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By C. Montoya

This paper shows, through a case study, the impact of multivariate grade modelling upon mine design and mine planning. A deposit explored by drill holes is considered, in which the grades of five elements (copper, silver, molybdenum, arsenic, and antimony) are of interest. Forty alternative models of the deposit are constructed by fitting the joint correlation structure of the grade variables and using conditional cosimulation. In addition, a reference model, obtained by averaging the alternative models, is also considered. The study shows that the resulting mine design (final pit characteristics and production schedules) is sensitive to the grade model under consideration, and that the design based on the reference model may not be optimal when compared to the alternative models based on cosimulation. However, when assuming a given long-term plan and extraction sequence, the grades and net present value (NPV) calculated on the reference model are unbiased with respect to those calculated on the alternative models with the same extraction sequence. The latter allow assessing the possible dispersion of the actual grades and NPV around their expected values, and are useful for the planner in order to determine the probability of meeting given production targets and of exceeding or falling short of given threshold grades. Additionally, unlike cosimulation, the separate simulation of each grade variable leads to unrealistic resource models and to biased results in mine design and mine planning. This approach should therefore be avoided, unless the grade variables are spatially uncorrelated.

Jan 1, 2012

By P. T. L. Koh, M. P. Schwarz

A series of parametric studies were carried out for a flotation cell using computational fluid dynamic (CFD) modelling to determine the local response of hydrodynamic performance measures to change in operating conditions. As an example, an Outotec cell was used to carry out the response analysis. The hydrodynamics of the flotation cell has been previously investigated by laboratory measurements presented by Schwarz et al (2019), and a CFD model of the cell was developed and validated using these measurement data (Schwarz et al., 2019). In this work, parametric studies have been performed by modelling the flotation cell at different stirring speeds and gas flowrates, varying above and below standard conditions. Predictions of void fraction, bubble size, bubble surface area flux and particle–bubble collision rate are presented showing the effects of increasing and decreasing stirring speed and gas flowrate around the base case. Generally, the total gas holdup in the flotation cell was found to increase with increasing gas flowrate. The bubble diameter was found to decrease with increasing stirring speed and increase with increasing gas flowrate. The collision rate increased with both stirring speed and gas flowrate. The parametric results show that there is a correlation between the bubble surface area flux Sb which is affected by stirring speed and gas flowrate, and the particle–bubble collision rate. With the collision rate as an indication of flotation collection, it is also possible to show that cell performance can improve more by increasing stirring speed than by increasing gas flowrate in a situation where everything else remains constant. The CFD results can form the basis for a Response Surface Method (RSM) analysis which can then be used for automated optimization of cell performance. Keywords: Flotation kinetics, computational fluid dynamics, bubble surface area flux, particle-bubble collision rate

Jan 1, 2020

By E. Dervaric

The main purpose of this paper is to introduce the main strategic restructuring aspects of companies that are directly (coalmines) or indirectly (companies that depend on coalmines) linked to coalmining. An attempt is also made to determine the principal factors required for the successful execution of a restructuring process in companies focused on the basic activities of coalmining, such as companies that provide supporting activities. The restructuring process exerts an influence on the whole area that relies on coalmining. So coordination of activities among the government, the local community, and the coalmine is very important. This is the major premise of this paper. The first section of the paper focuses on identifying and analysing the key factors in restructuring and a selection of key methods, drawing on past and present practice. The key factors to be considered in a model of enterprise restructuring in the coalmining sector are considered. The second section is dedicated to the actual design of the model of enterprise restructuring in the coal industry. The proposed model is based on positive experiences in the restructuring of coalmining companies in Europe, with an emphasis on Slovenia, successful approaches to crisis management in corporations, and identifying key areas in bringing about a strategic turnarounds in company operation. To support the argument for the key business areas, a brief summary of empiric findings has been included to demonstrate the applicability of the proposed model and the restructuring process. The summary is based on the survey done in both Slovenian coalmining companies (especially in Velenje Coal Mine) and their subsidiaries. The conclusion integrates key findings and outlines issues for further consideration and discussion. Keywords: restructuring, coalmining, Velenje Coal Mine, strategic factors, restructuring model.

