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By I. Mc Dougall

Finite element models were generated of two submerged arc furnaces of different geometries. A 48MW circular furnace and a 68MW 6-in-line rectangular furnace were studied. The electrodes, raw material, slag and molten metal were included in the model. ANSYS/Multiphysics was used to predict the current density distribution in the electrodes, raw material, slag and molten metal as a result of the three phase AC current. The effect of the electrode immersion on the current path was studied. The ?proximity effect? caused a pronounced asymmetry in the electrode currents in the circular furnace, whilst the electrode currents in the rectangular furnace exhibited radial symmetry. The current distribution in the melt in both furnaces indicated that the bulk of the current flows between phases. The current density is greatest between electrodes. Results were compared to qualitatively similar published work, operating experience and results of furnace dig-outs.

Jan 1, 2007

By R. J. Kendall

As we enter the new millennium, the South African mining industry has to ensure that it becomes more competitive if it is to survive in the ever more demanding global environment. Traditionally, mechanization in narrow stopes has been limited to the use of scraper winches, and numerous mechanization attempts have been restricted to pilot projects operated on an extremely limited scale (with varying degrees of success). The benefits of hydropower are well documented, and Northam Platinum has shown these benefits to be achievable on a mine-wide basis. However, the equipment originally developed for hydropower systems has followed the traditional labour-intensive approach commonly used in deep level narrow stoping operations. The problems experienced with the hydropower system are discussed and the rationale for developing alternate technologies is explored. The hydropower system has shown to be a versatile powering medium which can be harnessed for a diversity of uses. It (hydropower) enables the mining engineer to change traditional paradigms and to design an entirely new approach for optimizing the mining operation based on explosive techniques. The system developed for Northam consists of the following: ?Purpose-built stope drill rig operated off the hydropower system with special features to ensure accurate drilling patterns throughout the length of the blast hole ?Purpose-built high rate cleaning system for rapid transfer of fractured ore to the stope orepass ?Redesigned stope layout to facilitate in-stope water control and to recover fines from the run-off water ?Purpose-built drill rig for rapid establishment of reef raises and advanced strike gullies ?Purpose-built drill rig for flat end development. On both types of development end rig, emphasis is placed on ensuring accurate drilling patterns throughout the length of the hole to maximize linear advance per blast. The paper discusses the implementation of the Northam system on a large scale as well as current initiatives to further improve on the efficiencies of mining operations. It concludes by emphasizing that mechanized hydropowered stope technologies are in their infancy and thus offer unlimited scope in progressing beyond today?s paradigms to present as yet unthought of solutions for optimizing deep level ore extraction.

Jan 1, 2000

By P. Dennis, T. Pieters, A. De Kievit, S. Ganguly

TEMCO has been producing manganese ferroalloys in submerged arc electric furnaces for over 40 years. The furnace linings all along have been of conventional insulation type until 2001 when a freeze lining of UCAR concept was installed for a 20 MW Furnace. Continuous improvement of furnace lining performance has been a key component in improving the business competitiveness of TEMCO. The expected minimum campaign life of the freeze lining is fifteen years as compared to the ten years of the conventional linings. The success of the freeze lining is very critical to the quanta and direction of heat flow through the lining that control the freeze protection. Under freeze protection can lead to reduced lining life and over freeze protection, on the other hand, can lead to operating difficulties and loss of smelting efficiency. It was, therefore, necessary to develop a computer based system to monitor and control the freeze protection. The computer based monitoring and control system uses the basic principles of heat transfer, activeX object and heat flux from dual thermocouples and that is reviewed.

Jan 1, 2004

By D. Pohl

The past decade has seen rapid expansion in the West African mineral exploration environment. This expansion has been largely driven by changes in ?Political climate ?Fiscal and legal regimes ?Exploration approaches ?West African geology. Major regional mapping and geochemical surveys by the UNDP, and the BRGM in the late 1970s and early 1980s laid the foundation for the rapid development of mineral exploration and resources during the past decade. An additional driving impetus was the discovery by native artisanal miners of many significant new gold occurrences at Libiri, Essakan, Bouda and Tirahori, during the great droughts of the late seventies and early eighties.

