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By J. C. van Dyk

The objectives of this study were firstly to characterize and quantify the inorganic material in the Secunda gasification feedstock. Secondly, the effect of washing on coal properties and sulphur content was investigated. Coal from a single source and a coal blend from 6 different mines were tested. Composite samples were visually sorted by a geologist in the groups containing roof, floor, C-shale, pyrite, carbonates and siltstone material. Inorganic mineral types from the single source and coal blends were characterized separately. Characterization results indicate that the average mineral matter distribution (mass %) of the coal tested was as follows: carbonates (6%), carbon-shale (19%), pyrite (12%), roof (18%), floor (46%) and siltstone (22%). The roof, floor, pyrite, carbon-shale, carbonates and siltstone in the single source and coal blend have similar chemical properties and characteristics, except for the ash melting temperatures of pyrite and kaolinite in the siltstone. By implementing selective mining and increasing mining management practices, the percentage discard in the run of mine coal can be significantly reduced, by up to 45%, if the mining of roof and floor material can be avoided. No significant impact of mining practices on sulphur content is expected in this case due to the low concentrations of sulphur in the roof and floor material. In summary, selective mining practices will probably result in almost45% decrease in the discard content in the run of mine to gasification, an increase in the carbon content from 55.0% to 58% (air dry basis) and a decrease in sulphur content from 1.1% to 0.9% (air dry basis). It is clear from this study that the main source of sulphur is not in the high ash-content mineral types (e.g. floor and roof), but in situ in the coal structure. Keywords: inorganic material, effect of washing, roof, floor, pyrite, C-shale, carbonates and siltstone

Jan 1, 2005

By M. Verri

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Jan 1, 2009

A shortage of technical skills in all areas of the mining industry is being experienced worldwide. This has significant consequences for design, operations, productivity and safety and, therefore, needs to be seriously addressed, both in the short and longer term. It is therefore both a strategic and a tactical issue. Importantly, however, since mining is a long-term business, the shortage of skills must be dealt with from a strategic point of view to ensure the supply of the necessary skills for future mining. This paper will deal specifically with the provision of high level technical skills, that is, university graduates in mining engineering, and the outlook for the institutions that are currently producing such graduates.

Jan 1, 2009

By L. Jeffrey

The Waterberg Coalfield has vast potential to become a significantmining and industrial centre in South Africa. Its future developmenthinges on a number of critical decisions that must be made jointly by government, power utilities and industry, and on some technical and economic challenges that must initially be overcome. Sufficient water is the primary key to enabling exploitation, together with an adequate market for the large volumes of low-grade coal. As the most likely consumer of this coal will be either a power station or a petrochemical complex, the need for additional energy will be a driving force in the development of this coalfield. Conventional mining methods can exploit the shallow coal resources in both the Grootegeluk and the Vryheid formations, but alternative technologies such as coalbed methane extraction and underground coal gasification are the only currently known technologies that may be able to exploit the deep Grootegeluk Formation resources. However, extensive research is still required into these procedures, particularly with respect to the Waterberg coals. Transport infrastructure to the region is currently not sufficiently well developed to support large-scale exploitation of the region?s coal resources. In particular, the railway line would have to be extensively upgraded to allow the increased export of coal. Alternative transport methods such as pipelines would also have to be pursued to serve a large Sasol-type petrochemical complex or coal gas extraction. The road network would also require improvement, as only the roads between the main commercial centres are currently tarred. Dr Con Fauconnier, Kumba CEO, concluded his presentation to the Investing in African Mining Conference 2004 with the words: Again, it?s all about infrastructure? when it?s there, it enables the development of bulk mining projects which attract the resultant economic benefits for the region and country as a whole. These words aptly sum up one of the stumbling blocks to the future development of the Waterberg Coalfield.

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 C. Kloppers

The aim of this investigation was to reduce the cost of primary steel de-oxidation by substitution of aluminium primary de-oxidation with a practice that uses carbon. The cost of carbon is four times lower than that of aluminium. The application of carbon would directly result in raw material cost savings. Investigations were conducted at Iscor?s Newcastle steel plant on various steel grades. Specific production aspects were emphasized to ensure that the cost savings accrued would not create secondary expenses. These production aspects entailed: ?Yields on de-oxidation elements ?De-oxidation capabilities ?Alloying yields (Mn and Si) ?Carbon-pickup ?Nitrogen-pickup ?Temperature loss during tap ?Steel cleanliness ?Slag morphology. This project proved that carbon de-oxidation, apart from reducing de-oxidation raw material cost due to cheaper raw materials being used and lower consumption rates, resulted in steel that is cleaner and has lower nitrogen concentrations. Carbon primary de-oxidation has been implemented at Iscor?s Newcastle plant on a large range of steel grades, ranging from ultra-high carbon (> 0.60% C) to ultra-low carbon (< 0.03% C) grades. A net saving of between R100 000 and R200 000 per month was achieved.

