Search Documents

By P. Venter, N. Naude

"Coal mining is a thriving industry and 53% of the coal mined in South Africa is used for electricity generation. Mechanization has made coal mining more efficient, but fines generation has subsequently increased. Up to 6% of the run of mine material can report to the -200 µm fraction. Common problems associated with fines handling include dust formation, storage problems, and high moisture levels. A method to turn this material into a saleable product instead of stockpiling it can add value to a company.Briquetting is a pressure agglomeration method where loose material is compacted into a dense mass (FEECO International, 2014). The briquettes must be able to withstand rigorous handling and transport operations without disintegrating. This study aims to investigate the optimum binder and moisture conditions required to produce a mechanically strong briquette using two different binders - a PVA powder (binder A) and a starch powder (binder B).It was found that for binder A the optimum moisture level was 12% to 14%. At this moisture level the greatest compression strength gains were observed, and low amounts of fines produced in impact and abrasion tests. The minimum amount of binder added while still obtaining a strong briquette was 0.5% binder A. For binder B the optimum moisture level was also 12% and the minimum amount of Binder B to be added was found to be 1%. Briquettes that were dried outside reached their peak strength after about four days, whereas the briquettes that dried inside took about 20 days to reach their strength plateau. Hardly any degradation took place on the surface of the binder A film after exposure of 300 hours of artificial weathering. Thermogravimetric analysis confirmed that neither binder A nor binder B will add to the ash content of the coal fines, as both binders totally decompose above 530°C.Binder B yielded stronger briquettes after 15 days and also generated less fines. It is therefore superior to binder A and would be recommended for further use.Paper written on final year project work carried out in partial fulfilment of B.Eng degree in Coal Beneficiation"

Jan 1, 2015

By C. Ringas

Pipelines are used extensively in industry to convey various products. Internal corrosion of pipelines can lead to perforation and leakage of the product. A growing problem, not often accurately recognized, is internal corrosion of pipelines caused by bacteria. Microbiologically-induced corrosion (MIC) refers to corrosion caused by a variety of micro-organisms. This form of corrosion is not widely recognized in many industries, although it is widespread and causes many corrosion problems in pipelines, both internal and external. Sulphate-reducing bacteria (SRB) are responsible for the bulk of the corrosion problems caused by MIC. Corrosion caused by SRB is found extensively in water pipelines conveying raw, potable and waste water, as well as in pipelines conveying slurries. This problem also occurs in pipelines conveying crude oil. This paper describes internal corrosion problems of slurry pipelines caused by bacteria and outlines mitigation methods to improve slurry pipeline integrity, thereby extending the life of such pipeline

Jan 1, 2007

By W. Bryszewski

As a result of strategic analysis in respect of the needs for air quality management a new advanced and holistic approach to air quality management process was introduced in the North West Province (NWP) of South Africa. The process is based on the principle of co-operative management. It involves both active participation of all Interested and Affected Parties (I&AP) and the holistic approach to solving problems with the underlying principles of shared ownership and sustainable development. The process consists of the followings phases: ? Industrial process quantification ? Quantification of impacts ? Formulation of the required control measures ? Definitions of certificate conditions ? Implementation of an adequate compliance management system at company level ? Ongoing co-operative air quality and system management with the strategic objective of continuous improvements The system has been successfully introduced in the North Province and proved to be an effective management tool and aids assurance of sustained environmental ability to cope with the pressure of industrial developments. The benefits and effectiveness are discussed using Hernic Ferrochrome as an example. Hernic Ferrochrome is one of the first companies, which successfully implemented this system.

