Search Documents

In their excellent paper, Milev and Spottiswoode have provided quantitative and definitive descriptions of an important phenomenon that hitherto has been largely the subject of conjecture. They convincingly show that ?site-response? can amplify the strong ground motions on the rock-wall of a stressed tunnel by a factor of 10 to 12 compared with the PPV in the solid rock mass (at the same distance from source). This knowledge gives us a firm foundation from which to begin to build an understanding of the mechanism of damage resulting from a rock burst. Regrettably this understanding is still far from adequate, in my opinion. The authors of this paper, however, have made some statements that are too reassuring and which tend to reinforce the sense of complacency that prevails among many members of the rock engineering community on the deep gold mines.

Jan 1, 2006

By I. Alp

Application of magnetic separation was investigated for the enrichment of colemanite ores by removing the magnetic gangue fraction. The detailed XRD analysis of the ore has indicated that the gangue fraction is composed predominantly of the iron-bearing silicates such as smectite and, to a lesser extent, illite. Magnetic susceptibility measurements of the colemanite and gangue samples have proved that colemanite is diamagnetic in character whereas gangue fraction is weakly paramagnetic to allow the removal of this fraction by magnetic separation. Magnetic separation of the crushed and sized ore samples (-5 mm +75 µm) was performed using a high intensity permanent magnetic separator. Under the test conditions a colemanite concentrate (41.29 wt.% B2O3) was found to be produced from the crushed ore (30.76 wt.% B2O3) at a recovery of 96.76%. These findings suggest that magnetic separation has great potential as an alternative process for the production of a concentrate of commercially sufficient grade.

Jan 1, 2009

By J. Härkki, R. Hiltunen

The Akanvaara intrusion (surface area 50-55 km2) in Savukoski, Northern Finland, hosts 23 distinct monocumulate layers of small euhedral chromite crystals enclosed in a silicate matrix. These chromitite layers have been divided into four groups; UC (upper chromitite), ULC (uppermost lower chromitite) LC (lower chromitite) and LLC (lowermost lower chromitite). The driving force for investigating the Akanvaara chromites and their reduction behaviour originated from their very low MgO content and relatively low Al2O3 content, giving them a unique quality which based on thermodynamics should facilitate the reduction. Another interesting feature is the high amount of V2O3 present especially in the upper chromitite. The chromites included in this study are from the UC and ULC layers (24.9 and 22.7 per cent Cr2O3 respectively). To obtain a better understanding of the reduction behaviour of Akanvaara samples in comparison to MgO-bearing chromitites, Kemi chromite from the ferrochrome works in Tornio, Finland, was included in the study as a reference sample. The reduction experiments were isothermal in a temperature range of 1000-1400°C in CO atmosphere. Experiments were also conducted with coke addition in pellets and briquettes in CO/Ar/H2 atmospheres. The results of the reduction experiments complemented with microanalytical research indicate that the Akanvaara chromites do reduce to a higher degree than the Kemi chromite. Although the aim was to characterize the mechanisms of reduction focusing on gas-solid reactions, the nature and amount of the gangue minerals was such that a considerable amount of slag phase was formed, which affected the reduction mechanisms extensively. The structural features together with low MgO and high FeO content in both Akanvaara chromites are important factors resulting in better reducibility than in the Kemi chromite.

Jan 1, 2004

By S. Kauvosaari, M. Olofsson, O. Haavisto, M. Kosonen, J. Martikainen

The target in grinding circuit operation is usually to maximise the throughput and energy efficiency while keeping the product particle size on an optimal level for downstream operations. Furthermore, feed ore variations in size and hardness need to be compensated in order to stabilise the process. This is a challenging task for any circuit and requires good instrumentation, combined with careful control design. This study investigates the control of a two-stage iron ore grinding circuit with an AG and pebble mill at LKAB Kiruna KA3 concentrator in northern Sweden. A new control approach based on multivariable model predictive control (MPC) is designed, implemented and evaluated for the circuit. Additionally, advanced instrumentation including a volumetric charge measurement for grinding mills is utilised. The MPC control approach starts with step tests that are used to model the effect of manipulated variables (MVs) like feed rate, water addition and primary mill speed on controlled variables (CVs) such as final product particle size, power consumption and volumetric charge of the mills. In the control implementation phase, the models are then utilissed together with current process measurements and known operating limits to predict optimal future changes for the manipulated variables in order to reach the desired process output values. It is shown that the new control approach improves the stability of the circuit and reduces energy consumption. Keywords: Model predictive control, grinding, optimisation

