Search Documents

By B. M. Kunar

It is well known that job-related hazards and individual factors influence occupational injuries. However, research involving coalminers has been limited. This case-control study assessed the relationships of job-related hazards and individual/life style factors with injuries among underground coal miners. It compared 245 cases with at least one injury during the previous two-year period with 245 matched controls with no injury. The data were gathered via personal interview and analysed using the conditional logistic model. The significant risk factors were materials handling (adjusted OR 5.15), poor environmental/working conditions (2.63), geological/strata control-related hazards (2.35), lack of formal education (3.00), sleep disorders (1.86), alcohol consumption (2.32), disease (2.23), having a large family (5.40), and risk-taking behaviour (9.40). Machine-related hazards, sleep disorders and alcohol consumption primarily affected workers aged less than 45 years; whereas, environment/working condition-related hazards, presence of disease, smoking, risk-taking behaviour and large family size were more likely among workers aged 45 or over. Keywords: Occupational injuries, sleep disorders, job hazards, alcohol, coal miners

Jan 1, 2010

The influence of varying amounts of magnesia, silica, and alumina in iron ore sinter on its mineralogy, reducibility index (RI), reduction disintegration index (RDI), physical breakdown (AI and TI), and production properties (coke breeze rate) were examined. It was found that the mineralogy of iron sinter can more easily be predicted from its chemical composition than from the RI, RDI, AI or TI. Anticipating the consequence that varying amounts of MgO and SiO2would have on sinter properties is complex, and not necessarily predictable. High concentrations of Al2O3in the sinter result in high concentrations of the SFCA phase, but with drastically deteriorated properties. This study also confirmed that the form in which fluxes are added to the raw material sinter mixture affects the mineralogy and properties of the produced sinter.

Jan 1, 2010

By P. C. Carrasco

Knowing the origin of the relevant and irrelevant components of the nugget effect is essential to optimize the process under study. This paper describes the causes of the nugget effect and, its dependency on the sample support, sampling density, and on the QA/QC procedures. Several examples of natural and ?human? nugget effect are given. A method to estimate the magnitude of the relevant and irrelevant components is suggested. Finally, the economic consequences of misunderstanding the nugget effect are analysed.

Jan 1, 2010

By P. van der Steen

This paper examines the historical developments in diamond beneficiation technology and the impacts on the industry. The art of diamond beneficiation has given way to the application of scientific process, but at considerable capital expenditure. The shift in beneficiation methodologies has been disruptive to the traditional skills set of the industry, but evolutionary change continues and has been beneficial to the quality of the final product.

Jan 1, 2010

By H. Rosen

The pump is the heart of most industrial and mining plants, providing the energy to separate valuable minerals from process feed. The actual effect of the pump, both in terms of production costs and overall process efficiency, is often assumed or misunderstood by engineers due to insufficient pump performance data. Pump performance can be understood and corrected, where required, through continuous performance monitoring, leading to dramatic improvements in both pump life cycle costs and system efficiencies. The performance of every pumping application is subject to variation and the main contributing factors are as follows: ?Unavoidable deviations from pump supplier curves ?Pump wear ?Pump curve derating factors for slurry pumping ?System curve variation ?Deviation from basic principles of centrifugal pump operation. These are discussed in detail through case studies and the author?s personal experiences. This paper shows ways to minimize the effect of these variations, thereby reducing performance loss and preventing damage to the pump. The paper discusses the benefits of efficient pump operation, the requirements of pump performance monitoring, and its practical application to pump operation in the slurry and water environments. The cost of remedial actions is explored and compared against the savings in both power and plant reliability, resulting in a reduced life cycle cost of the pump.

Jan 1, 2010

By S. M. Spottiswoode

Much as one hopes to predict whether damaging seismicity might occur somewhere in the next shift, this is not possible at present. Recently, an analysis of seismicity at two mines has shown that a small increase in seismicity occasionally occurs before both large and small events. This analysis is extended here to five mines, with the same results. Earthquake seismologists forecast hazard in terms of the average incidence of earthquakes over the last 50 years, adjusted on an hourly basis according to the possibility of aftershocks of events that have happened. The rate of seismicity in any area remains approximately constant when expressed as seismicity per area mined, or better still, per unit of elastic strain energy released. It is suggested that seismic hazard in mines be estimated using historical seismicity and forward modelling, adjusted according to the possibility of aftershocks. In summary, medium-term forecasting of seismicity is viable; short-term prediction of large events is not.