Jan 1, 2001

By G. H. Lind

This paper discusses the traditional costing approach currently used in the underground coal mining industry. Activity Based Costing (ABC) is identified as being a potentially more effective manner in which to cost underground coal mining systems. With the use of a costing framework developed by the author incorporating new thinking to eliminate the shortcomings identified in the traditional costing approach, a comparison of two types of underground coal mining systems, viz. continuous miner and longwall, is conducted. It is found that under certain criteria, in all cases, irrespective of the way in which the systems are costed, the continuous miner system is currently the better investment. It is also observed that when a system is costed using ABC that better investment decisions result when compared to costing the same system using traditional costing techniques. It is further seen that traditional costing techniques tend to overestimate the total costs of a mining system. This paper shows one application of ABC that can be incorporated as a management tool.

Jan 1, 2001

By M. G. Wimberger

The Merensky Reef zone, as developed on Impala Platinum?s Rustenburg Operations, displays a gradational mineralized zone, with grades decreasing from the Merensky Pegmatoid Unit into the footwall and hanging wall. A system of identifying a manageable method of defining the mining cut is introduced, termed the grade profile attenuation cut-off grade. Although horizontal grade selectivity is not applied in the mining of the Merensky Reef zone, low extraction of the orebody, due to manageable and non-manageable factors, can contribute to a reduction in revenue, even losses, due to fixed cost contributions in the mining and beneficiation of the ore. A model is proposed that integrates all variables affecting the revenue of the mining operation, including the grade profile attenuation cut-off grade, the extraction factors, commodity prices and exchange rates, utilizing numerical simulation techniques in a PC-based environment. A breakeven extraction factor for a specific cut-off grade is delivered for a range of market conditions. The breakeven extraction factor is a useful guide when designing mining layouts in structurally complex and low metal content areas. Incorporating distribution functions for individual commodity prices and exchange rates into the model provides mineral resource managers with a risk profile for individual mining areas. Shaft areas have varying grade profiles and each area should have individual models run, to prevent generalizations being made about acceptable risk levels on mining areas.

Jan 1, 2004

By J. de Villiers

Through the application of the Rietveld method, X-ray diffraction analysis has developed into a fully quantitative method for phase analysis. The Rietveld method itself has progressed from an unstable method that required constant operator intervention to a stable and robust method suited even for routine analysis. The method, however, requires a good initial calibration and periodic checks on its precision and accuracy. Several examples from minerals processing, pyrometallurgy, and materials science show the strengths and applicability of the method. The limitations and sources of error are also discussed.

Jan 1, 2007

By H. P. Kritzinger, T. C. Kingsle

"Rotary kilns are used for a variety of mineral processing operations. Hatch makes use of a kiln model developed from first principles to evaluate designs for its clients. This tool has been applied to a variety of pyrometallurgical applications, including ferrovanadium, nickel carbonate, nickel laterite, iron ore reduction, and spodumene (lithium) production.This paper illustrates the application of numerical optimization techniques in combination with the kiln model in the interrogation of a generic iron ore reduction process. The fundamental modelling concepts are explained, followed by a description of the optimization approach. The results show how the combination of the two methods, with modern computing power, can generate a large number of viable design and operating candidates."

Jan 1, 2015

By A. McLean, M. Iwase, K. Wakimoto, K. Katogi

For many decades control strategies have been based upon samples taken from liquid steel, molten slag and gas phase as well as from solid products. Because of recent developments in the areas of dynamic control models, artificial intelligence and expert systems, there is an increasing incentive to develop diagnostic sensors, which permit in-situ rapid determinations of concentrations of various elements in molten steel. In this paper, an overview is given on recent developments in the areas of sensors for use in ferroalloy and steel production. Particular emphasis will be given on (i) innovative application of sensors for on-line determinations of dissolved elements, Si, P, N, H and Cr in molten iron and ferroalloys, (ii) evaluation of inclusions in liquid metal and (iii) rapid determinations of slag compositions.