Jan 1, 2020

The development of 3D multi-parametric models facilitate the provision of resource information well in advance of the mining face. Using the model, one can evaluate mining areas not only for grade and tonnage predictions but also for predictions of rock mass quality. Blast design and milling requirements can be derived from the rock mass quality predictions. This information can be used for overall mine planning and evaluation, costing, production optimization and slope design. This allows the full range of mining activities and costs to be interconnected, thereby lowering costs and improving efficiencies through the application of the multi-parametric model. Feasibility studies for new projects require an expected budget expenditure estimate to within 5% of actual costs. This level of accuracy is expected by mining companies and investors but cannot be achieved without a sound knowledge of the rock mass variability. By developing a 3D multi-parametric model as part of the feasibility study and using the same geological model exploration boreholes, a significantly better understanding of the rock mass conditions can be obtained. This rock mass information can be used for equipment selection, economic pit layouts, processing plant design, underground mining layouts and support requirements, to name but a few design parameters that depend on rock mass conditions. The initiative at Anglo Platinums, Potgietersrust Platinum Ltd.?s (PPRust) operation, has delivered significant results showing improvements across the mine to mill value chain. These include increased loading rates, reduced electricity and crushing consumables, as well as higher plant throughput. The ore reserve model has gained international acceptance as an invaluable tool for a mining operation. Certainly most financial organizations will not invest in a mining project that does not have an ore reserve model. There is the potential for multi-parametric models to be recognized as vital tools in the mining process, as is the case with ore reserve models.

Jan 1, 2007

By M. Steyn

[Zr(C9H6NO)4]?(HCON(CH3)2)?(H2O), where (C9H6NO) = 8-hydroxy quinoline (oxH), was synthesized and characterized. This tetrakis-coordinated zirconium complex crystallized in the triclinic crystal system (Pi, Z=2) along with water and N,N?-dimethylformamide(DMF) solvate in the asymmetric unit. The metal atom is surrounded by four N,O-donating bidentate ox-ligands that are arranged around the metal centre to give a square antiprismatic coordination polyhedron with a small distortion towards a dodecahedral geometry. Crystal packing is stabilized by intermolecular interactions of adjacent oxine ring systems in neighbouring molecules, as well as hydrogen bonding of the aqua and DMF solvate molecules, linking the molecular entities into a supramolecular three-dimensional network.

Jan 1, 2013

By C. Sawmliana

Deep-hole blasting operations in opencast mines are always associated with some annoyance to the surrounding areas in terms of ground vibration, noise, flyrock, etc. These become more severe when underground mines run parallel to them. Blasting in opencast mines may pose danger to the underground mines in terms of roof/side failures, damage of water dams, isolation/ventilation stoppings and other underground installations. The paper discusses a case study in India on the impact of deep-hole blasting in Ramagundam Opencast Project ? III on the stability of various water dams of GDK-6B Incline coal mine operating in close proximity. The stability of underground water dams of GDK-6B Incline mine was endangered due to deep-hole blasting at OCP-III. There were 15 water dams in seam 3 and 16 dams in seam 4 of the underground mine. The physical strength tests using a Schmidt Hammer instrument were carried out in all the 15 water dams of No. 3 seam and 16 water dams of No. 4 seam. The test revealed that there is a decrease in compressive strength values of three dams of seam 3, namely 6A, 6B and 7. Theose three dams were also directly connected to the water source. Water seepage was also observed from the surfaces of the three dams. However, they were found to be stable in accordance with their design parameters and damage point of view while considering a threshold value of ground vibration as 25 mm/s. It was found that the value of tensile stress generated by a vibration of 25 mm/s was much lower (i.e. 0.171N/mm2) than the tensile strength of the two weakest concrete dams (1.85 N/mm2). Ten experimental blasts were conducted at different working benches of the opencast mine and the ground vibration data were recorded in roof and pillars near various underground water dams. The maximum value of vibration data recorded was 5.9 mm/s in roof near dam no. 1 in seam 3 with the dominant peak frequency of 22 Hz. No adverse effect on either of the dams was observed after that blast. During the period of study, no deterioration/adverse impact was found in any dam of the mine. Based on the results of the study and the analyses of the data, optimized blast design parameters and explosives weight per delay were suggested for the opencast mine to maintain the safety of the underground water dams. Keywords: Opencast blasting, damage, water dams, underground mine, ground vibration

