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By J. W. Latilla, J. J. van Wijk

In late 1997 a request was received to assist with determining the powered support unit (shield) load capacities for the planned 2 seam short wall. This project had a number of aspects which made it attractive to utilize numerical modelling in conjunction with other more conventional design tools in the design of the shields. Amongst these were: The 2 seam panels were to be laid out about 25 m below the previously short walled 4 seam, the 4 seam had in turn been over-mined by the 5 seam long wall, the proposed face height of the 2 seam short wall was 5.5 m while the 4 seam had been mined at 4 m. The top seam in the area (5 seam) had been mined at between 1.5 and 2.2 m high, the face conditions with about 95 m of broken material applying dead weight loading to the 2 to 4 seam inter-burden septum were hard to predict and cyclical loading due to the presence of strong sandstone bands in the 2 to 4 seam inter-burden. The basic thrust of the study was to take the known, and successful, situation (4 seam short wall) and carry out comparative modelling to enable prediction of likely 2 seam conditions. Some two dimensional aspects studied were: 5 m goaf hanging up behind shields, stresses in beams to determine likely first goaf roof span, stresses in cantilever beams to asses cyclical loading due to sandstone bands in the interburden being loaded by the overlying goaf and stresses on chain and crush pillars adjacent to the goaf edge. Three dimensional aspects that were investigated included: Load distribution along face for close goafing and 5 m goaf hang-up and load in a 1 m wide rib modelled in the position of the powered support units. From the modelling it was possible to determine the optimal shield leg capacity of the new 2 seam equipment. These outputs were used when drawing up the technical specifications for manufacture of the new equipment. The face was successfully commissioned in August 2002. Fin 1997, requête fut faite pour aider à la détermination des capacités de charge pour l’unité de soutènement mécanisée (bouclier) pour la couche 2 courte taille en projet. Certains aspects de ce projet le rendaient intéressant pour utiliser la modélisation numérique en même temps que d’autres méthodes conventionnelles pour la conception des boucliers. Parmi ces aspects se trouvaient : Les panneaux de la couche 2 devaient être placés environ 25 m au dessous de la couche 4 courte taille ; la couche 4 avait été remplacée par la couche 5 longue taille ; la hauteur de taille proposée pour la couche 2 courte taille était 5.5 m, tandis que la couche 4 avait été exploitée à 4 m. La couche supérieure de la région (couche 5) avait été exploitée entre 1.5 et 2.2 m de hauteur ; il était difficile de prédire les conditions de taille, avec environ 95m de matériaux cassés ajoutant une charge morte à la plaque de séparation entre les couches 2 et 4 et un chargement cyclique causé par des bandes de grès dans l’entre-fardeau 2-4. L’idée principale de l’étude fut de prendre la situation connue et réussie (couche 4 courte taille) et de faire une modélisation comparative pour prédire les conditions probables de la couche 2. Certains des aspects à double dimension qui furent étudiés étaient : Un accrochage de remblai de 5m derrière les boucliers ; contraintes dans les poutres pour déterminer le premier intervalle probable entre remblai et toit ; contraintes dans les poutres en porte-à-faux pour évaluer le chargement cyclique causé par les bandes de grès dans l’entre-fardeau qui est accablé par le remblai et les contraintes sur les piliers par chaîne et d’écrasement adjacents au bord du remblai. Aspects à trois dimensions qui furent étudiés : Distribution de la charge le long de la taille pour les remblais proches et l’accrochage de remblai de 5 m et la charge dans une nervure de 1 m de large modelée dans la position des unités de soutènement mécanisées. La modélisation a permis de déterminer la capacité de portée optimale du bouclier du dispositif nouveau pour la couche 2. Ces résultats furent utilisés pour dresser les spécifications techniques pour la fabrication de l’équipement nouveau. La taille fut commissionnée avec succès en août

