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By A. K. Singh

Between the main fan and the coalface in a mine a lot of air is lost through leakage at stoppings, doors, air-crossing etc. so that a much larger quantity of air has to be circulated by the fan in order that the stipulated quantity of air reaches the face. Stoppings are of vital importance not only for effective ventilation of underground mines but also for isolation of areas affected by fire or susceptible to spontaneous heating. Generally, isolation stoppings are made of brick in cement mortar. If the area is far from the pit or unapproachable, it is very difficult and sometimes impossible to build these stoppings. To overcome these difficulties, particularly near fire affected zones, an alternate successful attempt was made in Indian mines to make a plug underground, from surface through borehole, using cement concrete. In this paper the salient features of the methodology adopted for construction of the plug and the experimental procedure for the measurement of air leakage by SF6 tracer gas is described. Measurements of air leakage through rows of ventilation stoppings in two mines viz. Moira (Jambad and Kajora seams) and Kuardi11/12 (Niga seam) collieries of Eastern Coalfields Ltd. (ECL) have been incorporated. Results of experiments conducted at the Central Mining Research Institute (C.M.R.I) to determine leakage through25 and 38 cm thick brick stoppings are also discussed. Results of all these studies are compared, which show that the efficacy and reliability of the remote filled cement concrete plug in respect of air permeability is satisfactory.

Jan 1, 2004

By H. Griesel

The overall supply of platinum is forecast to rise more than the demand, and market deficit will narrow somewhat, but is still substantial at about 480 000 ounces. Because of this deficit, the price of platinum is expected to remain high, not taking into account the impetus from funds and speculators. With this strong demand for platinum and the high price, platinum producers still need to initiate projects to not only sustain current production, but also expand output into the high demand. However, the rise in the platinum price does not entirely offset the drop in revenue due to the strong rand. Consequently, in the current economic environment, executives and managers are under extreme pressure to initiate only the highest yielding projects and implementing them successfully. During the initiation phase of a project, the cost of changing concepts is the least, and strategic project decisions are the most important. It is during this phase that the most value can be added to a project, therefore requiring inputs from highly skilled, creative and experienced people. This paper will discuss thought processes and paradigms during the initiation of projects that will assist project owners in the selection and initiation of successful and profitable projects. The project initiation process will also be discussed outlining selection models, risk analyses and funding considerations.

Jan 1, 2004

By J. C. van Dyk

The objectives of this study were firstly to characterize and quantify the inorganic material in the Secunda gasification feedstock. Secondly, the effect of washing on coal properties and sulphur content was investigated. Coal from a single source and a coal blend from 6 different mines were tested. Composite samples were visually sorted by a geologist in the groups containing roof, floor, C-shale, pyrite, carbonates and siltstone material. Inorganic mineral types from the single source and coal blends were characterized separately. Characterization results indicate that the average mineral matter distribution (mass %) of the coal tested was as follows: carbonates (6%), carbon-shale (19%), pyrite (12%), roof (18%), floor (46%) and siltstone (22%). The roof, floor, pyrite, carbon-shale, carbonates and siltstone in the single source and coal blend have similar chemical properties and characteristics, except for the ash melting temperatures of pyrite and kaolinite in the siltstone. By implementing selective mining and increasing mining management practices, the percentage discard in the run of mine coal can be significantly reduced, by up to 45%, if the mining of roof and floor material can be avoided. No significant impact of mining practices on sulphur content is expected in this case due to the low concentrations of sulphur in the roof and floor material. In summary, selective mining practices will probably result in almost45% decrease in the discard content in the run of mine to gasification, an increase in the carbon content from 55.0% to 58% (air dry basis) and a decrease in sulphur content from 1.1% to 0.9% (air dry basis). It is clear from this study that the main source of sulphur is not in the high ash-content mineral types (e.g. floor and roof), but in situ in the coal structure. Keywords: inorganic material, effect of washing, roof, floor, pyrite, C-shale, carbonates and siltstone

