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By M. J. U. T. Van Wijngaarden, A. T. Pieterse

An account is given of the performance of a 37 MVA electric-arc .furnace in which bottom stirring with inert gas by an indirect-contact stirring-plug system was applied. The system, which was developed and patented by Thyssen-Stahl AG, and which is the first inert gas stirring system to be installed in South Africa, was commissioned in January 1992. Initial problems were experienced due to the blockage of stirring plugs by molten steel. The causes of these malfunctions are examined, and an account is given of how they were overcome. The system is described and evaluated. A comparison with direct-contact stirring systems shows why Iscor Vereeniging Works considered it to be more suitable for their Vaal Melt Shop. The results show that, through the successful application qf this technology, Iscor Vereeniging Works has achieved an annual cost saving of more than R2,5 million.

Jan 1, 1994

By L. A. Vermeulen

A simple argument shows that it is impossible for the flight of a rod in contact with a litter bar in a rotary mill to be initiated at that point on the upside of mill rotation when all the forces acting on the rod are in equilibrium. The argument was confirmed experimentally in a study showing that the lift of litter bars is a function of their height, that the rod velocity at the point of departure has a significant radial component, and that the subsequent flight of a rod is along a parabolic trajectory as predicted by elementary mechanics. A quantitative account of the observed effects, which is based on a dynamic theory of the sliding interaction between rods and litter bars, revealed interesting properties of the motions of rods down the surfaces of litter bars when the latter are in uniform circular motion during the rotation of a mill.

Jan 1, 1985

By J. J. C. Heynike

The relationship between population growth and steel consumption since the beginning of the twentieth century is indicated, reference being made to the increasing capacity of production units and the resultant increased pollution in the same area. The need for the control of fugitive emissions with its associated high cost is pointed out. There is a direct relationship between energy and pollution, and examples are given of several improvements that have been made to achieve better energy usage and reduced pollution. Several practical examples of air-pollution control systems are described as applicable to the main metallurgical steel processes of today. In conclusion, reference is made to the fact that, with the improvements attained in reducing pollution, the public will not tolerate a decline in the standards already attained. Environmental control and better energy utilization will continue to be important aspects of steel-plant design and operation.

Jan 1, 1978

The Institute has concluded an agreement with the Chamber of Mines whereby the Chamber Librarian maintains a section in the Library for the Institute. Surface effects of underground mining South Africa is blessed with vast mineral resources. It is essential to exploit those reserves if the country is to remain economically viable. Surface-mining equipment The Goldfields Mining Expo '86 is to be held in Kalgoorlie, Western Australia, from 30th October to 1st November, 1986, in conjunction with the Annual Conference of the Western Australian School of Mines. Mintek reports Report M142D Characteristics of gold and pyrite flotation at the Chemwes plant. (1st issued May 1984.) Report M159D Beneficiation tests on andalusite ore from the Marico district. (1st issued Aug. 1984.) Report M164D The recovery of tungsten from South African low-grade schee/ite concentrates. (1st issued Sep. 1984.)

Jan 1, 1986

By P. M. Vercruijsse

Dredging is an industry in constant transformation. It has changed tremendously in the last decades. The traditional dredging activity, like construction and maintaining ports and harbours, desilting of drainage and irrigation channels, keeping reservoirs at depths and removing sediments from waterways, is still of importance. However, it is surpassed by other applications of dredging technology. Reclamation is an important example, where large amounts of sand are dredged, transported over large distances and used to make new land for industrial, housing, airport and other infrastructural purposes. Beach nourishment and other protective measurements should be mentioned here as well. Other applications like offshore winning of oil and gas, environmental clean-up, mining of interesting minerals like gold, diamonds, titanium and tin as well as aggregates from inland and offshore deposits are of importance. For all of these dredging applications equipment is required, and with changing circumstances and constraints, the design and use altered significantly. Larger dredging depths and increasing capacities require an impressive scale-up of equipment and tools. A demand for higher accuracy and selectivity set the requirement for a higher level of automation and control in combination with a well trained crew. Operations under more difficult circumstances and with other soil characteristics necessitated the development of new dredging components and systems. A sound basis for all developments was and still is a better understanding of the various dredging processes. This paper will highlight some eye-catching developments in the dredging industry. It will focus on issues in the field of hydraulic transport such as ever increasing capacity and dredging depth, as well as the pumping of large size materials.

