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Models are used in engineering to reproduce reality as faithfully as possible so that the expected response of a system for given actions or inputs can be determined. In the field of rock engineering, both empirically based and numerical models are widely used to determine the likely response of the rock surrounding excavations. Many of the empirical models are developed from statistical analysis of case histories or from direct observation; however, empirical models are limited because they should be used only within the range of conditions of the observational database. Synergy exists between empirical and numerical models, because empirical models can be used to calibrate and validate numerical models. The empirical approach can benefit from the capability of numerical models to investigate specific mechanisms, which would not be possible using observations alone. Two cases are presented in which the synergy between empirical and numerical models is demonstrated. The first case examines the analysis of discontinuity effects on the strength of slender pillars in limestone mines, and the second case evaluates the effects of stress orientation on coal mine entry stability. It is concluded that numerical model calibration and verification comprises an important first stage in the successful application of models in rock engineering design. Application of numerical models allows mechanisms and interactions of various parameters to be analysed, greatly improving the understanding of the system. The improved understanding can be used to extend the application of empirical design methods, resulting in improved safety and efficiency of rock engineering designs.

Jan 1, 2014

By P. J. N. Pells

A good thing is becoming a bad thing. Rock mass classification systems, that are so excellent for communications between engineers and geologists, and that can be valuable in categorizing project experience, are emasculating engineering geology and rock mechanics. Some engineering geologists have been sucked into thinking that Q and RMR values are all that is needed for engineering purposes, and seem to have put aside what can be learned from structural geology and geomorphology. Many rock mechanics engineers seem to have forgotten the scientific method. This paper attempts to redress the situation by showing how mechanics can be used in rock engineering to design with a similar rigour to that used in the fields of structural engineering, hydraulics and soil mechanics. It also attempts to remind practitioners of what can be achieved by skilled engineering geology.

Jan 1, 2008

In a gravity separation device, particle shape, size and density all play a role. The combination of these determines where each individual particle reports to in the viscous fluid, where particle crowding (solids to water ratio) also plays a role. To understand the performance of gravity separation devices in the heavy mineral industry, these particle characteristics need to be measured. There are various challenges in analysing particle density and particle size simultaneously for the purpose of quantifying gravity separator performance, not to mention particle shape. These analytical challenges include the high cost of high-density sink-float fractionation, toxicity of high-density sink-float media, inability of sink-float media to fractionate at densities greater than 4.0 g/cm3, and the time-intensive nature of these fractionations. The use of the detailed particle-by-particle output from Qemscan® particle mineral analyses (PMA) as a fast and cost-effective alternative is evaluated. The size and density outputs from the Qemscan® were employed to characterize the performance of a heavy mineral spiral concentrator as an example. Critical analytical requirements are to be addressed before the Qemscan® output data can be utilized. Keywords Gravity separator, performance, heavy minerals, Qemscan® particle mineral analysis

Jan 1, 2011

By G. A. Bezuidenhout, J. P. T. Kapusta, D. K. Chibwe

"Peirce-Smith converters (PSCs) are extensively used in the copper, nickel, and platinum group metals industries. The typical converting operation involves lateral purging of air into molten matte through a bank of tuyeres. This blowing operation occurs at low pressure from the blowers, resulting in a bubbling regime that is considered inefficient from both a process and an energy utilization perspective. Inherent drawbacks also include recurrent tuyere blockage, tuyere punching, and low oxygen efficiency.Western Platinum embarked on a full-scale industrial evaluation of generating a jetting regime by using sonic injection. Prior to industrialscale tests, a numerical assessment to ascertain the feasibility of implementing sonic injection into a PSC was conducted. The work included flow characterization at high-pressure injection achieving sonic velocity at the tuyere exit. The 2D and 3D simulations of the three-phase system were carried out using the volume of fluid method together with the RKE turbulence model to account for the multiphase and turbulent nature of the flow.This paper discusses the key findings in understanding plume extension, velocity distribution, shear wall stress analysis, and phase distribution characteristics in the system. Plant trials are also discussed with reference to the commercial aspects of a full-scale implementation of sonic injection in the smelter."

