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By B. Genc, C. Gous

Spontaneous combustion during coal mining operations is a major problem that affects the health and safety of workers and causes environmental problems. The phenomenon is associated with the presence of coal, coal shale, and pyrite. In 2020, a premature detonation incident occurred at an iron ore mine where the waste material contains black carbonaceous shale units known to be associated with pyrite. The spontaneous combustion propensity and properties of samples of the black carbonaceous shales from the mine were examined and compared with samples from the Witbank Coalfield. The spontaneous combustion liability indexes of these samples were correlated with X-ray fluorescence (XRF) and proximate and ultimate analyses using linear regression. The Wits-Ehac Index classification results show that the samples were between medium and high risk. The linear regression analysis showed very poor correlations between the Wits-Ehac Index results and the XRF and proximate and ultimate results. The most valuable relationship found is between the presence of relatively high sulphur (greater than 3%) and ground reactivity with nitrate-bearing explosive emulsion.

Jun 5, 2023

By A. V. Aleksandrov, T. N. Aleksandrova, N. V. Nikolaeva

Using complex thermal analysis methods, flotation concentrates were classified depending on what the organic and nonorganic carbon form is. The possibility of ultrafine particles of valuable components (noble metals and diamonds) extraction using physical actions of different genesis in the processing of ‘unconventional’ mineral raw materials is considered in the paper. Electromagnetic treatment is one of new technologies in the field of mineral processing. The features of the electromagnetic effect on substances include uniform heating throughout of the volume, high speed and low inertia of heating, as well as the possibility of selective heating. A selection of studies including gravity, flotation and extraction methods of enrichment using energy effects, as well as thermal analysis was conducted to establish the availability and possibility of extracting valuable components. Due to microwave and high-temperature exposure, minerals and gas-liquid inclusions are decremented, and crystal-chemical water is released, resulting in additional defects. As a result, self-cleaning of sulphide minerals from atoms of scattered gold occurs by distilling it into peripheral parts of grains and intergranular space, where ultradispersed individuals are formed. Keywords: Refractory gold-bearing ores, physico-chemical properties, ore preparation, flotation, modelling, simulation, selection

Jan 1, 2020

By R. Dehghan, M. Zarei, A. Tohry, S. C. Chelgani

Typical depressants for selective reverse flotation of iron oxides from complex silicates do not generally show high levels of efficiency. Therefore, as a hot topic, there are several ongoing investigations in this area. The main aim of this paper is exploring the potential of using humic acid (HA) as a depressant in reverse cationic flotation of hematite from complex silicates. For such a process, the wettability and flotation behaviour of pure minerals (hematite and silicates) was investigated at pH 10 in the presence of HA and cationic collector. Adsorption mechanism of HA on these minerals was measured by zeta-potential and FTIR. Results of flotation tests showed that at the lower concentrations of HA, selective separation of silicates from hematite is beneficial, where the floatability of amphibole was higher than pyroxene. A higher separation efficiency of hematite through reverse flotation was observed in the presence of amphibole, in comparison with the presence of pyroxene. Wettability studies showed that HA has a significant effect on reducing the hydrophobicity of treated minerals with the collector. The adsorption, ZPC and FTIR test results indicated that HA was adsorbed on both silicates and hematite. However, the absorption intensity onto hematite was much higher than silicates. It was found that the adsorption mechanism of HA on hematite takes place through both strong H-bonding and ligand exchange. Keywords: Reverse cationic flotation, humic acid, iron oxide, complex silicates, surface adsorption

Jan 1, 2020

By R. Zivojinovic, S. Vujic, T. Tanaskovic

The problem of determining the optimum exploitation life of machinery, namely the optimum time for machinery and equipment replacement, represents a complex and highly responsible engineering task. Taking into consideration the situation prevailing at coal pit mines in Yugoslavia, the tasks of this class are very complex and difficult. To make a decision on replacement of capital equipment and machinery, such as bucket wheel excavators within the mentioned systems, understands a management task of utmost responsibility. It requires high professional and analytical knowledge as well as the reliable arguments, based on multidisciplinary professional approach. In this paper, the authors present their views on the problem of establishing the optimum exploitation life of bucket wheel excavators, offering an algorithm, based on dynamic programming, as a solution. Keywords: Bucket wheel excavators, exploitation life of machinery, optimization, operations research, theory of replacement, dynamic programming

