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By M. A. Amarante

Beneficiation studies were conducted on a Portuguese feldspar ore, in order to obtain final products capable of being used in the ceramic industry. A simple scrubbing operation is enough to break the lumps in the feed. The ore deposit contains ca 35 x 106tonnesfrom which, by screening, three main products could be obtained. This paper focuses on the beneficiation of the 500/74 µm fraction, which constitutes about 27% of the ore, assaying 9.42% Al2O3,equivalent to approximately ca 46% feldspar, with a mean iron content of 0.29% iron oxides. Magnetic separation and froth flotation testwork was carried out, in order to decrease the iron contamination and increase the feldspar content. Magnetic separation alone decreased the iron content of the feed to values between 0.04 and 0.08% iron oxides with an average yield greater than 90%. Flotation with HF, provided a feldspar recovery of 45?46% with a concentrate assaying 17.6% Al2O3. The use of H2SO4, gave a recovery of 35?36% of feldspar concentrate, assaying 16.1% Al2O3. However, economic and environmental advantages of using sulphuric acid may compensate for the lower mass recovery. The iron content of0.12% iron oxides in these concentrates, could be reduced to 0.04?0.05%, by further magnetic separation.

Jan 1, 1997

By R. Butcher

Mud rushes are hazardous occurrences that have occurred frequently in mines in South Africa, and have been the cause of numerous fatalities in the past. Mud rush incidents not associated with accidents are believed to be common occurrences that are not generally reported. Many such incidents are probably associated with the operation of chutes and box fronts. This paper describes the conditions necessary for mud rush occurrences, postulated mud rush mechanisms, and methods of combating the mud rush hazard.

Jan 1, 2005

By A. V. Peake

Continuous Mining presents an opportunity to extract reef in the stope ?continuously? by integrating the drill and blast activity using propellants or low energy charges. To date, the majority of effort spent on Continuous Mining systems has focused on developing an effective rock breaking process (micro breaking process), and to some extent, eliminating fumes and dust. The perceived benefits of applying low energy charges have been identified as: ?Concentrated mining yielding face advances of 40 to 60 m per month ?Lower stoping widths through better-controlled breaking ?Increase in the advance per blast ?Increase in labour productivity ?The potential to mine reefs where specific conditions make conventional mining uneconomic e.g. reefs with shales in the immediate hangingwall. However, the ability to successfully use low energy charges to create a ?Continuous or Semi-Continuous? mining method is dependent on overcoming the following challenges. ?Improving reliability of rock breaking. This is dependent upon achieving:? Improved drilling accuracy, and? Successful stemming or gas confinement, particularly in fractured rock ?Reducing gas and dust levels ?Reducing high costs. Through the research carried out in Future Mine, many different low energy rock breaking methods and systems were investigated. Whilst detailed results cannot be published here, the guidelines for overcoming low energy rock breaking challenges are discussed.

Jan 1, 2003

By C. Kasatuka

Globalization creates investment opportunities for enterprises around the world. Attracting foreign investment has been a key challenge for economic growth in developing countries. Corruption, political instability, armed conflict, and other internal problems affect foreign direct investment (FDI) inflows negatively. A framework of criteria provides a basis for comparing non-commercial risk (NCR) among twenty-three mineral economies. Countries competing for foreign direct investment inflows are ranked from least to most risky. This study compares Inward FDI Performance Index (IND) with NCR ratings in developing countries and shows that risk is increasingly mitigated by means of appropriately structured insurance. Given the option for countries with similar mineral potential, investors will generally invest in the country that offers lower non-commercial risk. Keywords: foreign direct investment, non-commercial risk, developing countries.

Jan 1, 2006

By R. L. Gibson

Manpower competencies in the mining, minerals processing and energy industries in South Africa into the next century will, to a large extent, derive from the nature and quality of the teaching which pupils receive at school. This paper provides an overview of the current developments towards a new National Curriculum in South African Schools and highlights areas in which the Minerals Industry might provide input into this process.