Jan 1, 2008

By T. Feroze, B. Genc

"Blind headings in room and pillar coal mines are a major source of methane and coal dust. Most methane and coal dust explosions therefore occur in the blind headings. The primary cause of these explosions is the disruption of the local ventilation system. Line brattice (LB) ventilation systems are used to ventilate blind headings by directing air from the last through road (LTR) into the heading. The amount of air available to ventilate the face of the empty heading depends on the heading dimension, settings of the LB, and velocity of air in the LTR. LBs are commonly installed by underground supervisory staff based on work experience, which may result in ineffective ventilation. The correct installationof LBs remains a challenge. In this study, a validated computational fluid dynamics (CFD) model has been used to analyse the effect of the LB ventilation system variables on the air flow rates close to the face of the empty heading. Full-scale three-dimensional models with various heading heights, heading depths, LB settings, and LTR velocities were simulated. The air flow rates and patterns at various locations inside the heading were analysed. A comparative study was carried out to quantify the effect of each of these system variables on the flow rates close to the face of the heading. Based on the findings, a user-friendly numerical model was formulated that can be used to estimate the flow rate close to the face of an empty heading for different practical settings of the system variables. This model can help the supervisory staff to swiftly implement the ventilation plan according to the regulations and the mine standards. The model can also serve as part of the curriculum for educating future mining engineers."

Jan 1, 2017

By T. Feroze, B. Genc

"Blind headings in room and pillar coal mines are a major source of methane and coal dust. Most methane and coal dust explosions therefore occur in the blind headings. The primary cause of these explosions is the disruption of the local ventilation system. Line brattice (LB) ventilation systems are used to ventilate blind headings by directing air from the last through road (LTR) into the heading. The amount of air available to ventilate the face of the empty heading depends on the heading dimension, settings of the LB, and velocity of air in the LTR. LBs are commonly installed by underground supervisory staff based on work experience, which may result in ineffective ventilation. The correct installation of LBs remains a challenge.In this study, a validated computational fluid dynamics (CFD) model has been used to analyse the effect of the LB ventilation system variables on the air flow rates close to the face of the empty heading. Full-scale three-dimensional models with various heading heights, heading depths, LB settings, and LTR velocities were simulated. The air flow rates and patterns at various locations inside the heading were analysed. A comparative study was carried out to quantify the effect of each of these system variables on the flow rates close to the face of the heading. Based on the findings, a user-friendly numerical model was formulated that can be used to estimate the flow rate close to the face of an empty heading for different practical settings of the system variables. This model can help the supervisory staff to swiftly implement the ventilation plan according to the regulations and the mine standards. The model can also serve as part of the curriculum for educating future mining engineers."

Jan 1, 2017

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

Geologists in some underground gold mines collect grab samples from broken ore piles or trucks as a method of grade control. It is often known as muck sampling. Generally, the goal of grab sampling is to try and reconcile the mined grade at the ore source to the predicted grade and/or predict the mill feed grade. The mass of the sample collected is limited by health and safety issues, as well as the capacity of the laboratory to process the samples within a given timeframe. In general terms, grab sampling is known to be problematic because samplers tend to over sample the fines, and/or pick out high-grade fragments; surface sampling of piles does not test material within the pile; muck piles in development drives/faces are likely to be zoned due to the blasting sequence; high or low-grade material may preferentially segregate in the pile during mucking; the five percent mass reject size of the material in muck piles is very large from underground blasting; some correlation usually exists whereby the larger fragments are enriched or depleted in the critical component of value; and the average error made in estimating the true stockpile grade is likely to be high. The method is prone to chronic fundamental sampling, grouping and segregation, delimitation, and extraction errors. Substantial warnings must be given with respect to the use of grab sampling for grade control in gold mines. The method may appear to work sometimes, which can be attributed to a fine gold particle sizing and more disseminated distribution. As with all sampling methods, its appropriateness must be determined by ore characterization and heterogeneity testing to ensure the method suits the ore type.

Jan 1, 2009

By S. Kok, D. Delport, J. Calitz

Altering the microstructure in order to improve the tensile properties of bow shackles resulted in inconsistency in the fatigue performance. This raises the question whether the inconsistency in fatigue life can be attributed to microstructural changes along the profile of the shackle or to decarburization at the surface. Bow shackles forged from 080M40 (EN8) material were subjected to different heat treatments in order to alter the microstructure. The shackles were subjected to five different fatigue load cases, which represented typical loads experienced at termination points for an overhead power line with a span length of 400 m, with changes in conductor type, configuration, wind, and ice loading. Although the change in microstructure does improve both the tensile and fatigue performance, we found that the depth of the decarburization layer has a greater effect on the high cycle fatigue life of bow shackles than the non-homogeneous microstructure.