Jan 1, 2004

In a gravity separation device, particle shape, size and density all play a role. The combination of these determines where each individual particle reports to in the viscous fluid, where particle crowding (solids to water ratio) also plays a role. To understand the performance of gravity separation devices in the heavy mineral industry, these particle characteristics need to be measured. There are various challenges in analysing particle density and particle size simultaneously for the purpose of quantifying gravity separator performance, not to mention particle shape. These analytical challenges include the high cost of high-density sink-float fractionation, toxicity of high-density sink-float media, inability of sink-float media to fractionate at densities greater than 4.0 g/cm3, and the time-intensive nature of these fractionations. The use of the detailed particle-by-particle output from Qemscan® particle mineral analyses (PMA) as a fast and cost-effective alternative is evaluated. The size and density outputs from the Qemscan® were employed to characterize the performance of a heavy mineral spiral concentrator as an example. Critical analytical requirements are to be addressed before the Qemscan® output data can be utilized. Keywords Gravity separator, performance, heavy minerals, Qemscan® particle mineral analysis

Jan 1, 2011

By C. Musingwini

The subject of optimal planning of level and raise spacing for inclined narrow reef deposits has received intermittent attention over the years because the subject matter is inherently complex. Previous work has approached the problem as simply that of simultaneously minimizing the total excavation and haulage cost associated with the development workings. However, when level and raise spacing are altered, other factors such as productivity are negatively affected, thus requiring a delicate trade-off of contradicting planning or optimization criteria. The paper concludes that the problem is actually of the multi-criteria decision analysis (MCDA) type, contrary to traditional thinking that the planning problem is achieved solely by minimizing waste development.

Jan 1, 2010

By G. van Aswegen

Seismic monitoring became commonplace in the deep South African gold mines in the early 1990’s. The discipline has, to a large extent, developed beyond the ‘research’ stage, and a ‘Guide to Seismic Monitoring in Mines’ has been accepted by the Department of Minerals and Energy1. Although ongoing research is a requirement for the achievement of all the objectives of seismic monitoring in mines, sufficient knowledge exists to apply seismic monitoring for routine seismic hazard assessment as an aid to risk management. The design and management of seismic monitoring systems can be tested against requirements spelled out in the ‘Guide’. Assuming the seismic monitoring system performs as per requirement, the best practice for routine seismic hazard assessment in mines includes • Long term seismic hazard assessment: through back analysis of seismic data and correlation with numerical modelling output, reasonable tests for planned mine designs are possible. • Medium term seismic hazard assessment: o Spatial analysis through contouring of seismic strain related parameters, with superimposed contours or event plots of stress related parameters allow the delineation of potential instabilities in space. o Quantitative and statistical analyses of seismicity in smaller spatial units (usually encompassing production sites) allow the comparative seismic hazard rating of different areas/sites so that rock engineering input and risk management can be optimised • Short term seismic hazard assessment relies mainly on time history analyses of particular seismicity parameters. The temporal patterns are controlled by a combination of temporal and parameter filters, the optimisation of which determines the success rate.

Jan 1, 2003

By E. S. Peters, M. J. van Rensburg, M. Le Roux, Q. P. Campbell

"The demand for energy has continued to rise worldwide in line with population growth. The majority of South Africa’s electricity is supplied by coal-fired power stations. The amount of fine coal (-2 mm) generated at coal processing plants has increased, due mainly to mechanized mining methods. Fine coal retains more water, which lowers its heating value.Drying the coal is costly and it is difficult to achieve the required moisture content. Consequently, coal fines are often discarded. An estimated 8% of the total energy value of mined coal is lost1.Fluidized bed technology is often used to dry coal thermally, but this method is expensive and has an adverse environmental impact. The objective of this study was to investigate the removal of moisture from fine coal (<2 mm) in a fluidized bed operated with dry fluidizing air at moderate temperatures as the drying agent. The effects of different air temperatures and relative humidity levels were investigated in a controlled environment. The study further investigated the influence of coal particle size on moisture removal.The drying rate was found to increase with increasing temperature. The relative humidity of the drying air had a more pronounced effect on the drying rate, even at temperatures as low as 25°C.. It became more challenging to remove moisture as the particle size decreased. The gain in calorific value was greater than the energy required to dry the coal samples, showing that a fluidized bed using moderately warm dry air is an energy-efficient drying technology. The energy efficiency of the fluidized bed compared favourably with other thermal drying methods.Paper written on project work carried out in partial fulfilment of Degree in Chemical Engineering(NWU) - Pursuing Masters in Coal Beneficiation"