Jan 1, 1998

By F. Crundwell, A. J. Lathwood

A number of base-metal operations would like to increase production to take advantage of the higher metals prices. In general, this higher production should not be achieved with major operating changes. In hydrometallurgical facilities, leaching and pressure leaching represents one area where upfront limitations may be a bottleneck to the capacity of the entire plant. An assessment of the capacity of the leaching tanks and autoclaves was performed using a predictive model within the AweSym flowsheet simulator. The model is described, and the results of the application of the model to a number of different leaching reactors are presented. It is argued that the leaching number, which relates the residence time, particle size and the leaching rate, is of prime importance. Finally it is shown that there are some unexpected catastrophic events in increasing production capacity without a thorough understanding of the leaching operation.

Jan 1, 2007

By M. Q. W. Jones

This paper summarizes important features of a compilation of thermal properties of stratified rocks from Witwatersrand gold mining areas. The database consists of more than 1000 thermal conductivity measurements, more than 700 density measurements, and nearly 100 heat capacity measurements. Most important rock types and stratigraphic units are well represented. Heat capacity does not differ significantly from one rock type to another, and density is relatively uniform although particular rock types are characterized by distinct average values. Different rock types also have distinct thermal conductivities, but this parameter varies by a factor of four to five. Primary factors controlling the thermal properties are mineral composition, degree of metamorphism, and porosity. In addition, the temperature dependence of thermal conductivity and heat capacity of quartzite may significantly decrease the thermal diffusivity of this rock at deep mining levels.

Jan 1, 2003

By R. P. H. Willis

Uranium is back on the radar. Uranium has always been a controversial metal, from its role in the arms race to its claim to be the only viable alternative to fossil fuel. This paper will cover its properties and use, its occurrence and production in South Africa, the current market drivers and its future role as a primary energy fuel. It will highlight the difference between uranium used to make a bomb and uranium used in a power station. The recent significant uranium price rise will be put into context of the market drivers including geopolitical issues. Planned expansions in nuclear power station capacity will be reviewed, as will new mine production. Future demand will also be speculated on.

Jan 1, 2006

By N. Ogbonna

A mathematical model for bioleaching at the agglomerate scale is developed. The agglomerate is defined as a unit volume of a heap which contains a solid phase (a size distribution of ore particles), a liquid phase (stagnant and flowing leaching solution) and a gas phase (flowing air and air pockets). Leaching at the level of an ore particle is modelled using a diffusion-reaction equation, and oxidation by attached and detached microbes is treated separately. With the aid of the mathematical model, the effect of particle size distribution on the bioleaching of an ore containing a mixture of chalcocite and pyrite, and a culture of iron oxidizers, is investigated.

Jan 1, 2006

By S. K. Gilman, V. E. Hugo

A common problem encountered in the mineral sands industry is that the mineralogical measurements used in defining the resource are not readily converted to metallurgical recoveries, which are used to predict the quantity of the final products. The problem stems from the different objectives of the exploration and metallurgical assessment programmes, and is often compounded by the use of different laboratory techniques and mineral definitions. Common mistakes include the misapplication of routine analysis, incorrect interpretation of mineral recovery, the confusion of mineral recovery with product yield and inconsistent definition of the same mineral. Experience has shown that unless these potential mistakes are identified, the measurement techniques used during exploration and metallurgical assessment are not compatible, often resulting in large errors in the prediction of mineral production. There are no easy solutions to the problem, as there is no universal assay technique which can cost effectively characterize all the mineral sands resources. The recommended course of action will therefore require several iterations to optimize the assay technique to suit the resource. Fundamental to the success of the measurement technique is the understanding of the mineralogy, its behaviour during mineral processing and the quality requirements for the final products.

