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By A. Whillier

Note: Hydraulic rock drills and their effect on the underground environment by A. WHILLIER, Pr. Eng Se. D., (M.tT.) (Fellow) In any situation where hydraulic rockdrills are used underground, it is evident that an amount of heat equivalent to the total electric input to the power pack would enter the ventilation air. Book review Australian Mineral Industry 1972 Review. Australia, Department of Minerals and Energy. NIM report Report no. 1691 The determination of zirconium and aluminium by 14MeV neutronactivation analysis. Automation in Mining, Mineral, and Metal Processing The International Federation of Automatic Control (IF AC) is to hold its second symposium on the above subject in Johannesburg on 13th to 17th September, 1976. V Simposio de Mineracao A symposium is being arranged for 6th to 9th August, 1975, in Ouro Preto, Brazil. ACHEMA 1976 The 18th Chcmical Engineering Exhibition-Congress and European Meeting of Chemical Engineering will be held in Frankfurt from 20th to 26th June, 1976, and thc Chemical Engineering World Congress Sixth Underwater Mining Institute The above Institute will be held on the main campus of the University of Wisconsin in Madison, U.S.A., on 2nd and 3rd October, 1975.

Jan 4, 1975

By M. Steyn

This article captures the intrinsic differences of thermal coal products, their utilization and their substitution characteristics. South Africa produces approximately 245 million tonnes of coal annually. Eskom consumes 46% (approximately 112 million tonnes), 26% (approximately 65 million tonnes) is exported, and SASOL Synthetic Fuels consumes 18% (approximately 44 million tonnes) and a further 9% (approximately 22 million tonnes) is consumed by domestic users in various different industries. Marketing theory contributes significantly to understanding the importance of technical product and quality appreciation and comprehension, encompassing elements of price, distribution, and promotion. Coal product specification is determined by the inherent geology of a resource and the number of complex actions to market the product to a specific consuming market. Sampling, analyses, beneficiation application, and an array of parameters contribute to matching thermal coal products to the value-in-use it provides to the different markets and its consuming industries. Coal producer shave come under increased scrutiny since South Africa has been experiencing electricity shortages since early 2008. General misunderstandings were declared on public forums and in the media by both legislators and the South African public since a perception developed that South African coal producers are exporting coal that could be utilized by Eskom.

Jan 1, 2010

By S. K. Murphy

A partial shaft pillar extraction project was embarked on at a mine in the West Wits mining region in South Africa. Prior to the extraction, a rock engineering assessment was conducted with the main objective being to establish which areas of the shaft pillar could be extracted without unduly affecting the stability of major infrastructure within the shaft pillar. Standard numerical modelling methods were used to conduct this assessment and several areas were identified for extraction. However, during the extraction process, it was found that the infrastructure was affected more than was originally predicted by linear elastic modelling. In addition to this, several large events resulted in far more large aftershocks than would normally be predicted. In order to gain an understanding of this phenomenon, seismic data was integrated with numerical modelling as follows: > The seismic data in the form of displacements was integrated in 3D space within the model to assess the effect of static stress changes associated with seismic activity > Data from large events was integrated onto specific structures, where displacements associated with large events were integrated onto the plane of structure in question. This paper describes the methodology and results obtained from each of the above processes and include insights into the mining process that were previously unfathomable using standard linear elastic numerical modelling. The way forward for this rock engineering assessment of partial shaft pillar extraction is also discussed.

Jan 1, 2012

By A. Drumond, J. F. C. L. Costa, M. G. Lemos, A. L. Rodrigues, F. G. Niquini

The past decade has seen a renewed possibility of using machine learning algorithms to solve a large collection of problems in several fields. Data acquisition for mining operations has increased with the growth in sensor-based technologies, and therefore the amount of information available for mining applications has dramatically increased. Ore sorting equipment is available for separating ore from waste based on differences in physical properties detected by a real-time analyser. The separation efficiency depends on the contrast in these properties. In this study we investigate the application of machine learning models trained using data from the output of a dual-energy X-ray ore sorting apparatus at a gold mine. The particles were first hand-sorted into ore and gangue classes based on their mineralogical composition. Classification models were then used to help decide the balance between the number of true and false positives for ore in the concentrate, with a view to economic parameters, using their receiver operator characteristic (ROC) curves. The results showed AUC (area under the ROC curve) scores of up to 0.85 for the classification models and a maximum reward condition Fpr/Tpr around 0.5/0.9 for a simplified economic model.

