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By C. Scheffer

This paper describes a model that can simulate the behaviour of a pneumatic intensifier that is generally referred to as an ?air pump? (AP). The AP is used in many South African underground mines, and utilizes compressed air with pressures between 0.3?0.6 MPa to pump water up to pressures of 12?18 MPa. The high pressure water is used in numerous underground mines to pressurize props and roof bolts that act as safety and roof support devices. The simulation model reproduces the intensifier's operation under various conditions and therefore can be used to investigate the AP's sensitivity towards environmental conditions, design parameters (such as spring stiffness, plunger diameter, nozzle diameter etc.) and operating conditions. Model validation by comparison with laboratory experiments showed good correlation. The model can subsequently be used to investigate design changes aimed at improving the AP's performance and reliability over a wider range of operating conditions.

Jan 1, 2005

By C. J. Van Niekerk

The study comprised of the investigation into the sensitization characteristics of AISI 409 titanium stabilized ferritic stainless steel during low heat input welding. AISI 409 is a fully ferritic stainless steel used in catalytic converters and tubing for automotive exhaust systems due to the supposition that sensitization does not occur during low heat input welding. Two plates of 2 and 4 mm were tested for sensitization during low heat input welding. The study confirmed that chromium carbide (M23C6) precipitation occurs on the grain boundaries in the heat-affected zone with consequent depletion of Cr adjacent to the grain boundaries during welding. In the 2 mm plate sensitization occurred in the heat input range of 0.1 kJ/mm to above 0.25 kJ/mm and in the 4 mm plate sensitization occurred in the heat input range of 0.2 to 0.9 kJ/mm. Ti stabilization is ineffective at the heat inputs used in this investigation due to the rapid cooling rate through the temperature region where TiC precipitates. The presence of N was found to be detrimental since it consumes Ti on cooling, forming TiN, effectively lowering the amount of Ti available for TiC formation during rapid cooling after welding. Annealing for 5 minutes at 725°C does not improve the sensitization characteristics of the welded plate. There is a linear increase in grain size as heat input increases. The resistance to pitting corrosion decreases in the sensitized, welded plate in theheat-affected zone adjacent to the fusion line of welding. Keywords AISI 409 ferritic stainless steel, sensitization, grain growth, resistance to pitting corrosion, low heat input welding.

Jan 1, 2011

By G. Kelly

A new minerals engineering education programme is being developed in Australia which aims to provide tertiary institutions with a package of educationally sound, high quality courses for undergraduates, postgraduates and professionals. The programme is jointly funded by the Minerals Council of Australia (MCA) and the Department of Education Training and Youth Affairs (DETYA) and brings together academics from a number of leading Australian universities, each developing modules in their particular area of expertise. The University of Queensland (UQ) and the Julius Kruttschnitt Minerals Research Centre(JKMRC) are jointly responsible for modules in several areas including comminution, physical separation and circuit design and optimization. Other modules are being developed by the University of South Australia (with the Sir Ian Wark Centre), Curtin University and Murdoch University. The major challenge of the programme is to provide a high standard of education that is accessible to students who may be located at several different institutions and some of whom maybe a long distance from the primary course leader. Rather than taking existing course material and putting it ‘on the web’, the programme aims to improve on past teaching practice through creative pedagogy and the development of interactive multimedia learning resources. Communications technology is used in an unobtrusive way, and the World Wide Web is used to create a flexible, user-friendly learning environment rather than to facilitate delivery of content. This paper describes the instructional design template currently being used and results of early implementation trials with groups of local and remote students.

Jan 1, 2003

By L. Joncourt, N. Touchard, G. Pochart, C. Perdon

Worldwide, the major Manganese ores can be separated into three different types: ?Oxidized ores (MnO2): in Australia, Gabon, Brazil,?. ?Semi-oxidized ores (Mn2O3): in South-Africa, Australia,?. ?Carbonated ore (MnCO3): in Ghana, South Africa, Kazhakstan?. The other Manganese ores are less rich but can be used locally or in the neighbour countries (China, Ukraina, India?). Since the beginning of the 20th Century, Manganese has played a big role in the steel industry process average usage ratio: 9,5 kg/mt of steel). The recent grow-up of this industry has led to an increase of Manganese ores demand. In parallel, several companies have increased their Manganese ore producing capacity. In this presentation, we explain the link between the main Manganese ores characteristics and the key different factors for an effective and low cost Mn alloys production (HCFeMn and SiMn): ?Chemistry ?Size ?Reactivity Then we will point out the advantages of Comilog ore and Sintec ® usages in various Manganese alloy metallurgical process compared with the other main ores and with the local ores. Some advised formulations for the different kinds of furnaces and alloys will be also discussed.

