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By J. R. L. Read, A. N. Ogden

This paper describes mining industry funded research that is being undertaken to address the critical gaps and uncertainties in our knowledge so that we can develop new approaches and create more effective ways for predicting the reliability of rock slopes in large open pit mines. It is envisaged that this research will not only lead to more effective pit slope design but further reduce the potential for unforseen geotechnical risks by enabling the geotechnician to communicate the risks more effectively with management and to optimise site specific control measures. To achieve this, several research tasks are in hand. The first is to accurately represent the structured rock mass with a 3D computer model (Siromodel) that creates polyhedral blocks from structural distribution data characterised by position, orientation and persistence. Siromodel is being coupled with particle flow and other numerical codes to evaluate how the structured rock mass deforms in the stress environment of an open pit and how a candidate failure surface may propagate through the dilating rock mass along the path of the least shear and/or tension resistance. A beta version of the Siromodel software has been distributed to 20 Sponsor mine sites for technical evaluation. The end state is to develop methods of analysis that characterise the reliability of a described candidate surface, and the probability of the candidate surface propagating to failure, recognising that the rock mass strength may well be defined in a different way than before.

Jan 1, 2006

By T. Bezuidenhout, J. D. Visagie

In recent years the requirements for a barrier system between the waste body of tailings storage facilities (TSFs) and the natural ground (NG) has necessitated the use of HDPE-lined TSFs in South Africa and other countries. The addition of an HDPE liner creates an interface between, inter alia, the tailings and surrounding soils on the footprint of the TSF. It is known that low-strength materials beneath slopes can cause slope instability. One method which can theoretically mitigate this instability of a lined TSF is the addition of stability bunds along the footprint of the TSF. Altering the profile of the footprint to include slope changes which oppose the direction of the failure creates passive slices in a limit equilibrium analysis. The passive slices actively oppose the movement of active slices, resisting the mobilization of tailings, thus greater active slice forces are required to develop a failure surface running along the liner interface. Two scenarios are presented and compared. The first scenario retains the ground profile unaltered and the second scenario includes stability bunds along the ground profile. An in-depth assessment is made of the interslice forces and the interface shear stresses for each scenario. The theoretical background is discussed in greater detail to determine the mechanisms of reinforcement provided by the bunds.

Jun 2, 2022

By Turgay Gurun

"Digital simulation can be used as an analytical tool to optimize the design of crushing plants without need for large-scale experimental programs.General mathematical description of a crushing operation permits the simulation of a crushing plant flowsheet under various operating conditions. The process model encompasses multistage open- and closed-circuit crushing of hard and soft rock. Crushing balances are analyzed in the light of crusher and screen performance and a comparison of different closed-circuit arrangements is made in terms of process and layout criteria.The simulation model allows comparison of process alternatives to be made in terms of equipment selection and capital and operating cost estimation. It thus provides the pertinent practical information to maximize plant efficiency, and to minimize expenditures in such items as equipment, structures, power consumption, and so on."

Jan 1, 2014

By S Sondashi, F. J. Chidley, W. A. Grobler

Some of the challenges facing the flotation of base metal sulphides are the opening of new and varying ore bodies as well as maintaining essential skills in plants. Flotation reagent research focuses not only on improving flotation grade and recovery, but also on producing reagents robust enough to cope with changes. A group of recently developed co-collectors, activators, depressants and frothers are described together with a summary of results measured on base metal sulphide ores.

Jan 1, 2005

By V. Oberholzer

The presence of fines (particles smaller than 6 mm in diameter) causes hydrodynamic problems in gasifiers and therefore it is of great importance to minimize the amount of fine coal in the feed. This serves as motivation for understanding coal?s breakage mechanisms, which could lead to the ability to predict the generation of fines. The aim of this project was to simulate the pulsating effect of the conveyor belt in order to investigate factors influencing the breakage. Results indicated that an increased initial particle size had an increasing effect in the amount of fines generated. Weathering had an insignificant effect on the breakage of coal. To conclude, a breakage model was developed to describe the rate of breakage out of the top size when a combination of two breakage modes is present.