Jan 1, 2007

By L. E. Kun, R. O. Oelofsen, E. J. J. van Vuuren

High-rate floc-blanket clarification of gold pregnant rotary filtrate was introduced at the Vaal Reefs South gold plant of the Anglo American Corporation during February 1978. A. daily 12 000 to 15 000 t of filtrate, with an average suspended-solids concentration of 350 mg/I, is continuously clarified to a concentration of less than 2S mg/I of suspended solids in a modified plant pachuca (10 m in diameter) at throughput rates of 7,7 to 8,5 ma/m2.h by the addition of 5 g/t of ferric chloride inorganic coagulant and 0,2 g/t of Superfloc NI00 flocculant. The pachuca overflow is then clarified further in seven Stellar candle pressure filters of 54,S m2 surface area to under 5 mg/I of suspended solids. The combined clarification cost when the hopper clarifier is used in conjunction with the Stellar filters is R0,0032 per ton of liquid treated, which is approximately 60 per cent lower than the cost of Stellar filtration on its own. The savings are mainly due to the reduced use of filter pre-coat, the consumption of which has dropped by 70 per cent since the introduction of hopper clarification.

Jan 1, 1979

Underground mining and particularly dipping narrow tabular orebodies are difficult to mechanize appropriately, given the low gold price and other external factors. Particularly in the deep level mines in South Africa, there is little choice left but to mechanize if the industry is to remain competitive and a significant global player. This paper presents a design philosophy for appropriate mechanization intended to generate solutions that can be implemented using the people currently employed in South Africa mines. The design philosophy is based on the ability of high-pressure water (hydropower technology) to deliver enhanced performance to users and on simplicity in the eyes of the user. Four examples of systems and equipment are described to illustrate the approach to Appropriate Mechanization. These include: • The Development End System, • The Monorail Raise Climber, • Automatic Pump Control Valves, and • The Energy Recovery Pump. The equipment is presented with the following critical issues foremost in mind: Safety, Working Environment, Performance, Cost effectiveness and Implementation. Although the appropriate mechanization approach is described in the context of the South African underground mining industry, much of the Appropriate Mechanization equipment has worldwide applications. Key Words: Hydropower, Mechanization, Tunnel Development, Raise Development, Monorail, Raise Climber, Pump Control Valve, and Energy Recovery

Sep 1, 2001

By Penswick D.

From the perspective of management control, most mining operations can be represented by a hierarchy comprising four layers. The base of this hierarchy consists of the individual pieces of equipment that are used to break and transport rock. The next level comprises the coordinated interaction between different pieces of equipment, termed a process. An operation results from the bringing together of different processes within a common discipline, such as mining or hydrometallurgy. Finally, an enterprise is formed when the separate mining, concentrating and smelting business units are combined. To date, much of the literature written on the topic of mining automation has focused on the equipment level, specifically on removing the operator from production mining equipment. This focus should not, however, overshadow advances registered in automation at both the process and enterprise levels. Only at the operations level of the hierarchy has little progress been made. While automated equipment, process management and enterprise resource planning are a current reality; it is argued that the benefits from automation have, to date, been largely elusive. It is further argued that full benefits of automating other levels will only be fully achieved when this ‘gap’ in the mining automation hierarchy has been addressed and an uninterrupted, process-wide information flow across the entire operation is achieved. Furthermore, it will be reasoned that so-called vertical integration can only be achieved with an automated operational level in place. It is believed that all the necessary building blocks are in place and that the industry is ready for this development. The paper concludes by presenting a vision for what operational level automation would achieve.

