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By R. M. Goktan

Point-attack picks are one of the most widely used tools for the mechanical excavation of rock and coal. In the literature, some practical formulas have been developed to estimate their performances under varying cutting conditions such as the pick geometry, cutting depth and cutting geometry. In this study, it is shown that Evans?s theoretical model, the most cited in the literature, has serious limitations concerning the changes in the cutting geometry. Analysis of the two independent full-scale linear rock cutting experimental data reveals that both his theory and its recent modification can not fully explain the mechanism of rock breakage under asymmetrical attack. The cutting force predictions made by employing such models are shown to be too significantly weak to be of any service in practice. In this study, a semi-empirical approach was followed by means of which cutting forces under varying cutting geometries could be made. By analysing the full-scale rock cutting test data, prediction equations of the peak cutting force and mean cutting force have been developed. Comparisons of laboratory determined and predicted force values indicate that the suggested prediction equations are applicable to quite different rock materialsm which have uniaxial compressive strength in the range of about 30?170MPa, and valid for different cutting geometries. It is also shown by regression analysis that the established prediction equations are statistically significant.

Jan 1, 2005

By M. Natarajan, C. J. Cutler, E. Mponda

Keywords: Pyrometallurgy, furnace, KCM Nkana, Zambia The Nkana smelter was initially commissioned in 1931, with two reverberatory furnaces, two Peirce-Smith converters, and blister copper casting facilities. Reverberatory furnaces were the mainstay of production up until 1994, when an El Teniente Converter (CT) was installed to upgrade reverberatory furnace matte to white metal, prior to converting in conventional Peirce-Smith (PS) converters. In 2000, a decision was taken to increase the proportion of concentrate smelted in the CT by introduction of bone-dry concentrate injection through the tuyeres. A flash dryer with a nominal capacity of 1 200 metric tons per day of dry product, and associated tuyere injection system was commissioned in March 2004. Based on the projected concentrate arisings from the KCM mines into the future, as seen in 2004, it was decided to develop the CT to be the primary smelting vessel at Nkana, to handle a minimum of 1 250 tons per day of concentrate, and to operate only one reverberatory furnace in slag-cleaning mode pending a full evaluation of alternative slag-cleaning technologies. The anticipated cathode production from Nkana was to be in the range 140 to 150 000 tons per annum. This paper details the outcomes from trials that were carried out in August and September 2004, using two reverberatory furnaces for slag cleaning. The results of these trials, plus further work in October and November, provided confidence to move to one reverberatory furnace for slag cleaning in December 2004. With the advent of Vedanta as the majority shareholder in KCM at the end of 2004, the approach has been to maximize the available smelting capacity. Currently, two reverberatory furnaces and the CT are on-line, with the higher silica concentrates going to the reverberatory furnaces with an appropriate amount of pyrite, and the cleaner concentrates going to the CT. Expansion of the smelter is currently under investigation.

Jan 1, 2006

By A. Z. Toper

This is a sampling of the papers presented at the conference, the proceedings can be bought from the SAIMM An extensive research programme to address the issue of rockburst control has been undertaken over a number of years. This paper discusses the development of preconditioning techniques to control face bursts, for safer mining in seismically hazardous areas. Preconditioning involves regularly setting off carefully tailored blasts in the fractured rock immediately ahead of a mining face, so as to encourage slip on pre-existing fractures, in order not to allow the accumulation of high strain energy density in the rock mass. Two different preconditioning techniques have been developed, namely face-perpendicular preconditioning and face-parallel preconditioning. Both have prevented face bursting in areas to which they have been applied, even though several large seismic events have occurred close to the faces in some areas. In addition, minimal overall damage was observed in the preconditioned panels following these events, compared to similarly exposed unpreconditioned panels. Preconditioning has also provided some protection to the face area from distant events, through the capacity of the preconditioned ground to absorb energy. An improvement in hangingwall stability and productivity has also been noted in preconditioned areas. In order to determine the optimum blast parameters for achieving the most effective preconditioning, an extensive optimization study was carried out for the face-perpendicular preconditioning technique. While optimum values for parameters such as hole length, diameter and spacing were determined, it was ultimately concluded that the differences in results obtained by varying the preconditioning parameters were less significant than the clear positive differences observed when comparing preconditioned areas with non-preconditioned areas.

