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By J. M. Benson

Metal powder compaction offers unique advantages in the manufacture of net-shape components using techniques such as laser sintering, conventional press and sintering, metal injection moulding, direct rolling, direct forging, and hot isostatic pressing. If the output from the primary metal production process is in powder form, then considerable cost and energy savings can be realized by direct conversion to semi-finished or final shapes. This possibility exists for titanium and possibly also for Ta, Zr, Hf, and Nb metals. However, these attractive benefits are associated with some significant risks. The high surface-to-volume ratio of powder particles coupled with the reactive nature of these metals means that special care must be taken when handling them. Powder explosions are unfortunately still a regular occurrence internationally and these often result in serious injury and loss of life. Even seemingly 'safe' compounds such as sugar, flour, and grain can be extremely hazardous when handled or milled and dust clouds are produced. In addition, exposure to airborne particles can have adverse effects on the human body, especially when particles are inhaled on a regular basis. Furthermore, the medical consequences of these are not fully understood, especially in the case of nanoparticles. The impact is often not observed immediately and debilitating illnesses may emerge only years or decades later. As far as is known, there are no South African guidelines for handling of metal powders. This paper attempts to provide an awareness of the risks associated with metal powders (including those produced indirectly by other metalworking/finishing operations) as well as some guidelines for their safe handling, based on international best practices.

Jan 1, 2012

By C. Musingwini, A. S. Nhleko

"Since the Global Financial Crisis (GFC) in mid-2008, capital has been more difficult to access. Mining projects must contend with projects from other industries for scarce capital. A decision to invest available capital in mineral projects requires that valuation be conducted to assess the expected return on the projects. The discounted cash flow (DCF) analysis is generally applied for the valuation of mining projects, whereby future cash flows are discounted to present value using an appropriate discount rate. The discount rate significantly affects the outcome of a valuation. Economic and finance theory provides tools to calculate discount rates. The discount rate must account for factors such as the risk and stage of development of the mineral project; hence the appropriate discount rate to utilize in a project is often a subject of debate.The discount rate is the weighted sum of the cost of debt and equity. There are several methods for determining the cost of equity. This study considers the commonly applied Capital Asset Pricing Model (CAPM) and Gordon’s Wealth Growth Model because of their simplicity and availability of parameters required to estimate the cost of equity. This study explores how differences in the cost of equity obtained by these two methods can be explained for a mining environment. Data for empirical analysis were collected from the I-Net Bridge, McGregor BFA, and Bloomberg databases. It was found that Gordon’s Wealth Growth Model provides better estimates of the cost of equity compared to the CAPM under depressed market conditions. Therefore, this research recommends that Gordon’s Wealth Growth Model be used to estimate the discount rates for mining projects during periods of depressed market conditions."

Jan 1, 2016

By A. C. du Preez

Mintek has been involved in extensive test work since the early 1990s on the recovery of nickel and cobalt from leach liquors saturated in calcium, using synergistic solvent extraction systems. During this period the Nicksyn? reagent was developed, optimized, commercially manufactured, and tested by Tati Nickel on a demonstration plant for more than 2800 operating hours. Efficient recovery of nickel without the co-extraction of calcium, thus avoiding gypsum formation in the extraction and stripping circuits, was illustrated. This synergistic system was recently evaluated on a laboratory scale for the recovery of nickel and cobalt from synthetic lateritic sulphate leach liquor containing about 3 g/L nickel, 0.5 g/L cobalt, 0.7 g/L manganese, 20 g/L magnesium, and with calcium at saturation. Extraction and stripping parameters were determined for this feed liquor and are discussed in this paper.

Jan 1, 2014

Comminution is a vital part of minerals extraction, and therefore of the South African economy. The high cost and throughput-limiting nature of comminution forms a strong motivation for research directed at improving the efficiency of the process. Building on a ten year background of fundamental charge motion research, a new formal UCT flotation and communication group has been formed. The group is also moving strongly into the field of milling circuit modelling and simulation, based on close links formed with the Julius Kruttschnitt Mineral Research Centre (JKMRC) of Australia, and an international collaborative research programme.

