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By X. Jia

The ability to perform three dimensional imaging at micron-scale resolution of real mineral floc sediments and structures using commercially available Micro X-ray Tomography (XMT) instrumentation can be used for the analysis of aggregates and granules, liberation and dewatering of sediments. This paper presents are view of recent work by the authors relevant to the mining and minerals industries. It covers three main topics: X-ray imaging of agglomerates and multi-component mineralic particles,, permeability of sediments, and dissolution of granules with potential application to heap leaching.

Jan 1, 2008

By T. T. Matuludi

Kleinkopje Colliery has five Wemco drums that were installed and commissioned in 1978. Over the years, there have been remarkable changes in mining and geological conditions at the colliery. First, an increase in the percentage of fines was recorded, which resulted in an uneven split or an imbalance in silo levels between material feeding the cyclone (-12 mm) and Wemco drum (+12 mm) sections respectively. This problem was solved by doing modifications around the banana screens to allow finer material to the drums. The imbalance challenge was then followed by spontaneous combustion that takes place in situ and results in low product yield. The results obtained from efficiency tests indicate that although there is a limit in the percentage of -6 mm material in the feed, Wemco drums are still very efficient and applicable to the current mining conditions. These results also suggest that it is essential to lower the throughput when the drums are treating low yielding coal.

Jan 1, 2010

The key functions of project evaluation are to assess potential profitability and to develop an effective operational design. For mining projects, design aspects include mining methodology, ore treatment methodology and production rates. All of these characteristics impact on project economics and overall value. Resource models, which form the ultimate basis of project evaluation, typically consist of tonnes above cut-off, grade above cut-off and the spatial distribution (connectivity) of tonnes/grade above cut-off, for one or more variables. Dilution, ore loss and metallurgical recovery are all modifying factors applied to the resource model during evaluation and determination of profitability. A key issue is: how is the value determined? In addition to traditional combination of in situ tonnes/grade, the following merit serious consideration: the concentration of deleterious elements, throughput rates, mining/processing costs and - importantly - metallurgical recovery. Geometallurgy is an emerging field targeted at integrating these issues by identifying either direct measures or proxies for throughput (hardness, grindability), recovery (liberation, mineral shape/texture, etc) and concentrate quality from easily collected macro-, meso- and microscopic data. These 'geometallurgical variables' drive project costs and revenues in a fundamental way. For geometallurgical characterisation to have a real impact on business design, it must enable improved mine planning. When creating spatial estimates for such variables, it is preferable to find proxies that can be measured as close to the intact rock mass as possible. However, spatial estimation of proxies for geometallurgical properties and responses is complex and requires special consideration. Unlike grades, both proxies and absolute measures of geometallurgical variables are not necessarily linear or additive and therefore require very careful geostatistical consideration. In some cases, models must predict extreme values of geometallurgical attributes rather than averages. Incorrect characterisation of metallurgical recovery/throughput can (and has) led to misspecification of the scale of projects, and thus can be seriously value destructive. Aspects of geometallurgy have long been important in iron, bauxite, manganese and coal deposits and are increasingly on the radar for base and precious metal miners. However, as more metallurgically complex deposits are developed and mining of large-scale, low-grade deposits becomes more commonplace, the importance of characterising the metallurgical response in order to generate properly optimised projects will rapidly increase. It is possible that in many `traditional' (ie grades and tonnes) reserve models, the variables that drive the project are missing!

Jan 1, 2007

One of the key issues facing gold producers is the management of cyanide and the implementation of the International Cyanide Management Code. Many operations now use cyanide destruction processes to ensure that the material being discharged to the tailings dam is compliant with regulatory requirements and the International Cyanide Management Code. One of the problems for operations is the quantification of both cyanide species and their reaction products throughout the leach and destruction circuits. Therefore methods have been developed utilizing high performance liquid chromatography (HPLC) to measure free cyanide, cyanide complexes of metals such as copper and iron, and other species formed from reactions in leaching and cyanide destruction, including cyanate, thiocyanate, and sulphur species (eg. sulphite, thiosulphate and sulphate). This enables a complete mass balance for cyanide and sulphur in both leaching and cyanide destruction. This paper outlines the methodology which has been developed and discusses the application of these methods in the fundamental research currently being conducted on the impact of sulphide minerals in cyanidation and cyanide destruction chemistry.

