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By S. Mohanta, I. D. Behera, B. Sahoo

"Run-of-mine coal contains particles of different sizes with different specific gravities, and when this coal is crushed, the amount of material present in a particular density class changes. This alters the washability characteristics of the coal, which affects the quantity, quality, and separation efficiency of the gravity-based coal washing process. The degree of difficulty in washing a typical coal at a particular specific gravity depends mostly on the amount of material occurring within ±0.1 specific gravity range, which is known as ‘near-gravity material’ at that particular specific gravity of separation. In this paper, two numerical indices, namely ‘near-gravity material index’ and ‘index of washability’, are used to quantify the distribution of near-gravity material in different density classes and to evaluate the degree of difficulty involved in the washing process. The results of this preliminary investigation indicate the uniform distribution of near-gravity material in all density classes for finer size fractions, whereas for coarser size fractions more near-gravity material is present in the lower density classes, making the washing process more difficult at a lower specific gravity of separation. IntroductionThe prime objective of coal beneficiation is to remove physical impurities as effectively and economically as possible. The beneficiation process includes various operations on the asmined coal to make it more suitable for enduse application without destroying the physical identity of the coal. There are several coal beneficiation processes, but gravity-based separators remain the most efficient unit operation for removing the undesirable gangue material from run-of-mine coal. These separators exploit the difference in density between coal particles and gangue particles to effect a separation. The feed is introduced into an aqueous suspension of ultrafine magnetite with a particular density. The feed particles with a relative density less than that of the suspension (clean coal) float to the top surface of the suspension, whereas particles denser than the suspension density (gangue material) sink to the bottom. When the difference in density between the particle and the aqueous suspension is large, the separation is easy, but when this difference is less the separation becomes much more difficult since the settling velocity of the particles is very low. This lower settling velocity increases the probability that particles that should report to floats report to sinks, and vice versa, hence increasing the amount of misplaced material. Therefore, the degree of difficulty in beneficiating a typical coal at a particular specific gravity depends on the amount of material occurring within ±0.1 specific gravity range. This is known as ‘neargravity’ material, also termed ‘near-dense’ material, at that particular specific gravity of separation."

Jan 1, 2016

By F. Peer

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

Jan 1, 2003

By M. Somerville, S. Sun

The liquidus temperature and viscosity of a range of melter slags produced in South Africa were determined. Drop-quench experiments were carried out on the supplied plant samples to determine the liquidus temperature and phase relations at sub-liquidus temperatures. The temperature measurement range covered 1300°C to 1630°C. Results from these experiments show liquidus temperatures for the melter slags to be in excess of 1500ºC with the chromium containing spinel as the primary crystalline phase. At lower temperatures, an olivine or pyroxene phase co-existed with the spinel phase. The viscosity of the slags was determined over a temperature range of 1350 to 1550°C, under a controlled atmosphere. Results show two orders of magnitude variation in the viscosity (0.2 to 20Pa s) with strong effects of slag chemistry and temperature. Slags with lower SiO2and Cr2O3concentrations were more fluid. Slags with the lowest FeOx and highest SiO2concentrations were the most viscous. These observations are in accord with general behaviour of silicate slags. While the presence of a spinel phase may have an effect on the viscosity of the melter slags, results obtained to date indicate a much stronger effect due to the presence of an olivine or pyroxene phase at lower temperatures. Keywords: phase equilibria, liquidus, viscosity, slags, olivine, spinel, pyroxene

Jan 1, 2004

By M. K. Roberts

The approximately 2800 Ma old Ventersdorp Contact Reef is a unique Witwatersrand orebody, from which about 6% of the world?s gold production is derived. A major portion of this production is mined at depths exceeding 2500 m and deepest levels of mining are at about 3600 m. The orebody?s hangingwall consists of volcanic rocks. This differs from the older Witwatersrand orebodies, which have quartzitic hangingwalls. The thickness of the Ventersdorp Contact Reef is generally about 1.20 m, but is highly variable, at an average dip of about 18°. A pronounced unconformity beneath this orebody is also expressed by varying footwall rock type characteristics and frequent rolling of the reef plane. These rolls follow topographic variations of the palaeo-surface. More geological than rock mechanics studies were performed on the Ventersdorp Contact Reef prior to 1992. Recently, however, a multidisciplinary team comprising various rock engineering and geological disciplines has delineated geotechnical areas by a novel technique. Geotechnical areas are defined by distinct footwall/hangingwall rock assemblages. The presence of three footwall and two hangingwall rock types results in the definition of six geotechnical areas across a distance exceeding 60 km, including about 10 gold mines. Distinct rock mass behaviour has been documented in three of the six geotechnically defined areas. Different rock mass behaviour is expressed by features such as mining-induced fracturing, closure rates, fall of ground characteristics and seismic character. Some geological features override the rock mass behaviour as defined for the individual geotechnical areas. These are undulations of the orebody or the frequency, characteristics and attitude of major discontinuities. It is concluded that the concept of geotechnically subdividing orebodies is not only important for facies delineation and the associated grade, but also needs to be considered for safety aspects, in determining factors such as the appropriate support to be employed.