Jan 1, 2007

By J. Dienenthal

Automatic Charging and Stoking Machines for use at ferroalloy furnaces are in operation for more than 20years. Dango & Dienenthal Maschinenbau GmbH (short: DDS) has developed several machine generations. Today advanced solutions help to achieve better charging and stoking results to minimize cost and to improve the working environment around the furnaces. Three different alternatives can be considered: Rail-mounted solution The machine(s) travel(s) on an overhead monorail to one or several furnaces and is locked in the desired working position from where charging and stoking is performed. Mobile solution This machine travels on the charging platform and is also locked at the respective working position to perform charging and stoking. Automation of a standard mobile charging and stoking machine A standard charging and stoking machine can be adapted for automation. A reliable navigation system is included. Charging and stoking is performed with the moving machine. Advantage versus other solutions: considerable lower investment cost and possibility to upgrade the mobile charging and stoking machine for later automation. Overall, automatic charging and stoking can save up to 10 per cent of the specific smelting energy. A better and more consistent furnace operation can be achieved. Different programs are used to cope with different furnace conditions and changing raw materials. All machine movements can be recorded and correlated to other furnace parameters. Working environment on the charging platform is greatly improved.

Jan 1, 2007

By H. Dong

This paper presents a heat conduction model to determine the erosion profile of freeze linings in a ferronickel submerged arc furnace. Kirchhoff transformation was adopted to simplify the nonlinear equation governing heat conduction. The boundary element method (BEM) and Nelder-Mead simplex optimization method were employed to solve an inverse heat conduction problem. Erosion profiles could be obtained when calculated temperatures at sensor locations agreed well with measured temperatures. The model was validated by comparing the heat loss through the linings, which was calculated by BEM and integral operation after erosion profiles were obtained, with the value calculated from industrial data such as actual power consumption, tap-to-tap time, and ferronickel output. The optimal solution for the erosion profile could be acquired when the difference in heat losses calculated by these two methods is at a minimum.

Jan 1, 2014

RME has a vision for a new grinding plant operational paradigm made possible by RME's fast, safe Mill Relining System. Some new liner designs can degrade SAG mill performance because of mill volume loss, ball strike (rotational speed limitations) and other issues often brought about by modifying liner design for maximum life and without a backward glance at metallurgical consequences. Freshly relined mills can initially produce as little as 80 per cent of their maximum throughput, that maximum occurring toward the end of the liners' wear life. RME's proposition is to see new liners designed for maximum commercial performance. This may mean more frequent mill relines but with liners designed to yield optimum grinding, metallurgical and profitability performance, not maximum life. In other words, mill liner profiles and mill relining speed become key operational controls and not simply `must do' maintenance functions. Taken to the extreme, liner profiles may prove capable of `tuning' a grinding plant for maximum profitability in any metal price environment. Following the introduction, the first section of this paper provides an update describing recent and significant developments within RME's range of Mill Relining Systems, the enabling technologies which permit more frequent liner exchange without incurring additional downtime imposts. The second section outlines RME's vision of a `liner profile versus profitability' commercial model, developed either intuitively or by using a combination of new measurement and modelling technologies. These new measurement and modelling tools provide the opportunity to predict the optimum commercial outcome, off-line in the virtual world, before committing to an expensive liner experiment.

