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By J. Githiria, D. Wachira

The conventional truck and shovel haulage system has become expensive to operate in most mines due to current strict environmental conditions, increase in depth and size of open-pit mines, increase in labour costs, and fuel costs. These factors have motivated the search for alternative material haulage options in open-pit mines. In-pit crushing and conveying (IPCC) system has been regarded as a plausible alternative in material haulage systems. However, usage of IPCC has been limited to a few mines due to limited knowledge of IPCC performance, and other technical factors of the system. This paper investigates, and evaluates the productivity performance of four types of IPCC systems (fixed, semi-fixed, semi-mobile, and fully mobile IPCCs) using mine productivity index (MPi). Using a model developed by MATLAB, the MPi for the four systems is computed using input variables such as availability, utilisation, performance and number of trucks and shovels in a limestone quarry. The mine productivity index for fixed, semi-fixed, semi-mobile, and fully mobile IPCC is obtained as 67.13%, 69.02%, 70.52%, and 71.52% respectively. In conclusion, the fully mobile in-pit crushing and conveying system is the most appropriate IPCC in the quarry, due to its better productivity performance compared to the other three IPCC systems and the truck and shovel system currently in use.

Sep 1, 2021

By E. Van Der Lingen, A. Paton

"The South African ferrochrome industry has been faced with various challenges during the past few years, such as influences from the market, manpower strikes, China’s control over the demand for both ferrochrome and chrome ore from South Africa, and electricity supply constraints, placing increased pressure on the local industry to improve output in order to remain globally competitive. The year 2016 brought a dramatic change in the local ferrochrome industry, being marked by higher chrome ore prices and the takeover of some idle smelters.This study investigates the methods of technology acquisition used in various parts of the ferrochrome smelter value chain throughout a business cycle, and whether there is a preference for a specific acquisition in an explicit part of the value chain. The study also considers whether companies prefer to partner with local or global institutions for collaborative development, and the methods used by companies to protect their technologies.IntroductionSouth Africa holds the world’s largest chrome ore reserves and was the world’s largest producer of ferrochrome until 2012, when China became the leading ferrochromeproducing country. South Africa’s chrome ore (chromite) supply into the Chinese market has risen significantly from 36% of China’s total chrome ore imports in 2010 to more than 70% in 2016 (Fowkes, 2014; Creamer, 2017). China controls the demand for both ferrochrome and chrome ore from South Africa (Fowkes, 2014). China’s high import rate of chrome ore has resulted in ferrochrome prices being driven down and a depressed ferrochrome market. The South African industry meets the chrome ore demands but loses out on ferrochrome beneficiation.Furthermore, the local ferrochrome industry has been threatened with the overall poor competitiveness over the past few years, resulting in four of the eight producers ceasing operations at the beginning of 2016. Challenges experienced by the producers, some of which are directly linked to production costs, include influences from the market, productivity that was affected by wildcat strikes, China’s control over the demand for both ferrochrome and chrome ore, and electricity supply issues (Fowkes, 2014, 2013; Biermann, Cromarty, and Dawson, 2012). Ferrochrome production is energy-intensive and South African producers have faced higher electricity costs, electricity supply complications, and a weaker currency exchange rate since 2009."

Oct 1, 2018

By John W. Harbaugh, Alfredo Prelate

The goal of the study described here is to develop objective. quantitative methods for estimating the outcome probabilities of exploratory oil wells. The study employs the 're-experience' approach, in which historical data are used in a manner which attempts to recreate the past. Our past experience, of course, is the principal guide to the future. To appraise present-day oil prospects, however, we must analyze prospects that have been drilled in terms of how these former prospects were interpreted before they were drilled. An analysis of how they are interpreted after they were drilled is an inadequate guide to the future because our hindsight knowledge is superior to our foresight knowledge. Objective calculation of future outcome probabilities, then, requires that we attempt to treat past information in a manner analogous to that in which we must treat present information in forecasting future outcomes.

