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By Darelle T. Janse van Rensburg

Some of the more recent developments in Paint Technology are solvent free materials. These coatings have mainly been formulated to overcome the negative attributes of solvent-based coatings, i.e. environmental, safety and health risks, potential for solvent entrapment and osmotic blistering, as well as the formation of micro-pores during the curing process. Two solvent free liquid epoxy coatings have been used extensively on power generation plant. However, very little is known regarding their long-term performance under different exposure conditions, as well as whether these coatings actually perform better than their solvent-borne counterparts. In addition, solvent free materials are generally used where outage periods are restricted and coatings need to be applied within a very short period. Though these materials have reportedly much shorter curing times than other conventional solvent-borne coatings, little is known regarding their limits with respect to maximum film thicknesses and being put into service while still being wet/partially uncured. The latter has become common practice at many power stations in the past two years or so. In addition, the application and curing methods of solvent free materials are different to that of solvent-borne materials, and may require equipment and application process changes. This paper covers the application and performance properties of solvent free coatings in comparison to solvent-borne materials primarily intended for immersion service. Numerous coatings were evaluated under immersed static and cyclic hydrostatic pressures. Other tests included short curing / early immersion tests, dry-to-touch and dry-through curing times, adhesion tests, surface tolerance tests, etc. The results show that the solvent free materials have clear benefits with respect to safety, health, environmental and long-term performance, but will be more difficult to apply compared to solvent-borne materials.

Jan 1, 2006

By N. Boegman

The meteorological conditions in South Africa are not conducive to the effective dispersion of air pollutants. In the light of this, and because of the magnitude, concentration, and future growth potential of the metallurgical industry, control of air pollution is essential. Methods of abatement are discussed for each branch of the metallurgical Industry, as well as for open-cast mining and bulk ore storage. Some recommendations are made regarding potentially rewarding research and development.

Jan 1, 1978

By E. R. Davis, R. J. Knott

The paper discusses some of the tools of management in the field of project control, especially in engineering. Project control includes planning and cost engineering, and involves various phases: the conceptual Design and Planning Phase, the Definitive Design and Capital Budgeting Phase, and the Implementation Phase. Each of these phases is discussed in in, together with the use that can be made of data banks, progress reports, and computer systems.

Jan 1, 1982

By B. C. Alberts

This. paper indicates how the South African Iron and Steel Industrial Corporation Limited (Iscor), as a major consumer of raw materials, determines the tonnage and quality of essential raw materials required to satisfy an increasing demand for steel and how this led to the establishment of a coal mine with a highly sophisticated beneficiation plant in the Waterberg coalfield, near Ellisras in the Transvaal. The planning of the project, with specific reference to the limited reserves of metallurgical coal in South Africa, the quality and quantity of the coal to be produced, and the way in which the project was managed is discussed briefly.

Jan 1, 1982

By M. Jacobs

Keywords: Smelting, converting, sulphide, sulphide smelting, platinum, platinum group metals, PGM, base metals, nickel, copper, matte, slag, furnace, electric furnace, Söderberg, electrode, granulation, converter, flash drier, sulphuric acid, acid plant, Ausmelt, Sirosmelt, pyrometallurgy, metallurgy, Anglo Platinum, South Africa Waterval Smelter complex is situated in Rustenburg, in South Africa?s North West Province. The smelter objective is to process wet concentrate to produce crushed, slow-cooled, sulphur-deficient nickel-copper matte rich in platinum group metals (PGMs), gold, and base metals for despatch to the Magnetic Concentration Plant at the Base Metals Refinery. Throughout its history, the smelter complex has been continuously upgraded in line with increasing production demand, changing feeds, environmental initiatives, and advances in available technology. The smelter receives filter cake and slurry from Anglo Platinum concentrators and joint ventures. Wet concentrate is fed through a flash drying process utilising coal-fired, fluidised bed hot-gas generators, to produce dry feed material for the electric furnaces and slag-cleaning furnace. For primary smelting, two electric furnaces are used, each with a rated capacity of 34MW. Furnace matte, containing the bulk of the base metal sulphides and PGMs, is tapped periodically into refractory-lined ladles and granulated using high-pressure water jets, then dried through electrically powered pneumo-driers to become the main feed to the Anglo platinum Converting Process (ACP). Slag is tapped semi-continuously, granulated, and treated through the slag mill. The ACP treats the combined matte output of Waterval, Polokwane, and Mortimer smelters. It is a top-blown furnace, with furnace matte, air, and oxygen being injected into the converter via a lance submerged in the slag. Converter matte is tapped and bottom cast into moulds, slow-cooled, crushed, and despatched to the refineries. Slag is granulated and dried for recycling to the slag-cleaning furnace. ACP slag is fed to the slag-cleaning furnace along with a reductant and a sulphur source. Slag-cleaning-furnace matte is granulated for processing by the ACP, while slag is granulated and processed in the slag mill. The slag mill and flotation circuit treats granulated slag from the electric furnaces and slag-cleaning furnace to recover entrained matte containing valuable PGMs and base metal sulphides.