Jan 1, 2007

By C. Lemmer

The resolution with which the different categories of resources are forecast for Witwatersrand gold reefs should ideally tie in with block sizes that are optimal in terms of the variability structures of the reefs. A tool, called the ?variancegram?, is proposed as a basis for block size choice. A variancegram is intrinsic to the particular reef and mine concerned. A further requirement is the ability to attach global confidence limits to weighted average estimates built up from combinations of local kriged estimates. Approximations to derive global kriging variances based on variables derived from local kriging deliver hugely inflated results if ordinary kriging is used, and markedly better, but not accurate, values if simple kriging is used. These approximations improve as the number of samples used in kriging each block is increased. It is shown that the behaviour of the different components of the global kriging variance with increasing number of samples, all differs, but they all link to the variancegram for the particular reef. The variancegram can thus be used to correct the different components to the values they would have had if all samples were used in kriging each block, and so deliver the ?correct? global kriging variance, even though only a limited number of samples were used in kriging each block. The desirability of having very stable solutions implemented in production systems is taken into account in the proposals. It is anticipated that the same variancegram findings will also hold for other densely sampled deposits, but this remains to be investigated.

Jan 1, 2014

By K D. Wilkes

The WEMCO Heavy Media Drum Separator was first introduced by WEMCO in California in the 1940`s, initially from their base in San Francisco and later when the company moved to Sacramento. The WEMCO Company became a part of EIMCO Process Equipment in 1985, and in 2002 EIMCO became a part of the GL&V Group when Dorr-Oliver EIMCO was created. Throughout this period of time the WEMCO Drum has been installed on a variety of different applications and is now operating at the heart of many of the world?s largest Minerals and Coal Processing Plants, as well as being used by many smaller producers and metal re-cycling operations. This paper looks at the practical aspects of using WEMCO Drums in a representative range of processing applications.

Jan 1, 2006

The 106th Annual General Meeting of The South African Institute of Mining and Metallurgy was held in the J.C. Lemmer Auditorium, SA National Museum of Military History, 22 Erlswold Way, Saxonwold, Johannesburg on Wednesday, 13th August, 2003. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations, also to recipients of awards, senior members of industry, Honorary Life Fellows, Past-presidents, our Members and other guests, among them the following: Kevin Moxham, President, Association of Mine Resident Engineers Prof. Jay Barton, Vice President, The Geological Society of South Africa Dr Gus Muller, President, Institute of Certificated Mechanical and Electrical Engineers, South Africa Marius van Rooyen, President, Institute of Mine Surveyors of South Africa Benjamin Ngulube, Deputy Vice President, South African Institution of Electrical Engineers Dr Francois Malan, Chairman, South African Institute of Rock Engineering Dr Paul Jourdan, President, Mintek

Jan 1, 2003

By J. de Villiers

Through the application of the Rietveld method, X-ray diffraction analysis has developed into a fully quantitative method for phase analysis. The Rietveld method itself has progressed from an unstable method that required constant operator intervention to a stable and robust method suited even for routine analysis. The method, however, requires a good initial calibration and periodic checks on its precision and accuracy. Several examples from minerals processing, pyrometallurgy, and materials science show the strengths and applicability of the method. The limitations and sources of error are also discussed.

Jan 1, 2007

By S. Z. Pethö, H. Yilmaz

South Deep Mine is currently undertaking numerous voidfilling projects using low strength aerated cement products. Representative samples from one such site, were taken and tested for the load deformation behaviour under uniaxial loading conditions. The process of sample collection, laboratory preparation and testing are explained in detail. The results of testing were analyzed and the critical aspects pointed out as a design consideration to be implemented as part of the quality control and assurance program. Design aspects and underground application of the aerated cement product are discussed for the particular site on 58 level SV1. A simple instrumentation has been designed and installed to enable monitoring of any future movements in this area. A quality control and assurance process has been formulated enabling all aspects of the support installation in this excavation to be signed off.

Jan 1, 2003

By G. A. Bezuidenhout, J. P. T. Kapusta, D. K. Chibwe

"Peirce-Smith converters (PSCs) are extensively used in the copper, nickel, and platinum group metals industries. The typical converting operation involves lateral purging of air into molten matte through a bank of tuyeres. This blowing operation occurs at low pressure from the blowers, resulting in a bubbling regime that is considered inefficient from both a process and an energy utilization perspective. Inherent drawbacks also include recurrent tuyere blockage, tuyere punching, and low oxygen efficiency.Western Platinum embarked on a full-scale industrial evaluation of generating a jetting regime by using sonic injection. Prior to industrialscale tests, a numerical assessment to ascertain the feasibility of implementing sonic injection into a PSC was conducted. The work included flow characterization at high-pressure injection achieving sonic velocity at the tuyere exit. The 2D and 3D simulations of the three-phase system were carried out using the volume of fluid method together with the RKE turbulence model to account for the multiphase and turbulent nature of the flow.This paper discusses the key findings in understanding plume extension, velocity distribution, shear wall stress analysis, and phase distribution characteristics in the system. Plant trials are also discussed with reference to the commercial aspects of a full-scale implementation of sonic injection in the smelter."