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 M. Tangstad, B. Monsen, H. Midtgaard, R. Ishak, M. Syvertsen, I. Solheim

Charcoal is an interesting reducing agent because it is produced from growing wood which is renewable and does not contribute to global warming, provided that there is a balance between the felling of timber and growth of trees. In the biocarbon project the possibilities for using charcoal is investigated as well as other biological based and renewable reductants for ferroalloy production. The background for the project is that the Norwegian ferroalloy producers wish to contribute to reduction of CO2- emissions. This paper focuses on the use of charcoal instead of coke for the production of manganese alloys, and the consequences of doing so. Results from practical SiMn smelting experiments on a pilot scale have previously been reported, where only 12-14 % Si in the metal was obtained when charcoal was used. Recently we have attained satisfactory 18 %Si also for charcoal, but good results are indeed dependant on good furnace performance. There is no tradition for using charcoal for manganese production in Norway. A change from using mainly coke to the use of some charcoal will demand new routines for furnace operation, raw material and off-gas handling. Hence, characteristic properties of charcoal, which may cause change of furnace operation, have been measured and are compared to coke. The following results are presented: ?Thermal abrasion strength together with CO2- reactivity; important parameters for the performance of the upper part of the furnace. ?Coke-bed resistance; it will increase with the use of charcoal (a review of new results). ?Slag reactivity; a relevant method for testing slag reactivity of industrial reductants is of interest. The suggested method can serve for comparing slag reactivities towards graphite.

Jan 1, 2007

By Phillip M. Dight

A number of impending and actual pit wall failures have been observed and documented which have been interpreted to initiate on newly generated structural features. This infers failure through intact rock. Failure mechanisms have been postulated resulting from circumferential stress, extensional strain and brittle flexure. These will be discussed in the context of the failures and the associated monitoring. The implications of failure initiating on ?unknown? features has a significant impact for deep open pit mines where designs are based on the expected structural regime. Being able to anticipate such failures is important for design. Equally important is management of such changes as they arise. In this context, monitoring using high resolution microseismic techniques will be discussed as a means of providing early warning of such failures.

Jan 1, 2006

A typical sub-level block cave mining extraction method employs an undercut level to establish a cavity in hard rock, and as such requires special support methods and products to be installed during the development phase. The undercut level development in the block cave orebody is then sacrificial, and support elements will eventually report to the crusher and perhaps conveyor belt systems for transportation to surface. The choice of support products installed in the undercut level development should take cognizance of the detrimental effect these could have on the mining system such as cutting of conveyor belts, obstructing crushers, safety aspects, and productivity. This work explores the probability and practicality of making use of new-generation support products to make the operation safer as well as enhance productivity in the development phase and during the undercut operation. This paper will investigate the use of glass reinforced plastic(GRP) rockbolts and GRP mesh instead of conventional steel bolts and mesh along with resin capsule-filled holes with the GRP bolts. Complementing this with thin spray liner (TSL) application as another means of creating a safer operating environment, as well as a productive support medium, will also be addressed. These proposed items are envisaged to reduce production downtime and improve the safety of our people. These items are all easy and light to handle, cuttable and crusher friendly, as they will break up during the crushing process.

