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By M. Balamurali, K. M. Seiler

Modelling stockpiles is a key factor of a project’s economics and operation in mining, because not all the mined ores are not able to mill for many reasons. Furthermore, the financial value of the ore in the stockpile needs to be reflected on the balance sheet. Therefore, automatically tracking the boundaries of the stockpile facilitates the mine scheduling engineers to calculate the tonnage of the ore remaining in the stockpile. This paper suggests how the dynamic of stockpile shape changes caused by dumping and reclaiming operations can be inferred using polygon models. The paper also demonstrates how the geometry of stockpiles can be inferred in the absence of reclaimed bucket information, in which case the reclaim polygons are established using the digger’s global positioning system (GPS) positional data at the time of truck loading. This work further compares two polygon models for creating 2D shapes.

Sep 1, 2021

By Steven M. Rupprecht

"The artisanal mining sector in Central Africa is largely informal, yet provides an essential livelihood for many (directly or indirectly) participants, as well as facilitating an important source for the flow of income into many communities. Artisanal mining varies from site to site, but appear largely well structured despite its informality. The artisanal mining sites in Central Africa have some inherent management structure and the extraction itself is often organised. Artisanal mining is labour intensive and is generally conducted utilising hand digging methods e.g. shovels or hand chisels. Artisanal mining is generally more dangerous than small-scale or large-scale modern mining operations. This is especially true as artisanal operations are generally subsistence activities with artisanal miners focusing more on immediate concerns than the long-term consequences of their activities. When miners have no other source of income, they will usually find ways to evade controls and carry on working. The objective, through proper/dedicated training of artisanal miners is to migrate Artisanal mining to establish a small-scale mining (SSM) industry in Central Africa. Through developing the necessary skills in the fundamental areas of mining it is proposed that Artisanal Mining can become more productive and safer mining operations. The paper reviews the above focus areas, highlighting the skills and tools that are necessary to assist in establishing a sustainable small scale mining industry migrating from manual labour to semi-mechanised mining and processing. The purpose of the transformation process is to create a safe, healthy, environmental and community oriented mining operation with the objective to uplift the skills and wealth of the mineworkers and the general community."

Jan 1, 2015

The University of New South Wales (UNSW Australia) has been a world leader in the development of innovative virtual reality technologies over the last 15 years. AVIE (Advanced Visualisation and Interactive Environment) was developed by iCinema as a collaborative venture between UNSW?s Faculties of Engineering and the College of Fine Arts. This is the world?s first 360°-surround, virtual reality (VR) stereo projection theatre system. The School of Mining Engineering at UNSW Australia has developed 18 different virtual reality modules aimed at mine safety training and mining engineering education. These modules are being regularly used in both the mining industry and the university. The School of Mining Engineering is continuously involved in the development of different modules. Research is also currently being conducted on the implementation of other technologies into this environment. Artificial intelligence (AI) and fuzzy logic are tools that the authors would like to consider implementing in future module development. This paper will review current research in both these areas and consider options for applying these technologies.

Jan 1, 2014

By C. Scheffer

This paper describes a model that can simulate the behaviour of a pneumatic intensifier that is generally referred to as an ?air pump? (AP). The AP is used in many South African underground mines, and utilizes compressed air with pressures between 0.3?0.6 MPa to pump water up to pressures of 12?18 MPa. The high pressure water is used in numerous underground mines to pressurize props and roof bolts that act as safety and roof support devices. The simulation model reproduces the intensifier's operation under various conditions and therefore can be used to investigate the AP's sensitivity towards environmental conditions, design parameters (such as spring stiffness, plunger diameter, nozzle diameter etc.) and operating conditions. Model validation by comparison with laboratory experiments showed good correlation. The model can subsequently be used to investigate design changes aimed at improving the AP's performance and reliability over a wider range of operating conditions.

