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By J. H. Cloete, S. M. Bradshaw, D. K. Chibwe

"Modern tundishes have evolved as vessels to serve as the final step in refining of molten steel by removing inclusions and promoting thermochemical homogeneity.In this study the flow behaviour in a four-strand tundish was investigated by means of a ½-scale water model as well as numerical modelling. The numerical and physical models were used to characterize residence time distribution and calculate properties pertaining to tundish flow regime. Three different tundish configurations were investigated: a bare tundish with no flow control devices, a tundish with a turbulence inhibitor, and a tundish with both a turbulence inhibitor and a dam.The physical and numerical models showed that a tundish without flow control devices is prone to significant short-circuiting. A tundish with a turbulence inhibitor was shown to be successful in preventing shortcircuiting and provided surface-directed flow that might assist the removal of inclusions from the melt. However, it was also observed that the upward-directed flow caused the maximum turbulence kinetic energy near the surface to increase dramatically. The potential for slag entrainment should therefore be considered during the design and operation of tundishes with turbulence inhibitors."

Jan 1, 2015

By M. J. Nicol

Mr Vegter has analysed, in some depth, the approximations made in the treatment of the kinetic data presented in the original by ourselves (ref.1) and has come to the conclusion that ?under the experimental conditions used by Adams and Nicol (1986) the steady-state assumption was inaccurate?. We are acutely aware of the fact that the experimental method adopted does not permit the attainment of a true steady-state in the elution reactor. However, this does not eliminate the attainment of a pseudo steady-state by a suitable choice of the experimental parameters with the accompanying simplification of the analysis of the data with the aim of drawing the reader?s attention to the most important objective of the paper viz. the effect of various operating parameters on the rate of elution of gold.

Jan 1, 1997

By J. Gholamnejad

The aim of short-term production scheduling is to decide which blocks of ore and waste to mine in which time period (shift, days, weeks or months) so that several operational and geometrical constraints can be satisfied simultaneously. Since 1960s several mathematical programming approaches were developed for solving production scheduling problems that are based on a combination of various operational research approaches such as linear programming (LP), integer programming (IP), dynamic programming (DP), etc. A number of models have been developed in the past three decades but some models have limited application especially to geometrical mining constraints. One of the geometrical constraints is block accessibility. All blocks must be accessible to mining equipments on the same bench. In this paper a binary integer programming model is developed in order to incorporate block accessibility constraints in an efficient manner. This mathematical model insures that each block has been open and can be loaded and transported easily by shovels and trucks.

Jan 1, 2008

Tunnelling under squeezing ground conditions poses significant challenges. There are fundamental differences in the choice of support for mining as opposed to civil engineering. This paper reviews ground support strategies that have been used to control large deformations in mining excavations based on field data from five different mines in Australia and Canada. Recommendations are made for improved ground control strategies in squeezing rock conditions.

Jan 1, 2008

By R. Weideman, M. Le Roux, F. B. Waanders, Q. P. Campbell, E. Fosso-Kankeu, D. Moyakhe

"*Paper written on project work carried out in partial fulfilment of B.Eng (Chemical Engineering) degreeSynopsisSpent coffee grounds were transformed into biochar using a hydrothermal method. Some of the biochar product was pre-treated through surfactant impregnation with sodium dodecyl sulphate (SDS) to enhance its adsorption capacity. The non-treated(NT) and pre-treated(PT) biochars were characterized using FTIR spectroscopy and SEM-EDS analyses, which revealed that the products had the potential for adsorption of heavy metals from solution and confirmed the successful impregnation of biochar with SDS surfactant. The two adsorbents were then used for the removal of cadmium from solution and the adsorption behavior and capacity determined through adsorption isotherm, kinetic, and thermodynamic studies. It was found that the cadmium was adsorbed in several concentric layers on the surface of the adsorbents through a chemisorption mechanism. The PT biochar was identified as a superior adsorbent, with a capacity of qe = 10.67 mg/g compared to the NT biochar with qe = 4.82 mg/g. The adsorption of cadmium onto the PT biochar was further determined to be spontaneous and endothermic. It was therefore concluded that the PT biochar shows potential as an adsorbent and could be considered for implementation in the treatment of metal-polluted effluents. IntroductionCoal mining operations are notorious for producing large amounts of waste tailings, which are disposed of in the form of a slurry on tailings dams. This inadvertently contributes towards environmental problems (Jin, Mansour, and Thomas, 2017). Heavy metals are one of the most common pollutants that originate from solid mine waste disposal facilities, and these can leach into groundwater supplies, contaminating them and rendering the water unsuited for human consumption (Salomons, 1995). Cadmium occurs in conjunction with metalliferous ores and can cause severe damage to agricultural soils and drinking water supplies in the vicinity of mining sites (Dudka et al., 1995). It has a tendency to migrate into the surrounding vegetation, which in turn can cause harm to humans and animals when consumed (Marquez et al., 2018)."

