temperature dependence of viscosity is described by the Eyring?s formalism. The well-known cell model is used to define the SiO44- tetrahedra in the silicate melts. Composition dependence is expressed in term of viscous activation energy, which is characterized by the binary structural units. The viscosities in ternary and higher order systems are hence predicted using the binary activation parameters. The model has been used to calculate the viscosities in the whole liquid composition range of ferromanganese slag.

Jan 1, 2007

By L. A. Cramer

Platinum metal was first utilized by the Inca civilization in South America where it was found in alluvial deposits along the San Juan and Atrato rivers that lie between the Andean mountain range in Colombia and the Pacific Ocean. The nuggets found in these rivers average between 77% and 86%platinum, 7%?8% iron and small amounts of copper, gold and other Platinum Group Metals (PGMs). The Incas often alloyed platinum with copper to increase its workability and fabricated various ornaments from it.

Jan 1, 2001

By J. Utt

Recent developments in circulating fluidized bed (CFB) once-through supercritical technology (OTSC) have enabled this technology to be offered as a utility-scale alternative competing head-to-head with pulverized fuel (PF) OTSC offerings. One clear example is the CFB supercritical unit at the Lagisza Power Plant in Poland, owned by PoludniowyKoncernEnergetyczny SA (PKE). This unit has now been in commercial operation for three full years, exhibiting very good performance, and has validated Foster Wheeler's performance model at this utility scale as well as for units in the 600 MWe and 800 MWe size ranges offering net efficiency of -43 per cent (LHV basis). This operating unit has also proven the use of the world's first FW/BENSONTM vertical-tube OTSC low mass flux technology. Since the Lagisza original international tender specified OTSC PF technology, it is important to note that the alternative selection of CFB OTSC technology over conventional PF technology is of historic significance, not only for the validation of the CFB supercritical platform as a viable alternative to conventional PF technology, but it also positions the CFB OTSC with fuel flexibility for offering of sizes up to and including 800 MWe units. This paper explores the differences between CFB OTSC technology and standard PF OTSC in utility power generation. Selection criteria, fuel burning range in both technologies, and other selection drivers are discussed. Economic analysis of both technologies, based on existing cases, is also provided. Also discussed are the technical advantages and uses of each technology. Foster Wheeler has recently been awarded a contract for four units of CFB OTSC technology, which utilizes a 2 on 1 configuration of two 550 MWe CFB OTSC boilers on two single 1000 MWe turbines. Essentially this provides a fuel-flexible low-emissions alternative to a 2 x 1000 MWe solid fuel power block.

Jan 1, 2012

By L. Roux

The initial evaluation of a coal deposit often raises uncertainty with regard to the accuracy of the reported Resources and Reserves. Reconciliation of results from mining and beneficiation with the original raw field data highlights deficiencies in original estimations. Credible Resource and Reserve estimation forms the basis on which an entire mining enterprise is motivated, initiated, funded, and established as a commercially viable proposition. This is required for sustainable extraction purposes and to support vital downstream industries such as power generation. Accurate determination of the density of the matrix of the material being evaluated is the key to credible values being obtained for Resources and Reserves. Losses between 15% and 20% of the Resource/Reserve can be realized if incorrect densities are applied to the tonnage derivation. Coal plies and particles have different relative densities, determined by the maceral composition, rank, and mineral and moisture content. These factors in turn contribute to the moisture, volatile matter, ash and carbon contents of a coal, which affect the overall density of the raw coal. More specifically, the relationship of ash to density and the effective matrix porosity were found to be critical in solving the greater majority of the problems in predictive calculations. A major deficiency identified is the inability to determine effective porosity, allowing absorption of adventitious moisture and altering the mass of the core sample. Although the volume of the raw material is altered through crushing, the change in mass after controlled air-drying, used with the original geometrical volume of the raw material, provides a credible air-dry density and allows the determination of the volumetric change related to effective porosity. This parameter can be validated through the evaluation of proximate ash using the ash-adjusted algorithm and a correction for the inherent moisture applied to also give a credible relative density value for an air-dried sample. A combination of theoretical, empirical, and reconciliatory evaluations of the available data, taken from the exploration phase through the mining process to final production, has shown that an integrated approach using the ash-adjusted density (AAD) methodology, in conjunction with other evaluative techniques, provides credible results with a considerably higher degree of accuracy than is currently possible.

