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By T. Szendrei, S. Tose

The fracturing and movement of rock that occurs in the vicinity of a stemmed borehole charge in open pit mining operations are described by examining the effects of the emitted stress waves – shock and elastic – and the expansion of high-pressure detonation product gases. Three principal modes of momentum transfer to fractured rock are identified, all linked to gas expansion work. This work can be delivered radially (burden), axially (stemming), and in the collar zone (cratering). Flyrock is generated under unusual combinations of blast parameters and rock properties. Although infrequent and seldom predictable, the generation of flyrock can nonetheless be interpreted and modelled in terms of the principal mechanisms of rock projection described in this study. The physical processes underlying these principal mechanisms are identified and will permit the development of predictive models for flyrock velocities.

Dec 13, 2023

"This study examines the problems faced by open pit mine superintendents who make choices about how to direct their materials, either to the waste dump or to the mill. The paper explores the effects of introducing a 10% sampling error and a 0.9-times to 1.1-times sampling bias on positively skewed distributions for precious and base metals, negatively skewed distributions in the case of bulk commodities, and normal distributions as is the case for coal deposits. Parent distributions for each commodity were created on a 25 x 25 m grid using transformations of gold, iron ore, and coal data-sets, spatially based on a nonconditional Gaussian simulation. Ordinary kriging of grades for the three commodities into a 10 x 10 m grid provided the reference case against which the distributions with the sampling error and sampling bias for the commodities were compared. Imposing cut-off grades on the actual-versus-estimated scatterplots of the three commodities allowed the distributions to be classified into components of waste, dilution, ore, and lost ore. Ordinary kriging of values for each deposit type acted as the reference data-set against which the effects and influence of 10% sampling error and 0.9-times to 1.1-times sampling bias are measured in each deposit type. Indications are that the influence of error and bias is not as significant in gold deposits as it is in iron ore and coal deposits, where the introduction of small amounts of error and bias can severely affect the deposit value.IntroductionThe effects of poor sampling and the financial implications for mining companies, traders in mineral assets, and sellers of metal as dore or commodities is documented in a number of studies, the most notable of which is that by Carasco (2004). He examined the financial impact of poor sampling practices in the Chilean copper industry and found that finacial losses due to poor sampling amounted to hundreds of millions of dollars over the life of a mining operation. Holmes (2004) examined the effects of correct sampling and measurement as the foundations of metallurgical balances, and found that revenues from the sales of large iron ore shipments may be profoundly affected by poor sampling practices. In South Africa the way in which sampling of in situ gold-bearing reefs affects the mine call factor has been an ongoing study since the disparity between the estimation of gold in the reef and the actual gold bullion produced was noted by early investigators such as Beringer (1938), Jackson (1946), Sichel (1947), Harrison (1952), and a number of others."

Jan 1, 2017

By M. Pierce, E. Karampinos

"One of the main challenges in the numerical modelling of ground support in underground excavations is to reproduce the performance of the sequential installation of the reinforcement while capturing the rock mass behaviour of an advancing face in 3D. The 3D modelling approaches used to simulate the progressive advance of excavations are mostly continuum and often cannot reproduce the rock mass failure mechanisms. The 3D discrete element method (DEM) can better reproduce structurally controlled rock mass failure mechanisms and can explicitly represent the reinforcement elements. This paper builds on previous work that reproduced the structurally controlled squeezing conditions in an underground hard-rock mine using 3D DEM and the in situ behaviour of reinforcement under pull conditions. It addresses important issues on the way reinforcement is explicitly introduced in discrete element models. A pseudo-3D model is employed to overcome the computational restrictions and time limitations of a 3D modelling approach. The work focuses on the scaling of the material properties of the ground support elements when the thickness of the model is not equal to the out-of-plane spacing of reinforcement. It demonstrates the scaling methodology based on the type of the modelled reinforcement elements used and investigates the significance of this approach. The advantages and disadvantages of this approach with respect to 2D and 3D methods are discussed. The results are compared with field data and previous modelling work done at the mine. IntroductionNumerical models can provide significant insight into the anticipated behaviour of underground excavations. The modelling of ground support, however, is not a trivial exercise. An effective representation of ground support in underground excavations should capture the behaviour of both the rock mass and the support elements. When numerical models are used for design purposes, the complexity of the problem requires significant time and expertise (Sweby, Dight, and Potvin, 2016).At a laboratory scale, numerical models have successfully reproduced the results of laboratory tests on rockbolts by explicit modelling of the bolt, the borehole, and the grout. Chen and Li (2015) used a continuum FLAC3D (Itasca Consulting Group Inc., 2012) model to simulate the mechanical behaviour of D-bolts as observed experimentally. Grasselli (2005) used a 3D finite element code to model the behaviour of fully grouted rods and expandable bolts under shear."