Jan 1, 1999

By A. Bothma

The Impala No. 1A ventilation shaft is located approximately 15 kms north of Rustenburg and is accessed via the R510road from Rustenburg to Northam/Thabazimbi. This situation is shown on the location plan in Figure 1. The geology at the site consists of an upper layer of black turf of about 1 metre in thickness, grading into weathered norite. The depth of weathering is generally less than 5 metres. Zones of deeper weathering may occur along fracture zones associated with faults and dykes. Groundwater occurs mainly within the weathered/fractured aquifer system. The ventilation shaft is a 5.1 m diameter upcast shaft ,and forms part of a system of ventilation shafts to complement the existing infrastructure as mining progresses down the new twin decline extension of Impala 1 shaft. The principal reason for these shafts is to lessen the risk of an extended RAW and also to counter the effects of the heat build-up as the mining goes deeper, with the resultant effect that the existing cooling centre (fridge plant) becomes more remote from activities. The No. 1A shaft (upcast) is positioned approximately 1,2 km on down dip from the main shaft and the No. 1Bshaft (downcast) approximately 1,2 km further. Geological information was used from a borehole 1,2 km away on strike from the upcast shaft. The first shaft (1A) is a 5,1 m diameter hole to be fitted with two 2,2 MW fans, whilst the second shaft (1B) is 4,1 m diameter to accommodate a 7MW fridge plant.

Jan 1, 2001

By L Tolmay, L Nair

Investor confidence can be compromised when one observes large discrepancies between the SAMREC reserves and the mining plan. It is therefore up to the responsible persons to ensure that all contributing factors get taken into account when determining a reserve declaration. Confounding factors could be further aggravated by large oscillations in the commodity price thus resulting in major changes to the mining plan, if the accepted price was either too optimistic or pessimistic. Additional factors that must receive our attention are, uncertainty in geological facies type, mining practices, geology and grade estimation. The paper outlines (in the authors? opinion) some of the important factors that need to be taken into account, in order to ensure proper alignment between the estimates of the life of mine (LOM) reserve grades, and the corresponding actualisation of the mining plan. These parameters provide an historical insight into what actually happens when attempts are made to implement the mining envisaged in the LOM plan. In turn these allow judicious application of discount factors that enable a realistic estimate of SAMREC reserve classification and declaration. Some of the factors that will be covered are: - 1) Flexibility of developed reserves and the ability to maintain this. 2) Mining control mechanisms and their overall efficacy. 3) The ability to extrapolate facies types and its effect on grade control. 4) The ability to control the mining mix and value variation. 5) Finding a happy medium between optimism and pragmatism.

Jan 1, 2007

By R. A. Puchner

The location of a decline shaft portal can have far reaching implications if the geotechnical conditions are not suited for safe and cost effective excavation. Ideally the portal should be positioned in an area where the excavation requires minimal support and the portal can be formed in reasonably competent rock. In many cases, however, the shaft is linked to an underground mining plan and the shaft may have to pass through poor ground conditions. Determining the optimal position at which tunnelling can commence i.e. the portal, is critical and requires a thorough geotechnical investigation. Methods used to acquire information for the assessment of the ground conditions are discussed in this paper. Selection of the appropriate methods is dependent on the anticipated ground conditions, the phase of investigation and restrictions due to site access and budget. Non-invasive techniques are often used during preliminary phases and invasive techniques for the detailed investigation. The methods used during each phase of investigation are discussed. Two case studies are then presented to provide examples of the investigative methods used in two different environments. The first being a flat featureless site with thick soils and deeply weathered bedrock, while the second is a mountainous site with differentially weathered rocky outcrops. Based on these cases, it is clear that an understanding of the geology and geomorphology of the site is vital to the final geotechnical assessment. Key words: Decline shaft, boxcut, geology, geomorphology, geotechnical, portal.