Jan 1, 2015

By M. A. van Nierop

Load behaviour in an industrial mill has been measured directly by inserting probes through liner bolts. The data from conductivity probes have indicated the presence of premature centrifuging during manipulation of the load mass. Overloading conditions were also encountered. Overloading and premature centrifuging both reduce the power drawn by the mill. These effects have been successfully modelled.

Jan 1, 1997

By H. Kotzé

Titania slag is used as feedstock in the production of titanium dioxide pigment. It (titania slag) is the product of ilmenite smelting,a process whereby ilmenite is reduced at high temperature utilizing anthracite as a reducing agent. Although various slag tapping configurations are employed throughout the ilmenite smelting industry, the method of tapping the slag from the furnace into bell shaped cast steel pots, was the subject of investigation in this study. The paper describes the formulation of a cooling model used to calculate and subsequently predict the temperature profile of a slagblock during its cooling within the various cooling environments of pot cooling, air cooling and water cooling. The model was calibrated against actual internal slag temperature measurements and verified with information obtained from both pilot and industrial scale blocks. The paper concludes with solidification results and their practical implication.

Jan 1, 2010

By S. Pule, Z. Ndabezimbi, A. Hefer, E. Cupido

This article outlines various projects implemented at Rand Refinery to reduce effluent generation and freshwater consumption. The refinery generates about 2800 m³ of effluent annually and has initiated projects such as granulation water recycle and silver leach optimisation to address these issues. The granulation water recycle project has successfully reduced effluent volumes, while the silver leach optimisation has further decreased effluent by implementing stoichiometric addition of HCl and NaClO3. The vibratory shear enhanced processing (VSEP) trial showed promising results for gold recovery from wastewater, though further trials are recommended. The water savings of the effluent reduction projects are monitored by measuring the amount of effluent pumped to service yard effluent storage facilities with the use of flow meters connected on SCADA. Since the effluent reduction initiative of granulation effluent recycle in FY23, the effluent reduced to 2676 m³. In FY24, the stoichiometric addition of HCl and NaClO3 was implemented in the silver leach process, further reducing the effluent to 2083 m³.

Mar 5, 2025

By A. T. Visser

"SynopsisAlmost 20 years have passed since the cutting-edge research by Thompson and Visser on the design and management of opencast mine haul roads was conducted in South Africa. This system is based on three principles, namely the structural ability to support the ultra-heavy truck loads, the selection of vehicle and environmentally friendly riding surface, and an appropriate level of maintenance to counteract wear and tear. Obviously, proper layout and geometry are essential.These principles have been implemented worldwide, and it is useful to review the lessons learned. The objectives of this paper are to present a critical review of the status of mine haul road design and management, and the impact that these principles have made on operations, particularly the cost-effectiveness. The paper briefly reviews the principles of the haul road design and management and the extent to which they are applicable. Case studies of a number of implementations are presented to demonstrate that the principles are sound and have been applied effectively. For example, at an international operation the transport cost of coal was 40% more expensive than anticipated in the feasibility stage, and this made the mining operation uneconomic. Correction of this problem resulted in a viable enterprise. Although designed for opencast operations, the principles are equally valid for underground operations, and initial development work will be discussed.The main conclusions are that the research approach is valid and its effectiveness has been demonstrated in a number of applications. The anticipated financial benefit has been derived, and has made the mining operations that used the principles more effective. Of major importance is the application of opencast haul road design principles to the future thrust of using driverless vehicles in opencast and underground mining, where the road quality is not negotiable as there is no driver that can avoid obstacles or severe road deterioration.IntroductionAlmost 20 years have passed since the cutting-edge research by Thompson and Visser on the design and management of opencast mine haul roads in South Africa (Thompson and Visser, 1996a, 1996b, 1998, 1999, 2000a). This system is based on three principles, namely the structural ability to support the ultra-heavy truck loads, the selection of vehicle and environmentally friendly riding surface, and an appropriate level of maintenance to counteract wear and tear. Obviously, proper layout and geometry are essential."