Jan 1, 2015

By A. M. Hearn, J. R. Henning, A. S. J. Van Rensburg

The lining, together with the electrodes, forms the heart of the operation of a submerged arc furnace. Subsequent to a lining failure on M12 furnace during the early 1980s, Metalloys was active in investigating the concept of thermally efficient ?freeze? linings for its furnaces. The theory revolved around that, not only would, thermally efficient linings result in significant cost savings, but they would also last longer as a result of being subjected to less harsh operational conditions. After having proved the concept on the .smaller. furnaces, Metalloys decided to implement the concept on its largest submerged arc furnace, M12 Subsequent to having recovered from an impending failure of a lining installed in 1981 in M12 in the mid 1980s, Metalloys managed, through rigid lining management, to extend the life of this lining to 1999. At the end of 1999 the decision to replace the lining in the furnace with a ?freeze? lining was made and planning and design proceeded in earnest. This paper discusses the options considered in making the final decision. The features of the design of the lining are also discussed. Consideration is given to the furnace shell cooling system as a result of its importance in maintaining the thermal equilibrium in the lining. Note is made of the fact that the purchase of a .freeze. lining is an expensive exercise but that the time savings in the installation of the lining and the efficiency improvements during operation far outweigh the additional capital cost. The experience on M12 has been that the payback period of the marginal capital expenditure is less than three years. As a result of the opportunity to reline a furnace the size of M12 not presenting itself very often, the learning points from the installation of the lining and the operational advantages and disadvantages are significant. Finally, the point is made that the project had its pros and cons but overall the success of the project has been evident and, as such, the ?freeze? lining is likely to become the norm at Metalloys.

Jan 1, 2004

By Martin Banda, Gift C. Chisakuta, Moses Chabinga

KCM made a major modification to the Nchanga Tailings Leach Plant (TLP) changing the circuit from feeding post leach thickeners in parallel with leach discharge for solid ?liquid separation to a Counter Current Decantation (CCD) configuration utilising most of the existing equipment. The new circuit is aimed at improving copper recovery from approximately 70% to 79% through enhanced wash efficiency. The re-introduction of CCD circuit at elevated throughput of 46 000-tpd design was made possible due to the EIMCO E-Duc technology design which is an auto-dilution system that enhances solids settling rate. Commissioning (manual operation) which accommodated on-going operational requirements was phased and completed in January 2004. The circuit stabilised in subsequent months and in March alone an all time record copper recovery of 81.8% was achieved which contributed an extra 779 tonnes copper above the plant?s projected production plans. 100% of the project cost was paid back by end of April 2004 This paper discusses the work involved and the challenges faced during the re-commission

Jan 1, 2005

By M. Yavuz, M. Aksoy, G. Once, M. Iphar

This paper is concerned with a study on the floor heaving in the transport road of the GLI Omerler Colliery in Tuncbilek-Turkey. This gallery has been opened at the depth of 200 m through the formation of marl in 4.6 m width and 3.5 m height in cross section. Floor heaving occurred up to 70 cm in height in maximum and caused severe problems in railway and band-conveyor transportation in the main road. In addition; after the current panel mined out, the shield support units could not be transferred to the new panel because of the deformation of roadway cross-section. The I-profile steel arch supports also sank into the weak floor rock. This situation has been studied by numerical analysis using the FLAC3Dfinite difference program in order to investigate the rock mass behaviour around the opening. The obtained outputs of the numerical model have showed consistency with the amount of floor heaving in the gallery at 200 m depth. A new gallery has been driven at the depth of 115 m and M4 longwall panel has just been taken to production. So as not to encounter with the same problems at 200 m depth, especially longwall face moving problem, various numerical models have been studied in order to keep the floor heaving in the acceptable limits required to move shield support units. Keywords: Floor heave, Numerical modelling, FLAC3D, Failure criteria, RocLab

