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By J. D. Flint

A description is given of the extraction of pillars in a seam of coal which normally varies in thickness from 10 feet to 14 feet using conventional trackless mechanised units. By using the pocket and fender method of pillar extraction, the high capital cost of hydraulic supports is eliminated, and a volumetric extraction of 85% to 90% of the seam of coal is possible. This method of mining opens up the possibility of extracting vast tonnages of coal which hitherto would have been left in situ as pillars. The major benefits likely to accrue from this technique are seen as follows: 1. Greater volumetric extraction of the seam; 2. Longer panel life with less frequent transferring of sections; 3. Preservation of our natural resources. The authors deal with the history of this development at Springfield Colliery, discuss the present results and outline the future trends in the light of current experience.

By X. H. Zhang, J. G. Cai

This paper discusses the behaviour of large-span tunnels and caverns in hard rock in a major underground storage project. In-situ stresses were measured using hydraulic fracturing during site investigation and 3-D overcoring during construction, with both showing a horizontal stress ratio of 2-3 times the vertical stress. Rock reinforcement design was based on the Q-system combined with numerical modelling for special design cases. Tunnel design and performance were checked and monitored by in-situ instrumentation during rock excavation, including measurements of deformation, convergence, and load on rock bolts. Deformation measurements using borehole extensometers included one borehole drilled into the virgin rock before rock excavation, which provided a direct and very insightful comparison with the various deformation measurements made during rock excavation. These measurements coupled with numerical calculations have proven that the high horizontal stresses to be very favourable to the stability of the large openings.

Jan 1, 2003

By E. Mpoloka

Debswana together with ADP as their design partner have embarked on an RDP project at Jwaneng Mine. The objective of the project is to install a 2 million ton per annum mineral processing plant that will fast track the recovery of diamonds from the Debswana tailings resource to ensure maximum return on investment for the company. Due to the prevailing economic conditions Debswana has had to review the way they used to build plants in the past and consider simple, fast and effective ways of doing things. The rapid deployment plant concept is therefore the most suitable means of achieving this objective. Debswana is also considering an operating partner who will operate far more efficiently and cheaply compared to the larger more cumbersome and less agile Debswana.

Jan 1, 2010

By G. M. Dunn

Pressure leach autoclave circuits are employed in the leaching of ores, concentrates, mattes, alloys and intermediates for the recovery of metals into solution. Once the metals are extracted into solution, the value metals can be recovered by hydrometallurgical means such as by purification followed by electrowinning, hydrogen reduction, pyrohydrolysis, crystallization and other unit operations. In many of these integrated flowsheets the pressure leach step is pivotal to the recovery of the value metals from the host material. Furthermore, the autoclave circuit invariably is a high capital cost component of the plant and an area that is carefully scrutinized when debottlenecking and capacity increases are being considered. This paper identifies a unique proven way of increasing the capacity of existing or new exothermic pressure oxidative leach autoclave circuits by as much as two or three times.

Jan 1, 2009

By P. M. Swash

A mineralogical investigation of the main causes of refractoriness of some metalurgicaly complex gold ores in South Africa is reported. It is shown that this refractoriness is related to the presence of submicroscopic gold, carbonaceous material, pyrhotite, and base-metal sulphides. Gold ores can be classified according to their content of these components. Electron-microprobe analysis shows that gold occurs in arsenopyrite and pyrite, the gold contents of which can be up to 2700 gft. The gold and arsenic contents of these minerals are closely corelated. Furthermore, within zoned arsenopyrite grains, the concentration of gold closely folows that of arsenic. Mossbauer spectroscopy caried out on samples of concentrate from the Barberton area indicates that the submicroscopic gold within the sulphides is in a non-metalic form. The mineralogical examination of beneficiation products is important, since it sheds light on some fundamental aspects of the behaviour of the ore and gangue components during milling and flotation. Such basic information will lead ultimately to a better understanding of the problems in the beneficiation of these ores. Investigations have shown that the overmiling of the auriferous arsenopyrite and the disseminated nature of the sulphide mineralization are the main problems during beneficiation.