Jan 1, 2009

Mr Colin M. Spence took office as President of The Federation of Societies of Professional Engineers on 1st July, 1984. Colin Maynard Spence was born in November 1921, and was educated at the Durban Preparatory and High Schools, in both of which he was a Dux Scholar. He graduated from the University of Natal in 1942 with a B.Sc. degree in civil engineering. In 1958 he received a Diploma in Town Planning from the same university. Cessation of Membership In accordance with Clauses 7.6.1 and 12.1 of the Institute's Constitution, Rules and Policy, the following members have been struck off the Membership list.

Jan 1, 1984

Metso Minerals Cisa have developed VisiofrothTM - a system which calculates parameters of the froth surface using vision from remote cameras mounted about individual flotation cells. The parameters calculated from this system can be utilised within process control strategies to achieve stabilisation or optimisation of the flotation process. As part of a JKMRC AMIRA P9 field campaign, froth vision was collected from various cells operated at different air rates and froth depths within Rio Tinto's Northparkes copper roughing and scavenging circuit. At the same time, samples were collected to determine the cell metallurgical performance at each operating condition. These froth images have been processed using the VisiofrothTM system with froth velocity, bubble size, froth collapse rate and various froth colour parameters calculated. These parameters have been compared to the measured concentrate flow and concentrate grade produced at each condition. This analysis shows that the concentrate tonnage flow is strongly correlated with froth velocity whereas the concentrate grade is best correlated using froth velocity in combination with a bubble stability parameter which affects the bubble size distribution on the top surface of the froth. This paper summarises the results from this analysis as well as an overview of the VisiofrothTM system and the parameters that are measured by the software.

Jan 1, 2007

The application of modifying factors to the Merensky Reef and UG2 Chromitite Layer has a number of challenging aspects as the deposits are tabular and consist of a number of separate geological entities that are grade bearing. The important aspects of the conversion include mineral holdings, dilution with grade bearing material, mining and geological losses, marginal cut offs and recoveries especially where open pit or weathered material is being considered. It is considered inappropriate to add material for dilution at zero grade as the associated material generally comes with an associated low grade. The Merensky Reef Is typically a pegmatoidal feldspathic pyroxenite with bounding chromitite layers. The Merensky Reef is senso stricto too narrow to be considered as a mineable entity and therefore any reserve must include material at low or marginal grades. This is further complicated as the typical mine cut or approach varies across a mine of project. This variation must be included in the mineral reserve conversion. The UG2 Chromitite Layer is typically lithologically bounded i.e. chromitite hosted. However, this adds interesting aspects particularly where leaders are intersected in the hangingwall. These can contribute to unstable hangingwall. It may be considered appropriate to include these in the mineral reserve. One of the overarching principles is that the reserve can be demonstrates to be feasible i.e. can be mined at a profit. Here aspects of a feasibility including infrastructure (power, water etc) needs to be properly considered. The paper will attempt to describe these and other relevant issues and highlight examples from experience together with proposed solutions.