Jan 1, 2009

By R. A. Puchner

The location of a decline shaft portal can have far reaching implications if the geotechnical conditions are not suited for safe and cost effective excavation. Ideally the portal should be positioned in an area where the excavation requires minimal support and the portal can be formed in reasonably competent rock. In many cases, however, the shaft is linked to an underground mining plan and the shaft may have to pass through poor ground conditions. Determining the optimal position at which tunnelling can commence i.e. the portal, is critical and requires a thorough geotechnical investigation. Methods used to acquire information for the assessment of the ground conditions are discussed in this paper. Selection of the appropriate methods is dependent on the anticipated ground conditions, the phase of investigation and restrictions due to site access and budget. Non-invasive techniques are often used during preliminary phases and invasive techniques for the detailed investigation. The methods used during each phase of investigation are discussed. Two case studies are then presented to provide examples of the investigative methods used in two different environments. The first being a flat featureless site with thick soils and deeply weathered bedrock, while the second is a mountainous site with differentially weathered rocky outcrops. Based on these cases, it is clear that an understanding of the geology and geomorphology of the site is vital to the final geotechnical assessment. Key words: Decline shaft, boxcut, geology, geomorphology, geotechnical, portal.

Jan 1, 2009

By G. Konak

In-pit crusher location selection has had an important role recently, since increasing diesel prices. One way of reducing the haulage costs is to shorten the truck haulage distance by bringing the truck dump point into the pit. This study covers the work done on the optimum crusher location definition for a company that produces aggregate near Izmir, a city of Turkey located in the west. This paper will discuss the effects of pit geometry and mine access requirements on optimum crusher location selection that are mainly based on the establishment of minimum haulage distance. The method will be introduced first and then the computer algorithm developed for this study will be discussed later in the paper. Keywords: in-pit crushing, optimum location selection, optimizing haulage, computer aided design.

Jan 1, 2007

By M. Görnerup, M. Hayashi, S. Seetharaman, C. -Å Däcker

The mould flux plays a crucial role in the continuous casting operation of steel due to its multi-functional assignment as lubricator and heat flux controller. In reality, the commercial fluxes can fall short of the expectations of the operator. In such cases, the performance of the mould flux reduces production throughput in the casting machine. This paper presents the results of a study of two different commercial mould fluxes in continuous casting of steels. The results of online sampling during casting, as well as off-line measurements in the laboratory, are presented. Mould flux powder and slag samples from the caster have been characterized with respect to melting behaviour, interfacial tension and thermal diffusivity, using various measuring techniques. An experimental technique has been developed in order to simulate the melting behaviour of a flux in the mould, which has been found to be useful for qualitative studies. A cross-sectional view of different powders reveals that up to four different material layers may exist in the bed: a loosely packed powder layer, sintered layer, semi-solid layer and liquid slag layer. It is found that the melting rate of the mould flux is dependent on the liquid slag layer thickness. Thus, in a continuous casting operation the melting rate is likely to be non-uniform with position in mould due to the difference in liquid slag layer thickness. Mould slag composition is found to be influenced by the starting powder for as long as 30 min, representing a large part of the first heat casting time. Observations of gas formation indicate that interfacial reactions between the steel and slag take place. Keywords: continuous sacting, mould flux, mould slag, properties

Jan 1, 2004

By A Weber, L MacNamara, H Schreiber

Design and development of the world?s largest flotation cell was completed in 2002. This was the first 257 m3 flotation cell installed in the mineral industry and represents a major development in the design of larger flotation cells. This cell has a 50% increase in volume over the widely installed 160 m3 WEMCO® Smartcell? flotation machine. In the next few years it is anticipated that 257 m3 flotation cells will be incorporated into rougher-scavenger flotation circuits in many more world class copper sulphide concentrators. The prototype 257 m3 cell, No.250 Smartcell? flotation machine was installed at Minera Los Pelambres in the front of Row 1 in the existing rougher flotation circuit. This cell is followed by nine No. 130 Smartcell? flotation cells. After the successful development phase, this unit has been incorporated as part of a row of No. 250 Smartcell? flotation machines at Minera Los Pelambres. A key to the successful development of the equipment has been the emphasis placed on fundamental hydrodynamic scale-up criteria. Hydrodynamic factors include superficial gas velocity, water (pulp) circulation through the draft tube, and pulp mixing (distribution) characteristics. This paper will review the scale-up criteria of the No. 250 flotation cell, and present a case study of the in-plant equipment testing. The case study will document the metallurgical and hydrodynamic performance of the machine. It will also illustrate the economic benefits derived by incorporating larger flotation cells in a modern copper sulphide concentrator.