Jan 1, 2003

By Du Sichen, K. Mukai, S. Seetharaman

Viscosities of slags constitute an important physical property needed for an understanding of the mass transfer phenomena in metallurgical processes. Viscosity is also the key that leads to a better understanding of the structure of slags. It is well known that the viscosities of silicate slags decrease with the addition of basic oxides due to the breaking of the silicate network. The measurements of slag viscosities often pose experimental challenges, especially to the choice of materials. The keynote lecture takes up the experimental problems and the various techniques adopted. Dynamic viscosity measurement, as a powerful tool towards an understanding of the kinetics of some high temperature reactions, is brought out. A number of semi-empirical models have been developed to estimate the slag viscosities in the case of multi component slags. A critical survey of these models is presented in the lecture. Earlier models by Riboud et al., Urbain et al. and Mills et al. have been developed further into a new generation of models. Some of the current important models are (1) Model by Iida et al. (2)CSIRO model (3) Pyro research Model (4) Model by Tanaka et al. (5) Model approach by Reddy et al. and (6) KTH-model. The predictions and capabilities of the various models are compared. Estimations of viscosities from thermodynamic data and prediction of liquidus temperatures from viscosities are presented. The concept of surface viscosities with reference to slags and viscosities of two-phase mixtures are also taken up in the presentation.

Jan 1, 2004

By I. Cameron, S. Ramjee, A. M. Garbers-Craig

The cause of reduced workability and increased ageing of a blast furnace taphole clay was examined. The investigated taphole clay contained 60 mass% alumina, with phenol-formaldehyde resole resin and liquid pitch serving as the binder system. The workability and Marshall extrusion pressure of the as-manufactured clay samples were evaluated to assess the extent of ageing of the clay. The wettability of all the raw materials was investigated to confirm compatibility between the dry raw materials and both the resin and liquid pitch, while the dry raw materials were analysed using XRF, XRD, and SEM-EDS. The characterisation of the resin and liquid pitch, as well as an analysis of their interaction, was performed using viscosity measurements, Fouriertransform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). The analyses confirmed a chemical interaction between the resole resin and liquid pitch, where the chemical structure of the resole resin changed when mixed with pitch, preventing the typical curing behaviour of the resin. Upon ageing of the resin-pitch mixtures, the resin underwent premature cross-linking, causing the curing process to initiate at lower temperatures, i.e., earlier onset of curing. This premature cross-linking was likely due to secondary amines present in the liquid pitch, which acted as a catalyst for the curing process of the resin. This reduction in curing temperature after ageing was confirmed by an increase in binder viscosity, which was identified as the primary cause of reduced workability, accelerated ageing, and increased Marshall extrusion pressure of the taphole clay.

Jul 23, 2025

By M. F. Handley

Sequential grid mining has been employed as the primary mining strategy at the AngloGold West Wits Elandsrand Mine since the inception of stoping operations from the sub-vertical shaft system in 1988. Little has been published on sequential grid mining as a mining strategy since, and the purpose of this paper is to describe sequential grid mining, its history, its implementation at Elandsrand, and the outcome to date. The results obtained using sequential grid mining have been evaluated from seismic data, productivity statistics, and rock related accident statistics. Comparisons with neighbouring mines namely Western Deep Levels and Deelkraal, have been made to substantiate the improved conditions observed at Elandsrand, and to compare sequential grid mining directly with longwall mining in similar conditions and at similar depths. Sequential grid mMining is shown to be cost-effective, more flexible, and safer than long wall mining in similar conditions, at least on the Ventersdorp Contact Reef in the western part of the Carletonville Goldfield. More work is necessary to establish it as the favoured mining strategy at depths exceeding 3000 metres, and for reefs other than the Ventersdorp Contact Reef.