Jan 1, 2003

By R. M. Morris, G. A. Matthesius, M. J. Desai

Slow pyrolysis experiments were caried out on samples of coal from north em Natal having a volatile mater content ranging between 10 and 25 per cent by mass and a constant particle-size distribution. The tests were conducted at atmospheric pressure in a helium atmosphere, and ata heating rate of 10 KImin and a final temperature of 1220 K. The pyrolysis products were taken as coke and volatile mater (tar and eight other species), and tMir respective yields were measured. The experimental results were used in the modification of an existing mathematical model and in the derivation of new corelations for some of the parameters of the model, so that the volatile products of a coal can be predicted from ultimate and proximate analyses of the coal. The pyrolysis tests showed good agreement between the model predictions and the experimental results.

Jan 1, 1987

By R. P. Plasket, D. A. Ireland

Ancillary smelter operations and sulphuric acid manufacture at Impala Platinum Limited by R. P. PLASKET. Pr. Eng.. M.Sc. (Chem. Tech.). Natal (Fellow) and D. A. IRELAND. Pr. Eng.. B.Sc. (Chem. Tech.). Natal (Member) The de-watering, spray drying, and converter operations at Impala are described, aspects that may be new to the minerals industry in South Africa being elaborated. Air-pollution control necessitated the installation of a sulphuric acid plant to limit the emission of sulphur dioxide to the atmosphere. Closer control of the smelting and converting operations was required for successful operation of the acid plant on the inherently Iow and varied concentration of feed gas from converter blowing. Approximately 82 per cent of the sulphur entering the smelter is converted to sulphur dioxide, of which 67 per cent is fed into the sulphuric acid plant.

Jan 8, 1976

By R. D. Beck

The minerals industry needs the support of al sections of the population if it is going to be able to supply the new materials required for future development. It will achieve this support only if its image is good. Perceived images of the minerals industry are examined in respect of history, technology, environment, safety, education, and economics. Concern is expressed about the low technological image of the industry and the declining number of students enrolling in minerals-related disciplines. It is concluded that it is the professionals, through institutes like The South African Institute of Mining and Metallurgy, who must take the lead in improving the image of the minerals industry. The Presidential Address gives data to support this thesis; data that, is hoped, can be used in efforts to educate people about the minerals industry.

Jan 1, 1991

By G. Humphries, E. Wolmarans

The PPRust North project is an expansion of existing operations on the ?Platreef? orebody in the Limpopo Province of South Africa. Anglo Platinum has been mining and processing the Platreef since 1993 at the adjacent Sandsloot and Zwartfontein South open pits at a current rate of approximately 4.5 million tons per annum. This paper describes the origin of the proposed process flow sheet. A comprehensive test work programme has been conducted evaluating the best process flow sheet for the very hard and variable ore in the proposed mining area. The selection of the comminution circuit is discussed where conventional crushing and SABC options were analysed based on both extensive test work and analyses of current operational data at the existing concentrator. The application of the high pressure grinding roll technology has significant advantages?it replaces the 3rd and 4th stage crushing stages in a conventional circuit. This programme has been conducted over several years and has involved work done at site at pilot scale, internally at the company?s research facilities and externally at various sites. The on-site pilot work was completed over a 7-month period at the existing concentrator facility using a ThyssenKrupp-Polysius, ?Polycom?, 950 mm by 350 mm, high pressure grinding rolls (HPGR) machine. In excess of 185 000 tons of ore was processed through the unit during the trial period. This paper describes the test work programme and particularly the proposed application of high pressure grinding technology and its potential for further application in the platinum industry.

