Search Documents

By F. Terblanche, M. Holton, A. Kruger

The paper presents an optimal mine planning system designed to simultaneously optimize all the underground mines of large South African gold and platinum mining corporations. The system, code named PlanIT-OPTIM, is a multi-stage solution involving the use of adetailed 3D CAD-based mine planning system (CADSmine™V4). The mine design and scheduling rules defined in CADSmine™ are responsible for simulating mining sequencing, rock mechanics, and ventilation, etcetera. Feasible production ranges generated by CADSmine™ and various high-level mathematical models are used as inputs to a mathematical optimization engine. The optimization engine produces optimal production profiles (i.e. key business indicators such as tonnages, mineral and areas extracted per time period) by maximizing net present value. Other objectives such as profit continuity, production continuity and maintaining available reserves can also be specified as optimization criteria. The final step in the PlanIT-OPTIM process is to convert the optimal production profiles into practical and attainable business plans. This is achieved through the CADSmine™ Detail Optimization Engine that modifies the original CADSmine™ schedule to match the optimal production profiles. With current methods it is an impossible task to find the best business plan for a mining corporation in any reasonable period of time should conditions change (e.g. gold prices, exchangerates, grade estimates, etcetera). The fast turn around time achieved through PlanIT-OPTIM makes it possible to do several ‘what-if’ scenarios in a reasonably short time. PlanIT-OPTIM has already been used in the gold mining industry to find optimal business plans for a mine.

Jan 1, 2003

By D. McCarthy

Contract is a PC-based software program designed to satisfy the main features that have been identified to be lacking from cost estimation systems currently in place in the Australian coal industry. Contract was developed in conjunction with an Australian contracting company to refine the existing core structure used by the company for project evaluation. The key feature of Contract is the availability of analysis functions to explore multiple options within a contract project by altering identified variables. The ability to update project files has been incorporated into Contract to ensure that it is user-friendly and relatively simple to use. Lists of mining equipment and consumables are stored in MS ACCESS database files, along with the supplier details for each item. Each time a project is initiated there is a dynamic link to the database files and the most recent current information is retrieved and linked with the project. Contract provides an option to calculate the changes in metre unit cost as a function of the average development cost. Keywords: Contracting, cost estimation, sensitivity analysis.

Jan 1, 2003

By W. W. de Graaf, M. J. Ntsekhe

Klipspruit Colliery is experiencing coal losses, which leads to a negative impact on coal production and subsequently loss in revenue. This study aimed to identify the possible causes of coal losses in the No. 4 upper and lower seams. The objectives were to identify potential sources of coal losses through a literature survey, to identify areas where the coal losses occurred, to determine factors affecting coal losses, and to identify the most cost-effective methods to reduce coal losses. Highwall losses, top-of-coal losses, and coal edge losses were identified as the major areas of coal loss at Klipspruit. These losses were mostly attributed to the drilling and blasting practises of the pre-split, interburden waste, and the coal seams. Recommendations include re-visiting the current pre-split design and the tolerances adopted for the interburden and coal seam drilling and blasting design. It is furthermore recommended that Klipspruit implement a continuous improvement plan for the drilling and blasting and refresher training for the blasting crew and operators.

Jun 10, 2024

By P. R. Scheller

Reactions between metal and slag are of decisive importance for metallurgical processing. In the continuous casting process, where metal solidifies at the metal-slag interface, reaction products can cause surface defects, with quality damages of the cast products as a consequence. These investigations are focused on the contact area between casting flux and metal. The samples were taken from the mould during the casting process. The results show that layers up to approximately 300 nm from the slag/metal interface represent a specific reaction space. Sodium in this layer on the slag side plays a specific role, which is explained on the basis of experimental results. The transport of oxygen near the interface and the charge transfer is explained on the basis of the ionic character of the slag. The mass transfer rate of oxygen crossing the interface is calculated from measured data, and conclusions concerning the stability of the interfacial tension are made. Keywords: mass exchange, metal slag reaction, interface, ion transport, oxygen transfer, oxidation, casting slag, flux, sodium

