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By H. Kotzé

Ticor SA began with a detailed feasibility study in 1995. The Hillendale mine (situated between Richards Bay and Empangeni) and mineral separation plant were approved in 2000. The smelter, just outside Empangeni, consists of two 36 MW DC arc furnaces that were commissioned in 2003. Experiences gained during the initial commissioning of the furnaces proved valuable in later commissioning work, as shown by the increase in ramp-up rates. The capacity of the plant is 250 kt/a TiO2slag and 145 kt/a of pig iron.

Jan 1, 2006

By H. F. Fuls

The quality of Pregnant Leach Solution (PLS) at Skorpion Zinc is of utmost importance for efficient operation of the Solvent Extraction (SX) Plant. Suspended solids in the PLS forms CRUD in the settlers, resulting in reduced zinc transfer capacity and increased impurity carry over to Electrowinning. The Ishigaki Fibre-Wakishimizu filter (fibre media rapid filtration equipment) has been identified as polishing filter that potentially could remove solids from the PLS of Skorpion Zinc. A pilot unit with 20m³/h capacity was tested on site over a period of 9 months under plant operating conditions in the refinery. The FW filter produces a clear filtrate, acceptable for the Solvent Extraction. Turbidity is improved by 72%. Gravimetric analysis indicates a 47% removal of solids. However, the gravimetric method is biased by a co-precipitation of saturated salts during the analysis. Filter media is blinded by the Skorpion Zinc PLS solution, as result of suspended solids and process chemistry. The media could not be regenerated to acceptable conditions. Further testwork to investigate the impact of process solution chemistry modification on blinding is undertaken. Based on the outcome of this investigation a final decision on the FW filter can be taken.

Jan 1, 2008

By S. Badr, R. Mendoza, M. U. Ozbay, M. D. G. Salamon

ABSTRACT: The use of coal pillars at depth is fraught with problems due roof control difficulties and the possible occurrence of coal or pillar bumps. In the USA the largest and most important application of pillars at depth is in longwalling, where chain pillars are the customary supports of the multiple entry developments. At first, the chain pillars were designed using conventional approaches, where the principle is that the strength of the pillar should exceed the load imposed on it. Such approach to design led to larger and larger pillars at great depths, but instead of eliminating, it tended to aggravate the roof control problems. Eventually the idea was born that small sized yielding pillars, which have proved to be successful elsewhere, might provide the answer to this pressing problem as well. The aim of this paper is to study the modes of pillar failure at great depths, using two solution methods. The first of these comprises some elementary solutions obtained with the aid of a simplified conceptualization of the rock mass. This model consists of a strain-softening coal seam sandwiched between two stratified masses. The second approach utilizes FLAC3D, which is a commercially available three-dimensional numerical modeling software package. To gain a better insight, both the strain-softening and ideally plastic Mohr-Coulomb constitutive laws embodied in FLAC3D were exploited. As expected, the width to height ratio of the pillar has proved to be the primary factor that determined the behavior of the pillars. Narrow pillars fail in a stable manner without the occurrence of instabilities. Intermediate w/h ratio pillars under the appropriate loading conditions, may fail suddenly and may even collapse totally. Squat pillars do show the potential for sudden, coal bump like side failure, but because the remaining large width of the inner core, the ruble around the pillar provides sufficient confinement so as to reestablish stability. Finally, the study revealed that the traditional Mohr-Coulomb law does not provide a useful insight into the failure of coal pillars. RESUME: L’utilisation des piliers de charbon dans les mines souterraines de grande profondeur occasionne des problèmes due aux difficultés de control de plafond et possibles fracture ou explosions au niveau des piliers. Aux Etats-Unies d’Amérique, l’utilisation des piliers dans les mines souterraines de charbon comme moyen de support est considèrees comme étant la plus grande et la plus importantes des méthodes utilisée dans le ‘’ longwalling method’’ ou une série des piliers sont disposé de manière à supporter les multiple entrées d’exploitation de charbon. En premier lieu, cette série des piliers étaient construit de manière conventionnelle avec un principe basé sur le fait que le poids exerce sur les piliers doit être inférieur a la force que ces piliers exerce sur le plafond. Ce principe a conduit a ce que le volume des piliers augmente au fur et à mesure que la profondeur au de la mine augmente. Malheureusement, au lieu de résoudre le problème de support, ce principe n’a fait qu’aggraver le problème de contrôle de plafond. Eventuellement une idée s’est dégagé allant du fait que les piliers endommagés de taille moyenne qui se sont avérés être efficaces ailleurs, pourraient fournir un indice à ce particulier problème. Le but de cette recherche est celui d’étudier les différent types de ruptures qu’un pilier peut occasionner lorsqu’il est utilisé a grande profondeur, tout en utilisant deux possible méthodes. La première d’entre elle comprend quelques solutions élémentaires obtenues avec l’aide d’une méthode simplifié et conceptuelle de la masse de la roche. Ce modèle consiste à prendre en sandwich la bande de minerais de charbon entre deux masses stratigraphiques sans pour autant endommager le plafond. La seconde méthode nécessite l’utilisation du ‘’ FLAC3D’’, qui est un logiciel commercialisé disposant d’un modèle numérique en 3 dimensions. Dans le but d’obtenir