Aug 8, 2024

Production caving started for Lift 2 at Northparkes in August 2004. In a period of less than 3 months, more than 10 000 seismic events were recorded. Events up to local magnitude +2.9 were induced near the mine during caving, with event rates of up to 500 per day. This paper documents the seismicity related to cave initiation and cave propagation during the initial production of Lift 2. The seismogenic zone of events initially moved at a rate of about 0.5 metres per day, accelerating to 2 to 3 metres per day after a few months of cave production. Seismic data analysis infers that the crown pillar between Lift 1 and Lift 2 was destressed over a vertical height of about 100 metres. As the seismogenic zone approached the crown pillar, a macroseismic episode occurred, with more than 20 events of at least local magnitude +1 occurring in a two-week period. Based on the seismicity recorded for Lift 2 at Northparkes Mines, a caving mechanics model is proposed. Comments and suggestions are made for seismic data analysis and design of seismic monitoring systems in block caving mines.

Jan 1, 2008

By Z. L. Xue, J. L. Li, X. Y. Wang

"In low-carbon energy-efficient basic oxygen furnace (BOF) steelmaking processes, limestone partly or completely replaces the active lime. The effects of limestone calcination temperature (1200–1500°C) and time (5–15 minutes) on lime reactivity and CaO grain size were investigated. The reactivity was evaluated by titration with hydrochloric acid, and the CaO grain size was analysed using scanning electron microscopy. The results revealed that for calcination temperatures higher than 1300°C, the reactivity reached a maximum and then decreased . The higher the temperature, the earlier the peak of reactivity appears. The CaO grains grow with increasing temperature and time, which leads to the decrease of reactivity. Notably, the effects of temperature on CaO grain size and reactivity are more marked than that of time. To obtain active lime calcined at ultra-high temperature by flash heating, the calcination conditions should be 1300–1400°C for 10–15 minutes, or 1400–1500°C for 8–10 minutes. IntroductionLime is one of the most important slag-making materials for dephosphorization and desulphurization in the basic oxygen furnace (BOF) steelmaking process. The reactivity of lime is a measure of its capability to take part in slag-making. Lime having a reactivity of more than 300.0 mL (4 N HCl), determined by hydrochloric acid titration is generally referred to as active lime (Rusjan et al., 2007; Zeman, 2008). At present, the active lime used for BOF processes comes primarily from a kiln or shaft kiln, where limestone is preheated at 700– 900°C, and then calcined at 1050–1200°C (Drenhaus et al., 2010; Oates, 2007)."

Jan 1, 2016

By J. Petersen, A. E. Lewis, J. Chivavava

Rare earth elements (REEs) have special properties that prompted their extensive use in high-tech applications. The demand for REE has, therefore, increased over the past years, resulting in the supply risk of the materials. Extraction from non-conventional low-grade ores, like easy-to-mine ion adsorption clays (IACs), by hydrometallurgical methods is being explored to supplement the supply of REEs. The extraction of REEs from low tenor IAC leach solutions requires enrichment using cost-effective methods such as precipitation. Therefore, the aim of this study was to understand the recovery of REEs from IAC leach solutions using various reagents for precipitation. In the first part of the study, recoveries of REEs from IAC leach solutions through direct precipitation using H2C2O4 and NH4HCO3, as well as antisolvent crystallization using C2H5OH, were predicted via thermodynamic modelling using OLI Stream Analyzer. Verification experiments were then conducted through the use of an agitated reactor. Simulation results showed that high yields of REEs were possible using each of the reagents, but large quantities of C2H5OH were required. Experimental results confirmed the high yields predicted from simulations. Precipitation with H2C2O4 was found to selectively recover REEs while rejecting Al. However, utilization of NH4HCO3 and C2H5OH resulted in the co-precipitation of Al. Furthermore, the yield of Y from antisolvent crystallization was significantly lower than the theoretical value. The product recovered from antisolvent crystallization consisted of well faceted, large crystalline particles, which filtered faster than the fine, amorphous REE carbonates recovered using NH4HCO3. REE oxalates were crystalline, larger than the REE carbonates and, overall, showed the highest filtration rate.