Jan 1, 2000

By U. Kumar

Product designed characteristics like reliability and maintainability affect maintenance cost, service performance, and therefore product support strategy must be defined during design stage in terms of these two dimensions. Furthermore product support and service delivery strategy has considerable influence on the total life cycle cost and the economic viability of industrial systems/products. he paper presents a concept for the development of service delivery strategy for industrial products with a special reference to mining systems. In this paper we emphasize that the strategy for product support should not be centred only on ‘product’ but it should also take into account the service delivery capability of the manufacturers/suppliers and users service organization, users competence and capability, product use location, logistics and infrastructures, etc., to arrive at the best performance and economic results. Such strategy should invariably include services supporting the client apart from considering services supporting the product. The discussion in the paper is based on the experiences from the manufacturing industry engaged in manufacturing of mining systems and the observed trends in technology and management of operation and maintenance of mining systems. Keywords: Maintenance and product support, Service supporting client, Service delivery strategy, Products reliability and maintainability, Product use location, Operating environment, etc.

Jan 1, 2003

By T. Chikande

"Falls of ground pose costly hazards to personnel and equipment and thus measures should be taken to prevent them. This study endeavours to improve the support systems used in geotechnically poor ground at a Zimbabwean platinum mine by analysing the status quo and recommending an effective support system. Various techniques were used to determine the quality of ground conditions, predict the rock mass behaviour, and to identify the appropriate rockbolt type. An analysis of the current ground control methods and their limitations was also undertaken.The results showed that the current support system and mining practices in poor ground need to be modified to improve safety and productivity. Stoping overbreak is influenced by poor ground conditions and the explosives currently used. The use of emulsion is recommended to replace ANFO. Redesigning of pillars is also recommended in poor ground conditions. An evaluation of the current roofbolt system indicated an opportunity for improvement. With new insight on the performance of the shorter length roofbolts currently in use, a new support system was recommended taking into consideration cost-benefit analysis. Barring down using pinch bars in poor ground was seen as a risky and time-consuming exercise, hence the use of mechanical scalers is recommended to achieve zero harm and to meet production targets. Smoothwall blasting is recommended in poor ground to minimize excavation damage. Other recommendations include the use of hydrological surveys to determine groundwater levels and implement corrective measures. Both empirical and numerical modelling approaches need to be utilized in determining the optimum support. IntroductionThe presence of geological discontinuities such as faults and joints weakens the rock mass. Adequate support is critical in achieving zero harm in underground mines. This paper reviews the current support systems used in poor ground conditions at a Zimbabwean platinum mine. The area of research is located on the Great Dyke of Zimbabwe. The mine exploits platinum group elements (PGEs) and base metals. It is shallow, having a maximum depth of less than 300 m. The Great Dyke is the second largest reserve of PGEs, following the South African Bushveld Complex (Oberthur et al., 2012). It is a linear layered intrusion that extends for about 550 km with a maximum width of 11 km (Prendergast, 1989). The generalized section of the Great Dyke is almost like a trumpet, comprising layers that dip towards the centre. The reef exploited at the mine, the Mineralised Sulphide Zone (MSZ), is located in the pyroxenite layer, which is hosted in the ultramafic sequence. The MSZ is a uniform layer about 2– 3.5 m thick, dipping at around 10–14° from surface outcrop towards the axis of the basin, and located between bronzite and websterite horizons. The visible disseminated sulphide mineralization shows a typical and consistent vertical distribution of platinum group metal (PGM) and base metal values. The research was undertaken to review the current support systems used in geotechnically poor ground conditions in a bid to improve both safety and productivity."