Sep 1, 2001

By K. Andres

This paper presents the vibrating mill technology and summarizes the grinding principle of ultra fine grinding. In addition, a variety of operations is described and the benefits of these different operating modes? product size and efficiency are specified. A case study of an industrial application is presented to show the integration of vibrating mills into grinding circuits. The primary focus is the overall process scheme of this technology, the installation and operating costs, as well as the design parameters required for best performance. The vibrating mill can be used in a wide range of applications for process engineering duties. For a wide range of applications, from soft to extremely hard products, which require ultra fine grinding, surface activation or homogenization, the vibrating mill is well proven. Due to its easy operation, versatility and operation efficiency, the PALLA? vibrating mill gains in importance in the mineral processing industry. Keywords: Coal, comminution, grinding, mineral processing

Jan 1, 2010

By Thomas V. Fame, William E. Porter

"As geological and mining conditions become more complex, and as overall mining economics become more marginal, short- and long-range decision-making regarding multiple-seam surface mining becomes more difficult. The decision-making problem involves a study of economics, cut-off grades and ratios, equipment capabilities, sequencing and selective mining practices.This paper is concerned primarily with multiple-seam mining of bituminous coal. The research has led to the development of an economic decision-making model for use as a day-to-day tool to aid mine operators and pit geologists to decide what and how to mine.The model is designed as an aid for feasibility decision-making in multiple-scam situations and for situations where selective mining is needed or desired. In effect, a simulation of the feasibility and preliminary mine planning phases has been developed. The model is divided into four separate segments: decision-making, simulated mining, cost calculations and the determination of the discounted cash flow return on investment."

Jan 1, 2014

By C. Ringas

Pipelines are used extensively in industry to convey various products. Internal corrosion of pipelines can lead to perforation and leakage of the product. A growing problem, not often accurately recognized, is internal corrosion of pipelines caused by bacteria. Microbiologically-induced corrosion (MIC) refers to corrosion caused by a variety of micro-organisms. This form of corrosion is not widely recognized in many industries, although it is widespread and causes many corrosion problems in pipelines, both internal and external. Sulphate-reducing bacteria (SRB) are responsible for the bulk of the corrosion problems caused by MIC. Corrosion caused by SRB is found extensively in water pipelines conveying raw, potable and waste water, as well as in pipelines conveying slurries. This problem also occurs in pipelines conveying crude oil. This paper describes internal corrosion problems of slurry pipelines caused by bacteria and outlines mitigation methods to improve slurry pipeline integrity, thereby extending the life of such pipelines.

Jan 1, 2007

By C. Musingwini, M. Woodhall

An often overlooked factor in the analysis of mine layouts and schedules is technical operating flexibility, mainly due to its nebulous nature. If one glosses over technical operating flexibility the resultant mine layouts and schedules tend to be sub-optimal. The need to incorporate technical operating flexibility into the analysis and comparison of mine layouts and schedules is increasing in importance. This paper illustrates the nature of technical operating flexibility, reviews previous work on valuing operating flexibility and proposes how technical operating flexibility can be quantified for tabular reef mines by using a platinum reef deposit as a case study. Once technical operating flexibility is quantified it becomes possible to explore its incorporation into the analysis of mine layouts and schedules and subsequent optimization processes. The work described in this paper is part of a current PhD study at the University of the Witwatersrand. Keywords: mine plans, layouts, schedules, technical operating flexibility, ore availability.

By T. De Lange

Extensions to the beneficiation plant at the Grootegeluk Coal Mine are currently being planned in order to provide power station coal for Escom's Matimba Power Station, presently under construction. A simulation model was developed on the Olivetti M-24 microcomputer to facilitate the development of the envisaged flowsheet. The computer program simulates the heavy-medium separation and screening unit operations. The model is based on the construction of the Tromp partition curve described by an arctangent function, allowing ideal and non-ideal separations. The paper discusses the determination of the parameters required by the arctangent curve from standard process parameters such as Epm, Wolf cut-point, Tromp cutpoint and screening efficiency. The accuracy and shortcomings of the model are discussed, while an overview of the application of the model to evaluate borehole and bulk sample analyses is also given. It is concluded that the model is an invaluable aid to general flowsheet development.