May 1, 2021

By Z. van Zyl

The southern African coal industry is facing the reality that coal reserves are becoming deeper and harder to mine than before. Alternative visions need to be considered to offset the impact of these challenges on productivity, cost, and profitability. One of the main challenges is to maintain current production levels under more difficult conditions, and improve productivity where conditions allow. There is a need to move from the reactive event-based management system towards the more adaptable and flexible process-based management system. This paper focuses on underground coal mining, but the principles are also applicable to other commodities and mining methods. This paper is based on research undertaken by the personnel from Mining Consultancy Services Pty Ltd (MCS) on trends in the underground coal mining sector, as well as practical experience over a period of 16 years in the field of electronic monitoring of mining machinery and productivity optimization.

Jan 1, 2015

By A. Kapito

The ferrite-pearlite microstructure is the most popular microstructure for alloys used in structural applications, including railway wagon wheels. These alloys have been designed through alloying and thermo-mechanical processing to have a refined microstructure. Ferrite-pearlite alloys are low cost, weldable, have good fabricability, and are reliable under extreme conditions. Given these performance attributes, it seems unlikely then that their dominant position as structural steels would ever be challenged by alternative microstructures. One major achievement in the development of ferrite-pearlite steels has been in the refinement of their interlamellar spacing to very fine distances of the order of < 0.3 um. A refined microstructure increases the hardness of the alloy, thus increasing its life under wear conditions. The interlamellar spacing in pearlitic steels has, however, been refined almost to its theoretical limit. The increasing demand for speed and increased axle loading on railway wagons requires the use of stronger, tougher, and more durable materials. This has opened the window for the development of novel bainitic steels. Bainitic alloys have a higher level of microstructural refinement than pearlitic ones. They have shown to have good wear resistance and rolling-contact fatigue resistance, and high toughness. This paper will discuss the progress to date on the development of bainitic railway wheel alloys. Four alloy chemistries have been chosen for possible further development.

Jan 1, 2012

By D. Tsweleng

In the Evraz Highveld production process, iron ore is prereduced in rotary kilns prior to charging into submerged arc furnaces (SAFs). Owing to the highly aggressive slags that are formed within the combustion zones of these kilns, chrome-oxide-containing lowcement castables have been used for some years in the kiln lining. Due to concerns around the potentially harmful effects should Cr(V1) be present in the spent linings, Highveld and its suppliers of kiln castables devoted time to developing alternative chrome-free lining materials. Such materials needed to be cost-effective and ensure good performance and improved kiln availability. This paper discusses all the parameters surrounding this development. Keywords Low-cement castable, chrome-oxide free, chrome (VI), titaniferous magnetite ore, rotary kiln, submerged arc furnace, open slag bath furnace, Evraz Highveld Steel & Vanadium Limited.

