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By F. P. Greyling

The aspect of sustainability of ferroalloy processes has long been a serious matter for consideration in many of the world?s industrialized countries. A number of countries can be named where ferroalloy plants that were once flourishing, have all but disappeared. One of the most important factors playing a role in this type of occurrence is the cost and availability of quality raw materials. Given that all natural resources will be depleted with time, users are compelled to develop new processes that are sustainable in the changing environment. The DC arc smelting furnace is one such process that has proved itself, and has gained increasing popularity over the past two decades. This process, amongst other benefits, directly addresses the use of more readily available and more affordable raw materials in ferroalloy production. Since early in the new millennium, GLPS has been involved in various studies for different clients of furnaces for the production of ferroalloys. Two of these recent studies have culminated in the design, construction and commissioning of DC arc furnaces for the production of ferrochrome. One of these furnaces is a 10 MW unit at Mogale Alloys, and the other a 60 MW unit at the Middelburg plant of Samancor Chrome. This paper discusses the approach taken in the design and construction of these two furnaces, which, although varying significantly in size and capacity, are very similar in many other aspects of their design. Keywords Furnace, DC arc, and ferrochrome.

Jan 1, 2010

By E. E. Almási, G. Mucsi, G. Rákhely, Á. Rácz, B. Csőke, Zs. Pap, K. Bohács, N. Halyag

Wet stirred media milling is a widely applied grinding process in the field of mineral processing to produce <10 μm ground materials. In this paper, the results of wet stirred media milling of different Ti, Fe and Cu-oxide and phosphate minerals are presented. During the experimental work, grinding of ilmenite, vivianite, hematite and cuprite was carried out in a continuous operation wet stirred media mill. During the experiments, the particle size distribution and specific surface area of the ground materials were determined after a certain grinding time, as well as measuring the specific grinding energy, thereby determining the grinding kinetics of the different minerals. The measurement results showed the differences and similarities in the grindability of the individual minerals. Nano particulate vivianite, hematite and ilmenite was successfully manufactured in a stirred media mill; however cuprite was characterised as the coarsest final product for the same grinding circumstances. Keywords: Wet stirred media mill, cuprite, vivianite, ilmenite, hematite

Jan 1, 2020

By J. R. Percival, L. Ip, M. D. Piggott, S. J. Neethling

Component wear due to particle-laden flow is a significant challenge in the minerals processing industry in the handling and transportation of abrasive mineral slurries. Studying wear through experimentation is time-consuming and expensive; therefore possessing the ability to accurately simulate, understand and predict wear in these complex environments is highly desirable. The ability to predict wear is important in both the design of equipment in order to maximise the performance over the wear life of the components, as well in minimising potentially costly and dangerous failures and unscheduled maintenance.. Particle-induced wear is a complex problem, requring an understanding of coupled fluid-solid motion, geometry deformation in response to fluid-solid behaviour, moving geometries and wear modelling. Although the literature demonstrates that rebounding particles and changes to surface profiles can have a significant effect on subsequent wear rates and patterns, the challenge of implementing a model to account for this effect in complex geometries has been addressed by only a few authors in the literature. This paper describes a new wear simulator, leveraging fluidity, an open-source, massively parallel, finite element based CFD simulator capable of unstructured adaptive meshing. The wear simulator includes the ability to model particle-laden flow using representative Lagrangian particles and dynamic remeshing of geometry in response to wear and component movement. These capabilities are demonstrated using wear and the associated dynamically deforming boundaries within a Coriolis tester arm, with the results comparing favourably with the experimentally observed wear patterns. Keywords: CFD, wear, two-phase flows, anisotropic mesh adaptivity, boundary deformation