Jan 1, 2007

By S. Lohmeier, D. Gallhofer, B. G. Lottermoser, T. Schirmer

At a time of resource consumption, it is important to study the chemical composition of mining and metallurgical wastes to prevent the dissipative loss of metals and metalloids from the mining value chain. In particular, the recovery of critical elements from wastes is an option to increase the resources of such materials that are economically significant and have an overall supply risk. In this paper we report on the chemical composition, in particular the critical element content, of granulated slag originating from historical smelting activities in the Tsumeb area, Namibia. Laboratory-based inductively coupled plasma–mass spectrometry (ICP-MS) and X-ray fluorescence (XRF) analyses as well as portable X-ray fluorescence (pXRF) demonstrate that the slags are on average enriched in base metals (Cu 0.7 wt%, Pb 2.7 wt%, Zn 4.7 wt%), trace metals and metalloids (Cd approx. 50 mg/kg, Mo approx. 910 mg/kg) as well as critical elements (As approx. 6300 mg/kg, Bi approx. 3 mg/kg, Co approx. 200 mg/kg, Ga approx. 100 mg/kg, In approx. 9 mg/kg, Sb approx. 470 mg/kg). While metals and metalloids such as As, Mo and Pb can be determined reliably using pXRF instruments, the technique has inherent limitations in evaluating the contents of certain critical elements (Ga, Sb). However, there are positive correlations between the As, Mo, and Pb contents determined by pXRF and the Ga and Sb contents obtained through ICP-MS and XRF. Thus, quantitative pXRF analysis for As, Mo, and Pb allows calculation of Ga and Sb abundances in the slags. This work demonstrates that pXRF analysers are a valuable tool to screen smelting slags for their chemical composition and to predict the likely contents of critical elements.

Mar 1, 2021

By J A. H Campbell

AK6 is a Cretaceous aged kimberlite located in the north-east of Botswana, close to Debswana's Drapa and Letlhakane Mines. It was discovered by Debswana in 1969, but was considered unattractive from an economic perspective. In 2003, Debot Prospecting Pty Ltd ('Debot') re-assessed the area and with the advent of new prospecting technology, particularly large diameter drilling ('LDD') and more detailed ground geophysical surveys found AK6 to be of interest. In 2005, the Boteti joint venture was formed between Debot and African Diamonds plc ('AFD'), which covered a number of Prospecting Licenses, including that which contained AK6.

Jan 1, 2010

By H. Zhong, S. Wang, Q. Sun

The flotation performance of 2-(benzylthio)-acetohydroxamic acid (BTHA) to diaspore was first evaluated by micro-flotation tests. The adsorption mechanism was further investigated through adsorption experiments, molecular dynamics simulation, zeta potential and X-ray photoelectron spectroscopy (XPS). The results demonstrated that BTHA had a stronger ability to collect diaspore in comparison with another diaspore collector, benzohydroxamic acid (BHA), especially under the condition of weak alkalinity, the flotation recovery can reach 90%. The more negative interaction energy (ΔE) between BTHA and diaspore from molecular dynamics simulation results revealed that BTHA had an easier adsorption ablity onto diaspore than BHA, which matched with adsorption results. The zeta potential and XPS revealed that Al atoms might bond with -C(=O)NHOH by formation of Al-O bonds. Keywords: Diaspore, flotation; adsorption; 2-(benzylthio)-acetohydroxamic acid

Jan 1, 2020

By G. Akdogan, C. Dorfling, L. Bumhira

Hydrometallurgical recovery of rare earth elements from phosphors obtained from end-of-life fluorescent lamps involve leaching followed by extraction of dissolved metals from solution. The similar properties of rare earth elements make selective recovery of individual elements challenging. The aim of the paper was to investigate the extraction of primarily Ce and Tb from a hydrochloric acid leach solution also containing other REEs (Y and Eu) as well as impurity metals (Ca and Al). Batch solvent extraction tests were performed with di-(2-ethylhexyl) phosphoric acid (DEHPA) at various extractant concentrations, pH conditions and organic-to-aqueous ratios. Extraction isotherms and separation factors for the range of conditions tested in the project are presented in the paper. Separation of individual REEs was not possible at the conditions investigated, but a mixed REE product can be obtained in a single extraction stage operated at a pH of 0.5 using 1 M extractant at an O/A ratio of 1; these conditions resulted in complete Y and Eu, 95 % Ce and 99 % Tb extraction with Ca and Al coextraction below 7 %. A better quality mixed REE product can be produced by operating at lower pH and extractant concentration conditions, but this would require a larger number of extraction stages. Keywords: Cerium, fluorescent lamps, phosphors, rare earth elements, solvent extraction, terbium