Jan 1, 2004

Council for 2001/2002 President A.A.B. Douglas President-elect S.J. Ramokgopa Vice-presidents Senior F.M.G. Egerton Junior Prof. T.R. Stacey Immediate Past-president Dr L.A. Cramer Honorary Treasurer J.A. Cruise

Jan 1, 2002

By D. S. F. Silva

A survey of 120 recent NI 43-101 technical reports was conducted to evaluate the current state of practice regarding resource classification techniques. The most common classification techniques are based on search neighbourhoods (50% of recent reports), drill-hole spacing (30% of recent reports), and/or kriging variance (6% of recent reports). Two new techniques are proposed. The first is based on kriging variance and involves removing one or more drill-holes with the highest weights while performing kriging and using the resultant kriging variance for classification. This technique has the advantages of variance-based techniques and reduces artifacts. The second technique is based on conditional simulation and uses a moving window approach for classification at the desired selective mining unit resolution based on larger production volume criteria. This technique has the advantage of accounting for heteroscedasticity, which is a common characteristic in mineral deposits, and also reduces artifacts since a production volume scale is considered for the actual classification. The drill-hole spacing, search neighborhood, kriging variance, and simulation-based techniques are described and compared for 2D and 3D examples with regular and irregular drilling patterns to highlight the advantages and disadvantages of each method.

Jan 1, 2014

By O. Nyandoro, K. Khoza-Shangase, M. Madahana, N. Moroe

"Occupational noise-induced hearing loss (ONIHL) is classified as the leading work-related disability in the mining industry. ONIHL has a negative impact, on not only the health and occupational productivity of affected individuals, but arguably also on the country’s mining industry and economy. Hearing conservation programmes (HCPs) are an effective strategy in the management of ONIHL. However, current literature indicates that HCPs are not achieving the anticipated and desired outcomes in the South African mining sector despite the efforts focused on the management of ONIHL. Therefore, the purpose of this study is to propose the use of a feedback-based noise monitoring model as a tool for monitoring and managing ONIHL in the South Africa’s mining sector. This model is a basic static feedback model with practical applications such as estimating, monitoring. and providing quantitative information to aid miners, mining administrators, and policy-makers in decision-making around HCPs. Additionally, the model could form part of an early intervention and management strategy for ONIHL in the workplace. The strength of this model, although currently static, is that it encompasses all the pillars of HCPs and takes into account the policies concerned with the management of ONIHL in the mining sector. IntroductionHazardous noise levels (above 85 dBA) in the workplace place exposed employees at risk of developing a disabling occupational noise-induced hearing loss (ONIHL). ONIHL is the ‘partial or complete hearing loss in one or both ears as a result of one’s employment’ (Nandi and Dhatrak, 2008, p. 1). This type of hearing loss develops gradually as a result of being exposed to continuous or intermittent high levels of noise over a long period of time (McBride, 2004; Patel et al., 2010; Rappaport and Provencal, 2001). A hearing threshold below 40 dBs is classified as a disabling hearing loss (Yadav et al., 2015), resulting in a hidden condition that does not readily manifest itself (Tye-Murray, 2009, p. 3). Dugan (2003) describes disabling hearing loss as the ‘most prevalent, least recognized and least understood physical disability’, while Copley and Frederichs (2010) and Hermanus (2007) argue that permanent disabling hearing loss is a major contributor to the global burden of disease on individuals, families, communities, and countries."

Jul 1, 2019

By Y. He

Early research showed that the separation of particles based upon their density was not possible in steadily rising air streams. The terminal velocities of moving spheres are determined by their aerodynamic characteristics. This prevents particle separation by density in standard air classifiers. Passive pulsing air classifiers have accelerated airflow in certain regions, which achieves density-dominant separation. Numerical simulation of airflow within passive pulsing air classifiers was done to estimate airflow patterns near a damper. Analysis of those results shows the significant acceleration of the airflow above the damper. Laboratory trial separations have shown that passive pulsing classifiers are superior to standard air classifiers. Keywords: pulsing airflow, passive, simulation of airflow models, acceleration effect, density