Jan 1, 2005

By G. H. Lind

This paper discusses the traditional costing approach currently used in the underground coal mining industry. Activity Based Costing (ABC) is identified as being a potentially more effective manner in which to cost underground coal mining systems. With the use of a costing framework developed by the author incorporating new thinking to eliminate the shortcomings identified in the traditional costing approach, a comparison of two types of underground coal mining systems, viz. continuous miner and longwall, is conducted. It is found that under certain criteria, in all cases, irrespective of the way in which the systems are costed, the continuous miner system is currently the better investment. It is also observed that when a system is costed using ABC that better investment decisions result when compared to costing the same system using traditional costing techniques. It is further seen that traditional costing techniques tend to overestimate the total costs of a mining system. This paper shows one application of ABC that can be incorporated as a management tool.

Jan 1, 2001

By H. P. Kritzinger, T. C. Kingsle

"Rotary kilns are used for a variety of mineral processing operations. Hatch makes use of a kiln model developed from first principles to evaluate designs for its clients. This tool has been applied to a variety of pyrometallurgical applications, including ferrovanadium, nickel carbonate, nickel laterite, iron ore reduction, and spodumene (lithium) production.This paper illustrates the application of numerical optimization techniques in combination with the kiln model in the interrogation of a generic iron ore reduction process. The fundamental modelling concepts are explained, followed by a description of the optimization approach. The results show how the combination of the two methods, with modern computing power, can generate a large number of viable design and operating candidates."

Jan 1, 2015

By M. Rafie, M. Rinne, F. Samimi Namin

"SynopsisRock mass classification systems constitute an integral part of empirical underground excavation design. One system that is commonly used to classify rock mass is the Rock Mass Rating, or RMR, system. The RMR system has evolved over time to better reflect the perceived influence of various rock mass factors on excavation stability. While the introduced modifications have enhanced the applicability of this classification system, there are still areas that cause potential ambiguity. The RMR system cannot deal with input data ambiguities, uncertainties, and vagueness. To deal with the uncertainty, a Fuzzy Rock Mass Rating (FRMR) has been developed. This study aims to describe the main concept of the fuzzy approach, which is implemented in the FRMR to classify rock mass. The FRMR considers the uncertainty associated with the input data (uncertain variables) used in rock mass classification. The Gol-e-Gohar (GEG) area 3 iron ore deposits in the south of Iran were chosen as the case study for investigating the applicability of FRMR. The results of this study show that the FRMR software tool can easily be used for rock mass classification, even if uncertain input parameters have been used. FRMR consists of three parts, each of which is suitable for certain conditions.IntroductionNowadays, rock engineering classification systems, which constitute the backbone of the empirical design approach, are widely employed in both civil engineering and mining engineering. Rock mass classifications have recently been quite popular and are being used mostly for the preliminary design and planning purposes of projects. According to Bieniawski (1989), a rock mass classification scheme is intended to classify the rock masses, provide a basis for estimating deformation and strength properties, supply quantitative data for support estimation, and present a platform for communication between the exploration, design, and construction groups."

Jan 1, 2015

By Stefan Basista, Janusz Tomala

Modern constructions of electric ferroalloy furnaces are still based on applying in the lower "liquid" areas the standard carbon materials. What can be illustrated by the experience from several years, in the part of tap hole, hearth walls and bottom, is that so-called carbon or semigraphite microporous materials are successfully being applied. These materials, compared to the standard carbon, give better resistance to the attack by liquid metal and other wear factors. Generally this group includes materials characterised by considerable share of pores of diameters below1µm (significantly exceeding 90% of total porosity). The microporosity increases the resistance to the infiltration of the liquid metal. The effect of microporosity can be obtained by introducing silicon (or its compound) additive to materials based on electrically (or gas) calcined anthracites, electrographite and binder. Moreover, by introducing other ceramic additives, the microporous materials are more resistant to dissolution by the liquid metal. Observing the trends of "improving the materials" in the last years, it is clearly seen that the share of non-carbon additives is bigger and bigger, so we can reasonably speak of rather carbon-ceramic materials. In this paper, the survey of the most important quality criteria, which must be met by the carbon furnace linings, as well as the new testing methods will be presented.

