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By R. P. King

An Analytical Solution to the Batch comminution Equation R. P. King, Pr. Eng., B.Sc. (Eng.), M. Se. (Eng.), Ph.D. (Visitor). An analytical solution to the batch-grinding equation is presented in terms of the generalized hypergeometric series and the confluent hypergeometnc function. This solution is valid for selection functions that are describe~ piece-wise by functional forms of the type KOXB and by normalized breakage functions of the type B(x,x') = (x/x')x. These functional forms are sufficiently general to Include most practical cases. In particular, they can be used to describe selection functions that have a maximum.

By J. E. Friant, R. P. H. Willis, J. Maaren

Considerable effort is currently directed towards the development of non-explosive mining methods with the potential to allow continuous mining in narrow reef conditions. Besides improving productivity, continuous mining results in concentrated mining which has a significant impact on reducing infrastructure costs. CSIR: Miningtek recognized the potential of mini-disc cutters in a long or short wall application for selective hard rock mining in 1999. EEA was chartered to build a 780 mm diameter by 800 mm deep drum cutter head. While EEA designed and built the head, CSIR designed and built the drive mechanism and chassis for the trial machine. After assembly and shop testing at CSIR’s facility, the machine was shipped to a platinum mine for trials. This paper traces the development of mini-disc cutters and their application in South Africa.

Sep 1, 2001

It is well understood that to develop wagon wheels with higher abrasion resistance, fracture toughness, and fatigue resistance, steels with lower amounts of inclusions need to be used. Clean steels are produced with technologies that minimize the amount of inclusions in the microstructure. The demand for cleaner steels is high, and lowering of non-metallic oxide inclusions and controlling their morphology, composition, and size distribution is vital. Reduction of residual impurity elements such as sulphur, phosphorus, hydrogen, nitrogen, and trace elements is essential in the production of cleaner steel. Material cleanliness is vital for fatigue endurance, since oxide inclusions may act as stress concentrators and initiation points for fatigue cracks. To better understand the relationship between the cleanliness and toughness of the 34-inch cast wagon wheels, two samples of different levels of cleanliness were supplied for investigation. This paper presents the results of metallurgical analysis using scanning electron microscopy(SEM), energy-dispersive spectrometry (EDS), and mechanical tests for the pearlitic high-performance cast rail wagon wheel (identified as Class B) that are currently being used. The Charpy V-notch impact test results for the three samples from wagon wheels were compared. With the aid of SEM/EDS analysis system, non-metallic inclusions in these steels were detected, and it was possible to determine the position, size, shape, and composition of each particle. Alumina and manganese sulphide inclusions could be identified as the dominant inclusion types in the investigated samples. Fracture surface analysis of the Charpy specimen with high inclusions indicated that transgranular cleavage was the predominant fracture mode. Fractography of fracture surfaces of Charpy impact test samples also showed improvement of toughness properties on the clean sample.

Jan 1, 2013

The successful commissioning of the Cerro Verde project in Peru at the end of 2006 marked the culmination of the efforts of many in the industry over many years to have high pressure grinding roll technology recognized and accepted as a legitimate alternative to the conventional approach to large-scale hard rock comminution circuit design. Other hard-rock projects that have recently adopted HPGR include Freeport (Indonesia), Boddington (Australia) and Amplats Potgietersrus (South Africa). With the increasing acceptance of this technology, the need for technical presentations and articles exhorting the industry to adapt has diminished somewhat, and it is considered appropriate now to shift the emphasis to the provision of information for those considering embracing change. This article endeavours to answer frequently asked questions on the subject of high pressure grinding roll technology, with particular reference to its application in the hard rock minerals processing sector.

Jan 1, 2010

By M. E. C. Snyman, N. Naudé

"Coal fines produced during processing are difficult to dewater and result in a lower quality product and consequent lower value. A South African coal mine experiences severe difficulties with belt filter dewatering operations due to the presence of fines reporting from the thickener underflows. Plant 2 currently handles super-fine particles of size -34 µm and has low belt filter efficiency: excessive moisture retention lowers the product quality and strains downstream processing. It was necessary to determine an alternative method for dewatering these fines. Blending of fine material with coarser material was proposed as a solution. The effect of coal particle size and layering during ultrafines belt filter dewatering was evaluated using various blends of the fine Plant 2 material with coarser Plant 1 material. The best layering arrangement of the two materials and its optimum blend required to achieve reduced filter cake moisture content was determined in practise using a vacuum filter to simulate belt filtration. A blend of the two materials gave improved dewatering efficiency for the belt filters compared with that of the Plant 2 material alone. The best layering configuration was with Plant 2 material at the bottom and Plant 1 material on top. The optimum blend for industrial applications comprised 48% fines from Plant 2. IntroductionFines are produced during the processing of coal. It is estimated that 2 to 3% of run-ofmine coal reports to the ultrafine portion (-100 µm) (le Roux, 2005). The particle size of coal is inversely proportional to the amount of water adsorption, so smaller particles adsorb more moisture. Moisture removal requires either mechanical processes or thermal drying: mechanical processes are less expensive, but the fines still have high moisture retention. Discarding of fines leads to economic losses, so it is essential that they be dewatered so that they can then be sold as a product: fines need to be treated for both resource management and conservation reasons (Kenney, 1994). Removal of free surface moisture from ultrafine coal particles using a belt filter therefore remains a process that needs to be continuously improved. Ultrafine coal originating from a thickener underflow is known to be difficult to dewater owing to factors such as filter cloth blockage and moisture retention due to clogging. Mixing of finer and coarser materials has been proposed to deliver better dewatering efficiency and improved the quality of the recycled water (Kenney, 1994)."