Jan 1, 2004

By M. Arlandi, J. C. Monge

In this paper, the finite element method is used to obtain deformations of a rock tunnel. More than 3,000 numerical simulations and calculations were carried out. The analysis of this results has allowed to achieve mathematical formulations and graphs, to obtain in advance support monitored displacements in tunnelling construction, so they can be predicted before excavation and supporting woks. The application of the presented formulations and charts will aid engineers to control tunnel monitoring, reducing decision time when problems occur. The analysis is limited to cases involving elastic behaviour of the terrain for tunnels of average to good quality in rock, and to excavation sections of average or smaller dimensions for road tunnels. The results show that, in all cases, mathematical expressions to obtain induced displacements around tunnel excavations, have similar pattern than Kirsch (1898) expressions for circular excavations. As corollary of the achieved results, a method to estimate in situ natural geostress ratio K0=sh/sv , by means of convergence measurements, is presented. In diesem Beitrag wurden die Verschiebungen eines Tunnels durch die Methode de Finiten Elemente berechnet. Mehr als 3000 numerische Simulationen und Berechnungen wurden ausgeführt. Die Analyse dieser Resultate hat es ermöglicht, mathematische Formeln und Grafiken zu entwickeln, die zur Voraussage der Verschiebungen in Tunnel dienen, auch unter Betrachtung der verschiedenartigen Abstützungen. So können die Verschiebungen vor den Erdarbeiten und dem Bau der Abstützung abgeschätzt werden. Die abgeleiteten Formeln und Grafiken werden vor allem einen grossen Dienst für Ingenieure bei der Mithilfe zu zeitsparenden Entscheidungen im Tunnelbau und bei der Tunnelkontrolle leisten. Die analysierten Fälle sind auf eine elastische Modellierung des Baugrunds beschränkt, sowie auf eine mittlere bis gute Qualität des Felsens und auf die Aushebung von Abtragungsabschnitten mittlerer oder geringer Grösse für den Strassenverkehr. Die Resultate zeigen, dass in allen Fällen die hergeleiteten Formeln zur Berechnung der durch den Tunnelbau verursachten Verschiebungen um den Tunnel die gleiche mathematische Struktur haben wie diejenigen von Kirsch (1898) für kreisförmigen Bodenaushub. Als Korollarium der ausgeführten Berechnungen wird eine Methode zur Abschätzung der vorherrschenden in situ Geospannungs-Verhälniss K0=sh/sv angegeben, die von den Messungen der Verschiebungen im Tunnel ausgeht. Dans cet article, la méthode des éléments finis est utilisée pour obtenir les déformations d’un tunnel creusé dans la roche. Plus de 3000 simulations numériques et calculs ont été effectuées. L’analyse de ces résultats a permis de définir des modèles mathématiques et des abaques afin de prédire, avant l’excavation et les travaux de soutènement, les déplacements auscultés pendant la construction du tunnel. L’application de ces modèles et abaques permettra donc aux ingénieurs de contrôler les déplacements durant l’auscultation du tunnel et de réduire le temps de décision lorsque des problèmes surviennent. L’analyse est limitée au cas du comportement élastique du terrain pour des tunnels creusés dans de la roche de moyenne a bonne qualité, et à de sections d’excavation de petites à moyennes dimensions pour des tunnels routiers. Les résultats montrent que, dans tous les cas, les expressions mathématiques permettant d’obtenir les déplacements induits autour des excavations de tunnel, présentent des similitudes avec celles de Kirsch (1898) pour des excavations circulaires. Comme corollaire aux résultats obtenus, une méthode pour estimer le rapport des