Jan 1, 2009

By J-C. Lv, S. Zhao, F-L. Zhang, T. Yan

"To eliminate nozzle clogging during continuous casting of ship plate steel and reduce the calcium addition required, the composition of CaO-MgOAl2O3 inclusions in the liquid phase region must be controlled. Thermodynamic calculations using FactSage show that when the balanced Al content is 0.03 mass %, aCa in the liquid steel is 1–10 ppm, and aMg is 0.01–0.3 ppm; and when the balanced Al content is 0.06 mass %, aCa in the liquid steel is 1–30 ppm, and aMg is 0.05–0.9 ppm. The CaO-Al2O3-CaS inclusions can be controlled in the liquid region below 1600°C at aCa values of 5 ppm, 15 ppm, and 30 ppm, and the balanced Al content should be controlled in the range of 0.001–0.050, 0.005–0.250, and 0.010–0.50 mass %, respectively. Based on theoretical analysis, the refining slag composition should be controlled to 45–53 mass % CaO, 30–37 mass % Al2O3, 6–12 mass % SiO2, and 6–8 mass % MgO. Optimization of the slag system and steel composition can reduce, or even eliminate, the requirement for calcium treatment. The total oxygen content in the slab can be controlled to 15–21 ppm, with typical micro-inclusions ??10 ??m in size, with compositions in the CaO-Al2O3-MgO and CaO-Al2O3-CaS systems. Introduction With the rapid growth in steel output in China and the changes in the macroeconomic environment, competition in the steel industry has become more intense. The technology for economical cleaning of high-grade steel is important for improving product quality and reducing production costs. However, the functions of refining equipment have not been fully taken into consideration, and the combination of refining methods has not been optimized completely. These problems have become a bottleneck, restricting modern steel enterprises from developing an economic clean steel production process. Ship plate steel produced by the converter long process has been selected as the example in this study. The composition of the steel is shown in Table I. This steel is a high-strength low-alloy steel for rolling media and heavy plates, mainly used for ocean-going vessels and other steel structures. The carbon content in the steel is far from the peritectic point, and the crack sensitivity of the slab surface is weak, so impurities and gas content are strictly limited. Therefore, the process route BOF (basic oxygen furnace) – LF (ladle furnace) – CC (continuous casting) needs to be studied."

Jan 1, 2018

By Willem J. Marais

The management of unpaved mine road networks on large surface mines rarely results in optimal road maintenance strategies and minimised total road-user costs. This is ascribed mostly to the complex and dynamic combination of variable road networks and loading and discharge points. In a dynamic mining environment - typically those mines in which production is managed by a centralised truck dispatch system ? there is no guarantee that a particular road maintenance intervention will contribute significantly to reducing total road-user costs or increasing productivity. Most large surface mines operating ultra-heavy mine trucks rely on an integrated on-board diagnostic data collation, communication and GPS-asset location system as a real-time fleet management tool. By extending this system to incorporate a multi-sensor analytical procedure in which specific truck vital signs are monitored and filtered, a road defect can be recognised and a trigger level set to relay the location of defects on the mine haul road to the centralised truck data management system. Previous work established the feasibility of the multi-sensor approach to road defect recognition on large mine haul trucks, and outlined the defect recognition, analytical and modelling issues and system limitations. This paper presents the development of the analytical procedure used as a basis for evaluating the truck on-board data to establish maintenance priorities amongst a network of mine roads. Following an introduction to the system architecture, the results of system field trials are analysed and the results discussed in the light of defect density and traffic volume as the primary variables in an approach to prioritising road maintenance. The paper concludes that by supplementing the existing mine communication and asset management systems, road maintenance can be managed on a near real-time basis and maintenance equipment dispatched to where most immediate benefit will realised from a maintenance intervention on the network, thereby generating the maximum improvement in service and reduction in cost per ton hauled.

