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By Gerard de Vries

pipeline industry and are still growing in size. Liquid epoxy and polyurethanes are an excellent choice for whatever the aggressiveness of the substance transported and whatever the harmful outside influences, maximum protection is required. They can be used as coatings on all kind of pipelines varying from the mainline coating to the field joint coating. Compared with traditional systems like dual layer FBE and 3-layer polyolefin there are some benefits to be considered like easiness of repairs, amount of coats, application temperature and film thickness. The interior coating renders the pipe surface so much smoother that considerable savings can be realized in pump stations. Apart from the interior of the pipeline, the industry is faced with new challenges like higher operating temperatures of lines and an emphasis on product benefits in order to save money. Key words: liquid epoxy, liquid polyurethane, phenolic epoxy, pipeline, field joint coating, internal coating, corrosion control

Jan 1, 2006

By R. J. Durrheim

The seismicity of the Witwatersrand Basin and Bushveld Complex has been analysed, revealing significant differences in source and damage mechanisms. A comparison of mining taking place at similar depths and extraction ratios indicates that the seismic energy release rate is considerably lower in the Bushveld Complex. Technologies introduced in the past decade to manage the risk of rockbursting are reviewed and assessed. These include geophysical methods to detect hazardous structures ahead of mining, new mining layouts and support systems, and the mechanization of in-stope processes. Despite important differences in geology, in situ stress, mining layouts and methods, there are many opportunities for the reciprocal transfer of knowledge, experience and technology between the gold and platinum mining sectors to improve the management of the rockburst risk.

Jan 1, 2005

The reality of rising electrical power costs and the haunting prospect of decreasing electrical power availability are a threat to the growth of new projects and expansion programmes that could negatively affect the sustainability of mining operations. These threats require the adoption of effective power saving measures aimed at three principal objectives: the elimination of wastage, the reduction of power usage particularly during peak demand periods and, more importantly, improving the efficiency of high power-demand processes. It is reasonable to assume that the greatest impact will be achieved by concentrating on those processes that are large electrical power consumers. For Anglo Platinum operations, mine ventilation and, currently to a lesser extent, mine cooling are two continuous processes that fall in this category. It is estimated that these may consume fifteen to thirty-five per cent of the power delivered to the shaft head-depending on the shaft's design. Mine ventilation systems suffer from inherent, historical inefficiencies that lead to excessive power consumption. Air cooling systems are designed to be energy-wise in terms of modulating refrigeration plant operation to meet the underground requirements while maximizing use of 'free' cooling from surface conditions. Currently about ninety-five per cent of the refrigeration capacity used in Anglo Platinum mines is dedicated to surface bulk air coolers. The net thermal efficiency of these systems is compromised as mines expand in depth and on strike. Looking to the future, this practice will be complemented by more energy demanding underground cooling tactics requiring considerably higher electrical power consumption per unit ton produced. To counter this increase in power consumption, more energy-efficient systems and advantageous transient strategies such as thermal storage and the use of ice-on surface and possibly even underground-are being considered. This paper describes work currently undertaken and planned by Anglo Platinum operations to reduce power consumption by main fans during off-shift periods, the associated efforts currently introduced to reduce underground air leakage, the possibility of introducing more efficient auxiliary ventilation systems, the feasibility of thermal storage, and a brief look at energy recovery system as a means of countering the anticipated power demand associated with underground cooling. Keywords Mine ventilation, mine air cooling, energy efficiency, chilled service water, energy recovery, air wastage, fan selection.

Jan 1, 2011

By C. Musingwini

Traditionally, mineral reserves management at most underground mines in Zimbabwe focus on maintaining large mineral reserves so that the time between development and production is as long as possible. Historical data at Shabanie mine, a Zimbabwean sub-level caving underground mining operation, confirms this practice. However, the high cost of underground development means that the luxury of large buffer mineral reserves cannot be justified. Furthermore significant increases in the costs of production, exacerbated by the current unfavourable economic climate, make the wisdom of extending development workings well ahead of use questionable. Poor ground conditions at Shabanie mine, mean that some development ends have to be re-mined two or three times due to partial or complete closure between the time they are mined and the time they are utilized. In order to reduce the inordinately high support costs associated with closure of development ends a new ?just-in-time? (JIT) approach that provides development ends as and when they are needed, has been adopted. Accordingly a model to determine an appropriate ?just-in-time? rate of development has been created. The JIT development model indicated that the mine could reduce development rates from 330 m/month in 2001, to 160 m/month in 2002 and achieve savings of about 50% on annual support costs, but still assure customers of a long-term product supply. The mine accepted the model in November 2001 and began implementing it in 2002. Results of the implementation will be reviewed in 2003.

