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By A. Kapito

The ferrite-pearlite microstructure is the most popular microstructure for alloys used in structural applications, including railway wagon wheels. These alloys have been designed through alloying and thermo-mechanical processing to have a refined microstructure. Ferrite-pearlite alloys are low cost, weldable, have good fabricability, and are reliable under extreme conditions. Given these performance attributes, it seems unlikely then that their dominant position as structural steels would ever be challenged by alternative microstructures. One major achievement in the development of ferrite-pearlite steels has been in the refinement of their interlamellar spacing to very fine distances of the order of < 0.3 µm. A refined microstructure increases the hardness of the alloy, thus increasing its life under wear conditions. The interlamellar spacing in pearlitic steels has, however, been refined almost to its theoretical limit. The increasing demand for speed and increased axle loading on railway wagons requires the use of stronger, tougher, and more durable materials. This has opened the window for the development of novel bainitic steels. Bainitic alloys have a higher level of microstructural refinement than pearlitic ones. They have shown to have good wear resistance and rolling-contact fatigue resistance, and high toughness. This paper will discuss the progress to date on the development of bainitic railway wheel alloys. Four alloy chemistries have been chosen for possible further development.

Jan 1, 2012

By D. J. de Clerk

Global trends stipulate the need to optimize existing assets while reducing environmental impacts. This paper illustrates the procedure that was followed to achieve such goals at one of the coal burning flash dryer units at an Anglo American smelter. An in-depth study of the process and related literature led to the development and installation of a revised control philosophy. This system includes modifications to the existing regulatory control structure as well as a hybrid rule-based and model-predictive advanced process control (APC) layer. Since commissioning of the APC, this flash dryer?s average throughput has increased by more than 6%, despite higher feed moistures. Furthermore, even though coal consumption has increased slightly, operating efficiency has improved by close to 5%. This was made possible by improving stability of the drying column outlet temperature by approximately 40%, which in turn enabled selection of a more optimal setpoint. Recent data has shown that APC utilization now exceeds 95%. This is indicative of a successful controller installation with good site acceptance. The same philosophy has therefore since been rolled out to most of the other flash dryers in the group.

Jan 1, 2012

By A. Mitchell

On 25 August 2011, Andrew Mitchell, Lucas Moalusi, and Matthew van der Want of Bell Dewar hosted a presentation on Mining and Communities in Mooinooi, in the North-West Province. The conference was attended by traditional leaders in the North-West Province, officials from the Department of Local Government and Traditional Affairs, and executives from the mining industry. The presentation concerned traditional governance in mining, communities? rights in terms of applicable legislation, and the corporatization of community affairs.

Jan 1, 2012

By F. Lombard

We consider in this paper the use of a modified version of Hotelling?s statistic in the analysis of particle size distributions. The statistic can be adversely affected by the presence of outliers among the data. We propose a competitor to the statistic that is based on ranks, and hence is less sensitive to outlier effects. The results of a Monte Carlo study suggest that the rank test is highly competitive with the Hotelling test in its ability to detect differences between two mass size distributions. The calculation of the rank statistic is explained in detail and its application is illustrated on two sets of data.

Jan 1, 2012

By A. L. Edwards

A retrospective study was conducted on the Rand Mutual Assurance (RMA) noise-induced hearing loss (NIHL) compensation claims from 1998 to 2008 to determine if the 2008 milestone agreed at the 2003 Mine Health and Safety Summit was achieved. The number and costs of NIHL compensation claims in different commodity sectors and workplaces were collated. A secondary analysis of the ages of employees compensated after 2008 was conducted. A complementary retrospective analysis of audiogram data investigated the percentage loss of hearing (PLH) shift in different homogeneously exposed groups and occupations at two gold mines. The compensation claims analysis indicated a significant decrease in NIHL claims from 1998 to 2008, but the milestone was not achieved. The reason may be either that claims have not been submitted timeously as required by Instruction 171 and that the current submissions are a result of pre-2003 noise exposure, or that employees who were baselined are still developing NIHL owing to ineffective hearing conservation programmes in place in the mining industry. On the basis of best practice for hearing conservation, recommendations are made for leading indicators in hearing conservation programmes and for reducing the risks of NIHL in order to achieve the 2013 milestone.