Jan 1, 1997

Paper written on project work carried out in partial fulfilment of M.Sc. (Chemical Engineering)degree Identification of non-linear systems can be a daunting task and in the process industries the problem is complicated considerably by the presence of noise from various sources, non-stationarity of the data and intermittence, such as observed in particulate flows. Traditional methods, such as frequency analysis and linear model-ling do not handle these systems well. Similar problems arise with the application of non-linear theory developed over the last few decades, where much of the analysis depends on embedding of the data in a phase space or pseudophase space, since these methods were not originally designed to deal with noisy systems. In contrast, singular spectrum analysis is a method which can be used to identify structure and distinguish noise from important information in multivariate data, such as the trajectory matrices of time series measurements. It provides an orthogonal basis onto which the data can be transformed, so that components of the time series can be investigated individually. With Monte Carlo methods, the components can be compared with those from linear surrogate data in order to identify possibly non-linearities in the data. In this paper, this versatile technique is briefly explained and illustrated by means of case studies.

Jan 1, 2003

By F. Peer

In most coal preparation processes, water is a necessary medium, but the presence of water in coal after it has been cleaned has a negative impact on transportation costs, handling and specific energy values. The utilization of super absorbent polymers (SAP) in the nappy application is well known. The concept of utilizing these polymers was investigated for the purposes of dewatering coal and other fines, generated by preparation processes such as flotation. SAPs are granular highly cross-linked synthetic copolymers with excellent water-absorbing properties. The dewatering process is characterized by three main stages: (a) contact of super absorbent polymer with high-moisture fine coal; (b) separation of dewatered fine coal from super absorbent polymer; and (c) regeneration of used super absorbent polymer, by exploiting its response to changes in conditions such as pH or temperature. Preliminary tests showed the separation step to be very difficult. The novel idea of encasing a given amount of polymer in a water permeable cloth solved this problem (of separating the swollen polymer from the dewatered coal). Preliminary tests investigating the effectiveness of the sachets of polymer showed a drastic decrease in the moisture contents of slurries. Furthermore, it was shown that it was possible to regenerate the polymer (still within the sachets) through thermal drying. A full-scale experimental programme was then followed to accurately determine the feasibility of using sachets of SAP. The experimental variables were initial slurry moisture content and polymer dosage. It was observed that the sachets seemed to work fastest and most effectively at high moistures and also at higher dosages of SAP. Regeneration of the polymer was also investigated, using two methods: thermal regeneration and pH-induced regeneration. The experimental variables, for investigating the regeneration process, were method of regeneration and grade of water used. Thermal regeneration at 70°C seemed to work successfully. Although the cost of using thermal energy is still a problem, the safety aspect (fire hazards) has been addressed since the polymer does not ignite when heated, unlike fine coal particles that may do so. The alternative method of regeneration, which exploits the pH-sensitivity of the polymer, was less successful, and further work needs to be conducted.

Jan 1, 2003

By J. Kerr

The first stage of the development of a new modified 201-type low nickel austenitic stainless steel is described in this paper. The alloy is intended for use as a structural alloy, and so requires a yield strength >400MPa as well as acceptable weldability and toughness. The low nickel content will give a lower material cost in comparison to more conventional austenitic grades, and the processing route is required to be similar to that of Type 304 to keep the processing cost low. The base alloy was designed using empirical methods developed for stainless steel, and the properties of the base alloy were verified using a range of small-scale melts. The base alloy had a 0.2% proof strength of ~320-400MPa, and so it is planned to use V additions of ~0.15% to bring about precipitation strengthening in the hot rolled condition, so raising the alloy?s proof strength above the 400MPa minimum.

