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By M. S. Shishvan, J. Sattarvand, R. S. H. Meij

Navigating miners during an evacuation using a smart evacuation technology can significantly decrease the evacuation time of an underground mine in case of an emergency. This paper presents a mathematical programming model to calculate the most efficient escape path for each miner as a critical component of the smart evacuation technology. In this model, the total evacuation distance of the crew is minimised and scenarios with blocked pathways, and stamina categories for the miners are simulated. It was found that all the tested scenarios are technically feasible. Using the feature that filters out blocked pathways has no downsides, as safer routes are calculated, and there is no penalty in the computation time. The paper also discusses the social and technical issues that need to be overcome before the algorithm can be implemented as an actual escape solution.

Sep 1, 2021

By M. Smit, N. C. J. Dempers, S. Lunkov, C. Saguru, J. Nel

A common method for the recovery of copper is by heap leaching, solvent extraction, and electrowinning. During solvent extraction, the solution is continuously recycled, and it is necessary to remove impurities that build up in the raffinate. For the process investigated in this study, the main impurities include Fe, Co, As, and Zn. Recovery of these impurities can provide economic benefits while adhering to legal and environmental constraints. Such impurities are often removed by precipitation utilizing a neutralizing agent, such as limestone or lime, but it is also possible to remove the impurities by sulfide precipitation. Sodium hydrosulfide (NaHS) is used to selectively precipitate copper, arsenic, and zinc from a solvent-extraction raffinate stream. The resulting sulfide precipitate is bagged and sent to a roaster for further treatment. The design of the sulfide precipitation was investigated to optimize the processing conditions (including temperature, pressure, and residence time), the materials of construction, and the toxicity and explosive nature of the hydrogen sulfide gas produced

Jan 1, 2023

By R. W. O. Kersten

"The aim was to investigate stable pillar design procedures currently in use on chrome and platinum mines, subject them to a critical appraisal, and review some of the alternatives proposed in the literature. It is concluded that these pillar design methodologies suffer from drawbacks that can be detrimental to the mining industry and that an improvement is essential.It was decided that the increased availability of analytical models and failure criteria could be exploited to update the empirical to an analytical/empirical method. The proposed methodology adopted FLAC2D simulations using the Hoek-Brown failure criterion to calculate full stress-deformation curves for typical pillars. The mine stiffness concept was introduced to determine the pillar load, integrating the influence of the pillar and strata stiffness and mining geometry.The proposed methodology was calibrated by comparing experimental and predicted deformations and failure depth of pillars in one hard-rock mine. The conclusion was that the methodology is an improvement over the one currently in use. An improved factor of safety is given by the intersection point of curves for the stiffness of the system and the pillar strength. IntroductionThe paper describes part of the findings of a PhD thesis (Kersten, 2016) on an alternative stable pillar design methodology. This publication contains sufficient information to implement the method for further interpretation and testing. A detailed comparison of measured and predicted data is dealt with in the thesis, and the results show that there is promise in the methodology.The design of stable pillars in mining is of fundamental importance, not only in the Bushveld Complex mines but throughout the mining industry. Wherever mining occurs, pillars are formed at some stage and it is essential to predict their behaviour, i.e. whether they will burst, yield, or remain stable. Although of crucial importance, pillar design still suffers from major shortcomings and weaknesses."

May 1, 2019

By K. C. Corin, M. S. Manono

The mining and mineral concentration of Cu-Ni-PGM sulfide ores in South Africa occurs in semiarid regions. The scarcity and availability of water resources in these regions has become one of the biggest challenges facing mineral concentrators.S Owing to this challenge, concentrators have to find ways through which they can manage and control their water usage. Recycling and re-use of process water in mineral concentrators has therefore become common practice. This practice is beneficial in that it reduces reliance on municipal water, harnesses compliance to stringent environmental regulations on water usage, and it also offers a better response to the Sustainable Development Goals. This could however be somewhat concerning to the operator as recirculated water often has higher concentrations of ions compared to fresh or potable water. The unintended change in the process water quality may potentially affect critical aspects of flotation such as the stability of the froth. This has led to the need to find those process water ions that have the greatest impact on froth stability. Thus, this paper investigates the effect of various ions common in process water of a typical Cu-Ni-PGM concentrator on froth stability. Bubble size, water recoveries, foam height, and dynamic froth stability in both twophase and three-phase flotation systems are used as proxies for froth stability. Findings of this study are deemed crucial towards the development of a process water management protocol in sulfidic Cu-Ni- PGM ore concentrators. Keywords: Bubble diameter, electrolytes, flotation, froth stability, water quality