Jan 1, 2009

By M. Dhainaut

This paper presents computations of the electric field inside a furnace. We first look at the effect of contact between two coke particles from an electrical point of view. We give values for the amount of contact resistance in the total resistance of the system formed by the two coke particles. We show that the effect of contact resistance decreases rapidly with increasing contact area. We then look at the complete electric field inside a full scale furnace. The aim is to evaluate the amount of current that short-cuts the metal bath for different vertical positions of the electrodes. We show that electrodes high above the metal bath are undesirable since they offer a larger surface of conductive charge materials where current can flow through. On the other hand, deeper electrodes force the current to go the whole way down to the metal bath. Ohmic heating along this path ensures a high temperature of coke and slag that are beneficial for metal recovery.

Jan 1, 2004

By W. Mbhalati

"Conzal Mine was not meeting production targets in 2013, and it was established that this was caused by the inability of the load haul dump machines (LHDs) to tram the required tonnages. An investigation of the LHD productivity was therefore conducted to identify the inhibiting factors. This was accomplished by carrying out a literature review on LHD operations to gain in-depth knowledge and conducting observations in the working environment. The relevant information and data on the LHD type used at Conzal was also acquired.The major inhibitor was found to be excessively long tramming distances in all the sections of the mine. The one-way tramming distances were all significantly greater than the 90 m set in the mine’s code of practice (COP), with the Main Shafts section having the longest average one-way tramming distance of 260 m. The other inhibitor was LHD utilization, which in 2013 was only 47% against a target of 70%. Simulation of the LHD operation, taking these two factors into account, showed that production could be increased by more than 100%. As a result, it was recommended that conveyor belts should be extended regularly in order to keep tramming distances within the recommended one-way distance of 90 m. In addition, utilization can be improved by minimizing employee absenteeism as well as by modifying the travelling routes such that LHDs do not encounter unnecessary delays.Paper written on project work carried out in partial fulfilment of BSc. (Mining Engineering)"

Jan 1, 2015

Rockbursts continue to be a scourge in the mining industry, being responsible for accidents and damage to mining excavations. Although the problem has been present for more than a century, and although much research has been carried out, a solution is still elusive. Determination of, firstly, the demand on the support system imposed in the rockburst and, secondly, the capacity of the support system, cannot be carried out with any confidence, and therefore rockburst support cannot be designed using a conventional design approach. In contrast with the conventional approach, observations of rockburst damage in a mine have revealed a possible alternative approach to rockburst support ? sacrificial support. It was observed, in rockburst events, that a support system consisting of concrete panels restrained by grouted cables was destroyed, and the concrete panels were ejected. However, the rock behind the panels remained apparently undamaged and in place. This behaviour reignited the concept of sacrificial support, conceived more than 20 years ago, and which is described in this paper. The remedial solution implemented on the mine, involving cables wrapped over the panels and retained by grouting into boreholes, has been subjected to rockburst loading and has confirmed the validity of the sacrificial support concept. The concept of sacrificial support may be controversial, but is deliberately presented here with the aim of generating discussions and contributions, and with the ultimate aim of improving safety and reducing rockburst damage in mines. Keywords rockburst, seismicity, seismic waves, rock support, support design.