Jan 1, 2006

By А. V. Aksenov, S. G. Rybkin, А. Y. Senchenko

Recovered activated carbon fines result from processing of ore and concentrates via cyanide leaching and sorption of valuable metals on carbon at gold-mining plants. This intermediate product is characterised by the particles sized smaller than 0.6 mm and gold grade up to 300-500 g/t. Processing of carbon fines with recovery of valuable metals is not available at many plants due to the lack of optimal technology. The paper describes the testwork and development of an efficient technology to process carbon fines with the recovery of valuable metals into the target gold alloy. This innovative technology involves pelletising of fine activated carbon particles using an organic binder, drying and further firing of pellets in a grate fired furnace at 800-900 °С. The produced ash is subject to sintering with sodium nitrate and hydroxide at 600-700°С. The sintered ash is then leached in water. The insoluble residue containing gold and silver is removed by filtration, dried and smelted to produce gold alloy. Water solution containing sulphur and arsenic is subject to detoxification. Processing of recovered carbon fines according to the developed technology implies the use of standard full-scale equipment. The offered method to treat gold-bearing carbon fines was patented by the Eurasian Patent Office. Key words: Fine activated carbon particles, valuable metals, pelletizing, firing, ash, sintering, leaching, smelting

Jan 1, 2020

There are presently no suitable underground mine production scheduling optimisation models available for application to sublevel stope mining. Scheduling underground production for maximum return is therefore still a manual process, which generally involves scheduling production from the next available highest cash flow stope within the operational constraints of the project. In most mining operations, the scheduling problem is too large and complex to guarantee truly optimal results through manual scheduling. This paper reviews some general optimisation studies that have been proposed for underground hard rock mining. Furthermore, an example of a mixed integer programming model is presented for a small conceptual sublevel stoping operation. Comparative results of a schedule generated by a mixed integer programming (MIP) production scheduling model and a manually generated model on a nine stope example is presented. Results indicate that the potential benefits of the MIP production scheduling model for the purpose of maximising NPV are significant. Finally, a new constraint was formulated to limit multiple exposures of fill masses for use in an existing MIP production scheduling model. Testing of the formulation took place on the central stope of the nine stope example, which showed that the formulation performed its task without breaking other operational constraints.

Jan 1, 2007

By A. A. Oakes, P. M. C. Wilson

This paper describes some aspects of the planning of a new colliery which commenced production in the Middleburg district in 1966. An account is given of some of the problems encountered in the early years of operation and of what was done to solve them. The conclusion is reached that design of plant and machinery should be flexible to permit multiplication of units.

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 R. C. Dunne, W. A. Gilbert, I. J. Corrans, K. S. Liddell

After bench-scale and pilot-plant tests in which it was shown that wet high-intensity magnetic separation (WHIMS) can achieve good recoveries of gold and uranium from Witwatersrand residues, a production size machine was installed at a gold mine. The mechanical and metallurgical performance of this machine have been satisfactory, and the economics of the process are attractive. WHIMS can be combined with other unit operations like flotation for the optimization of overall gold and uranium recoveries. This concept is shown to be relevant, not only to operations for the retreatment of tailings, but to processes for the treatment of coarser material. In the latter, there is a saving in energy consumption compared with the energy required for the fine grinding of the total feed, and a material suitable for underground backfill can be produced. Improved. more cost-effective WHIMS machines currently under development are also described.

Jan 1, 1983

For practical reasons all basic input data for the gold mines of the Anglovaal Group conform to a regular grid of averages of sample values within 25-ft squares in the plane of the ore body; individual sample values with their metric co-ordinates are input and converted by a computer program to the basic 25-ft square averages. At the Prieska copper mine the bore- hole data are forced on to a regular grid of 15-m squares corresponding to the coordinates of the grid points nearest to the actual borehole intersections. As for the gold mines the Prieska ore body, although some 3 to 30 m thick, is also dealt with on a two-dimensional basis (Krige, 1973). On the gold mines the data subjected to geostatistical analysis cover: gold values (in cm g/t), uranium values (cm kg/t), and channel widths (cm). The gold and uranium values are normalised on the basis of log (value plus constant) and all the geostatistical analyses are performed on these transformed values. The channel widths usually conform reasonably well to the normal distribution and are, therefore, not transformed. At Prieska the metal grades analysed cover the two main products, copper and zinc, as well as the impurities lead and bismuth; in addition the specific gravity values and the hanging- and foot-wall deviations from a projection plane are also handled. These were all previously used on an untransformed basis but because of problems associated with the proportional effect the lognormal-de Wijsian model is now used for some of the grade variables. The key computer pro- grams can be summarised briefly as follows:

Jan 1, 1981

By D. Limpitlaw, A. Alsum, D. Neale

"Ecological footprint analysis (EFA) was first described in 1996 as a measure of carrying capacity appropriated by human activities. EFA is a resource and emissions accounting tool designed to track the demand on the biosphere’s regenerative capacity. Ecological footprints are increasingly used as indicators of organizational and corporate environmental performance and product sustainability. There is a compelling argument to develop an EFA tool for mining companies.To determine the size of a mine’s ecological footprint, land requirements for all categories of consumption and waste discharge must be summed. This land is only made up of the ecologically productive land and water in various classes (cropland, pasture, forests etc.) required on an ongoing basis to provide all energy and material resources consumed and absorb wastes.A challenge in conducting an EFA for a mine is the shortage of accessible data. Undertaking an EFA for a corporation or individual site entails compiling consumption and emissions data (which can be used for other reporting applications). The footprint results themselves highlight the most critical aspects of an organization’s impact on the environment and provide a platform for focusing actions and for educating the workforce to improve their contribution to best-practice operations. This paper discusses the benefits and challenges of undertaking an EFA for a mining company, and provides examples of the various components of ecological footprints associated with mines, as well as showing how an EFA can be used to understand and communicate some of the impacts associated with mining activities.IntroductionFundamental biophysical and economic limits are now being experienced in many countries around the world. Herman Daly, a former World Bank economist, described this scenario as ‘uneconomic growth’, where the costs of growth exceed the benefits (Daly, 2005). This occurs when the economy’s expansion encroaches excessively on the surrounding ecosystem, sacrificing natural capital. Under such conditions the sacrificed natural capital is more valuable that the resulting economic growth. Consequently, the world faces largescale threats to sustainability and especially to the viability and continued existence of the ecosystems that support human settlements (El Zein et al., 2014). In recognition of this sustainability imperative, mining companies are increasingly concerned with their ecological footprint (EF)."

Jan 1, 2017

By R. du Preez

Tati Nickel is currently operating a hydrometallurgical demonstration plant in Botswana, using the Activox® process developed by LionOre Technology to produce nickel cathode and a cobalt salt from a sulphide concentrate. Cobalt is extracted using Cyanex 272. This reagent also extracts all the iron, aluminium, copper, zinc, and manganese from the nickel stream. Versatic 10 carboxylic acid is then used as extractant to recover nickel from the stream, separating it from calcium and magnesium, and upgrading it to provide a suitable advance electrolyte for nickel electrowinning. However, the selectivity of Versatic 10 for nickel over calcium is limited, and gypsum formation in the extraction circuit is a problem when attempts are made to maximize the recovery of nickel. Mintek has developed a synergistic system with Versatic 10 for improved separation of nickel from calcium and magnesium. Laboratory testwork was conducted on the raffinate of the cobalt solvent extraction circuit to optimize the Versatic 10/Nicksyn? (Mintek synergist) system to be employed. Extraction and stripping parameters suitable for this stream were optimized in the laboratory and then applied on the demonstration plant. A commercial batch (0.5 tons) of Nicksyn? reagent was produced for the demonstration plant. The laboratory testwork results and the demonstration plant performance are discussed in detail in this paper.

Jan 1, 2007

Book review Doyle, William S. Strip Mining of Coal; Environmental solutions. Park Ridge (New Jersey), 1976. 352 pp. $32. Surface mining of coal is still in its infancy in South Africa. The environmental repercussions following large-scale disturbance of the land surface, and the secondary effects of the disposal of waste products and effluents from mining, have not yet become apparent.