Mar 1, 2019

By P. N. Harris

On 23rd November, 1982, a party of 80 members of The South African Institute of Mining and Metallurgy left the Wanderers Club grounds at 07hOO, and were driven in two luxury coaches to the stainless-steel mill of Southern Cross at Middelburg. Southern Cross is a trade name adopted by MS & A (Middelburg Steel and Alloys), who operate two Alloy Divisions (at Middelburg and Krugersdorp) and one Steel Division (at Middelburg). METAL '83 The International Precious Metals Institute has scheduled a seminar on the platinum -group metals for Williamsburg, DB.A., on 10th to 13th April, 1983, and has announced its keynote speakers for each of the seminar's five sessions. Metee '83 METEC - the International Exhibition for Metallurgical Technology and Equipment with Congress - which was to have been held in Dusseldorf from 14th to 20th May, 1983, has been cancelled, and will probably take place in June 1984. Sampling Sampling and sample preparation are crucial activities in many areas of chemical engineering, in the energy and food industries, in metallurgical processes, and in mining and mineral engineering.

Jan 1, 1983

By A. M. P. Henderson

Twelve members of the Witbank/Middelburg Branch, on a technical excursion, were hosted by the Technical Department, Pinelands site, of AECI on 10th February, 1989. The tour opened with some well-presented talks on 'Permitted Emulsion Explosives', and the application of the 'French' test to the development detonators.

Jan 1, 1989

By E. J. Maunders

This paper describes briefly a computerised model of the South African electricity system which has been developed jointly by the Atomic Energy Board and the Electricity Supply Commission. The results of an analysis of this system have been subjected to a fairly extensive sensitivity analysis which reveals that up to the year 1990 between 680 and 700 million tons of coal will be required for electric power generation, together with between 7 000 and 10 000 tons of uranium. This result is fairly insensitive to data variations, but the prediction of a cumulative requirement up to the year 2000, of between 1 300 and 1 800 million tons of coal and 25000 to 70000 tons of uranium, proves to be very data-sensitive.

By J. P. Beukes

The production of ferrochrome alloy from chromium bearing chromite ores is conducted at high temperature under highly reducing conditions. However, albeit completely unintended, it is impossible to completely exclude oxygen from all high temperature process steps, with the corresponding possibility arising for the generation of small amounts of Cr(VI) species. Certain Cr(VI) species are regarded as a carcinogenic, with specifically airborne exposure to these Cr(VI) species being associated with cancer of the respiratory system. With approximately three-quarters of the world?s viable chromite ore reserves located in South Africa, and annual ferrochrome production approaching almost half of total annual global output, aspects of Cr(VI) generation and control are of particular relevance and importance to the local industry, and naturally to the global industry at large. This paper seeks to examine theoretical and practical aspects associated with Cr(VI)generation (based largely on experience within the local South African industry, but considered to be generally encountered in the broader global industry context), together with mitigating measures that can be applied within the context of the production processes. From the discussions it is clear that significant improvements in various Cr(VI)-related aspects have been made by the South African ferrochrome industry. However, it is also evident that several areas of uncertainty still exist, which require further research in order to better quantify risks and enhance the efficacy of mitigating steps. Keywords Hexavalent chromium, Cr(VI), ferrochrome production, South Africa.