Aug 1, 2013

By A. N. Clay

In recent times, there has been criticism of the minerals industry over the lack of quantifiable boundaries between inferred, indicated, and Measured resources. A recent initiative through the United Nations aims to try to converge the mineral resource classification systems. Since the oil and gas industry uses a probabilistic approach to defining reserve boundaries, it is appropriate to introduce a similar statistical methodology for minerals. The Venmyn Variance Tower has been developed based upon traditional statistics to utilize historical and ongoing information in order to quantify variance of geological and chemical parameters and the boundaries and logic for quantitative mineral resource classification. It is proposed that a less than 50% variance from the mean of all sample parameters is required to achieve the classification threshold to define an inferred Resource whereas between 20-10% is needed for an indicated Resource and less than 10% variance from the mean is needed to declare a Measured Resource. These limits are similar to those used by the oil and gas industry, and it is suggested that these thresholds be adopted as an industry standard to ensure consistent quantitative reporting. While this process is intended to use statistics of an orebody to provide quantifiable and defendable boundaries, it cannot be carried out unless the geology of the mineral deposit is understood and the borehole samples can be categorized into appropriate populations for which the statistics are valid. This means that competent geologists are always required to work with and understand the implications of the Variance Tower results. This paper is intended to form the basis of a series of publications that establish a process to take mineral projects along a quantifiable and logical development path. Hence, no specific field example of the practical application of this process is given here.

Jan 1, 2012

By M. W. Hildyard

The aim of this paper is to demonstrate that active seismic measurements could have an impact in helping solve rock engineering problems experienced in the South African mining industry. The paper presents a variety of experimental and numerical results where seismic waves show clear differences in wave-speed and amplitudes due to different degrees of fracturing. It presents results from the ?Omnibus? project commissioned to develop new ultrasonic technologies for diagnosing fracturing for nuclear waste repositories. This included using models to investigate assemblies of cracks where the effects of crack density and crack size on waveforms are shown to be coupled. Results indicate that these effects can be decoupled in the frequency domain, where the Fourier amplitude aids in estimating crack size, while the low frequency phase-difference has a direct relationship to crack density. Models are also shown to aid interpretation of waveforms by isolating geometric effects from the effects due to cracks. Two rock engineering problems experienced in the South African mining industry are investigated through numerical examples. These demonstrate that determining whether ?crush? pillars have failed and determining the degree of fracturing in the hangingwall of stopes, may be possible through the use of active seismic surveys.

Jan 1, 2005

By D. Nyungu

Despite observations of spalling and damage of mine excavation wall rock in the Bushveld Complex (BC) over the passage of time, there have been very few time-dependent or creep tests carried out in South Africa on rock, particularly on BC rock types. The research described in this paper deals with the investigation of stress and strain conditions influencing spalling of wall rock in BC mine excavations, and the influence of time on the tensile strength of several BC rock types. Time-dependent laboratory testing of BC rocks was carried out in indirect tension. The results show that the magnitude of the tensile strength of BC rock types is approximately 5% of their uniaxial compressive strength magnitudes. The average long-term uniaxial compressive strength of the BC rocks, interpreted from the axial stress-volumetric strain graphs, is 56% of the UCS value. The long-term tensile strength is shown to be less than 70% of the normal tensile strength. Extension strains at tensile strength failure ranged between 0.16 and 0.21 millistrain. Values corresponding with the long-term tensile strength are less than 70% of this range, namely, 0.11 to 0.15 millistrain. These results represent new knowledge, since such rock testing and analysis does not appear to have been carried out previously on BC rock types. Elastic numerical modelling was carried out to illustrate the extents of tensile stress zones and extension zones around of typical BC mine excavations. The models showed that large zones of extension strain can occur around BC excavations, and that the magnitudes of the extension strain can substantially exceed the critical values determined from the laboratory testing. The implication of this is that there are substantial zones surrounding BC mine excavations that will be prone to time-dependent spalling conditions and perhaps more significant failure.