Jan 1, 2003

By H. Hu, T. S. Golosinski

The paper reports on use of neural network algorithms to model performance and condition of mining trucks. The model inputs are selected digital data streams collected by truck Vital Information Management System, VIMS, during its operation in a mine. The models built as the result of this work allow for projection of truck condition and performance into future. As such they facilitate more efficient management of mine truck fleets. Keywords: Modelling, modeling, neural networks, mining equipment, Vital Information Management System, Intelligent Miner, mining truck

Jan 1, 2003

By J. F. Reddick

The South African coal mining industry is currently disposing of about 10 million tons of ultra-fine coal (<150 µm) per year. Once discarded, these sulphur-containing ultra-fines contribute to several environmental problems. As part of a project initiated by the Water Research Commission to investigate the use of Cleaner Production (CP) in the mining industry, a study was carried out to determine whether a CP approach could be used to identify opportunities to reduce this coal waste, and to determine which of these opportunities would be most feasible. In order to do this, a CP assessment was conducted at three case study collieries in the South African Witbank coalfield. Mass-balancing and sampling, followed by laboratory characterisation tests and site surveys, were used to determine the quantity, quality and sources of the ultra-fine coal at the three collieries. Literature reviews, brainstorming sessions and interviews then followed to generate the CP options. An environ-mental, economic and technical feasibility assessment was then prepared for each option, to determine the most viable interventions for implementation. A number of opportunities were identified through the assessment. By preventing coarser coal from being discarded with the ultra-fine coal, the quantity of coal disposed of could be decreased at all three collieries, and by up to 24% in one case. Increasing the crusher top size would reduce the amount of coal that is milled to less than 150 µm, so that less is wasted. The ultra-fines that have already been disposed of on slurry dams can be completely reclaimed and converted into a valuable product, which can be sold as power station feedstock. The newly processed ultra-fines could be beneficiated using flotation and exported together with the coarser coal. The results of the assessments thus suggested that workable CP opportunities to reduce ultra-fine coal wastage exist at the sites investigated, and that their feasibility is colliery-specific. The associated financial benefits of the proposed options suggested that CP is a realistic approach to addressing environmental problems. Keywords: Cleaner Production; coal mining; coal-washing; ultra-fines

Jan 1, 2007

By A. Lane

The socio economic risks of mining in South Africa have been emerging for some time now, and have been brought into sharp relief by recent events in the platinum sector. The slow pace of social upliftment in the country has lead to widespread social unrest with consequent calls for different forms of resource nationalism. Fundamentally, the key stakeholders are not fully aligned, and are not engaging productively. This poses significant above-the-ground risk to mining companies. Measuring social impact, deploying inclusive solutions and engaging effectively with stakeholders are three ways in which mining companies can mitigate this risk.

Jan 1, 2013

By C. Kasatuka

Globalization creates investment opportunities for enterprises around the world. Attracting foreign investment has been a key challenge for economic growth in developing countries. Corruption, political instability, armed conflict, and other internal problems affect foreign direct investment (FDI) inflows negatively. A framework of criteria provides a basis for comparing non-commercial risk (NCR) among twenty-three mineral economies. Countries competing for foreign direct investment inflows are ranked from least to most risky. This study compares Inward FDI Performance Index (IND) with NCR ratings in developing countries and shows that risk is increasingly mitigated by means of appropriately structured insurance. Given the option for countries with similar mineral potential, investors will generally invest in the country that offers lower non-commercial risk. Keywords: foreign direct investment, non-commercial risk, developing countries.

Jan 1, 2006

This paper reviews ore pass practice in some Canadian mines in Quebec and Ontario. In particular it reviews ore pass configuration, flow control mechanisms and monitoring practice. A review of the type of problems encountered and the tools to restore flow is also presented.