Dec 1, 2018

By J. Preussner, U. Glatzel, R. Völkl, S. Prins, M. Wenderoth

Platinum base alloys are very corrosion resistant and have got a high melting point. Similar to Ni-base superalloys, which are used for jet turbines, the hardening effect of the intermetallic L12Pt3Al phase is used to receive a material that is creep resistant at high temperatures. Chromium is added to the alloy system to stabilize the L12phase down to room temperature. With the right amount of nickel the misfit and shape of the precipitates can be controlled. Various alloy compositions have been melted and analysed. With scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) a microstructure can be observed, which is very similar to the one in Ni-base superalloys. To support alloy development with simulations, a thermodynamic database of the Pt-Al-Cr-Ni system is about to be established. The SEM and EDS measurements provide useful input to the thermodynamic optimization. Also many data from the literature have been used to receive the best approximation. The Cr-Pt binary phase diagram has been reassessed and the latest results of thermodynamic modelling are presented.

Jan 1, 2006

By S. L. Crouch

A. C. Dieringt The procedure described by Professor Crouch for the modelling of mining in faulted ground allows the elastic and inelastic deformation to occur simultaneously, that is, fault slip occurs while an element is being mined. The energy release rates (ERR) shown in Crouch's Fig. 10 are apparently calculated from his equation 9 using the i total deformation Din (see the upper load line of Fig. I) Refractories The institute of 'Gesteinsh iittenkunde' of the technical university at Aachen, the Refractories Research Institute at Bonn, and the Verein Deutscher Eisenshiittenleute (VDEh) at Diisseldorf are to hold the XXII International Refractory Colloquium on 27th and 28th September, 1979, at Aachen.

Jan 1, 1979

By S. M. H. Ahmadi, K. Barani, F. Moradpouri, R. Ghaedrahmati

As exploration is time-consuming, costly, and risky, determination of the erosion surface of a metalliferous deposit before geophysical surveying and exploration drilling might be very helpful. Geochemical haloes can be used to determine whether the erosion surface is supra-ore or sub-ore and thus reduce the risk of exploration operations. The aim of this investigation is to determine the erosion surface of the North ROK porphyry deposit (NRPD) in northwestern British Columbia in Canada using linear productivity (LP), which is the content of an element defining the halo multiplied by the width of the halo. A total of 2045 soil samples from the B horizon were analysed using ICP-MS for 36 elements, including Cu, Mo, Pb, Zn, Au, As, Ag, Ni, Co, Fe, and Mn. The data-set was snalysed to obtain the statistical parameters and the elements Cu, Mo, Pb, and Zn were chosen to calculate the linear productivity and the total linear productivity. These four elements were modelled using probability plots to identify and separate subpopulations in terms of anomalous haloes and background, including the threshold values of each subpopulation. The results of the probability plot modelling and thresholds values were then used to map the distribution of each element in a GIS to calculate the linear productivity. The total linear productivity indicated that the erosion surface is supra-ore. Finally, a 3D orebody model of the Cu, Mo, Pb, and Zn distributions was constructed using borehole data and used to validate the results.

Feb 6, 2023

By Z. Halifa, P. G. Geyer

Tapping a blast furnace is necessary not only to deliver the product, but is also essential for the safety of the furnace and workers in the cast-house. This paper will highlight the practices at ArcelorMittal’s blast furnaces in the Vanderbijlpark Works, with specific focus on tap-hole design and monitoring as well as casting practice. Extension of the tap-hole life and hearth campaign will be illustrated with reference to the methods of maintenance of the tap-holes, troughs, runners, and cast-house equipment. The importance of proper cooling, good thermocouple installation, and temperature monitoring will be explained.