Jan 1, 2014

By V. Yahorava

Resin-in-pulp (RIP) technology has recently often been considered for the direct recovery of base metals and uranium from dense pulps. Implementation of RIP will eliminate the requirement for any solid-liquid separation downstream of leaching and has the potential to combine the recovery and purification steps, hence reducing both capital and operating costs. The recovery of the valuable metal is expected to be higher when RIP is used, especially where the leached solids are difficult to settle or filter, and to wash. The main concerns about the use of RIP for uranium recovery from dense pulps are the impact of silica on the resin?s metallurgical performance and the operating costs that would be associated with resin loss. Although a number of resin manufacturers have been developing much improved RIP-grade resins, it is critical that the most cost-effective resin be selected. Mintek currently is doing a significant amount of work on silica fouling of RIP-grade strong-base resins in acidic leach liquors and the effect it has on the performance of the resin, including its durability. This paper describes the results of the test work done on silica fouling and its impact on plant design input data. Resin durability test work was done using various laboratory techniques, but durability was also evaluated on a relatively large scale using actual pumps, screens, and mechanical agitation. Based on the results generated, a preliminary economical evaluation was done to estimate the impact of resin loss on the overall economic viability of a specific application. Keywords: resin-in-pulp, silica fouling, resin loss, equilibrium, kinetics, elution, durability, mechanical strength, resistance to attrition.

Jan 1, 2009

By C. Legote

"This paper investigates the conditions leading to the indefinite termination of production in four critical primary panels at an underground coal mining operation, the observed shortcomings in the mining approach, and the proposed strategy to mine through the affected panels. Initial assessment of the abandoned panel conditions indicated time-dependent strata failure,(i.e. bolted roof failure overrunning intersections), which occurred from mere minutes to up to four weeks post-production, with and without prior warning of failure. This prompted the constant re-supporting of back areas, which raised safety and productivity concerns. Investigation of the initial mining conditions revealed that the failures were due to a critical combination of factors, the chief of which was isolated horizontal stress. Other factors that were initially overlooked by the mine (i.e. influence of hydraulic stress, misinterpretation of borehole data), resulted in the conditions being described as abnormal. Remedial actions were determined, and in so doing, a new strategic approach was formulated to thoroughly address all failure concerns. The four panels were explicitly planned to serve as the main intake and return airways for the recently commissioned secondary ventilation shaft, as well as providing access to millions of tons in proven coal reserves. It is thus imperative to mine the panels. A feasibility study showed that the proposed strategy set for implementation would be financially viable. Paper written as project work carried out in partial fulfilment for BEng(Mining Engineering) degree"

Jan 1, 2015

By W. S. Steinberg

Keywords: Pyrometallurgy, furnace, open slag bath, Evraz, Highveld In 1963, the full-scale engineering study for the development of an Iron, Steel, and Vanadium plant was initiated. This was the birth of Evraz Highveld and its process flow as it is known today. Highveld started out as a steel works that produced steel and vanadium-bearing slag by using a titaniferous magnetite iron ore mined from its own mine site near Steelpoort. The process utilized co-current rotary kilns for pre-reduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to Open Slag Bath (OSB) operation, in order to enable the maximum production of iron and vanadium while improving the control over operational parameters. The conversion proved to be highly successful and, since 2005, three furnaces have been converted to OSB operation. The fourth furnace will be converted in the first half of 2011. The conversion to OSB furnaces not only yields higher vanadium recovery to the metal at the iron plant, but also improves the overall throughput of the steel plant. This is the result of a higher carbon content of the liquid iron from the OSB furnaces, eliminating the need for anthracite addition to the shaking ladle process. This reduces the blowing time by approximately 60%. The conversion of the furnaces to OSB configuration is seen as an enabling technology change and a prerequisite to the implementation of other plant improvements that are envisaged. The long-term vision of EHSV is to convert five furnaces to OSB mode, and permanently decommission the two remaining submerged-arc furnaces. This will allow EHSV to maintain current steel and vanadium production but at a significantly improved overall efficiency.

Jan 1, 2011

By M. Royker

Gold has been demonstrated as a possible catalyst for oxidation reactions. Some evidence for a possible promotion effect of platinum has also been recorded. The influence of platinum as promoter for Au/?-Al2O3 prepared via anionic ion-exchange for the oxidation of glycerol was investigated in a batch reactor at 60°C. It is inferred that the addition of platinum reduces the catalytic activity and therate of deactivation, resulting in an overall higher final conversion of glycerol with increasing platinum loading. The addition of platinum to the catalyst favours the formation of the desired product, glyceric acid.