Jan 1, 2007

By M. H. Farjadi, J. Azari

Cost analysis of chrome ore reduction is one of the important issues facing ferrochrome producers in today?s competitive environment. Much of this depends on quality and various ratios in the actual ore. The latter can have a direct bearing on electricity consumption and optimum efficiency of the furnaces. While the industry has been successful in reducing costs by designing larger and more efficient furnaces, the role of the optimum blend of ore has perhaps been given less emphasis. This paper will discuss the general specification and metallurgical characteristics of various chrome ores for producing high carbon ferrochromium on industrial scale. By analysing the results obtained from smelting, including chromium recovery and energy consumption, the determining parameters in total cost of ferrochromium i.e. chrome ore; reductant and energy consumption can be optimized. Our study is based on actual experiences obtained from Faryab Ferroalloy Plant over a period of approximately three years.

Jan 1, 2004

By O. Nyandoro, K. Khoza-Shangase, M. Madahana, N. Moroe

"Occupational noise-induced hearing loss (ONIHL) is classified as the leading work-related disability in the mining industry. ONIHL has a negative impact, on not only the health and occupational productivity of affected individuals, but arguably also on the country’s mining industry and economy. Hearing conservation programmes (HCPs) are an effective strategy in the management of ONIHL. However, current literature indicates that HCPs are not achieving the anticipated and desired outcomes in the South African mining sector despite the efforts focused on the management of ONIHL. Therefore, the purpose of this study is to propose the use of a feedback-based noise monitoring model as a tool for monitoring and managing ONIHL in the South Africa’s mining sector. This model is a basic static feedback model with practical applications such as estimating, monitoring. and providing quantitative information to aid miners, mining administrators, and policy-makers in decision-making around HCPs. Additionally, the model could form part of an early intervention and management strategy for ONIHL in the workplace. The strength of this model, although currently static, is that it encompasses all the pillars of HCPs and takes into account the policies concerned with the management of ONIHL in the mining sector. IntroductionHazardous noise levels (above 85 dBA) in the workplace place exposed employees at risk of developing a disabling occupational noise-induced hearing loss (ONIHL). ONIHL is the ‘partial or complete hearing loss in one or both ears as a result of one’s employment’ (Nandi and Dhatrak, 2008, p. 1). This type of hearing loss develops gradually as a result of being exposed to continuous or intermittent high levels of noise over a long period of time (McBride, 2004; Patel et al., 2010; Rappaport and Provencal, 2001). A hearing threshold below 40 dBs is classified as a disabling hearing loss (Yadav et al., 2015), resulting in a hidden condition that does not readily manifest itself (Tye-Murray, 2009, p. 3). Dugan (2003) describes disabling hearing loss as the ‘most prevalent, least recognized and least understood physical disability’, while Copley and Frederichs (2010) and Hermanus (2007) argue that permanent disabling hearing loss is a major contributor to the global burden of disease on individuals, families, communities, and countries."

Jul 1, 2019

By K. Liddell

Current practice for the recovery of platinum group metals (PGM) from flotation concentrates is by energy-intensive smelting processes followed by separation and refining of the base and precious metals. Energy costs are rapidly increasing in South Africa and this trend is forecast to continue in future years. Moreover, the smelting operations are highly susceptible to deleterious constituents, particularly chromite; and the increasing tonnages of UG2 chromititic ore being mined results in an increasing chromite content of smelter feeds. Hence there is a substantial incentive to assess and implement alternative processes to smelting for the treatment of PGM concentrates. The Kell process is a patented hydrometallurgical alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations (pressure oxidation leaching of base metals and sulfur, roasting and chlorination of precious metals). The Kell process provides the opportunity for existing and new PGM producers to significantly reduce their energy consumption, and in particular their consumption of electricity, by removing the need to smelt PGM concentrates. Energy costs, greenhouse gas emissions and installed power requirements are also much reduced. Compared with smelting and refining these reductions are calculated as: ? Total energy consumption-50% reduction ? Electrical energy consumption-84% reduction ? Energy consumption costs-76% reduction ? C02 emissions-70% reduction ? Installed power requirement 92% reduction. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection and process optimization. The applicability of Kell to treating low-grade 'dirty' concentrates with high UG2 content as well as to polymetallic concentrates containing base metals as the major payable metals with subordinate PGM means that these savings can also be expected when the process is used for treating a range of concentrate types and grades. Keywords PGM,UG2, Merensky, smelting, chromite, electricity, hydrometallurgy, Kell Process, Eskom.