Jan 1, 2005

By F. T. Cawood

This article is a continuation of a series of publications by the authors on the international debate on resource nationalism, with specific reference to South Africa. Previous outcomes have shown that mine nationalization is not a solution for South Africa, and that maintaining stability of the current mineral and tax regimes is fundamental. It will not be wise to replace existing law and policy instruments until there is a better understanding of the distinction between fact and public perception about the impact of the current system. The new scheme of state custodianship linked to a mining royalty that effectively targets economic rents provides for effective resource use. The methodology in this article is to consider how South Africa&apos;s mineral tax regime can be tweaked to achieve optimal management and benefit from mineral extraction and associated rents by avoiding changes feared by investors. The major finding is that the current suite of instruments can be considered a suitable platform for optimal management of resource rents. However, it will be necessary to first investigate ways of improving the mineral beneficiation intent of the royalty structure, and secondly investigate whether the mineral rent portion of the royalty formula can be ring-fenced for the purpose of establishing a sovereign wealth fund.

Jan 1, 2013

Abrasivity and wear resistance are not intrinsic properties of materials, but rather parameters describing the interaction between the wear part and the material exerting the wearing action. Moreover, wear or, at least, that part of the wear which is due to the cumulative effect of minute scratches, is linked to the hardness disparity concept. Abrasivity, in this context, is a relative concept, pertaining to a metal-rock pair, rather than to a rock. Based on this assumption, a methodology has been developed and checked against actual cases, enabling description of the abrasiveness of a rock or the abrasion resistance of a metal through the ratio of comparable quantitative indicators. The paper describes the methods and provides examples of applications to practical cases (namely: rock cutting, excavation by means of tunnel boring machines (TBMs), rock crushing, and hydro-mill cutting).

Jan 1, 2012

By F. M. G. Egerton

Mechanisation of mining operations is not a new concept in the world of mining. Machinery has been developed, manufactured and used for many decades in massive orebodies and coal mines, both locally and abroad. Because of their size and the huge tonnages available, massive ore bodies lend themselves very easily to mechanisation. However, little progress in mechanisation has been made in narrow tabular orebodies in South Africa. The equipment available for narrow tabular orebodies requires excavations of a size that introduce large volumes of waste dilution. Nevertheless, it is essential for South African miners to experiment with mechanisation and to find a solution to the problem. This address looks at current conventional mining methods and compares them to bord-and-pillar type mining methods. Off-reef mechanisation is also touched on. It then looks at different hybridised mining methods that are being used, i.e. a mixture of conventional mining and mechanisation. It finally looks at future prospects for mechanisation in narrow tabular orebodies.

Jan 1, 2004

By S W. Robertson, A Vercuil, P Craven

Mintek is currently developing a design approach for the heap leaching of low-grade primary copper sulphide material. Since the leaching of chalcopyrite requires elevated temperatures, the generation and management of heat within the heap is crucial. Furthermore, the precipitation of iron needs to be managed to prevent premature blinding of the heap, and acid consumption needs to be limited to contain cost and limit the dissolution of gangue impurities. Standard column tests using jacketed 1-m and/or 6-m columns do not allow accurate prediction of temperature changes and heat generation in an actual heap. Mintek therefore utilizes a computer model to calculate the energy balance and heat generation with time, based on the measured sulphide oxidation rates in the column. The temperature in the column is then adjusted to reflect the computer-predicted temperature in an actual heap. Using this approach, an overall copper extraction of 70% was achieved in 120 days, using 1-metre columns, when treating an ore blend containing 1.36% chalcopyrite, 0.23% chalcocite, 0.07% covellite, 3.8% pyrite and silicate gangue (92%). The chalcopyrite contribution to the total copper content in the feed was 75%. This was followed by 6-m columns using a similar approach, and the column results will be validated on a 23,000 tonne test heap. Key Words: heap; bioleach; chalcopyrite

Jan 1, 2005

By A. Wedepohl

Selective leaching of phases in charge chrome is used in a variety of industrial processes for the production of chromium chemicals. A mineralogical study was made of a range of local charge chrome samples, at various stages of leaching in sulphuric acid (20g/l at 90°C), using mainly a scanning electron microscope (SEM) together with an energy-dispersive spectroscopy analyzer (EDS), and X-ray diffraction techniques. It was found that the leaching behaviour of the different types of charge chrome depends largely on the nature of the secondary phases, which in turn depends upon whether the silicon content is above or below 4 per cent by mass. The leaching behaviour of high-chromium ferrite is anomalous, and it is postulated that the process is analogous to the corrosion of brass by dezincification. Keywords: charge chrome leaching, scanning electron microscope

Jan 1, 2000