Jan 1, 2020

By M. Mathey

The application of the Monte Carlo technique to production planning and everyday economic decisionmaking in mine production management is demonstrated. The logic is detailed using an example of underground production with continuous miners (CMs) and truck haulage. It is argued that availability of equipment and personnel are the predominant variables influencing mine output and productivity and that those availabilities may be well represented by binomial probability distributions. The probabilistic model is implemented in a standard Excel® spreadsheet with Palisade’s @Risk add-on to facilitate simulations. Starting from model calibration against data obtained from a mine’s annual reports, some general interdependencies of availability, utilization, productivity, and costs of production processes are outlined. Finally, several possible options and their consequences as regards production improvements are explored.

Dec 13, 2022

By Jonty Tshipa

The Mine Site Technologies, MST BlastPED ST is a wireless/remote blasting system used in more than sixty (60) mines (including two mines in Zambia and one in Tanzania) since its release in 2002. The system consists of a controller and signal tube initiator which communicate wirelessly using spread spectrum frequency. This technique ensures a robust and secure wireless link between the controller and the signal tube initiator. The configuration of the system ensures ease of use with all the instructions for initiating the blast printed on the equipment. This means little or no formal training is required to use the system. The technology enables you to have your blasting point at a distance of up to 4 km, line of sight (LOS), as opposed to the traditional distance of 500m from the blast. This ensures the blast takes place from a safer and secure location. The paper and presentation will provide the audience with the benefit of many years of international mining know-how in this technology as well as more recent local African experiences. There will be references to demonstration blasts done in South Africa, current users in Africa and elsewhere. Practical Return on Investment (ROI) calculations and references to safe blasting practice will also be included.

Jan 1, 2008

By M. Stachowiak, M. Nowicki, K. Walas, A. Skoczylas, P. Stefaniak

In this paper the authors present a walking robot dedicated to the inspection of a belt conveyor’s transportation system in an underground mine. The developed robot can independently diagnose all of the key rotating elements of the belt conveyor (pulleys, bearings, drums, gears, engines) based on vibration and acoustic signals as well as typical RGB (red, green, blue) and thermal images. The article presents key diagnostic procedures applied to real industrial data obtained during robot testing.The work was developed as part of the ‘THING–subTerranean Haptic INvestiGator’ project. The authors presented the main assumptions of the research methodology developed for the needs of technical diagnostics of conveyor elements typical of inspection work performed by mining staff. Based on industrial data, the use of algorithms for elements such as rollers, drive stations, and the conveyor belt were shown. The main assumption of the research is to develop a robot adapted to the conditions of a deep mine, capable of carrying out an autonomous inspection of mining infrastructure. The conducted tests and the developed fault detection algorithms were aimed at preparing the robot for underground tests in the operating conditions of the mine.

Sep 1, 2021

By S. Stuurman

Inorganic acids such as sulphuric acid have found use together with certain reducing agents in leaching of copper-cobalt oxide ores. These reagents are not ideal due to the adverse effect the inorganic acids generally have on the environment and the high costs of the reducing agents. In this study a copper-cobalt oxide ore from the Central African Copperbelt was leached in two different environments; sulphuric acid in conjunction with hydrogen peroxide as a reducing agent and tartaric acid. The effects of acid concentration, reducing agent concentration, and temperature were independently determined for both leaching environments. The sulphuric acid concentration was varied between 0.4 M and 1.2 M and the concentration of hydrogen peroxide between 4.0 M and 6.5 M, while the tartaric acid concentration was varied between 0.15 M and 0.35 M. The temperature was varied between 20°C and 50°C. The results showed that the extraction of both copper and cobalt increased with sulphuric acid concentration, reaching a peak at approximately 0.8 M and then decreasing at higher acid concentrations. A similar increase and decrease in metal extraction was observed when the reducing agent was increased. In leaching with tartaric acid, the extraction of cobalt was much higher than that of copper, although extraction of both metals increased with acid concentration. Additions of small amounts of hydrogen peroxide were found to increase cobalt extraction in tartaric acid but had a minimal effect on copper. An increase in the solution temperature had a significant effect in the organic acid environment, with the effect on cobalt extraction being much more pronounced than on copper.

