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Council for 2003/2004 President T.R. Stacey President-elect F. M. G. Egerton Vice-presidents Senior W. H. van Niekerk Junior R.P.H. Willis Immediate Past-president S.J. Ramokgopa Honorary Treasurer J.A. Cruise

Jan 1, 2004

A physical modelling study has been carried out to simulate the slag-metal dispersion induced by a high-strength bottom gas injection. Water and kerosene were utilized to simulate metal and slag respectively. A water model of CLU (Creusot-Loire Uddeholm)vessel was used with three different nozzle orientations, namely, off-centre, triangular off-centre and centre. The gas flow rates changed from 0.00599 m3/s to 0.01081 m3/s. Height of heavy and light phases was kept fixed at 0.23 m and 0.02 m respectively. The dispersed phase hold-up was determined at various axial and radial distances, gas flow rates, and tuyere configurations. The observations revealed that at a fixed gas injection rate, as the vertical distance increased in the centerline, straight off-centre orientation resulted in greater dispersed phase hold-up values than those of the centre configuration and the triangular off-centre orientation. The dispersed phase hold-up was found to increase with gas injection rate and decreased with axial distance. The variation of the dispersed phase hold-up with the dimensionless axial distance and the gas injection rate was correlated by using the modified Froude number. The experimental values of the dispersed phase hold-up were found to be in reasonable agreement with the correlated values obtained from the modelling equations. The findings of the present study may be utilized in the ferroalloy refining vessels in terms of designing tuyere locations for optimum processing conditions.

Jan 1, 2004

By R. J. Durheim

Detailed investigations have been conducted into 21 rockbursts which caused damage to excavations in deep South African gold mines, in many instances resulting in the death or serious injury of workers. The objective of this study is to determine the principal factors controlling the severity and distribution of damage, so that strategies to reduce the hazard of rockbursts may be developed. It was found that the source mechanism is often controlled by the mine layout, and regional structures such as faults and dykes; while local rock conditions and support systems strongly influence the location and severity of damage. In the short term the most important lever for reducing the rockburst hazard is the effective implementation of existing rock engineering knowledge and technology.

Jan 1, 1998

By R. M. Whyte

The Konkola Deep Mining Project (KDMP) seeks to exploit the deep level potential of the Konkola Deeps orebody, producing high grade copper concentrates for treatment at the Nkana Smelter and Refinery. As an alternative to smelting, Konkola Copper Mines (KCM) has examined a processing route involving pressure leaching of the Konkola concentrates at Nchanga, with the leach liquor being treated by solvent extraction and electrowinning to produce high purity copper cathode. The solvent extraction circuit would be operated to achieve a high ?delta? copper, thereby providing a strong acid raffinate which can be used in the existing Tailings Leach Plant (TLP) to treat Nchanga oxide copper materials. The main focus of the hydrometallurgical option is to capitalize upon the synergy that exists between the treatment of sulphide copper concentrates (acid producing) and oxide copper ores (acid consuming). The paper discusses the key features of a comprehensive piloting campaign carried out at Anglo American Research Laboratories, which involved the co-treatment of Konkola copper concentrates and Chingola refractory ore in a fully integrated pilot plant circuit.

Jan 1, 2001

By Andrew Jones

This paper discusses the worldwide market and cost environments for the bulk ferroalloys namely manganese alloys (ferromanganese, silicomanganese), ferrosilicon and ferrochrome (high-carbon ferrochrome, charge chrome). Annual average market prices since 1993 are presented graphically and analysed, and the main supply and demand trends for manganese, ferrosilicon and ferrochrome are summarized. The paper shows carbon and stainless steel output data for 1995, 2000 and 2005, mainly to demonstrate the rising importance of China as a ferroalloys market. Developments in ferroalloys capacity worldwide from 1991 to 2007 are discussed (plant start-ups and closures, ownership changes). Finally, the paper examines developments in the main cost factors for the bulk ferroalloys, i.e., chrome and manganese ore, electricity, carbon reductants and labour. Note that data for 2006 are estimated based on information available in November 2006.

Jan 1, 2007

By S. Dalton

The use of coal for power generation is being questioned in many developed countries, as a result of ever-tightening environmental restrictions and concerns about the potential impact of CO2emissions on climate. Coal will continue to be the fuel of choice for new power plants for many developing countries with large percentages of the world?s population, because of its relatively low cost and broad availability. Even in many of the developed countries that are under pressure, coal will continue to fuel large percentages of power due to the installed base. Using coal efficiently and in an environmentally responsible manner will be a challenge for technology and politics in this new century, with the politics played out on the world stage. Coal use will vary in the next few decades, including short-term changes such as the use of more diverse coals and the increased use of efficient ultra-supercritical boilers to longer term ?refining? of coal to produce a range of energy and chemical outputs. This paper outlines EPRI?s Global Coal Initiative aimed at needed developments and demonstrations that support the long-term vision of environmentally sound and economical coal use for power generation, and discusses some of the forces that are driving this development effort.