Jan 1, 1977

By R. C. More O’Ferrall

The author mentions some of the problems he has encountered, together with their solutions. These include the stoping of isolated pillars, the reduction of the size of shaft pillars, the stoping of a new horizon above or below a horizon that has already been stoped out, and the mining of thick bands of reef left behind in the footwall or hanging wall.

Jan 1, 1981

By L. C. Woollacott

A computer-aid is described that is designed to calculate steady-state material balances for ore-dressing circuits. The program determines the material balance from a specification of the process condition. No mathematical models or data adjustment techniques are employed. As such the program complements existing simulation and material balance 'smoothing' packages. The process condition is specified using performance indicators. These are significant parameters in the industry with which all practising mineral processors are very familiar. The program employs an equation-oriented technique for material balancing and so has had to deal with the difficulties peculiar to that approach.

Jan 1, 1987

Palabora Mining Company is operating a copper block cave mine in the Limpopo Province of South Africa. The mine was developed in the late nineties with a target ore reserve of 220 million tonnes of carbonatite at 0.69% copper. At 30,000 tonnes per day the operation had an estimated life of mine of approximately 23 years. Cave induced open pit side wall failure occurred in late 2004 with 130 million tonnes of waste reporting to the bottom of the open pit. This failure resulted in potential sterilization and dilution of the ore reserve and subsequent reduction in life of mine. Physical and numerical modelling indicated potential losses of up to 30% of the original ore reserves. Cave Management tools based on throughput principles are utilized to manage the failed waste ingress and ensure an optimum life of mine. Extracting the maximum rate possible, as soon as draw points are commissioned, with the view of achieving the highest production in the short term, is any mining operation?s goal as more money is required sooner. This approach, of course, improves the cash flow but presents a risk in the cave propagation profile as overall draw control is compromised. At Palabora it is evident from a Mineral Resource Throughput Management (MRTM) point of view that maximum production in the short term is not the solution. If high production rates are achieved and the profile of the cave is not manage correctly, this results in failed waste reporting to draw points earlier with adverse effects on grade. This would effectively and significantly shorten Palabora?s Life of Mine. The applications of good MRTM principles are required to assist the value chain for sustained profitability. The process commenced with change management paving the way for a better understanding and a holistic view for all role players.

Jan 1, 2007

By C. J. Alberts

The perception exists in many organizations that, once an energy management system is employed, there need not be any further adjustments to such a system. This is not true, as the field of energy management is a dynamic field, and constant feedback and adjustments are needed to enhance the efficiency of a system to the point that substantial pay-back can be obtained. It is stressed that for any energy management system to be successful, careful planning should permeate through the organization, from the top level decision-makers to the workplace. This paper describes a dynamic technique by which energy management strategies can be evaluated by viewing the effects of the strategies on the organization as a whole.

Jan 1, 1997

By R. S. J. Du Toit

SYNOPSIS This paper is based on a thesis dealing with the problem of basing the current rate at which money is collected from mine owners to pay compensation for pneumoconiosis in the future, on the current dust hazard on mines. The certification of pneumoconiotics and the incidence of pneumoconiosis are discussed against the background of existing legal provision for collecting funds for compensation. The various pneumoconiosis indices are considered. In the data analyzed, the only pneumoconiosis index common to a number of classes of mines is the time it takes to develop pneumoconiosis. Sets of dust indices and pneumoconiosis indices are computed. Expressions are derived for the time it takes to develop pneumoconiosis as a function of the dust hazard, and for the collection of funds as a function of the time available for collection. From these two expressions follows an expression for the rate of collecting funds as a function of the dust hazard.