Jan 1, 2010

By I. du Plessis

The metallurgical response of a difficult to treat coal and an easy to treat coal orebody were investigated in terms of the coal yield and the coal quality in a basic coal recovery flowsheet. The purpose of this paper is to show trends and derive principles for the treatment of different coal types. This investigation entailed using the LIMN simulator to simulate the metallurgical response by varying the plant operational parameters. The controllable plant variables investigated were: ?Cyclone size ?Screen and hydro-cyclone cut points ?Medium cut density ?Feed particle size distribution.

Jan 1, 2010

By A. M. Neale

Kriel Colliery has experienced some sub-standard blast results on the overburden. Blast results are considered poor when the fragmentation is too big, back break into the new highwall, capping is experienced and/or excess overburden material is thrown into the void. Poor blasting leads to lower productivity, equipment breakdowns, and poor drilling and blasting results on the adjacent blast, contamination of coal or loss of coal. A simulation was developed in Microsoft Excel to model blasting results while changing various parameters. From the simulation results, it could be seen that a change of blast design could be beneficial. As an example, smaller drilling patterns were simulated (10 m x10 m to 8 m x8 m, and 8 m x8 m to 7 m x7 m in Pit 5 and Pit 6 respectively) in combination with changes in explosives (P700 emulsion vs. ANFO) and drill bit diameter (311 mm vs. 251 mm). The results show that each of the options has a specific scenario that will be most beneficial to the mine. These results are quite specific and subject to variable inputs. The purpose of the example is to demonstrate how the simulation can be used as a tool to asses blast design variations.

Jan 1, 2010

By S. O. Bada

Coal is a complex mixture of organic and mineral constituents and is the most abundant resource of fossil energy in the world. In recent years, significant research into dry coal beneficiation has gained much attention, primarily due to the need to improve grades and reduce the environmental contaminants in coal without the use of water, and to achieve this in as cost-effective manner as possible, relative to wet beneficiation processes. This paper seeks to review the application of various electrostatic separators with their process principles, to draw comparisons between different dry beneficiation techniques with specific emphasis on the tribo-electrostatic separation method, and finally to report the results of tribo electrostatic separation conducted on various South African coals. Previous research conducted on Indian, European and American coals has indicated that this technique is likely to lead to significant economic benefit through the reduction of ash content, NOx and more specifically Sox by separating out the liberated Fe-S-bearing minerals prior to utilization. The removal of the latter suite of minerals is also likely to significantly reduce or eliminate the emissions of associated trace elements, including mercury and arsenic. The research results reported in this paper indicate that the rotary tribo-electrostatic process has the potential for significant upgrading of high ash pulverized South African coal. The impact of various operational parameters was investigated and key factors established for the optimum recovery of low ash and low sulphur fine coal.

Jan 1, 2010

By D. M. C. Valbom

The introduction of new diamond sorting technologies as well as additional manufacturers I vendors, has increased the equipment selection and combinations available for recovery flowsheet design. This paper describes the methodology used and the benefits realized in the design of recovery plants by ensuring a fundamental understanding of the advantages and limitations of the technology embodied in the equipment, a comprehensive knowledge of the ore body characteristics, and the effective matching of this information in combination with operational commercial requirements.

Jan 1, 2010

By M. Seeger

The demographics and the growing numbers of people provide a strong signal that the demand for electrical power in Southern Africa will grow considerably over the foreseeable future. Without a steady and increasing supply of electricity development of the continent is likely to be constrained. The inventory of solar, wind, hydrothermal, geothermal and biomass resources will probably provide sources of energy for the future The parallels between extraction of natural resources in the minerals industry and the green energy industry is striking, and the well-established project development process in the minerals industry provides an ideal and useful template for comparing the establishment and development of green energy projects. The potential levels of power generation and carbon savings are described.

Jan 1, 2010

By F. Riedel

In May 2009 a test work programme was carried out at the sorting laboratory of CommodasUltrasort in Germany which was aimed at establishing the efficiency of X- ray transmission sorting for the recovery of unliberated diamonds in a size range of +8mm. A PRO Tertiary XRT belt sorter with a working width of 600mm and a belt speed of -3mJs was used for the test work. Dual energy X-ray transmission sorting is a type of sensor-based sorting which uses an X-ray scanning system, The attenuation of the transmitting X-rays is measured at two different energy levels, Thereby it is possible to eliminate the effect of the particle thickness on the measurement result. The effective measurement results in a classification by elemental order based on the periodic table.