Jan 1, 2011

By Dolly Chakraborty, S. Ranganathan, S. N. Sinha

Pre-reduction of chromite outside the submerged-arc furnace (SAF) can significantly lower the specific power consumption in the SAF process. Conventional processes for the pre-reduction of the ore operate at relatively high temperatures, at 1400-1500°C. It is possible to enhance the rate of reduction at low temperatures by optimizing the flow rate of inert gas over the reaction site. The influence of the flow rate of inert gas on the rate of reduction of chromite ore was investigated. The rate of reduction initially decreased wit the flow rate of the gas. It increased subsequently at higher flow rates to be followed by a decrease again. There was an optimum flow rate at which maximum reduction could be obtained. It was possible to achieve high levels of reduction at 1200°C by optimising the flow rate of the gas. The degree of reduction obtained was comparable to that obtained at 1400-1500°C, by conventional process routes.

Jan 1, 2007

By C. Kloppers

The aim of this investigation was to reduce the cost of primary steel de-oxidation by substitution of aluminium primary de-oxidation with a practice that uses carbon. The cost of carbon is four times lower than that of aluminium. The application of carbon would directly result in raw material cost savings. Investigations were conducted at Iscor?s Newcastle steel plant on various steel grades. Specific production aspects were emphasized to ensure that the cost savings accrued would not create secondary expenses. These production aspects entailed: ?Yields on de-oxidation elements ?De-oxidation capabilities ?Alloying yields (Mn and Si) ?Carbon-pickup ?Nitrogen-pickup ?Temperature loss during tap ?Steel cleanliness ?Slag morphology. This project proved that carbon de-oxidation, apart from reducing de-oxidation raw material cost due to cheaper raw materials being used and lower consumption rates, resulted in steel that is cleaner and has lower nitrogen concentrations. Carbon primary de-oxidation has been implemented at Iscor?s Newcastle plant on a large range of steel grades, ranging from ultra-high carbon (> 0.60% C) to ultra-low carbon (< 0.03% C) grades. A net saving of between R100 000 and R200 000 per month was achieved.

Jan 1, 2001

By L. Munsamy, B. J. Madden

OpenRisk, an open cast risk rating system, takes into account relative differences in the importance of hazards, as experienced on each mine as a result of different combinations of geotechnical factors and mining conditions. The system is based on critical geotechnical and operational parameters that have been identified by mining personnel and rock engineers. The primary advantage of this risk rating system is that all the strip mines would use an identical system, which enables the user to compare their risk to the risk at neighbouring mines and/or other open cast mines. The system can be adjusted to meet local, mine specific requirements. This system has been made practical and easy to use. Therefore, this tool can be used by personnel from other disciplines not directly related to rock engineering. OpenRisk system has been in operation at nine Anglo Coal and other open cast mines. It adequately detects areas of high risk and generates adequate remedial solutions to reduce the risks. Awareness of the personnel has been higher at the sites that use OpenRisk. The proactive approach of OpenRisk ensures that all personnel are aware of risks in the pits and how to deal with potential risky areas.