Jan 1, 2006

By M. J. Little

Potgietersrust Platinums Ltd is Anglo Platinum?s only open pit operation and annually extracts 57 million tonnes of rock from 2 open pits. Over the past 3 years ~220 km of exploration drilling has been done, ~1000 km of rock face have been exposed for face mapping and over 7000 laboratory and field tests have been conducted. This has produced large amounts of geotechnical data to be utilised for feasibility studies, initial slope design and ongoing slope optimisation. It was necessary therefore to develop geotechnical databases to manage the vast amounts of data collected. SABLE and MineMapper 3D databases were created for logging and mapping respectively, with rock testing data incorporated into both. A pit inspections database was developed in MS Access and the existing groundwater and slope monitoring database was improved. The databases were linked to AutoCAD and Datamine to ensure that the latest geotechnical data is used for planning, draughting and modelling. The use of geotechnical databases ensures that no data is lost, standards are maintained and analysis can be easily performed. This increases the confidence of the analysis and allows the geotechnical engineers to optimise slope designs and blast designs on a regular basis. This reduces the risk of slope failure thus making the open pits more economical and safe.

Jan 1, 2006

By I. Matsunaga, K. Aoki, W. -j. Jung

Blasting is widely used in mining and basic construction because of its speed and economy to destroy the rocks. Blasting has the advantages of reduced excavation costs and shorted construction time when compared to the use of heavy machinery for excavation and cutting such as that with a tunnel boring machine. There are numerous problems with blasting, including the noise, vibration and fly rock. So it is necessary to accurately evaluate fracture mechanics of rocks on the dynamic loading condition to control the fracture process of the blasting. The tests using Hopkinson's effect for the dynamic condition using the precise detonators were performed for various strain rates on three different kinds of rocks. In the tests using Hopkinson's effect for the dynamic condition, the high-speed camera was used to observe the fracture process of the test sample rocks. As the results of experiments there was an increase in the tensile strength of rock with an increase in the strain rate for three kinds of rock on the dynamic loading. The tensile strength of rocks with high porosity on the water saturation condition was decreased on the both static and dynamic condition. It is clear that the strain rate and water saturation were influenced to the tensile strength of the rocks.

Jan 1, 2003

By J. M. Stewart

Mining fatality rates in many countries have not changed substantially over the past ten years. This demonstrates not only that there is an inherent risk in mining, but also that current approaches to improving safety need to be rethought. An analysis of productivity and fatality data in the United States, United Kingdom, and South 4frican coalmining industries shows that the impact of legislation on safety is overlain by other significant factors. Although improvements in safety and productivity usually occur together, the data warn that safety legislation can sometimes cause a significant reduction in productivity. Based on the data and experience considered, it is concluded that legislation should be aimed at creating a framework within which a positive attitude towards the implementation of more productive and safer mining methods, work practices, and technology can flourish, rather than attempting to enforce excessively prescriptive provisions. This later approach is even more problematic when safety standards and legislation are transferee from well developed to less developed countries. A legislative framework in which the mine manager is required to take al reasonably practicable measures to procure safe working conditions in accordance with mine-specific codes of practice is outlined. Within that framework, the value of adopting widely accepted standards is recognized. A performance-based external audit arrangement is outlined as a basis for ensuring that detailed attention is focused on those areas most needing improvement.