Jan 1, 2005

By S. J. Frank

Ferroalloy furnaces are well known to be extremely difficult to control from a metallurgical perspective. Mostly metallurgical control is still reactive in nature, causing a significant amount of reworking and product blending to achieve a proper product specification. Despite numerous efforts towards the model based control of primary smelting operations, actual metallurgical feed forward control seems to remain elusive. One of the key reasons in the failure to model these metallurgical reactors well, is that fundamentally orientated pyrometallurgists, statisticians, data miners and control engineers very often have diverging ideas how to model these systems. Furthermore, metallurgists have often come to rely on their ability to develop empirical regression models of furnace behaviour, as they have lost their faith in the ability of thermochemical and metallurgical engineering fundamentals to accurately predict the outcomes from furnaces. This paper shows how good thermochemical modelling can be combined with proper technological and systems analysis, as well as a proper inventory model, to predict the alloy and slag chemistry with good accuracy one tap into the future, at a time horizon of typically around 4 to 6 hours. For this modelling approach, a number of tools will be used, such as data reconciliation, thermodynamic modelling using Fact Sage®, inventory and heel estimation, neural networks and statistical data exploration. Furthermore, systems identification theory will be combined with the approaches given above to develop a truly dynamic predictive model. This paper seeks to demonstrate the need for a hybrid approach, which incorporates plant data and readily accessible thermodynamic data to develop a proper dynamic model.

Jan 1, 2004

By T. Nghipulile, G. Dzinomwa, J. Kurasha, M. Amwaama, B. Mapani, K. Maweja, T. E. Moongo

The effect of mineralogy on the grindability was investigated using three copper ores – two sulphides and one oxide. The dominant copper minerals were identified by optical microscopy and mineral chemistry derived from SEM-EDS analysis. The sample designated sulphide 1 was borniterich, sulphide 2 ore was mainly chalcopyrite, and the oxide ore was predominantly malachite and minor azurite. The gangue minerals were identified using semi-qualitative XRD analysis. Sulphide 1 contained more than 80% (w/w) of quartz compared to about 70% in the other two ores. The Bond work indices were 13.8, 21.6, and 17.3 kWh/t for sulphide 1, sulphide 2, and oxide ore respectively. This suggested that the chalcopyrite-rich ore is the hardest, while the malachite-rich ore has intermediate hardness, and the bornite-rich ore is the softest. The brittleness indices of the ores were calculated using the chemical composition of the gangue, and a good correlation between brittleness indices and Bond work indices was observed, which highlights the importance of the gangue composition in determining the fracture behaviour of the ores. There is scope for further investigation into the relationship between ore mineralogy and comminution behaviour using other breakage characterization techniques.

Mar 30, 2023

By J. C. Vreugdenburg, B. A. Dippenaar, J. Muller, T. L. de Vries

Iron ore fines are agglomerated to produce sinter, which is an important feed material for blast furnaces worldwide. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed mixtures is evaluated. The model aims to predict sinter quality, including chemical quality and physical strength, as well as key sinter process performance parameters such as production rate and fuel consumption rate. The model uses the finite difference method (FDM) to solve heat and mass distributions within the sinter pot over the height and time dimensions. This model can further be used for establishing empirical relationships between modelled parameters and measured sinter properties. Inputs into the model include the feed material physical properties, chemical compositions, and boundary conditions. Submodels describe relationships between applied pressure differential and gas flow rate through the bed of granulated fine ore particles, combustion of carbonaceous material, calcination of fluxes, evaporation and condensation of water, and melting and solidification. The model was applied to typical sinter test conditions to illustrate the results predicted, and to test sensitivities to parameters such as feed void fraction, feed coke percentage, and the fraction of combustion heat transferred to the gas phase. A model validation and improvement study should follow, ensuring sinter test results are free from experimental errors by conducting repeated tests.