Jan 1, 2008

By F. Bourgouin

Thirty-one years ago, African leaders met in Lagos for the drafting of the Lagos Plan of Action for the Economic Development of Africa, 1980?2000. The main objective of the plan was to increase Africa?s self-sufficiency and in this regard, the plan had a section pertaining specifically to redressing the ills of an unproductive mining and minerals industry and harnessing its potential for socio-economic development. However, if we look at the nature of this sector on the continent today, its characteristics resemble the diagnosis of the sector given in the plan back in 1980: lack of information on endowments of minerals; lack of value added in the sector; low development and use of those endowments that are not of interest to transnational corporations (TNCs); and most importantly, low contribution to socio-economic development. The primary consequence of the lack of visible benefits to African states, despite growth and development of the sector in terms of increased mining activity led by Foreign Direct Investment is that countries with mining industries are characterized by dysfunctional internal processes. Improvements in governance, monitored with indices such as those set out in the Extractive Industries Transparency Initiative, the Millennium Development Goals, and other such ?good governance? agendas, are being asserted. However, before we prescribe the introduction of initiatives or guidelines based upon highly subjective norms which we believe to fit this diagnosis, it is necessary to review how it is that we got to this situation that we are in today. How is it that, 31 years after the Lagos Plan of Action, we have not seen any major changes in the role the industry can play in socio-economic development, despite the vast increase in mining activity on the continent?

Jan 1, 2011

The imbalance between the coal resources contained in thin seams (1,5 m or less) and the production from them is outlined. It is suggested that an Increase In the exploitation of thin coal seams is necessary, and that drum-type continuous miners can produce a substantial amount of any increase. Continuous miners are employed in a number of mining methods including bord-and-pillar, pillar extraction (stooping), rib-pillar extraction, and shortwalling. These techniques of mining are evaluated with respect to production rates and the cost of extraction for South African conditions included in these evaluations are the types of equipment used to transport coal from the mining machine to the section conveyor belt. Computer simulation techniques are used to generate the required production levels, and interpretations are made of other results from the computer modelling. For thin, coal seams, bord-and-pillar mining utilizing continuous haulage is apparently the most productive and cost-effective of all the methods using the continuous miner. The relative efficiencies of the other techniques of mining and of coal-transportation vehicles are also outlined.

Jan 1, 1984

By C. Musingwini

The South African platinum mining industry is using a number of different mining methods, including variations of the same method, to extract the narrow reef tabular platinum deposits of the Bushveld Complex. These mining methods fall into three broad categories, namely conventional, mechanised and hybrid mining. A question sometimes asked in the industry is whether mechanized mining methods are more efficient than conventional mining methods. An objective answer requires the methods to be evaluated against multiple criteria simultaneously, whereby each criterion has a relative degree of importance in the overall decision. The most efficient method is the one that scores highest on each criterion. However, some of the criteria can be conflicting, such as by increasing dilution the shaft head grade decreases. The analytic hierarchy process (AHP) methodology was selected for the study because it is used to solve problems of this nature. A survey was carried out to determine the relative importance of each efficiency criterion by drawing on the knowledge and experience of mine technical services and project management practitioners in the industry. Efficiency data for four different mining methods drawn from the Egerton (2004) study were used as a case study. The conventional mining method ranked as the most efficient mining method from the four methods considered. The exercise indicates potential for the AHP to be used in the South African platinum mining industry as a tool for selecting optimal layout designs, conduct regular evaluation of the performance of production shafts, or objectively evaluate line managers for promotion. The work described in this paper is part of the methodology used in a current PhD research study at the University of the Witwatersrand. Keywords: Analytic hierarchy process (AHP); multiple criteria decision analysis (MCDA); decision-making; conventional mining, hybrid mining, mechanized mining.