Jan 1, 2000

Milling circuits are known to be difficult to control. In order to address these difficulties, it was decided to develop and test a model predictive controller (MPC) for a milling circuit. A milling simulator was written using Microsoft Visual C++ and used to design and test the MPC controller. Due to the large number of tuning parameters in a controller of this type, an optimizing algorithm was written that automatically tunes the controller. Good, robust control was obtained when the controller was tuned using this algorithm. Control was further improved by combining feedback and feed forward control and by using quadratic programming in the MPC algorithm. The movement of the manipulated variables was reduced by using a novel technique that allows the controlled variable to vary within a specified region around the set point. An optimiser controller was also successfully implemented to control the circuit at its maximum throughput.

Jan 1, 2000

By P. Rice, A. Photolo, A. C. Barnard

Introduction -Sampling Tool Project (STP) -History -Results to date -Costs -Questions

Jan 1, 2005

A South African gold mining rock-related fatal accident database has been analysed in order to determine rock-related fatality trends in the gold mining industry over the period 1990 to 1998. This analysis was extended further to include some of the individual reefs mined and focused particularly on the Carbon Leader Reef, the Ventersdorp Contact Reef, the Vaal Reef and the Basal Reef. Rock-related accident locations are also presented. A stope rock-related risk is proposed, where the fatality rate in terms of rock-related fatalities per million square metres mined for the gold mining industry as a whole is compared to individual reefs, allowing a stope rock-related risk to be attributed to the individual reef. This comparison is extended further by removing the contribution by the reef being evaluated from the industry data, thereby allowing this reef to be directly compared to the rest of the industry with respect to a stope rock-related risk.

Jan 1, 2001

By D. B. Rebuli

Seismic networks in deep gold mines of South Africa are often planar owing to the tabular geometry of the orebody and, therefore, the mining infrastructure. Consequently, seismic event locations are poorly constrained in the direction perpendicular to the reef plane, and symmetrical locations above and below the reef plane may fit the observed data equally well. This problem may be resolved in situations where the strata above and below the reef plane have significantly different seismic velocities, which is the case for the Ventersdorp Contact Reef at Kusasalethu mine (previously Elandskraal, the amalgamation of Deelkraal and Elandsrand). A location method using a layered location model that takes into account the velocity contrast between the layers was tested. Observed direct- and head-waves were used to determine the velocity bounds of the P-wave velocities in the two-layer model. The data-set was also used to find the best P- and S-wave velocities for the two layers by grid searching over a range of velocities and minimizing the sum of the travel-time residuals. The results from the grid search and those from the calibration of velocities using direct- and head-waves give similar P-wave velocities for each of the two layers. A second set of seismic events was then relocated with this layered model and locations closer to reef were found. This simple layered location method goes some way to reduce the reefperpendicular location errors for Kusasalethu mine in particular. Keywords mine seismology, velocity model, location methods.

Jun 1, 2013

By M. Nduna

Surface properties of metal sulphides have a great significance in various areas of engineering and science, such as acid mine drainage, contaminant sorption, and metal separation. In various attempts at producing metal sulphide particles from synthetic solutions, prodigious quantities of nuclei that grow only to colloidal dimensions have been frequently reported. This copious nucleation is promoted by the high levels of supersaturation that characterize most precipitation reactions. Colloidal particle formation in precipi¬tation-based separation processes results in sub-optimal solid-liquid separation, which is alleviated by the production of more highly crystalline particles or agglomerates. The current work approaches this challenge from an electrochemistry perspective, by measuring surface charge potential of precipitant particles during metal sulphide precipitation with respect to the concentration of metal sulphide lattice ions in solution. Electrophoresis was used to measure the metal sulphide particle zeta potential and the settling properties were obtained by performing settleability measurements using an Imhoff settling cone. A suspension of copper sulphide particles was precipitated from synthetic solutions of copper and sulphide ions at equimolar concentrations. Immediately after precipitation the copper sulphide particles had a zeta potential of -50 mV and a settleability of about 7 ml.l-1. With the addition of copper ions the settleability increased by a factor of nearly three times and the zeta potential also increased to a maximum of -40 mV. A decrease in zeta potential to a minimum of -60 mV was observed after the addition of sulphide ions and this was associated with a settleability of 0 ml.l-1.

Jan 1, 2013

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 S. Sarac

Solving ventilation networks of natural splitting is a basic problem in mine ventilation. Several mathematical techniques are used to solve this problem. This paper proposes a new method which combines the advantages of both classical Hardy Cross method and unconstrained optimization techniques. The trials carried out on model networks have shown that the method offers some facilities in the analysis of mine ventilation networks. Keywords: Ventilation network analysis, Hardy Cross method, Steepest Descent method.