Jan 1, 1995

By R. Dippenaar

Traditionally, iron ore has been reduced with coke in a blast furnace and the hot-metal product of the blast furnace containing carbon, manganese, silicon, sulphur and phosphorous, was subsequently refined in a steelmaking furnace. During iron making as well as during steelmaking, significant amounts of slag are produced. Two decades ago, more than 13 m tonne of blast furnace slag and 4 m tonne of steelmaking slag per annum were produced in the USA alone. It is, therefore, not surprising that many attempts have been made to re-use iron and steelmaking slags. However, these slags are not merely metallurgical waste products but, on the contrary, their compositions and physical properties are judiciously designed to optimize the operations in the respective metallurgical reactors. The variation in composition and properties of blast furnaces lags are largely determined by the gangue in the ore and ash in the coke and much progress has been made in the re-use of such slag. With respect to steelmaking slag, emphasis has in recent years been placed on hot-metal treatment before refining and ladle treatment after decarburization. The bulk removal of silicon, phosphorous and sulphur from the hot-metal product of the blast furnace by specially designed slags prior to refining in a basic oxygen furnace, has reduced tap-to-tap time, lowered cost and produced steel of much higher quality. The use of synthetic slags in ladle refining techniques subsequent to decarburization in the basic oxygen furnace has resulted in reduced hydrogen and nitrogen contents and reduced solute impurities. Moreover, inclusion shape and composition control, again by the use of specially designed slags has led to the achievement of much improved mechanical properties of the steel. In these revised process routes, slag of different compositions are produced in the variety of unit processes and hence the re-use of steelmaking slags has become much more complex. Clearly, a thorough understanding of the design and use of these different slags is a pre-requisite to the development of re-use strategies. Japanese steelmakers have spearheaded attempts to reduce slag volumes in the individual unit processes and to strive towards ‘slagless steelmaking’ by recycling slags internally. Steelmaking slag volumes have been reduced on commercial scale from about 140 kg/tonne steel to 60kg/tonne steel. Moreover, model predictions have shown that, in principle, all slag can be recycled and the phosphorous extracted to produce fertilizer. This development is of particular significance since the supply of low-phosphorous iron ores is diminishing at an ever increasing rate. Keywords: slag, environment, iron, steel,

Jan 1, 2004

By R. P. King

Held on the 22nd March 1972 at Kelvin House. Four papers were presented at this colloquium, which was attended by approximately 120 people. The first paper, 'Flotation Research Work at the N.I.M. research group, University of Natal on the modelling of a Flotation Process' was presented by Dr R. P. King, the leader of the N.I.M. Research Group in the Department of Chemical Engineering at the University of Natal. A discussion panel, under the chairmanship of Dr R. E. Robinson with Mr M. Dawson (PMC), Mr E. Roux (FOSKOR), and Dr B. K. Loveday (NIM), discussed the potential application of the theoretical work on flotation modelling to industrial processes, and alternative approaches to providing a way of control of flotation plants. The second paper, 'Fundamental Studies of the Flotation Process the Work of the National Institute) for Metallurgy', was presented by Dr N. P. Finkelstein. The discussion panel for this paper was under the chairmanship of Professor D. D. Howat,and had as its members Mr H. P. Carlisle (JCI), Professor D. le Roux (University of Pretoria), and Mr E. Rudolph (Anglo American Research Laboratories). A lively discussion on this paper ensued, with several contributions from the floor. After lunch, Mr S. K. de Kok, Assistant Consulting Metallurgist, Anglo Vaal, presented a paper on 'The Flotation of Copper and Zinc Sulphide from Prieska Ore'. The paper was discussed by a panel comprising Dr V. C. Lovell (NIM), Mr A. Gilbert (General Mining), and Dr D. Legge (Anglo Vaal), under the chairmanship of Dr L. Bushell. This discussion, in which many members of the audience participated, revolved around the difficulties associated with the production of copper and zinc concentrates and the lack of fundamental information on the behaviour of copper and zinc sulphides in flotation. The final presentati0n was a paper, 'The Recovery by Flotation of Cassiterite contained in Gravity Concentration Plant Tailings', presented by Mr E. B. Viljoen (Metallurgy Department, Goldfields South Africa Limited). The discussion, led by a panel consisting of Mr O. Tant (Goldfields Laboratories), Mr J. Levin (NIM), and Mr R. I. Shanks (NIM), under the chairmanship of Mr H. Cross (Goldfields South Africa Limited) referred particularly to the use of new reagents for the flotation of tin, with particular emphasis on the fundamental relationship between reagent composition and its ability to float this type of mineral.