Jan 1, 1988

By J. W. de Kock

The estimation of some properties of South African coals from proximate analyses by J. W. de KOCK, Pr. Eng., Ph.D. (Chem. Eng.) Cantab. (Fellow) and J-P. FRANZIDIS, B.Sc. (Chem. Eng.) (Visitor) Correlations have been obtained whereby calorific values, ultimate analyses, and Hardgrove Indices can be estimated from proximate analyses of South African coals. This has been done by the application of stepwise multiple linear-regression analyses of a mass of data published by the Fuel Research Institute.

By S. -H. Chang, C. -I. Lee, Y. -K. Lee

Based on results from triaxial compressive tests, an experimental damage model to simulate post-peak behaviours as well as nonlinear behaviours before peak strength was developed. In order to consider pre-peak behaviours, variations of elastic constants at each damage level were regressed by functions of confining pressure. In addition, post-peak behaviours were simulated successfully by using Hoek-Brown constants. As results, the experimental model could predict nonlinear behaviours, peak strengths and stiffness changes observed in experiments. Basé sur des résultats des essais compressifs à trois axes, un modèle expérimental de dommages pour simuler des comportements de poteau-crête aussi bien que des comportements non-linéaires avant la force maximale a été développé. Afin de considérer des comportements de pré-crête, des variations des constantes élastiques à chaque niveau de dommages ont été régressées par des fonctions de pression d'emprisonnement. En outre, des comportements de poteau-crête ont été simulés avec succès en employant des constantes de Hoek-Brunes. Comme résultat, le modèle expérimental a pu prévoir des comportements non-linéaires, des forces maximales et des changements de riidité observés dans les expériences. Auf Basis der Ergebnisse des dreiaxialen Drucktests wurde das experimentelle Schadensmodell, das sowohl das nicht-lineare Verhalten vor der maximalen Stärke als auch das Verhalten nach der maximalen Stärke simulieren kann, entwickelt. Um das Verhalten vor der maximalen Stärke zu berücksichtigen, wurden die Veränderungen der elastischen Konstante bei dem jeweiligen Schadensniveau durch die Funktionen des begrenzten Drucks zurückgegangen. Außerdem wurde das Verhalten nach der maximalen Stärke unter Benutzung von Hoek-Brown Konstanten erfolgreich simuliert. Schließlich konnte das experimentelle Modell das nicht-lineare Verhalten, die maximale Stärke und die Veränderungen bezüglich der Steifigkeit während der Experimente voraussehen.

Jan 1, 2003

By P. C. van Aswegen

The Schools A school on 'Measurement, Process Control and Optimization in the Minerals Industry', organized by The South African Institute of Mining and Metallurgy, was presented twice by course leader Dr Ken Garner, ably assisted by the staff of the Measurement and Control Division of Mintek. The first school was held from 16th to 20th July, 1984, at the University of the Witwatersrand, and the second from 11th to 15th February, 1985, at Mintek. Project development The Sydney Branch of the Australasian Institute of Mining and Metallurgy will hold a second Project Development Symposium in Sydney between 7th and 10th October, 1986. This second symposium will extend the range of topics covered by its predecessor in 1983 to emphasize planning (including strategic planning), construction, and project commissioning.