Jan 1, 2012

By S. O. Bada

Fine phosphate feed is considered to be slime and normally disposed of as a discard in settling ponds or dumped as landfill. The purpose of this research was to establish whether commercially acceptable qualities and yields could be obtained from this material using dry separation methods. The results obtained from the electrostatic separation of <105 µm phosphate ore are presented. An existing separator was upgraded in order to improve on product and flotation concentrate recovery, to test different mineral, and to reduce particle residence time between the charging chamber and the separating zone of the separator. The operating conditions were varied according to the charges imparted to the particles in the electric field, and according to other device parameters. Parameters such as splitter position, charge reversal, rotation speed, charging voltage and separating voltage. The <105 µm phosphate feed was concentrated under both triboelectrification and inductive charging. The use of inductive charging and charge reversal resulted in a significant increase in grade for <105 µm phosphate feed, with the P205 grade increasing from about 12 per cent to 20.50 per cent, and a recovery of 26.30 per cent under a single stage of separation. It was found that better separation was achieved at rotation speed of 6000 r/min, -8 kV charging voltage, and 25 kV separating voltage.

Jan 1, 2012

By C. Montoya

This paper shows, through a case study, the impact of multivariate grade modelling upon mine design and mine planning. A deposit explored by drill holes is considered, in which the grades of five elements (copper, silver, molybdenum, arsenic, and antimony) are of interest. Forty alternative models of the deposit are constructed by fitting the joint correlation structure of the grade variables and using conditional cosimulation. In addition, a reference model, obtained by averaging the alternative models, is also considered. The study shows that the resulting mine design (final pit characteristics and production schedules) is sensitive to the grade model under consideration, and that the design based on the reference model may not be optimal when compared to the alternative models based on cosimulation. However, when assuming a given long-term plan and extraction sequence, the grades and net present value (NPV) calculated on the reference model are unbiased with respect to those calculated on the alternative models with the same extraction sequence. The latter allow assessing the possible dispersion of the actual grades and NPV around their expected values, and are useful for the planner in order to determine the probability of meeting given production targets and of exceeding or falling short of given threshold grades. Additionally, unlike cosimulation, the separate simulation of each grade variable leads to unrealistic resource models and to biased results in mine design and mine planning. This approach should therefore be avoided, unless the grade variables are spatially uncorrelated.

Jan 1, 2012

By S. Özgen

In this study, the possibility of beneficiation of chromite tailings in the Uckopru/Fethiye-Turkey region by a combination of hydrocyclone and multigravity separator (MGS) was investigated. The two significant operational parameters of hydrocyclone, which were diameter of the apex and diameter of the vortex, and the three significant operational parameters of the MGS, which were drum speed, tilt angle, and wash water, were varied and the results were evaluated with the central composite rotatable design. In order to produce a chromite concentrate by hydrocyclone and MGS, mathematical model equations were derived by computer simulation programming, applying the least-squares method using Minitab 15. Second-order response functions were produced for the grade and recovery of chromite concentrates.

Jan 1, 2012

By M. M. Makhofane

Anhydrous zirconium tetrafluoride can be used as a precursor for the manufacturing of nuclear-grade zirconium metal. This can be done by fluorinating plasma-dissociated zircon with ammonium bifluoride in a batch reactor. This paper describes the batch process. It was proved that anhydrous zirconium tetrafluoride can be manufactured by this route as confirmed by X-ray diffraction. The process shows potential for scaling up to the kilogram scale and possibly the tonnage scale.

Jan 1, 2012

By B. O. Odera

The Pt-based alloys have a high potential for replacing some Ni-based superalloys (NBSAs) used in the highest temperature and most aggressive environments, and vanadium would be a beneficial alloying element. Six alloys of average compositions Pt-26.6Al-9.1V, Pt-23.1Al-17.8V,Pt-9.6Al-21.1V, Pt-17.4Al-6.4V, Pt-22.3Al-7.9V, and Pt-6.0Al-10.1V (all in at.%) were manufactured by arc-melting and examined in the as-cast condition using scanning electron microscopy and X-ray diffraction (XRD). Five samples were heat treated at 1 000°C for 1 500 hours and water quenched, then examined. The phases were identified using energy-dispersive X-ray spectroscopy and the identities were confirmed by XRD. In most of the samples, the phases existing in the as-cast condition were different from those at 1 000°C after ~1500 hours heat treatment. A solidification projection, an isothermal section and a liquidus surface projection were determined for the Pt-rich corner.