Jan 1, 1987

By J. H. E. Perry, V. H. Wiik

"The ore deposits of the Zambian Copperbelt occur in sedimentary strata that have been subjected to relatively mild, flexure-type folding. Unrolling serves to reconstruct the original depositional geometry of the folded sedimentary strata and is in common usage on the Copperbelt both for geological analysis of drill hole data and in routine ore reserve estimation.A computerized method of unrolling was introduced at Roan Consolidated Mines in 1969 based on a standard contouring program. A contour map of the geological structure is drawn from a regular grid of elevations, interpolated from the original, irregularly-spaced intersections. Unrolling is performed across this grid, perpendicular to one or two axes specified by the geologist. Each intersection is unrolled independently, and the new co-ordinates are subsequently processed to produce unrolled maps.The technique has been used successfully at RCM over the last two years in both the estimation of ore reserves and exploration planning."

Jan 1, 2014

By G. A. Bezuidenhout

Lonmin Platinum installed a concentrated mode dual-alkali scrubber at the smelter in Marikana in 2002. The dual-alkali scrubber was the technology of choice at that time as a sulphur fixation plant, due to the perceived benefits of handling both the high SO2 concentrations of converter off-gas and the swings in SO2 concentration that are linked to Peirce-Smith operation. Owing to current and impending legislative requirements for air quality and waste, Lonmin is currently considering additions to the dual-alkali plant, but is also evaluating alternative technologies for sulphur fixation. This paper reviews the decision of Lonmin to install a concentrated mode dual-alkali scrubber and presents plant performance achieved. It also describes the important control variables and sensitivities of the plant, and the final product that is produced by the operation of the plant. The legislative requirement that drives the Lonmin technology evaluation is also discussed.

Jan 1, 2012

By G. A. Bezuidenhout

Lonmin Platinum installed a concentrated mode dual-alkali scrubber at the smelter in Marikana in 2002. The dual-alkali scrubber was the technology of choice at that time as a sulphur fixation plant, due to the perceived benefits of handling both the high SO2 concentrations of converter off-gas and the swings in SO2 concentration that are linked to Peirce-Smith operation. Owing to current and impending legislative requirements for air quality and waste, Lonmin is currently considering additions to the dual-alkali plant, but is also evaluating alternative technologies for sulphur fixation. This paper reviews the decision of Lonmin to install a concentrated mode dual-alkali scrubber and presents plant performance achieved. It also describes the important control variables and sensitivities of the plant, and the final product that is produced by the operation of the plant. The legislative requirement that drives the Lonmin technology evaluation is also discussed.

Jan 1, 2012

By P. J. Petit

Financial evaluation is necessary to investigate the viability of implementing and/or utilising new technology in mining projects. It establishes a techno-economic base for decision-making and justifies capital expenditure. This paper aims to present a monetary appraisal of the electric rock drilling system in a typical feasibility project, whose purpose is to increase the production rate. The in situ environment is a platinum orebody, and the stoping operations occur in UG2 reef. The results are a function of production requirements, technical parameters and financial outlay of the drills. The costs involved in implementing and operating electric rock drills are assessed to the current method of drilling, namely the compressed air operation. A comparison of the electric and pneumatic rock drills in terms of financial outlays for drilling and service requirements, peripheral equipping and training is discussed. Other factors that affect the business case are technical advantages, safety and risk management and the environmental objective of the company.