Jan 1, 1985

By J. H. Viljoen, A. Heyns, J. F. Morrison, C. H. Wyndham, N. B. Strydom

Discussion M. J. Martinson* (Associate Member): This is another interesting paper in the series which the Human Sciences Laboratory is publishing on the physiological cost of the more strenuous manual tasks performed underground. As a mining engineer-albeit presently an academic one -this contributor is more concerned with the practical significance of the study in the field of stope cleaning than with physiological niceties, but before discussing some of the practical issues raised by the paper perhaps the authors would care to reply to lay comment on three physiological matters. Firstly, in two places the authors make statements to the effect that the maximum oxygen intake of 'average' (sic) Bantu mine workers is 3.0 l/min. What do the authors mean by 'average'? Maximum oxygen intake in the individual is probably some function of inter alia age, physical fitness, state of health, ambient partial pressure of oxygen, diurnal and/or seasonal changes in metabolism, and possibly cumulative exposure to dust and other occupational contaminants. Since maximum oxygen intake is apparently such an important quality in manual labourers we ought to have a clear picture of its distribution in the entire labour force, and also know precisely how the individual's quantum is affected by factors such as those mentioned above. Secondly, arising out of the same statements and ignoring the reservation implicit in the previous paragraph, is it correct to say that the 'average' Bantu mine worker has a maximum intake of 3.0 l/min? In the August 1966 issue of the South African Journal of Science four of the present co-authors reported the mean maximum oxygen intake of a random sample of 338 Bantu recruits of different tribes to be 2.63 l/min with a standard deviation of 0.542 l/min, and these figures were repeated in a paper published in the November 1968 issue of this Journal. Admittedly the mean maximum oxygen intake of the six subjects used in the present study was 3.05 l/min, but since they were selected on the grounds of previous shovelling experience they can hardly be regarded as being 'average' recruits. Thirdly, it seems to me that the authors are perhaps a little uncritical in their acceptance of the '50 per cent of maximum oxygen intake' level of activity for endurance work. I am not unmindful of the evidence upon which this level is based, but I suggest that the evidence is at best tenuous and that the whole topic of fatigue and 'optimum' levels of productivity under conditions of high muscular activity and considerable psychological stress is a lot more complicated than would appear from the authors' ready acceptance of the 50 per cent level. Under present working conditions the question is largely rhetorical because it would need an army of supervisors to ensure that all members of a typical gang work at 'optimum' levels throughout the shift, but if individual performance should ever become more readily determinable the issue might become crucial to management and malayisha alike. So much for physiological matters; now a few random thoughts on some wider, practical issues raised by the paper. In the paragraph headed Material the statement is made that 'The mixture (of fine, medium-sized and bigger rocks) was considered to be representative of an average underground rock sample'. Elsewhere in the report the authors specifically draw attention to the effect of particle size on the oxygen consumption of men shovelling graded material, and intuitively one imagines that the size distribution of the material being shovelled would be highly significant in a study such as this. Presumably the authors were forced to assess size distribution subjectively because of the lack of objective data on the subject, and possibly the necessity for this assumption highlights how little we know quantitatively about any of the variables in stope cleaning systems. In this connection it may be remarked that although the present study was largely designed to show how dip and stoping width effect energy expenditure in shovelling, no data are given-nor, probably, are they available-to show how the industry's stoping tonnage is distributed in terms of these two factors. It seems to me that if the mining industry seriously hopes to improve stope productivity it must start by measuring the basic variables in existing systems. Elaborating somewhat on the previous paragraph, there also seems to be a tremendous gap between the present study-and its predecessors-and the prospect of gainfully using the information so carefully garnered by the authors. It would be reassuring to hear from the authors that their work on the physiological aspects is being integrated in some master plan for increasing productivity of manual labour. This I fear is not the case, and if productivity has changed at all in recent years I would hazard a guess that the change has been brought about by random factors rather than by systematic engineering design. The Human Sciences Laboratory has worked extensively in stopes in the past, and possibly the time has come when it should widen the ambit of its operations to include engineering-type analyses of cleaning systems, with particular emphasis on the economics of rapid cleaning by manual labour. Perhaps experiments could be conducted with stakhanovite-type gangs consisting of men selected for their high maximum oxygen intake and superior motivation; these men might be offered special incentives in the shape of extra pay

Jan 10, 1969

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 M. Seerane, R. Machaka, P. Ndlangamandla