Jan 4, 1972

By M. Rakoma

Following the blasting fatality on 17 December 2009, Landau Colliery was forced to change from the blasting practices that had been utilized since the start-up of the mine. Since then, attempts have been made to optimize blasting results. The challenge is rooted to the mining environment - during the early life of the mine, mining took place in virgin areas, whereas currently mining is taking place in areas overlying old underground bord and pillar workings. The underground bord and pillar workings aggravate phenomena such as spontaneous combustion, hot holes, and sinkholes. The 2009 fatality was attributed to hot holes causing premature detonation. Landau has been struggling with poor results from their overburden and coal blasts; leading to poor fragmentation of overburden and the PI parting that lies between the No.1 and No.2 coal seams. An extensive literature survey was completed in order to identify possible alternative solutions that could be evaluated for this unique mining environment, which demands a high degree of caution during mining to ensure factors such as dragline stability and personnel safety. The literature survey confirmed that the previous blasting technique, which was mainly characterized by air decking, was indeed the more efficient, although it was deemed unsafe because of the possibility of hot holes and the high sensitivity of detonators. Potential modifications to the blasting technique were modelled in a Microsoft Excel simulation that was available from the mine, and pit visits were conducted in order to determine whether implementation would be a problem. From the model it is evident that results can be improved by changing the current burden and spacing ratio. Visiting the pit revealed that the tie-in pattern and drilling inaccuracies are contributing to problem areas.

Jan 1, 2013

By M. K. Elmouttie, G. V. Poropat

The analysis of structure using joint set statistics is well known. Other data such as the position of discontinuities and the contacts between rock mass units cannot be easily incorporated in simple statistical analysis based on orientation alone. Algorithms to model the structure of rock slopes using measurements of the orientation and position of discontinuities are being developed by CSIRO Exploration and Mining. These algorithms provide a capability to model the structure of a rock slope and estimate the likelihood of the formation of hazardous blocks in existing or proposed rock slopes and identification of the location and size of these blocks. The algorithms provide the basis of structural modelling to identify potential failure mechanisms in rock slopes.

Jan 1, 2006

By M. Yavuz

One of the challenging problems for optimization in mining operations is to choose the best equipment among the alternatives. Equipment selection is an important task for mine management due to its operational cost, and is also an integral part of mine planning and design. Equipment selection is not a well-defined process because it involves the interaction of several subjective factors or criteria. Besides, decisions are often complicated and may even embody contradictions. Therefore, equipment selection is considered as a multi-criteria decision-making process, and suitable decision-making methods should be employed in this process. In this study, the loader selection for Aegean Lignite Colliery was made by using both the analytic hierarchy process and Yager’s method. Owing to the misusage of Yager’s method in the past, a new procedure is proposed in this paper for making proper decisions. It is highly recommended in this purposed method that criteria or alternatives should be grouped so as not to exceed the limitations of human performance (nine criteria/alternatives). The most appropriate solution for the loader selection was investigated by obeying this limitation for each method, and the results were compared. At the end of the decision-making process, a sensitivity analysis was applied for each method in order to see how a criterion affects the final decision. The advantages and disadvantages encountered during the application of each decision-making method are presented.