Jan 1, 2003

By W. Banda

Paper written on project work carried out in partial fulfilment of Phd. (Process Engineering) degree* The recovery of cobalt and copper from waste slag was studied in a plasma DC-arc furnace in reducing conditions. Three fluxes, CaO,CaF2, and TiO2, were investigated for their influence on selective recovery of cobalt into an iron-rich alloy. A further investigation on the influence of furnace power on the reduction of slag to recover cobalt to the alloy showed that a change in power setting had an unexpected effect on the recovery of metals to the alloy, in that selectivity of base metal recovery over iron recovery decreased at an increased power level. Keywords: DC-furnace, reduction, nonferrous, slags

Jan 1, 2004

By R. J. Davidson

Arguments are presented in favour of a new interpretation of the chemistry pertaining to the dissolution of gold, when this takes place in typical gold plant leach circuits where calcium is present in solution. It is suggested that under these conditions the standard chemistry, as it applies in the absence of calcium, is no longer valid. Thus the concept of very soluble sodium and aurocyanide ionic species in solution is replaced by the presence of weakly soluble calcium aurocyanide, which is a covalent coordination complex that is non-ionic. Supporting evidence for this is provided and the implications that the presence of calcium in gold plant circuits may have for operational efficiency are discussed. In particular, because of the formation of this weakly soluble calcium complex, the addition of lime to the leach circuit is questioned. Arguments for the use of a sodium hydroxide/sodium carbonate/sodium bicarbonate buffer solution as a means of controlling pH and of increasing ionic strength in a so-called ?soft? leach are presented. Such a lime-free system, besides benefiting the leaching of gold, would have many downstream benefits in existing CIP circuits. Furthermore, the direct electrowinning of gold from the leach now becomes potentially feasible.

Jan 1, 2007

By I. Matsunaga, K. Aoki, W. -j. Jung

Blasting is widely used in mining and basic construction because of its speed and economy to destroy the rocks. Blasting has the advantages of reduced excavation costs and shorted construction time when compared to the use of heavy machinery for excavation and cutting such as that with a tunnel boring machine. There are numerous problems with blasting, including the noise, vibration and fly rock. So it is necessary to accurately evaluate fracture mechanics of rocks on the dynamic loading condition to control the fracture process of the blasting. The tests using Hopkinson's effect for the dynamic condition using the precise detonators were performed for various strain rates on three different kinds of rocks. In the tests using Hopkinson's effect for the dynamic condition, the high-speed camera was used to observe the fracture process of the test sample rocks. As the results of experiments there was an increase in the tensile strength of rock with an increase in the strain rate for three kinds of rock on the dynamic loading. The tensile strength of rocks with high porosity on the water saturation condition was decreased on the both static and dynamic condition. It is clear that the strain rate and water saturation were influenced to the tensile strength of the rocks.

Jan 1, 2003

By B. J. Buys

Rock bolt integrity is a critical issue for the mining industry because of its influence on the safety of mining operations. Guided ultrasonic wave testing of the defects associated with resin-anchored rock bolts was investigated. Axisymmetrical and three-dimensional finite element models were built, one of a partially encapsulated bolt and the other of a bolt with a simulated local corrosion crack. Experimental bolts were then installed in a testing block and typical responses were compared to finite element models of different defect scenarios. Encouraging results were obtained for the smaller axisymmetrical and three-dimensional finite element models, as well as during the experimental investigation. It is recommended that software with energy-absorbing elements should be utilized to consider higher frequencies and longer bolts. Once the integrity of models such as these has been established, the models could in principle be used to train neural networks for use in commercial equipment to determine the integrity of the installed bolt.

Jan 1, 2009

Paper written on project work carried out in partial fulfilment of BSc Engineering (Mining) The aim of this project is to determine whether certain pillars occurring within the no. 1 shaft and no. 2 sub-shaft ground are feasible for extraction. The extraction of these pillars is essential in prolonging the life of Kloof Main Shaft as its VCR resource becomes depleted. Extraction of these pillars will require a combination of designs and factors, with rock mechanics and ventilation being the main considerations. Primarily for the pillar extraction, an initial production target of150 kg gold, mine able in one year from commencement of ?opening up? was set. The planned target has been exceeded and the feasible pillars identified are expected to yield an additional 1 390 kg of gold to the shaft?s production profile. However, not all the required ventilation designs have been completed to date, the reason being that at the time of the project, many of the pillar areas were inaccessible and thus ventilation conditions are unknown. This project is therefore an ongoing process and will require further design once all targeted pillar areas have been opened up. A preliminary costing analysis of the pillar mining was performed and it was found that all targeted pillars with the exception of 38?61 pillar are profitable.