Jan 1, 2008

The development of short- and medium-term mine production schedules in isolation from each other has meant that only a local optimum can be achieved when each scheduling phase is carried out. The globally optimal solution, however, can be achieved when integrating scheduling phases and accounting for the interaction between short-term and medium-term activities simultaneously. This paper addresses the task of integrating short- and medium-term production plans by combining the short-term objective of minimizing deviation from targeted mill feed grade with the medium-term objective of maximizing net present value (NPV) into a single mathematical optimization model. A conceptual sublevel stoping operation comprising 30 stopes is used for trialling segregated and integrated scheduling approaches. Segregated medium- and short-term scheduling using separate models achieved an NPV of $42 654 456. The final scheduling approach involved integrating the two scheduling horizons using the newly-developed globally optimal integrated production scheduling model to achieve an NPV of $42 823 657 with smoother mill feed grade. The larger the stope data set, the larger the difference between the two scheduling approaches is likely to be. At the very least, an integrated approach ensures feasibility across the two scheduling horizons, which cannot always be assumed when using a segregated approach.

Jan 1, 2012

By Keith Rowley, Neal Harries, David Noon

The management of risks associated with slope instability is an essential process in the safe and economic operation of open cut mines. The ?slope stability radar? (SSR) has been developed to better manage those risks. The SSR remotely scans rock slopes to continuously measure any surface movement and can be used to detect and alert users of wall movements with sub-millimetre precision. The high level of movement precision and broad area coverage of the rock face can allow for a better understanding of the geomechanics of slope deformation, including magnitude of potential failures and additional warning time of impending instability. Additionally, radar waves adequately penetrate through rain, dust and smoke to give reliable measurements, 24 hours a day. SSR systems have been deployed in many mines in Australia, Indonesia, South Africa, Zambia, Chile and the United States. Greater than 70 rock falls and waste dump failures (from several to millions of tonnes) have been monitored, and on every occasion precursor ?warning? movements were recorded by the SSR. This technology enables a radical change in the management of risks in open cut mining. This paper will present recent case studies of the SSR operation in coal and metalliferous mines.

Jan 1, 2006

By K. Moxham, B. McKeown

The South African gold and platinum deposits were formed in very different ways and yet both have many similarities. They are flat dipping tabular orebodies, extremely narrow and located in hard abrasive country rock. The mining methods employed are also similar. Primary access is via shafts or declines; secondary access is via haulages and cross-cuts; and tertiary access is from raises. The proposed solution for rapid access described in this paper is focused on the haulages and cross-cuts.

Jan 1, 2006

In the wake of the financial crisis that affected world markets in 2002, there has been an increasing international focus on corporate governance. Various corporate governance codes of practice have been introduced, such as the Sarbanes-Oxley legislation in the USA, the Combined Code in the UK, and King III in South Africa. This focus on corporate governance has increased since the most recent financial crisis in 2008, the effects of which are still being felt world-wide. In the mining and minerals industry, reliable metal accounting is essential to sound corporate governance and is also becoming a focus of increased attention and concern, particularly as the figures generated by the metal accounting system feed directly into the financial accounts of mining companies. Mass measurement, sampling, and analysis provide the input data for the metal accounting system and sound corporate governance requires that the procedures used are based on best practice and that the data generated is accurate and handled correctly, transparently, and consistently to produce the accounting reports. The AMIRA Code of Practice for Metal Accounting has been widely adopted in the industry as a means to achieve this, and the compilers of the Code have conducted numerous metal accounting audits at operations, both in South Africa and abroad. These audits have shown that there is a real need for such a code of practice. Keywords metal accounting, AMIRA Code, corporate governance, risk management.