Jan 1, 2003

By K. Sugawara, Y. Hirakawa, A. Sato

The rock mass properties such as deformability and permeability are highly dependent on the existence of cracks. The Ratio of Crack Opening Dependency (RCOD) was proposed as a new index to evaluate the deformability of infinite jointed rock mass. The RCOD is defined as the ratio of total amount of crack opening and the total deformation of jointed rock mass. The theoretical relation between the RCOD and the effective compliance of jointed rock mass is discussed and confirmed through two-dimensional numerical analysis by the SC-DDM, together with the applicability to the rock engineering. Les propriétés de masse rocheuse telles que la déformabilité et la perméabilité sont très dépendantes de l'existence de fissures. Le rapport de dépendance d'ouverture des fissures a été proposé comme un nouvel index d'évaluation de la déformabilité de masse rocheuse à assemblage infini. Le rapport de dépendance d'ouverture des fissures est défini comme étant le pourcentage de quantité totale d'ouverture des fissures et de déformation totale de la masse rocheuse assemblée. Le rapport théorique entre le rapport de dépendance d'ouverture des fissures et la compliance efficace de masse rocheuse assemblée sont traités et confirmés au travers d'une analyse numérique à deux dimensions par SC-DDM en même temps que l'applicabilité à l'ingénierie des roches. Die Felsmasseneigenschaften wie Verformbarkeit und Durchlässigkeit sind hochgradig abhängig von dem Vorhandensein von Rissen. Das Verhältnis der Riss-Öffnungsabhängigkeit (RCOD) wurde als neuer Index der Verformbargkeit von infinit zerklüfteter Felsmasse vorgeschlagen. Der RCOD wird als Verhältnis der Gesamtmenge der Rissöffnungen und der Gesamtverformung der zerklüfteten Felsmasse definiert. Die theoretische Beziehung zwischen RCOD und der effektiven Verformbarkeit von zerklüfteter Felsmasse wird diskutiert und durch zweidimensionale numerische Analyse mit SC-DDM bestätigt, zusammen mit der Anwendbarkeit auf Bergbautechnik.

Jan 1, 2003

By N. Demirel, O. Gölbasi

Draglines are massive machines extensively utilized in opencast mines for overburden stripping. The demanding working environment induces fractures, wear and tear, and fatigue failures in dragline components and eventuates in extended maintenance, lengthy downtimes, and loss of production. The bucket is the main source of external loads on the machinery, since interactions with ground materials take place in this region. This study aims to develop a generic finite element model of the stress on an operating bucket. This entails (i) three-dimensional modelling of a dragline bucket, (ii) analytical estimation of resistive forces in the bucket movement, (iii) three-dimensional simulation of the moving bucket using finite element analysis (FEA), and (iv) sensitivity analysis to examine the effect of formation characteristics on stress variation. Simulation results imply that the drag hitch and digging teeth are the elements of the bucket that are most prone to failure. In addition, sensitivity analysis indicates that internal friction angle of the formation is the dominant parameter leading fluctuations in stress values. Changes in stress level are least influenced by formation density.

Jan 1, 2015

A wide range of drill holes and process streams are sampled for resource estimation, grade control, and contractual purposes in the minerals industry. However, despite the availability of training courses, conferences and both national and international standards on correct sampling practices, it is still surprising how often little attention is given to ensuring that representative samples are collected for analysis. The reason for this is that the responsibility for sampling is often entrusted to personnel who do not appreciate the significance and importance of sampling, with cost being the main driving force rather than whether the sample is representative of the material from which it was extracted. This seriously undermines the precision and accuracy of the analyses subsequently generated and can render the analysis process a total waste of time and money and expose mining companies to serious, potential, financial losses. Company management needs to reverse this situation and ensure that sampling is given the attention it deserves to generate representative samples for analysis.

Jan 1, 2010

By M. G. Maruma

The effect of the amount of cold reduction and annealing temperature on the evolution of the texture of AISI 441 steel is reported. The steel was cold rolled by 62%, 78%, and 82%, followed by isothermal annealing of each sample at 900°C, 950°C, and 1025°C for 3 minutes. The crystallographic texture was determined by Phillips X?Pert PROMPD texture diffractrometer. Microstructures were characterized using optical microscopy and scanning electron microscopy (SEM).The results show that sample that received 78% cold reduction and annealing at 1025°C presented the highest Rm-value and lowest ?R-value, which would enhance its deep-drawing capability. In addition, this sample showed the highest intensity of shifted ?-fibre, notably {554}<225> and {334}<483>. It can therefore be concluded that the ?-fibre, which favours deep drawing, is optimal after 78% cold reduction and annealing at 1025°C.