Jan 1, 2005

By A. Bhattacherjee

The Shewhart [X]?and R charts are still the most popular control charts in use today for continuous monitoring of quality data. However, for these charts to function properly, the underlying assumption of normality and independence of data must be satisfied. When either independence and/or normality of data are not present, which is a common feature of ore quality data, an application of the conventional Shewhart [X]?and R charts may introduce false alarms in the analysis of the data. To address these issues, a guideline is proposed for construction of appropriate univariate and multivariate control charts for a variety of situations. A use of this guideline to a bauxite mine suggested the construction of special cause control chart for the analysis of individual variables namely, Al2O3% and SiO2%; whereas, the multivariate T2 chart based on residuals is proposed for the bivariate analysis of the variables. The case study clearly revealed that without considering the data correlation, one may be in a state of false impression about an out of control condition while using the Shewhart [X]?and R charts for univariate and the Hotelling T2chart for multivariate analysis. To compare the effectiveness of the control charts, specifically the Shewhart [X]?and the special cause control charts, a simulation study was conducted. It was found that the conventional Shewhart chart provided lower probability of coverage than the special cause control chart. It was also revealed that the quality specification of Al2O3% is met as the variation of Al2O3% is well within the specification limits; whereas, it is difficult to meet the quality specification of SiO2% on a regular basis.

Jan 1, 2002

By J. W. Neale

Mintek and BacTech have joined forces to provide the metallurgical industry with bacterial-oxidation processes for the treatment of sulphide ores. The processes are aimed at both refractory gold-bearing and base-metal concentrates. Previously, BacTech had commercially implemented the refractory gold process at the Youanmi Gold Mine in Western Australia. More recently, the process has been incorporated in the Sulphide Treatment Plant at the Beaconsfield Gold Mine in Tasmania, Australia. In addition, Mintek and BacTech have recently signed an agreement with the Laizhou Gold Metallurgy Plant in China?s Shandong Province, which will see the third commercial realization of the technology for refractory gold. Development of the base-metal technology is the subject of several papers in the proceedings of this colloquium. The implementation of the refractory gold technology at Beaconsfield is discussed in detail. Some important aspects that are covered include: ?Test work, and the choice of bacterial culture ?Process design choices, and the advantages of the Mintek-BacTech process ?Inoculum build-up ?Plant commissioning ?Plant performance. Besides the Laizhou project, Mintek and BacTech are currently investigating several other commercial prospects for the technology. These include the use of the technology for a gold-copper deposit, where the production of both gold and copper is envisaged.

Jan 1, 2000

By T. R. Roy

A prediction model, developed by Central Mining Research Institute (India) for evaluation of fire risk rating of underground coal mine panels in bord and pillar working in respect of their proneness to spontaneous heating, is presented in this paper. The concept used in this model is innovative and user friendly. This model may be applied to a panel where extraction is carried out using any of the techniques: i) depillaring with formation of small pillars as final operation, ii) extraction by broadening of galleries, iii) depillaring with hydraulic sand stowing, and iv) depillaring with caving. Here, major fire risk parameters are short-listed and divided into three broad groups in accordance with the nature of their contribution to the spontaneous heating of a mine panel. The paper describes the procedure for estimating the fire risk rating of individual groups using separate objective type models developed for this purpose. Then it evaluates the overall fire risk rating of the panel by combining the fire risk ratings of all the three broad groups. The model is tested with the field data collected from different collieries spreading across the country and with the laboratory data for critical assessment of fitness. Keywords : prediction model, fire risk rating of panel, spontaneous heating of coal, underground panel, bord and pillar working.

Jan 1, 2003

By G. Cockburn

Nkomati Nickel JV exploits the ores of the Uitkomst Complex near Machadodorp in the Waterval Boven district in South Africa?s Mpumalanga Province. Due to factors such as the remote location, stellar growth in production, opencast mining methods, and ore characteristics, a number of innovative processing options were selected. Nkomati has undertaken numerous initiatives over the last few years to improve plant running times, metallurgical performance, and operational profitability. Great emphasis has been placed on effectiveness of management control systems. A number of initiatives such as short interval control and time?in-state metrics have been implemented. A focus on improvement on availability and asset utilization of key items of equipment has been particularly effective. While the ores are remarkably similar to the Merensky and UG2 reefs, the relatively high base metal sulphide content and mineralogical characteristics make metallurgical treatment somewhat different to the ores of the Bushveld Complex. The low head grades and flotation kinetics distinguish Nkomati from other base metal operations. Numerous milling and flotation optimization initiatives have resulted in dramatic improvements in throughput, recoveries, and concentrate grades. This paper discusses the metallurgical, operational, and management challenges and the outcomes obtained.

Jan 1, 2014

By C. Sahyoun

The influence of microwave treatment on copper flotation has been investigated. Comparative batch flotation tests carried out on ore treated at 5?12 kW for 0.1?0.5 s showed that improvements in copper recovery of between 6?15 % could be achieved compared with untreated ore. Both recovery and cumulative grade increased with increasing treatment time and power. A preliminary economic analysis showed that microwave treatment will be economically viable if recoveries similar to those determined on laboratory scale can be achieved on a plant. Keywords: microwave treatment, copper ore, flotation, liberation, recovery

Jan 1, 2005

By F. Sawyerr

A bubble population balance model is proposed for the prediction of Sauter mean bubble diameters in mechanical flotation cells. In the model, the flotation cell is treated as two separate, statistically homogeneous zones?the impeller zone, and the bulk tank zone. Balance functions for the rates of bubble breakage, coalescence, recirculation and inlet-outlet events are proposed based on classical chemical engineering research in two- and three-phase fluid mixing systems. An initial simulation of the population balance model shows trends in bubble size distributions comparable to measured distributions in industrial mechanical flotation cells.