Jan 1, 2012

By H. Möhle

Premier Mine is a large underground diamond mine, situated at Cullinan in the Gauteng Province of South Africa. The mine hoists over 3 millions tons of diamond bearing kimberlite per year, from a modern, mechanized panel retreat block cave mining operation. Troughs sited at the base of the cave are developed into the overlying caved ore, allowing loading access to the ore through draw points. Trough opening is therefore a vital aspect of the mining operation. Most of the production is dependent on fast, reliable and safe trough opening. Successful trough openings are achieved under difficult mining conditions due to restricted void, long up-holes and the inherent properties of kimberlite?soft, elastic rock with a high swell factor. Early in 1998, Premier Mine undertook a joint development project (with an electronic initiation system supplier) to determine whether the use of a fully programmable electronic detonator system would enhance the mining cycle in the trough opening process. Blasting commenced in February 1998, initially with blasts of a similar size and duration to those that had been previously blasted with shock-tube systems, to confirm the operational capabilities of the blasting system. The accuracy, reliability and flexibility of the electronic delay detonators (EDDs) minimized associated risks for re-engineering of the trough opening process. Further, as blast timing was optimized, larger blasts were successfully initiated. To date over 20 troughs have been opened successfully with the use of EDDs. Not only did it take less time to open troughs, but also drilling and blasting operations have been optimized, as well as an overall improvement in safety. This paper details the benefits that EDDs have delivered to Premier Mine in this area. The logic followed is: ?Review of the original trough opening practices ?Re-engineering of the trough opening process ?Implementation of EDDs ?Evaluation of improvements and conclusions.

Jan 1, 2000

1. New books P. Sarnoff. Trading in gold. Cambridge, Woodhead- Faulkner, 1980. 136 pp. £3.50 by airmail. Environmental Planning Professions Interdisciplinary Committee (EPPIC). Proceedings: Joint EPPIC/Habitat Symposium: Shaping Our Environment. Johannesburg, EPPIC (P.O. Box 61019, Marshalltown 2107), 1980. R3 per set of 2 issues. H. P. Patra and K. Mallick. Time-varying geoelectric sounding. Amsterdam, Elsevier, 1980. 420 pp. D.S. $87.75. Die Suid-AfrikaanseSteenkoolverwerkingsvereniging. Steenkoolvoorbereidingskursus. J ohannes burg, die Vereniging, 1930. 335 pp. Members of Chamber of Mines of South Africa R15, nonmembers R40. D. R. Derry. A concise world atlas of geology and mineral deposits. London, Mining Journal Books, 1980. HO pp. £26.25 byairmail. 2. Journal Remote sensing of environment (RSE). 3. NIM reports Report No. 2064 The on-line monitoring of gold in barren solutions. Report No. 2065 The determination, by X-ray-fluorescence spectrometry, of gold, silver, and base metals on activated carbon. Report No. 2068 The determination of platinum, palladiuim, rhodium, and gold in ores and concentrates by the fusion technique with lead as the collector. Report 2061 The determination, by anodic-stripping voltammetry, of copper and lead in silicate reference materials. Report 2062 The reduction by computer of photoplate data obtained by spark-source mass spectrornetry. Report 2071 The determination, by X-ray-fluorescence spectrometry, of tin and tungsten in scheelite and ca8siterite ores and concentrates. Tunnelling Tunnelling &apos;82, the third international symposium in the series, is being organized by the Institution of Mining and Metallurgy, with the co-operation of the British Tunnelling Society, the Institution of Mining Engineers, and the Transport and Road Research Laboratory.