Oct 1, 2021

Limestone formations in the United States can be subject to relatively high horizontal stresses due to the existence of tectonic loading of the limestone strata. Underground limestone mines use the room-and-pillar method, in which 12- to 18-m-wide rooms are typically excavated. The stability of these excavations can be compromised by the horizontal stress, resulting in a rockfall hazard. Rockfalls are the cause of 15% of all reportable injuries in underground limestone mines. Horizontal stress related damage can occur in the form of guttering along one or more sides of an excavation, roof beam buckling or oval shaped roof falls, with the long axis perpendicular to the major horizontal stress. Numerical analyses show that the pillar layout and orientation of the mine workings have an effect on the horizontal stress distribution within the roof. The effects of high horizontal stresses can be mitigated by orientating the heading development direction parallel to the maximum horizontal stress, reducing the number of cross-cuts and offsetting the cross-cuts to limit the potential lateral extent of horizontal stress related roof falls. The modeling approach described in this paper can be used as a tool to evaluate potential roof failure and optimize the stability of room and pillar layouts.

Jan 1, 2008

By G. Chunnett

Platinum metal prices have risen significantly during the past 18 months, and have remained at elevated levels. Driving these bullish prices are sustained jewellery demand, mainly from the Far Eastern markets, and ongoing autocatalyst usage in response to ever more demanding global environmental legislative requirements. Within South Africa, the areas north and south of the Steelpoort River in the Eastern Bushveldare well known for their significant resources of platinum. The bulk of the resources have lain dormant in anticipation of the very situation that is currently occurring in the marketplace. Anglo Platinum is the largest primary platinum producer in the country, and is uniquely positioned to take advantage of the current elevated metal prices and shortfall in supply of platiniferous metals. In addition to its production capabilities, Anglo Platinum holds an extensive portfolio of mineral reserves and resources which underpin its ability to implement expansion projects to continue growth in platinum group metal production. It also has access to, and is actively expediting, the exploration of a range of properties where the company can further expand current production capacity or supplemented depleted production levels.

Jan 1, 2006

By E. Kumar, L. A. Kumar

"A methodology is proposed to develop an optimization model to understand the impact of transporting minerals, from mines to the final destination, on air quality. Recently, there has been increasing concern about the combined effects of multiple activities over many years, and the regional environmental changes brought about by a single project. Environmental issues in the iron ore industry have highlighted the need to broaden the cumulative impact assessment. In this study, we simulated the optimal routes and quantity of materials needed to meet the destination plant demand based upon environment constraints (level of air pollution), as well as the cost of transportation and availability of materials. Multiple scenarios were developed to analyse the effects of changes in routes, alternative transport system (or multi-modal split), traffic congestion, and the cumulative impacts on air quality. The air quality impact zones of the study area were demarcated using a GIS technique. The expected outcome of the study is the selection of a suitable transport system for a particular site with the least impact on air quality, including the transportation route, relative to the minimum cost of transportation of the minerals from the mines to their final destination. The proposed methodology is evaluated with a case study. IntroductionIn India, the process of environmental impact assessment (EIA) has been focused primarily on the local impacts of projects, without considering regional environmental effects. Environmental clearances for proposed projects are based on reports of local impacts. However, any developmental project poses a potential risk to the environment as a whole, and not just in the immediate vicinity of the project. Recently, there has been increased concern about the combined effects of multiple activities over many years—the regional environmental changes due to development of a single project (Dutta, Mahatha, and De, 2004). Environmental issues throughout the country, particularly in the iron ore industry, have emphasized the need to broaden the analysis to include the combined impacts, or those forecast for a proposed region, on an existing environment. The most significant adverse environmental consequences of iron ore transportation are the deterioration of biodiversity and air quality (Kumar and Ajay, 2015)."