Dec 11, 2024

By and M. V Roper, H. N. Engelbrecht

Quality control interventions emanate from process upsets and trends that move product quality beyond the natural variation expected in a stable process. The ability to detect upset conditions and react in an effective manner protects both resource utilisation and compliance to specifications. Product quality control on coal processing plants traditionally relies on the reference (combined sampler and laboratory) system to measure product qualities. The introduction of online analyser (OA) technology, applied in different configurations, creates a second source of measurement information for control decision making. The case study was done on the primary sample stream of the final product stream at Exxaro’s GG7 and 8 plants, part of the Grootegeluk complex. It explores the OLA system’s ability to meet the OEM performance guarantee, perform equally to the reference system without analytical delay time, and assesses the effort to achieve this performance in a by-line analyser (BLA) configuration. In the paper, a conceptual comparison of the two measurement systems is done and the theoretical and practical comparison of measurement performance is discussed. Results demonstrate that the OA outperformed the OEM’s performance guarantee and achieved similar levels of performance to the reference system without the response delay. Keywords: Online analyser (OLA), by-line analyser (BLA), coal quality measurement, measurement performance

Jan 1, 2020

By S. Banisi, M. R. Yarahmadi, S. R. Mortazavi

Nowadays the development of automatic on-line sampling systems has enabled large amounts of data to be available to plant managers. These data are inevitably prone to random and sometimes systematic errors. Data reconciliation methods are used to deal with random errors. In these methods, the measured data are adjusted in accordance to their error, so that the mass conservation law is satisfied at the same time. Measured data may also contain systematic errors, using these data in mass balancing software will result in inaccurate or even irrational results. In this paper three methods for detecting systematic errors (global test, node constraint test and maximum power constraint test) were presented. A step by step method to locate the systematic errors was demonstrated. Then, the new version of Movazen©, a mass balancing software, was introduced and used to locate systematic errors in the measurements taken from the Sarcheshmeh pilot plant copper flotation circuit. Keywords: Mass balancing, data reconciliation, random error, systematic error

Jan 1, 2020

By H. Karabulut, S. Gündüz, K. Karacif, M. A. Erden

The corrosion properties of iron-based composite materials containing graphite and silicon carbide (SiC) reinforcement were investigated. The effects of silicon carbide reinforcement were investigated by adding 0.5% graphite and 1%, 2%, and 4% SiC. A powder metallurgy method was used to produce the composite samples. Iron, graphite, and silicon carbide powders were blended for one hour with a threeaxis mixer and then unidirectionally pressed under a pressure of 750 MPa. After pressing, the composite materials were sintered at 1100°C for one hour. The corrosion properties and microstructure, density, and hardness properties of the composite materials that can affect the corrosion properties were also investigated. It was determined that the pore ratio and hardness of the composite material increased, and corrosion resistance decreased, with increasing silicon carbide content.

Jun 2, 2022

By Ri McCrindle

"Analytical Chemistry is moving rapidly towards a concept where technicians have to do no more than press a button and print the result from an instrument that is a featureless ""black box"". In this environment we must ask how much traditional ''wet chemistry"" is still required for undergraduate students.Methods that can be fully automated will become increasingly important. An example of such a method is that of the slurry nebulisation and ICP-OES analysis of precious metal concentrate. Grinding the sample and adding Triton X100 as dispersant, complete analysis time is in the order of 90 min as apposed to the traditional Carius tube method which could take as long as 24 h. For most of the elements studied, the results using ""in-house"" reference material for calibration and as samples as well were within the 95% confidence level. Elements of low concentration in the sample (As, Bi and Se) were not within that level."