Jan 1, 2012

By S. Ngidi

Palabora Mining Company operates a low grade underground copper mine situated in the Limpopo Province, South Africa. Full production was first reached in May 2005 after a successful transition from an open pit operation to an underground block cave operation. The operation faces a number of technical and operational challenges, not the least being fragmentation of a competent rock mass and external dilution. The cave is subdivided into three main sectors being the east, the west and the central sectors. Caving was initiated from the weaker central sector, which has the majority of its drawpoints located directly under the open pit bottom currently filled with about 130 million tons of waste material from the pit wall failure incurred in 2004. About 48% of the ore reserve has to be extracted from the western sector, which has a much courser fragmentation compared to the other two sectors and only 25% from the central sector with the finest fragmentation. The main constraint during the ramp-up stage has been secondary breaking of drawpoint blockages. Ground-breaking secondary breaking and cave management initiatives and practices have made it possible for Palabora to realize and sustain high production rates.

Jan 1, 2007

By K. Lombard

"‘Roof support awaiting time’ (RSAT) is a term used at Goedehoop Colliery’s Simunye Shaft to describe the potential production time lost due to the continuous miner (CM) standing idle waiting for roof support to catch up. Investigations revealed that in 2013, Simunye Shaft had approximately1400 hours of RSAT, which suggests that the mine could have potentially produced an additional 280 000 t of coal. This project consisted of two parts. Firstly, the causes of the high RSAT and means to improve the situation were investigated. Secondly, as insisted by mine management, the CM cutting sequence was investigated as a possible cause of high RSAT. Machine-related challenges due to the roofbolter installing support too slowly, geological conditions (mostly hard roof conditions and slips),logistical challenges pertaining to the CM cutting sequence, man-related challenges related to operator fatigue, re-support, operator inexperience, and the absence of support targets were identified as main contributors to RSAT. Furthermore, results showed that the roofbolters in the sections at Simunye Shaft are slower than the CMs. A target of 28% reduction in RSAT was set. Experts from Kennametal and Fletcher were consulted to find solutions for the identified causes. In total, eight solutions for RSAT were identified, but the solution that contributed most significantly to reducing RSAT was to use hard roof drill bits as a standard product at Simunye Shaft. Calculations showed that by using hard roof drill bits, RSAT can be reduced by 43%, which is more than the specified 28% target. The cutting sequences at Kriel, Greenside, and Simunye Shaft, togetherwith three newly developed cutting sequences, were simulated using the UCMS (Underground Coal Mining Simulation) program. A re-aligningprinciple was incorporated into the newly developed cutting sequences toalign the cutting sequences to general support work and to reduce RSAT. A decision matrix revealed that a cutting sequence in which boxing takesplace in R3 (third road to the right of the belt road) and in which the re-aligning principle has been incorporated will be the best option for Simunye Shaft. The recommended cutting sequence will lead to a 5% increase in production.The work presented in this paper was carried out as partial fullfilment for the degree BEng (Mining Engineering)"

Jan 1, 2015

By A. A. Angelov

This paper presents a unique method of monitoring the effectiveness of the planning process as well as the execution of mine plans. The method primarily determines the degree of deviation from the original mine plans by comparing actual mined areas to initially planned mining areas. The performance of mining operations is also measured by comparing actual and planned tonnages for a particular period. Once the degree of deviation from mine plans has been established the cause/s of the deviation can be determined through a simple fault tree analysis. Accurate identification of the reasons of deviation can aid the mine in selecting possible methods to correct the deviation. It is, however, beyond the scope of this paper to discuss the methods employed in correcting such deviations, as each mining operation will have unique causes of plan deviation and methods of remedying them. Deviations from the plan greatly affect the yields obtainable, which in turn affects the life of mine, thus having negative economic and financial implications. Accordingly, this paper presents a project management method which aims to reduce risk by improving planning systems to ensure optimum overall extraction of coal reserves.

Jan 1, 2010