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By Peter N. Calder, Alan Bauer

The complexity of modem open pit load-haul-dump systems is described, and the need for realistic working models is pointed out. Both standard and probabilistic simulation procedures are discussed, probabilistic simulation being indicated as the more powerful and practical technique. Acquisition of the necessary pit operating data required for simulator construction and general modelling procedures are described. Finally, results from a typical open pit simulator are used to indicate the scope of the technique.

Jan 1, 2014

By M. F. Handley

This paper covers in situ stresses in the Earth?s crust prior to any man-made disturbances, such as mining. It introduces the Southern African Stress Database, which contains primitive stress measurements obtained from locations spread all over southern Africa. The measured stress data shows large variability without any visible trends, except a relationship with increasing depth. The stress database is reviewed briefly, establishing means to measure the variability or dispersion in the measurements, and showing that the dispersion is not as much a result of experimental error as it is a feature of primitive stress. The paper demonstrates from the beginning that the state of stress in rock is highly variable, but that there are well-defined maximum and minimum limits to all the stress components in rock. Formal error analysis is introduced to check the consistency of the database and to separate out a database of consistent stress measurements for use in a primitive stress model. The aim is to provide a picture of primitive crustal stress based on objective stress measurements together with interpretations of how the primitive stress can be affected by the five main influences; namely, depth, rock mass properties, tectonism, isostacy, and erosion. Four elementary models for primitive stress are introduced and compared with the measured data. It is quite clear that none of the elementary models is sufficient to describe the data. In the absence of a better model, this paper suggests a generic model based on the Hoek-Brown failure criterion and the consistent stress database, since it incorporates the variability in the stress tensor that is likely to be encountered underground all over southern Africa. Rock engineers should take every opportunity to obtain local primitive stress data at every mining operation and civil engineering project, and to adjust the proposed model accordingly Keywords primitive stress, Southern African Stress Database, error analysis, generic primitive stress model.

Jun 1, 2013

By J. G. Goodey, G. J. van der Linde

This paper describes pilot-plant tests on the recovery of apatite from a hitherto untapped material. This materialhydro- separator overflow-is very fine (80 per cent smaller than 45 µm and 32 per cent smaller than 10 µm). . The pilot-plant tests proved that the recovery of apatite from this material is economically and technically viable. This was confirmed by plant trials, which, in the early stages, produced concentrate assaying 36,6 per cent P2O5 at a recovery of 65,5 per cent.

Jan 1, 1983

By M. L. Smith

A new approach to strategic planning, the Life of Business Optimisation System (LOBOS) optimises production systems from the scale of stopes in a single mine to an entire business strategy consisting of multiple mines and products competing for capital and processing capacity. LOBOS has optimised cash flow for a wide variety of operations, including large metalliferous or coal mines and as an aid to high-level strategic business optimisation solution to multi-mine/processing/product complexes. This paper discusses the application of optimisation technology to strategic planning with an emphasis on project evaluation with examples on the application of LOBOS to a variety of recent projects.

Jan 1, 2007

By K. Dewar

The catalytic converter industry is composed largely of global multinational manufacturers who supply to vehicle manufacturers (original equipment manufacturers ? OEMs) from facilities strategically located internationally, including plants in South Africa. The South African catalytic converter production facilities were established at the request of the OEMs and commenced manufacture in the early 1990s. This near 100 per cent export focused industry exists in South Africa because of the incentives offered by the Motor Industry Development Programme (MIDP), which ultimately provide the OEM with import duty rebates. The South African catalytic converter industry is a complex vertically-integrated supply chain with a local content in excess of 85 per cent, substantially more than any other exported automotive component. The industry remains one of the very few downstream manufacturing industries where South Africa has a significant global footprint. This is even more important when it is considered that this industry is the key end-user for two of South Africa?s most important mineral resources, namely platinum group metals (PGMs) and chromium, and is in an industry which will see massive global growth as the developing nations of the BRICs grow their auto industries. In over 15 years of existence in South Africa, the catalytic converter industry has achieved remarkable growth, averaging compound growth in the region of 14 per cent per annum. The industry is the highest contributor to automotive component export revenue. South Africa holds >8 per cent% of global PGM reserves. During 2011, South Africa supplied 59 per cent, 29 per cent, and 72 per cent of the global demand for platinum, palladium, and rhodium respectively, as well as over 50 per cent of the global chromium demand. Global autocatalyst production remains the largest consumer of PGMs, and South Africa alone beneficiated 15 per cent of locally mined PGMs in the production of catalytic converters ? all is converted from PGM sponge (powdered metal) into PGM solutions for coating onto catalysts. Beneficiation of PGMs also takes place via the production of jewellery and electronic goods; but compared to catalytic converters, this volume is negligible. The industry is also the largest consumer of locally produced stainless steel (>50 000 t/a), exceeding 38 per cent of local consumption. The industry is a substantial generator of highly skilled employment, with over 5 000 direct jobs (excluding OEMs and stainless steel manufacture) and an estimated more than 30 000 indirect jobs resulting from upstream and side-stream suppliers. The industry places a high focus on skills transfer and development, with all companies providing high-tech training and education both locally and overseas. The industry has invested in excess of R5 billion in plant, equipment, people development, and process development over the last 15 years to support transfer of production and new technologies to South Africa. This has resulted in significant skills development in the support industries as well as within the catalytic converter industry. The current projections for local PGM beneficiation via catalytic converters reflect a downward trend as a result of production being moved to other global locations due to uncertainty around changes to government incentive programmes. The industry is currently capacitated to support 23.7 million units per annum. During 2011 it utilized about 70 per cent of this capacity, but forecast projections suggest that this will be at 46 per cent of this level by 2016. At full capacity the industry would represent 19 per cent of global autocatalyst production compared with the current 13 per cent in 2011. The industry believes that there is potential to make South Africa the preferred location for catalytic converters worldwide, given suitable support from the mines and Government.