Jul 1, 2013

By M. K. Sichone

Anglo Platinum?s Waterval smelting complex based in South Africa operates the Anglo Converting Process (ACP) that produces SO2 offgas. This SO2 offgas is treated in a double-contact, double-absorption acid plant allowing for conversion efficiencies higher than 99.90 %. The catalytic converter used in the acid plant to convert the SO2 to SO3 is a 4-bed reactor loaded with a combination of cesium-promoted and conventional vanadium pentoxide catalysts. In June 2008 there was a shutdown, in which one of the main activities was to screen the catalyst. Before this shutdown, the operator would control the converter pass temperatures manually, via the SCADA, especially during plant start-ups after which some of the automatic temperature controllers were used. After the shutdown, the control philosophy was revisited and all temperature controllers were put on auto mode during plant start up. Furthermore the set points of the pass inlet temperatures were reduced to maximize conversion in the first two passes. The result has been a reduction of SO2 emissions, from a daily average of 50 ? 70 ppm to as low as 20 ppm for similar sulphur dioxide and oxygen concentrations. Further work has been done to maintain high bed temperatures in the third and fourth passes at low SO2 strengths by splitting the gas stream between pass 1 and 2 thus increasing the SO2 content in the gas to pass 2. This increases the temperature of the gas exiting the second pass, which results in higher temperatures in passes 3 and 4. Comparison of the converter performance prior to and after the changes is made. The benefits of partially bypassing the first pass to increase the SO2 content in the gas to the second pass are shown. Conclusions and scope for further work have been drawn from the comparisons.

Jan 1, 2009

By P. Mbele

Iron ore concentrate is not easily transported to, or processed in, ironmaking plants, therefore it is necessary to agglomerate. This paper will determine the possibility of agglomerating Sishen concentrate into suitable ironmaking feedstock. Pelletizing is one of the conventional and preferred agglomeration processes for iron ore concentrate investigated at Kumba Value-In-Use Laboratories. Sishen concentrate was mixed with binder, and then pelletized using a laboratory pelletizing disc; afterwards the green pellets were indurated at high temperatures to give strength high enough to survive handling and lessen disintegration in the shaft during ironmaking. Sishen pellets have satisfactory physical and metallurgical properties which make them suitable feedstock for the direct reduction processes. These were tested under Midrex shaft operational conditions and performed well, with a metallization of 94.47% being attained.

Jan 1, 2012

By G. M. Cresswell

The 2 360 t/h two module Phola coal preparation plant represents anew era of large plant in the Witbank coalfield designed to extend its life to 2020 and beyond. The plant uses the optimum processing model for Witbank coals, receiving a feed coal size of -50 mm, wet screening it into coarse and small coal fractions 50 x12 and 12 x0.63 mm before processing them in parallel through two primary DM cyclone sections, in order to make a 27.5 MJ/kg export floats product. The sinks are processed through a common high density DM cyclone section to produce a 21.5?23 MJ/kg thermal coal middlings product. The plant design incorporates the largest size DMS equipment used to date in South African coal preparation plants, i.e. 1 150 mm large diameter pump fed DM cyclones and 4.2 m width banana screens. The fine coal is conventionally processed by spirals, whereas the raw coal slimes are filtered using automated plate and frame filter presses and added to either the middlings or discards depending on its quality. The paper describes the database, innovative design concepts, construction, and commissioning.

Jan 1, 2010

By W. Valderrama, D. G. Almond

Operation of large SAG mills requires a change in the conceptual approach to grinding processes. The traditional energy consumption criteria are now enhanced with new criteria derived from the mechanical dynamics of the mill load. This new approach demands instrumentation capable of providing accurate information about the load movement and the ratio of balls and ore inside the mill. This paper discusses two new performance enhancing tools available to meet these needs.