Jan 1, 2014

By K. E. H. K. Ishak, S. R. M. Zan

Cement production requires significant energy, and entails high costs and CO2 emissions. This is because the clinker requires very fine grinding. Grinding aids can improve production and fineness and decrease energy consumption by reducing the agglomeration of particles and protecting the balls and liners in the mill. In this study we compare the effects of three different grinding aids on clinker grinding using a ball mill. A commercial grinding additive, triethanolamine (TEA), and two industrial grinding aids (GAA079 and GAA088) were compared by ball milling tests, with additions of 0.05, 0.25, 0.50 and 1.00 wt%. The industrial grinding aids were characterized using gas chromatography-mass spectrometry (GC-MS). Particle size and morphological analyses were performed using SEM and XRD. The best results were obtained with 0.25% GAA088, which has a higher active component of diethanolamine isopropanolamine (DEIPA) than TEA. The unique combination of TEA and DEIPA in GAA088 enhances grinding efficiency and significantly improves the particle size distribution compared to TEA alone.. The grinding aids produced smooth rounded particles, which have a smaller specific surface area, enhancing the quality of the cement. XRD showed no significant structural distortion with or without grinding aids, and it was also found that the grinding aids helped decrease ball coating during grinding. The use of grinding aids can significantly improve clinker production and fineness while decreasing energy consumption, which can help reduce the costs and CO2 emissions associated with cement production.

Sep 6, 2023

By J. S. Contreras, E. Córdova, I. Gottreux, A. Anani, A. Ferrada

Cave mining is an underground mass mining technique. The largest projects, which are known as ‘super caves’, produce hundreds of thousands of tons of ore per day, which involves large footprints with considerable column height, and have a life of mine of over 20-40 years. These operations are typically located deep, under high stresses and in competent rock masses, making initiation and propagation of the caving process harder to manage. These challenges must be confronted by optimizing the fragmentation of the orebody to achieve smaller size blocks that will result in consistent caving and improved flow of the ore from the drawpoints. To achieve better performance from the drawpoints, preconditioning is applied to fragment and damage the material required to cave. We present a proposed design for preconditioning in underground mines, considering the challenges that these large-scale mines are already facing, based on a comprehensive analysis of current design parameters, case studies, and sensitivity analyses using numerical models.

Feb 2, 2021

By B. Besa, S. Nalukui

Globally, the demand for mineral products is ever increasing. Extraction of these mineral resources results in the continuous production of a huge volume of waste material, including tailing dumps. The mass of tailings usually exceeds the actual resource and often contains hazardous contaminants. This study investigated the effects of tailings disposal on soil, water, and air quality in the Nampundwe area. Water, soil, and dust samples were collected from different locations in the surrounding communities. The constituents analysed in the samples included copper, cobalt, iron, sulfate, and silica. According to the results obtained, some seepages occurred from the tailings impoundment to the shallow aquifer in the area. However, the general water quality meets the Zambia Environmental Management Agency (ZEMA) statutory limits. Recorded concentrations of sulfate (1500 mg/l), copper (1.5 mg/l), cobalt (1.0 mg/l), iron (2.0 mg/l), and silica were between 0.003 mg/l and 705 mg/l, which is far below ZEMA’s statutory limit. Silica concentration was also evident in the air. The highest concentration recorded was 260 ppcc (particle per cubic centimeter) recorded in July 2019 from the northern direction of the tailings dam. The concentration was below the statutory limit of 350 ppcc. The topsoil from the northern part of the tailings recorded a silica dust concentration of 39.9 ppcc. Iron was evident in the underground soil with a concentration of 8.01 ppcc, cobalt 0.005 ppcc, copper 0.051 ppcc, while sulfate was recorded as 0.41 ppcc.