Jan 1, 2001

By U. Sachse

This paper explores a systematic approach for mining decision-makers to use when faced with choosing which method to use for a specific rockpass length. The different excavation methods available in the broad South African mining industry are compared against a number of critical parameters, as applied to rockpasses of varying length. This approach is not meant as a definitive, prescriptive planning tool, but rather as a proposed approach to enable designers and planners to choose the best system to excavate their specific rockpasses

Jan 1, 2005

By R. Flatabø, K-E. Johansen, L. Hunsbedt, P. M. Cowx, J. A. Bustnes

Eramet and Tinfos are two producers of manganese alloys in Norway, which have worked hard for several decades to improve both the internal and external environment. Furnaces producing ferro- and silico- manganese alloys generate large amounts of off-gas that contains substantial amounts of dust, heavy metals and organic by-products. The dust is separated from the gas in venturi scrubbers by washing with water. The water is cleaned and recirculated, and the surplus water coming from moisture in the raw materials, is discharged to the adjacent fjords after further treatment. Emission figures show that the discharge of suspended solids, manganese, zinc and PAH (polycyclic aromatic hydrocarbons) have been reduced substantially over the last three decades as a result of process improvements and installation of state of the art environmental control measures. The two plants were the first world wide to install mercury cleaning of the off-gases from the furnaces. Mercury emission reduction has exceeded 90%. Concerning other environmental issues, such as utilisation of off-gases for energy recovery and chemical purposes, both plants have achieved good results. Major effort in the environmental work has come from the plants themselves, but other players like FFF, The Norwegian Ferroalloy Producers Research Association, and SFT, The Norwegian Pollution Control Authority, have contributed to the achieved results.

Jan 1, 2007

The paper deals with the results of dynamic tests carried out on a range of surface support liners consisting of combinations of mesh (various types), shotcrete, and wire rope lacing. The testing was carried out over the period 1993 to 1998. The dynamic testing method made use of drop weight impact loading of test samples which attempted to simulate realistic in situ conditions, and the range of loading imposed was equivalent to small to severe rockburst conditions. The results of the testing provide quantitative data, in the form of input energy, which is relevant for support design and for the choice of support types appropriate for situations in which significant mine-induced seismicity occurs or is expected to occur. In addition to the wire mesh and shotcrete liner systems tested, estimates of energy capacity are made for other, untested, systems.

Jan 1, 2001

By Y. Poornachandra Rao, P. C. Sudhakar, L. Malakondaiah

NBV commissioned a 27.6 MVA furnace in the year 2005. This paper explains: a)Furnace design features b)Furnace process control, Direct slag granulation c)Continuous casting, Waste heat recovery, Sintering d) Gas cleaning plant, Protection of Environment. Keywords: Furnace Equipment, SiMn Production, Casting, Heat Recovery and Low hood

Jan 1, 2007

By I. V. Lunkin, E. B. Rakishev, B. R. Rakishev

In mining the method of statistical tests is used by solving of problems, exposing to influence of random factors. Such problems are: rational selection of equipment set; co-ordination in time of different processes; interaction between some processes and kinds of works. Usually it is considered that Monte Carlo method proves its value in the first place in that problems, which allow theoretical-probabilistic description. Analysis of numerical solution of mining-economic problems shows that the method of statistical tests may be used successfully by solving of determinate problems, which are solved usually analytically or by the methods of mathematical programming. We are talking about the problems of optimal use of resources, expedient placing of equipment, effective use of investments, rational planning of stripping and extracting works, groups of mining enterprises and about different variants of transport problem. In the report possibility of the method use is studied at an example of typical technical-economic problems solving. By solving of these problems the variant of the method with uniform distribution of random quantity had been applied and built-in random number generator of visual modelling system VisSim had been used. By algorithms elaboration it seems very perspective to use combination of the Monte Carlo method with traditional methods of numerical solving of the problems (methods of linear, nonlinear and dynamic programming and so on). Keywords: method of statistical tests, mining-technical problems, diapason of random number sample, efficiency function and its extremum.

Jan 1, 2003

By S. Sun

Recent studies on the physico-chemical properties of molten slags and oxide solid solutions of interest is reviewed. The review covers redox and phase equilibria in slags, viscosity, diffusivity, electrical conductivity, kinetics of interfacial reactions between slags and CO-CO2, interfacial properties and phenomena. Some highlights from ongoing work on modelling phase diagrams, component activity, viscosity and electrical conductivity of multi-component slags will be presented and results compared with published experimental data on slags with or without suspended solid phases.