Jan 1, 2012

By O. G. Motlogelwa

Any company operating a fleet of trucks will be greatly advantaged if the associated fuel costs can be decreased. The optimal tonnage that trucks should be hauling to ensure minimum consumption of diesel fuel has been investigated. The fuel consumption in litres per ton for a fleet of trucks hauling different tonnages of iron ore was recorded in a time-motion study and the optimal tonnage was determined. The following points emerged as a result of the research: > The diesel fuel consumption in litres per ton decreased with increasing tonnage, which means that in order to improve fuel efficiency, the trucks should carry 21 t > As a result of queuing, Africa Truck Hire (one of the two equipment contractors) loses R282.57 per day to diesel that the trucks burn when they are left idling. It is thus advisable that the company adopt a policy of requiring the drivers to switch their engines off while queuing at the stockpile > Filling up the trucks during each shift or rationing the quantity of diesel to 200 litres each shift has a negligible impact on the trucks' fuel efficiency > For the company to spend 35% of their revenue on fuel, the diesel price would have to be between R8.14 and R8.78 per litre.

Jan 1, 2013

By J. Githiria, C. Musingwini, J. Muriuki

"The maximization of net present value (NPV) is a primary objective in open pit mine planning processes. In an attempt to meet this objective, cut-off grades are considered in all the stages of mining. There are three stages involved in resource extraction, namely mining, processing, and refining/marketing, which are all defined in Lane’s approach. Using Lane’s approach, the economics involved in each stage are identified independently and interact to provide an optimum cut-off grade.A hypothetical block model is used to illustrate how a computer application (Cut-off Grade Optimiser) that was developed in this study is used in the optimization of cut-off grades using Lane’s algorithm. This paper analyses the application of Lane’s approach for a single element in cut-off grade optimization as applied in the calculation of the optimum cut-off grade through a computer-aided application.Although Lane’s approach is not complex it is not widely applied to maximize the NPV of mining operations as the iterative calculations can be lengthy. The computer application developed in this study shows how Lane’s algorithm combined with a linear programming function can optimize cut-off grade with regard to the complex situations faced by mining operations. The application saves users from performing otherwise lengthy, iterative calculations.Background and previous researchAn open pit mining complex constitutes multiple pits, ore processing streams, and metal refining options. An open pit mine produces ore (valuable) and waste material. Ore is transported to an appropriate processing stream for producing concentrate. A refinery processes the concentrate to produce marketable metal product (Lane, 1964, 1988).Cut-off grade optimization is based on Lane’s theory, where a mining system consists of three major stages such as mining, milling, and refining. In this approach the cut-off grade selection is done between six cut-off grades that involve all stages of a mining operation. Selection of the optimum cut-off grade influences the net present value (NPV) by maximizing the net cash flows from the operation."