Jan 1, 2014

By U. König, N. Norberg

Ore mineralogy defines the properties during processing and metal extraction. Fast and frequent monitoring of the mineral content and related process parameters brings value to the mining operation and material processing. Decreasing ore qualities and increasing prices for raw materials require a better control of processed ore and a more efficient use of energy. Traditionally quality control in mining industries has relied on time consuming wet chemistry or the analysis of the elemental composition. The mineralogy that defines the physical properties is often monitored infrequently, if at all. The use of highspeed detectors has turned X-ray diffraction (XRD) into an important tool for fast and accurate process control. XRD data and their interpretation make the difference in the identification of minerals, in describing their distribution in ore bodies and in their beneficiation during processing. The use of statistical techniques such as Partial Least-Squares Regression (PLSR) or Principal Component Analysis (PCA) on XRD raw data has been successfully trialled to determine raw materials and processed ores, in addition to well established methods for mineral identification and quantification. PLSR can be used to correlate process parameters directly from the XRD pattern without investigating the mineral content. Hidden information present in the XRD pattern but not determined with traditional methods can be used to improve the characterisation of the analysed materials. The practical use for the direct determination of process relevant parameters during exploration and ore beneficiation will be illustrated in several case studies from mining and ore processing. Keywords: Geometallurgy, mineral monitoring, X-ray diffraction, process efficiency

Jan 1, 2020

By Q. Liu, S. Liu, Y. Cui

To reduce the frequency of mining incidents and improve safety and production efficiency, it is important to develop technology for the autonomous positioning and navigation of mining equipment, without the assistance of satellite navigation signals. In this study we review the current technological environment for positioning and navigation underground and present several integrated navigation strategies. Existing underground positioning and navigation technology is described, and the performances of different methods based on this technology analysed and compared. The combination types and positioning effects of underground positioning and navigation strategies are discussed. Recent research directions for filtering methods and positioning estimation algorithms for underground positioning and navigation are reviewed. Finally, we summarize the future direction of underground positioning and navigation technology and related algorithms.

Jun 1, 2021

By L. Scott, M. A. Goncalves

Effective communication is a sought-after non-technical skill in the health, safety, and environmental (HSE) function and is fundamental in achieving an organization’s safety objectives. While different channels are used to communicate HSE matters, many organizations employ posters, videos, and/ or signs containing images to convey information. Communication through signage and graphical hazard symbols has been regulated in standards, but vast sections of HSE communication are bespoke communications and exist outside the sphere of standards. Effective HSE communication through images requires an understanding of the organizational culture in which the images will be used, as well as an understanding of the semiotics of the images themselves. Creative interpretation within HSE communication can create situations where the message that was received is not the message that was intended, leading to confusion and misinterpretation. This paper is aimed at elucidating the semiotics of South African HSE visual content. It was found that the indexical mode of images was most preferred in visual communication, and text-only designs the least preferred. Senders and receivers of messages differ in their opinions on the complexity of HSE communication.

Feb 2, 2021

By C. Birch, J. Perold

"Due to the challenging geological environment of the Postmasburg Manganese Field (PMF), a study was conducted to determine if any benefits would derive from the inclusion of resistivity data during threedimensional (3D) modelling of the manganese resource. This was achieved by estimating manganese resources from 2011/2012 drilling data and comparing them with manganese resources estimated from the same drilling data and resistivity data collected during 2013 and 2017.Both models were adjusted to limit their extent to the same 3D modelling space. Significant volume and tonnage differences were observed for all lithological units. The greatest differences were noted in the manganiferous zones of alteration – 7.200 Mt for the geological model versus 3.700 Mt for the geoelectric model.This study showed that the inclusion of resistivity data can reduce exploration costs significantly, as a direct consequence of the resistivity data allowing more accurate siting of boreholes. This decreases the number of boreholes, samples, and analyses required due to the 3D electrical delineation of mineralized areas prior to drilling.An additional benefit is the ability to more correctly forecast the net present value of an operation due to more accurate estimation of manganese resources and stripping ratios. This is clearly demonstrated by the estimated gross profit estimation of R409 million for the geological resource model versus R264 million for the geoelectric resource model.The addition of resistivity data can, therefore, reduce exploration costs and can increase confidence in geological and financial modelling. It would be reasonable to conclude that this approach could also be used for karsthosted massive sulphide deposits. IntroductionAccording to Corathers (2014) and Gajigo, Mutambatsere. and Adjei (2011), South Africa holds between 75–80% of global manganese reserves, followed by Ukraine (10%), Australia (3%), India (3%), and Gabon (2%). The known, land-based, manganese resources located elsewhere are estimated at 2%.The majority of economically important sedimentary manganese ore deposits in South Africa are situated in the Northern Cape Province (Gutzmer, 1996). Manganese ores of the Postmasburg Manganese Field (PMF) were discovered in 1922, and the Kalahari Manganese Field (KMF) in 1940. According to Astrup and Tsikos (1998) and Gutzmer (1996), mining of manganese ore from the PMF ceased during 1989 in favour of the superior quality of manganese ore from the KMF."