Jan 1, 2006

By L. A. Cornish, S. N. Prins, R. Süss

The work is being done using the Thermo-CalcTM software, and the database is being built up by obtaining good thermodynamic descriptions of all of the possible phases in the system. The database supplied did not cover all of the phases, and these had to be gleaned from literature, or modelled using experimental data. Similarly, not all of the experimental data were known, and where there were gaps or inconsistencies, experiments had to be undertaken. A preliminary version of the database was constructed from assessed thermodynamic data-sets for the binary systems only. The binary descriptions were combined allowing extrapolation into the ternary systems, and experimental phase equilibrium data were compared with calculated results. Very good agreement was obtained for the Pt-Al-Ru and Pt-Cr-Ru systems, which was encouraging and confirmed that the higher-order systems could be calculated from the binary systems with confidence. Since some of the phase models in databases were different, these phases had to be remodelled. However, more work is ongoing for information concerning the ternary phases present in the Al-Cr-Ru, Pt-Al-Ru (two ternary compounds in each) and Pt-Al-Cr (possibly more than three ternary compounds) systems. At later stage of the work, problems with the thermodynamic descriptions of the Cr-Ru and Pt-Cr binary systems were found. A programme of experimental work to overcome these has been devised, and is being undertaken. Keywords: Pt-based alloys, phase diagram calculations.

Jan 1, 2006

By R. T. Jones

The 20 Mt reverberatory furnace slag dump at Nkana in Zambia contains a substantial quantity of cobalt. A 40 MW DC arc furnace has been built at Chambishi for the purpose of recovering cobalt from the slag. The technology was jointly developed by Mintek and Anglovaal Mining Ltd (Avmin), and the furnace was designed by Bateman Titaco. Testwork at the 150?250 kW scale was conducted at AVRL, and larger scale piloting was conducted at Mintek (in partnership with Avmin) in a 3 MW DC arc furnace. Approximately 840 tons of Nkana dump slag (ranging from 0.66% Co) was processed at power levels around 1-2 MW. Good overall cobalt extraction was achieved, and approximately 100 tons of cobalt-bearing alloy was produced (containing 5 to 14% Co). This testwork demonstrated that the Nkana dump slag could be processed in a DC arc furnace of suitable design, to produce a cobalt-bearing alloy suitable for further hydrometallurgical processing. Bateman Titaco were contracted to design and build the furnace, and the design team contained representatives from Avmin and Mintek. The project was conceived as a fast-track exercise, and many activities had to be run in parallel. Notable features of the furnace include an ABB power supply, a Concast conductive hearth, the refractory design, and copper cooling in the sidewalls. Power to the furnace was switched on during January 2001.

Jan 1, 2002

The effect of composition on electrical conductivity (resistivity), viscosity and liquidus temperature of the slags encountered in electric smelting of PGM-containing suphide concentrates is reviewed along with the relationsip between slag composition, slag-matte separation and metal losses to slag. Optimization of slag composition at furnace temperature is attempted on the basis of opposite and parabolic trends of the viscosity-conductivity relationships of the slags. The importance of surface tension of slags is emphasized using available and estimated information, which are grouped into a useful correlation. These values are coupled with or incorporated into slag viscosity plots to illustrate the correlation between the two factors which influence slag-matte separation as well as refractory attack. The electrode in the slag-resistance furnace is the central factor in the design and operation of the furnace by its role of conveying the smelting power. The obvious parameters are the size and positioning in the slag bath, which are defined by slag resistivity, furnace resistance, cell constant and power input. The flow of heat generated by the electrode current determines the energy distribution and furnace dimensions creating viscosity profiles, which in turn affect flow conditions. Thus the flow of slag and matte isdiscussed in conjunction with the furnace geometry, stirring action of the electrodes, buoyancy and electromagnetic effects. The action of the electric furnace as a settler is discussed. The rectangular furnace is considered as a channel reactor in this analysis and the action of the electrodes is described to indicate a balanced settling rate in the area of electrode action. Discussion of the design and production capacity of the electric furnace with reference to operating current, power input, furnace dimensions and electrode size are based on considerations derived mainly from slag properties such as its resistivity, viscosity and liquidus temperature.