Jul 1, 2019

By S. J. Oosthuizen

This article explores the Fray Farthing Chen (FFC) Cambridge process, a novel method for the electrochemical deoxidation of metal oxides in molten salt, discovered at the University of Cambridge in 1997. The process was hailed as a highly promising, potentially low cost, novel method for the production of titanium metal direct from its oxides. The article should inform researchers in the field of some of the challenges in the commercialization of a novel, high profile process involving multiple stakeholders. The author, former senior process engineer at British Titanium Plc, the company originally tasked with commercializing titanium production via the FFC Cambridge process, reviews the latest literature and discusses past and present progress in the pursuit of low cost titanium metal via this process. Topics explored include the history of the process, attempts at commercialization, NASA?s alternative application, and present status of the process. Keywords FFC Cambridge, titanium, molten salt.

Jan 1, 2011

By J. F. Papp

In the United States, chromium has been consumed in three major markets: chemical, metallurgical, and refractory. The predominant end use for chromium in the United States is in the metallurgical market as an alloying element in the production of stainless steel. In addition to being a major stainless steel-producing country, the United States is a major world producer of chromium-containing chemicals and has used substantial amounts of chromite ore for refractory applications. Chromium use is not easily further subdivided within the chemical and refractory industries because there is insufficient publicly available information to do so; however, chromium use can be subdivided among metallurgical industry uses based on the American Iron and Steel Institute (AISI) reported shipments of stainless steel by market classification (agricultural, aircraft, automotive, etc.). It is the goal of this study to determine the distribution of U.S. chromium apparent consumption among major markets in the United States. The distribution is expressed in the form of dimensionless fractions that are computed based on documented chromium consumption by major market. The distribution of chromium among markets within the metallurgical market is computed in a similar manner. Distribution factors are first computed for the major markets, then for markets that are subdivisions of the metallurgical market. The distribution of chromium among major markets has changed substantially over the time period of analysis. The fraction of chromium consumed by the metallurgical market has increased while that of the chemical and refractory markets has declined. Within the metallurgical market, the service industry market accounts for the greatest fraction of chromium consumption followed by transportation. Electrical, machinery, and fabricated products markets account for a substantial share of the metallurgical chromium consumption.

Jan 1, 2004

Publications on hard rock tunnel support design in the South African mining industry have originated primarily from the goldmines during the past 50 years. Little has been published to date on the platinum and chrome mines of the Bushveld Complex. This paper covers the search for a suitable design methodology for off-reef tunnels at Impala Platinum Mine, situated on the Western Lobe of the Bushveld Complex. The fall of ground accident statistics for off-reef excavations of the mine are presented and the available rock mass quality evaluation systems are reviewed. The Q-Tunnelling Quality Index (or Q-Index) is selected because it assesses the important driving factors behind falls of ground at Impala. Two off-reef excavations are evaluated using the Q-Index, and it is shown that minor modifications are required for implementation at Impala. It will take some time before support design throughout the mine is based on the outcome of proper geotechnical investigations based on the Q-Index. Widespread implementation of such support designs should help to solve the fall of ground problem in off-reef excavations while at the same time reducing support costs.