Jan 1, 2013

By Z. W. Nkosi, M. Sephton, J. H. Potgieter

The exhaust system is a complex assembly of various components performing important tasks in harsh environments. Carbon steels have been used extensively in exhaust systems, but pressure for lower cost, increased fuel efficiency; lower hazardous emissions, weight savings and increased life expectancy have shifted the emphasis to stainless steels. In response to the growing consumption of stainless steels in automotive exhaust systems, the need to properly evaluate their corrosion resistance properties in order to ensure their appropriate use, has increased substantially. This paper evaluated the most common corrosion and oxidation tests developed that are used and applied it to four common stainless steels often employed in hot end exhaust components. In a summary considering the weight loss of an alloy, it general corrosion rate and pitting resistance under all the test conditions for hot end exhaust components, results indicate that 434 was by far the most corrosion resistant alloy, followed by 1.4509 and 321, and lastly 304 was the least corrosion resistant. In general, the ferritic stainless steels, especially 434, outperformed the austenitic ones under all the test conditions.

Jan 1, 2006

By S. M. Spottiswoode

Crush pillars are widely used in mine workings on the Merensky Reef in the Bushveld Complex to prevent panel collapses. Crush pillars are expected to fail as or soon after they emerge from the face and failure should occur non-violently. Unfortunately, violent failure occurs frequently and is said to be the main cause of seismicity associated with mining of the Merensky Reef. Recent work by Napier, Malan, and du Plessis has shown that limitequilibrium quasi-static models are able to simulate pillar failure using three states of strength of rock in pillars, namely intact, residual after failure, and decayed strength after later time-dependent (viscous) weakening. We have previously introduced an additional state of strength to account for the dynamic failure that results in seismic events, and found that this approach could be used to generate synthetic seismic catalogues similar to observed seismicity for deep-level gold mines, where seismicity takes place mostly on advancing faces. The less brittle seam material of the Merensky Reef, compared to the brittle quartzites and lavas of the Witwatersrand reefs, results in little or no face bursting and is modelled with an assumed plastic strain of some 0.005 over an effective stope width of 2 m before failure. When this plastic yield is surpassed, we allow the reef to fail ?seismically?. We show that synthetic seismic catalogues modelled in this way have some of the features of observed seismicity. Analysis is greatly facilitated using our custom-built software that reads the mine?s survey data into a database and presents results in an interactive graphical form.

Jan 1, 2014

By B. K. Loveday, N. V. Ramlall

A study was carried out to evaluate various batch flotation models for the recovery of minerals in a UG2 platinum ore. The major minerals in a UG2ore can be grouped as platinum group minerals, chromite, and siliceous gangue. This study also examined the entrainment of minerals during flotation. The models were ranked using statistical methods and an analysis of model-fit residuals. Entrainment parameters obtained from model fitting were evaluated for logic using a simple mineral-to-water ratio versus time plot. The foremost conclusion from the study was the importance of entrainment modelling. The measurement of water recovery increased the size of the data-set, and the inclusion of a simple entrainment model was statistically significant. The overall fit to the data was improved, and the entrainment model provided logical information on the recovery of gangue minerals that were not considered to be floatable.

Jan 1, 2015

By L. Forsbacka, M. Nakamoto, L. Holappa

Viscosity of the slag is one of the central parameters when producing FeCr in submerged arc furnaces. It contributes to smelting behaviour and reduction kinetics of chromite ore as well as to the Cr recovery by influencing the separation of dispersed metal droplets from the slag. A typical FeCr process slag contains 5-10pct chromium oxides, CrO and CrO1.5. The neural network computation was applied to the evaluation of viscosity for slags containing chromium oxides, and the prediction of viscosity in FeCr process slag was conducted. The main results in this estimation were that the chromium oxides in FeCr process slag lower its viscosity, and that the effect of CrO on the viscosity decrease is greater than that of CrO1.5.