Jan 1, 2015

Work undertaken in the field of cut-off grade optimization has not advanced much beyond the work undertaken by Lane in 1988. His definitive work is based on the calculus of the Net Present Value criterion which is the most widely understood, consistent, and appropriate method by which sequential cash flows arising from the extraction of mineral reserves from an exhaustible resource can be represented. Although the mathematics is not complex Lane’s method is not a widely appreciated or applied approach to maximizing the value of a mining operation through selection and balancing of operational cut-off grades. Three stages in a mining operation namely, mining, processing and marketing were defined by Lane and the economics of each stage are identified and isolated to provide an optimum cut-off for each stage. Points of intersection along the present value curves for each stage of a mining operation are used to identify balancing cut-off grades at points where the capacity of the mining, processing and marketing stages is fully utilized and the Net Present Value of the operation is optimized. Data that simulate a small, deep-level Witwatersrand-type gold mine with an average grade of 6 g/t Au and a logrithmic variance of 1.2,are applied to the model to illustrate the benefits of representing cut-off grades in terms of present value curves for different segments of a mining operation. Keywords: Cut-off grade, Net Present Value, grade-tonnage curve, balancing cut-off grade, mining, processing, marketing.

Jan 1, 2003

By F. T. Wang, Y. Yuan, S. H. Tu, X. G. Zhang

Hydraulic support instability (HSI) is one of the most common causes of disasters in underground coal mining, posing a threat to the safety of mine workers and normal operation of the equipment. It is prone to occur in fully-mechanized mining faces with a large mining height (FMMLMH), especially when the dip angle of the coal seam is large. The key to controlling HSI is to deduce its mechanism and employ effective control techniques. This paper focuses on the analysis of HSI types, the key parameters and techniques to control HSI in FMMLMH, the establishment of a model of HSI in FMMLMH, and a multi-parameter sensitivity mechanical model of different HSI forms in the no. 7219 longwall face in Xutuan Coal Mine, Huaibei Mining Group, by using sensitivity analysis . The results show that HSI mainly presents in three forms: hydraulic support gliding (HSG), hydraulic support tilting (HST), and hydraulic support tail twisting (HSTT). The occurrence of the above three forms depends mainly on support anti-instability capability. In the no. 7219 longwall face, HSG and HST are the main two forms of HSI. The dip angle of the working face and the friction coefficient between floor and hydraulic support are the sensitive parameters for HSG, while HST is strongly dependent on the dip angle of the working face and the friction coefficient between roof and hydraulic support. By the applications of measures such as the oblique layout of the working face, cutting the floor into a step pattern, moving the support under pressure, and raising the setting load, the support stability was controlled effectively.

Jan 1, 2015

[Ferro Alloys Producers Association The South Africa Institute of Mining and Metallurgy www.saimm.co.za Mintek www.mintek.co.za Eskom www.eskom.co.za ]

Jan 1, 2004

By J. A. Cruise

With the end of the official apartheid legislation in the early 1990s, South Africa was heralded as a non-racial country. However, racial awareness has been reintroduced into the country with the Affirmative Action and Black Economic Empowerment legislation. Gender and racial transformation are the current order of the day. All organizations are required to reflect in their make-up the demographics of the population as soon as possible. Scorecard shave been drawn up to measure the rate of transformation for gender and race in organizations. The mining industry in South Africa has been in the forefront of this transformation legislation and scorecards. This paper seeks to show the effect of gender and racial transformation on mining engineering education and professionalism by analysing the changing demographics of graduating mining students at both the South African universities offering a degree in mining engineering, the professional registration of mining engineers with the Engineering Council of South Africa (ECSA), and the membership of the Southern African Institute of Mining and Metallurgy (SAIMM), the vocational institute for mining engineers. It also demonstrates the absurdity of gender and racial quotas based solely on the demographics of the current population of the country. This paper shows the degree to which mining engineering has transformed in both gender and race.