Jan 1, 2005

By Mark Van Kleek

CONTENTS ?The Falcon C ?Data from a Production Trial ?Methodology ?Scale-up ?Test Results ?Circuit Configurations ?Conclusion

Jan 1, 2006

By I. Bhattacherya

Over the last three decades, the mining industry has been moving towards underground mechanized mining methods and the number of load haul dump (LHD) vehicles utilized has increased. The growth of mechanization and automation has benefited both workers and mining companies. However, due to the design constraints with LHD vehicles and the limitations of the operating environment, restrictions to operator visibility has contributed to a number of accidents, including fatal injuries. Past researchers have used the light filament technique to collect obscuration zones around mobile equipment and have produced 2D visibility charts (shadow diagrams) of this information. The light filament method involves manually collecting visibility data, which results in errors and is time consuming, requiring around three hours to complete. This research utilizes a MENSI GS100 laser scanner along with 3D modelling software (3Dipsos) to collect and process operator visibility profiles for underground mobile equipment. Results from this test work indicate that a laser scanner can be successfully used to rapidly collect this data and utilize this information for improved mobile equipment design from a visibility perspective. Nomenclature FERIC Forest Engineering Research Institute of Canada ISO International Organization for Standardization JACK Software for digital human modelling and ergonomics LHD Load haul dump vehicle LOS Line of sight MASHA Mines and Aggregates Safety and Health Association (based in Ontario, Canada) PVD Polar visibility diagram SAMMIE3D human modelling computer aided ergonomics design system WSIB Workplace Safety and Insurance Board

Jan 1, 2006

By G. Apsey

Eutectic freeze crystallization (EFC) is a novel technique for the recovery of pure salt and pure water from hypersaline waste brines. It is therefore a promising technology for the treatment of industrial waste waters. The impurities caused by crystallizing salt out of multi-component brines by EFC have not yet been investigated, however. To these ends, the selenium impurity found in sodium sulphate, produced from the waste brine of a platinum operation, was investigated. It was believed that the similarity between sulphate and selenate ions allowed isomorphous substitution of selenate ions into the sodium sulphate crystals, which was the likely cause of impurity uptake. It was found that the presence of sodium chloride in the industrial brine promotes the uptake of selenium, while ionic strength of the brine and mass deposition rate of sodium sulphate did not have a significant effect on the selenium uptake. Isomorphous substitution is predicted to be the most significant mechanism by which all impurities will be taken up when applying EFC to other industrial waste brines.

Jan 1, 2013

By R. Scott

This article describes and evaluates the establishment of Kuyasa Mining including the search for a suitable deposit, the ongoing lack of finance, and market constraints. Despite the dramatic initial growth and success of their Ikhwezi Colliery near Delmas, Mpumalanga, Kuyasa?s experiences offer some sobering arguments for significant changes to mineral rights ownership, the attitude of financial institutions and government policy if South Africa is to have a dynamic and successful junior and small-scale mining sector.

Jan 1, 1998

By G. Taylor

A 21st Century worker is one who works less with his physical power and more with mental ability. Such a worker is more skilled than a labourer and is consequently rewarded accordingly. A21st Century supervisor is one who ensures that workers are constantly supported so that they can maximize safety and productivity. A 21st Century manager is one who constantly searches for ways to maximize returns for the various stakeholders. Given the well-known constraints in narrow reef mining, all of the above is meaningless unless a mining method is found which provides conditions which support the 21st Century initiatives. [ ] The identified mining method is a continuous non-explosive stope breaking system using rocksplitter technology. Rocksplitting is defined as: The fragmentation of rock through high energy pulse wave transmission in a fluid-filled hole or hydro fracturing. Shotholes are effectively filled with a water-based geland 30 grams of explosive after which the hole is closed off with a ?rocksplitting gun?.

Jan 1, 2000

By S. J. Frank

Ferroalloy furnaces are well known to be extremely difficult to control from a metallurgical perspective. Mostly metallurgical control is still reactive in nature, causing a significant amount of reworking and product blending to achieve a proper product specification. Despite numerous efforts towards the model based control of primary smelting operations, actual metallurgical feed forward control seems to remain elusive. One of the key reasons in the failure to model these metallurgical reactors well, is that fundamentally orientated pyrometallurgists, statisticians, data miners and control engineers very often have diverging ideas how to model these systems. Furthermore, metallurgists have often come to rely on their ability to develop empirical regression models of furnace behaviour, as they have lost their faith in the ability of thermochemical and metallurgical engineering fundamentals to accurately predict the outcomes from furnaces. This paper shows how good thermochemical modelling can be combined with proper technological and systems analysis, as well as a proper inventory model, to predict the alloy and slag chemistry with good accuracy one tap into the future, at a time horizon of typically around 4 to 6 hours. For this modelling approach, a number of tools will be used, such as data reconciliation, thermodynamic modelling using Fact Sage®, inventory and heel estimation, neural networks and statistical data exploration. Furthermore, systems identification theory will be combined with the approaches given above to develop a truly dynamic predictive model. This paper seeks to demonstrate the need for a hybrid approach, which incorporates plant data and readily accessible thermodynamic data to develop a proper dynamic model.