Jan 1, 2007

By L. W. Burger

The need to establish and harmonise methodologies to quantify air emissions, atmospheric dispersion and the consequences of air pollutants (especially hexavalent chromium) from the ferrochrome industry became important aspects with the increasing demands for comprehensive impact assessments. The paper includes a synthesis of current knowledge on the following aspects: ? Locally and internationally accepted methodologies for the quantification of chromium emissions, including sampling methods and emission factors; ? A compilation of recognised and accepted air quality sampling and laboratory analysing techniques; and, ? Dispersion modelling and impact assessment tools. Depositing and removing materials from the chromium ore stockpile and wind erosion of exposed stockpiles result in mainly chromite emissions unlikely to contain significant amounts of hexavalent chromium. Pre-treatment processes such as drying, crushing and screening also produces chromium emissions, but mainly as trivalent chromium. The smelting of chromium is the major source of chromium emissions - open furnaces have the highest uncontrolled chromium emissions, followed by semi-closed and closed furnaces, respectively. Based on the current knowledge on emission rates, interim emission factors for particulate, total chromium and hexavalent chromium releases are provided. Ambient sampling and analytical methods to determine environmental exposure of the general public require that hexavalent chromium needs to be quantified in very low concentrations. Suggested sampling and analytical methods for both source characterisation and ambient monitoring are provided. The selection between dispersion models needs to be based on the size of the modelling domain and the complexity of the terrain. The discussion on dispersion models includes the US EPA?s Industrial Source Complex Model (Version 3), the AERMET/AERMOD suite of models and the CALMET/CALPUFF suite of models. Guidelines are also proposed for environmental exposure assessments including cancer and non-cancer health effects.

Jan 1, 2004

By D. P. Venter

When Oryx Mine down-scaled in 1994, focus was placed on development, with the primary aim being the exposure and proving of ore reserves. In order to achieve this aim, development ends had to be advanced to reef at the maximum possible rate. This in turn called for support methods which could keep up with the advancing faces, taking up minimum space and time for installation, while providing on the face a real coverage and effective long-term support. In the majority of the development ends which were located in fairly competent ground, the grouted rod development support proved to be adequate until such time as secondary support in the form of meshing and lacing could be installed. The ends developing towards the eastern boundary of the mine, especially in the ?C? block, encountered extremely adverse ground conditions due to the presence of smectite zones within the footwall quartzites. Smectites are a group of montmorillonite clay materials, mainly composed of hydrous aluminosilicates. They occur as minute platy crystals in the rock mass and are especially notable for their ability to absorb liquids. Generally, the zones are found in between the bedding planes of the host rock, and may vary considerably in thickness over short distances. Wherever the smectites were exposed by the development blasting, the rockwalls weathered as the smectites absorbed water and the condition of the tunnel rockwalls deteriorated rapidly. When the smectites were left exposed and allowed to weather, it became almost impossible to install secondary permanent support such as meshing and lacing at a later stage. To minimise the exposure time and subsequent deterioration of the smectite zones, it was recommended that all development ends encountering smectites be shotcreted as soon as possible after blasting. In developing a shotcreting support methodology, both a drycreting and wetcreting system were investigated. The situation at the time ruled out the use of a wetcreting system on the basis of the extensive and costly infrastructure required, as well as its limited manoeuverability. Instead, it was decided to opt for as maller scale but more manoeuverable drycreting system. The system utilized a number of portable drycrete machines with pre-bagged cement, which could support several development ends in close proximity. Initial trials using normal 30 MPa shotcrete on 19level proved successful and the system was implemented.

Jan 1, 1998

By J. M. McKinley

Mineral exploration programmes around the world use data from remote sensing, geophysics, and direct sampling. On a regional scale, the combination of airborne geophysics and ground-based geochemical sampling can aid geological mapping and mineral exploration. Since airborne geophysical and traditional soil-sampling data are generated at different spatial resolutions, they are not immediately comparable due to their different sampling density. Several geostatistical techniques, including indicator cokriging and collocated cokriging, can be used to integrate different types of data into a geostatistical model. However, with increasing numbers of variables the inference of the crosscovariance model required for cokriging can be demanding in terms of effort and computational time. In this paper a Gaussian-based Bayesian updating approach is applied to integrate airborne radiometric data and ground-sampled geochemical soil data to maximize information generated from the soil survey, enabling more accurate geological interpretation for the exploration and development of natural resources. The Bayesian updating technique decomposes the collocated estimate into two models: prior and likelihood models. The prior model is built from primary information and the likelihood model is built from secondary information. The prior model is then updated with the likelihood model to build the final model. The approach allows multiple secondary variables to be simultaneously integrated into the mapping of the primary variable. The Bayesian updating approach is demonstrated using a case study from Northern Ireland. The geostatistical technique was used to improve the resolution of soil geochemistry, at a density of one sample per 2 km2, by integrating more closely measured airborne geophysical data from the GSNI Tellus Survey, measured over a footprint of 65 x 200 m. The directly measured geochemistry data were considered as primary data and the airborne radiometric data were used as secondary data. The approach produced more detailed updated maps and in particular enhanced information on the mapped distributions of zinc, copper, and lead. The enhanced delineation of an elongated northwest/southeast trending zone in the updated maps strengthened the potential for discovering stratabound base metal deposits..