Jan 1, 2014

By G. Akdogan, C. Bergmann, C. J. Coetzee, Q. G. Reynolds, S. J. Baumgartner

Submerged arc furnaces (SAF) are used extensively in the production of ferrochrome, where charge material – consisting of mixtures of carbonaceous reductants, fluxes such as silica, and ore in the form of pellets – is fed through chutes into the vessel. The feed typically forms a thick bed or ‘burden’ of solid particulates above a bath of molten material below. This burden layer surrounds three electrodes, which are typically arranged in a triangular configuration in circular SAFs. A major challenge in the industry is the availability of sought-after reductants, volatile market conditions, and increasing electricity tariffs in South Africa. A good understanding of the physical properties of the raw materials in the charge is therefore of great value in order to best deal with the reductants available at any given time, and thereby maximising furnace throughput. This paper presents a study of the effects of different particle properties on particle flow behaviour relevant to SAF operations. Discrete element model (DEM) simulations were used to estimate the sensitivity of the particulate flow of beds of charge material to properties such as the coefficients of friction, particle shape and size, and others. The present study lays the groundwork for the development of full DEM models of the SAF that will greatly improve understanding of the flow of complex mixtures of solid particles in the submerged arc furnace, and how the relative physical properties of each component in the charge can influence electrical behaviour of the burden.

Sep 1, 2021

By F. L. D. Cloete

The following discussion relates to the paper by G. S. Hansford, C. D. Levy, and J. W. de Kock that appeared in the March 1976 issue of the Journal (vol. 76, no. 8, pp. 363-369) Competition for student members Each year the South African Institute of Mining and Metallurgy offers a prize (or prizes should the entries warrant it) of up to RI00 for the best paper or dissertation on a topic appropriate to the interests of the Institute. Engineering in South West Africa The SW A Engineering Profession Steering Committee was established on 4th April, 1977, its purpose being to formulate an Act covering the engineering profession in South West Africa.

Jan 1, 1978

By S. Kirkpatrick, J. Mukendwa

"The mining operation at Namdeb’s Southern Coastal Mine (SCM) is unique. It targets gravel layers up to 30 m below sea level, which continue to dip deeper, further west, under the Atlantic Ocean. On this storm-dominated coastline, severe water seepage into mining areas, rugged orebody footwall characteristics, and highly variable resource grades all contribute to a challenging operational environment. Namdeb has a proud history of innovation, and as the mine progresses further westwards and associated technical and economic challenges increase, this innovative culture has become essential to the future of the mine. The Theory of Constraints (ToC) has been widely used at SCM, and across the mining discipline, to focus efforts on improving overall business profitability. Through analysis of the mining processes, opportunities were identified, solutions developed, and initiatives implemented with staggering results across all three mining disciplines, i.e. stripping, load and haul, and bedrock bulking and cleaning. This paper outlines the solutions adopted and the results of the ToC analysis. IntroductionSouthern Coastal Mine (SCM) is one of three Namdeb operations located in the southwestern corner of Namibia, between the Orange River in the south, the Namib Desert to the east and the Atlantic Ocean to the west (Figure 1). These three geographical features set the backdrop for the world’s greatest marine diamond mining placer (Badenhorst, 2003). SCM is situated along the coastline extending from the mouth of the Orange River to Chameis Bay approximately 120 km to the north. The active mining area, called Mining Area 1 (MA1) is, however, limited to very narrow strip, 30 km in length, in the south of the licence area, close to the town of Oranjemund.Namdeb, a wholly owned subsidiary of Namdeb Holdings, is a 50/50 joint venture between De Beers and the Government of Namibia. Diamonds were first discovered along the Namibian coastline in April 1908, close to the town of Luderitz, but mining operations started in the SCM mining area only in February 1929 (Schneider, 2009). Initially all Namdeb mining operations exploited massive land-based deposits, producing nearly 40 million carats from MA1 between 1920 and 1977 (Schneider, 2009) when mining targeted onshore raised beaches west of the high water line. Since 1977 however, SCM and Namdeb have developed a unique mining method to economically extract the resource which extends westward under the Atlantic Ocean."

Feb 1, 2019

By J. Cilliers, R. Seitz, D. Drinkwater

Mineral processing produces a saleable product from high-cost ore. The Mineral Processing Engineer must constantly improve the separation to create the most value from the ore and reduce the associated costs. Graduate Metallurgists (or Chemical Engineers) have had the university theoretical training required, but often are illprepared to perform their plant roles. The in-work Metcelerate programme was designed specifically to develop the practical skills that Mineral Process Engineers require, by combining three key elements: 1. Knowledge transfer through self-paced, on-line training; 2. Practical skills acquisition through assessed, practical plant exercises; 3. Skills development through online tutorials. A final process improvement project adds significant value to the operation that far exceeds the training cost. Experience from Metcelerate clients has indicated improved staff retention, greater confidence, and pro-active process intervention.