Jan 1, 2016

By Y. -L. Chiang

Paper written on project work carried out in partial fulfilment of BSc (Eng) (Chemical) The generation and control of manganese sulphide particle size distribution using various mixing configurations were investigated. Specifically, this paper discusses how varying mixing intensities on a macro and micro scale affect the resultant manganese sulphide particle size distribution (PSD) at a constant concentration. The mixing variations were achieved using various Y- and T-mixers as premixing devices into a jacketed, agitated vessel. The reagents used to generate the seeds were aqueous manganese sulphate and sodium sulphide solutions. The results showed that the absence of micromixing resulted in very poor control of the particle size distribution, the particle size and the number of particles produced. This was due to the fact that the macromixing time is much greater than the corresponding precipitation time, resulting in different mixing regions existing within the reactor. From the micromixing experiments, the T?mixer was found to be the most effective mixing device at lower concentrations due to the T-mixer providing a faster mixing time than the other mixing configurations, thereby effectively localizing the supersaturation and hence controlling the precipitation. The results obtained from the direct addition without the extension pipe (i.e. short mixing time) indicated a general increase in mean particle size and decrease in total particle number at reagent concentration of 0.007 mol.dm-3as compared to the corresponding micromixing experiments. The phenomenon may be due to incomplete crystallization at the immediate exit of the mixing device. Further experiments need to be conducted before any conclusions can be drawn about the precipitation mechanisms.

Jan 1, 2007

By R. Sun, R. G. Gillies, R. S. Sanders, J. Schaan

The pipeline transport of paste, backfill or thickened tailings slurries is an important component of the tailings disposal process in many mines around the world. These mixtures contain significant fractions of fine (clay) and coarse (sand) particles, causing them to exhibit non-Newtonian flow behaviour and high frictional pressure gradients. There is often economic incentive to operate these pipelines in the laminar flow regime. Irrefutable evidence has shown that coarse particle settling can occur during the laminar flow of these slurries even when static settling tests show no indication of such behaviour. Previously, a ?rule-of-thumb? minimum frictional pressure gradient of ~1.5 to 2 kPa/m was suggested to ensure effective sand transport, based on the results of tests conducted using viscous Newtonian oils. In this paper, we examine the results of laminar flow tests of non-Newtonian, coarse-particle laden slurries conducted with pipeline loops of 50, 100, 150 and 250 mm in diameter. The results indicate that the ratio of the mean wall shear stress to the mean surficial particle stress is abetter indicator of laminar flow settling tendency than frictional pressure gradient.

Jan 1, 2007

By P. Pięta, A. Surowiak, T. Niedoba

In a flotation process of copper ore three factors were measured: copper grade in concentrate (β), copper grade in tailings (J) and recovery of copper in concentrate (e). The experiment was conducted by means of the Jameson cell. The factors influencing the quality of the process were particle size (d), time of separation (t), type of the collector (k) and dosage of the collector (s). The considered vector function was then [β(d, t, k, s), J(d, t, k, s), e(d, t, k, s)]. Optimisation achieved was based on determining the values of the adjustable factors (d, t, k, s). The goal was to obtain the highest possible values of functions β and e (maximum) and the lowest possible values of function J (minimum). To this purpose the taxonomic methods were applied. Keywords: Flotation, copper ore, lithology, flotation agents, particle size distribution, taxonomic methods

Jan 1, 2020

By W. J. Whiten

"Models of cone crushers and vibrating screens are described. These models have been constructed from actual plant data using a systematic model-building technique. Included in this technique is regression analysis using multi-dimensional spline functions.The models have been used to simulate complete crushing plants and hence to design and evaluate a control system for crushing plants."

Jan 1, 2014

By K. Hodgson, Cook. N. G. W.

Most structures are designed so that the possibility of failure is eliminated. However, some degree of failure in the rock around deep mine excavations is inevitable if mining operations are continued. The presence of failed rock constitutes a hazard the magnitude of which can be predicted by computer models from calculations of the energy change per unit area mined in stopes, or the field stress around service excavations. Empirical relationships between these calculable quantities and the incidence of rock failures and delays associated with them have been established. Experiments on the computer using different layouts enable the mining engineer to select the least hazardous of otherwise acceptable alternatives, and to predict the incidence of damage ahead of actual mining, so that appropriate measures to maintain an adequate degree of safety and productivity can be planned in advance.

Jan 1, 2014

By El-Sayed M. Sherif, J. D. Comins, Erasmus R. M.