Mar 1, 2019

By O. Koatlhai

Mine closures have traditionally prioritised environmental rehabilitation, often overlooking the deep socio-economic disruptions that follow, particularly in mining-dependent communities. This paper argues that mine closure should not mark the end of prosperity but rather the beginning of a sustainable transition. The coproduction model, which integrates community participation, governance, and economic planning, offers a transformative approach to closure planning. Drawing on case studies from Ghana, Zambia, and Indonesia, this research examines the successes and failures of past closures, highlighting the critical role of stakeholder engagement, skills development, and economic diversification. By incorporating emerging technologies such as AI-driven economic forecasting, blockchain for governance transparency, and decentralised finance (DeFi) models, mining companies can ensure a just and sustainable post-mining future. This study challenges outdated closure models and presents a forward-looking strategy that sees mine closure not as an endpoint, but as a catalyst for social resilience and economic transformation. It underscores the need for policy reforms, stronger governance, and investment in alternative industries to prevent mining towns from becoming economic wastelands. By shifting the paradigm from remediation to regeneration, this research calls for a new era of mine closure planning that puts people and prosperity at its core.

Apr 25, 2025

By R. Rumpold

The platinum group metals (PGMs) palladium, platinum, and rhodium represent the key materials for automotive exhaust gas treatment. Since there are currently no adequate alternatives, the importance of these metals for the automotive industry is steadily rising. The high value of PGMs in spent catalysts justifies their recycling. The state-of the-art technology is to melt the ceramic carrier and collect the precious fraction in a liquid metal bath. As the feed material has quite high melting points, huge amounts of energy are required for this process. Hydrometallurgical treatments of the spent catalysts offer the possibility to recycle the PGMs with less energy and time demands. Moreover, automotive catalysts contain further valuable materials to improve the exhaust gas treatment. These compounds, like cerium oxide, cannot be recovered in pyrometallurgical processes. This paper deals with a special process that uses hydrometallurgical principles to recycle the valuable metal fraction from spent automotive catalytic converters. Hydrochloric acid in combination with hydrogen peroxide is used as leaching agent. This combination selectively dissolves the PGMs and the cerium, which can be recovered in separate steps. As the leaching solution is regenerated and reused, wastewater generation is minimized. Furthermore, the process residues constitute potential byproducts.

Jan 1, 2012

By T. Grewar

"South Africa is a water-scarce country, rated as one of the 30 driest countries in the world. Worryingly, government expects water demand to outstrip supply as early as 2025. The South African government believes that substantial volumes of water can be made available through the reuse of treated mining-impacted water. Currently, however, large volumes of treated mining-impacted water are produced, often with no end use in mind other than discharge or disposal, when these treated effluents may have further uses in applications which are currently and unnecessarily using high-quality water. Treating the wastewaters to levels that meet ’fitness-for-use’ guidelines for alternative applications such as agriculture, sanitation, or industrial processes will reduce the treatment cost burden compared to potable water production. The primary conclusion of this review is that the most suitable option for re-using treated mine-impacted water is in agriculture, for irrigation of crops (food, forage, or energy crops), which currently and unnecessarily makes use of the majority of South Africa’s high-quality resources or potable water. Other findings include the realization that although guidelines and legislation for water re-use in South Africa exist and are readily available, they tend to be contradictory and confusing in many cases. It is imperative that these ambiguities and incongruities in the available guidelines and legislation for water re-use be clarified and updated swiftly IntroductionSouth Africa is a water-scarce country and is currently rated as one of the 30 driest countries in the world, with an average rainfall of 490 mm/a, approximately half of the global average. As an indicator of the degree of regional variability in South Africa’s water supply, it has been shown that 70% of all runoff is from approximately 20% of the land area. Regardless of the water scarcity faced in South Africa, our water conservation track record is poor, with an average consumption of 280 L/d per person, almost 60% more than the global average of 175 L/d per person. Around 40% of this allocation is utilized in watering lawns and gardens (Zhuwakinyu, 2017).The South African government predicts water demand to outstrip supply as early as 2025. On an international scale, the situation appears just as dire, with the United Nations High Level Panel on Water (HLPW) expecting a 40% water shortfall by 2030, which may affect up to 1.8 billion people based on current water demand trajectories (Zhuwakinyu, 2017)."