Jan 1, 2000

By John V. Simmons, Peter J. Simpson

Excavated slopes in open pit coal mines are designed to be as steep as possible consistent with stability and safety requirements. Slope failures occur for many reasons, including oversteepening. This paper is concerned with slope design and excavation experience in the Bowen Basin coalfields of central Queensland (Figure 1), [ ]

Jan 1, 2006

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

By T. E. Pogue

This paper traces the co-operative initiative undertaken by South Africa?s gold mining companies through the Chamber of Mines Research Organization (COMRO) in development of hydraulic technologies. After a brief description of the structure of these technologies? development under COMRO?s stewardship, the paper turns to an overview of the structure of innovation within which these hydraulic technologies were developed. A central focus of this paper is systematic review on whether similar technologies are likely to emerge in the present system of innovation and the role played by innovation policy.

Jan 1, 2006

Sandsloot open pit is situated on the northern limb of the Bushveld Complex, 250 km north east of Johannesburg, South Africa. Sandsloot is currently the largest open pit platinum mine in the world and is one of six potential open pits in the area. The geotechnical strength properties of the Platreef have posed significant mining and processing challenges to the PPRust operation since inception in 1992. In order to optimize the whole business as opposed to isolated cost centres a mine to mill initiative was embarked upon in 1997. Initial work focused on ore characterization and an entire suite of data was collected for each rock type. This included mineralogy, geochemistry, geotechnical, blast ability indices, as well as metallurgical strength data. The second phase involved the clear definition of customer requirements, namely the optimum performance criteria for the plant and mining departments. This involved extensive field trials and data capture to measure the interaction and influence of the mine to mill value chain. Once the design targets were defined, a 3D geotechnical model was constructed to ensure that the targets were consistently achieved. The model is very similar to an ore reserve model; however, it is populated with geotechnical, metallurgical and blast index data. Through software queries the appropriate blast powder factor for each mining block can be obtained, thereby ensuring the correct fragmentation is blasted for the plant and mining operation. The initiative has delivered significant results showing improvements across the mine to mill value chain. These include increased loading rates, reduced electricity and crushing consumables, as well as higher plant throughput. Additionally, the initiative has benefited both brownfield and greenfield projects on the PPRust operation

Jan 1, 2006

By Lutz Markworth, Wolfram Jaspers, Johannes Kottmann

PNEUFLOT® technology has been applied for the past 20 years in coal, ore and other minerals processing plants. During the last two years this technology has achieved a breakthrough with some 42 units being sold signifying a rising trend. »Humboldt Wedag Coal & Minerals Technology« has performed extensive research and development work over the last five years. The results of which were used to design a new fourth generation aerator. Humboldt Wedag, through its association with EKOF, can offer a holistic solution encompassing both flotation equipment and reagents. It is the only company in the world able to offer such a package. The association with EKOF strengthens the Humboldt Wedag product offering, especially as the company in-troduced pneumatic flotation cells to the South African market in the form of the PNEUFLOT®. Before starting pilot scale test work, a mineralogical analysis has to be carried out to determine the mineral com-position as well as the liberation grade. HW-CMT works together with independent institutes. Different reagent regimes can be tested in laboratory scale. Pilot machines, each packed in a 20? container, are available to carry out extensive test work at customers? processing plants. A group of engineers from HW-CMT is involved in the pilot test work. The flexible pilot machines are designed to cater for coal, ores and other minerals. The small feed rates of 7 ? 12 m³/h only means the pilot machines do not disturb the operation of process plants. Batch tests have to be carried out to determine the numbers of PNEU-FLOT® stages. New applications in iron ore, copper ore, platinum group minerals, rock phosphate and potash were suc-cessfully tested in the last three years. In applications where the feed material is very fine, PNEUFLOT® technology is able to achieve high recoveries with particle sizes where conventional technology failed.

Jan 1, 2007

The use of a time series variogram as an aid in controlling the quality of a product was pioneered by Pierre M. Gy and is described. The ability to analyse and interpret covariance relationships time series data is possible using the variogram. The concept of stream heterogeneity allows sources of variability in process streams to be identified and isolated. Principally this is distributional heterogeneity that is due to a short range effect of segregation in the process stream related to size or composition distribution of the material on a local scale and due to a long-range change in the size and grade of the material stream. The variogram is simply a tool for representing these sources of variability in a way that is explicit, allowing identification of the source and providing important insights to temporal continuity between samples. This paper describes the chronologically related large-scale variability in an iron ore process stream (%Fe), and illustrates the control and mitigation of variability at various stages within the process using a variogram. Three main sources of variability are identified including the random variability V[0], the process variability V[1], and the variability due to cyclical phenomena V[cyclic], arising from human routine or mechanical defects. These sources of variability can be represented on the control chart that provides the plant superintendent with insights as to the sampling capability of the systems in place. Maintaining levels of variability within customer specification limits requires that production systems be controlled without overcorrecting for the trends in changing quality. This can be done only by representing the limits of control relative to the limits of specification on a control chart. Where the specification limits encroach on the control limits, one or the other, or both, may need to be changed; specification limits that constrain the control limits lead to reactive decision making that is expensive and stressful for plant operators.