Jan 1, 2004

By J. H. Potgieter

This paper describes an investigation to separate and selectively recover silver, gold and platinum from jewellery and laboratory wastes, and produce technical grade material suitable for training purposes. Nitric acid was employed to dissolve and separate silver and other impurities from gold and platinum, which were then dissolved in aqua regia and precipitated selectively. The current work quantified the effects of temperature, stirring rate, leaching agent concentration and solid: liquid ratio on the recovery of the various noble metals and in summary yielded the optimum treatment conditions in each case. It was found that increased leaching reagent concentration (in the case of Ag), temperatures and stirring rates enhanced the recovery kinetics and optimum yield of the three noble metals. An increased liquid to solid ratio also enhanced the recovery of the silver. Recovery yields 97.1%, 99.9%and 99.4% for silver, gold and platinum, respectively, were obtained. The recovered silver, gold and platinum had purities of, respectively, 98.3%, 99.1% and 99.0%. A cost saving of approximately R10 000 per kilogram of scrap refined could be achieved by the in-house treatment of the waste, not to mention the time-saving benefit.

Jan 1, 2004

By F. T. Cawood

This article is a continuation of a series of publications by the authors on the international debate on resource nationalism, with specific reference to South Africa. Previous outcomes have shown that mine nationalization is not a solution for South Africa, and that maintaining stability of the current mineral and tax regimes is fundamental. It will not be wise to replace existing law and policy instruments until there is a better understanding of the distinction between fact and public perception about the impact of the current system. The new scheme of state custodianship linked to a mining royalty that effectively targets economic rents provides for effective resource use. The methodology in this article is to consider how South Africa&apos;s mineral tax regime can be tweaked to achieve optimal management and benefit from mineral extraction and associated rents by avoiding changes feared by investors. The major finding is that the current suite of instruments can be considered a suitable platform for optimal management of resource rents. However, it will be necessary to first investigate ways of improving the mineral beneficiation intent of the royalty structure, and secondly investigate whether the mineral rent portion of the royalty formula can be ring-fenced for the purpose of establishing a sovereign wealth fund.

Jan 1, 2013

By M. Verri

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Jan 1, 2009

By C. F. Strydom

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree The Self-directed work team concept is the product of relentless performance pressure on American industries during the late eighties and early nineties from other world industrial leaders like Japan. The concept proved to be a successful vehicle by which the Americans could increase their production and improve their safety statistics. The aim of this study is to evaluate the concept as a means to improve the overall performance on South African goldmines. he study is directed by a historical research section, answering questions like: ?Why do we need to change? ?What is a Self-directed work team? ?What are the principle advantages of the concept? ?What are the essential requirements for the concept to succeed? The study also includes an empirical research section that focuses on the current Self-directed work team situation in the South African gold mining industry. The empirical research section is limited to three case studies within Anglogold due to a study period of only six weeks. The mines chosen for the case studies have been labelled Mine 1, Mine 2 and Mine 3. The latter being the base mine allowing for a more in depth study. This includes a perception analysis towards Self-directed work teams within the mine. The study proves the truth of the Latin proverb ?Tempora mutantur, nos et mutamur in illis? meaning ?The times are changing, and we are changing with them?. The chief change catalysts identified are a dwindling gold price and a projected labour crisis. From the study it is evident that the Self-directed work team concept disposes of the critical parameters required for a dramatic improvement in performance. The study also indicates that for the concept to succeed, certain factors like top-level commitment and management-employee trust have to be in place. Sadly, the concluding part of the study proves that very few of the identified critical success parameters are present in the South African gold mining industry. This can serve to explain why the industry only has success with the concept when monetary gain is the chief motivator. The study only focuses on the reasons why the concept is not performing to its full potential and does not wander into explaining the reasons for the current unsupportive milieu in the industry. Self-directed work teams could well rescue the South Africangold mining industry but currently we are driving a square pin into a round hole! [Terminology SDWT?Self-directed work teams AEL?Adventure Experiential Learning ISW?In-stope worker POLC?Plan, organize, lead and control TEC?Total employee costed Silo?The confinement of departments preventing networking JCI?Johannesburg Consolidated Investment Co. Ltd]

Jan 1, 2002