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By T. Celik, B. Genc, C. Musingwini

"This paper discusses a new methodology for defining and measuring mine planning software utilization in the South African gold mining sector within an evolving data-set framework. An initial data-set showing the mine planning software providers, their corresponding software solutions, as well as the software capabilities and information on the number of licences was collected and compiled in 2012 in an online database for software utilized in the South African mining industry. Details of the database development and implementation were published in the Journal of the Southern African Institute of Mining and Metallurgyin 2013. In 2014 the data-set was updated with additional and new information. Using the 2012 and 2014 timestamps, a methodology for estimating the software utilization was developed. In this methodology, the three variables of commodity, functionality, and time factor were used to define and measure the software utilization in order to ultimately inform decision-making strategies for optimal software utilization. Using six different functionalities, namely Geological Data Management, Geological Modelling and Resource Estimation, Design and Layout, Scheduling, Financial Valuation, and Optimization, utilization in the gold sector was measured. This paper presents the methodology employed for measuring the mine planning software utilization. The methodology is useful for stakeholders reviewing existing software combinations or intending to purchase new software in the near future and who want to estimate the comparative attractiveness of a certain software package. These stakeholders include mining companies, consulting companies, educational institutions, and software providers. The work presented in this paper is part of a PhD research study in the School of Mining Engineering at the University of the Witwatersrand."

Jan 1, 2015

By Z. W. Nkosi, M. Sephton, J. H. Potgieter

The exhaust system is a complex assembly of various components performing important tasks in harsh environments. Carbon steels have been used extensively in exhaust systems, but pressure for lower cost, increased fuel efficiency; lower hazardous emissions, weight savings and increased life expectancy have shifted the emphasis to stainless steels. In response to the growing consumption of stainless steels in automotive exhaust systems, the need to properly evaluate their corrosion resistance properties in order to ensure their appropriate use, has increased substantially. This paper evaluated the most common corrosion and oxidation tests developed that are used and applied it to four common stainless steels often employed in hot end exhaust components. In a summary considering the weight loss of an alloy, it general corrosion rate and pitting resistance under all the test conditions for hot end exhaust components, results indicate that 434 was by far the most corrosion resistant alloy, followed by 1.4509 and 321, and lastly 304 was the least corrosion resistant. In general, the ferritic stainless steels, especially 434, outperformed the austenitic ones under all the test conditions.

Jan 1, 2006

By V. Yahorava

Resin-in-pulp (RIP) technology has recently often been considered for the direct recovery of base metals and uranium from dense pulps. Implementation of RIP will eliminate the requirement for any solid-liquid separation downstream of leaching and has the potential to combine the recovery and purification steps, hence reducing both capital and operating costs. The recovery of the valuable metal is expected to be higher when RIP is used, especially where the leached solids are difficult to settle or filter, and to wash. The main concerns about the use of RIP for uranium recovery from dense pulps are the impact of silica on the resin?s metallurgical performance and the operating costs that would be associated with resin loss. Although a number of resin manufacturers have been developing much improved RIP-grade resins, it is critical that the most cost-effective resin be selected. Mintek currently is doing a significant amount of work on silica fouling of RIP-grade strong-base resins in acidic leach liquors and the effect it has on the performance of the resin, including its durability. This paper describes the results of the test work done on silica fouling and its impact on plant design input data. Resin durability test work was done using various laboratory techniques, but durability was also evaluated on a relatively large scale using actual pumps, screens, and mechanical agitation. Based on the results generated, a preliminary economical evaluation was done to estimate the impact of resin loss on the overall economic viability of a specific application. Keywords: resin-in-pulp, silica fouling, resin loss, equilibrium, kinetics, elution, durability, mechanical strength, resistance to attrition.