Oct 9, 2024

By D. F. Malan, R. P. Els

The limit equilibrium model, used in displacement discontinuity codes, is a popular method to simulate pillar failure. This paper investigates the use of physical modelling to calibrate this model. For the experiments, an artificial pillar material was prepared and cubes were poured using the standard 100 mm × 100 mm civil engineering concrete moulds. The friction angle between the cubes and the platens of the testing machine was varied by using soap and sandpaper. Different modes of failure were observed depending on the friction angle. Of interest is that significant loadshedding was recorded for some specimens which visually remained mostly intact. This highlights the difficulty of classifying pillars as failed or intact in underground stopes where spalling is observed. The laboratory models enabled a more precise calibration of the limit equilibrium model compared to previous attempts. Guidelines to assist with calibration of the model are given in the paper. The limit equilibrium model appears to be a useful approximation of the pillar failure as it could simulate the stress-strain behaviour of the laboratory models.

May 3, 2023

By J. A. Theron

"This paper provides guidelines on performing mass and energy balance modelling involving coal and coal derivatives. Usually, the inputs to a pyrometallurgical process would be specified in terms of elements and compounds. Reliable thermochemical data is more widely available for species involving uniquely defined, relatively smaller molecules. However, in the case of coal, the molecules are extremely large and not uniquely defined. Consequently, modelling processes involving coal and its derivatives have several potential pitfalls. These are outlined in the present paper. The main findings are as follows:•,Coal proximate analysis should not be regarded as absolute; it could vary with several parameters, including heating rate •,For modelling, the use of ultimate analyses should be considered a preferable option to proximate analyses, where, ‘fixed carbon’ and ‘volatiles’ are not defined in terms of chemical composition •,Significant errors could be made if the larger molecules are neglected during calculation of the calorific value (CV) of coal gas (the gas liberated when coal is heated in the absence of oxygen) •,For elemental analyses, the oxygen content (which is calculated by balance) should be checked to ensure it is within the expected range •,For representation of sulphur in coal, double-counting due to SO3 in the ash analysis should be avoided •,Potentially, oxygen in coal could be represented as O2, H2O, CO, or CO2; however, use of some of these species without considering the experimentally determined gross CV results in significant errors in the energy balance. If coal enthalpy is calculated from elemental analyses without correction, representation of coal oxygen as H2O(l) gives reasonable accuracy (up to 6.9% error for a set of South African coals). Coal volatiles could be represented by a complex mixture of compounds, even using different oxygen-containing species than the abovementioned four, provided the enthalpy is corrected •,It is recommended that an ‘enthalpy correction value’ is incorporated in energy balances involving combustion, devolatilization, or conversion of coal and coal derivatives, e.g. coke, char, or tar. That would imply that proximate analysis, elemental analysis, as well as the gross CV would be required for all solid or liquid coal-derived substances being modelled. No other correction due to the form of carbon being different than graphite should be used, as that would imply doublecounting some effects."