Jan 1, 2007

A wide range of materials are used in hydraulic backfilling operations and the pipeline flow behaviour of these mixtures varies considerably. It is shown that despite the large differences in constituent materials and flow behaviour, a common approach can be applied to analysing the flow of all hydraulic backfills. This is extended to include a rational design approach for backfill distribution systems. The use and limitations of pipe loop tests as a design aid is discussed. Backfill quality control is identified as a key area where improvement needs to be made to enhance the reliability of backfill system operation.

Jan 1, 2001

By L. J. Olivier

The possible closure and subsequent flooding of South Deep Gold Mine?s (SD) neighbouring Randfontein Estates Limited No. 4 Shaft (REL 4) necessitated the construction of five concrete plugs in the connecting tunnels to prevent the ingress of groundwater into REL4 from flooding SD. This paper describes the proposed controlled flooding of REL 4, the planned in-service monitoring of the five plugs and the water barrier between REL 4 and South Deep Mine, and the long-term maintenance of the plugs and rock mass in the immediate vicinity of the plugs.

Jan 1, 2006

By A. S. Macfarlane

The introduction of new technology into mining operations is seen as a strategic necessity by many mining companies, in order to improve safety and to improve operational effectiveness. Many attempts have been made in recent years to introduce new technologies into mining operations in southern Africa. Amongst these are noteworthy successes, as well as some disappointing failures. Often, the reason for failure does not lie with the technology itself, but with the work system into which the technology is introduced. Such failures may come with a significant opportunity cost, and have a detrimental effect on future development, simply because the system has not been adequately engineered, and the risks have not been adequately assessed and managed. This paper examines the reasons for such failures, and proposes a methodology to be followed to ensure successful and sustainable implementation of new technologies, such as to reduce technical and financial risk to the company, and to energize the workforce into ensuring the initial objectives of the project are met. The paper also focuses on the application of appropriate technology, and the development of technological applications which are commensurate with the level of development of the work environment into which it is introduced. The paper therefore focuses on the application of risk management, change management, systems engineering and feasibility analysis as being key elements of a successful and holistic technology implementation programme.

Jan 1, 2001

By A. Hotta

Reduction of CO2 emissions is the key driving force behind the development and implementation of new solutions for energy production. One solution is circulating fluidized bed (CFB) combustion technology combined with a high-efficiency once-through water-steam cycle. Foster Wheeler's CFB technology is today commercially available in capacities up to 800 MWe with ultra-supercritical steam parameters. Simultaneously, the Flexi-Burn® CFB technology is being developed to provide capability of flexible operation in air firing and oxy-combustion for carbon capture. CFB technology can offer an attractive solution for the reduction of CO2 emissions, owing to advantages such as fuel flexibility and low emissions that the air-fired CFB technology offers today. Pilot test facilities provide information about the performance of CFB oxy-combustion technology, and the acquired knowledge is being incorporated in boiler modelling and design tools. One of the European R&D initiatives on carbon capture and storage (CCS) is the Technological Centre for CO2 Capture and Transport, which is supported by the Spanish Government through the Fundación Ciudad de la Energía (CIUDEN). CIUDEN is a research and development institution created by the Spanish administration in 2006 and fully conceived for collaborative research in CO2 capture, transportation, and storage. The Technology Development Centre for CO2 Capture and Transport comprises two technologies on oxy-combustion: pulverized coal (PC) and circulating fluidized bed (CFB). This paper will focus on the design and main characteristics of the 30 megawatt-hour thermal capacity (MWth) oxy-CFB boiler. Foster Wheeler is the technology provider of the Flexi-Burn CFB unit, for which commissioning has been completed in the first quarter of 2011. The CFB unit design allows operation either under conven¬tional combustion with air or under oxy-fuel conditions. The size of this experimental boiler is sufficient to allow the scaling of the results to commercial units. In this way, multiple fuels and operating conditions can be tested economically. The results will validate the design of a future 330 MWe supercritical Oxy-Combustion Power Station (OXY-CFB-300 Compostilla Project) intended to demonstrate the CCS technology at commercial scale. The Compostilla OXY-CFB-300 Project is one of the six CCS demonstration projects funded under the European Energy Programme for Recovery (EEPR) of the EU. The project is based on a future 330 MWe CFB supercritical oxy-combustion plant, with CO2 storage in a deep geological formation. The first phase of the project, granted by the EEPR programme and led by the Spanish utility ENDESA, includes all studies and characterization work needed on CO2 capture, transport, and storage, as well the costs, financing, and regulatory and permitting required, prior to the final investment decision for the construction phase of the plant by the end of 2012.