Jan 1, 1998

By J. du Plooy

Mintek has implemented a training scheme that provides students with the experiential training requirement for the National Diplomas in Chemical Engineering and Extraction Metallurgy. This note describes the main features of the scheme and the course content, and our view of future developments in this area.

Jan 1, 1998

By A. Feather

Avmin have developed a flowsheet for the refining of copper, nickel and cobalt from Nkomati concentrates. Cobalt is recovered from calcium-saturated solution using Cyanex® 272. Nickel is subsequently extracted using versatic acid. The loaded organic is stripped using spent electrolyte, producing advance electrolyte for recovery of nickel by electrowinning. Cobalt was recovered with >99.5% extraction efficiency, reducing cobalt from 1.8 g/l to <10 mg/l. The cobalt/nickel ratio in the cobalt product solution was >1500. Nickel solvent extraction was optimized to recover 99%, reducing the nickel concentration from 32 g/l to <0.3 g/l, while minimizing calcium deportment to the nickel electrowinning circuit.

Jan 1, 2002

By C. C. Oosthuizen

Paper written on project work carried out in partial fulfilment of Technikon Practical Training Frank shaft is mining both Merensky reef and UG2 reef. The Merensky orebody is almost depleted and this was the reason for starting to mine the UG2 ore reserves. It was decided to mine the UG2 orebody with trackless equipment using a bord and pillar mining method. Frank shaft has been mining the UG2 orebody for nearly 5 years. The T-cut mining method was introduced to see if it could improve the grade of the run of mine (ROM) as well the extraction percentage.

Jan 1, 2005

By R. T. Jones

The 20 Mt reverberatory furnace slag dump at Nkana in Zambia contains a substantial quantity of cobalt. A 40 MW DC arc furnace has been built at Chambishi for the purpose of recovering cobalt from the slag. The technology was jointly developed by Mintek and Anglovaal Mining Ltd (Avmin), and the furnace was designed by Bateman Titaco. Testwork at the 150?250 kW scale was conducted at AVRL, and larger scale piloting was conducted at Mintek (in partnership with Avmin) in a 3 MW DC arc furnace. Approximately 840 tons of Nkana dump slag (ranging from 0.66% Co) was processed at power levels around 1-2 MW. Good overall cobalt extraction was achieved, and approximately 100 tons of cobalt-bearing alloy was produced (containing 5 to 14% Co). This testwork demonstrated that the Nkana dump slag could be processed in a DC arc furnace of suitable design, to produce a cobalt-bearing alloy suitable for further hydrometallurgical processing. Bateman Titaco were contracted to design and build the furnace, and the design team contained representatives from Avmin and Mintek. The project was conceived as a fast-track exercise, and many activities had to be run in parallel. Notable features of the furnace include an ABB power supply, a Concast conductive hearth, the refractory design, and copper cooling in the sidewalls. Power to the furnace was switched on during January 2001.

Jan 1, 2002

By R. Scott

This article describes and evaluates the establishment of Kuyasa Mining including the search for a suitable deposit, the ongoing lack of finance, and market constraints. Despite the dramatic initial growth and success of their Ikhwezi Colliery near Delmas, Mpumalanga, Kuyasa?s experiences offer some sobering arguments for significant changes to mineral rights ownership, the attitude of financial institutions and government policy if South Africa is to have a dynamic and successful junior and small-scale mining sector.

Jan 1, 1998

The corrosion behaviour of a low carbon steel was investigated in natural seawater and various synthetic seawaters. It was found that the steel corroded nearly four times faster in a 3.5% NaCl solution than in natural seawater for an exposure time of 21 days. The corrosion rate after immersion in synthetic seawaters (ASTM D1141 and Marine Biological Laboratory seawater) is similar to the corrosion rate after immersion in natural seawater. Calcium carbonate (aragonite) deposits were found on the surface of the steel after immersion in natural seawater and the synthetic seawaters. Some magnesium-containing deposits were also found after immersion in the natural seawater. These deposits act as a barrier against oxygen diffusion and thereby lower the corrosion rate. The morphology of the calcium carbonate deposits that formed during immersion in the natural seawater is different from those formed during immersion in the synthetic seawaters. This may explain the slightly lower corrosion rates obtained in the natural seawater. X-ray diffraction also showed that the oxy-hydroxides formed in the 3.5% NaCl solution differed from those formed in the other solutions. Keywords: Corrosion, seawater, low carbon steel, 3.5% NaCl, aragonite

Jan 1, 2006