Jan 1, 2004

By A. J. Lynch

Mineral processing models have been discussed for many years but it was not until digital computers became available about 1960 that serious attempts at circuit simulation could be carried out. Even then the work was primarily academic until PCs could be used by engineers in plants and design offices in the mid-1980s. Since then simulation has moved quickly and it is now at the point that most processes can be simulated reasonably accurately for purposes of design and optimization. There are still some significant deficiencies, notably in dry grinding and separation, and in the chemical interactions in flotation. Future work will involve: ?improvements of existing models ?dynamic simulation for automatic control and, in particular ,for training which is a weak link ?using advanced simulation models to predict liberation and separation from data acquired from SEM-based liberation analysers. Eventually mineral processes models will be part of total simulation systems which will incorporate mining and downstream processes including all environmental impacts.

Jan 1, 1999

By P M. Bradbury

The nature of aggressive process chemical requirements typically in the Platinum Refinery Industries, lend themselves to the use of Polymer Composite Glass Reinforced plastics for pipework and other associated equipment in these types of Plants. This paper discusses the basic characteristics of a Polymer Composite glass reinforced piping system and gives sample examples of applications in current present day use.

Jan 1, 2006

By R. Thomason

Thank you Dr Barcza, President of the South African Institute of Mining and Metallurgy, for inviting me to share our experiences in Australia as regards the competency movement and my Association?s experience in assisting engineers become managers. This is my second visit to South Africa, and I am struck by the similarities between our countries. This extends to the professional issues associated with engineering and competencies in particular. I propose to outline two exciting stories today. ? Development of competency standards for professional engineers in Australia. ? Development of a management programme which has assisted professional engineers regain positions of leadership in Australian industry and government. First of all I would like to outline the Association of Professional Engineers, Scientists and Managers, Australia(APESMA).

Jan 1, 1997

The 103rd Annual General Meeting of The South African Institute of Mining and Metallurgy was held in the Gold Room, Transvaal Automobile Club, 60 5th Street, Lower Houghton, Johannesburg on Wednesday, 16th August, 2000. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations. Also to recipients of awards, senior members of industry, Honorary Life Fellows, Past Presidents, our Members and other guests, among them the following: Reinie Meyer, President, The Geological Society of South Africa Dr Nielen van der Merwe, Chairman, The South African Institute of Rock Engineering Chris Fourie, President, Institute of Mine Surveyors of South Africa

Jan 1, 2001

By M. Bhandari, D. Norval

The bulk of plain carbon steel is produced through conventional Basic Oxygen or Electric Arc Furnace routes where the development of the AC Ladle Furnace has made it possible to also produce alloy steels. Smaller Ladle Furnaces have limitations such as lower efficiency; high electrode consumption and diminutive yields rendering them uneconomical to operate and making the processing of low carbon steel grades difficult due to carbon pick up. The demand for special steels and alloys with strict specifications is increasing while commodity prices remain competitive. The production of special steels and alloys have specific process control requirements and the development of the induction melting furnace (IMF) has made it possible to produce smaller batches economically. Refining and alloying of the melt in the IMF further enhance the efficiency. The INDUREF furnace offers increased productivity and flexibility through increased thermal efficiency and can be utilised for holding molten metal for further processing such as granulating, atomising, nitriding, alloy additions and desulphurisation of Ferro-alloys and steels. The system utilises a specially engineered ladle which is placed in an induction-heating assembly comprised of a stationary water-cooled copper coil and lamination packs. The addition of equipment for vacuum degassing and decarburisation of steels and alloys is also feasible. Benefits are: ? No electrode consumption or carbon pick-up ? Lower installation, operation and maintenance cost. ? No line-flicker facilitates operation on a weak power grid. ? Good power factor and balanced load ? No skull formation and reduced refractory consumption ? Higher yield of Fe-alloys ? Automatic controlled stirring