Jan 1, 2012

The optimal design of production phases and ultimate pit limit for an open pit mining operation may be generated using conventional or stochastic approaches. Unlike the conventional approach, the stochastic framework accounts for expected variability and uncertainty in metal content by considering a set of equally probable realizations (models) of the orebody. This paper evaluates the performance of a new stochastic network flow approach for the development of optimal phase design and ultimate pit limit using a gold deposit as the case study. The stochastic and conventional frameworks as considered here utilize the maximum flow and Lerchs-Grossman (LG) algorithms, respectively. The LG algorithm is restricted to considering an estimated (average-type) orebody model, while the stochastic maximum flow algorithm is developed to simultaneously use a set of simulated orebody realizations as an input. The case study demonstrates that, when compared to the conventional LG algorithm as used in the industry, the stochastic approach generates a 30 per cent increase in discounted cash flow, a21 per cent larger ultimate pit limit, and about 7 per cent more metal, while it maintains a consistency in phase size.

Jan 1, 2012

By L. D. van Dyk

The extraction of iron and lead from their oxides with a volatile organic ligand such as acetylacetone in the gas phase offers potential advantages of lower energy consumption, recycling of the extractant, recovery of pure metals, and a reduced environmental impact compared with conventional extraction processes. The influence of reaction temperature, ligand flow rate, and metal oxide levels on the extraction and rates of reaction of iron and lead from single metal oxide (synthetic haematite (Fe2O3) and synthetic massicot (PbO)) systems in a fluidized bed was studied. It was found that at the investigated acetylacetone flow rates, the influence of mass transfer was limited, but that the reaction suffered from reactant starvation. When the metal load increased the effect of starvation on the rate of reaction also increased. The reaction kinetics increased with an increase in temperature for both systems. At low metal oxide concentrations more that 80 per cent of the iron and lead could be extracted from their respective metal oxides after only four hours.

Jan 1, 2012

By J. Abdollahisharif

Optimal cut-off grade is one of the most critical parameters in open-pit mine design because it defines the ore and waste and thus determines the maximum net present value possible from the mining operation. Although the algorithm presented by Lane (Choosing the optimum cut-off grade. Colorado school of Mines Quarterly, vol. 59, no. 4, 1964. pp. 811-829) is the most common one in the literature, it does assume constant capacities of the mine, processing, and refinery. In this paper, Lane&apos;s original algorithm has been modified to consider variable processing capacities in order to determine the optimal cut-off grade in open-pit mines. The new algorithm proposed here is compared to both Lane&apos;s original algorithm and to a previous modification that incorporated rehabilitation costs into the cut-off grade estimation. The algorithm proposed here that permits variable processing capacities is shown to be superior for the determination of optimal cut-off grade to both these previous versions. In addition, a computer-based program was developed in Microsoft Office Excel© to calculate the optimal cut-off grade as proposed here.

Jan 1, 2012

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 J. G. van der Watt

Due to increasing concerns of global rare earth element shortfalls in the near future, possible alternative sources of rare earth elements have recently become of economic interest. One such alternative is decanting acid mine water originating primarily from abandoned old mines in the Witwatersrand region of the Republic of South Africa. In this study, a novel way of rare earth element removal from the acid mine drainage was employed, making use of bentonite clay, which has very good adsorbent properties, as a rare earth element carrier material. The process can be economically viable only, if the elements can be selectively removed from the bentonite clay carrier material so as to yield reusable clay. Acid leaching was proposed to liberate the adsorbed rare earth elements from the bentonite clay. Accordingly, acid leaching experiments were performed to study the desorption of three commonly-found rare earth elements, namely neodymium, samarium, and dysprosium, from bentonite clay in the presence of sulphuric and hydrochloric acid. It was established that the three rare earth element species could be selectively removed as a group from iron, magnesium, and manganese metals through the careful manipulation of the pH. An investigation into the kinetic aspects of the rare earth element desorption process from the bentonite clay was also undertaken. The applicability of various kinetic models such as zero-order, pseudo first-order, pseudo second-order, elovich, parabolic diffusion, and power function were tested to describe the time-dependent desorption of rare earth elements from bentonite clay. It was determined that the pseudo second-order kinetic model represented the dissolution processes for neodymium, samarium, and dysprosium from bentonite clay the most accurately.

Jan 1, 2012

By P. Falcão Neves

A detailed analysis of the geomechanical behaviour in rock cutting with a diamond saw is provided to obtain a better understanding of the mechanisms involved in the process. The energy of elastic deformation (before failure) and plastic deformation (post failure) was determined in uniaxial compression tests as well as the energy consumed per unit volume in the cutting process. The test samples are White and Ruivina marbles from Borba - Vila Viçosa in Portugal. Correlations between total deformation specific energy and cutting specific energy, normal and tangential forces and diamond indentation are analysed, and some conclusions are presented.