Jan 1, 2020

By E. Van Der Lingen

Within the context of the overall gold market industrial demand plays an important role. Industrial demand for gold was 430 tonnes in 2008, approximately 12% of total end-user consumption. The dominant consuming industry in this market for gold remains the electronics sector, consuming an estimated 300 tonnes, primarily through the use of gold bonding wire for computer chips and plated contacts and connectors. Substantial demand also derives from dental applications, with other smaller industrial markets and decorative uses of the metal (non-jewellery) constituting the balance. In each market gold faces tough competition from alternative lower cost materials, such as silver and copper (electronics) and ceramics (dental). As well as the obvious benefits to the gold market resulting from this constant physical demand, there are an umber of additional positive factors concerning the use of gold in industrial applications: ?Price inelasticity: demand for gold from the major consuming industries has so far proven to be relatively robust in the face of significant increases in gold price. ??Stickiness?: the gold consumed by industrial uses tends not to return easily to the market (i.e. the demand is ?sticky?) because it is highly dispersed. ?Image: the beneficial environmental and medical applications of gold (e.g. gold used in the treatment of prostate cancer and in purification of contaminated water) are helpful to the positive image of gold. ?Added-value: new industrial uses for gold can create substantial added value in the supply chain, particularly in gold producing countries.

Jan 1, 2009

By H. Karabulut, S. Gündüz, K. Karacif, M. A. Erden

The corrosion properties of iron-based composite materials containing graphite and silicon carbide (SiC) reinforcement were investigated. The effects of silicon carbide reinforcement were investigated by adding 0.5% graphite and 1%, 2%, and 4% SiC. A powder metallurgy method was used to produce the composite samples. Iron, graphite, and silicon carbide powders were blended for one hour with a threeaxis mixer and then unidirectionally pressed under a pressure of 750 MPa. After pressing, the composite materials were sintered at 1100°C for one hour. The corrosion properties and microstructure, density, and hardness properties of the composite materials that can affect the corrosion properties were also investigated. It was determined that the pore ratio and hardness of the composite material increased, and corrosion resistance decreased, with increasing silicon carbide content.

Jun 2, 2022

By P. A. P. Fouché

Processing confidence for a bankable feasibility study on a green field heavy mineral deposit is inmost cases achieved only through bulk sample processing. Bulk sample is classified as a large enough concentrate sample that is processed into final products to satisfy market sample demand as well as further processing demands such as smelting. In this case study the demand was to produce 500 tons of heavy mineral concentrate from more than 5 000 tons run-of-mine on are mote location with limited to no infrastructure. The various challenges faced and lessons learned are documented as an outcome of the success of this mission.

Jan 1, 2007

By A. Madowe

This paper discusses the mine planning process for Letseng diamond mine in the Kingdom of Lesotho, in conjunction with the various software packages used during the process. The major pillars of the long-term mine planning process at Letseng are pit optimization followed by pit design and scheduling. Letseng uses Gemcom Whittle and GEMS for pit optimization and design and Runge XPAC for scheduling. The output of the mine planning process results in the generation of published mineral reserves and provides input into the Letseng overall business plan. The process of defining the key inputs for the entire mine planning process is discussed, which covers: ? Pit optimization ? Slope design as an input ? Diamond price inputs ? Operating and capital cost inputs ? Haul road design ? Generation of pit shells ? Selection of an optimum pit shell and interim cutbacks using operational scenarios ? Sensitivity analysis on the selected optimum pit shell. ? Pit design ? Slope design criteria in the detailed design ? Split shell vs concentric pit design ? Practical mining widths to determine cutback design ? Ramp design ? Pit design process in the GEMS software package. ? Detailed scheduling ? Development of scheduling scenarios in the XPAC software package ? Planning through mining production bottlenecks. ? Company-level NPV model ? Comparing scenarios and input of the different schedule scenarios into the company NPV model. Keywords pit optimisation, mine planning, pit shell, recovery, dilution, revenue factor, pit design, split shell, sensitivity analysis, scheduling, production bottleneck, NPV, discounted cashflow.

Jul 1, 2013

By A. Navarra, A. Quelopana

The mine production scheduling problem (MPSP) has been studied since the 1960s, and remains an active area of computational research. In extending the concepts of the MPSP, the automated mine may now be regarded as a hierarchical intelligent agent in which the bottom layer consists of distributed robotic equipment, while strategic functionality occupies the higher layers. Here we present a disambiguation of artificial intelligence, machine learning, computational optimization, and automation within the mining context. Specifically, the Q-learning algorithm has been adapted to generate the initial solutions for a high-performing strategic mine planning algorithm, originally developed by Lamghari, Dimitrakopoulos and Ferland, based on the variable neighbourhood descent (VND) metaheuristic. The hierarchical intelligent agent is presented as an integrative conceptual platform, defining the interaction between our new Q-learning adaptation and Lamghari’s VND, and potentially other hierarchically controlled components of an artificially intelligent mine, having various degrees of automation. Sample computations involving Q-learning and VND are presented.