Corrosion of copper in aerated acidic chloride pickling (0.5 M HCl) solutions and its inhibition by 3-amino-1,2,4-triazole-5-thiol (ATT) have been investigated using electrochemical techniques and weight-loss measurements, along with Raman spectroscopy. Electrochemical measurements for copper after varied immersion periods of 0, 24 and 48h showed that the presence of ATT and the increase of its concentration significantly decrease cathodic, anodic, corrosion (jCorr) currents and corrosion rates (KCorr), as well as the dissolution currents at 300 mV vs. Ag/AgCl, while increase polarization resistance (Rp), degree of surface coverage (?) and inhibition efficiency (IE%) to a great extent. Weight-loss measurements after different immersion periods of 6 ~ 48h revealed that the dissolution of copper decreased to a minimum and the corresponding IE% increased with ATT concentration increases. The detection of ATT molecules on the copper surface by Raman spectroscopy indicated that inhibition of copper corrosion is achieved by strong adsorption of ATT molecules onto the copper surface. Aerated acidic pickling solutions; 3-Amino-1,2,4-triazole-5-thiol; Copper corrosion; Corrosion inhibition; Raman spectroscopy

Jan 1, 2006

By Stuart Marsland

"Reference materials have always been important for validating and controlling analytical methods', They have recently become even more important as quality requirements have become more stringent and customer demands for properly verified and controlled results increase. Clients, especially from the resource exploration industry demand critical validation of all results reported. Mintek has been producing geological and semi processed ore references since the early 1970's and recently due to increase in demand other manufactures have entered the South African Market.This paper describes Analytical challenges from the customer's perspective. The customer being the metallurgist, mine geologist, environmental scientist and geologists from resource companies. Reference Materials and their appropriate use and good understanding of them can aid greatly in building confidence in the results, choosing the right Laboratory for a project, deciding which set of results arc correct and providing evidence to the customer's clients that the results obtained are the very best possible.Throughout the world there are hundreds of reference materials produced by over 80 organisations and these are mainly ores, rocks, semi processed ores, metals, and many more. Mintek is one of the top 10 producers with over 75 products. Many of these producers including Mintek and their respective standards organisations belong to the ISO REMCO committee and their respective work groups. This committee's main task is to draw up guide lines for the use, manufacturing and certifying reference materials. In South Africa a mirror committee has recently had its inaugural meeting the function is to give clear mandate to the South African representative on the main ISO REMCO committee, the South African delegate bas an opportunity to influence the contents of the guides.Tile SARM program has since the year 2000 increased its sale three fold, the question is why? There is more accountability needed in our world. That means Analytical results have to be the very best possible and risks associated to them must be well quantified. Consider that the risk of wrong results of wrong decisions made from a result is trivial to laboratory, in comparison to the laboratories customers. The consequence to a laboratory could be a loss of income or some one may lose their job. To the customer he may dig up 1000 of ton's of rock with nothing in it or worse still don't mine it when the grade is high enough. This is seriol1s money."

Jan 1, 2014

By D. D. Howat, J. van der Colf

This paper is the first in a series of three dealing with this subject and also with the rate of oxygen removal from the slags in the presence of solid carbon and with the physicochemical properties of the reduced slags. For selected members of the system, the melting temperatures and primary crystallization products were determined. as were the viscosity and the electrical resistivity of the corresponding melts. All the experiments were conducted in a neutral atmosphere. Where determined, the primary phase was found to be either perovskite or magnesium aluminium titanate. The composition variable exerting the most pronounced influence on viscosity or resistivity was found to be the basicity expressed as the mass ratio (CaO + MgO)jSiO,. The ratio CaOjMgO became important only at Iow basi<:ity values. Although generally there is a direct proportionality between log (viscosity) and log (resistivity), slags h&apos;lving either a very high silica content or a very high titania content have anomalously Iow electrical resistance.

Jan 1, 1979

By D. Amariei, G. Bartolacci

Preconcentration of precious and base metal ore types is becoming more relevant with the discovery, the development and the operation of many lower grade deposits around the world. Ore preconcentration designates an operation consisting of sorting an ore to reduce the quantity of waste material sent to the concentrator. It can be seen as rejecting waste material as much as possible, without compromising the recovery, or as the recovery of as much valuable metal as possible into an optimum mass yield. Benefits of preconcentration are multiple: grinding energy savings, costs reduction, lower environmental footprint, extension of the reserves, etc. However, all of these benefits do not apply simultaneously and are not applicable to each ore type. Technologies employed for preconcentration are highly dependent on ore properties, especially on the particle size at which the gangue is liberated. Thus, from coarser to finer particle sizes, technologies such as screening, ore sorting, gravity separation (Dense Media Separation (DMS) and jigs) and coarse flotation could be used for the rejection of liberated gangue. The difficulty starts when a benchmark is needed to select a suitable technology, especially for low-grade gold deposits. This paper presents the challenges of comparing lab-scale technologies (DMS versus jig) for gold preconcentration. The experimental data will show to what extent comparing two lab-scale gravity technologies for gold preconcentration can be challenging. An attempt to evaluate the energy savings by assessing the hardness of the tailings after gravity separation will also be presented. Keywords: Challenges in gold preconcentration, gravity separation, jig, dense medium separation