Jan 1, 2002

By T. O. Hagan

A simulated rockburst experiment was conducted underground at a deep level gold mine. This was done by means of a large explosion detonated in solid rock close to a tunnel sidewall. The resultant shake-out damage is typical of that associated with a small seismic event in close proximity to a tunnel that is subjected to the estimated field stress, as in this case, of 50 MPa. The experiment involved: ?the design of a blast to mimic a seismic source ?seismic monitoring using a dense seismic array ?high speed video filming ?a study of rock mass conditions (fractures, joints, rock strength etc.) before and after the simulation using mapping and ground penetrating radar ?special investigations to evaluate the mechanism and the magnitude of the damage ?a study of support behaviour under excessive dynamic loading.

Jan 1, 2001

By N. D. L. Burger

A low noise blast hole drilling system was developed to limit the risk of noise-induced hearing impairment in mining operations. Noise- induced hearing loss has been identified as a major occupational health risk in SA mines. The noise generated by pneumatic percussion drills is a major contributor to such noise-induced hearing loss. This motivated the South African Safety in Mines Research Advisory Committee (SIMRAC) to commission the development of a low noise rock drill system. The system had to be designed, manufactured, tested and demonstrated in a simulated underground mining environment. The specification required noise levels below 90 dBA. Other important design considerations were ease of manual transport, setting up and operation. The primary design concept was to encapsulate a standard SecoS215 pneumatic rock drill in a composite material tube. The tube is pushed onto the rock face by a pneumatic cylinder and is sealed at the rock face by an elastic seal. The drill is pulled towards the rock face by a rope and pulley mechanism fitted inside the tube. This mechanism is powered by a second pneumatic cylinder. The actions of moving and setting the drill require two persons. However, the team can carry out the drilling function itself on several drills simultaneously because of the self-thrusting design. The drill is supported by two camlocks. The exhaust (air containing dust, water, rock debris, oil and grease) is removed from the encapsulating tubes via an exhaust tube to the end of the stope. In this way exhaust noise and air pollutants are disposed of away from personnel. Tests were conducted in a test stope. Noise levels of under 90 dBA were achieved, thereby attaining the primary design specification. This was achieved without materially compromising ease of handling. Penetration rate was somewhat improved compared to that of the standard drill, so that productivity could be maintained. Keywords: Drill, rock drill, quiet, noise, mine, underground.

Jan 1, 2004

By J. Gholamnejad

In open pit mine planning and design, push back mine sequencing is widely used for long-term production planning. In push back design, a series of nested pits is generated and then considered as possible push backs with regard to the minimum push back width requirements. These nested pits are produced by parameterizing on one economic parameter like commodity price, mining or processing cost, stripping ratio, etc. The most important characterization of these push backs is that the innermost push back has the highest value per ton, the second innermost push back has the second highest value per ton, and so on. These nested pits are generated based on the best estimates of grade within a representation of the orebody in a three-dimensional matrix form. Therefore, the inherent uncertainty associated with reserve estimation (for our discussion, grade uncertainty) is not taken into account when push backs are designed. These methods do not attempt to establish which part of the deposit is likely to be worth most. This paper introduces a new algorithm that incorporates ore grade uncertainty during the pushback design process. The suggested strategy tries to seek to schedule risky blocks later in the extraction sequence. Keywords: open pit mine, push back, ore grade uncertainty.