Jan 1, 2023

By N. Sinclair

"In open pit dozer bulk push operations, the material left resting against the highwall after blasting poses an issue. This is because dozers cannot physically get in behind the waste to begin the bulk pushing process. Instead, an excavator can be used to side-cast this waste for the dozers to access. An alternative technique is to have the dozers ‘side-cut’ the material, which involves the dozers running parallel to the wall, digging out the material, and eventually rotating their blades to begin bulk pushing. Industry practices suggest the latter technique is less productive and economical than using an excavator. However, such excavator sidecasting ‘economic viability’ assumes that smaller/ancillary type excavators are used (i.e. less than 23 m3 bucket capacity). So, what happens if some mine sites are restricted to using relatively larger excavators (> 23 m3 bucket) that are preferred for higher priority digging tasks? When can they avoid using their excavator? This paper explores multiple scenarios that have been designed and developed to simulate data results, which identify conditions in which the dozer side-cutting technique becomes more economically viable than excavator side-casting in terms of decreased unit cost per loose cubic metre. IntroductionOptimizing the cost of waste removal operations is important for the profitability of opencast coal mines. In the past decade, dozer bulk pushing has emerged and taken over from traditional waste removal operations such as dragline and truck-and-shovel methods at various sites around the world (Beatty, 1994). In a typical bulk push operation, once the bench has been blasted, waste is left resting against the highwall, which can either be cleared using a loading unit or by having the dozers ‘side-cut’ the highwall.Dozers perform most effectively when slot dozing side-by-side, perpendicular to the highwall. However, when dozers are required to remove material off the highwall, they must push parallel to the highwall, rather than perpendicular, hence ‘side-cutting’ the material to ensure a clean face. While dozer sidecutting is possible, it has been found that the majority of mine sites use a loading unit in this situation to avoid dozer inefficiency. Other perceived issues with dozer side-cutting include higher maintenance requirements and safety risks to dozer operators working in close proximity to the highwall."

Jan 1, 2019

Introduction to high temperature oxidation of metals, by N. Birks and G. H. Meier, London, Edward Arnold, 1983. 19S pp. R30,25. Reviewers: M. B. Cortie and G. G. Garrett Seam gas drainage with particular reference to the working seam, edited by A. J. Hargraves. Woollongong, The Australasian Institute of Mining and Metallurgy. 370 pp. $A30. Reviewer: C. J. Fauconnier New books Solvent extraction Part I, by G. M. Ritcey and A. Ashbrook. Amsterdam, Elsevier, 1983. Elektronishche Steuerungen und Mikroprozessoren im Bergbau. Sicherheit und Zuverlassigkeit Environmental impact control. Philosophical and procedural guidelines for the planning professions Mineral processing and extractive metallurgy. Reagents in the minerals industry.

Jan 1, 1984

By A. R. Barnes, C. W. P. Finn

The prereduction and smelting characteristics of UG-2 ore were studied and compared with those of Winterveld chromite ore. The UG-2 ore proved more reducible, and substantial prereduction (over 70 per cent reduction after 30 minutes at 1250oC) was obtained. No difficulty was experienced in the production oh high-carbon ferrochromium alloy containing 48 to 50 per cent chromium. Calculations of the energy balance show that UG-2 chromite has lower total energy requirements (both on the basis of unit of ferrochromium produced and of total chromium content). More than 50 per cent of the energy required for reduction can be supplied outside the smelting furnace.

Jan 1, 1983

By S. Soren, K. Deo Mehta, G. Jha

The paper aims to find a sustainable sintering process through cleaner means, in order to achieve the desired outputs with zero environmental impact. At present, sintering has no control over its environmental impacts. These impacts occur when fossil fuels such as coal and coke are used in metallurgical sintering. These fossil fuels are undoubtedly effective in their assigned reducing task, but simultaneously emit about 220 kg of GHGs (greenhouse gases) per tonne of sinter produced. The current attempt has focused on reducing these emission levels by switching from coke to a renewable fuel source such as biomass. Biomass is a cleaner fuel source with a significantly lower emission footprint compared to coke. In the experimental campaign, sawdust and wood-charcoal were used in substitution for coke. Experiments were designed in a progressing substitution to obtain the maximum substitution ability without compromising the sinter properties. Sawdust as raw biomass source optimally substituted 10% of coke. The substitution levels were remarkably higher (30%) for wood charcoal due to its low moisture and high calorific values. A fuel blend with 30% biomass and remaining coke succeeded in producing a sinter with acceptable quality indices. Sinters prepared with or without biomass contribution shared an identical phase transformation and microstructures. In order to to maintain consistency in the process, every effort was made to maintain all operational and process parameters identically, except for the fuelling framework. Keywords: Sintering, sustainable, biomass, GHGs, fuel substitution