Jan 1, 1998

By J. Wills

The use of drilling rigs to increasingly mechanize stope drilling has been acknowledged as important for the S.A. mining industry in it ís efforts to tackle the challenges of low productivity, AIDS and an ageing driller workforce. The spin-offs of increased safety, cost-effectiveness and better mining performance provide advantages to all?from the driller to the shareholder. However, implementation or product rollout has varied from outright success to dismal failure. A study of various cases by Novatek and Anglogold TDS showed clear reasons for these differences. Whereas the successes were characterized by clear objectives, accountability, user buy-in, a commitment to make the technology work and no-nonsense reporting, these were typically absent in failed implementations. The attitude at unsuccessful mines was to ?trial? the equipment?even subconsciously, a ?trial? is a test where failure becomes an acceptable outcome. During the study it became clear that mining management are not adequately trained to manage the often-tricky rollout process. They are often also not empowered or clearly mandated to deal with the organizational, human and technical issues that must dovetail to create a success. The output of the study was to develop a basic rollout process that could be used to formally manage the implementation of new drilling technology. Creating an alignment between the mine, workforce and supplier promotes a win-win situation that will not otherwise spontaneously arise.

Jan 1, 2002

By R. T. Jones

Base metals and platinum group metals can be collected in metallic alloy form, via a wide variety of smelting processes. The recovery, or degree of collection, of the valuable metals is a function of the extent of reduction in the furnace, which, in turn, is indicated by the fraction of iron present in the feed materials that report to the alloy. An equation has been developed that relates the recovery of various metals (such as Ni, Co, Cr, and PGMs) to the recovery of Fe. This recovery equation (for each metal) is characterized by a single parameter (K?) that can either be empirically fitted to the data, or expressed in terms of the equilibrium constant and the ratios of the activity coefficients involved. Data from a number of varied DC arc furnace campaigns are presented to illustrate this behaviour.

Jan 1, 2009

By E. Pizarro, A. Videla, G. Compan

One of the main problems related to mining investment decisions is the use of accurate prediction models. Metallurgical recovery is a major source of variability, and in this regard, the Chuquicamata processing plant recovery was modelled as a function of geomining-metallurgical data and ore characteristics obtained from a historical database. In particular, the dataset gathered contains information related to feed grades, ore hardness, particle size, mineralogy, pH, and flotation reagents. A systemic approach was applied to fit a multivariate regression model representing the copper recovery in the plant. The systemic approach consists of an initial projection of the characteristic grinding product size (P80), based upon energy consumption at the particle size reduction step, followed by a flotation recovery model. The model allows for an improvement in the investment decision process by predicting performance and risk. The final geometallurgical model uses eight operational variables and is a significant improvement over conventional prediction models. A validation was performed using a recent data-set, and this showed a high correlation coefficient with a low mean absolute error, which reveals that the geometallurgical model is able to predict, with acceptable accuracy, the actual copper recovery in the plant.

Jan 1, 2015

By L. du Preez, J. D. Steenkamp

This paper introduces the concept of clean steel production from a pyrometallurgist’s perspective to the broader metallurgical community. A simplistic overview of the steelmaking process from iron ore to car body manufacturing is followed by an introduction to the South African steel industry and the technologies that it utilizes. The process is illustrated by an overview of the flow sheet and technologies for the production of clean steel at Saldanha Steel, South Africa.

Jan 1, 2015

By G B. Gnoinski

The Skorpion Zinc Mine and Refinery is situated approximately 25 km north of Rosh Pinah, south-western Namibia. The supergene zinc oxide deposit at Skorpion is hosted in a volcano-sedimentary succession within the para-autochthonous Port Nolloth Zone of the Gariep Belt. Rock types hosting the ore deposit include altered and metamorphosed volcaniclastic and clastic sediments, limestone and rhyolite. At Skorpion, the metallurgical process is unique and the plant design requires minimal fluctuations within a selected feed grade. In addition, the presence of limestone inter-fingered with ore in some areas of the deposit results in dilution problems which may increase gangue acid consumption and therefore processing costs. Hence, selective mining is necessary to ensure the delivery of suitable ore to the processing plant, in order to keep the overall operating costs at a minimum. A complex control system is in place and is capable of a high degree of selectivity. The paper describes the grade control system in place at Skorpion Mine which ensures that the qualities of the blocks planned for mining and the material being mined meet the stringent process requirements of the refinery, i.e zinc grade, gangue acid consumption and deleterious elements that may impact on the efficiency and costs of the metallurgical process. Keywords: Skorpion zinc, zinc oxide, supergene, volcano-sedimentary, grade control