Jan 1, 1980

By J. W. Klokow, K. L. Riemer, R. I. L. Ferreira

As a result of the increased depth of mining in the South African gold mining industry mining induced seismicity is a severe problem. One of the strategies within the industry to contain the problem is to incorporate a system of regularly spaced stabilising pillars into mine layouts. At the Driefontein Gold Mine a system of closely spaced dip pillars is used to contain seismic energy emissions. Comparisons of seismic data for several mining clusters initially indicated a possible measure of success in the containment and occurrence of larger events. A detailed analysis of data over a 5-year period since the start of mining however, has revealed a delayed seismic response to the increasing strike spans. Significant changes marked by an increase in certain seismic variables have been observed at mining spans of between 100 to 120 meters and could be of significance to pillar spacing in the design of deep level mining layouts. La sismicité occasionnée par l’exploitation minière est un problème grave dans les mines profondes de l’industrie minière aurifère en Afrique du Sud. Une des stratégies utilisées dans l’industrie a été de maîtriser le problème en incorporant un système de piliers de stabilisation régulièrement espacés dans la disposition des mines. A la Driefontein Gold Mine, un système de piliers de pendage proches les uns des autres est utilisé pour contenir les émissions d’énergie sismique. Au début, des comparaisons de donnés sismiques pour plusieurs groupes d’extraction ont indiqué un succès possible dans la limitation et l’occurrence d’évènements sismiques. Cependant, une analyse détaillée des données sur une période de 5 années a révélé un délai entre la progression de l’extraction et une réponse sismique accrue. Des changements considérables dans les variables sismiques ont été observés dans des intervalles d’extraction entre 100 et 120 mètres, ce qui pourrait être significatif pour l’espacement des piliers dans la conception de la disposition des mines de fond. Resultierend aus den zunehmenden Tiefen des Bergbaus in der südafrikanischer Goldbergbauindustrie stellt sich die vom Bergbau hervorgerufene Seismizität als bedrohliches Problem dar. Es war eine der Strategien innerhalb der Industrie, das Problem dadurch einzudämmen, daß regelmäßig plazierte Stabilisierungspfeiler in den Bergbaulayouts inkorporiert wurden. In der Driefontein Gold Mine wird ein System von knapp aneinandergesetzten im Abfallbereich befindliche Pfeiler benutzt, um seismische Energieemissionen einzudämmen. Vergleiche der seismischen Daten für mehrere Bergbaugruppen zeigten anfangs ein mögliches Maß von Erfolg in der Eindämmung und im Auftreten von größeren Fällen an. Eine ausführliche Analyse von Daten über einen 5jährigen Zeitraum hat jedoch ergeben, daß eine Verzögerung zwischen der Progression des Bergbaus und einer erhöhten seismischen Reaktion besteht. Bedeutende Änderungen in den seismischen Variablen wurden an Bergbauspannen von 100 bis 120 Metern beobachtet und könnten für Abstandsbemessung von Pfeilern im Design des Tiefbergbaulayouts von Bedeutung sein.

Jan 1, 2003

By T. G. Carter

Support system design for tunnels and underground excavations has for many years relied heavily on the use of rock mass classification systems and the Hoek-Brown failure criterion as a means for characterizing rock mass behaviour. Because of their development, both the GSI system and the Hoek-Brown criterion admirably characterize most ?normal? rockmasses from the viewpoint of their behaviour for rock excavations. They, however, run into difficulties when applied at the two ends of the rock competence scale. This is largely because block size and incipient strength are such that rockmass behaviour in these domains tends not to be controlled by interblock shear strength but rather by material strength. At the low end of the rock competence scale (UCSi <<15 MPa and GSI generally <30) discontinuities play less of a role and rock mass strength tends to matrix strength. Similarly, at the high end of the scale (GSI >>65, mi>>15), because discontinuities are now widely spaced, block size becomes so significant that again, intact material behaviour rather than the fracturing becomes the dominant factor controlling rock mass strength. In this paper several case examples are presented to illustrate the application of the high-end (spalling) and low-end (weak ground) transition Hoek-Brown relationships proposed by Carter, Diederichs and Carvalho (2007) as a basis for better defining rockmass behaviour at the extreme ends of the rock competence scale.

Jan 1, 2008

This paper describes a simple finite element (FE) modelling approach which leads to the computation of seismic energy release rate (ERR) and strain energy storage rate (ESR) which result from mining. The concept of critical strain energy is introduced as a means to help evaluate the strainburst potential in mine structures. A new, energy-based, burst potential index (BPI) is proposed. The use of ERR, ESR and BPI is demonstrated by a cut-and-fill stope case study. The merits of using such energy parameters in the interpretation and analysis of strainburst phenomena are discussed. While the study gives promising results, site-specific back analyses would be required to first calibrate the model and fit it with the local mine conditions, before it can be adopted as a routine design tool.