Jan 1, 2010

By P. R. Jochens, D. D. Howat, R. B. Atmore

INTRODUCTION The Miller chlorination process has assumed a preeminent position in the refining of gold bullion, a position it has maintained for over half a century. In the early sixties considerable interest was aroused by the idea of producing a consistently high grade bullion at the mine smelthouses themselves. However, as the use of chlorine in industrial plants is associated with considerable hazards, oxygen was considered a natural alternative, apart from bing less expensive than chlorine. Partial refining at the mine smelthouses would considerably decrease the requirements made on Rand Refinery Limited as well as indicating the possibility of reducing final refining costs. An added factor would be the purer silver chloride obtainable, after prior removal of the base metals by oxygen injection, which would facilitate the production of high-purity silver. The free energies of formation of the oxides of the metals;- silver, copper, lead, zinc, iron and bismuth indicate that, with the exception of silver, these metals should be capable of removal as oxides by oxygen injection. Rose1 had shown that during injection of gold bullion, considerable loss of silver to the boraxsilver slag occurred and, furthermore, that copper removal was not efficient and oxide attack on the refractories was severe. Plant test work2 had confirmed the difficulty of copper removal, but had shown that zinc and lead were almost completely removed. The difficulty of copper removal by oxygen injection warranted further investigation. Also, the high decomposition pressure of silver oxide suggested that by suitable control of the slag composition it might be possible to reduce to very small proportions the silver carried into the slag as oxide. The oxidation of copper by oxygen injection and subsequent dissolution of the oxide in a slag may occur according to the following reactions; Reactions 4 and 5 were considered because of the relatively high solubility of oxygen in molten silver and silver alloys. Thermodynamic data indicate that there is little possibility of any reaction involving the formation of CuO occurring at temperatures above 1 000 °C. To ensure that the operative reactions 1 and 4 take place to the maximum extent, the following factors He significant. (a) an increase in the activity of the copper in the bullion, (b) an increase in the partial pressure of oxygen in the system, (c) an increase in the activity of the oxygen in solution in the metal, (d) a decrease in the activity of cuprous oxide in the slag. From practical considerations, the operative variable most easily susceptible to control is the composition of the slag. SOLUBILITY OF COPPER OXIDES IN BOROSILICATE SLAGS Very scanty information exists on systems containing copper oxides but the indications are that slags containing considerable amounts of boric oxide would possibly prove to be the best solvents for cuprous and cupric oxides. This is attributed to the fact that the activities of copper oxides are much lower in boric oxide slags than in slags in which silica is the main network former. The number of possible slags containing boric oxide was limited by consideration of liquidus temperature, viscosity, corrosive action on refractories, volatilization, and ultimately cost (for industrial application). Slags in the systems soda-boric oxide-silica and lime-boric oxide-silica were selected paying due attention to the above limitations. Additions of 5, 10 and 15 per cent cupric oxide were made to the finely ground, premelted slags. These mixtures were then reground and 2g quantities held in re crystallized alumina crucibles at temperatures of 1150°C and 1 250°C respectively for 30 minutes. The crucibles were removed from the furnace, rapidly cooled, cut in half longitudinally, and a thin section taken from one half was subjected to microscopic examination.

By A. L. Hinde, A. A. Bradley, P. J. Lloyd

The results of slow crushing tests in a stiff testing machine for both small and large step reductions of particle size are given. The energy consumption required to produce a given weight of minus 74 um material was determined when both single-crystal quartz and Witwatersrand reef were crushed. For comparison the two materials tested were also comminuted in a ball mill under optimum conditions. There are indications that slow crushing under stiff conditions is the most efficient method of breakage that can be devised. The comparison with ball milling results thus yields a value for the efficiency of ball milling of approximately 80 per cent. These results confirm that the best current estimates of milling efficiency, which are based on the free boundary surface energy of the material being milled, are probably too low by at least one order of magnitude.

By J. P. G. Pretorius, T. C. Partridge

The analysis of angular atypicality of lineaments as an aid to mineral exploration by J. P. G. PRETORI USc, M.Sc. (Pret.) (Visitor) and T. C. PARTRIDGE, Ph.D. (Natal) (Visitor) In an exploration project, data pertaining to 84000 lineaments in an area of 25 000 km2 were recorded. The total length of lineaments in intervals of one degree was determined. Angular intervals with Iow length densities were regarded as atypical. The proportion (by length) of lineaments with such atypical orientation was calculated for 5 km X 5 km grid squares. This index of angular atypicality was contoured and, used in conjunction with conventional photogeological techniques, contributed in a large measure to the success of the investigation.

Jan 5, 1974

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

By G. R. J. Cooper

In recent years attempts have been made to develop software packages for shallow seismic refraction data analysis. In most cases, mainframe computers were used which were generally non-interactive, did not support graphics and were unfriendly to operate. With these facts in mind, a user-friendly interactive processing package written in PASCAL has been developed for the IBM PC. The package allows the following operations to be performed. (1) data tying, equalisation of reciprocal and common shot times; (2) overburden velocity analysis; (3) refraction leg identification on time-distance plots; (4) elevation correction of refractor data; (5) forward and backward phantoming; refraction leg extrapolation; (6) 'bedrock' velocity analysis; (7) 'time-depth' plot computation; (8) depth calculation. Numbers (6) - (8) above involve Palmer's generalised reciprocal technique of refraction data interpretation. The program is extremely flexible and makes much use of interactive high resolution graphics and 'popup' onscreen menus. The velocity analysis sections have statistical routines built in to provide error estimation. The programs allow data interpretation to take place in the field with a portable microcomputer while the data are still being collected; this is obviously not possible with any cumbersome mainframe-based software. Hence it becomes possible to see the effects of varying the data collection parameters (such as geophone spacing) upon the resulting interpretation and so enable adjustments to be made where necessary. Hard copies of the data may be obtained at all stages of the interpretation process using a small (A3) plotter, or the graphics may be dumped to a dot- matrix printer if a suitable plotter is not available.