Dec 1, 2021

By D. Sager

Middleburg Ferrochrome (MFC), a company in Samancor Chrome, commissioned a new ferrochrome smelter in March 2009. This is a 60 MW DC-arc furnace with a DC power supply for the smelting of Transvaal chromite ore fines. With the benefit of 12 years&apos; experience with this technology while operating a 44 MW DC-arc furnace, MFC mitigated all known challenges and considered up-scaling risk in the new plant, which had a rapid ramp-up to full power in 02 of 2009. Good operating practices, as made possible by robust equipment selection, including a thyristor rectifier set of proven technology, and operation with optimal slag chemistry, leads to a safe and effective plant operation. With the optimized furnace design and a correctly sized power conditioning system, using only standard (static) harmonic filters and a correctly sized smoothing reactor, the arc furnace is not a &apos;dirty load&apos; for the utility, staying well within IEC limits for power quality. A patented arc compensation system is installed and allows for full arc position control (to compensate for magnetic field induced arc deflection) so that a symmetrical crucible is maintained, significantly benefiting refractory life. The principal benefits gained from the MFC process is the fact that ore fines are processed, without metallurgical coke, and higher chrome recoveries are achieved compared to other smelting technologies when using a DC open arc for smelting. Keywords Samancor Chrome, Middelburg Ferrochrome, ABB, smelting, DC arc furnace, arc compensation, power factor correction, anode, harmonics, thyristor, reactor, maintenance, refractory, ores, reductants.

Jan 1, 2010

By S. C. Thorley, J. R. Menasce

Trackless mining in low profile (LP) and extra low profile (XLP) platinum stopes has forced equipment designers to re-evaluate their equipment profiles to match the undulating reef. Low profile equipment designed to work in conditions with smooth and flat floors will simply not function with undulating floors and roofs and will become wedged between the floor and roof, beached on undulations due to lack of ground clearance, or suffer excessive mechanical damage. Tyres, too, need special evaluation, as conventional tyres for trackless mining do not work in an extra low profile environment.

Jan 1, 2004

By L. M. Tavares, T. M. Campos, P. M. Faria, R. M. Carvalho

Recent advances in mechanistic ball mill modelling are expected to allow for more accurate predictions that overcome the well-known limitations of phenomenological approaches, including their inability to predict the effect of liner geometry and their wear, in grinding. Although able to describe continuous operation, the UFRJ model of ball mills has only been validated in the past in mills that operate in batch mode, either in laboratory or pilot scale. The present work demonstrates the application of the mechanistic UFRJ ball mill model to predict fine grinding of iron ore in a pelletising plant in Brazil, the first application of such a mechanistic modelling in continuous mode. It shows that the model provides accurate descriptions of flows after iterations in a closed-circuit with hydrocyclones. Keywords: Ball mill, iron ore, grinding, modelling, particle breakage

Jan 1, 2020

By A. S. Nhleko, P. R. Lobe, H. Mtegha

"Government’s equity role in the minerals sector is one of the nationalist measures implemented in order to ensure greater control and management of a country’s mineral resources. This paper evaluates the Tanzanian government’s equity participation in the minerals sector from 1996 to 2015. The research methodology included determination of the number of mineral rights, minimum allowable exploration expenditures in prospecting licences (PLs), and forms of equity role of the government. Data was collected and analysed for PLs, mining licences (MLs), and special mining licences (SMLs).The study revealed a number of challenges faced by the Tanzanian government as regards its equity strategy in the mineral sector. One of the major challenges was the secrecy surrounding agreements and contracts entered into between the government and private sector investors, which were concluded via various business ownership and mineral development projects. This secrecy resulted in non-transparency and lack ofaccountability in the mining industry.The financial benefits accruing to the government were inadequately realized, evident through inconsistent payments of corporate income tax and mining royalties by the mining companies. Furthermore, the government does not have solid mechanisms and frameworks for assessing non-financial benefits, thus it is difficult to measure the impact of these factors.It is recommended that the Tanzanian government review the Mining Act and Regulations of 2010 to include the provision of solid mechanisms and frameworks for all forms of government equity role.This paper is based on an MSc research study undertaken at the University of the Witwatersrand.IntroductionGovernments can grant private companies mining rights to extract mineral resources, or take a stake in the companies as well as establish state companies to oversee their interests in the minerals sector. The establishment of a state company to oversee government interests in the mining sector implies the direct participation of government by way of equity participation. Equity participation or role is defined as the holding of shares in an enterprise, company, or asset by individuals or a body corporate (Otto, n.d.; Brown, 2013; Natural Resource Governance Institute, 2015)."