By P. J. A. Beukes, C. C. La Grange

INTRODUCTION Some years ago the authors proposed a modified procedure1 for carrying out micum index determinations2. The modifications consisted of using a drum of 50 cm internal length, i.e. half the length of the standard micum drum (a modification also adopted by the B.S.J.3), and the use of a + 25 mm coke instead of + 60 mm coke for the test. The proposed modified test and formulae for converting results obtained from it to standard micum test results and vice versa were based on the results obtained during the investigation of about 200 test cokes made in ovens of the South African Steel Industrial Corporation Limited (Iscor), the Fuel Research Institute co-operating with the experiments. Extensive testing of cokes has since been done at the Fuel Research Institute using both the standard and the modified procedures. The numerous test results obtained during this trial period fully support and strengthen the confidence originally expressed by the authors in the modified testing procedure. The scope of the modified micum index determination has in the meantime been extended by applying the testing procedure also to test cokes made in the Institute's experimental coke ovens, and also in this case the modified procedure has proved its usefulness. A difficulty is that when comparing the characteristics of cokes made in the Institute's two experimental coke ovens with each other and with those of cokes made from similar blends in commercial coke ovens, for example those of Iscor, the index values obtained invariably do not check exactly due mainly to inherent differences between the different types of oven4. For instance, resistance to abrasion of a coke made in Iscor's ovens is always appreciably higher than that of a coke made from the same blend (and having a similar moisture content) in the experimental ovens. This makes direct comparisons and the prediction of quality to be expected from commercial products, based on experimental coke oven results, difficult. It may also be added that workers in Great Britain some years ago reported a similar experience5. In the authors' opinion the main reason for the discrepancy is the relatively low height of the experimental ovens resulting in a much lower static pressure on the charge during coking than that obtaining in a commercial oven. The difficulty was pointed out and briefly discussed in a publication4 which appeared at a time when the micum test for coke evaluation had only just been introduced at the Institute, so that only B.S. shatter and abrasion test results were available for discussion in the publication. Needless to say, the introduction of the micum test by no means solved nor even alleviated the problem. On numerous occasions during the past few years the Institute has had to conduct contract investigations in its experimental coke ovens on behalf of companies which invariably desired an indication of the quality of coke likely to be obtained from certain coals or blends when coked commercially, more particularly in Iscor's type of coke ovens. It was, therefore, essential to accumulate statistical data which would enabe the prediction to be readily made. Fortunately the compilation of comparative coke-quality index values for the three types of oven under consideration has become possible as a result of coking investigations conducted in co-operation with Iscor over a number of years. During this period Iscor, on numerous occasions, kindly made available to the Institute portions of coals and blends coked in the Corporation's coke ovens, thus enabling parallel coking tests to be carried out in the Institute's experimental ovens. In this way enough statistical data became available to establish relationships between coking results obtained in Iscor's ovens and results obtained on similar coal charges in the Institute's ovens. The most practical and acceptable method of overcoming the problems of finding a suitable and simple basis enabling direct comparison between the cokes of the different origins mentioned to be made, is the assignment of descriptive arbitrary quality ratings, as indicated below, to the cokes obtained, it being argued that the quality rating assigned to coke made from a given coal or blend in the different coke ovens under standardized conditions should be the same, irrespective of differences in the index values obtained when subjecting the cokes to the usual coke evaluation tests. The system, which should enable the sponsors of coking investigations in the Institute's experimental ovens to make their own interpretations of the results obtained, is explained below. ARBITRARY QUALITY CLASSIFICATION OF COKES The Ml0m index1 (percentage material smaller than 10 mm after the test) of a blast furnace coke is a measure of its tendency towards breeze formation during handling -a low value indicating a low tendency. This is generally of greater importance under ruling South African conditions, than the M'40 index1 (percentage material larger than 40 mm after the test), which can be regarded as a measure of resistance to shatter. In fact, if the M10m value of a coke as made in Iscor's ovens is higher than about 11, the tendency of the coke to form breeze during handling and in the blast furnace is relatively so high that hardly any notice need be taken of its M'40 value, even if this is comparatively high. For this reason, therefore, much more weight should normally be assigned to Ml0m indices in the quality evaluation of cokes made from South African coking coals and blends, as the coals