Jan 1, 2014

This paper examines the new water-hydraulic (hydropowered) drill rigs that have been developed and proven in the last decade primarily in tabular, shallow-dipping, narrow-reef hard-rock South African mines. These include drill rigs for flat-end tunnel development, narrow inclined raises and winzes, large inclines and declines and longhole-based developments such as ore passes and vent raises. The hydropower technology rigs offer advantages both in safety and performance over traditional compressed-air-powered, hand-held development, and are generally more cost-effective than imported oil electro-hydraulic drill rigs. Furthermore, hydropowered rigs are inherently energy-efficient. The benefits of hydropower are discussed and a ?comprehensive development model? is presented which demonstrates that ore-bodies can be accessed in significantly shorter times. ?Localized? half level hydropower systems are introduced and a range of ancillary equipment available is listed.

Jan 1, 2012

By V. K. Risinggård, M. Sparta

We report on the development of a finite-element method model for a pilot furnace for the production of manganese alloys. The model is a multiphysics model that addresses material flow, electrical conditions, heat transfer, and physical and chemical transformations. It is capable of studying both quasi-steady and transient states in time-dependent simulations. The model includes common charge materials and fluxes and can simulate production of both ferromanganese and silicomanganese alloys with acid and basic slags, as well as changing charge compositions. The model output provides access to the material distribution in the furnace during furnace runs, temperature profiles, current paths, energy balances, and alloy and slag production rates and compositions.

Apr 16, 2024

By G. Akdogan, S. M. Bradshaw, A. P. Van Wyk, T. Punt

Recycling has become an important part of the lithium-ion battery (LIB) life cycle due to the growing demand for energy storage in applications like electric vehicles and renewable energy. Recycling spent LIBs provides a secondary source for strategically scarce metals, like lithium and cobalt, helping to reduce the environmental impact of LIBs. Organic acids have been proven to be effective lixiviants with the benefit of reduced environmental impacts, amongst which citric acid has shown to exhibit similar extraction performance when compared to mineral acids. Leaching LCO and NMC batteries with 1.5M citric acid and 2 vol.% H2O2 at 95°C, 20 g/L for 20 minutes achieved 93% Al, 90% Co, 96% Li, 94% Mn and 94% Ni dissolution. The strong chelating property of citric acid affects the separation of the metals, providing unique extraction opportunities. The first extraction uses 12 vol.% D2EHPA at a pH of 2.5 and O/A ratio of 2 to separate 96.4% Mn and 100% Al from the PLS in two counter-current stages. Stripping the loaded organic with 1.25M citric acid at an A/O ratio of 3 allows for up to 91% stripping of the manganese in a single stage. The second extraction then separates 96.5% Li from the PLS in three counter-current stages using 20 vol.% D2EHPA at a pH 5.5 and O/A ratio of 5. The raffinate remaining after the second separation contains 48.4 wt.% Co and 50.3 wt.% Ni. Keywords: Hydrometallurgy, lithium-ion batteries, metal recycling, citric acid, solvent extraction

Jan 1, 2020

By W. A. Smith, M. C. Bekker, C. Marnewick

Projects or project-orientated approaches have become a common form of work in nearly all sectors of economies. This has led to concepts such as ‘projectified’ and ‘project orientated’ organizations. By defining projectification of a company, industry, or economy as the share of project work in total work, one can reasonably determine the impact that project management, and by default projectification, has had on that company, industry, or economy in terms of staff optimization and allocation. This paper presents the results for such a projectification study of the South African mining industry. This sector has long been a significant contributor to the country’s economy from a gross value added (GVA) and employment point of view. Understanding the impact of projectification and the project management way of work on this industry may potentially add significant value to both the mining and project management knowledge areas. We show that although the mining industry is considered by some to operate in archaic ways, the level of projectification has increased over time, and now represents approximately one third of all work conducted.