Jan 1, 2009

By W. D. Northrop

This paper gives an account of the development of a technique whereby the vertical limits of geological horizons may be identified by the use of vertical variograms on the mineral of economic interest. This information may supplement or guide the correct subdivision of the individual horizons into meaning full data sets by diligent geological observation. This process then improves the quality of the variance modelling of the gold distribution in the plane of the individual layers and therefore enables better estimates to be made into the grids or blocks of the mine model. The technique is explained by an account of the development work, which was performed, on duplicate superimposed reef horizons in the Kimberley formations. The paper then shows how the correct approach was developed to evaluate the mineralized layers in a multiple stacked conglomerate layer sequence in the Elsburg reefs of the Witwatersrand Rand System at the Target deposit. The method of categorization of resources according to confidence in the estimate is also explained. The feasibility processes carried out on the three-dimensional model, in accordance with the SAMREC code are also described. An example of the development of a reconciliation process utilizing chip sampling is also explained.

Jan 1, 2003

By R. M. Goktan

Rock brittleness plays an important role in the cutting action of picks on rock surfaces. It controls the ease with which cracks can propagate through the rocks. Although rock brittleness is known as a property that contributes to the cuttability of rocks, despite considerable research effort, there is still much uncertainty about the relation between rock brittleness and rock cutting efficiency. This fact can be attributed to the lack of a universally accepted brittleness concept and a brittleness measurement method. The existing publications of some researchers have, in a way, tended to confuse the understanding of brittleness in the general field of rock excavation where it is expected that the energy consumption of cutting should decrease with increasing brittleness of rock, other conditions being equal. However, this sometimes conflicts with the brittleness concept commonly used in rock mechanics, where the more brittle the rock the higher its mechanical strength. The ratio of rock compressive strength to tensile strength is considered by many authors to give a valuable brittleness index for drag pick operations. Hence, in this contribution the ratio of uniaxial compressive strength to tensile strength BI is considered as an index of rock brittleness, and a new methodology is proposed for its use in rock cutting efficiency analyses of drag tool operations. Validation of the suggested approach is supported by available experimental data in the literature. Contrary to the conclusions reached previously by other authors, it is shown that an increase in rock brittleness is accompanied by an increase in the cutting efficiency, other conditions being equal. Keywords: brittleness index, rock brittleness, cutting efficiency, specific energy, rock excavation.

Jan 1, 2005

By C. Scheffer

This paper describes a model that can simulate the behaviour of a pneumatic intensifier that is generally referred to as an ?air pump? (AP). The AP is used in many South African underground mines, and utilizes compressed air with pressures between 0.3?0.6 MPa to pump water up to pressures of 12?18 MPa. The high pressure water is used in numerous underground mines to pressurize props and roof bolts that act as safety and roof support devices. The simulation model reproduces the intensifier's operation under various conditions and therefore can be used to investigate the AP's sensitivity towards environmental conditions, design parameters (such as spring stiffness, plunger diameter, nozzle diameter etc.) and operating conditions. Model validation by comparison with laboratory experiments showed good correlation. The model can subsequently be used to investigate design changes aimed at improving the AP's performance and reliability over a wider range of operating conditions.

Jan 1, 2005

By Rajendra Singh

Underground depillaring of contiguous coal seams/sections is a difficult problem, which becomes even more complex if the interburden/parting between them is thin. Conventionally, the depillaring with caving of contiguous seams/sections is done in descending order. However, if the parting is thin, the influence of the top sections/seams working over the standing pillars of bottom the sections/seams becomes extremely important for the safety and optimal exploitation of coal. Field investigations were carried out at Nowrozabad East mine where superimposed pillars of the Johilla top section were depillared above the developed pillars of the Johilla bottom section with a 3 m thick parting between the two sections. The competency of the 3 m thick parting (which consists of alternate layers of shale, sandstone and shaly sandstone) was improved by reinforcement (underpinning). The strata control investigations did not show any considerable instability problem of the 3 m thick reinforced parting and pillars of the bottom section due to top section depillaring. On the basis of this field investigation and a laboratory study on simulated models, simultaneous extraction of both the sections, along with reinforcement of the parting, was suggested for the geomining conditions of the Johilla top and bottom sections. Adopting the suggested simultaneous depillaring process, two sub panels of Johilla top and bottom sections have successfully been extracted without any strata control problem. This paper presents this case study along with the results of the strata monitoring conducted to evaluate performance of the underground structures during the field trial.