Jan 1, 2017

By A. Sampson-Forsythe, P. Morissette, A. R. Punkkinen, D. R. Chinnasane

"The performance of ground support systems under dynamic loading is typically assessed in a qualitative and subjective manner. As a result, it is difficult to develop an explicit knowledge on the mechanisms of action and interaction of support elements subjected to rockbursts. This paper examines rockbursts that have occurred at Creighton, Copper Cliff, and Coleman mines since 2000, 2004, and 2006, respectively. The mines are located in the Sudbury Basin, in Ontario, Canada. The majority of pertinent information was obtained through on-site field assessments, seismic system records, and numerical elastic stress modelling. Passive monitoring is used to link the evolution of the frequency and severity of rockbursts to the evolution of mining and support practice at the three mine sites. Based on the collected data, ground support elements that enhanced the capacity of support systems to withstand dynamic loads are identified. IntroductionThe selection of appropriate mining methods, extraction sequences, rock mass de-stressing techniques, and ground support systems is of great importance in mitigating the level of rockburst-related risk. In burst-prone conditions, the design of support systems should account for the anticipated dynamic load demand and the capacity of the available support options. Furthermore, an economical design should, implicitly or explicitly, take into consideration the consequences of a rockburst and its impact on worker safety and mine productivity. Stacey (2012) has argued that we have a limited understanding of the mechanisms of rock mass behaviour in seismic conditions. This is compounded by a ‘lack of understanding of the mechanisms of action and interaction of support elements under dynamic loads’ (Stacey, 2012). Consequently, the design of support systems required to manage dynamic loads is usually based on experience. The assessment of the dynamic performance of ground support systems is typically subjected to qualitative (and sometimes subjective) interpretations from ground control personnel."

Jan 1, 2017

By G. R. Drennan, N. J. Wagner, M. J. T. Sebola

The Soutpansberg Coalfield hosts South Africa's hard coking coal reserves. However, coals in this region are understudied compared to other coalfields in the country. This study characterizes the properties of fine-float fraction samples extracted from a wide diameter borehole core in the Makhado Project, Tshipise sub-basin, Soutpansberg coalfield. Conventional analyses were used to determine the coal quality, petrographic composition, mineralogy, geochemistry (including trace element and rare earth element composition), and free swelling index of samples from six coal horizons and three partings from the economic No.6 Seam. The coal samples are classified as medium rank bituminous C coals (0.88 %RoVmr, 0.92 %Rmax) and are highly vitrinitic in composition (97 vol% mineral matter free (mmf)). The samples show strong caking potential (FSI of 9). The total rare earth concentrations range between 570 and 3193 ppm in the ash samples. Preliminary analysis show all but two samples are promising sources of rare earth elements as the total concentrations exceeded the 1000 ppm cut-off grade. Further research is required to confirm these preliminary findings.

Aug 2, 2022

By R. A. Govender, A. Mudau

"Rockbursts continue to be a major contributor to mine accidents and cause of damage to mine excavations, particularly at great depth. The problem of rockbursts has also escalated in civil engineering tunnels driven at depth, due to high levels of in situ stress at such depths. Attempts have been made in the past to mitigate the impact of rockbursts, with rock support remaining the ultimate method for providing stability in rockbursting environments. However, records show that, on many occasions, conventional support elements such as rockbolts, wire mesh, shotcrete, and lacing fail to withstand severe rockburst events.Recently, a support method termed ‘sacrificial’ support was proposed as a potential additional method to prevent rockburst damage, based on observations made after rockburst events in a mine. The philosophy behind a sacrificial support system is that, under dynamic loading conditions, support in the form of a liner must fail; leaving behind, undamaged, what was previously supported rock mass. The sacrificial support concept reported herein is applicable in situations where the source (i.e. seismic event) of the rockburst is located remote from where rockburst damage is likely to occur.Spalling tests based on the split Hopkinson pressure bar (SHPB) technique were conducted to study some aspects of dynamic rock fracturing in tension at high strain rates and the role a sacrificial layer plays in combating dynamic rock failure. A single Hopkinson pressure bar, with a long cylindrical intact rock specimen attached at the bar free end, was impacted by a striker on the opposite free end in order to generate a dynamic stress pulse responsible for spall failure upon reflection from the specimen free end. Different liners and liner combinations were then introduced at the specimen free end as support. Such a simple, yet robust, experimental set-up allowed the potential benefits and failure mechanisms associated with sacrificial support under dynamic loading to be demonstrated and compared with ‘sacrificial support’ behaviour observed in real rockburst events in a mine. Analysis of the results revealed that varying liner thickness and mechanical impedance between rock and support liner play a significant role in limiting rockburst damage."

Jan 1, 2016

By J. Danoczi

South Africa is running out of fresh water and is looking at ways to improve water usage. This report addresses how a diamond mine in Gauteng has improved the utilization of its water resources. In the past, water from the local river was deemed the most suitable to use in the grease recovery plant but subsequent tests on the water from the slimes dam have shows that this water source is in fact more suitable for diamond recovery. Utilizing the slimes dam water provides a more stable water source than the local river while also reducing the impact of the mine on the water resources in the area.