Jan 1, 2014

By J. Petersen, T. Moyo, D. Maharaj

This study investigates the effect of ammonium thiosulfate on the leaching of gold from the contacts of unpopulated cut electronic printed circuit boards (PCBs). Studies in the literature show ammonium thiosulfate to be a viable option in comparison to the commonly used but hazardous cyanide leaching route. However, the simultaneous dissolution of Cu interferes with the Au leaching reaction, often limiting the extraction to moderate levels. To optimize the system, an ammoniumthiosulfate system containing 0.5M ammonia, 0.5M ammonium thiosulfate, and Cu(II) sulfate at varying concentrations was studied as an alternative hydrometallurgical option for the recovery of gold from PCB. Tests were done with unpopulated standardized model PCBs (cut to 15 x 30mm pieces). Gold extraction of 47.3% was achieved after a 24-hour leaching experiment with a 0.02M copper background concentration. Further experiments focused using different initial background Cu concentrations (0M – 0.1M) to determine its effect on both gold and copper extractions. An initial Cu concentration of 0.045M resulted in the highest gold extraction, with 93.7% extraction after 6 hours of leaching. Further analysis of the data shows that the kinetic rate of gold leaching is correlated in a first-order dependence with the actual copper concentration in the solution, which increases with the concomitant dissolution of copper and gold from the PCBs. A lower threshold of 0.017M and an upper threshold of 0.15M copper in solution were determined, in between which gold extraction shows this first-order rate increase. The upper threshold is potentially linked to the onset of copper precipitation, which blinds the metal surfaces, slowing further leaching. The findings of this study suggest that in an industrial recovery operation of gold from waste PCB using the thiosulfate method, copper concentrations need to be carefully monitored, and the process should preferably operate with uncut or coarsely cut untreated boards to minimize exposure to copper circuits.

Dec 11, 2024

By D. G. Millenbruch

An account is given of a four-phase system for the appraisal of a mineral project while it is still in the exploration stage, and for continual consideration of a favourable appraisal until the production stage is reached. There are ten stages from the idea of a likely project to the production stage, and all the staff that are eventually to be concerned with the development of the project are involved at an early stage.

Jan 1, 1979

By I. Wigden

This paper discusses system integration and installation of High-Tec systems in underground mines. ABB has the capability to be a System Integrator and co-operates with partners in different areas of technology. Today it is difficult to find one Company that is responsible for the complete Automation System. The design of the system is also dependent on the caving procedure that is currently being used in mines. Most of the engineering must be done during the feasibility study and the design phase. Any mistakes made during these phases will be costly to rectify in the commissioning phase. The paper will also include a presentation of the benefit of using Automation in an Underground Mine, and the importance of integration with the people component. Most of the experience and discussions in this paper are from different technologies that have been developed in Scandinavia and adopted from LKAB in Kiruna. The author of this paper was responsible for the Automation projects in Kiruna Mine during1994 - 1999. These projects include: • Broadband communication of data, audio and compressed video in one data stream. • Control System for Haulage -1045m • Automation of Load Haulage and Dumping machines (LHD) • Control of Production Drilling Rigs from a Central Control Room.

Sep 1, 2001

By G. E. Blight

Several aspects of the behaviour and properties of backfills consisting of cemented cyclone underflow tailings are illustrated by means of examples, and guidelines are given on the optimization of the performance of cemented fills. The stretch characteristics of the geofabric used to contain freshly placed backfill are described, as well as the relationship between these characteristics and the forces acting on retaining barricades. The properties required to achieve a self-supporting, stable free face in cemented backfill are explored, and a graphic relationship between stable height and shear strength is presented and compared with that for uncemented (classified) tailings. After a description of the characteristics of Witwatersrand quartzite gold-tailings backfill and commonly used cements, the process of drainage and air entry into backfill is outlined. Following this, the early-age gain in strength and the shear-strength characteristics, as well as the compressibility characteristics of cemented backfill, are described. Two phenomena that are potentially damaging to cemented backfill are seismic effects (or blasting acceleration) and the closure that takes place during the curing of cement. Investigations show that neither of these phenomena is actually significantly deleterious to gold-tailings backfill: liquefaction does not Occur as a result of seismicity, and hydration of cemented fill is not significantly impeded by closure.

Jan 1, 1996

By D. G. Krige

The problem of a realistic investment analysis for a new mining venture that sells its products on the international metal markets IS studied against the background factors, firstly, of different inflation rates between the countries hosting the mines and those. hosting the metal markets; and, secondly, of the changing pattern of currency exchange rates between such countries. The purchasing-power parity theory is used to establish a pattern of relationship between these two factors, and to develop a more logical approach to the long-term forecasting of metal prices in the currency of the country in which the mine is situated.