Jan 1, 1999

By D. P. Roberts

This investigation aimed to simulate the experiments performed by Nic Gay (Gay, N.C. 1976. Fracture growth around openings in large blocks of rock subjected to uniaxial and biaxial compression. International Journal of Rock Mechanics and Minining Sciences and Geomechical Abstracts, vol. 13. pp. 231-243) on fracture growth around openings in blocks of rock subjected to uniaxial and biaxial compression, using the Elfen discrete element code. The results of the physical experiments indicated a number of trends that were successfully replicated in the numerical simulations, including crushing ahead of the face, the formation of a sub-vertical tensile fracture at centre-span, the formation of groups of fractures originating from the crushed face zone, the formation of large corner-to-corner fractures which precede sample failure, and linking of slot corner and sample corner fractures leading to sample failure. In addition, other features were apparent that were not reported by Gay. It is believed that these took the form of conjugate shear fractures (as reported by Gay in a previous paper) and other features that may have been altered or inhibited by the presence of pre-existing structure in the physical samples. It was found that the samples, though nominally made up of the same rock type, must have had significantly differing properties. The presence of pre-existing structures may have contributed to this discrepancy. Strain measurements from the physical experiments were reasonably well matched, except where the gauge lay directly in the path of advancing fractures.

Jan 1, 2012

By L. Hansen

Sulphuric acid plants now and then see unexpected increases in SO2 emissions. Our experience is that it is not always easy for the acid plants to pinpoint the exact reason for the SO2 increase. Sometimes a catalyst bed is sacrificed even though reliable temperature readings and gas analyses could have verified satisfactory activity. Hence the leaking heat exchanger is never discovered and after the shutdown the SO2 emissions are still too high. This paper will look into some basic catalyst management tools: good record keeping is a necessity for collection of representative catalyst samples; reliable operating data is an inevitable starting point for all analysis; and trending of operating data is a must for plant optimization and troubleshooting. In addition, these catalyst management tools will give continuous updated knowledge of the catalyst status in each bed, providing the basis for a more effective replacement strategy. The most typical reasons for increasing SO2 emissions will be presented together with easy guidelines for cross-checking operating data, temperature optimization and good record keeping.

Jan 1, 2009

By S. E. Cook

This article uses the case of the Royal Bafokeng Nation to argue that royalties and dividends from mineral resources, if managed well, can provide direct benefits to the surrounding community even while the state collects its share of mining revenues through taxation. The key to this model is the effective management of the resource income flowing into community coffers. Where some of this income may fund urgent interventions in the community, a portion of the income can also be used to establish an intergenerational wealth fund to meet the needs of future generations. As a depleting resource, minerals like gold and platinum are not a sustainable source of income, and must be replaced over time by more regenerative income streams. These strategies and dynamics are manifest in the Royal Bafokeng Nation?s status as both community and quasi-municipality, a labour hosting and a labour sending community, a mine operator and a mine owner. The Royal Bafokeng Nation also owns one of South Africa?s largest community-based investment companies, which channels revenue derived from platinum deposits into a broad investment portfolio that in turn funds an aggressive social development program for 150,000 people living in twenty-nine rural villages.

Jan 1, 2013

By A. K. Anyimadu

Ongoing development work on ultra-fine grinding for various applications at the Group?s concentrators has been conducted by Anglo Platinum over the last few years. Current potential applications for mainstream grinding and concentrate grinding are the subject of a group-wide research and development programme. The first 10 000-litre 2.6 MW IsaMill was jointly developed by Anglo Platinum, Xstrata Technology and Netszch for installation at the Western Limb Tailings Re-treatment project in Rustenburg, South Africa. The unit was commissioned in late 2003/early 2004,and has operated in an intermediate concentrate regrind application successfully since. This paper describes the operational performance to date, as compared with the original duty specifications and objectives. The first mainstream M10 000 IsaMill with a 3 MW drive will be operational in November 2006 at the Potgietersrus Platinum (PPL) ?Platreef? Sandsloot Concentrator in South Africa?s Limpopo Province. Keywords: Western Limb Tailings Re-treatment Plant, IsaMilling, Platreef, platinum, palladium, PGMs, tailings.

Jan 1, 2007