Jan 1, 2004

By Mark Coleman

Pnuematic Conveying and Process Injection Technologies have been implimented in the metals markets for the last 40 years and have consideribly improved the productivity and the performance of many processes. There have been many steps forward in handling technology and this paper seeks to consider those now offered by Clyde Materials Handling who as an established customer-driven solutions provider, which has turned its attention to supporting the Metals Market. Clyde seek to utilises its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries. With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets. Operators within the metals market have developed and deployed pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustain-able solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes. Operators, such as Codelco in Chile, Corus Steel in the UK, and many others across the World have seen pneumatic injection solutions transform their process and costs. To inject a consistent, pulseless and accurate flow of material to a copper concentrate bath smelter, or injecting granular or pulverized coal as a coke substitute in to a blast furnace via the Tuyeres helps to increase the operational capacity, availability and productivity and reduce the cost of the operation. This paper will discuss and highlight the ways in which pneumatic conveying and injection technologies, created by Clyde Materials Handling, and applied in partnership with the customer, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Lead and Zinc Industries. With examples from Zinc Fuming in Australia, Zinc Calcine and Powder Handling in Korea, Precision coal injection to QSL and TSL Furnaces, and metered distribution of Zinc Calcine to Reactors.

Jan 1, 2008

By A. V. Pavlov, V. A. Grygorian, Kossyrev, A. E. Semin, A. Korostylev

A new way of producing low-silicon ferrosilicon from iron-ore materials in a new type of aggregate-oxygen reactor is presented. The oxygen reactor process is based on using the calorific combustibility and reducibility of carbon materials inside the aggregate. The key to the process is successful post-combustion of carbon monoxide above a layer of a solid coke bed. Initially the possibility of production of grades of ferrosilicon containing 20 to 25% Si (FeSi20-FeSi25) was studied on a laboratory model of the oxygen reactor. Quartz sand and iron ore concentrates (from Russia and India) were used in the laboratory tests. This test work demonstrated that a ferrosilicon grade FeSi15 could be obtained directly from raw iron ore (containing 75.9 % Fe2O3 and a maximum of 23.8 % SiO2) without using rich iron-ore concentrates. The process was successfully tested on a pilot furnace at Serovsky metallurgical plant. Very promising results and efficiency parameters were achieved. The consumption of materials for 1t of ferrosilicon (15 % Si) production was as follows: 1567 kg raw iron ore, 591 kg of coal (in a composition of ore-coal briquettes), 299 kg of coke (for coke bed formation), and 815 m3 of oxygen.

Jan 1, 2004

A Life Cycle Assessment (LCA) of stainless steel production, including that of the nickel, ferronickel, ferrochromium and iron feedstocks was carried out using inventory data derived from the literature. The environmental impact categories considered in the study were Global Warming Potential (GWP), Acidification Potential (AP) and total (or full cycle) energy consumption. The effects of different sources of electricity (black coal, natural gas and hydroelectricity) were also examined in the study. The results of the LCA showed that when ferronickel is used as the nickel source, the total energy consumption for stainless steel production is approximately 50% higher than when nickel metal is used as the nickel source (75 MJ/kg cf. 49 MJ/kg). This result comes about largely because the Fe units in ferronickel have a much higher energy intensity than do the Fe units in pig iron, and the greater the use of the former at the expense of the latter, the greater is the total energy consumption. The results also showed that the production of ferronickel made by far the largest contribution (59%) to the total energy consumption for stainless steel production when this feedstock is used as the nickel source, but when nickel metal is used as the nickel source the contributions of the various stages are more evenly distributed. It was also observed that the electricity consumption of the electric furnaces used in the production of ferronickel, ferrochromium and stainless steel contributed approximately 50% to the total energy consumed in stainless steel production. Given the relatively low efficiencies associated with electrical power generation, significant reductions in the total energy of stainless steel production could be anticipated if more direct use of thermal energy was made in the ferronickel, ferrochromium and/or stainless steel smelting stages, for example by utilising bath smelting processes.