"Metal injection moulding (MIM) is a near-net-shaping powder metallurgy technique suitable for the cost-effective mass production of small and complex components. In this paper, the effects of the metal powder particle size on the final properties of 17-4 PH stainless steel are reported. Three different particle sizes (d50 33.0, 7.91 and 4.04 µm) were used to prepare the injectable MIM feedstocks using a CSIR-developed wax-based binder system at a fixed solids loading of 60 vol.%. The distribution slope parameter and the rheological flow index behaviour were used to predict the flowability of the feedstocks. The effects of the particle size on MIM products were established. The results are discussed in terms of the subsequent microstructural and mechanical properties of MIM 17-4 PH stainless steel against the established MPIF Standard 35. IntroductionMetal injection moulding (MIM) is a near-netshape manufacturing process established as an alternative to produce complex small-tomedium shaped components that were previously fabricated by conventional methods at higher costs (Attia and Alcock, 2011; Todd and Sidambe, 2013).Although recent advances in micromanufacturing (mainly machining and electrodeposition-based) have enabled the fabrication of complex micro-size geometries directly into miniaturized parts, these processes are generally neither routine nor easily accessible at present (Attia and Alcock, 2011).Typically, the MIM process consists of four steps: mixing, injection moulding, debinding and sintering. Mixing involves blending of the desired metal powder composition with carefully selected multicomponent organic binders at the right proportion. This mixture, which is called feedstock, is then injected into a mould of a required shape to form a ‘green part’. Debinding is the removal of the binders by chemical, thermal, or catalytic means while maintaining the shape of the part. Finally, the debound part is sintered to a full or near-full density part (Sotomayor, Varez and Levenfeld, 2010). The MIM process is essentially a combination of plastic injection moulding with conventional powder metallurgy technologies."

Jan 1, 2016

By R. K. Brummer

The support of stopes and tunnels in South African gold mines subject to rockburst damage requires special attention. The interaction of a seismic wave with either a stope or a tunnel is subject to a number of variables, namely the distance from the source of the event, the ground velocity, the orientation of the excavation with respect to the direction of the seismic wave, and the geology and fracturing around the excavation. This paper discusses these factors in relation to the support requirements in stopes and tunnels. The need for the integration of hydraulic props with stope support and the use of yielding anchors for tunnel support are emphasized.

Jan 1, 1988

By H. H. McGregor

SYNOPSIS Changes in the national productivity (gross national product per head of the population) have been assessed in order to derive a target figure for the required annual increase. The conclusion reached IS compared with the targets of the economic development programme of the Republic. Productivity and management structure in the gold mining industry is then analyzed together with investment in plant, machinery and equipment for rock handling purposes. The conclusion is drawn that productivity improvement does not appear to have accorded with the massive expenditures in plant and equipment, and in augmented management. The productivity of the manufacturing and construction sectors of the economy has been examined. The principal difficulty is that the main avenue of approach is the value of product divided by the total labour force. This introduces inflationary questions, and the use of a suitable deflator becomes of prime importance. Severa1 different methods of assessing the productivity improvement in the industrial sector have been used with what is regarded as a comparatively high degree of compatibility. Improvements in productivity in the manufacturing industry up to 1966 appear, from the information available, to have substantially exceeded comparable figures for the mining industry. There is however evidence that thereafter productivity of the manufacturing industry has not maintained this satisfactory rate of increase. If the economy is to achieve the planned rate of expansion, there is no doubt that greater attention to this aspect will be required in the future than has been accorded to it in the past.

By E. Ringdalen

Keywords: Pyrometallurgy, research, Norway, SINTEF, NTNU The Norwegian Ferro-alloy Industry and the model for research cooperation between SINTEF, NTNU, and the Norwegian ferro-alloy industry is presented as an introduction. The research within pyrometallurgy is illustrated by examples from characterisation of Mn-ores and characterisation of carbon materials. Examples from studies of reaction mechanisms in laboratory- and pilot-scale experiments are presented, in addition to an example of industrial off-gas measurements. Education possibilities at NTNU are also described.