Jan 1, 2004

Instability in rockpasses at deep levels often initiates as a result of stress induced fracturing of the rock on the walls of the pass. This may then progress to a stage at which the geological structure of the rock mass becomes dominant and permits large joint-defined blocks and slabs to become unstable. In this paper, a technique is described in which jointing parameters and their variabilities?orientations, spacings and lengths?are taken into account in estimating the extent of failure that may develop around a typical unsupported deep level gold mine rockpass. The results of this prediction are compared with the results obtained from a review of pass performance in the gold mining industry.

Jan 1, 2005

By J. L. Deutsch

Block model estimates are commonly calculated by the well-established technique of kriging. The mathematics are well established, but implementation details require site-specific considerations. Checking and measuring the performance of the estimates is important to ensure the block model is suitable for its intended purpose. There are different criteria for long-term planning and short-term planning. The implementation of kriging should be checked with cross-validation and assessed for conditional bias and departure from theoretical optimality with the calculation of kriging efficiency. A new expression of kriging efficiency, which compares the kriging variance with the theoretically optimal kriging variance, is developed to aid in this assessment. The assessment tools presented here can be applied in a number of situations; however, ordinary kriging with a reasonably large search performs well in most cases.

Jan 1, 2014

By C. Erichsen, J. Werfling

ABSTRACT: A three-dimensional elastic constitutive model for rock salt is proposed. This stress strain law takes into account the three phases of creep (transient, steady state and accelerated creep), dilatancy, as well as the failure and post failure behaviour. The model was implemented into a finite element program and validated on the results of laboratory tests and in situ measurements. A good qualitative and quantitative agreement with the test and measurement results is achieved. A stability analysis for an underground repository in rock salt is presented. ZUSAMMENFASSUNG: Es wird ein dreidimensionales elastisch-viskoplastisches Stoffgesetz für Steinsalz vorgestellt. Mit diesem Stoffgesetz können die drei Kriechphasen (primäres, sekundäres und tertiäres Kriechen), Dilatanz sowie das Bruch- und Nachbruchverhalten erfaßt werden. Dieses Modell wurde in ein Rechenprogramm, das auf der Methode der finiten Elemente basiert, implementiert und an Ergebnissen von Laborversuchen und in-situ-Messungen validiert. Die Versuchs- und Meßergebnisse lassen sich mit diesem Stoffgesetz qualitativ und quantitativ gut nachvollziehen. Als Anwendungsbeispiel wird der Standsicherheitsnachweis für eine Untertagedeponie im Steinsalz erläutert. RÉSUMÉ: Cet article présente un modéle constitutive élastique/viscoplastique à trois dimensions pour sel gemme. Ce modéle comprend les trois stade de fluage (fluage primaire, secondaire et tertiaire), la dilatation, le comportement de défaillance et d'après défaillance. Il est implanté dans un programme de calcul aux éléments finis. À l'aide des essais laboratoire et des mésures in situ, le modéle a été validé. Les résultats des essais et des mesures concordent qualitatifs et quantitatifs aux résultats des calculations.

Jan 1, 2003

By M. A. van Nierop

The Discrete Element Method (DEM) is a model that is used to simulate the motion of the media in a grinding mill. The sum of the energy that is lost in inter-media and media-wall collisions represents the power drawn by the mill. The fact that the DEM predicts the power drawn by grinding mills over a large range of diameters has been used to show the validity of the DEM. However, the power drawn by a mill is a function only of the sum of forces of the load on the shell liners. A more accurate and detailed validation of the DEM would be to measure these forces as a function of angular position as the liner moves under the load, and to compare these measurements with predictions generated using the DEM. An experimental mill has been developed to reproduce exactly what the 2-dimensional DEM simulates. The 0,55 m diameter mill has a length of 0,023 m, which is fractionally larger than the diameter of the media used in the mill. One of the lifters in the mill has been instrumented so that the forces on the lifter can be measured as the mill rotates. The DEM simulation will be used to predict these forces. This will give experimental evidence of the validity of the DEM for modelling load behaviour in rotating grinding mills.