Jan 1, 2004

By A. W. Bester

Paper written on project work carried out in partial fulfilment of B. Eng. (Mining Eng.) Cullinan Diamond Mine currently handles 3.2 million tons of run of ore per annum. This is done by means of an underground train system, which is located at 763 metre level. Four trains, one in each quarter of the pipe, collect ore from passes and transport it to centrally located tips in the north and south of the pipe. The ore is then split into coarse and fine fractions. The coarse fraction proceeds to the primary crushers in the north and south. Historically, mining has been performed in such a manner that an equal amount of ore has reported to each quarter of the pipe. However, the tonnage profile of the mine will change such that the ore will no longer be split equally. For approximately five years the majority of ore will report to the east and thereafter most of the ore will report to the western portion of the mine. This will continue for the remainder of the current infrastructure level?s operational life. Coupled with this is the fact that the mine is aiming to increase its annual production to 3.8 million tons. The result is that the current ground handling system cannot accommodate the additional tons and therefore alternative ground handling options have been investigated. The continued existence of Cullinan Diamond Mine relies on finding a system that can economically handle the additional tonnage. Three options were investigated. Firstly, a train option, which would be an upgrade of the current system, was investigated. Two truck options were also investigated, the first of which was a conventional truck option. The second truck option was more interesting and involved an unfamiliar Combi truck system. The truck options were investigated primarily due to the fact that the block height of the BA West (a new production block) can be increased by 15 meters if a truck option is decided upon. This would create a significant increase in revenue for the BA West project. Each of the options was assessed in terms of its physical and financial feasibility. In terms of the physical constraints, it was found that all three systems could work. Detailed financial analysis indicated that either of the two truck options would be a suitable solution. However, due to the limited information regarding the Combi truck option, it should be further investigated. This applies particularly to the actual running and maintenance costs for the equipment.

Jan 1, 2005

By L. Andrews

Keywords: mineralogy, phase-chemical, chemical-looping combustion, XRD, SEM, EDS, QEMSCAN, PGM, slag, matte, ilmenite Mineralogy, traditionally associated with concentrator studies, is being increasingly applied to problems in pyrometallurgy. Such investigations commonly make use of a number of techniques, and the results are combined for a meaningful interpretation, which can lead to a successful solution. Mineralogical applications are described from pyrometallurgical operations. Examples are given of studies and investigations involving mineralogy in chemical-looping combustion, feed monitoring to platinum-smelting furnaces, and losses to slag in base metal and platinum smelting.

Jan 1, 2011

By W. Carter, P. Chaubal, K. Spaleck, M. Schoeman, J. Bobek, W. Seegers

Keywords: Pyrometallurgy, steel, hearth, blast furnace The Mittal Steel Company operates about 36 blast furnaces on four continents. Furnaces range from 1100 m3 to 4800 m3 inner volume. The focus of the group is to push for increasing productivity and increasing campaign life. This has been especially challenging, as many of these furnaces were not equipped for long campaigns during their prior rebuilds. Monitoring and operating practices have to be modified to match the new philosophy. Mid-campaign hearth repair strategies and hearth design philosophies have had to be reconsidered. The paper describes experiences with the current hearth designs and measures taken for hearth life extension. Additionally, the philosophy of recent hearth re-designs is discussed.