Jan 1, 2007

By D. S. Richards

Computers have revolutionized the collection of data on modern mines. Never before has it been possible to collect data from all aspects of the mining value chain at rates now common. With this has come a new challenge. Deriving information from these copious amounts of data and disseminating it. This problem is being exacerbated by technical software systems, which use proprietary and binary data formats that severely inhibit the flow of data and information both across departments and the larger organization. Generally this had led to data duplication and data redundancy. The Gemcom Enterprise Mining System (GEMS) makes use of industry standard, secure and open databases for all its data objects. It manages multiple users accessing the same bits and bytes in the database, preventing data duplication and redundancy. Developed in the Microsoft BackOffice ® environment, GEMS is also able to leverage the enormous amount of tools available in this environment, whether it’s for e-mail notification, reporting or data capture. Microsoft’s® Active Server Pages are one of these tools. These are standards used to create dynamic and interactive web pages with links into databases and many other objects. The real example outlined in the text, demonstrates how a user anywhere in the world is able to login to a web page and run a query that returns a report with vector plots of performance for the user-selected time frame. As integration is tightened between the various components of the mining value chain, the importance and reliance on ASP pages will grow as the need for management information tools develops. Keywords: mines, computers, ASP, GEMS, integration, Microsoft, Management Information.

Jan 1, 2003

By T. Ertekin, X. Dong

This paper identifies the need for the development of specialized inverse solution techniques for the analysis of pressure transient data for the characterization of the transport and sorption properties of coal seams. Central to the proposed inverse solution technique is a specially structured artificial neural network (ANN). The most important transport and sorption characteristics of coal seams are butt and face cleat permeabilities, macropore porosity, Langmuir volume constant, Langmuir pressure constant, and sorption time constant. Conventional methods, such as type curve matching techniques and laboratory-derived measurements are handicapped in terms of being representative over the entire domain of interest. In this paper, we utilize analytical forward solution techniques for various combinations of characteristics of coal seams to generate training and testing patterns. These training patterns are shown to an ANN structured to learn the ubiquitous non-linear relationships that exist between coal seam properties, input conditions and the pressure transients measured. The trained networks are then extensively tested to ensure that they have effectively learned the training patterns. In the final stage of the development, the networks are run in the prediction mode. The responses of the networks are found to be in agreement with the input data. The developed networks are able to generate results generally within 5% error margin for permeability and porosity and 20% error margin for the sorption characteristics of coal seams. A number of examples highlighting the capabilities and degree of effectiveness of the network in characterizing the coal seams areincluded. Keywords: artificial neural networks (ANNs); coal seam characteristics; pressure transient analysis

Jan 1, 2003

By L. F. Contreras

In open pit mine design, it is customary for geotechnical engineers to define the appropriate slope design angles within practical limits. The conventional approach to slope angle design is based on the comparison of calculated stability indicators, such as the factor of safety (FS) and the probability of failure (PF), with generic acceptability criteria not directly related to the impacts of failure. A major drawback of this type of approach is related to the difficulty of defining meaningful acceptability criteria. An alternative methodology of pit slope design is proposed, where the economic impacts of potential slope failures are calculated and used as the elements on which to apply the acceptability criteria for design. The methodology is based on the construction of a graph, referred to as a risk map, that relates the probability of exceeding the economic impact of slope failure to the magnitude of the impact measured in monetary terms. The process includes the analysis of a selected number of representative years of the mine plan and slope sections of the pit areas to define the required inputs for the construction of the risk map. The paper discusses the concepts used in interpreting the probability of slope failure, and describes the approach followed for the estimation of the economic impacts of slope failure and the construction of the risk map. Finally, the two main uses of the risk map are discussed, including the comparison with acceptability criteria for the evaluation of a specific open pit design and the comparative analysis of open pit design options in terms of value and risk to identify optimum pit layouts.

Jan 1, 2015

By E. A. van Wyk, M. R. de Villiers

"Mining companies strive to increase and maintain production, while simultaneously remaining competitive in the global economy. Furthermore, they must ensure workers’ safety and maintain good safety records. The use of virtual reality (VR) facilitates the development of tools and systems for various purposes that can improve knowledge and understanding of the work environment. VR is a rapidly growing technology that uses the ever-increasing power of computing to simulate real-world and imaginary environments and situations with a high degree of realism and interaction. The availability of 3D modelling tools and simulation programming engines that work effectively with a mid-range desktop PC and standard 3D graphics card, make VR technology viable and attractive for mainstream training applications. The design, development, and implementation of interactive VR training systems is proposed as an innovative approach to augment safety training. However, in order to assess the impact of such VR training systems it is of particular importance to determine the effectiveness of the design of such systems. This article proposes an evaluation framework for this vital purpose. This framework comprises criteria to assess VR training systems, specifically relating to usability, instructional design, VR systems design, and mining industry context-specific aspects. Although the framework was developed as an evaluation tool to assess effectiveness of the design of such systems, it can equally well be used as a set of design principles to inform the design of VR training systems for mining. IntroductionMining in South Africa has been the main driving force behind the history and development of Africa’s richest and most advanced economy (Coka, 2012). The South African mining industry is frequently criticised for its poor safety record and high fatality rate (Stoddard and Skweyiya, 2016). Inadequate or insufficient training is often cited as a root cause of accidents (Van Wyk and De Villiers, 2009; Tichon and Burgess-Limerick, 2011). Virtual reality (VR) is a rapidly growing technology that utilizes the ever-increasing power of computing to simulate real-world and imaginary environments and situations with a high degree of realism and interaction (Webber-Youngman and Van Wyk, 2013). VR is currently being used or investigated as a training solution in a variety of industries. VR technology has developed rapidly and costs have fallen to levels where it can now be considered for mainstream training applications. The availability of 3D modelling tools and simulation programming engines that work effectively with a mid-range desktop PC and a standard 3D graphics card, make VR even more attractive to mine training centres (Van Wyk and De Villiers, 2009)."