Jan 1, 2015

By K. Coleman, C. Visser, N. Selby, X. W. Pan, T. Letwaba

A prototype weightometer soft sensor is under development at DebTech, De Beers in partnership with Venetia Mine. Its main function consists of an online data source; data validation; dynamic weightometer models; online detection of weightometer failure; alarming and replacing a weightometer when it fails. 31 dynamic models have been developed. All models with R2>= 85%are accepted as good models and they generally have satisfactory results with a daily error of less than 8% within 90% confidence level. By using those models, a set of soft sensors can be set up to cover all weightometers in the entire processes starting from primary crushing to the stock piles of dense medium separation (DMS). Some practical issues and concerns on model development are discussed, including data collection, data analysis, data pre-processing, variable selection, time delay, model training and model validation. When deploying the weightometer soft sensor system, the potential benefits could include: reduction in plant downtime; reduction in unplanned maintenance and even replacement of non-critical weightometers, particularly where nuclear weightometers are used. Keywords: soft sensor, weightometer, dynamic modelling, neural network modelling

Jan 1, 2003

Mineral Resource Throughput Management is based on the extraction of the maximum potential value from an ore reserve with the emphasis to generate maximum ROI and ROR (return on reserve). A steel producing company in India implemented MRTM to significantly improve their ROI and ROR. The value chain of this company consists of their own iron ore and coal mines, ore washing plants, sinter plants, steel plants, and sales and marketing division. The target for the mines was to produce at a stable and predictable rate and at specific quality requirements. These requirements were set to improve productivity and ROI of the steel plant. The implementation constituted the alignment of the reserve potential, total production chain, human resources and management culture at the mines with the requirements of the steel plant. Many typical mining practices were challenged and changed. Production targets regarding lump vs. fines ratio, consistent product tons, quality targets such as Fe, Al content and moist, and standard deviation on the quality targets were not achieved. A reverse distribution model with release mechanisms to satisfy the demand were developed and implemented at the mines. A stable and predictable flow of mine product with quality standards well within the required standard deviation targets were achieved. The contribution from the mines to significantly improve the Net Profit, ROI and ROR of the company were reached.

Jan 1, 2007

Keywords: Pyrometallurgy, furnace, Lonmin, platinum, PGM, UG2 Lonmin, earlier than any other primary platinum producer, had to deal with the concentrating and smelting of UG2-rich ores and concentrates respectively. Smelting was performed at a fairly modest scale compared to its industry peers in the Platinum Group Metals (PGMs) industry, and was focused on smelting concentrates obtained through low mass pulls while still maintaining high recoveries at its concentrators. Lonmin gradually smelted larger quantities of UG2 concentrates. Initially two 2.3 MW Infurnco furnaces were commissioned in 1982, followed by three 5 MW circular 3-electrode Pyromet furnaces in 1991. Deep electrode immersions and moderately high hearth power densities were used in all the designs. Lonmin decided to continue with circular furnace technology when it planned its new high-intensity No. 1 Furnace. Neither Lonmin nor the technology supplier and EPCM company foresaw the challenges that scale-up would bring when applied to the smelting of UG2-rich concentrate blends. Superimposed on the high chromite content, was the low base-metal loading, mineralogical difficulties, and fine particle size that came with milling of all concentrates (especially UG2 and recycle materials within the smelter). Through a process of fundamental diagnoses of furnace run-outs and wear patterns observed during repairs, the main challenges operating this high-intensity furnace were identified as sulphur vapour corrosion of the copper coolers, uneven and unpredicted movements of refractory bricks with associated copper cooler lift and matte tap-block movement, the formation of three-phase ?mushy? zones, high refractory and tap-hole wear rates, uncertainty in matte level and associated insufficient matte buffer height, and high furnace operating temperatures. These factors seldom worked in isolation and will be explored in more detail in the paper. The variability in furnace feed characteristics led Lonmin to re-design Furnace No. 1, to invest in back-up furnace capacity, and to invest in improved monitoring and control. These improvements consisted of online and high-frequency off-line feed chemistry and mineralogy monitoring, online pressure monitoring of water-cooled circuits, an alternative matte liquid level measurement in the furnace, and electrode immersion estimation. Improvements were also made at the converters by installing and utilising optical spectral analysis of the converter flame to characterise converter behaviour and achieve the desired iron end-point for white matte. This paper also briefly discusses the current and future expansion plans, as well as ancillary operations at the smelter such as flue-gas handling and materials handling.