Jan 1, 2014

Often plant performance suffers as a result of poor control. Poor control leads to low mill throughputs, poor classification and less than satisfactory concentrate grades and overall recoveries. By using the appropriate control tools, substantial gains in plant performance can be made. Mintek?s MillStar and FloatStar controllers have been implemented at various sites across the world. The MillStar controller incorporates leading technology that controls process units from the mill feed through to the flotation feed. Typical results show that milling circuit throughput is increased by 6-10 % and the final product grind size is tightly controlled, thereby enhancing flotation performance. The FloatStar controller is aimed at stabilising and optimising flotation circuits. Through improved level control alone, recovery improvements of up to 1 % have been achieved. Furthermore, by using on-line grade analysers, the controller stabilises final concentrate grades, whilst maximising flotation recovery.

Jan 1, 2005

By P. J. Hancox

Heavy mineral deposits have been known from Liberia since the1950s from both river and beach placers. The heavy mineral content of beach sands ranges between 28?62% and the suite includes ilmenite, rutile, zircon and magnetite. These occur together with kyanite, sillimanite, staurolite and garnet. The average ilmenite content is 82% with minor zircon (11%), rutile (6%) and monazite (1%). The ilmenite is, however, of poor quality with haematite intergrowths and a titanium content ranging from10?42.4% (average ±25% TiO2). The amounts of rutile and zircon, while of suitable quality, have also previously been deemed too low for economic exploitation.

Jan 1, 2000

Caving of the second lift of the E26 orebody at Northparkes Mines was monitored with a comprehensive package of instrumentation, including an ISS seismic monitoring system. Seismicity was collected by an array of 19 triaxial accelerometers and 9 uniaxial geophones, giving a high quality seismic data set. The seismic response to block caving at Northparkes has been divided into two papers. The first paper focuses on the seismicity during undercutting. The second paper deals primarily with the seismicity during cave propagation during initial cave production. In this paper, traditional seismic monitoring concepts are applied to seismicity during cave mining. More than 40 000 seismic events were recorded during cave undercutting between February and January 2004. Events up to local magnitude +1.3 were recorded near the mine during undercutting, with event rates of up to 500 per day. Analysis of frequency-magnitude distributions, S-wave to P-wave energy, and temporal variations in event magnitude all gave insight into the seismicity recorded. In addition, a new technique, called apparent stress time history, was shown to be sensitive to stress change from undercut blasting, and useful to identify significant periods during cave development. A significant difference was identified between the cave back location and the halo of seismic events above the cave. Throughout the undercutting, the a seismic zone of loosening was typically 50 to 70 metres in vertical thickness. Based on the seismicity, a stress driven rock mass failure model is proposed. Early in the undercutting, seismicity and movements in the seismogenic zone were directly triggered by stress change from undercutting. Towards the end of undercutting, seismicity was virtually uncorrelated with undercut blasting, and likely due to the onset of cave initiation.

Jan 1, 2008

By T. Mapeta, S. M. Rupprecht

Discussions on reasonable prospects for eventual economic extraction (RPEEE) include the CRIRSCO 2019 reporting template, JORC 2012, SAMREC 2016, CIM 2019 Guideline, and Regulation SK-1300. These reporting codes all conform to the principles of reasonable prospects for eventual economic extraction. To demonstrate that all mineral resources align with the RPEEE principles, the Competent Person is responsible for endorsing the mineral resource estimate. Moreover, establishing mineral resources and RPEEE requires technical input from numerous technical specialists, such as mining and geotechnical engineers, metallurgical engineers, social and environmental specialists, financial and governmental practitioners, and more. The aim is to improve the transparency of the disclosure of mineral resources and guarantee the investor or potential investor that the reporting of mineral resources is based on reliable technical, economic, environmental, social, and other relevant factors. This paper discusses the important protocols and definitions in some international reporting codes for the purposes of developing a guide memoire that will assist the Competent Person to interpret, establish and apply RPEEE appropriately and easily.

Jun 27, 2025