Jan 1, 2011

By T. Mwanza, B. N. Belford, P. Conradie

"Metix has introduced a three-piece ’deep-cooled’ copper slag tapblock into a six in-line copper matte settling electric furnace. The tapblock was designed without any internal refractory; it relies purely on the development and maintenance of a freeze lining on its hot face and within the tapping channel to protect the copper and promote the integrity of the surrounding endwall refractory lining. In addition, the geometry of the tapblock further supports the sidewall refractories, reduces the impact of funnelling and, therefore, the need for premature rebuilding of the furnace endwall, and facilitates easy removal and replacement of the wear components even under ’hot’ furnace conditions. Eighteen thermocouples embedded in the copper components ensure full resolution of the copper condition, enabling plant personnel to identify wear rates, estimate freeze lining thickness and stability, and schedule replacement of spares and wear components well in advance.At the time of writing the tapblock had been in operation for 6 months with approximately 350 000 t of slag having been tapped through it. Every indication is that the design will limit the need for premature relining of the furnace endwall due to rapid deterioration of the tapblock and its surrounding refractories. IntroductionNonferrous furnaces rely heavily on the maximization of refractory campaign life to increase profitability and reduce planned downtime. In large electric copper slag-cleaning furnaces utilizing insulating linings, campaign lives of six or more years are realistic if consideration is given to each aspect that can degrade the refractory lining during the campaign. An area that is particularly vulnerable is the slag tap-hole and the local surrounding refractory. To avoid premature relining of the furnace walls, every effort should be made to consider not only the tap-hole design itself, but also the selection of the sidewall refractory material and its construction immediately adjacent to the tap-hole, and furthermore the interplay between the tapblock and this adjacent refractory. A holistic approach to the design that considers these interdependent features in the slag tapping area can reduce the incidence of accelerated refractory wear (‘funnelling’), support the surrounding refractories to prevent their collapse, introduce easily replaceable wear components that can be exchanged with the furnace still ‘hot’, and encourage and maintain a stable freeze lining at the refractory hot face that maximizes the tapblock and refractory lifetime."

Jun 1, 2019

By I. J. Kotzé, R. T. Jones

Conventional PGM matte smelting requires the presence of a certain quantity of base metal sulphides in order to collect the platinum group metals in a molten sulphidic matte phase in the furnace. Furthermore, the quantity of chromium oxide in the feed materials is controlled in order to avoid the build-up of high-melting chromite spinels in the furnace. Mintek has developed a process for smelting difficult PGM-containing feed materials that contain low amounts of sulphur and/or high amounts of chromium oxide. A DC arc furnace is used to provide the appropriate conditions to generate an iron alloy that collects PGMs very effectively, leaving extremely low residual quantities of PGMs in the slag. Various feed materials have been treated successfully in furnace campaigns running at power levels up to 1.5 MW. The longest of these campaigns was run continuously for more than four months, treating more than two thousand tons of materials such as low-grade concentrates, revert tailings, and converter slag. The campaigns demonstrated the robustness and versatility of the process, and proved that it is possible to sustainably produce a PGM-containing alloy and discardable slags containing an average of less than 1.4 g/t of PGMs over the entire campaign. Keywords: DC arc, smelting, furnace, platinum, PGM, revert tailings, converter slag, ConRoast

Jan 1, 2004

By B. Mulcahy, M. Valenta

"The purpose of executing a project in a stagewise fashion is to evaluate all potential options in a cost-effective manner and develop an understanding of the project drivers, thereby minimizing overall project risk to the client. Among the more valuable tools for this exercise are production and financial models that can be used to quantify the sensitivity of the project to the critical parameters.The mine and concentrator used in this case study are located on the Kalahari Copper Belt, which extends from Zambia through northern Botswana into Namibia. This area of Africa has seen very little industrial development and the project will create much-needed employment and development in the region.The success of this project thus far can be attributed to the close cooperation between the geological, mining, and metallurgical disciplines. Regular updates of projected capital and operating cost estimates coupled with project outputs guided the teams in optimizing their various discipline models, ultimately delivering a compelling argument for the execution of the project. Key to the success was the development of a geometallurgical model for the prediction of concentrate tonnage, grade, and recovery for the life of the mine from the mining plan.This paper summarizes the metallurgical findings and the outcome of the various project stages. The development of the model is discussed, as are the challenges faced in developing a suitable metallurgical process route. IntroductionThe Kalahari Copper BeltThe Kalahari Copperbelt, which extends from Zambia across northwest Botswana into Namibia, is considered to be a broad time equivalent of the Central African Copperbelt, with a similar style of mineralization. However, at shallower depths (<25 m), chrysocolla and malachite exist in significant proportions in certain geological areas. As illustrated in Figure 1, the project is located in the Ghanzi-Chobe Fold Belt which forms part of the Kalahari Copper Belt. The Ghanzi Group, which overlies the lowest stratigraphic unit (the Kwebe Formation), consists of three formations, namely the Ngwako Pan, the D’Kar, and the Mamuno Formation (Hall, 2012)."