Jan 1, 2012

By H. Cevizci

In this study, a newly developed plaster stemming method is studied and compared with the usual dry drill cuttings stemming method for surface blasting in mines and quarries. Drill cuttings are generally used in open pits and quarries as the most common stemming material since these are most readily available at blast sites. However, dry drill cuttings eject very easily from blastholes without offering much resistance to blast energy. The plaster stemming method has been found to be better than the drill cuttings stemming method due to increased confinement inside the hole and better utilization of blast explosive energy in the rock. The main advantage of the new stemming method is the reduction in the cost of blasting. In one series of blast tests, blasting costs per unit volume of rock were reduced to 16 per cent by increasing burden and spacing distances. Also, better fragmentation was obtained by using the plaster stemming method. Blast trials showed that plaster stemming produced finer material. In the same blast tests, +30 cm size fragments reduced to 5.4 per cent of the total, compared to 37.7 per cent in the conventional method of drill cuttings stemming. With this method of stemming, vibration and air shock values increased slightly due to more blast energy being available for rock breakage, but these increased values were small and under the permitted limit for blast damage criteria.

Jan 1, 2012

By J. M. Ortiz

Grade control and short-term planning are usually based on the samples obtained from blastholes. These samples may carry a large sampling and sample preparation error. At El Tesoro copper mine in northern Chile, an advance drilling grid is used for short-term planning and grade control. These drill holes are sampled well in advance, and a short-term model that incorporates several variables and sophisticated estimation methods can be prepared for decisionmaking. An additional advantage of the advance drilling samples is that reverse circulation can be used instead of conventional down-the-hole equipment, and a very careful sampling and sample preparation process can be implemented, reducing the total sampling error. Advance drilling can be performed on a wider grid than blasthole drilling, hence the decision about the grid requires assessing the economic benefit of different sampling grids. Furthermore, this process allows the cost of poor sampling and the effect of different estimation procedures to be quantified. We demonstrate the optimization of the drilling grid for short-term planning and grade control at El Tesoro mine by means of the economic evaluation of the performance of different drilling grids, with different drilling techniques (which differ in the sampling error). The methodology is based on creating dense (exhaustive) geostatistical simulations of the grade distribution over a volume defined for a production period in respect of the geological model, and assuming each simulation as the true grade distribution. Then, samples are obtained from the exhaustive simulations at a spacing similar to the advance grid to be evaluated, and a sampling error is added. The short-term estimation procedures used on the mine are applied to determine the destination of each block and the profit obtained. This profit can be compared with the maximum profit (unachievable) and with the profit under different sampling errors and grids. The results show that the current 8 x 8 m drilling grid is appropriate and by reducing the sampling error, misclassification is also reduced, leading to an increase in profit of about US$ 5 million in 4 years.

Jan 1, 2012

By R. Altindag

Engineers and researchers need to estimate the mechanical properties of rocks from P-wave velocity. In previous studies, the researchers have investigated either the limited values or all the data belonging to sedimentary, igneous, and metamorphic rocks together in the same statistical analysis. In this study, the raw data pertaining to only sedimentary rocks was taken from previous studies and evaluated. For this purpose, a total of 97 samples of sedimentary rock types were subjected to statistical analysis. First, the relationships between P-wave velocity and physical-mechanical properties were investigated by simple regression analysis. All the data were then subjected to multi-regression analysis. Some empirical equations with high correlation coefficients were derived for rock engineers. The equations obtained from the analyses are compared with previous equations found in literature.

Jan 1, 2012

By C. Botha

The South African democratically-elected government instituted policies and legislation that are intended to bring about change and transformation in the country and have drastically affected different industries, among others, the mining industry. The Mineral and Petroleum Resources Development Act 28 of 2002 (MPRDA) and the Broad-based Socio-economic Empowerment Charter (Mining Charter) were introduced in order to redress previous inequalities and to promote women?s employment in the mining industry. This research evaluates the practical implementation of the MPRDA and the Mining Charter with specific reference to women in underground mining. A quantitative research paradigm was used. Data were collected through a process of a face-to-face interview surveys utilizing a structured questionnaire. The research setting was limited to the platinum-mining industry in the area of Rustenburg in the North West Province. The study population consisted of 195 available women working undergound at the mine. It is clear from the findings that mining companies are facing major challenges in their attempt to incorporate women in underground mining activities. Company policies regarding these issues must be firmly in place; however, the challenge lies in the translation of these policies into practice. In this regard, managers will have to play a leading role in the successful phasing in of women into the underground mining arena.

Jan 1, 2012