Mar 1, 2019

By N. Graham, C. Walker

The SORD Miner is a patented mining principle being developed to exploit mineral and energy resources that current technology can not access. SORD Miner is designed to operate in underground wet, granular, continuously collapsing geological environments such as alluvial and marine deposits. It is somewhat like a cutter suction dredge and should be capable of mining its way through any fine granular material like sand or gravel, pumping the slurry back to the surface. In areas where the target layer is covered, the SORD Miner is inserted below the water table and will tunnel its way to the mineral deposits at depth. This paper describes the development, concept testing and prototype construction of the SORD Miner.

Jan 1, 2007

By V. L. Nkuna, S. R. Amos, T. Naidoo

"Ivanhoe Mines’ Kamoa copper project is a recently discovered high-grade copper sulphide deposit in the Katanga Province of the Democratic Republic of Congo. The mineralization identified to date within the resource is typical of sedimentary-hosted stratiform copper deposits and comprises three distinct units: supergene, mixed, and hypogene mineralization. Since 2010, various metallurgical test work campaigns have been conducted on drill core from different areas within the deposit in line with resource expansion. The most recent bench-scale flotation test work has shown positive repeatable results. The work was conducted on a composite sample of drill core from the southern part of the Kamoa resource. The sample is representative of the first four to five years of planned production, when Ivanhoe Mines intends to produce clean, highgrade copper flotation concentrate. A detailed test work roadmap developed from first principles for the campaign led to an optimum flow sheet for treating the Kamoa mineralization. Copper recoveries of 88.3%, at a concentrate grade of 39.0% copper, were achieved using a composite sample — an improvement on the previously published 85.9% life-of-mine average copper recovery indicated in the November 2013 Kamoa Preliminary Economic Assessment. IntroductionThe Kamoa project is a newly discovered, very large, stratiform copper deposit with adjacent prospective exploration areas within the Central African Copperbelt, approximately 25 km west of the town of Kolwezi in the Democratic Republic of the Congo (DRC) and about 270 kilometres west of the provincial capital of Lubumbashi. Ivanhoe Mines holds its 95% interest in the Kamoa copper project through a subsidiary company, Kamoa Copper SA Limited SPRL, and DRC government owns 5%. The project location is indicated in Figure 1.In January 2013, a new independent mineral resource estimate ranked Kamoa as Africa's largest high-grade copper discovery and the world's largest undeveloped highgrade copper discovery. At this time, Ivanhoe Mines had estimated discovered Indicated Mineral Resources of 739 Mt grading 2.67% copper, containing 43.5 billion pounds of copper, and Inferred Mineral Resources of 227 Mt grading 1.96% copper, containing 9.8 billion pounds of copper, as demonstrated in the Preliminary Economic Assessment (PEA) (AMC, 2013). A 1% copper cut-off grade and a minimum vertical mining thickness of 3 m were applied in each classification."

Jan 1, 2016

By C. G. Carey, M. P. Mullins

BHPBilliton is a large (US$32bn market capitalization) diversified mining group. Significant organic growth is planned through the development of a number of mining, processing and oil and gas projects, totalling some US$5.2bn over the next three years. The investment standards underpin the capital approval process, and incorporate the requirements for range and risk analysis of key input variables, including mineral resources. Public reporting codes for mineral resources and ore reserves (such as JORC) stipulate deterministic reporting of estimates, but are generally silent on any requirement for range or risk assessment, although they acknowledge the risk and uncertainty in the production of resource estimates. In contrast, public reporting of petroleum reserves allow for the use of either deterministic or probabilistic estimation, and for the latter, mandate the level of confidence required for proven versus probable reserves. Conditional simulation techniques, popular in the petroleum industry, provide an ideal tool forrange and risk assessment of the range of outcomes of key resource parameters, such as tonnagesand grades. Examples of a diamond deposit and of a porphyry copper deposit are presented. The understanding and quantification of mineral resource risk through a technique such as conditional simulation provides quantified information on the potential upside or downside. These techniques should be more widely utilized in the high-risk minerals extraction industry. Keywords: mineral resources, conditional simulation, risk, capital investment standards, BHPBilliton.