Jan 1, 2011

By J. C. Taylor

The Rhodax inertial cone grinder, designed by France?s FCB Group Fives, is the result of three years, theoretical and mechanical research in the field of compression grinding by the research staff of FCB?s CRM minerals research centre. A number of potential uses have been assessed and will be discussed in the paper. The crusher is an inertial grinder that works on the pressurized bed fragmentation principle. The fragmentation force is caused by the rotation of unbalanced masses rather than by an eccentric mass, as is the case in a conventional crusher. This makes it possible to achieve very high reduction ratios. By controlling the speed of rotation of the unbalanced masses, the grinding force can be modified, thus changing the product size distribution. The paper describes the machine layout, operating principles, control parameters and will briefly describe the results obtained on reef, waste and ROM reject pebbles. Some comparisons are made with conventional crushing.

Jan 1, 1998

By A. Thoraval, K. B. Slimane, O. Ozanam

The REP experiment is part of the research programme conducted by Andra to investigate the possibility of reversible radwaste disposal in a Jurassic (Callovo-Oxfordian) argillite formation at the Meuse/Haute-Marne underground laboratory site in northeastern France. The experiment focuses on the hydromechanical response of the formation to sinking the laboratory access shaft. Modelling of boreholes and shaft sinking operations has helped to optimise measurement point locations based on initial stress tensor anisotropy, while minimising interaction between instrument boreholes. Analyses were made of model sensitivity to intrinsic rock characteristics, hydromechanical coupling properties and sensor installation procedures. L’expérimentation REP fait partie du programme de recherche pluridisciplinaire engagé par l’Andra pour étudier la possibilité d’un stockage réversible des déchets radioactifs dans la formation Callovo-Oxfordienne des argilites du site de Meuse/Haute-Marne (Commune de Bure - France). Cette expérimentation permettra d’étudier la REponse hydromécanique de la formation aux sollicitations engendrées par le fonçage du Puits d’accès du laboratoire souterrain de recherche. Afin d’optimiser le positionnement des points de mesures, compte tenu de l’anisotropie du tenseur des contraintes initiales, et de minimiser les interactions entre les forages d’instrumentation, des modélisations des forages et du creusement du puits ont été conduites. Des analyses de sensibilité aux caractéristiques intrinsèques de la roche, aux propriétés de couplage HM et aux protocoles d’installation des capteurs ont été faites. Die REP-Untersuchung ist Teil des multidisziplinären Forschungsprogramms, das die ANDRA im Callovo-Oxfordian-Tonstein in situ am Standort Meuse/Haute Marne (Gemeinde Bure – Frankreich) im Hinblick auf eine Eignung zur reversiblen Lagerung radioaktiver Abfälle durchführt. Dabei soll das hydro-mechanische Verhalten der Formation auf die Beanspruchungen, die durch das Abteufen des Zugangsschachts zum Untertage-Forschungslabor erzeugt werden, untersucht werden. Zur optimalen Positionierung der Messpunkte unter Berücksichtigung der Anisotropie des Tensors der Ausgangsspannungen und zur Minimierung der gegenseitigen Beeinflussung der Instrumentierbohrungen wurden ein Schachtabteuf- und Bohrmodelle entwickelt. Zur Untersuchung der inhärenten Eigenschaften des Gesteins, des gekoppelten HM-Verhaltens und der Installationsprotokolle der Messsonden wurden Sensibilitätsanalysen durchgeführt.