Jan 1, 2015

By Jerry Gagnon, Matt Burr, Dave Evans, Timothy Ellis, Davies Kakengela, Abbas Mirza, Larry Webb, François Leclercq, Andrew Johnston

Lead-based alloys are the primary anodes used in electrowinning from sulphate-based aqueous systems. Lead anode technology has evolved over the years, migrating from pure lead and lead-antimonial alloys to the present day lead-calcium-tin alloys for copper electrowinning and lead-silver alloys for zinc electrowinning. It has also migrated from cast to rolled microstructures in search of improved mechanical properties and higher corrosion resistance. Although great strides have been made in the development of new alloys and production processes, the industry still has unresolved issues related to untimely corrosion which limits anode life and may lead to higher contaminant levels in the metal being produced. Lead anodes corrode because of the difference in the chemical/electrochemical potential across the microstructural features of an anode. Given a very high purity material, we find that the grain boundary areas corrode significantly faster than the rest of the grain. The desire to minimize grain boundary corrosion by a balance of alloying element selection and microstructural design allows the grain boundary area to be engineered. However, operational issues can lead to unexpected corrosion behaviours which we will discuss moving forward. The comments in this work, though directed toward copper electrowinning, can be extended to similar phenomena in other metals electrowon from sulphate media (i.e., zinc, nickel, cobalt, manganese). The lifecycle of electrowinning anodes is dependent upon electrowinning tankhouse operating conditions and maintenance of the anodes, including cleaning and straightening. This paper will focus on the operational aspects of maximizing the utilization of lead electrowinning anodes.

Jan 1, 2015

By D Reddy

Rosh Pinah Zinc Corporation is a zinc-lead mine located in southern of Namibia. It is currently considering the development of a low grade ore body containing about 2.8% zinc. This ore can be utilised by the concentrator if it could be upgraded prior to the ball mill. Preliminary work indicated that the ore may be upgraded in a pre-beneficiating stage by using dense medium separation, X-ray sorting or a combination thereof to a feed grade of minimum 9% zinc. This paper describes the process followed in evaluating the technologies for pre-beneficiation. The results from test work indicated that the low grade ore is amenable to pre-beneficiation by both dense medium separation and X-ray sorting. A comparison between the two technologies showed that dense medium separation marginally outperformed X-ray sorting on grade and recovery. The results for the X-ray sorting were achieved by tuning the calibration curve specifically for the samples tested.

Jan 1, 2008

The influence of varying amounts of magnesia, silica, and alumina in iron ore sinter on its mineralogy, reducibility index (RI), reduction disintegration index (RDI), physical breakdown (AI and TI), and production properties (coke breeze rate) were examined. It was found that the mineralogy of iron sinter can more easily be predicted from its chemical composition than from the RI, RDI, AI or TI. Anticipating the consequence that varying amounts of MgO and SiO2would have on sinter properties is complex, and not necessarily predictable. High concentrations of Al2O3in the sinter result in high concentrations of the SFCA phase, but with drastically deteriorated properties. This study also confirmed that the form in which fluxes are added to the raw material sinter mixture affects the mineralogy and properties of the produced sinter.

Jan 1, 2010

By R. L. Castro

The extraction of ore in panel caving operations also involves the coextraction of non-economic material, known as dilution. Forecasting, avoiding, and understanding the mechanics of dilution is critical to longterm planning. The models of dilution that are currently in use in panel caving operations are those by Laubscher (1994), who postulated that dilution is due to gravitational flow and depends on the height of interaction, the column height, and the draw uniformity. This paper presents a back-analysis of extraction and dilution behaviour at Codelco?s El Salvador and Andina Divisions, which use panel caving as a mining method. This analysis was conducted in order to review the existent dilution entry mechanisms and calculation methods. Three sources of dilution were identified. The first source is ?gravitational dilution?, which is due to gravitational flow and mixing as dilution migrates by gravity from a sector located above the panel under analysis. The second source of dilution is ?caving dilution?, which occurs when an air gap is formed in a large area and a sudden propagation of a hang-up occurs, inducing early ingress of waste into the production level from a level above. The third mode observed is ?lateral dilution?, which occurs when the panel is located next to an exhausted sector and the broken material enters the draw column early during draw. In the last two cases, dilution could migrate large distances horizontally. The mine data indicated that draw and caving strategy are key for long-term planning of large panel caves.