Jan 1, 2006

Utilizing a very large database from a mined-out area on a South African gold mine, the relative efficacy of a method to mitigate the smoothing effect introduced by the algorithmic constraints imposed by kriging was investigated. Smoothing effects arising from limited data availability are differentiated from the smoothing arising from the application of estimation algorithms. Very little can be done to ameliorate smoothing of estimates because of too little data, barring additional drilling or sampling. However, the smoothing effects resulting from the kriging process are shown to be mitigated by use of an alternative algorithm. The primary criterion in the development of the new algorithm was to avoid re-introducing conditional bias. This paper examines firstly the smoothing effects introduced into estimates via the kriging covariance matrix, secondly the process for ameliorating the smoothing effect, and finally it uses a case study to demonstrate the effectiveness of the new algorithm on a very large database. The database was used to introduce a 60 m by 60 m drilling pattern which in turn was used to model the semi-variogram and produce 30 m by 30 m kriged block estimates. The follow-up database was then re-introduced (roughly 5 m by 5 m grid spacing) and averaged into 30 m by 30 m blocks to provide a direct comparison with the initial estimates. In this way the extent of smoothing and accuracy of the estimates before and after the corrections was tested.

Jan 1, 2014

By K. G. Matshika

"Nickel electroplating from sulphate electrolyte is an efficient process. To achieve good quality cathode, however, parameters such as temperature, nickel concentration, pH, electrode alignment, electrolyte flowrate and additives must be optimised, because these affect cathode morphology and current efficiency. It is also important to control the clarity and contamination of the electrolyte, as these have a considerable effect on the quality of the cathode surface. Delamination, surface roughness and pitting on the cathode surface can be caused by incorporation of solid particles or impurities form the electrolyte. Three types of solid particles were investigated: cuprous selenide, barium/ lead sulphate (co-precipitated) and ferric hydroxide. These particles can be found in industrial electrolytes, especially if there is a problem with the filtration step or contaminants have reacted to form insoluble particles. A rotating cylinder Hull cell was used for this investigation. It is found that the effects on morphology depend on the type of solid, concentration, particle size, current density and electrolyte flowrate. Cuprous selenide is the most detrimental, especially at higher concentrations, higher current densities and low flowrates. Increased rotational speed offers a uniform sheet of fine gas bubbles across the surface of the cathode which reduces the thickness of the diffusion layer of liquid adjacent to the cathode and increases the rate of mass transport to the cathode from the bulk liquid. INTRODUCTION Electrowinning operations are important when recovering associated by-products of nickel production, such as copper, cobalt and zinc, from pressure leach solutions. The base metal mineralization associated with platinum-group metal (PGM) production yields significant quantities of copper and nickel as by-products. The base metal refinery is vital in PGM processing as it increases the PGM concentration from mined ore by a factor of 400, in comparison with concentration by flotation (20 times) and pyrometallurgical processing (20 times) (Crundwell et al., 2011). Anglo American Platinum Ltd produces nickel cathodes by electrowinning and purges sodium from the base metal refinery in the form of sodium sulphate at the Rustenburg Base Metals Refinery (RBMR), as shown in Figure 1. This is the Sherritt acid leach process used in most base metal refineries to ensure no loss of PGMs and shows the subsequent purification steps for copper and nickel. Other refineries in Zimbabwe, such as Bindura and Empress, use the Outokumpu leach process (Pavlides, 2001)."

Jan 1, 2015

By T. J. Otto, G. C. Lindeque

Productivity is improved by increasing the ratio of output to input. In an operating open-pit mine, improving the productivity of heavy mining equipment (HME) enables the unit cost of production to be reduced. To optimize HME productivity, the Kolomela open-pit iron ore mine transitioned to an enhanced short-term mine planning (STMP) process that supports the application of a manufacturing-type operating model. At the core of the enhanced STMP process is a focus on integration across the open-pit mining value chain. The interdependencies between mining activities are highlighted and emphasized, thus ensuring that mining activities are synchronized. The improvements related to HME productivity were monitored from 2019 to 2020. The utilization of mining area in the Leeuwfontein pit improved from 71% to 90%, and the blasting frequency reduced by 14% while the average blast size increased by 17%. The distance travelled during shovel relocations between mining phases reduced by 16%, and the lost time associated with drills relocating reduced by 53%. These productivity improvements resulted in an 11% increase in the loading rate of the main waste shovel at Kolomela from 0.9 Mt/month in 2019 to 1.0 Mt/month in 2020. The enhanced STMP process can be adapted to other open-pit mining operations.