Jan 1, 2014

By S. Moodley

In the chloride process for TiO2 pigment production, various titania feedstocks (i.e. rutile, synthetic rutile, slag, and upgraded titania slag (UGS)) are chlorinated in a fluidized bed reactor with petroleum coke at temperatures between 1000°C and 1100ºC to yield gaseous metal chlorides. Although feedstock preference is largely based on TiO2 content, feedstock physical properties (i.e. density, sphericity, size distribution, and porosity) differ; these differences will affect fluidization behaviour and can inadvertently affect conversion efficiency. For example, a high carryover from the reactor reduces particle residence time and decreases conversion rates. Owing to dwindling rutile reserves in the world, most chloride producers are forced to feed blends of feedstocks to their chlorinators; and so it becomes important to understand whether blends have an effect on the hydrodynamic properties of the bed. This paper describes the physical characterization of different feeds and the determination of the elutriation constants for slag, rutile, synthetic rutile, and a blend (i.e. 50 wt% rutile, 50 wt% slag).A common feature of the tests was that particles finer than 75 µm tended more than any other size to be elutriated. The tested rutile, classified as a Geldart Group B material, had the lowest carryover, whereas the slags had the highest. Interestingly, the elutriation constant ([ki]) of the blend is lower than those of either of its individual components.

Jan 1, 2012

By J. Björkvall, L. Bååth, D. Malmberg, J. Malm

Microwave technology has for decades been a tool for astronomers to map and understand the complexities of the universe its composition and extent. It is also used on a laboratory scale by spectroscopists to examine properties of atomic and molecular compounds. In this novel work we will introduce microwave technology to be used for the investigation of liquid slag structures. The preliminary results indicate that the alteration of the slag composition could be correlated to the measured microwave refractive index. Investigations have been performed in the Al2O3-CaO-SiO2slag system. Keywords: Microwave technology, slag, structure, liquid, Al2O3-CaO-SiO2

Jan 1, 2004

By A. F. Mulaba-Bafubiandi

Pseudomonas spp was isolated from mine water and tailings samples collected from mining effluents and mine dumps in the Gauteng and Northern provinces of South Africa respectively. Adsorption properties of Pseudomonas spp were then tested for the removal of Cu and Co initially from their synthetic sulphate solutions, subsequently from effluents derived from metallurgical operations. The effects of experimental conditions such as pH, temperature, time, volume and metal concentration on the efficiency of the biosorption process were studied. Absorption of 45% Cu (pH 6, 37°C, 24 hours) and 40% Co (pH 6, 37°C, 24 hours) was observed from solutions with low concentrations (0.07 M). A maximum of 73% and 65% of Cu and Corespectively were recovered from the mine water samples derived from effluents.

Jan 1, 2009

By Neal Harries

The monitoring of rock slopes is a common procedure in the management of hazards associated with slope instability. Slope stability radar has become widely accepted as the state-of-the-art method for management of hazards associated with unstable slopes in open pit mines. This is confirmed by the rapid adoption of the technology since inception in mid 2003, with over 70 GroundProbe slope stability radars now in use at open pit operations throughout the World. The use of a monitoring system such as slope radar to identify slope hazards is only part of the solution to minimise the consequences associated with slope instability. The presence of the hazard must also be effectively communicated to the mine personnel, so that the correct response to the hazard can be enacted, and the risk mitigated to an acceptable level. In some surface mines, due to the geotechnical characteristics of the rock mass, hazards can develop rapidly; with slopes progressing from stability to ultimate collapse in just hours. In these situations, it is vital that efficient systems are developed to evacuate the area of the pit affected. Such a system has been developed by GroundProbe in South Africa, with the vital driving force for the project being provided by the Anglo Platinum Mogalakwena mine operation based at Mokopane. The mine based development of the system was perceived as an essential aspect in the development of the successful system. From an early stage, the mine provided essential input on both hardware and software developments to allow the system to be rapidly integrated into the mining operation. This paper describes the pit evacuation alarm system that was developed and discussed the benefits obtained from a mine based development program.