Jan 1, 2014

By F. T. Cawood

The distinction between real estate ownership and that of interests in the property is fundamental to the appraisal of mineral properties. This distinction affects the nature and understanding of security of tenure and, consequently, the perception of what constitutes fair value. Legal matters are a particular concern because of their influence on security of tenure, ownership definition and use restrictions. The dynamics of the market and the complex interrelationships between the factors of production define value at a specific point in time for the bundle of rights, interests and assets that constitute a mineral property. Because each mineral property is unique, physically immobile and of a wasting nature, its usefulness to its owner and society must be optimized. The US Appraisal Institute (2001) classified the forces that affect land use as the cultural, political and economic attitudes of society. These forces culminate in laws that often dictate the purposes for doing appraisals. Once the legal definition of the asset is understood, valuers can decide on the valuation process that will support the final valuation approach.

Jan 1, 2004

Assuming that a gold ore has been effectively ground to ensure maximum economic liberation of gold, the circuits that will have the most effect on the successful operation of a gold plant will be that of the leaching and carbon-in-pulp circuit (CIP). The reagent and utilities operating costs associated with leaching, adsorption, elution and regeneration would typically make up some 15% of total operating cost, whilst the capital costs associated with these areas is about 16% of the total. Although not largest (capital and operating costs associated with comminution are generally dominant) these items represent a significant proportion of capital and operating cost. Much more importantly, these plant areas represent the primary gold recovery process and their technical and operational efficiencies will have a significant impact on overall plant efficiency. The objective during process design of these sections is thus to develop a design which provides maximum technical and economic efficiency and which is robust to potential changes in ore throughput, mineralogical characteristics and head-grade. Experience has shown that, particularly for longer life and higher-grade projects typical of the South African underground gold mining industry, small changes in recovery and efficiency have a significant value over the life of the project.

Jan 1, 1999

By I. L. Follington

This paper describes the research and development programme to develop a prototype underground auger mining system aimed at developing and demonstrating an underground auger mining system able to provide economic access to thinner (<1.8 m) coal reserves of South Africa. Data concerning the performance of modern coal augers under South African coal mining conditions were gained from a proven surface auger which operated across a range of coal types. These data were analysed and considered in conjunction with historical information regarding previous attempts at building underground augers dating back to the 1950s. Drawing on these data a prototype underground auger mining system, the BryDet BUA 600 underground coal recovery auger, was designed and manufactured by the BryDet Development Corporation in collaboration with Eskom and Cutting Edge Technology Pty Ltd with support from Anglo Coal and the Ingwe Coal Corporation Ltd. The prototype BryDet BUA 600 underground coal recovery auger commenced trials in March 2000 at the Matla Mine near Witbank in South Africa. The initial trials were undertaken in an open cut to facilitate the commissioning and training associated with a prototype mining machine. A total of 30 holes was augered in the box cut before the machine moved underground. The prototype BUA 600 first achieved the target penetration depth of 80 m in its third hole. The prototype BUA 600 is a new underground mining system which has passed early testing with ?flying colours? and could provide access to extensive underground coal reserves unmineable by conventional mining techniques both in South Africa and elsewhere around the world.

Jan 1, 2001

By W. de Beer

We present aspects of one of several ongoing case studies used in the development of prediction techniques for major seismic instabilities. The current investigation centres on accelerated coseismic deformation described by the kinematics of failure and on softening, as well as the characterization of areas of interest by measures of the seismic response at such sites.