May 1, 2019

The 109th Annual General Meeting of The South African Institute of Mining and Metallurgy was held at The Country Club, Johannesburg, Napier Road, Auckland Park on Wednesday, 16 August 2006. Special General Meeting A Special General Meeting to consider the changes to the Constitution was held immediately prior to the AGM. 1. Purpose In order for the SAIMM to remain relevant and ensure maximum value to all members, Council propose three changes to the Constitution. 2. Background Three changes to the Constitution were proposed by the Council on 21 July 2006. These changes now have to be approved by means of a ballot at a Special General Meeting. These three proposed changes are discussed briefly below:

Jan 1, 2006

By R. G. Cawthorn

The vertical distribution of platinum-group elements (PGE) in the Merensky and UG2 chromitite Reefs is highly variable, but does follow certain general patterns that allow the testing of geological models. In the Merensky reef, historically popular geological representations and interpretations have suggested that the mineralization occurs in a pegmatitic pyroxenite bounded by two chromitite layers. However, there are now enough published exceptions to this relationship to expose its fallacy. The vertical distribution of the PGE depends largely upon the separation between these two chromitite layers or the absence of one chromitite layer. Where separation is small or only one chromitite layer is present, there is considerable PGE mineralization in the footwall below the pyroxenite and lower chromitite layer. With increasing separation between the two chromitites, the mineral¬ization occurs progressively higher in the succession, and tends to track the upper chromitite layer. The view presented here is that the entire Merensky package is comprised of three events of magma emplacement, in which each has produced variable reaction with, and erosion of, the footwall, causing recrystallization of pyroxenite into pegmatitic pyroxenite. The magma then produced a chromitite layer followed by pyroxenite. Each chromitite layer is associated with some mineralization, which was extensively complemented by the subsequent formation of a sulphide liquid carrying PGE that trickled down through about 1 m of permeable crystal pile. The sulphide liquid formed after, not coincident with, the pyroxenite layers. The distribution of PGE in the UG2 chromitite shows up to three upward depletion sequences of PGE, also suggesting three events. The PGE are associated only with the chromite. The contribution from a sulphide liquid is considered to have been minimal for two reasons. Cu and Ni are extremely low in the UG2 which would not be expected if sulphides had been present. Also, by analogy with the Merensky, downward trickling of sulphides would have caused some PGE to be present in the footwall. There are some PGE in the footwall, but only where remnants of chromitite occur, and the hanging wall is lacking in PGE. In the northeastern Bushveld the UG2 chromitite is thinner than elsewhere, and there is a UG3 chromitite layer, not present elsewhere, that has a high Pt/Pd ratio. It is surmized that in the rest of the Bushveld the UG3 only appears to be absent because it has merged with the UG2 to produce the high Pt concentration at the top of the composite UG2. The non-accumulation of the package of pyroxenite-norite-anorthosite between the UG2 and UG3 in the northeastern Bushveld, which is not seen elsewhere, creates an interesting challenge to the formation of silicate layering in the complex. The mineralization in the Platreef is not addressed here. Keywords Bushveld complex, Merensky Reef, UG2 chromitite, geological evolution.