Jan 1, 2006

By R. S. J. Toit

Discussion: T. L. Gibbs,* (Honorary Vice-President and Fellow): In terms of the Pneumoconiosis Compensation Act of 1962, a Pneumoconiosis Risk Committee was established whose function it is to estimate (by whatever means the committee deems fit) in respect of every controlled mine the pneumoconiosis risk to which persons employed in a dusty atmosphere at that mine are exposed. In estimating such risk the committee may estimate different risks in respect of individual mines or parts of mines or classes or groups of mines or occupations or localities at mines. The pneumoconiosis risk may be reviewed and re-estimated at any time. The Act provides further that the General Council for Pneumoconiosis Compensation shall apportion the levy imposed on owners of controlled mines on the basis of the pneumoconiosis risk determined by the risk committee and the numbers of persons employed in a dusty atmosphere. The task of the risk committee is a most responsible one and also a very difficult and complex one in view of the many different types of mines, rock formations, dust conditions, etc. Quite obviously, comparisons between mines cannot be made on dust concentrations alone as different mineral dusts have different toxicity or pneumoconiosis response factors. However, with its present knowledge, the risk committee is satisfied that the risk at mines, other than coal mines, is related to the mean quartz-equivalent dust concentration to which persons are exposed and the estimation of risks is based on this relationship. From the above, it will be clear that the work done by Dr du Toit on the problem of basing the current rate of levies to provide for pneumoconiosis compensation on the current dust hazard at mines has been of immense value to the risk committee. Up to now the risk committee has not been able to obtain complete and accurate information on the dust exposure of persons at all mines - and, in fact, it is doubtful whether it will be economic or practicable to obtain this in the foreseeable future - but reasonable assessments have been possible from routine dust sampling in some cases and from periodic comprehensive dust surveys in others. As a temporary measure the risks of some mines were estimated initially on a group basis relating to average dust conditions and the type of rock and mineral mined, but as more information became available, differentiation between individual mines became possible. It is the aim of the risk committee to eventually apply such a differentiation in all cases and to ensure that within the bounds of practicability each mine pays for its risk and for its risk only. In this connection, the relationship between the levies and the amounts actually paid out in compensation are examined regularly. In conclusion, I wish to add my congratulations to the author on his excellent paper. His findings will assist materially in the just administration of that very important piece of beneficial legislation, the Pneumoconiosis Compensation Act. G. K. Sluis Cremer MD (Visitor): Dr du Toit has made a valiant attempt to relate dust hazard and the rate of collecting funds for the purpose of paying compensation for Pneumoconiosis. In doing so he has had to make a number of assumptious, some of which touch on the medical aspects of pneumoconiosis. It is worth discussing whether these assumptions are justifiable. Pneumoconiosis is defined in our Pneumoconiosis Act as permanent disease of the cardio-respiratory organs which is caused by the inhalation of mineral dust. To a non-medical person this definition has probably a clear cut meaning. The doctors however have to deal with such conditions as silicosis and asbestosis where there is a well defined dose response relationship to the inhalation of quartz and asbestos respectively and on the other hand chronic bronchitis where the relationship to dust inhalation is poorly defined and where certainly no clear dose response relationship has emerged after many investigations in this country and overseas. Nevertheless since 1953 about half of our certifications for Pneumoconiosis are on the grounds of chronic bronchitis i.e. the X-rays show no evidence of silicosis, asbestosis or other relevant disease. This fact must affect Dr du Toit's computations. The next assumption we should examine is the manner in which toxicity factors have been allocated to the various mineral species. These allocations have in part been based on a restricted number of animal experiments carried out overseas but mostly in South Africa by Webster at the Pneumoconiosis Research Unit. To extrapolate the findings in a relatively small number of animal experiments to the expected reactious in man is a notoriously dangerous exercise. Furthermore the bracketing together of all silicates (except asbestos) and the insoluble metal oxides is entirely unacceptable. Talc (a hydrated silicate of magnesium) and muscovite mica (a silicate of aluminium and potassium) cause pneumoconiosis in their own right. On the other hand

Jan 3, 1970

By L. C. Woollacott

A computer-aid is described that is designed to calculate steady-state material balances for ore-dressing circuits. The program determines the material balance from a specification of the process condition. No mathematical models or data adjustment techniques are employed. As such the program complements existing simulation and material balance 'smoothing' packages. The process condition is specified using performance indicators. These are significant parameters in the industry with which all practising mineral processors are very familiar. The program employs an equation-oriented technique for material balancing and so has had to deal with the difficulties peculiar to that approach.

Jan 1, 1987

By I. M. Macleod

An adaptive steady-state on-line optimizing regulator is proposed as an integrated approach to the control of autogenous run-of-mine milling circuits. This optimizing regulator continuously estimates an internal model of the controlled process, and, based on this, determines mill fresh solids feed rate, mill water flow rate and sump water addition flow rate such that a circuit performance objective is optimized. The dual -requirement of controlling both the mill pulp load and the load of particles of grinding media size is thus directly and simultaneously addressed. The concept and theory underlying the operation of the adaptive optimizing regulator are discussed.

Jan 1, 1987