Jan 1, 2020

By B. R. Broekman, D. W. Penman

Discussion by P.J Lloydt Broekman and Penman describe (J.S. Afr. Inst. Min. Metal., vol. 91, Aug. 1991, p. 261) the addition of sodium cyanide and zinc sulphate to the flotation feed at Prieska. They note that for 'safety sake, lime was added to the rod mil to raise the pH to 9,5', and that 'personnel working in the vicinity of the rod mil were required to wear gas masks'. Author reply to P.J. Lloyd We thank Dr Lloyd for his interesting contribution. As he correctly points out, the Prieska float had run with cyanide solutions at pH values of 6,4. In fact, it ran safely for extended period with the pH slightly below 6.

Jan 1, 1991

By G. Bueno, L. M. Tavares, T. M. Campos

Iron ore pellet feed pressing has been one of the first and most successful applications of High- Pressure Grinding Rolls (HPGR) in the minerals industry. Vale S.A. has been one of the pioneers in this application, currently with six HPGRs in operation in the pelletising plants of the Complexo de Tubarão (Brazil). In spite of the important advances in the technology, risks still exist when scaling-up the process from small-scale information. The present work takes advantage of the recent advances in the mathematical modelling of the HPGR performance, using the population balance model to evaluate the modified Torres and Casali model prediction in iron ore pellet feed pressing for different scales of operation. Results are presented that compare the HPGR performance in different operational scales for iron ore pellet feed pressing, demonstrating the confidence of this model-based approach for scale-up to full-scale HPGRs used in pressing iron ore concentrates. Keywords: Scale-up, HPGR, pellet feed, modelling, simulation

Jan 1, 2020

By J. P. T. Kapusta

"The copper smelting industry faces increasingly stringent environmental regulations and must continue driving innovation to reduce energy usage in its production chain. With the coming of age of ‘bottom-blowing’ copper technologies in China over the last decade, much renewed attention has been brought to tuyere bath smelting for clean copper-making. Since bottom-blowing sonic injection was originally developed and implemented in steelmaking in the 1970s and lead smelting in the 1990s, the time seems appropriate to revisit the sonic injection concepts and dispel some myths. After reviewing the trends in the copper industry and providing a brief historical context of research and development related to sonic injection, the author presents a comparison of the main submerged tuyere bath smelting technologies, namely the Noranda Reactor (NR), the Teniente Converter (TC), and the Chinese Bottom-Blowing Smelting Furnace (SKS/BBS) for copper, and the Queneau-Schuhmann-Lurgi Reactor (QSL) for lead. The core of this article, however, consists of a brief description of the fundamental theories for sonic injection (jetting regime) and ‘sonic flow mapping’ to illustrate the relationship between the minimum tuyere back-pressure required to achieve sonic flow and the tuyere internal diameter. The article also offers a comparison between side- and bottom-blowing in jetting regime before concluding with the author’s vision of the new trend in submerged tuyere bath smelting. IntroductionIn the last decade, developments in the copper smelting industry have been driven by two key concepts: (1) increasing cleaner smelting capacity to meet the world’s growing copper demand, as illustrated in Figure 1, and (2) increasing process off-gas capture to comply with more stringent environmental regulations and abide by a corporate social responsibility ethic of a clean work environment (for smelter employees) and clean air (for families living around smelters). The copper smelting industry has also faced some major challenges in the last few decades, including (1) low treatment and refining charges (TC/RC or processing fees) impacting custom smelters, (2) lower concentrate quality and grades with higher levels of impurities (e.g. As and Hg), (3) higher processing and transportation costs due to the rising cost of energy, (4) restrictions in process intensification (tonnage oxygen usage) due to furnace integrity limits, and (5) scarcity of educated and trained personnel due to fewer metallurgists graduating from pyrometallurgical school programmes combined with a high retirement rate of skilled workers."