Jan 1, 2020

By A. Atta-Quayson

Since 2012, Ghana has been implementing local procurement regulations in the mining sector to broaden and deepen linkages between mining and other sectors of the economy. The regulations have been implemented in collaboration with the mining industry. This paper offers an in-depth analysis of how the local procurement regulations and related initiatives have been implemented so far. Primary data gathered with semi-structured interviews and secondary sources of data indicate a steady improvement in both in-country procurement and local manufacturing of inputs for the mining industry. There are, however, some challenges relating to tariff structure and support (financial and technical) for local suppliers and manufacturers to meet high standards and demands of the mining industry. This calls for a well-thought-out strategy and programme of activities to sustain and improve on progress made.

Feb 2, 2022

By C. Chibwe, M. Tadie

Copper electrowinning models are useful for prediction of process performance, optimisation and improved understanding of complex phenomena such as current distribution without the expense of physical experiments. Recently, finite element models such as those generated in COMSOL Multiphysics have been developed for the electrowinning process. The predictive capacity of these models is improved by incorporating physical and chemical phenomena. Since physicochemical properties of electrolytes can have a significant effect on the quality of copper produced, this work was conducted to investigate the effect of such properties on electrodeposition at varying levels of copper, sulphuric acid concentration, iron concentration and temperature, in the presence of a smoothing agent. Tests were conducted at conditions similar to those for industrial copper electrowinning. Mathematical correlations were developed for the following properties; density, conductivity and diffusivity which were compared to existing models in literature and thereafter applied in a COMSOL generated model. The model predicts, current distribution at the cathode surface, deposit thickness (morphology), concentration of species within the cell and current efficiency. Current distribution output shows the impact of several phenomena on the deposit generated including the relationship between increasing copper concentration and current density and lack of influence of acid concentration on this property. Keywords: Electrowinning, physicochemical properties, electrolyte composition, modelling

Jan 1, 2020

By A E. Paterson

General aluminium corrosion charts based on 1100 alloy listing product and temperature have been developed by AFSA, mainly from available sources. The categories of corrosion expectation are fairly wide. As a result the charts are more useful in indicating what is not suited as distinct from what is. The question of how to develop useful information is assessed. Having discarded improbable options one is left with the need to refine the possible. Within each alloy group corrosion potential differs. From an engineering application point of view, the corrosion resisting marine alloys, the 5xxx series show increasing corrosion as the percentage of Magnesium increases. An important issue is that as the welding filler used for 5xxx series is Mg rich (to avoid hot cracking), the filler is likely to show the weakest resistance. In addition, when subjected to fatigue loading, the preference for critical joints is to dress the joint to the level of the base material. Overheating of the weld extends the HAZ zone and weakens the material as Mg moves to the grain boundaries. Indicator chart refinement approaches suited to aluminium use in commercial transport are discussed.

Jan 1, 2006

By M. C. van Eeden, R. Vermeulen, K. B. Le Bron

This paper presents the lessons learnt during the transition from an open pit method to a sub-level open stoping method at the Koidu Limited kimberlite pipe. These learnings may assist other mines with planning, both from a practical implementation perspective (layout, charging up challenges), and a method for estimating potential dilution and stability challenges associated with the interaction between the surface and underground excavations. Predictive geotechnical stability modelling was successfully applied to highlight potential failure zones, which allowed modification and enhancement of the mining layouts and quantification of the potential dilution of the kimberlite from indicative instabilities.

Sep 1, 2025

By S. Kahraman

The prediction of rock properties from indirect testing methods is important, particularly for preliminary investigations since indirect tests are easier and cheaper than the direct tests. In this study, we investigate the predictability of the uniaxial compressive strength (UCS) and Brazilian tensile strength (BTS) of rocks from the indentation hardness index (IHI) obtained using point load apparatus. Forty-six different rock types, 14 of which were igneous, 15 were metamorphic, and 17 were sedimentary were tested in the laboratory. The UCS and BTS values were correlated with the corresponding IHI values and the results were statistically analysed. The influence of rock classes on the relationships was also investigated. A strong correlation between UCS and IHI was found for all data. The correlation between BTS and IHI is not as strong as the correlation between UCS and IHI, However, it is in the acceptable limits. When the regression analyses were repeated for igneous, metamorphic, and sedimentary rocks, the correlation coefficients were generally increased. The results show the UCS and BTS can be estimated from IHI, In addition, the effect of rock classes on the relationships between IHI and both UCS and BTS is important.

Jan 1, 2012