Jan 1, 2016

By A. D. Pelton, Y. -B. Kang, S. A. Decterov

Computerized thermodynamic databases for solid and liquid metal, slag and solid oxide phases in the Al2O3-CaO-CoO-CrO-Cr2O3-FeO-Fe2O3-MgO-MnO-NiO-SiO2-S system have been developed by critical evaluation/optimization of all available phase equilibrium and thermodynamic data. The databases contain parameters of models specifically developed for molten slags, liquid steel and solid oxide solutions such as spinels, pyroxenes, olivine, monoxide (wustite, periclase, lime), corundum, etc. By means of the optimization process, model parameters are found which reproduce all thermodynamic and phase equilibrium data within experimental error limits. Furthermore, the models permit extrapolation into regions of temperature and composition where data are not available. The databases are automatically accessed by user-friendly software that calculates complex equilibria involving simultaneously slag, metal, refractories and gases, for systems with many components, over wide ranges of temperature, oxygen potential and pressure. A short review of the available databases is presented. The critical evaluation/optimization procedure is outlined using the Al2O3-CaO-FeO-Fe2O3-SiO2and Al2O3-CaO-MnO-SiO2systemsas examples. Several applications of the databases to deoxidation of iron and to inclusion control in steel are discussed. Keywords: thermodynamics, phase equilibrium, phase diagrams, databases, ferrous metallurgy, steelmaking, inclusion control, slags, oxide systems.

Jan 1, 2004

By L. A. Cornish

Pt-based alloys for high-temperature applications in aggressive environments have been under development for over 10 years, and are targeted to be used as either as bulk, or as coatings. The alloys comprise Pt, Al, Cr, and Ru, and the microstructure has been improved by composition to a best possible analogue of the nickel-based superalloys, which these alloys could partially replace. This was necessary because the previous best alloy had a strengthening precipitate volume proportion of only approximately 40 vol.%, whereas the nickel-based superalloys have around 70 per cent, and a lower volume would mean that the strength would not be the best that could be obtained. The microstructures were assessed using electron microscopy, and have been related to the alloys? hardness values. The current microstructures are much more like those of NBSAs, with a high proportion of the strengthening ~Pt3Al precipitates. Since the samples have to be small (platinum is expensive), hardness has been used as an indication of strength. Nano-indentation studies showed that the hardness and Young?s modulus were higher for ~Pt3Al than the (Pt) matrix. More extensive oxidation studies have been undertaken on the previous optimum sample, and the effect of cooling rate after heat treatment has also been ascertained. In addition, the samples were studied after different heat treatment times, and cross-sections were made in order to characterize the alumina scale that formed. The oxide scales of Pt-11Al-3Cr-2Ru (at.%) up to 100 h exposure did not spall, and were at least as good as those of the ternary alloys. There was no discernable Al depletion zone in the substrate, although it could have been at a greater depth than thickness of the samples studied. Further additions to the Pt-Al-Cr-Ru alloys have been studied, to increase the melting temperature as well as to reduce the platinum content without compromising the properties. Reduced platinum content would have the benefits of reduced density and cost. The target elements include vanadium and niobium, of which vanadium is of special interest, since it is a South African product. Before these additions could be made, phase equilibria studies were undertaken so that the maximum addition could be ascertained, and also to check any possible ternary phases, which could be deleterious. Work on the Pt-Al-V system revealed a ternary phase, ~V27Pt54Al19 (at.%), which has a eutectic reaction with (Pt). The maximum V addition is likely to be around 15 at.%, otherwise ~Pt3V or the ternary phase will form, and not the required (Pt)/~Pt3Al phases.

Jan 1, 2012

OPENING SESSION Session Chairpersons: Dr. P.P. Jourdan & Dr. L.A. Cramer Transformation to Tackle the Challenges Facing the Ferro Alloy Industry in the Next Decade R.J. Linnell Electricity Supply in SA ? A 10-Year View T.S. Gcabashe IDC as the Catalyst for Growth in the South African Ferroalloys Industry J. Kriek Development in the Global Stainless Steel Industry V. Muñoz CLOSING SESSION Session Chairpersons: Mr. R.J. Linnell & Dr. O.F.R.A. Damm The Health of Vanadium T.E. Jones Steel Raw Materials - Nickel, Chrome, Stainless Steel Scrap and Manganese H.H. Pariser