Jan 1, 2010

By A. A. Angelov

This paper presents a unique method of monitoring the effectiveness of the planning process as well as the execution of mine plans. The method primarily determines the degree of deviation from the original mine plans by comparing actual mined areas to initially planned mining areas. The performance of mining operations is also measured by comparing actual and planned tonnages for a particular period. Once the degree of deviation from mine plans has been established the cause/s of the deviation can be determined through a simple fault tree analysis. Accurate identification of the reasons of deviation can aid the mine in selecting possible methods to correct the deviation. It is, however, beyond the scope of this paper to discuss the methods employed in correcting such deviations, as each mining operation will have unique causes of plan deviation and methods of remedying them. Deviations from the plan greatly affect the yields obtainable, which in turn affects the life of mine, thus having negative economic and financial implications. Accordingly, this paper presents a project management method which aims to reduce risk by improving planning systems to ensure optimum overall extraction of coal reserves.

Jan 1, 2010

Slope stability is a fundamental part of a successful mining operation. It impacts directly on the safety of personnel and the economics of the mine. The Jwaneng Mine in Botswana is planning a push back of 644m depth in the south east wall. Mining will commence in 2010 and be completed in 2024. This will put the mine in the deep pit category. The mine has invested in extensive geotechnical data gathering and design programs that started as far back as 2003 for the south east wall. The south east wail of Jwaneng Mine is characterized by foliation that dips adversely into the mining faces. The orienta1ion of the foliation is variable due to intense tectonic movements that have also caused the occurrence of faults that are sub-vertical. A considerable amount of information on the characteristics of structural patterns and the rock mass has been collected. This paper presents an overview of the feasibility level geotechnical design that is about to be concluded.

Jan 1, 2010

By C. J. Badenhorst

The scope of this project was to research, develop and eventually produce a personal occupational hygiene and safety exposure monitor system to assist in recording and analysing various stress factors that could affect the health, wellness and safety of employees, i.e. that could result in injury or ill health of workers, create stress build-up within individual workers that could negatively affect worker alertness and safety, and, may even result in permanent disability or death. Utilized systems at the time were all reactive, whereas the DOHEMS (Proactive Digital Occupational Hygiene and Safety Exposure Monitoring) System enabled the measurement of exposure (and associated risk) in a proactive manner via real-time exposure and digitized recordings. The idea of the development was to create a unit that is so cost effective, small and light that every worker can use a system on a daily basis. The development will eventually replace current, bulky and expensive monitoring equipment. The device must be a portable battery operated device and monitor the immediate working environment by periodic sampling for vibration, noise, toxic gasses (NO/NOX/CO/VOC, etc.), body temperature and heart rate. The samples must be time and date stamped, utilizing a real-time clock (RTC) synchronized with the closest regional secondary time source and related to synchronized real-time video captured samples. These samples are then recorded onto a rugged non volatile storage device with the capacity to store a vast number of samples covering the entire working shift of eight (8) hours plus. The system has been fitted with a clear visual local alarm indication system, indicating any excessive exposures or stresses, for the worker?s supervisor to respond to. This system allows for a pro-active approach. The system is also a wireless system (to the external environment) so as to not affect the mobility of an employee and flameproof to allow for use in explosive environments. Keywords: safety, digital, exposure, monitoring, proactive.