Jan 1, 2004

By Darelle T. Janse van Rensburg

Some of the more recent developments in Paint Technology are solvent free materials. These coatings have mainly been formulated to overcome the negative attributes of solvent-based coatings, i.e. environmental, safety and health risks, potential for solvent entrapment and osmotic blistering, as well as the formation of micro-pores during the curing process. Two solvent free liquid epoxy coatings have been used extensively on power generation plant. However, very little is known regarding their long-term performance under different exposure conditions, as well as whether these coatings actually perform better than their solvent-borne counterparts. In addition, solvent free materials are generally used where outage periods are restricted and coatings need to be applied within a very short period. Though these materials have reportedly much shorter curing times than other conventional solvent-borne coatings, little is known regarding their limits with respect to maximum film thicknesses and being put into service while still being wet/partially uncured. The latter has become common practice at many power stations in the past two years or so. In addition, the application and curing methods of solvent free materials are different to that of solvent-borne materials, and may require equipment and application process changes. This paper covers the application and performance properties of solvent free coatings in comparison to solvent-borne materials primarily intended for immersion service. Numerous coatings were evaluated under immersed static and cyclic hydrostatic pressures. Other tests included short curing / early immersion tests, dry-to-touch and dry-through curing times, adhesion tests, surface tolerance tests, etc. The results show that the solvent free materials have clear benefits with respect to safety, health, environmental and long-term performance, but will be more difficult to apply compared to solvent-borne materials.

Jan 1, 2006

By N. J. Wagner, D. G. Modiba

There is currently limited knowledge concerning South African coal deposits as hosts for rare earth elements (REE). This project aims to determine the concentration of REE, including yttrium and scandium (REY+Sc) in various coal seams and adjacent sediments in borehole cores from the Ermelo, Witbank, and Waterberg coalfields in South Africa. Coal petrography (maceral count and vitrinite reflectance), XRD, XRF, sequential chemical extraction procedure (SCEP) before ICPMS, and mineral liberation analysis (MLA) were conducted on the coal and associated sediment samples. The coals were inertinite-rich, medium-rank bituminous coal, with moderate to high ash content. The two dominant minerals in all the coalfields are kaolinite and quartz, except for sample ZBS2M, where dolomite was dominant. The dominant major oxides are Al2O3, SiO2, Fe2O3, and CaO, which concur with the XRD results. The ICP-MS results following SCEP indicated that both coal and the associated sediments were light REY+Sc dominant. There was also an elevation of medium REY+Sc in the Witbank coal’s associated sediment samples. Notably, the samples with the highest REY+Sc results were the sediment samples. The Waterberg samples had the lowest REY+Sc from both the coal (less than 2 μg/g to 7 μg/g) and associated sediments (2 μg/g to 15 μg/g). While the highest REY+Sc was yielded from the Witbank-associated sediments (500 μg/g to 2,500 μg/g). The carbonate fraction step proved to be the most successful leaching step, as most REY+Sc was recovered in that step for all coalfields. In addition to the carbonate fraction, the silicates and sulfide fraction in the Witbank samples, and the ion-exchangeable fraction for the Waterbergassociated sediments samples proved successful in leaching out the REY+Sc. MLA determined that monazite and xenotime in all the coal samples were the REY+Sc-bearing minerals.

Nov 6, 2024

By D. M. MacHunter, T. Lawson, D. K. Henderson

The development and commercialization of new generation high tension electrostatic separators has provided a basis for simplifying mineral separation plant circuitry. The inclusion of new design features including insulated plate electrodes that have resulted insignificantly improved separation efficiencies in electrostatic separators are described. The increase in separation efficiency has resulted in a reduction in the number of treatment stages required to produce final high grade mineral products. Comparative performance data on different feed types are presented. A comparison between mineral separation plant flowsheets using both conventional and new generation high tension electrostatic separation technology is presented. A 55% reduction in the number of installed electrostatic separators and a 36% reduction in plant area was achieved through the use of this new electrostatic separation technology.

Jan 1, 2003