Jan 1, 2003

By M. Bailey-McEwan

The application of refrigeration on deep South African gold mines is mostly achieved through the medium of chilled water which is produced in central installations either on surface or underground. The amount of refrigeration has been increasing rapidly over recent years, and the total installed capacity on all gold mines now exceeds 1000 MW(R), with annual running costs exceeding R100 million for electricity alone. Hence, there are strong incentives to design such installations for optimal cost-effectiveness. The duty required of these installations varies considerably, owing to daily and seasonal climatic changes and the varying nature of the water demand. It has long been recognized that a computer program to predict installation performance as a whole under any given conditions would be highly desirable. An interactive computer program, CHILLER, is described which enables the user to build an installation, consisting of any configuration of cooling towers, water storage reservoirs and packaged water chilling machines. Externally-dictated conditions such as the weather and chilled water demand must be specified, and all quantities under control of the installation, including internal water flow rates and compressor capacity regulators, must be set. The time-varying performance of the installation can then be simulated. Examples are given of the application of the program in the design of a new installation, and in evaluating the effect of any modifications to existing installations.

Jan 1, 1987

By T. G. Maepa

"The creation of mine excavations alters the stress distribution in the surrounding rock mass. In modern mining, resin-grouted rockbolts are used as a means of support in order to redistribute stresses and reestablish equilibrium in the rock mass. The success of resin-grouted rockbolting depends on the design of the system and the correct installation of the support units.The support design and rockbolt installation procedure at a platinum mine in the Bushveld Complex were investigated. A number of issues that resulted in poor installation were identified, including resin admixture, incorrect length and orientation of support holes, over- or under-spinning of the resin, and incorrect rockbolt tensioning. The support design used at the mine was reviewed and its limitations identified. A number of recommendations were made for optimizing the support design by reducing the diameter of the drill bit and reducing the length of the support holes. These changes will enable the mine to use different combinations of resin capsules. Implementation of the proposed changes will lead to a significant reduction in the cost of installation per support hole, as well as improve productivity and safety.IntroductionThe creation of any mine excavation disturbs the virgin state of stress in the Earth’s crust. This results in stress concentrations that interfere with the stability of the rock mass surrounding the excavation. It is essential to modify the internal behaviour of the rock mass surrounding excavations in order to reinforce the ground and stabilize excavations. Resin-grouted rockbolts are extensively used for this purpose. Esterhuizen (2014) stated that when effectively installed, the rockbolt exerts a clamping force and a bonding strength that keeps the rock mass together. This increases the cohesive strength of all discontinuities in the rock mass and enhances the stability of the excavation. Poorly designed and installed ground support is ineffective and constitutes a safety hazard. It is therefore crucial for every mine to ensure that any form of ground support is designed and installed correctly. This research evaluates the installation of resign-grouted rockbolts and identifies challenges and solutions for improved safety as observed at an operating hard rock mine. The support design used at the mine was reviewed and the design parameters optimized. The outcomes will enhance the efficiency of support and minimize the costs associated with the installation of resingrouted rockbolts."