Jan 1, 2004

By C. Maree

Paper written on project work carried out in partial fulfilment of B. Eng (Chem. Eng.) This paper describes the development and use of a process simulator to optimize gypsum recovery at Afmine, a small plant near Yzerfontein on the South African West Coast. The simulator consisted of models of the major plant equipment, viz. hydrocyclones, surge bins, settling tanks, a primary sieve and a dewatering screen. Experimental data suggested that the equipment could be modelled satisfactorily from data published in the open literature. Simulation studies have indicated that gypsum losses on the plant could be reduced substantially by means of some relatively minor modifications to the plant layout. Moreover, sensitivity analyses of the plant have indicated that optimization of the settling tanks should receive priority over the other process units.

Jan 1, 2005

By I. Bhattacherya

Over the last three decades, the mining industry has been moving towards underground mechanized mining methods and the number of load haul dump (LHD) vehicles utilized has increased. The growth of mechanization and automation has benefited both workers and mining companies. However, due to the design constraints with LHD vehicles and the limitations of the operating environment, restrictions to operator visibility has contributed to a number of accidents, including fatal injuries. Past researchers have used the light filament technique to collect obscuration zones around mobile equipment and have produced 2D visibility charts (shadow diagrams) of this information. The light filament method involves manually collecting visibility data, which results in errors and is time consuming, requiring around three hours to complete. This research utilizes a MENSI GS100 laser scanner along with 3D modelling software (3Dipsos) to collect and process operator visibility profiles for underground mobile equipment. Results from this test work indicate that a laser scanner can be successfully used to rapidly collect this data and utilize this information for improved mobile equipment design from a visibility perspective. Nomenclature FERIC Forest Engineering Research Institute of Canada ISO International Organization for Standardization JACK Software for digital human modelling and ergonomics LHD Load haul dump vehicle LOS Line of sight MASHA Mines and Aggregates Safety and Health Association (based in Ontario, Canada) PVD Polar visibility diagram SAMMIE3D human modelling computer aided ergonomics design system WSIB Workplace Safety and Insurance Board

Jan 1, 2006

By N. V. Moraka

In dealing with transformational aspects, the South African Constitution aspires for a balance between attempts to broadly represent the country’s demographics in the way in which organizations are structured and the need to maintain the necessary skills to ensure continual retention of skills for optimum and efficient organizational performance. Through the Mining Charter, government aimed to redress gender and racial imbalances in the mining industry as part of transforming the demographic representation of mining companies to include black people, women, and people living with disabilities in all job levels up to top management. While the Constitution calls for an appropriate balance between demographic representation and competency, this aspiration for mining poses challenges for companies due to the proficient and competent skills needed in this industry. To this end, the South African mining industry has been subjected to substantial criticism from government regarding the slow progress of transformation. The mining industry justifies its slow pace of transformation by pointing at inconsistent, varying legislation and definitions governing transformation, limited skills available from historically disadvantaged groups, and cautioning not to compromise the sustainability of mining companies by marginalizing white males and white youth with the objective of addressing racial imbalances. This lack of understanding between industry and the government has led to considerable confusion regarding the accountability of stakeholders in transforming the industry. This article presents the perspectives of ten mining executives on transformation in the South African mining industry. The theoretical description of transformation, as well as other mining stakeholders’ interpretations of transformation. is presented. Qualitative data from interviews with mining executives demonstrates their understanding of transformation through rich descriptions, interpretations, and implications in their contexts. The findings demonstrate that transformation in the mining industry is not simply about race and gender, but about cultural change, a change in mind-sets, embracing diversity, equalizing rights and opportunities, and attaining social justice. Moreover, transformation is clearly a gradual process. The article concludes with a recommendation for the definition of transformation to be corroborated with the views of mining executives and that of the Constitution of South Africa. This will create an overarching, simplified definition of transformation that can be accepted and interpreted by all stakeholders.

Jan 1, 2016