Jan 1, 2008

By M. S. Smith

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree The condition of tunnels at Premier has deteriorated to such an extent that an objective viewpoint on what leads to poor condition was required. Poor and untimely development results in schedule deviation, rehabilitation, and increased working costs. The project focused primarily on quality, and not on efficiency. The project gave management guidelines that need to be focused on in order to produce quality infrastructure. The conclusions were reached by doing literature searches, underground site investigations, benchmarking and computer simulations. From the results we can see that, in order to produce good quality tunnels, we have to have the basics working. This was found to be one of the major problems. Firstly, tunnel profiles are not to the design specification and no fixed blast designs existed. After revising tunnel profile statistics, over break increased to 10% (previously 7%) and development metres were 50 m short of target. Blasting was not monitored and designs not optimized for the conditions. Furthermore, geological factors are the main contributor to tunnel failure, although this process is initiated and aided by poor development (overbroken tunnels, incorrect profiles, direction and location) and blast damage. Continuing to develop tunnels in the current manner will cost R 1.5 million in additional costs for loading and supporting overbreak, whilst an additional 1 800 man-shifts will be required. Blast patterns were designed as a starting point for trials, while the implementation of a blast management system, development statistical database, tunnel hand-over procedures and a revision of the bonus system were proposed.

Jan 1, 2004

By M. J. King, A. Weissenberger, W. G. Davenport

Keywords: Pyrometallurgy, sulphuric acid, sulphur dioxide The raw material for sulphuric acid manufacture is clean SO2 gas. It comes from (i) burning molten by-product sulphur; (ii) roasting or smelting metal sulphide concentrates, and (iii) decomposing contaminated organic chemical process sulphuric acid catalyst. Efficient gas cleaning is required for metallurgical and contaminated acid decomposition gases, especially the former. Sulphuric acid is made from SO2 gas by (i) oxidizing the SO2(g) to SO3(g) in contact with supported liquid-phase catalyst then (ii) reacting the resulting SO3(g) with the water component of 98.5 mass% H2SO4, 1.5 mass% H2O acid. This paper discusses the reasons for these process steps and indicates how acidmaking can be controlled and optimized. Special emphasis is placed on SO2(g) oxidation efficiency and how it is influenced by feed gas composition, feed gas temperature, catalyst composition, catalyst bed pressure, number of catalyst beds, and double versus single contact acidmaking. In addition, a review of various other treatment methods for SO2-bearing gases is provided. A brief description of each process is included along with commentary on their technical and economic applicability for use at metallurgical facilities.

Jan 1, 2006

By Gerard de Vries

pipeline industry and are still growing in size. Liquid epoxy and polyurethanes are an excellent choice for whatever the aggressiveness of the substance transported and whatever the harmful outside influences, maximum protection is required. They can be used as coatings on all kind of pipelines varying from the mainline coating to the field joint coating. Compared with traditional systems like dual layer FBE and 3-layer polyolefin there are some benefits to be considered like easiness of repairs, amount of coats, application temperature and film thickness. The interior coating renders the pipe surface so much smoother that considerable savings can be realized in pump stations. Apart from the interior of the pipeline, the industry is faced with new challenges like higher operating temperatures of lines and an emphasis on product benefits in order to save money. Key words: liquid epoxy, liquid polyurethane, phenolic epoxy, pipeline, field joint coating, internal coating, corrosion control

Jan 1, 2006

A shortage of technical skills in all areas of the mining industry is being experienced worldwide. This has significant consequences for design, operations, productivity and safety and, therefore, needs to be seriously addressed, both in the short and longer term. It is therefore both a strategic and a tactical issue. Importantly, however, since mining is a long-term business, the shortage of skills must be dealt with from a strategic point of view to ensure the supply of the necessary skills for future mining. This paper will deal specifically with the provision of high level technical skills, that is, university graduates in mining engineering, and the outlook for the institutions that are currently producing such graduates.

Jan 1, 2009