Jan 1, 2004

By L. C. Stilwell

Input-output analysis is a major branch of quantitative economics, and is used to analyse the flow of goods and services between production sectors in a national economy. Its purpose is to determine the relative value-adding capacity of each sector. The model has also, in recent years, found increasing use in assessing the environmental and ecological impact of development projects. It has, however, never been applied to individual production facilities, such as large mines, which themselves have complex economic structures, through which there is a flow of goods and services. Conventional cost and accounting systems, as used on mines, treat production sectors as separate cost centres, and do not determine the inter-relationships between them. This can lead to incorrect conclusions on the relative value of sectors and their impact on the total economic performance of the facility. This paper explains the basic principles of input-output analysis, and presents an example of its application to a simplistic model of a mine, which is used in the absence of any real data. The paper concludes that, by forcing definition of the value adding function of each sector, input output analysis will facilitate control of inputs, or costs. This will result in optimal application of resources and exploitation of ore reserves. The authors realise the model needs to be tested on an operating mine, and hope this paper will result in an opportunity to do so. The authors wish to thank the anonymous referees for their valuable comments.

Jan 1, 2000

Records over the past ten years indicate that there is potential for serious multiple accidents due to engulfing associated with rockpasses. Significant attention is not usually given to the design of rockpasses, with the implication that mistakes leading to poor performance of the passes are often repeated. This paper outlines general guidelines for the design, support, operation and rehabilitation of rockpasses based on information obtained from the limited amount of literature on the subject.

Jan 1, 2005

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

Ongoing rockpass problems on mines within the South Africa region, prompted AngloGold Ashanti to embark on a risk assessment of major rockpasses. This commenced with the collection of relevant data to identify gaps in the available knowledge and identify existing problems. This was followed by an assessment of rockpass layouts to determine existing and potential interactions with other excavations. An initial risk assessment has been completed and the rockpasses have been ranked in terms of their risk profile. The lack of geological data and an easy and reliable method of surveying rockpasses have been identified as problem areas. Shortcoming is terms of rockpass management procedures have also been identified. Further work is required to quantify the risk in terms of probability of occurrence and consequences.

Jan 1, 2005

By N. R. Shoko, J. Chirasha

Zimbabwe Alloys has been producing Low Carbon Ferrochrome since 1953. A number of operational and technical advances have been made since then. Some of these advances improved production significantly. Process control, however, remained a challenge not only in the production process itself but also in the handling of finished product. In addition the handling of the slag created an environmental problem. Process control issues were addressed by Zimbabwe Alloys Limited and Japan Metal & Chemicals (JMC) entering into a Technical Transfer Agreement. The aim of the technical transfer was to improve production, alloy quality and, thereby, the financial performance of Zimbabwe Alloys. In addition, the Low Carbon Ferrochrome production process was made environmentally friendlier by modifying the final slag handling methodology. The aspects that are covered and discussed in this paper are, ladle refractory lining changes, improved control of the process, changes in the alloy casting methodology and granulation of the final slag. The improved control of the process was enhanced by the conversion from ladle duplexing to argon purging, introduction of on-line sampling and introduction of second stage process. The combined effect of the above was a significant improvement on on-grade material production, production efficiencies, unit cost of production and a cleaner working environment.

Jan 1, 2004

By A. More, J. Bullón

Metal casting is one of the most important operations in ferroalloys factories. After the tapping of the furnace and the depuration of the metal, the preparation for customers with cooling, crushing and sizing begins. In total production costs, this contains around 8 % of the total cost of the metal, depending on the value of the fines and other important parameters. From an investment point of view, this represents around 20% of the total capital for a new furnace. Casting onto a water-refrigerated copper plate is not new for molten metals. In steel, continuous casting machines are normal in every factory. Water granulation casting exists at some ferroalloys plants. However, the majority of plants and production technology still use the technology of lumping, crushing and sizing. This technology is time consuming, produces fines and requires a relatively large work force. In 2001, Ferroatlantica put into operation a new water-cooled copper casting-machine, which seems to be a very convenient solution to solve all these problems. It is in operation at a silicon factory; the same place where the new ELSA electrode was developed for silicon metal production. This paper describes our experiences using it.

Jan 1, 2004

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