Jan 1, 2017

By R. C. W. Webber-Youngman

The mining industry in South Africa faces real challenges with regard to the reduction of safety-related incidents. The purpose of this paper is to highlight the need for alternative interventions in addition to other safety improvement strategies already employed on mines. It furthermore supports an existing paradigm: incident investigations. An investigation into fatalities in the South African mining industry shows that although great progress has been achieved through the reduction in fatalities in all sectors of the industry over the last few years, more can and should be done to achieve status of ?zero harm?. Fatalities and lost time injuries on mines result not only in large financial losses, but also in disruptions of mining operations in general through Section 54 stoppages to resolve the situation. The approach of the paper is therefore not to try and prove whether there is high fatality rate and/or lost time injuries, but in what way incident reconstruction simulations (IRS) can have an impact in the future prevention of such incidents. The challenge therefore lies in the utilization of pro-active systems that would show employees the possible outcomes of being exposed to certain hazards. In real life, these incidents cannot be re-enacted and in most cases we can only learn through the previous mistakes of others. A virtual reality (VR) education and training system will enable employees to be ?exposed? to different hazards in a safe environment, and simulation, in a ?forgiving? environment, of the possible consequences of unsafe acts. According to the Occupational Safety and Health Act (OSHA), unsafe acts and unsafe conditions are indirect causes of safety-related incidents, but there are also direct causes; for example, unplanned release of energy and/or hazardous material, and basic causes, for example, management safety policies, personal factors, and environmental factors. The administrative workload associated with any incident investigation places a large burden on the investigation team, and in most cases other employees are informed through vague administrative processes what the ?real cause? for the incident/accident was. New preventative strategies are often put in place without showing the employees what the real causes of the incident/accident were. This can be mitigated through the use of interactive VR simulations/animations of the hazards that they are exposed to and how to deal with them. If VR interventions are not used as proposed by this paper, the real causes and consequences of almost all fatalities and lost time injuries may never be fully understood. This paper also emphasizes what potential impact IRS could have on the prevention of future mine incidents as part and parcel of a pro-active risk prevention strategy. The intention is therefore not to replace any other risk prevention strategies, but to visually enhance the reality of the incident. Keywords virtual reality, risk management, incident reconstruction simulations, interactive safety training, usability context analysis, mine safety.

Jun 1, 2013

By L. I. Boshoff, S. Gracie

This paper discusses pilot and laboratory-scale metallurgical test work conducted on bulk samples from a low grade heavy mineral deposit and provides an overview of basic practical metallurgical techniques applied to ascertain the suitability of existing production plants to process material from this orebody. Previous investigations have shown this specific orebody to be more challenging in terms of mineral beneficiation as it has a high gangue mineral content. Test work was conducted on targeted stratigraphic units based on lithology and assay results to enable identification of the stratigraphic units portraying quality issues. Unit specific metallurgical pilot work has never been conducted on any of the RBM orebodies and is a new field currently being explored. During this investigation focus was placed on potential quality and yield issues for ilmenite product, with particular reference to CaO quality. A basic evaluation of zircon and rutile separability was also conducted. The test work was conducted using a comparative baseline methodology with metallurgical test work methods specifically aiming at mimicking the existing production plant as closely as possible. This enabled not only the likely metallurgical performance to be assessed but also indicated whether current plant design would be suitable to process the low grade ore types into products of acceptable quality at acceptable yields. The methods and findings discussed in this paper indicate that although there is considerable variation between different units, a blended feed can be successfully processed. With unit specific metallurgical data applied to the existing geological block model, expected yields and recoveries using current plant designs could be predicted.

Jan 1, 2007

By S. Soren, K. Deo Mehta, G. Jha

The paper aims to find a sustainable sintering process through cleaner means, in order to achieve the desired outputs with zero environmental impact. At present, sintering has no control over its environmental impacts. These impacts occur when fossil fuels such as coal and coke are used in metallurgical sintering. These fossil fuels are undoubtedly effective in their assigned reducing task, but simultaneously emit about 220 kg of GHGs (greenhouse gases) per tonne of sinter produced. The current attempt has focused on reducing these emission levels by switching from coke to a renewable fuel source such as biomass. Biomass is a cleaner fuel source with a significantly lower emission footprint compared to coke. In the experimental campaign, sawdust and wood-charcoal were used in substitution for coke. Experiments were designed in a progressing substitution to obtain the maximum substitution ability without compromising the sinter properties. Sawdust as raw biomass source optimally substituted 10% of coke. The substitution levels were remarkably higher (30%) for wood charcoal due to its low moisture and high calorific values. A fuel blend with 30% biomass and remaining coke succeeded in producing a sinter with acceptable quality indices. Sinters prepared with or without biomass contribution shared an identical phase transformation and microstructures. In order to to maintain consistency in the process, every effort was made to maintain all operational and process parameters identically, except for the fuelling framework. Keywords: Sintering, sustainable, biomass, GHGs, fuel substitution

Jan 1, 2020