Jan 1, 2003

By W. M. Jansen

In many mineral processing operations, the reported production figures for an accounting period may not make the best use of available data. While most of the mathematical approaches, such as check-in/check-out, mass balancing, used in effective metallurgical accounting strategies are well understood, the sources and magnitude of measurement errors generally are not. As part of the 'AMIRA P754-Metal Accounting and Reconciliation' project, a study was undertaken at the Northparkes copper/gold concentrator near Parkes, New South Wales to examine the data used in their concentrator metallurgical accounting system. This paper summarises the results of a detailed examination of the mass measurement systems around the concentrator as well as the primary sampling system used for grade estimation. The goal of this work was to develop practical techniques to quantify the error (ie both accuracy and precision) of the measured metal accounting information. With this information, statistical confidence levels for this data can then be calculated. If the errors are small, the effect of error in each piece of measured data can then be propagated to other calculated production figures such as recovery and feed grade using a statistical technique called `the propagation of error'.

Jan 1, 2007

By Mark Van Kleek

CONTENTS ?The Falcon C ?Data from a Production Trial ?Methodology ?Scale-up ?Test Results ?Circuit Configurations ?Conclusion

Jan 1, 2006

By E. Laine

Rock density determinations are necessary for ore resource evaluations from estimated block grades in g/t. Rock density depends on the mineral composition and, thus, it is specific for each rock type. The rock density distributions for different rock types are often symmetric. Hence, the arithmetic mean is a good approximation for the average density for lithological units. However, there may exist spatial variation in density values due to alteration, fracturing and original heterogeneities such as layering. This study compares the kriged density model with the one with constant density values for different lithological units in the evaluation of metal amounts in rock blocks. The case study consisted of rock densities measured from the drill cores at Ahmavaara PGE deposit in northern Finland. The used Ni contents were simulated in accordance with the spatial distribution of rock densities. The Ni amounts in 2x2x2 m3blocks are higher for the kriged densities than for the average densities. The difference is increasing with the increasing metal amounts due to the nonlinear correlation between Ni content and rock density. The final effect on the resource estimation depends on the cutt off grade and prices of the metal, for example, for a very valuable metal the small differences are significant

Jan 1, 2003

By J. N. Van der Merwe

"The probability of survival of coal pillars is a more rational indicator of stability than the safety factor. Over time, pillars undergo reduction in size by progressive scaling of the sidewalls. The probability of survival is therefore not constant but reduces over time. The rate of scaling can be quantified, and the reduction of the probability of survival as a function of time can therefore also be quantified. The paper describes the link between the factor of safety, probability of survival, and reduction of the probability of survival. Using the safety factor, probability of survival, and the time at which the probability of survival will reduce to 50% is proposed as a more rational method of evaluating pillar stability than the safety factor alone.IntroductionCoal pillar strength has long been the subject of research in South Africa and several other coal-producing countries. However, it began receiving serious attention only after the Coalbrook disaster in 1960. The most important outcomes of the initial investigations were the groundbreaking research by Salamon and Munro (1967) that resulted in the well-known power formula for pillar strength, and the work by Bieniawski (1969) that resulted in a linear formula for strength. The former approach was based on empirical back-analysis of failed and stable pillar cases, and the latter on in situ strength tests on large specimens.The Salamon and Munro (1967) formula has been widely used in South Africa and even adapted for application to hard rock pillars by researchers such as Hedley and Grant (1972).At the time of the initial work by Salamon and Munro, there were only 27 failed pillar cases suitable for analysis. It was not possible at the time to determine site- or seam-specific strength, and the result was a general formula for use in all seams in all mining districts. Since that time pillars have continued to fail and the database continued to grow – as of 2013, there were 85 cases in the database. Using the additional data, there have been a number of re-evaluations of the strength formula and it has also become possible to differentiate between the different mining seams and areas."