Jan 1, 2011

By M. Soleymani Shishvan

"Continuous mining systems containing multiple excavators producing multiple products of raw materials are highly complex, exhibiting strong interdependency between constituents. Furthermore, random variables govern the system, which causes uncertainty in the supply of raw materials: uncertainty in knowledge about the reserve, the quantity demanded by the customers, and the breakdown of equipment. This paper presents a stochastic-based mine process simulator capturing different sources of uncertainties. It aims to quantify the effect of geological uncertainty and its impacts on the ability to deliver contractually defined quantities and qualities of coal, and on the system efficiency in terms of utilization of major equipment. Two different areas of research are combined: geostatistical simulation for capturing geological uncertainty, and stochastic process simulation to predict the performance and reliability of a large continuous mining system.The process of modelling and simulation in this specific production environment is discussed in detail. Problem specification and a new integrated simulation approach are presented. A case study in a large coal mine is used to demonstrate the impacts and evaluate the results in terms of reaching optimal production control decisions to increase average equipment utilization and control coal quality and quantity. The new approach is expected to lead to more robust decisions, improved efficiencies, and better coal quality management.IntroductionContinuous coal mining systems containing multiple excavators producing multiple products of raw materials are highly complex and exhibit strong interdependencies between constituents. A network of conveyor belts is used for transportation of the extracted materials to different waste dumps or the coal stockpile.Optimal decision-making in short-term planning and production control are impacted mainly by geological uncertainty associated with incomplete knowledge of the coal deposit represented in the reserve block model. These uncertainties cause deviations from expected process performance. For more robust decision-making, understanding the impacts of these stochastic elements plays a key role."

Jan 1, 2016

By L. Lehasa

The purpose of the project was to investigate the challenges faced by Khutala Colliery pertaining to underground road construction and maintenance. Furthermore the influence of these challenges on productivity and safety requirements were taken into consideration. The operating standards required for the construction and maintenance of the 2 seam road transport infrastructure was investigated, together with reasons why the standards of operating procedure are not met. The Code of Practice put in place by Khutala Colliery was used to view the standard operating procedures. Leading practices on underground road construction were researched. The project aims to discover the gaps that Khutala Colliery must bridge to implement enhanced practices with regards to underground road construction. During the period of study, observations were carried out to determine whether the road construction standards of operating procedure were being adhered to at all times for both road construction and road maintenance. Khutala Colliery has put in place a traffic management plan, which includes safety practices and work policies that must be adhered to while travelling on underground transport roads.

Jan 1, 2012

By G. Apsey

Eutectic freeze crystallization (EFC) is a novel technique for the recovery of pure salt and pure water from hypersaline waste brines. It is therefore a promising technology for the treatment of industrial waste waters. The impurities caused by crystallizing salt out of multi-component brines by EFC have not yet been investigated, however. To these ends, the selenium impurity found in sodium sulphate, produced from the waste brine of a platinum operation, was investigated. It was believed that the similarity between sulphate and selenate ions allowed isomorphous substitution of selenate ions into the sodium sulphate crystals, which was the likely cause of impurity uptake. It was found that the presence of sodium chloride in the industrial brine promotes the uptake of selenium, while ionic strength of the brine and mass deposition rate of sodium sulphate did not have a significant effect on the selenium uptake. Isomorphous substitution is predicted to be the most significant mechanism by which all impurities will be taken up when applying EFC to other industrial waste brines.

Jan 1, 2013

The 108th Annual General Meeting of The South African Institute of Mining and Metallurgy was held at The Country Club, Johannesburg, Napier Road, Auckland Park on Thursday, 11 August, 2005. 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: Dr Con Fauconnier, President, Chamber of Mines of South Africa Prof. Jay Barton, President, The Geological Society of South Africa V. Townshend, President, Institute of Certificated Mechanical and Electric Engineering, South Africa M. Livingstone-Blevins, President, Institute of Certificated Mechanical and Electrical Engineers, South Africa Prof. B. Lacquet, President, South African Institute of Electrical Engineers Dr F. Malan, President, South African National Institute of Rock Engineering

Jan 1, 2005

By I. Bock

Selective Blast Mining (SBM) makes use of milli-second sequential blasting technology to separate the valuable reef material from waste rock in the blasting operation at stope faces in the mining of tabular ore bodies such as exist in the gold and platinum mines in South Africa. The waste rock is cast blast to the back of the stoping area, and the reef material is fractured and deposited close to the stope face. Only the reef material is transported to the surface. A simplified economic model is presented to evaluate the economic benefits of SBM. Although premature, in that adequate experimental demonstration of the validity of the model has not yet been possible, the model is presented since it indicates substantial benefits in the case of narrow reef gold mines. It is suggested that many marginal mines should seriously consider SBM. Benefits can also be realised in platinum mines, but a lot more experimental work is necessary to establish cost parameters more reliably. Some practical experience in the use of SBM in the mining of the UG2 reef is presented.

Jan 1, 1998