Jan 1, 2011

By Haiping Sun, Samir Ganguly, Oleg Ostrovski, M. Yaser Lone

Wettability of graphite by synthetic SiO2-Al2O3-CaO-MnO slags with varied MnO content and by industrial slags was studied at 1350-1600 °C using sessile drop method under argon atmosphere. Initial contact angle was the lowest (110-115o) for the MnO-free slag. For slags with 10-40 wt% MnO, the initial contact angle was in the range 125-135o. The contact angle decreased with the contact time. The change in the contact angle with slag mass was found insignificant. The surface tension of slags obtained from the drop shape analyses was 500-800 mN/m and varied in a narrow range with temperature and MnO concentration. The reduction rate increased with increasing MnO content in the synthetic slag from 20 wt% to 40wt% and temperature. Increasing temperature also increased the rate of reduction. No correlation was observed between the reduction rate and MnO content in the synthetic slags in the range 0-20 wt% and in the industrial slags. The rate of SiO2 reduction from the molten slag was close to the rate of MnO reduction. The MnO-free slag had the largest contact area with graphite substrate. Keywords: reduction, wettability, graphite, slag, manganese, surface tension.

Jan 1, 2007

By G. H. Lind

Research into the safe and economic extraction of underground coal pillars in the Witbank and Highveld coalfields of South Africa highlighted that future practices will have to consider pertinent risks associated with this least safe of all underground coal mining methods conducted in South Africa. To this end, a computer-based program called A-PEP (Analysis for Pillar Extraction Potential) was developed to assess three aspects of this mining practice, viz. risks associated with the physical attributes, operational risk attributes and economic attributes. This intelligent tool can thus be used when planning to conduct underground pillar extraction to ensure that all pertinent risk elements and legislative requirements are considered to conduct this mining method safely before a submission is made to the Department of Minerals and Energy. Keywords: operational risk management, mine planning, underground coal mining, pillar extraction.

Jan 1, 2003

By C. Birch

"A mineral resource royalty is payment to the holder of mineral rights for the utilization of the mineral resource. In South Africa, this payment is made to the State as holder of the mineral rights (The Mineral and Petroleum Resources Royalty Act of 2008). The principle purpose of this research paper is to identify if the State is benefitting from the mineral resource royalty by considering its impact on seven individual Witwatersrand gold mines.For this study, a simple financial optimiser model was created in Microsoft Excel that links the ore flow, block listing and the cash flow (excluding or including the cost of the mineral resource royalty). Mixed integer linear programing (the Excel Solver function) is utilised to optimise either profit or NPV (at 9% and 12%) by adjusting the cut-off grade.The impact on each of the seven mines mine was different but overall R7.9 billion is estimated to be paid in mineral resource royalty over their expected remaining lives. Due to the cost of the mineral resource royalty and increasing the cut-off grades, the total revenue decreases by R10 billion. A significant portion of this lost revenue would have been paid to the State in the forms of other taxation including company income tax which decreases by R2.8 billion. It is recommended that an industry wide investigation be conducted to determine if the resource royalty is adding to the State’s revenue, or destroying value including premature job losses. IntroductionTaxation of mining companies has become a very topical subject in the context of the postapartheid South African economy. There have been increasing calls for equitable re-distribution of mineral asset wealth for the benefit of all South African citizens and not just to an elite few. As part of the Mineral and Petroleum Resources Development Act (MRDPA) of 2002, the Mineral and Petroleum Resources Royalty Act of 2008 was introduced and came into effect in 2010 (South African Revenue Services, 2008). A mineral royalty is payment to the holder of mineral rights for the utilization of the mineral resource. In the case where the holder of the mineral right is the State, then this payment is made to the State (Cawood, 1999). Studies on the potential impact of the mineral resource royalty on the minerals industry have been conducted during the formulation of the Act and subesquently. These include Cawood and Macfarlane (2003), who suggested a cap of no more than 3% (Cawood and Macfarlane, 2003), as well as Cawood (2011), who predicted rising cut-off grades and thus reducing mineral reserves. In 2013, Grobler completed a Masters in the Faculty of Economic and Management Sciences at the University of Pretoria and concluded that the impact of the mineral resource royalty on the economy is positive. She stated that the royalty has caused operating expenses to increase, but this does not appear to be significant. Furthermore, she stated that the royalty has not affected the way the mining industry operates (Grobler, 2014)."

Jan 1, 2016