Mar 1, 2019

By A. Lebedev

Application of dynamic simulation for a base metal processing plant is discussed. The plant receives ore of variable quality from two pits and blending had to be applied to maximise recovery. The plant employs multiple stage crushing, screening, dense media separation, two-stage milling, flotation and further filtration. Stockpiles and bunkers are used in the plant to cater for breakdowns and operating delays, the latter being appropriately incorporated in the model. A detail dynamic simulation model was constructed from the rock face to the filtration plant to assist the plant design, notably with definition of the ore blending method, sizing storage capacity and in-plant conveyors. The plant model was broken down to capital equipment items and various feed types and mass balances were tested to ensure that the production target is met. The dynamic simulation tested the proposed blending method, identified bottlenecks, produced risk profiles for all strategic storage facilities and overall helped minimise the project risks and improve confidence in the plant design. Keywords: Dynamic simulation, ore grade, blending, capacity, risk profile, throughput, utilisation

Jan 1, 2020

By N. C. J. Dempers, J. A. L. Parker, R. A. Wildenboer

More than half of global cobalt reserves are located in the Southern African Copperbelt, stretching over the northern tip of Zambia and southern area of the Democratic Republic of Congo. In these areas, cobalt is not typically produced as a primary product but as a byproduct of copper production. Ores from this region often contain uranium, which is readily leached under typical copper leach conditions and enters the process. Uranium does not pose a challenge to copper production, but it becomes a significant problem when it follows cobalt to the cobalt precipitation process and results in unacceptably high levels of U in the final Co product. This paper evaluates the existing process technologies that can be used to remove uranium from cobalt-bearing process streams, including phosphate precipitation and ion exchange. Advantages and disadvantages of the uranium removal processes are discussed, and important design considerations are highlighted.

Jan 1, 2023

By B. M. Thethwayo

Graphite blocks are currently used in the concentrate - slag zone in primary PGM smelters, and can possibly be extended to the matte zone. This project evaluates the interaction between synthetic matte and graphite blocks on a laboratory scale. Static crucible tests were performed where graphite crucibles (prepared from standard and high-grade graphite) were filled with synthetic matte (27.7 per cent S ? 46.1 per cent Fe ? 17.0 per cent Ni ? 9.2 per cent Cu) and heated to 1550°C for different time periods (1?5 days). Matte penetration was evaluated using a SEM, while graphite dissolution was evaluated by measuring the carbon content of the matte with a LECO carbon analyser. Matte penetrated into standard grade graphite up to approximately 2 mm, while matte infiltration into the high grade graphite was limited to the immediate hot face. The saturation solubility of graphite in the synthetic matte at 1550°C was 0.43 per cent. Copper, iron, nickel, and sulphur were detected in an accretion that formed in the water-cooled part of the furnace. This accretion consists of mainly Cu-S and Cu-Fe-S based phases.