Nov 1, 2021

By S. M. Spottiswoode

The aim of the hybrid location method is to improve seismic event locations by reducing the effects of errors in the wave velocity of ray paths between each event and each recording site. We report on further enhancements made to the hybrid location algorithm, which is based on the double-difference method developed by Spottiswoode and Milev1and Waldhauser and Ellsworth2. The term ?double-difference? refers to the residuals between the observed and theoretical travel-time differences and are obtained using either picked arrival times or various measures of time differences obtained from waveform pairs. These residuals are minimized for pairs of earthquakes at each station while linking together all observed event-station pairs. An important enhancement is that the double-difference term uses the median arrival time residuals to reduce the effect of outliers on the system of equations. In addition, the hybrid locations are further constrained by considering events of known locations, in this case along lines of development blasts. We relocated some 20 000 previously located seismic events in the Driefontein 5E area; 5 800 of these events were considered to have been development blasts and we constrained their locations to lie on the straight lines joining about 2 150 survey pegs from the mine?s database. Relocated events were shown to distribute more closely around advancing faces than had been the case before relocation. Wave velocities from the development blasts show evidence of anisotropy.

Jan 1, 2005

Ferrochrome is the major chromium source for stainless steel production, and submerged-arc furnaces (SAF) are most commonly utilised to smelt chromite ores into ferrochrome by using suitable carbonaceous reductants such as coke. Because of the complexity of feed structure and electrical-thermal-chemical interactions, there exist large gradients and wide distributions of temperature, mineralogy and other process variables in the furnace. This leads to various zones in the furnace, and different reduction mechanisms. Control of the furnace is thus often difficult due to the complicated physical and chemical situations in the furnace. The temperature profile in the submerged arc furnace has a great influence on the reduction rate and the production efficiency. Therefore, the energy generation through electrical arcs submerged in the solid feed and its distribution within the packed bed play an important role. In the present paper, an overall process model is illustrated to simulate inter-linked transport processes of fluid flow, heat transfer and reduction kinetics within the submerged arc furnace. The application of reaction kinetic data to simulate the chromite pellet/lumpy ore reduction with CO gas is presented and further adjusted to provide a submodel for a flow and heat transfer simulation for the packed bed by using computational fluid dynamics (CFD) technique. The comprehensive process model is aimed to simulate materials and gas flow, temperature and energy distribution throughout the furnace system. A preliminary model for gas flow and temperature distribution for the upper part of a 20 MW furnace (the packed bed) for high carbon ferrochrome production has been developed under simplified conditions. The integration of the reaction kinetic model into process simulation, and the future vision for a more comprehensive process modelling are discussed. It is expected that better understanding of the furnace insights through process modelling will help process optimisation and furnace control.

Jan 1, 2004

By I. Mc Dougall

Finite element models were generated of two submerged arc furnaces of different geometries. A 48MW circular furnace and a 68MW 6-in-line rectangular furnace were studied. The electrodes, raw material, slag and molten metal were included in the model. ANSYS/Multiphysics was used to predict the current density distribution in the electrodes, raw material, slag and molten metal as a result of the three phase AC current. The effect of the electrode immersion on the current path was studied. The ?proximity effect? caused a pronounced asymmetry in the electrode currents in the circular furnace, whilst the electrode currents in the rectangular furnace exhibited radial symmetry. The current distribution in the melt in both furnaces indicated that the bulk of the current flows between phases. The current density is greatest between electrodes. Results were compared to qualitatively similar published work, operating experience and results of furnace dig-outs.