May 1, 2021

By A. Mainza, A. Mabentsela

A finite element model of a 5 m radius DC arc ilmenite furnace in idling mode was used to test the notion that the slag solidifies when it comes in to contact with colder pig iron, thus constituting the initial step in the formation of solid slag at the slag-pig iron interface. It was found that a slag that is 150°C hotter than the pig iron does not solidify at the interface. The 150°C temperature difference between the slag and pig iron is a result of solid slag at the slag-pig iron interface, not the other way around as suggested in the literature. Calculations show that the thickness of the frozen slag at the slag-pig iron interface is 1.7 cm for the furnace used. It is proposed that slag solidification begins with the slow co-current flow of molten slag and pig iron in the outer parts of the furnace. This provides enough time for molten slag to interact with molten pig iron without solidifying. As the reduction products form due to reduction of the slag by carbon in the pig iron, the slag solidifies. This approach negates the need for the slag to solidify by merely coming into contact with an inherently colder pig iron. Making use of a low thermal contact conductance between the slag and pig iron was found to be sufficient to numerically capture the presence of solid slag at the slag-pig iron interface and to preserve the 150C difference between the slag and pig iron phase.

Mar 30, 2023

The Barrick North Mara Mine and the Advanced Systems Group at SGS Minerals collaborated on the implementation of a grinding expert system for the control and optimisation of a single semi autogenous (SAG) mill. Over the last 5 years, grinding expert control has gained wide acceptance by mineral processors. In this paper, two key factors for success are highlighted: the adaptability of the software tools and the interaction with site personnel. Created with SGS?s MET expert console (MEC) toolkit, and running on Gensym?s G2 real time inference software, the North Mara expert logic has been set up to keep a steady and on spec leaching feed slurry while striving to maximize throughput. Leach feed stability was achieved by standardizing operating practices across shifts; a result of successful collaboration with site personnel in developing a consistent control strategy. The strategy maintains the SAG load and power draw in an optimised range by manipulating SAG feed rates and inlet water flow. The project life-cycle was slightly longer than average due to site specific constraints. One of these was the high turnover rate of site?s workforce during the project, coupled with the availability of key staff on site due to the fly in fly out work roster. These constraints called for different, and innovative ways of project commissioning and hand-over. This paper describes details of the control solution, its implementation as well as results and conclusions.

Jan 1, 2009

By C. Steyn, J. D. le Roux

A dynamic model is used to represent the single-stage closed grinding mill circuit at Mogalakwena North Concentrator. The circuit consists of a ball mill closed by a hydrocyclone. The circuit is modelled according to a semi-mechanistic non-linear dynamic model available in literature. An algebraic routine is used to fit model parameters to steady-state process data. Preliminary validation results against dynamic data indicate that the model is capable of capturing the main dynamic trends of the plant. Since classical system identification techniques proved insufficient to produce accurate models; the non-linear model can be used as a reliable source for model-predictive controller design. Keywords: Grinding, modelling, process control, parameter estimation

Jan 1, 2020

By L. A. Cornish, J. W. van der Merwe

"The hydrofluoric acid (HF) industry in South Africa uses normalized mild steel (SA 516 Gr 70) for the storage and distribution of its technical-grade product (70% HF). The technical-grade acid is split from the anhydrous hydrogen fluoride (AHF) product during distillation just after HF is produced, in a stainless-steel-lined kiln, from the reaction of calcium fluoride (CaF2) with sulphuric acid (H2SO4). Uniform corrosion of the storage tanks is mitigated during commissioning by contacting the steel with 70% HF. A corrosive reaction takes place (2H+ + 2F- + Fe - H2 + FeF2) to form scale inside the tank which diminishes the attack of the steel by fresh HF, thus prolonging the service life expectancy of the vessels. This iron fluoride scale in the vessel grows continually, resulting in corrosion of the vessels continuing at a predictable rate (approx.0.5 mm/a) since the first commissioning of the tanks at Necsa in 1993. In early 2012, an increase in the average corrosion rate of the tanks to 3 mm/a measured at and below the liquid band in the storage vessels was noted. Three months later the corrosion rate had increased to 30 mm/a, just before the first leak from the tank was detected. The tanks were decommissioned shortly afterwards and an investigation revealed that the rapid corrosion was due to the presence of increased levels (>50 ppm) of nitric acid (HNO3) in the tanks, which attacked the fluoride layer protecting the steel.The oxidation characteristics of high concentrations of HNO3 with low concentrations of HF on stainless steel surface treatment are well documented. The effects of low levels of nitric acid on the corrosion of steels in sulphuric acid are also known, but no suitable published data currently exists on corrosion by high HF concentrations with low HNO3 concentrations. Establishing the rate and mechanism of corrosion by HNO3 (0.1 to 1%) in 70% HF is currently a high priority for the HF industry in South Africa and will become increasingly important in the near future due to depleting fluorite reserves and cheaper, but less efficient, processes producing H2SO4 with higher impurity levels, which were not anticipated in the original plant design. The aim of this study is to simulate the corrosion conditions in the plant on a laboratory scale in order to establish the corrosion characteristics of the steels used in the HF plant, which are increasingly exposed to the HNO3 impurities that tend to concentrate in the final technical-grade HF acid product."