Jan 1, 1979

By R. Thomas

A Honeywell TDC 2000 central process control system was installed at Rössing in 1984. The system controls the metallurgical operations from crushing to the finished product of uranium oxide and manufacture of sulphuric acid. The operation was previously controlled from nine separate local control rooms. The paper briefly reviews the design and commissioning of the control system on an operating plant and discusses the impact on manpower organisation and training needs. Development of the process control system during its first two years of operation is reviewed and a summary is given of the current status of computer control at Rössing. The impact of the new system on overall plant operation and performance efficiency is also briefly described. In conclusion, future developments of computer control and overall optimisation of metallurgical operations are reviewed.

Jan 1, 1987

By G. R. Baiden

Introduction The introduction of teleremote systems to underground mining can provide a significant improvement in the performance of a mine when compared with conventional mining techniques. This paper presents the concepts of teleremote mining in a case study showing how the systems work and the competitive advantage autonomation of mining techniques will provide for underground metal mining operations into the future. This paper is divided into two sections: the Mining Automation Program and What is next? On January 1st 1996 Inco Limited, Tamrock Oy, DYNO Explosives Group and CANMET formed a consortium for the development of teleremote mining equipment called the ‘Mining Automation Program’ or MAP. This program included a five-year research and development agreement that combines the talents of the above organizations to create mining equipment and systems for autonomating mining. The projects are based on the communication system currently sold and marketed by Automated Mining Systems Limited. The main components of the program investigated the development of a positioning and navigation module, autonomated systems using teleremote techniques for development and stoping, and software systems to support the use of this equipment. The program included the establishment of a test mine, at Inco’s 175 Orebody near Copper Cliff North Mine. This facility was unique allowing collaboration of companies and research organizations inthe design and testing of techniques and equipment used to apply autonomation to mining. Since the inception of the project other research alliances have been added to enhance the program. These include the application of ground support (Meyco/ Master Builders), muck pile recognition, the broadening of telecommunications links (PRECARN Associates Inc.-MALTA project) and the collection and processing of drilling core through the automated diamond drilling project (J.K.S. Boyles). MAP began as an idea a number of years ago with the fundamental question ‘Can an ore-body be profitably mined through autonomation?’ The concept was to design mining equipment and systems that would allow the teleremote operation of a mine. Automation was only one componentof this much larger teleremote mining issue. To start with, it was essential to prove or disprove the feasibility of this concept. The fundamental requirements are: • Telecommunications • Positioning • Navigation • Equipment • Software • Electronics • Mining Engineering • Organization. Each of these had to be considered. Technically, the feasibility of the project hinged on the successful development of a high capacity communication network, an accurate underground positioning system, a navigation system and finally the electronics and software that could integrate these. Mining equipment that could perform all the mining functions was the next requirement, along with explosive supplies that could be delivered to the holes teleremotely. Whatever the systems developed, they must be able to work in both bulk and selective mining situations and in varying conditions within a mine. Finally, the organizational issues of a change from our current method of operation to teleremote mining had to be understood. After five years of research and development the answer to the question ‘Can an orebody be profitably mined using autonomation techniques?’ is YES! There are still hurdles to overcome, however, the basic premise has been proven. The development and production of underground tunnels and stopes has been done. There have been interesting outcomes in terms of reduced effort to accomplish mining and the total time to mine. Definitions •Automationis the process by which a machine or system is run continuously including the ability for the system to self-correct. •Autonomationis the same as automation except that the process does not self-correct. •Teleremote operation is the operation of mining equipment over a network from any location out of line-of-sight of the machine. •Equipment Automationis the addition of technology to a machine that allows for unmanned operation of a machine and thus enhances the productivity of the operator. For example, a guidance system that allows a load-haul-dump to drive by itself, thus freeing the operator for other tasks. •Teleremote mining describes a mine process that combines the use of teleremote operation (potentially with some automation), positioning and process engineering, monitoring and control. •Tamrock DataSoloTMis a computerized drilling rig as shown in Figure 1. •Tamrock DataMini™ is a computerized development drill rig used for drifting and construction tunneling as shown in Figure 2.•Tamrock Toro 450™ is a LHD (Figure 3).

Sep 1, 2001