Jan 1, 1987

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 K. G. Lomberg

The integration of various highly sophisticated IT applications has been implemented at Bafokeng Rasimone Platinum Mine, a new platinum mine in the Anglo Platinum Group. This system is required to assist with compiling the necessary geological and grade information together with safety, environmental, ventilation, rock engineering and logistical constraints, to allow the design of the appropriate mining layout, to schedule this design, provide the necessary output for technical review and costing as well as budgeting to allow medium- and long-term business planning. In addition the production management and short-term planning needs must be met. This includes the plotting of all underground and surface infrastructure and excavations, giving the necessary mining and best cut instructions, daily production management, ore reserve and grade management as well as assisting with budgetary management. In addition all safety, health, environment and risk assessment requirements and legal requirements have to be met. The system at Bafokeng Rasimone Platinum Mine has met these criteria. Keywords: Platinum, Bushveld Complex, Mine Planning, Production Management

Jan 1, 2003

Guide Io Ihe Preparailon Of Papers For Publication In The Journal Of The South African Institute Of Mining And Metallurgy The following notes have been compiled to assist authors in the preparation of papers for presentation to the Institute and for publication in the Journal. All papers must meet the standards set by the Council of the Institute, and for this purpose all papers are referred to at least two referees appointed by the Council.

Jan 1, 1975

By E. L. Thyse, P. Bepswa

The Western Cape Mineral Processing Facility (WCMPF) is a collaborative educational initiative between the Department of Process Engineering at the University of Stellenbosch and the Chemical Engineering Departments at the University of Cape Town and the Cape Peninsula University of Technology. The primary objective of the WCMPF is to facilitate the education, development and graduation of suitably qualified engineering graduates and diplomats for the mining and mineral processing industries. In recent years the WCMPF has embarked on a number of initiatives aimed at improving the quality of mineral processing education which include, more importantly the introduction of novel ?end to end? or ?integrated? practicals. The practicals are developed around a specific mineral theme or route, which more than often includes the development of several new pilot plant practicals demonstrating key unit operations or processes in the selected mineral theme or route. The most recent mineral processing pilot plant practical programme is developed around the beneficiation of heavy mineral sands. The programme consist of the following developed pilotplant practicals: the online electrostatic separation of free flowing mineral sands using a Roche Mining Carrara high tension roll separator incorporating a Blue Cube Systems MQi in-line mineral quantifier; the production of titania-rich slag and pig iron from the smelting of ilmenite and anthracite in a 60 kW direct current (DC) plasma arc furnace as well as the mineralogical characterization of the feed and products; the continuous closed-circuit ball milling and screen classification of titania-rich slag. This paper illustrates the important role of a well-designed heavy mineral sands beneficiation pilot plant practical programme in facilitating the education and development of suitably qualified personnel for the mining and mineral process industries.

Jan 1, 2007

By J. Witley

"Narrow tabular platinum group element deposits in the Bushveld Complex of South Africa are typically evaluated by diamond core drilling from surface. Several short deflections are drilled from each mother hole in order to obtain multiple intersections at a close spacing (less than 1 m). Examination of the intersections from deflection drilling revealed the importance of these deflections in understanding the representivity of the borehole, obtaining an estimate of the nugget effect, and mitigating the undesirable effect of the high grade variability at the ultra-short range that is a characteristic of these deposits. The use of deflections in estimation was investigated by means of a number of techniques and scenarios in order to find the most appropriate way to use them in an estimate. A significantly improved level of confidence was gained from using multiple close-spaced intersections rather than a single borehole intersection. IntroductionThe Upper Group 2 chromitite layer (UG2 or UG2 Reef) is known for its remarkable geological continuity, being traced almost uninterrupted for tens of kilometres. However, what is often less well emphasized is the high variability in platinum group element (PGE) grade and thickness (and therefore PGE content) and internal reef stratigraphy over very short distances (several metres or even tens of centimetres).This paper examines the application of short drill-hole deflections in evaluating UG2 PGE mineral resources at Marikana in the western Bushveld Complex of South Africa."

Jan 1, 2017

By Kevin Peacocke

The future of Gravity ? Primary mineral recovery ? Enhancement of existing process efficiency ? Pre-Concentration ? Alternative? or ?New? production

Jan 1, 2006