Jan 1, 2012

By A. Pareek, V. S. Masampally, V. Runkana

Mineral processing plants, in general, consist of comminution and separation circuits. Rougher flotation is considered as the heart of the separation circuit with concentrate grade and mineral recovery being the key productivity and quality parameters that affect the downstream operations and profitability. Online prediction of these parameters can help improve process performance in real-time. Past efforts to predict flotation cell performance have focused on building physics-based or machinelearning (ML) based models. Although physics-based models are popular in process design applications, ML models are more appropriate for online monitoring, control and optimisation due to their lower computational requirements. Deep learning (DL) is gaining prominence nowadays for application in industrial operations where a large amount of data is available. We have developed a DL model based on long short-term memory (LSTM) neural networks to forecast the two key performance indicators (KPIs), namely, mineral recovery and concentrate grade in a mineral processing plant. Rougher feed characteristics such as mineral grade and particle size distribution, upstream measurable disturbances such as throughput of the comminution circuit and pulp density, and control variables such as aeration rate, pH, and collector addition rate are considered as explanatory variables to train the model. The model was tested with data from an industrial mineral processing plant. For real-time dynamic predictions, the trained model appropriately accounts for mismatch in measurement frequency of real-time process data and off-line laboratory analysis data. Such a time series model can be used as a state observer in model predictive control techniques for optimal control of unit operations in a mineral processing plant. Keywords: Mineral processing, flotation, time-series, dynamic modelling, deep learning

Jan 1, 2020

By N. Coulson, P. F. Stewart

The Mine Health and Safety Act No. 29 of 1996, as amended, embeds an occupational health and safety management system that facilitates communication between representatives of the state, capital, and labour. In underground mines, two communication loops between these role players serve to separate the production chain of command from the political tripartite relations. Worker-elected health and safety representatives are involved in both communication loops, but are severely constrained in escalating their occupational health and safety concerns to the legalpolitical level. This has a direct bearing on the exercise of the Right to Refuse Dangerous Work (RRDW). As previously reported, health and safety representatives were found to primarily consult their production supervisors in preference to their trade-union representatives. This follow-up article presents production supervisor perspectives on the RRDW. The study demonstrates how, for mineworkers, the two distinct communication subsystems constrain, rather than facilitate, implementation of the RRDW.

Apr 14, 2024

By J. Mothomogolo

Mining projects are capital-intensive and are also characterized by high technical and economic risks. These factors pose challenges to mining entrepreneurs when they seek to raise seed capital for mining start-ups. There are limited sources of mining investment funds in South Africa and each has shortcomings due to one reason or another. Another impediment is South Africa?s status as a developing economy, in which the standards of living ? which in turn influences the savings culture ? the limited GDPs and budget, the socio-political environment, and banking, mining, treasury and other regulations, determine the size of investments, particularly in mining ventures. The proposed funding mechanism was developed with the aim of filling the gaps identified in existing funding mechanisms that were developed by the government with the introduction of the Minerals and Petroleum Resources Development Act (MPRDA), 2002. The shortcomings identified were presented to the study participants as questions to obtain views that were used to define innovative ways of raising mining start-up capital. Most participants in the study supported the derived hypotheses and proposals, and these were used to refine the proposed mechanism for mining investment in South Africa. The proposed funding framework is aimed at encouraging interaction between mining entrepreneurs, government, and the investors to align goals and expectations when undertaking a mining investment.

Jan 1, 2012

By M. Le Roux, Q. P. Campbell, M. Fofana

The determination of densimetric information to predict coal washabilities is an important step in characterising the feed material, as well as the performance of operating plants. However, traditional methods like float-and-sink analysis are hazardous and time-consuming. This is especially true for finer particle size ranges, where very long settling times are required in a medium. De Beers Technologies recently developed a density analyser, known as the RhoVol, for use on diamondiferous kimberlite. Operating over size ranges from 25 mm down to 3 mm, it can determine the mass, volume, density, size and shape of all the particles in a given population and is thus able to provide information about the densimetric distribution on a single particle basis. A study was carried out to compare uncalibrated and calibrated RhoVol results to densimetric and size data obtained using traditional zinc chloride float-sink procedures, for three different coal samples in the size range 3 mm to 8 mm. The results indicate that the RhoVol can be used to provide simple, rapid and safe size-by-washability information for coal, provided proper pre-calibration is done, mainly to account for the effects of particle porosity in the density determination. Keywords: Coal washability determination, RhoVol, densimetric curve

Jan 1, 2020

By S Sondashi, F. J. Chidley, W. A. Grobler

Some of the challenges facing the flotation of base metal sulphides are the opening of new and varying ore bodies as well as maintaining essential skills in plants. Flotation reagent research focuses not only on improving flotation grade and recovery, but also on producing reagents robust enough to cope with changes. A group of recently developed co-collectors, activators, depressants and frothers are described together with a summary of results measured on base metal sulphide ores.