Nov 1, 2018

By D. D. Munro

Finsch Mine is a Kimberlite diamond mine located at Lime Acres in the Northern Cape of South Africa. The mine was founded in 1961 and started surface-mining in 1964. Underground production commenced in 1990 using a Modified Blast Hole Open Stoping method for the mining of Blocks 1,2 and 3. Block 4 is currently being mined as a Block Cave. The process of identifying and optimizing a mining method to mine the Block 5 ore body started in 1991 and in 2006 Inclined Caving was identified as being a technically feasible method. This report aims to document the process employed in developing this method by the Block 5 Pre-Feasibility Team as well as discussing the technical challenges encountered during this process.

Jan 1, 2010

By M. Nicolle

The Tati Activox® Project will be the first full-scale implementation of the patented Activox® process (The Tati Activox® project was deferred in 2008. Please refer to the Norilsk Nickel press issue on the topic for more info). The process was developed by Norilsk Process Technology and has been tested on Tati mine sulphide concentrates in laboratory, pilot and demonstration plant scales and demonstrated its viability. There are inherent risks to the final scale-up of the process from the demo plant and one of them will be investigated in this paper. Compartment 1 is designed to leach approximately 77% of the total nickel leached. For this reason agitation requirements in the first compartment of the autoclave are reviewed. An attempt is made to minimize the process and mechanical risks associated in achieving oxygen mass transfer into the slurry solution. The agitator powers for oxygen mass transfer are calculated using empirical correlations and compared to demonstration plant testwork. The resulting gassed power per unit volume (P/V) is higher than most commercial autoclaves and raises uncertainty on the viability of using such high unit power inputs. Additionally, there is concern about the ability of the autoclave shell to withstand and support the higher loading of large agitators. An alternative solution to designing for the increased P/V is assessed in which the number of compartments within the autoclave is reduced from 5 to 4 by removing the compartment wall separating compartments 1 and 2. This results in an enlarged first compartment containing 3 agitators instead of 2. Therefore the compartment 1 oxygen demand is supplied through 3 agitators, which lowers the P/V per agitator. The reduction in the number of autoclave compartments raises the potential for short-circuiting the mean flow pattern by slurry particles. Short-circuiting and low velocity zones could result in a lower recovery of metal and localized hot spots, respectively. A computational fluid dynamic (CFD) analysis was conducted to quantify these concerns and also to evaluate further design considerations. The results indicate that the proposed design change to 4 compartments affects short-circuiting. The impact of increased short-circuiting on the overall autoclave recoveries is not quantified, however; it is expected to be negligible based on testwork done in the Tati Demonstration Plant and similar modifications made to another operating autoclave. The CFD analysis also suggests that there will be no low velocity zones within the compartment.

Jan 1, 2009

By M. Grave

Rock Engineers are required to design safe cost effective support systems and stoping layouts for their respective mines. As each stope has its own unique environment, continual re evaluation is required in all stopes to maximize extraction and achieve value from the support standard. This paper presents numerical modelling used to plan early mining within the shaft pillar and a reevaluation of an existing stope support standard.

Jan 1, 2009

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 B. K. Loveday

The South African Institute of Mining and Metallurgy hosted a School on 'The Practical Design of Comminution Processes' at Megawatt Park (near Johannesburg) on 14th to 16th May, 1991 Derek Barratt, a Senior Consultant of Wright Engineers, Canada, and the main speaker, provided a good insight into how Wright Engineers design milling circuits, particularly large semi-autogenous mills. He was ably assisted by Jens Lichterof Allis Mineral Systems, who described some interesting examples of pilot-plant testwork and summarized South African milling practice. Mike Moys of the Witwatersrand University spoke on the influence of pulp viscosity on mill performance, and Johan Engelbrecht and Jeremy Bosman of Multotech

Jan 1, 1991