Jan 1, 1998

By G. M. Cresswell

The 2 360 t/h two module Phola coal preparation plant represents anew era of large plant in the Witbank coalfield designed to extend its life to 2020 and beyond. The plant uses the optimum processing model for Witbank coals, receiving a feed coal size of -50 mm, wet screening it into coarse and small coal fractions 50 x12 and 12 x0.63 mm before processing them in parallel through two primary DM cyclone sections, in order to make a 27.5 MJ/kg export floats product. The sinks are processed through a common high density DM cyclone section to produce a 21.5?23 MJ/kg thermal coal middlings product. The plant design incorporates the largest size DMS equipment used to date in South African coal preparation plants, i.e. 1 150 mm large diameter pump fed DM cyclones and 4.2 m width banana screens. The fine coal is conventionally processed by spirals, whereas the raw coal slimes are filtered using automated plate and frame filter presses and added to either the middlings or discards depending on its quality. The paper describes the database, innovative design concepts, construction, and commissioning.

Jan 1, 2010

Virtual Reality (VR) simulations are excellent tools for training, education, simulation of abnormal and dangerous conditions in mines and solving complex problems. Although the concept of VR has been around for nearly half a century, it has taken recent advances in hardware and software to bring this technology to within the budgetary reach of ordinary users and researchers. VR is now successfully being used in the minerals industry for: data visualization, accident reconstructions, simulation applications, risk analysis, hazard awareness and training. The Institute of Sustainable Minerals Industry, Advanced Computer Graphics and Virtual Reality Research Group (SMI-VR) at the University of Queensland, established in late 2000, has been involved in developing VR applications for the minerals industry in conjunction with various research centres. This paper illustrates the benefits of using advanced computer graphics and VR techniques in the minerals industry with some examples of applications developed.

Jan 1, 2003

By M. S. Raseroka

An experimental rig has been constructed to produce chloride stress corrosion cracks in Type 304L stainless steel tube samples. The samples are to be used to test possible in situ repair methods in future work. The factor which influences the time to failure most strongly is the sample temperature; the distribution of cracks within the sample is affected by local temperature variations and by the position of the water line. Low-frequency oscillations in stress, caused by the on-off temperature controller, did not appear to influence cracking in these tests.

Jan 1, 2009

By P. Venter, N. Naude

"Coal mining is a thriving industry and 53% of the coal mined in South Africa is used for electricity generation. Mechanization has made coal mining more efficient, but fines generation has subsequently increased. Up to 6% of the run of mine material can report to the -200 µm fraction. Common problems associated with fines handling include dust formation, storage problems, and high moisture levels. A method to turn this material into a saleable product instead of stockpiling it can add value to a company.Briquetting is a pressure agglomeration method where loose material is compacted into a dense mass (FEECO International, 2014). The briquettes must be able to withstand rigorous handling and transport operations without disintegrating. This study aims to investigate the optimum binder and moisture conditions required to produce a mechanically strong briquette using two different binders - a PVA powder (binder A) and a starch powder (binder B).It was found that for binder A the optimum moisture level was 12% to 14%. At this moisture level the greatest compression strength gains were observed, and low amounts of fines produced in impact and abrasion tests. The minimum amount of binder added while still obtaining a strong briquette was 0.5% binder A. For binder B the optimum moisture level was also 12% and the minimum amount of Binder B to be added was found to be 1%. Briquettes that were dried outside reached their peak strength after about four days, whereas the briquettes that dried inside took about 20 days to reach their strength plateau. Hardly any degradation took place on the surface of the binder A film after exposure of 300 hours of artificial weathering. Thermogravimetric analysis confirmed that neither binder A nor binder B will add to the ash content of the coal fines, as both binders totally decompose above 530°C.Binder B yielded stronger briquettes after 15 days and also generated less fines. It is therefore superior to binder A and would be recommended for further use.Paper written on final year project work carried out in partial fulfilment of B.Eng degree in Coal Beneficiation"

Jan 1, 2015