Jan 1, 2008

By G. M. Dunn

Pressure leach autoclave circuits are employed in the leaching of ores, concentrates, mattes, alloys and intermediates for the recovery of metals into solution. Once the metals are extracted into solution, the value metals can be recovered by hydrometallurgical means such as by purification followed by electrowinning, hydrogen reduction, pyrohydrolysis, crystallization and other unit operations. In many of these integrated flowsheets the pressure leach step is pivotal to the recovery of the value metals from the host material. Furthermore, the autoclave circuit invariably is a high capital cost component of the plant and an area that is carefully scrutinized when debottlenecking and capacity increases are being considered. This paper identifies a unique proven way of increasing the capacity of existing or new exothermic pressure oxidative leach autoclave circuits by as much as two or three times.

Jan 1, 2009

By L. Forbes, G. Forbes, J. Wang

Bubble size measurement is a vital part of flotation system analysis and diagnostics. Over the years, a great many different bubble size analysis tools have been developed. However, all of them rely on ex-situ measurement and in-pulp sampling techniques. This paper evaluates the Mettler Toledo ParticleView™ Measurement probe as a novel method for in-situ bubble size measurement. This device is then compared to the conventional Anglo Platinum Bubble Sizer (StoneThree). It was found that the in-situ bubble size analysis technology appears to be a more user-friendly and reliable option for determining bubble size in flotation. However, the current instrument design is not suited to industrial applications. Keywords: Bubble size measurement, bubble coalescence, PVM probe

Jan 1, 2020

By F. Smit

Mining and plant practices can benefit from preconcentration of UG2 platinum ores in a dense medium separation (DMS) plant. The main benefit of DMS is the selective discard of waste from the feed stream, thus improving project economics while reducing the power and water requirements for processing. On the mining side, with the correct combination of variables, implementing DMS as a pre-concentration step can reduce cut-off grades and, as a result, increase ore reserves. In addition, the use of DMS technology gives the mine team the opportunity to consider alternative mining methods for an operation. The challenges of balancing the mining tonnage, methods, and resulting grades with the process plant size, recoveries, and DMS discard volumes have resulted in the development of a model to optimize value on new projects or existing operations. This paper will focus on these benefits from a mining and plant perspective, quantifying the water and power savings, and look at the economic benefits of preconcentration and the effect of metal prices, plant feed grade, and DMS efficiency in different mining environments.

Jan 1, 2013

By J. R. de Wet

The Skorpion Zinc Project demonstrated the viability of the production of zinc from non-sulphide (commonly called ?zinc-oxide?) ores, using the leach/solvent extraction/electrowinning process route. The success of Skorpion raised the profile of a number of other zinc oxide deposits, considered to be similar. However, a study of three such deposits demonstrates that the application of whole-ore-leaching may be limited and that the concentration of zinc, or at least the separation from acid-consuming gangue minerals, prior to leaching is essential to the successful recovery of zinc from these deposits. The recovery of zinc is dependent on an understanding of the geology of the deposit, the mineralogical association of zinc minerals with gangue minerals (Boni, 2005) and limitations of mining practice. Flowsheet development and the associated metallurgical testwork to derive an economically viable treatment route from two of these deposits are discussed. Key parameters affecting zinc recovery by gravity separation and flotation are presented, demonstrating that even minor differences in mineralogy have a profound impact on zinc recovery and reagent consumption. The study also deals with the determination of appropriate design parameters through metallurgical mapping of the dense media separation process.

Jan 1, 2008

By F. Smit

Mining and plant disciplines can benefit from pre-concentration of UG2 platinum ores in a dense medium separation (DMS) plant. The main benefit of DMS is the selective discard of waste from the feed stream, thus improving project economics while reducing the power and water requirements for processing. On the mining side, with the correct combination of variables, implementing DMS as a pre-concentration step can reduce cut-off grades and, as a result, increase ore reserves. In addition, the use of DMS technology gives the mine team the opportunity to consider alternative mining methods for an operation. The challenges of balancing the mining tonnage, methods, and resulting grades with the process plant size, recoveries, and DMS discard volumes have resulted in the development of a model to optimize value on new projects or existing operations. This paper will focus on these benefits from a mining and plant perspective, quantifying the water and power savings, and look at the economic benefits of pre-concentration and the effect of metal prices, plant feed grade, and DMS efficiency in different mining environments.

Jan 1, 2012