Jan 1, 2007

The compilation of the sampling nomogram is an essential tool in the optimization of a sampling protocol and allows the operator to track the change in relative variance of the sampling error (the Fundamental sampling error) during steps of comminution and mass reduction in the process of recovery of the aliquot for analysis. The data required for the compilation of the nomogram are centred on the sampling constant K and the exponent, alpha (a) of the nominal fragment size. Five methods for establishing K have been identified, but two of them, the duplicate sampling analysis method and the heterogeneity test method purport to provide such constant. The step by step procedure for each of these two methods was examined using broken ores from three mines, Mponeng mine, Kloof mine, and Lily mine. Two of these mines (Mponeng and Kloof) are typical Witwatersrand-type gold mines, and the third is an Archaean-type shear related gold deposit situated in the Barberton Greenstone belt. The results suggest that the factor K derived using the heterogeneity test is very accurate, but applies only to a single size fraction in the spectrum of comminuted materials. The calculation of gold grain sizes using this method appear to be too small and do not conform with the results from detailed mineralogical studies. The factors K and alpha derived using the duplicate series analysis are appropriate for use across a wide spectrum of comminution sizes and also provide realistic gold grain sizes, comparable with the equivalent circular diameter of gold grains identified in mineralogical studies of the ores.

Jan 1, 2010

By M. Z. Emad, N. Abbas, Y. Majeed

Room-and-pillar mining is commonly employed for the extraction of rock salt in undergroundmines. Pillar stress is a major concern in these mines as it is directly related to stability and mineralrecovery. In this study a flat jack method was used to measure pillar stresses in three undergroundrock salt mines in Pakistan. The field work included determination of in-situ stress, in-situ elastic modulus, recording of field variables (pillar length and width, height and width of opening, opening width to height ratio, extraction ratio, and overburden height) and collection of salt block samples. The geomechanical properties of rock salt (uniaxial compressive strength, Young’s modulus, Brazilian tensile strength, and density) were also determined to estimate overburden stress, pillar strength, and factor of safety (both estimated and actual). It was found that the measured pillar stresses are proportional to the overburden stress values, with their magnitude ranging from 6.05 MPa to 11.97 Mpa, and the pillars were found to be stable. Regression analysis was performed to develop statistical models for in-situ stress and in-situ elastic modulus. Finally a quick guideline chart was developed to determine the suitable length of pillar for a given span and required level of safety.

Jun 5, 2023

This paper addresses the methodology of introducing risk into the development of mine plans for open pit mines. Recommendations are put forward for achieving a risk balance between mineral resource estimates and slope design. A design process identifying criteria for different stages of planning is presented. Business risk is separated from geological/geotechnical risk and procedures to address these within the development of mine plans are suggested. It is concluded that a formal design process improves communication between key decision makers and adds value to shareholders, investment.

Jan 1, 1997

By E. Robles

The Tati Activox® Project (TA®P) is the first step towards the implementation of the Norilsk Nickel Activox® process. The ultrafine grinding (UFG) and autoclave pressure leach process conditions are the heart of the Activox® patent. Low grade base metal sulphide concentrates are leached in the process to recover the base metals and to produce LME grade nickel and copper cathodes and cobalt carbonates. The downstream processing of the metal-containing liquor produced by this process includes solvent extraction circuits to extract and concentrate metal-rich solutions, before the various final products are obtained. This paper gives an overview of many of the relevant design aspects taken into consideration in the design of the Tati Activox® solvent extraction circuits. It addresses key design elements related to leach process conditions such as scaling, materials selection for corrosive solutions, pH control, crud formation and treatment, multiple SX trains designed to prevent organic cross-contamination, and design aspects related to the mitigation of fire risks.

Jan 1, 2009

By J. P. Theron

Paper written on project work carried out in partial fulfilment of Phd.(Process Engineering) degree Process modelling is an essential element in the development of advanced (model-based) process control systems, accounting for up to 80% of the cost of development. Often, models based on historic process data are the only viable option when dealing with processes that cannot be modeled cost-effectively from first principles. Despite major advances that have recently been made in the field of nonlinear process modeling, some basic idea of the dynamic behaviour of a process system is important prior to system identification. While many process systems seem unlikely to be linear, the possible nonlinear aspects of their dynamics are not necessarily supported by the data. This may have significant implications for subsequent system identification or interpretation of the data. For example, it is quite possible that an underlying nonlinear deterministic signal may be obscured by a high degree of measurement or process noise, to the extent that it may be critical in the choice of model to fit to the data. The method of surrogate data analysis has recently been proposed as a means to classify the underlying dynamics of complex systems, and in this paper the use of Fourier transform surrogates to classify process systems is explored. Keywords: modelling, process control, simulation, surrogate data analysis, nonlinear systems.