Jan 1, 2005

By E. Kuipa, J. N. Lekunze

The selection of an underground mining method stems from a multivariate analysis that considers geomechanical, geological, economic, and operational parameters. Even after identifying the most compatible method, there is no assurance that the mining company will achieve the best performance. The geological complexity of some deposits requires adaptations of methods described in the literature to obtain more selectivity and reduce mining waste. There are some studies on geometry of underground structures, but a methodology that describes an adaptation of a room-and-pillar mining method for ore bodies with down-dip varying from 20° to 25° is novel. The present work aimed to reduce dilution by adapting the traditional room-and-pillar mining method (TRP) to inclined ore boLittle attention has been paid to the rehabilitation of derelict and ownerless mines in South Africa after their lifespan. This paper aims to explore management gaps in legislation that have resulted in the non-rehabilitation of derelict and ownerless mines in South Africa. There is growing evidence that supports the distressing effects of mining on people living around these mines in the North West Province. This paper was motivated by the current socio-economic status quo of old mining towns, the influx of illegal miners (Zama Zamas), severe environmental damages, and the violence associated with derelict mines. Underpinning this research was an ecosystem approach and integrated resources management principles, which formed the foundation for the decision-making process.The researcher used a mixed-method approach and employed convergent techniques. A semi-structured instrument was used to collect data from 200 respondents. The results indicated that there is a dire need for community-based consultative processes, and an absence of clear guidelines for derelict and ownerless mines to pressure mine management to adhere to rehabilitation standards. Moreover, the mining charter is ambiguous regarding policy implementation, budgetary allocation, and duration of the rehabilitation of these mines. The paper concluded that management challenges associated with derelict mines can be reduced if all stakeholders follow the guidelines as outlined in the environmental legislative framework (NEMA) of South Africa while being open to innovations in line with international best practices. It also contributes towards the development of guidelines for the management and implementation of legislation related to derelict and ownerless mines in South Africa from a philosophical, theoretical, and policy perspectivedies. This new method is entitled short-hole room-and-pillar (SHRP). The equations that measure the dilution are defined according to the geometry of stopes and openings. The results comprise comparative analyses of the operational and planned dilutions to measure the performance of the SHRP method. The average operating dilution of the SHRP method was more than five times lower than the planned dilution according to the TRP method. Low operational dilution indicates high selectivity of the method and its potential to reduce underground mining tailings.

Oct 9, 2024

By K. Duffy, W. Valery, L. Pyle, P. Holtham

A conceptual scoping study was conducted to investigate pre-concentration options for upgrading ore from an Ag-Pb-Zn deposit. The low grade of the ore would result in only modest economic returns, given current market conditions. Several pre-concentration options were considered. These included: selective mining, crushing and pre-screening (following either standard or high intensity selective blasting), bulk ore sorting, particle sorting, jigging, dense medium separation, or combinations of these approaches. Flowsheets were developed for each option, and the upgrade performance was modelled using Limn to determine mass balances and stream tables. Due to the limited availability of test work data, the models were based not only on what test data was available but also on case study data found in the literature. The Bazin technique was used to derive assay by size data for different streams following crushing. Equipment lists and preliminary layouts were established based on the stream tables, and capital and operating costs were estimated for each flowsheet. This information was used to carry out a preliminary economic evaluation using net present value and sensitivity analysis. In this case, the most economically attractive process was found to be particle sorting; although further benefits may be realised by combining with bulk sorting. This paper describes the methodology used and the key findings of the study. Keywords: Pre-concentration, pre-screening, ore sorting, jigging, Ag-Pb-Zn, particle sorting, bulk ore sorting

Jan 1, 2020