Jan 1, 1999

By Jeremy Bosman, Johan de Korte

Traditionally the feed to coal preparation plants was de-slimed at 0,5 mm. The +0,5 mm size fraction was processed via dense-medium cyclones and the -0,5 mm size fraction was beneficiated with froth flotation, water-only cyclones or spirals. With the introduction of large diameter cyclones, the aperture sizes of de-sliming screens have progressively increased to about 3 mm in the belief that the larger cyclones are not able to effectively beneficiate coal which has a particle size below the ?breakaway? size. The efficiency of separation in the large dense-medium cyclones is improved by presenting a coarser feed to the units. At the same time, the capacity of the de-sliming screens is increased due to the larger screen apertures and in effect, the throughput capacity of the dense-medium section is increased. The 3 x 0,5 mm size fraction, which was previously processed in the dense-medium cyclones, is now added to the fine coal size fraction and processed by water-only methods such as Teetered Bed Separators (TBS) and spirals. Whether this practice is the most economical way to process the 3 x 0,5 mm size fraction requires further thought since the best processing route for the 3 x 0,5 mm size fraction will depend on a number of factors, amongst which are: o The washability of the coal and the amount of near-density material o Processing efficiency o Specification of the required product o The price paid by the customer for the product o The cost of processing the coal Breakaway size The ?breakaway? size is defined as the particle size below which the Epm of the smaller particles starts to decrease significantly. Bosman1 provides an approximate breakaway size versus cyclone diameter (Figure 1). It should be kept in mind though that the Epm of the small particles is a function not only of the cyclone diameter but also of feed pressure, medium density, medium viscosity, particle shape and density, top-size of particles in the feed, etc.

Jan 1, 2006

By B. Samanta

A quality characteristic analysed through construction of the Shewhart control chart is required to be normally distributed. In mining applications, this assumption is often violated as many quality characteristics follow skewed or lognormal distribution. In this paper, two methods were investigated using a heuristic approach for setting up the control limits for a skewed population. Based on these approaches a Mode chart, and a Weighted Variance (WV) control charts were constructed. The performance of the proposed methods was compared with the normal based Shewhart method through a case study conducted in a surface mine supplying iron ore to a steel plant. A simulation study was also conducted to evaluate the effectiveness of the proposed methods over the Shewhart method. The study revealed that the Shewhart control charts generated more out of control alarms compared with the Mode and Weighted Variance control charts for a skewed population of Fe%. The simulation results also revealed that for extremely high skewed population, the WV control chart and Mode control chart provided higher probability of coverage than the Shewhart method; although the detection rate (probability of detection) of out of control condition for these methods was slightly reduced compared with Shewhart method.

Jan 1, 2004

By H. S. Marshall

Optimum Colliery is an opencast strip mine producing 18Mt of bituminous coal per annum for the export and inland markets as well as for domestic power generation at the Hendrina PowerStation. Coal is exposed by four 60m3 and four 11m3 walkingdraglines and transported from the open cuts to the processing plants by twelve 130 ton coal haulers. Overburden and interburden areas are drilled by nine 250mm-diameter rotary drill rigs. Until 1997 all surveying tasks were conducted by electronictotal stations requiring accurate control points from which line-of-sight XYZ readings could be taken. In 1997 a GPS system was introduced which consisted of a fixed base station and two rovers. The rovers were able to perform most of the survey tasks assigned to total stations. In addition, two overburden drills were equipped with blasthole drill navigation systems, which includes the drill monitoring and material (strata) recognitions system. The rest of the drilling fleet will also be equipped with GPS systems. Blasthole positions are designed in the office based on survey and geological/geophysical information and transmitted via radio link to an industrial PC on the drills. Together with GPS positional data, both the planned and actual drill positions are displayed on an LCD screen. This eliminates the need for surveyed hole positions to be staked before drilling, and for actual hole positions to be surveyed after drilling. As holes are drilled, performance and rock property data transmitted back to the office. Future applications will include GPS monitoring of dragline positions and pad elevations. GPS receivers on the draglines will utilize the existing base station to calculate and transmit XYZ co-ordinates. Another application will be locating of boreholes in the field prior to the pumping of specified explosive charges into the blastholes. Charging instructions for each blasthole will be loaded into the computer on the explosives truck which will be equipped with a GPS system for hole identification.

Jan 1, 1998

By N N/A

To the members of The South African Institute of Mining and Metallurgy We have audited the annual financial statements set out on pages 239 to 245. These financial statements are the responsibility of the Institute?s Council. Our responsibility is to express an opinion on these financial statements based on our audit. Scope We have conducted our audit in accordance with statements of South African Auditing Standards. These standards require that we plan and perform the audit to obtain reasonable assurance that the financial statements are free of material misstatement. An audit includes: ?examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements ?assessing the accounting principles used and significant estimates made by management ?evaluating the overall financial statement presentation. We believe that our audit provides a reasonable basis for our opinion. Audit opinion In our opinion, the financial statements fairly present, in all material respects, the financial position of the Institute at 30 June, 2000, and the results of its operations and cash flows for the year then ended in accordance with South African Statements of Generally Accepted Accounting Practice.

Jan 1, 2000