Jan 1, 2004

By D. Yu. Paleev, O. Yu. Lukashov, A. Yu. Krainov, E. R. Shrager, I. M. Vasenin

The gas-dynamic method is presented of calculation of explosion-proof distances during an explosion of the methane-air mixture in mine working. On the basis of this method is modelled of shock waves interaction with explosion protective parachute partitions, obstructions and water barriers. Calculations have been carried out of attenuation factors of shock waves during their interaction with explosion protective structures, arranged near conjugation zones of mine workings. Possibilities have been analysed of suppression of intensity of shock waves and of propagation of shock waves control in mine working network of coal mines by installation of explosion protective structures.

Jan 1, 2003

By S. Sarac

In this study, graphical and mathematical methods used to determine operating points in single or multiple fan ventilation systems are summarized. The problem is mathematically formulized for parallel connected fans in which analytical solutions are not possible. For n number of parallel connected fans, a non-linear equation system that consists of n number of non-linear equation sis derived. The Newton-Raphson method, which is a numerical analysis method, is adapted to solve this non-linear equation system and the solution steps are given as an algorithm. A computer program based on this algorithm is written and its applicability is proved.

Jan 1, 2000

By X. Pan

Slag-metal equilibrium experiments were conducted at 1500ºC and1580ºC under 0.03 atm, 0.05 atm and 0.83 atm CO partial pressures using silica and Cr-oxide crucibles. The complex slags belonged toSiO2-CaO-Al2O3-MgO-FeOx-CrOxand the metal phase to the Cr-Fe-C-Si-(S) systems. The carbon saturation of the metal phase was avoided using oxide crucibles and thus the results are pertinent to ferrochromium refining slags and processes. From equilibrium data and thermodynamic calculations, the CrO /(CrO+Cr2O3) ratio in the slag was determined as 0.75, 0.80 and 0.86 under 0.83 atm and 0.05 atm of CO pressure at 1500ºC and 0.03 atm and CO pressure at1580ºC, respectively. The results clearly demonstrated that a higher chromium content of the metal results in higher Cr in the slag, and chromium in slag decreases with increasing SiO2. The results were also sensitive to the crucibles used as these oxide crucibles saturated the slag either with respect to SiO2or Cr-oxides. It was also demonstrated that the relative amount of CrO in the slag was higher when SiO2crucibles were used in accord with thermo-dynamic calculations. Iso-concentration curves for carbon and chromium of the metal phase in equilibrium with the slag were drawn on a pseudo ternary SiO2? (AI2O3+CaO+MgO) ?(Cr2O3+Fe2O3) diagram. The activity coefficients and activities of carbon and chromium of the metal phase were also calculated from the experimental data and available thermodynamics information and were plotted as iso-activity curves in the same pseudo ternary diagram. Keywords: chromium, slag, equilibrium

Jan 1, 2004

By J. Gummer, M. Williams, S. J. Hawksworth

A common problem encountered in British coal mines is bearing failure on conveyor system idler rollers, which on occasions has led to fires. The UK Mines Inspectorate initiated a study of such failures to assess the potential for ignition of explosive atmospheres. As part of this study HSL have developed a system to measure the temperatures generated within the bearings during controlled failure. Temperatures are measured using both infrared thermal imaging and contact thermometry. The work to date has shown that temperatures well in excess of the auto-ignition temperature of methane can occur.

Jan 1, 2003

The aim of this research was to study the absorption characteristics of thermally dried fine coal from South African collieries. After milling to ?150 µm and pressure filtration, the samples were subjected to either air drying or thermal drying at 150°C. The samples were then put into a climate box at 28°C and at three different relative humidity levels, namely 30, 60 and 94 per cent. It was found that the equilibrium moisture content of thermally dried coal at a specific relative humidity was lower than that of air dried coal. The relationship between the equilibrium moisture content and relative humidity is described by 1 ? RH = exp (-KTMen). There was no relationship between the volatile matter content and equilibrium moisture content, but there was an increase in the equilibrium moisture content of the coal with an increase in mineral content. The moisture uptake rate increased with an increase in temperature and a decrease in particle size. A model is discussed that fitted the experimental data and gave a good prediction for changes in the conditions. There was no evidence of greater moisture absorption by thermally dried coal. Keywords: Fine coal, thermal drying, drainage, South Africa, drying

Jan 1, 2002