Jan 1, 2016

By T. R. Curr, W. A. Gericke, J. Basson

South Africa is a leading player in the international ferro alloys industry. Historical factors that have contributed to this dominant position include an abundance of natural resources and relatively low cost electricity. A number of relatively recent developments are potentially threatening this position. These include new legislation affecting the mining and minerals industry, a shortage of some types of suitable reductants, depletion of surplus electricity generation capacity with resultant threat of real escalation of electricity prices and pressure resulting from the recent strengthening of the South African Rand. The industry is addressing these challenges in a number of ways to ensure long-term viability. Some of these measures include investments in more efficient technologies that have economy of scale benefits and are less dependent on expensive reductants and electricity. Local macro-economic impacts include new legislation regarding ownership of enter-prises, mineral rights and royalties on mineral sales, development plans for port and rail infrastructure, as well as initiatives to expand electricity generation and coke production capacity. The fundamentals for being a successful ferro alloy producer are still largely in place for South African producers. Therefore the South African ferro alloy industry will remain competitive and is well placed for continued growth in line with the international growth in ferro alloy demand. The industry should emerge leaner, more efficient and ready to respond to any future demands of the industry. This paper will cover the present status of the industry, the factors that are impacting thereon and a view on its future outlook.

Jan 1, 2007

By G. Howell, J. Wates, A. Coetzee, C. J. MacRobert

The Global Industry Standard on Tailings Management (GISTM) requires mining companies to make four key appointments as part of their tailings management structure. These four positions are an Accountable Executive with policymaking responsibilities, a Responsible Tailings Facility Engineer with operational responsibility, an Engineer of Record to ensure facilities are designed, operated, and closed safely, and an Independent Tailings Review Board to assess safety drivers regularly. Little guidance on the traits of these individuals is available in a South African context. Consequently, the tailings community of practice was surveyed to develop a table of ideal competencies and establish the flexibility in meeting these traits.

Jun 2, 2022

By R. Burger, M. Masukawa

Cato Ridge Alloys (CRA) is a joint venture company between Assmang of South Africa, Mizushima Ferro Alloy Company (MZK) and Sumitomo Corporation from Japan. Negotiations for the formation of the company started in 1992 with the joint venture agreement signed on the 19th September 1996. MZK was to supply the technical know how for the production of Medium and Low Carbon FeMn while Assmang was to manage the day to day activities of the company. Sumitomo Corporation was to act as facilitator between Assmang and MZK and, together with Ore and Metal are responsible for the marketing of the refined products. The conceptual design of the plant started in December 1996 and the first charge of molten high carbon ferromanganese metal was charged on the 19th January 1998. Problems experienced during the initial startup period were addressed resulting in substantial operational improvements. A build-up in the stock of fine metal was addressed through the development of a process to remelt the fine metal, the development of a market for fine metal and the upgrading of the crushing and screening plant to reduce the generation of fine metal. The mass yield from High Carbon Ferromanganese to Refined Ferromanganese was increased through the implementation of statistical process control, changes to the blowing patterns and the development of a sampling device for taking samples during the process. Converter refractory consumption was reduced. This was achieved on the converter by improving the cooling of the converters with the installation of cooling fans and cooling fins. The heating schedule of the converters was changed for improved refractory life. Production schedules were modified to allow cooling of the refractory between low carbon erromanganese charges. Additional changes made to improve operations were: ? Changing from mehanite casting trays to metal fines beds. ? Installation of sonic horns in the baghouse to prevent the bridging of dust. ? Improved welding on the lance tips.

Jan 1, 2004

By R. E. Wilmot

This paper is based on the experiences, over many years, on the part of numerous authors in the South African mining industry and that of the hot dip galvanizing process and its application as a corrosion protection system. The paper sets out the extensive development, financial resources and stringent operating requirements of the South African mining industry. After many years of research and operational experiences, hot dip galvanizing and when necessary, duplex systems, have been found to meet the demanding requirements of this particular industry. The paper sets out the requirements from the standpoint of corrosion criteria and is followed with a practical example; ?case history? where the corrosion protection properties of hot dip galvanizing are demonstrated. This case history traces the early investigation of the expected corrosive conditions to be encountered in a new mining operation (now 10 years on) and concludes with two follow up visits to the mine in order to examine actual performance of the corrosion protection system after ten years in service.

Jan 1, 2006