Jan 1, 2020

By S. M. Bradshaw

In order to assess the requirements for online matching when using a transverse electric field (E-field) applicator to treat mineral ores continuously, the effect of varying load properties on matching has been investigated by simulation. The effective permittivity of the ore to be treated is expected to show variation on both short (< 1 s ) and long (minutes) time scales. By modelling the ore as a series of slices with alternating effective permittivity values, it was shown that permittivity variations on the scale of the expected particle size are attenuated significantly and matching is not required. For variations in permittivity on the length scale of the free-space wavelength, variations in reflected power are at most within ±10% of the mean. This is not considered operationally significant, as extreme permittivity variation over this length scale is unlikely, given the expected distribution of ore particle sizes to be treated. At typical ore transport speeds through the applicator, these variations occur on a time scale an order of magnitude shorter than the response time of typical industrial online matching equipment. This implies that online matching is neither required nor possible for short time scale variation. Long-term variations in dielectric properties can be adequately compensated for by current matching technologies. It is concluded that the transverse E-field applicator is robust to changes in the dielectric properties of crushed ores within the expected range of their variation.

Jan 1, 2012

By R. W. O. Kersten

Backfilling is one of the options available to the mining engineer in mine design. The decision as to the type of backfill is dependent on the purpose for which it will be used. For example, in a situation where high-grade, steeply dipping multiple reefs are to be mined, the purpose would be the following: ? to facilitate maximum extraction; a ? to minimize loss of fines; ? to allow closely spaced multiple reefs to be mined; and a ? to create a working platform. The physical properties required which will satisfy the abovementioned requirements can then be defined; the design of the fill plant, as well as the transport of the fill, will be governed by these considerations. The same procedure is also adopted in deciding on backfill in single- reef gold mines. The first question to be asked is the purpose of the fill. It may be to reduce the energy release rate, for environmental reasons, to reduce timber usage, to improve productivity, to reduce stoping costs, to obtain higher mining extraction, and so on. Only after one, or a combination, of these factors has been selected, can the specifications for the fill be decided on, and the plant designed accordingly. The introduction of backfill at Sheba Gold Mine will be used to illustrate the procedure adopted by Anglovaal in determining the type of fill required.

Jan 1, 1988

By J. C. M. De Souza

The Samarco pipeline, the longest in the world for iron ore slurry transportation, started operation in 1977 to transport concentrate from the Germano facilities, in the state of Minas Gerais, to the pelletizing plant, located 396 km away, in the state of Espirito Santo, on the south-east coast of Brazil. Designed for a nominal capacity of 12 million tons per year, the pipeline reached 15.5 million/year due to operational improvement and, in late 2005, it was resized to transport 16.5 million tons per year, with the installation of a booster station. In order to ensure the accurate performance of the system, a pipeline cleaning programme was carried out and, since it has been29 years from the operation start-up, precise knowledge of the pipe condition would be fundamental to guarantee the success of the project. The cleaning programme demonstrated the potential of operational gains from this initiative, and its effect on the corrosion control and future measures, which should be permanently adopted to maintain the improved capacity. The intelligent pig runs provided essential data used to establish a pipeline integrity programme that allowed Samarco to develop a pipe repair plan based on the severity and significance of the features and to implement a future pipe replacement plan.

Jan 1, 2007

By F. Nakhaei, Z. Pourkarimi

Tailings produced from the iron ore industry present many challenges due to the high economic and environmental impacts involved with their disposal. However, the relative scarcity of high-grade iron ores has driven manufacturers to recover and recycle these valuable tailings (secondary sources). This study aimed at the purification of ultrafine tailings with high sulphur content from an iron ore concentrator via reverse flotation to produce pellet feed fines. A specially designed flotation column featured with a nano bubble generator and a conventional bubble generator were employed to assess the effects of nano bubbles on the desulfurisation performance of iron ore concentrate under different operating conditions. Results obtained from this study indicated that the sulphur content of iron concentrate could be reduced from 1.2% to 0.22% in the presence of nano bubbles. Also, the results showed that use of nano-micro bubbles increased sulphur recovery 20% more, in comparison to micro bubbles. Keywords: Column flotation, iron ore, tailings, slime, nano bubbles, desulphurisation

Jan 1, 2020