Jan 1, 2008

By J. A. L. Napier

The evaluation of stress distributions and deformations in the vicinity of tabular mine layouts has been carried out routinely for many years using the displacement discontinuity boundary element method (DDM). In this approach, mine layouts are approximated as irregular shaped planar cracks (or slits) where the ?width? of the crack, corresponding to the excavation height, is assumed to be negligible compared to the in-plane, lateral dimensions. Early implementations of this approach have employed square element tessellations with constant displacement discontinuity component values. This is generally restrictive when considering the analysis of irregular pillar layouts or the intersection of fault planes with excavations. This paper describes a general revision of this approach in which triangular or quadrilateral element shapes are introduced in conjunction with higher order variations of the displacement discontinuity shape functions. This facilitates an accurate evaluation of detailed stress and displacement components close to excavation surfaces and allows the investigation of local damage and failure behaviour associated with particular geological structures such as weak parting bands or weak layers. A method to embed these features in an efficient and accurate multi-level solution scheme is described. This formulation can be extended to allow the analysis of shallow-depth pillar layout problems, facilitating the assessment of the interactive response and stability of shallow depth pillar layouts. A simple deformation model is introduced to facilitate the assessment of pillar failure and bursting potential in shallow mine layouts. The computational techniques described here have been implemented in a computer code called TEXAN (Tabular EXcavation ANalyser) and are illustrated by the simulation of a particular multiple reef pillar mining problem in a shallow depth platinum mine.

Jan 1, 2007

A set of six design principles for rock engineering was developed by Bieniawski: design objectives; minimum uncertainty; simplicity of design components; state-of-the-art practice; optimization; and constructability. These principles translate into a ten-step design process. Although this methodology was developed for rock engineering, it is applicable to any design process, feasibility study, etc. Diligent use of such a process will ensure that a defensible design or evaluation has been carried out. Recently a ?strategic conversation? process has been identified by Ilbury and Sunter that includes the following ten steps: scope; players; rules of the game; key uncertainties; scenarios; SWOT analysis; options; decisions; measurable outcomes; and meaning of winning. A comparison of these steps with those of the design process shows a remarkable correlation. This is perhaps not surprising since engineering design is a strategic up-front issue, and front end loading in a project is critical to achieve the expected project performance. Based on the close correlation between the strategic conversation and engineering design processes, a circular design process, rather than a linear process, is proposed. The ?circle of design? better reflects the importance of review and monitoring in the two phases of successful design and implementation?defining the design, and executing the design.

Jan 1, 2009

By K. L. Riemer

The West Wits Line first began yielding gold in the mid-1930s and is among South Africa's leading gold-producing areas. Gold mining operations are carried out amidst the occurrence of seismic events which cause both damage to underground excavations and injury and loss of life to production personnel. The feasibility of establishing a system to minotor the seismicity on all the Gold Fields mines was investigated during the early 1980s. This led to the establishment of a centralized seismic network in 1981. The system was structured around three major objectives. It uses Perkin Elmer (now Concurrent Computer Corporation) 16 and 32 bit mini-computers. The hardware in use at both the central and remote sites is outlined, giving a good insight into the role of computers in the system. The system software reveals the fast flow of data through the network; it can be divided into three categories: (1) data logging and transmission - remote sites, (2) data capture and communications - central site, (3) applications and research - central site. Several examples are given which show how the system is measuring up to its objectives. These case studies also indicate how the computers are effective in representing the seismic data collected. It is concluded that the use of computers enables the pin-pointing of seismic events on the West Wits Line within about 3 -4 minutes of their occurrence. The choice of hardware is largely dependent on the objectives of system, and the Gold Fields Network has chosen mini-computers because of the speed of communication and the large amount of data and storage required for research applications.

Jan 1, 1987