Jan 1, 2016

By J. A. Maree

After the South Deep complex was purchased by Goldfields in 2006a re-feasibility study was done and the life of mine (LOM) was extended to 52 years. This also implied that the mine?s infrastructure would have to be enhanced. One of the changes was the proposal of five new main orepass systems to be excavated before the mine reaches full production in 2013. Excavations started to show signs of scaling, and in some cases, whole new excavations were lost. This particular area was exposed to very high stresses and the geology was prone to body delimination rendering the relevant areas unstable. This paper investigates the conditions at the location of one of the proposed orepass systems, and the best possible orientation was suggested to ensure that the orepass system would be stable and have a practical life. It was, however, found that the fourth leg of the orepass system would require further support to be classified as stable by the chief rock engineer and the section geologist of South Deep. Several support methods and orepass system linings would then be analysed and evaluated to give calculated recommendations on how to productively and practically support an orepass system. Keywords Main orepass system, stresses, body delamination, impact and abrasion, rock support, concrete lining.

Jan 1, 2011

By T. Gerritsen, A. Matyas, F. Stober, I. Candy

This paper describes developments in ferro-nickel furnace technology, specifically improvements to cooling methods, furnace controls, and high voltage furnace operating regime. The evolution of these technologies is briefly presented, as context for describing the current state of the art that has enabled ferro-nickel furnace operation at over 75 MW and specific energy consumption of less than 400 kWh/t dry ore. Examples from existing operations are used to illustrate present best practices, and potential future trends are discussed. The paper begins with an overview of the fundamental aspects of pyrometallurgical treatment of lateritic ores that drive ferro-nickel furnace design. Furnace wall cooling methods are related to the requirements resulting from specific furnace process conditions, including slag and metal compositions, as well as arc and bath power. The benefits of high productivity and low specific energy consumption resulting from high voltage (shielded-arc) operating practice are discussed, along with the furnace controls and electrical power train that enable such operation even with captive power generation.

Jan 1, 2004

By C. Lottering

Copper sulphate solutions are produced during the pressure leaching of first-stage leach residue in a typical base metal refinery process. Apart from impurities such as selenium and tellurium, this leach solution also contains other precious metals (Rh, Ru, and it) due to dissolution in the pressure leaching stage. Selenium and tellurium are removed from the leach solution by precipitation with sulphurous acid, since these elements negatively affect electrowinning. This study investigates the feasibility of modifying the Se/Te precipitation process step to achieve significant rhodium precipitation in addition to selenium and tellurium precipitation, in order to reduce the rhodium inventory of the process. Thiourea, S02, formaldehyde, formic acid, and sodium thiosulphate were evaluated to determine which of these reagents would achieve the highest Rh precipitation. Based on these screening tests, SO2 and thiourea were selected to be used as precipitation reagents in optimization tests. During these optimization tests, the operating temperature (80 to 150°C) and the amount of reagent added (80 to 140 per cent excess) were varied to evaluate the effects that these operating conditions have on the precipitation behaviour of Rh as well as Se, Te, Cu, and Ni, and to propose appropriate operating conditions. It was found that thiourea resulted in good Rh and Se precipitation (typically in excess of 90 per cent), but precipitated noticeably more copper and nickel from the solution than when SO2 was used. In addition, thiourea had poor Te removal characteristics. SO2 achieved a maximum of 70 per cent precipitation of the rhodium. Faster kinetics and a larger extent of Te precipitation were, however, observed when using SO2 compared to thiourea.

Jan 1, 2012