Jan 1, 2003

By R. M. Tyler

The importance of the heavy mineral sands to southern African economic well-being cannot be over emphasized. The value of the worldwide titanium dioxide industry is estimated at $7 billion. Six out of eight of the world?s proposed new project areas are in southern and eastern Africa, and a seventh at Tamil Nadu in India is partly owned by a South African company, Kumba Resources. The HMS industry can be highly lucrative; its return on capital is the best in the mining industry. There are, however, problems, particularly in the smelting technology. The often considerable affect of mining on environmentally sensitive coastal dunes is also becoming increasingly important. The medium-to long-term demand for Ti-dioxide pigment and ceramic grade zircon appears very healthy. If, as predicted, the costs of producing titanium metal can be reduced, then there is huge potential for the metal. In summary, the HMS industry is an attractive one to be in, with good returns and generally manageable risks. New business opportunities and their economic implications for Africa are discussed.

Jan 1, 2004

By F. T. Wang, Y. Yuan, S. H. Tu, X. G. Zhang

Hydraulic support instability (HSI) is one of the most common causes of disasters in underground coal mining, posing a threat to the safety of mine workers and normal operation of the equipment. It is prone to occur in fully-mechanized mining faces with a large mining height (FMMLMH), especially when the dip angle of the coal seam is large. The key to controlling HSI is to deduce its mechanism and employ effective control techniques. This paper focuses on the analysis of HSI types, the key parameters and techniques to control HSI in FMMLMH, the establishment of a model of HSI in FMMLMH, and a multi-parameter sensitivity mechanical model of different HSI forms in the no. 7219 longwall face in Xutuan Coal Mine, Huaibei Mining Group, by using sensitivity analysis . The results show that HSI mainly presents in three forms: hydraulic support gliding (HSG), hydraulic support tilting (HST), and hydraulic support tail twisting (HSTT). The occurrence of the above three forms depends mainly on support anti-instability capability. In the no. 7219 longwall face, HSG and HST are the main two forms of HSI. The dip angle of the working face and the friction coefficient between floor and hydraulic support are the sensitive parameters for HSG, while HST is strongly dependent on the dip angle of the working face and the friction coefficient between roof and hydraulic support. By the applications of measures such as the oblique layout of the working face, cutting the floor into a step pattern, moving the support under pressure, and raising the setting load, the support stability was controlled effectively.

Jan 1, 2015

By P. Share

As part of JAGUARS (JApanese-German Underground Acoustic emission Research in South Africa), high-resolution tiltmeters were installed during 2007 at Mponeng gold mine, South Africa, in an attempt to study and understand the risks posed by in-mine seismic events and to subsequently use the knowledge gained to mitigate these risks. In December 2007, an M2.2 event occurred at Mponeng and was detected by the tiltmeters installed. The tilt expected for the M2.2 event is modelled through the use of numerical and analytical tools and utilizing, as input parameters, characteristics of the event such as the rupture area, the amount of slip, elastic properties of the rock, the state of stress before the event occurred, and frictional parameters of the rupture. The calculated tilt values are correlated and compared with the recorded data, and are found to be of the same order. Certain input parameters, such as the initial rupture point, are further constrained by varying them, during modelling, until the calculated and observed tilt values are approximately equal. From modelling, it can be concluded that the rupture point had to be closer to the location of the tiltmeters. In addition, possible locations acting as source areas for the observed aftertilt are determined. Further modelling still needs to be done to quantify the effects of the tunnel close to the tiltmeters and plastic deformation of the rock mass. Keywords high-resolution tilt data, Mponeng gold mine, M 2.2 seismic event, analytical modeling, numerical modeling, rupture plane.

Oct 1, 2013

By P. Rosario

The application of high pressure grinding rolls (HPGR) has been growing in the mining industry for the last 10 to 15 years. The major benefits supporting this trend are better energy efficiency, improved grinding capacity, and higher metal recovery in downstream processes such as heap leaching and flotation. In general there is limited quantitative knowledge on the true benefits of HPGRs relative to SAG mills in comminution, and about which situations one deals with better than the other. This paper will present a structure for comparison of the energy requirements for HPGR versus SAG mill considering complete circuits for comminution of precious and base metals hard ores. The work presented is from the design of four complete circuits based on ore data from two sites.

Jan 1, 2010