Jan 1, 2010

The Namakwa Sands heavy mineral deposit is located along the West Coast of South Africa and the mine is a world class producer of high quality zircon, ilmenite and rutile concentrates from essentially unconsolidated marine and aeolian sands of Cainozoic age. The objective of this study was to characterize rutile with respect to distribution, grain size, textures, colour and mineral chemistry within the Namakwa Sands orebody with the aim to explain its overall poor recovery. A representative suite of heavy mineral concentrates from various sections of the orebody and stages in the recovery circuit has been investigated microscopically and by means of SEM-EDS and LA-ICP-MS. The rutile grain size distribution displays a wide range and is directly related to its variable chemistry and consequently density. In placer deposits such as Namakwa Sands, mineral sorting is a function of hydraulic equivalence, and high density grains are smaller than the lighter grains when deposited under similar conditions. Grain size is also a function of sediment maturity, and the highly mature red aeolians and (RAS) component of the deposit has a coarser grain size than the less mature orange feldspathic marine sands (OFS). The above primary characteristics of rutile are responsible for the loss of the coarse-grained fraction during screening and, given the empirically determined relationship that increased substitution elements reduce conductivity, also during electrostatic separation. Provenance studies using geothermometry have shown that the heavy mineral suite has been sourced mainly by the proximal medium-to high-grade Namaqualand Metamorphic Complex. The positive relationship between substitution elements and temperature of formation explains their high concentration in rutile of this deposit. The heterogeneity of rutile, produced by the combination of a high temperature primary source and the typical marine-aeolian placer genesis is deposit specific and unfortunately not conducive to high recovery levels in the current Namakwa Sands beneficiation circuit.

Jan 1, 2010

Bateman Engineering managed the establishment of a second diamond treatment plant at the Letseng Mine in the Mokhotlong District of northern Lesotho, about 100 km from the town of Buthe Buthe. Letseng Diamonds Proprietary Limited, is owned 70 % by Gem Diamonds and 30 % by the Government of the Kingdom of Lesotho. The second plant, which commenced construction in late 2006, doubled Letseng Mines' hard rock processing capacity from 2.6 million t/yr to 5.2 million t/yr, making it the worlds' seventh largest diamond mine by throughput. Bateman Engineering provided the engineering design, procurement and construction management of the new plant.

Jan 1, 2010

A high volume of slimes which are separated out during the mining of heavy mineral sands has a high environmental impact and results in great capital as well as operational expenses. The presence of clay minerals drastically increases the slimes volume that needs to be catered for due to its low settling capability as well as swelling characteristics. By adding coagulants in the form of cations and organics, one can improve the settling rate of the minerals as well as the degree of solid bed compaction. The addition of flocculant, which is currently used in industry to improve settling rate, is detrimental to solid bed compaction. By combining the cations and flocculant one can dramatically improve the solid bed compaction. This combination is, however, detrimental to the settling rate of kaolinite-rich slimes but improves the settling rate of smectite-rich slimes. Organics can also be used to produce a clear supernatant and improve the settling rate.

Jan 1, 2010

By H. Yilmaz

Tensile strength testing has been one of the most common physical property testing methods of thin spray-on liner (TSL) products worldwide. However, the variety of products tested has been insufficient for comparison purposes. Specimen preparation procedures and test parameters such as curing time and loading rate are not reported well. Comprehensive tensile strength testing on 20TSL products and one plain shotcrete brand was performed over 28days of curing period. Detailed information on the test procedures with particular attention on the important aspects during sample preparation and test execution are provided. As expected, the tensile strength increases with increasing curing period. The test results make the categorization and comparison of liner products possible.

Jan 1, 2010

By D. Sager

Middleburg Ferrochrome (MFC), a company in Samancor Chrome, commissioned a new ferrochrome smelter in March 2009. This is a 60 MW DC-arc furnace with a DC power supply for the smelting of Transvaal chromite ore fines. With the benefit of 12 years' experience with this technology while operating a 44 MW DC-arc furnace, MFC mitigated all known challenges and considered up-scaling risk in the new plant, which had a rapid ramp-up to full power in 02 of 2009. Good operating practices, as made possible by robust equipment selection, including a thyristor rectifier set of proven technology, and operation with optimal slag chemistry, leads to a safe and effective plant operation. With the optimized furnace design and a correctly sized power conditioning system, using only standard (static) harmonic filters and a correctly sized smoothing reactor, the arc furnace is not a 'dirty load' for the utility, staying well within IEC limits for power quality. A patented arc compensation system is installed and allows for full arc position control (to compensate for magnetic field induced arc deflection) so that a symmetrical crucible is maintained, significantly benefiting refractory life. The principal benefits gained from the MFC process is the fact that ore fines are processed, without metallurgical coke, and higher chrome recoveries are achieved compared to other smelting technologies when using a DC open arc for smelting. Keywords Samancor Chrome, Middelburg Ferrochrome, ABB, smelting, DC arc furnace, arc compensation, power factor correction, anode, harmonics, thyristor, reactor, maintenance, refractory, ores, reductants.

Jan 1, 2010