Jan 1, 2007

By Gift Chisakuta, Bravo Mbao, Nils Schwarz, Angus Feather, Anthony Mukutuma

Bwana Mkubwa is a 50 000 tons per annum copper cathode producer, owned by First Quantum Minerals and located in Ndola, on the Zambian Copperbelt. The Bwana Mkubwa solvent-extraction circuit was started up in 1997. In 2002, the plant began treating ore from First Quantum?s Lonshi mine located in the Democratic Republic of Congo. The Lonshi ore is exceptionally fine and the amount of solids in the feed solution reporting to the solvent-extraction feed solution increased dramatically. Initially, crud was filtered in a filter press, but this rapidly blinded and seldom produced anything better than a wet sludge containing large quantities of organic. In December 2003 the decision was made to install a Flottweg Z4E-3/441 Tricanter® centrifuge to recover organic from the crud. The installation was completed in June 2004 and has since led to significant improvements in plant operability and savings in organic consumption.

Jan 1, 2007

By P. Bracher

Most efforts to mechanize low seam (narrow reef) mining of platinum ore are presently based on board-and-pillar methods with1.6?1.8 m in reef excavation. This paper attempts to substantiate the benefits of low profile mining: primarily improved head grade with resulting reduced tailings losses. Board-and-pillar equipment supplied by DBT, facilitating1.1?1.2m mining height has been in operation in an Anglo Platinum mine since September 2001. Major aspects of the equipment, battery scoops (LHDs) and rotary bolting rigs, are described and presently achieved results reported. The medium term industry goal is rock breaking without the use of explosives. An outline of present DBT developments is presented.

Jan 1, 2003

By M. G. Maruma

The effect of the amount of cold reduction and annealing temperature on the evolution of the texture of AISI 441 steel is reported. The steel was cold rolled by 62%, 78%, and 82%, followed by isothermal annealing of each sample at 900°C, 950°C, and 1025°C for 3 minutes. The crystallographic texture was determined by Phillips X?Pert PROMPD texture diffractrometer. Microstructures were characterized using optical microscopy and scanning electron microscopy (SEM).The results show that sample that received 78% cold reduction and annealing at 1025°C presented the highest Rm-value and lowest ?R-value, which would enhance its deep-drawing capability. In addition, this sample showed the highest intensity of shifted ?-fibre, notably {554}<225> and {334}<483>. It can therefore be concluded that the ?-fibre, which favours deep drawing, is optimal after 78% cold reduction and annealing at 1025°C.

Jan 1, 2013

By L. Mabiza

Keywords: Pyrometallurgy, circular furnace, PGM, platinum, Peirce-Smith converter, Zimbabwe The Zimplats Smelter, located on the northern part of the Great Dyke, at the Selous Metallurgical Complex, is the only PGM smelter in Zimbabwe. Zimplats? operations currently consist of the Ngezi Platinum Mine, which is a 1.5 Mt/a open-cast and 0.7 Mt/a underground mine, and a Concentrator and Smelter to which ore is transported 80 km by road. The final converter matte product is transported to Impala Refining Services in South Africa for refining and marketing. The Zimplats Smelter operations consist of a concentrate filtration plant, a Drytech flash dryer, a modified Elkem / Hatch 13.5 MVA circular furnace, two 10? x 15? Peirce-Smith converters, and a matte granulation plant. The Zimplats smelter uses a three-field electrostatic precipitator, supplied by ELB-Brandt, for removal of particulates in the gas streams from both the converter and furnace. Construction of the smelter commenced in 1995, under the BHP / Delta Gold of Australia joint venture. The furnace was lined mid-1996, and smelting operations commenced in 1997. Due to design challenges, the Elkem furnace was modified by Hatch in 1998, and the smelter had not reached full capacity when operations were suspended in 1999. Re-commissioning took place in January 2002.

Jan 1, 2006