Jan 1, 2004

By F. M. G. Egerton

Mechanisation of mining operations is not a new concept in the world of mining. Machinery has been developed, manufactured and used for many decades in massive orebodies and coal mines, both locally and abroad. Because of their size and the huge tonnages available, massive ore bodies lend themselves very easily to mechanisation. However, little progress in mechanisation has been made in narrow tabular orebodies in South Africa. The equipment available for narrow tabular orebodies requires excavations of a size that introduce large volumes of waste dilution. Nevertheless, it is essential for South African miners to experiment with mechanisation and to find a solution to the problem. This address looks at current conventional mining methods and compares them to bord-and-pillar type mining methods. Off-reef mechanisation is also touched on. It then looks at different hybridised mining methods that are being used, i.e. a mixture of conventional mining and mechanisation. It finally looks at future prospects for mechanisation in narrow tabular orebodies.

Jan 1, 2004

By A. S. Macfarlane

This paper describes how knowledge of the orebody morphology and ore morphology can be used to optimize the planning, mining, and metallurgical output from an open pit copper mining operation, such as to significantly increase the stability of the whole value chain process, and increase the reliability and value of the process outputs. In the case under consideration, the orebody contains both copper and cobalt. This in itself provides a challenge, in that the two metals do not occur in consistent ratios across the orebody as a whole. Furthermore, mineralogical differences within the orebody have a significant impact on plant performance in terms of throughput rates, acid consumption, and recoveries. In order to stabilize and optimize the plant performance, it is necessary to firstly have a complete understanding of the geometallurgical factors that affect performance, and then to have a sound knowledge of how these are distributed within the orebody. These models then inform the mine planning strategy that optimizes cash flow and NPV, and also allow the development of a stockpiling strategy that not only stabilizes the plant, but also allows variations in the plant feed according to ore type and grade in volatile price scenarios. Integral to the realization of these opportunities is the establishment of an appropriate measuring, control, and reconciliation system, customized to the optimization objectives. The paper describes how all of these factors and strategies can be integrated to produce optimal value from the orebody through to final dispatched product. It also shows the significant value that can be released through such an approach.

Jan 1, 2014

By C. E. Doran

Since the early 1990s the underground mining industry has embarked on a vigorous program of improving process and eliminating costs. A leading development in this program has been the implementation of leaky feeder radio systems as an enabling infrastructure for future automation. El-Equip Inc. has led this development with more than 175 mines implementing mine-wide radio infrastructures for voice and data. In this paper, we describe the implementation of a digital radio network which supports existing installations through to an automation infrastructure employing full digital cellular communications with mobile video roaming capabilities. We outline the evolutionary path from existing low speed data communications links through to 155 Mbps and beyond.

Sep 1, 2001

By P. O. Akinseye, F. T. Cawood

Mineral royalties are one of the oldest forms of mining taxation, and were initially introduced to extract economic rents from mining. Over time, the royalty regime has become more complex as it was identified as an important policy instrument that can achieve more multi-faceted outcomes. Such a multi-tiered approach in the use of the royalty instrument is also the case with South Africa. With South Africa’s new mineral royalty regime now in place for ten years, it is perhaps time to assess its impact and effectiveness. To carry out this assessment, an econometric evaluative study was undertaken using four major commodities in South Africa, namely gold, platinum, iron ore, and coal. The study explored five different policy options for government to consider and tested them to determine the most favourable one that will realize the regime’s policy objectives. After the assessment, two major options stood out. Hence, this paper seeks to highlight which of the two options is the most favourable for consideration by policymakers. Based on that study, we find that the current structure is effective, but also recommend that the factors in the formula for refined minerals be ‘modified’ to reduce the capped profitability ratio from the current 60% to 30% and the maximum royalty rate for refined minerals from 5% to 3%. The minimum rate of 0.5% during times of depressed mineral prices and no or low profitability will not be affected.

Dec 1, 2021