Jan 1, 2012

By R. P. Goel, P. N. Chaudhary, R. K. Minj

The bulk of high carbon ferromanganese produced in India continue to have more than 0.35% phosphorus since they are produced by carbothermic reduction process. The low phosphorus manganese ores are depleting fast and ferromanganese manufacturers will have no option but to use medium and low grade ores having high phosphorus content resulting in high phosphorus in the product. A systematic study was taken up at NML to solve this problem. Initially, a thermodynamic analysis was carried out for which Ba-P-O ternary predominance diagrams were constructed at several temperatures to predict the most suitable conditions for selective removal of phosphorus from high carbon ferromanganese. These conditions required a usage of a flux having a high level of basicity, moderate oxygen potential as well as low melting temperature. The experimental results showed that it was possible to remove phosphorus from high carbon liquid ferromanganese from 0.56%to 0.18% using BaCO3 based fluxes at the rate of 16-wt% of the ferromanganese charged. However, the Mn loss varied in the range of 2-5%. The objective of the subsequent study carried out at the laboratory scale was to optimize the flux consumption as well as minimize the Mn loss with effective dephosphorization by using BaO based calcined pellets instead of BaCO3 based powders. It was felt that the handling of pellets under plant conditions would be easier and also eliminate the loss of flux as a dust, which occurs when powder is added. These pellets were forced towards the bottom of the melt for better efficiency. For this purpose, a plunging system was designed and fabricated in-house that helped in reducing the flux consumption to less than 5% and also improved the kinetics of the process. The desired results were achieved within 10 minutes of the addition of the flux. The know-how is ready for transfer to interested parties and authors are willing to conduct large scale trials with them.

Jan 1, 2007

The paper provides a brief review of a multivariate uniform conditioning and a localized multivariate uniform conditioning (LMUC) technique, and presents a production reconciliation case study based on a porphyry copper-gold deposit in Peru. The reconciliation study compares the longterm LMUC mineral resources model (typical of new mining projects, which are invariably based on drilling data on a relatively large grid) to the corresponding production blast-hole grade control model, as well as the final plant production.

Jan 1, 2014

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 X. Pan

Slag-metal equilibrium experiments were conducted at 1500ºC and 1580ºC under 0.03 atm, 0.05atm and 0.83 atm CO partial pressures using silica and Cr-oxide crucibles. The complex slags belonged to SiO2-CaO-Al2O3-MgO-FeOx-CrOxand the metal phase to the Cr-Fe-C-Si-(S)systems. The carbon saturation of the metal phase was avoided using oxide crucibles and thus the results are pertinent to ferrochromium refining slags and processes. From equilibrium data and thermodynamic calculations the CrO /(CrO+Cr2O3) ratio in the slag was determined as 0.75, 0.80and 0.86 under 0.83 atm and 0.05 atm of CO pressure at 1500ºC and 0.03 atm and CO pressure at1580ºC respectively. The results clearly demonstrated that a higher chromium content of the metal results in higher Cr in the slag, and chromium in slag decreases with increasing SiO2. The results were also sensitive to the crucibles used as these oxide crucibles saturated the slag either with respect to SiO2or Cr-oxides. It was also demonstrated that the relative amount of CrO in the slag was higher when SiO2crucibles were used in accord with thermodynamic calculations. Iso-concentration curves for carbon and chromium of the metal phase in equilibrium with the slag were drawn on pseudo ternary SiO2–(AI2O3+CaO+MgO)–(Cr2O3+Fe2O3) diagram. The activity coefficients and activities of carbon and chromium of the metal phase were also calculated from the experimental data and available thermodynamics information and were plotted as iso-activity curves in the same pseudo ternary diagram. Keywords: Chromium, slag, equilibrium

Jan 1, 2004

By A. H. Mokken

Failed attempts at amalgamation of a gold/osmiridium concentrate, recovered behind pebble mill liners during re-lining, led to the discovery that the gold particles were coated and that nitric acid only could remove the coatings. Following this treatment amalgamation was rapid and resulted in a complete recovery of the gold that otherwise would have been lost in plant residues. Investigations into the nature and formation of the coatings led to the realization that the coatings were impregnations of harder elements, associated with the gold during grinding and driven into the softer gold surface by high pressure, impact and attrition. It was further realized that this phenomenon could be part of gold ore milling, world-wide. With these thoughts in mind the question is asked whether concentration down to micron sizes prior to cyanidation, should not play a greater role in gold recovery.

Jan 1, 1999