Jan 1, 2016

By G. Chitiyo

Prediction of pothole characteristics is a challenging task, confronting production geologists at the platinum mines of the Bushveld Complex. The frequency, distribution, size, shape, severity and relationship (FDS3R) of potholes has a huge impact on mine planning and scheduling, and consequently cost. It is with this in mind that this study was initiated. Quantitative analysis of potholes indicates that pothole size (area covered) can be described by two partly overlapping lognormal distributions. These are referred to as Populations A (smaller) and B (larger). The range of observed pothole sizes conforms to a simple double exponential growth model based on Newton's Cooling Curve. A third size range of very large potholes (Population C) that could not be modelled properly within the proposed growth model is interpreted as to represent a very early phase of aggressive regional thermo-chemical erosion and potholing. In general, potholes are dominantly quasi circular with only a subordinate tendency of elongation. In the UG2, potholes with elongated forms are more prevalent in the size range between 20 and 500 m diameter. In the Merensky Reef elongated potholes are more common in the size range above 50 m in diameter. Although not distinctly visible, elongation of potholes in both the UG2 and the Merensky Reef show a net north/south orientation. Using shapes of pothole rims and floor areas, documented for the UG2 in the Waterval Shaft area, it is demonstrated that the northern, down-dip edges of potholes have steeper dips than the southern, up-dip edges. Spatial distribution studies using a uniform quadrant method suggest that in both the UG2 and the Merensky Reef, the potholes are randomly distributed, with a tendency towards clustering. Clustering appears to be more prevalent in the smaller Population A potholes. Bearing all findings in mind, it is found that the model of thermo-chemical erosion of the cumulus floor by new influxes of superheated magma best explains the observed data. Partial to complete melting of the cumulate floor occurred in three phases. The first represents the emplacement of hot magma. This magma, due to turbulent flow and high chemical and physical potential, aggressively attacks the existing floor (crystal mush on the magma/floor interface). Regional erosion is manifested by large, often coalescing potholes. During the second phase, when the magma emplacement process ceased and cooling in situ started, two distinct periods of pothole formation ensued. The first is related to rapid cooling along the relatively steep part of the Newton Cooling Curve, when Population B potholes nucleated randomly and grew rapidly with concurrent convective overturn and largely laminar flow condition. The second period of cooling occurred on the shallow-dipping part of the Newton Cooling Curve. Population A pothole growth became more subdued and nucleation appears to have been, at least locally, clustered. The final phase of this proposed 'super magma cycle' was introduced when chromitite crystallization and precipitation terminated pothole formation. This was followed sequentially by pyroxene and plagioclase crystallization to form the typical cyclic units of the Critical Zone. No suitable proxy could be found for the prediction of pothole density of potholes associated with the UG2 (likely due to limited spatial data coverage), and these are best predicted by extrapolation. The Merensky Reef slope index, in contrast, provides a proxy for pothole density, enabling prediction with reasonable confidence. This predictive model has been verified using underground information. The findings made during the course of this investigation have, when implemented, significant impact. Successful implementation will not only allow enhanced resource and reserve definition, but also better mine planning and scheduling.

Jan 1, 2008