Jan 1, 2003

By J. M. Ortiz

Grade control and short-term planning are usually based on the samples obtained from blastholes. These samples may carry a large sampling and sample preparation error. At El Tesoro copper mine in northern Chile, an advance drilling grid is used for short-term planning and grade control. These drill holes are sampled well in advance, and a short-term model that incorporates several variables and sophisticated estimation methods can be prepared for decisionmaking. An additional advantage of the advance drilling samples is that reverse circulation can be used instead of conventional down-the-hole equipment, and a very careful sampling and sample preparation process can be implemented, reducing the total sampling error. Advance drilling can be performed on a wider grid than blasthole drilling, hence the decision about the grid requires assessing the economic benefit of different sampling grids. Furthermore, this process allows the cost of poor sampling and the effect of different estimation procedures to be quantified. We demonstrate the optimization of the drilling grid for short-term planning and grade control at El Tesoro mine by means of the economic evaluation of the performance of different drilling grids, with different drilling techniques (which differ in the sampling error). The methodology is based on creating dense (exhaustive) geostatistical simulations of the grade distribution over a volume defined for a production period in respect of the geological model, and assuming each simulation as the true grade distribution. Then, samples are obtained from the exhaustive simulations at a spacing similar to the advance grid to be evaluated, and a sampling error is added. The short-term estimation procedures used on the mine are applied to determine the destination of each block and the profit obtained. This profit can be compared with the maximum profit (unachievable) and with the profit under different sampling errors and grids. The results show that the current 8 x 8 m drilling grid is appropriate and by reducing the sampling error, misclassification is also reduced, leading to an increase in profit of about US$ 5 million in 4 years.

Jan 1, 2012

By I. A. Mwamba

Titanium sponge, which is almost pure titanium, is extremely ductile and not easily processed into titanium powder. One method of producing powder is the hydride-dehydride (HDH) process, where titanium sponge is hydrided to form brittle titanium hydride (TiH2). Titanium hydride is easily milled to produce powder and is then dehydrided to form Ti powder. In this work, titanium hydride powder obtained from titanium sponge was used as a starting material for blending and mechanical alloying with elemental powders. Firstly, titanium hydride powder was blended with aluminium elemental powder to produce a homogenized powder, which was then compacted and sintered to produce powder metallurgy compacts. Secondly, titanium hydride powder was mechanically alloyed with aluminium elemental powder and then compacted. The mechanically alloyed powder was characterized in terms of particle size distribution, morphology and microstructure. In both blending and mechanical alloying, the green compacts were characterized by assessing the green density, while the sintered compacts were characterized by their sintered density, microstructure, and hardness. The two processes have resulted in the formation of TiA13 intermetallic compound. It was established that by simple mixing and homogenizing, titanium hydride can be used as a starting material to produce powder metallurgy components in which porosity is a benefit rather than a problem, much akin to metallic foams. From the products obtained in the TiHz-Al system, it appears that titanium hydride can be used as a precursor in mechanical alloying. However, the possible formation of complex hydrides may introduce detrimental properties, and needs to be further investigated. For the production of non-porous components, it would be advisable to dehydrogenate the TiH2 powder before milling i.e. producing titanium powder by the hydride-dehydride (HDH) method. Keywords Mechanical alloying, titanium hydride, titanium aluminide and blending

Jan 1, 2011

By L. E. Salinas-Farran, S. J. Neethling

Key variables in heap leaching include permeability, mechanical stability and mass transport. All of these properties can be manipulated by agglomerating and curing the ore before stacking it into heaps. The chemical and structural evolution of the agglomerates during curing is key to improving agglomerate properties and, ultimately, heap performance. It is possible to image the internal structure of agglomerates using SEM/EDX (e.g. QEMSCAN or MLA), although these methods are destructive and do not represent the 3D structure of the agglomerates. A non-destructive alternative is to image the agglomerates using X-ray Microtomography (XMT). Not only does this provide 3D information, it also allows the same samples to be repeatedly scanned, allowing the time evolution of the agglomerate structure and chemical composition to be tracked. In this paper we compared the behaviour of ores agglomerated using a combination of sulphuric acid and ferric sulphate with ones in which chloride ions are added to the recipe, since chloride leaching is gaining in popularity as a chemical alternative to bioleaching for sulphide ores. We tracked the curing process beyond the typical time scales to see the impact that this has on both the agglomerate structure and the subsequent leaching behaviour. Keywords: Heap leaching, curing extent impact, leaching kinetics, ferric-chloride leaching

Jan 1, 2020

By J. H. E. Perry, V. H. Wiik

"The ore deposits of the Zambian Copperbelt occur in sedimentary strata that have been subjected to relatively mild, flexure-type folding. Unrolling serves to reconstruct the original depositional geometry of the folded sedimentary strata and is in common usage on the Copperbelt both for geological analysis of drill hole data and in routine ore reserve estimation.A computerized method of unrolling was introduced at Roan Consolidated Mines in 1969 based on a standard contouring program. A contour map of the geological structure is drawn from a regular grid of elevations, interpolated from the original, irregularly-spaced intersections. Unrolling is performed across this grid, perpendicular to one or two axes specified by the geologist. Each intersection is unrolled independently, and the new co-ordinates are subsequently processed to produce unrolled maps.The technique has been used successfully at RCM over the last two years in both the estimation of ore reserves and exploration planning."

Jan 1, 2014

By S. R. Grobler, S. Bilessuris, M. E. Greenway

Ensuring that all the head ropes on a multi-rope friction winder share the load equally has been a design and maintenance issue since they were first developed. Accurate machining of the rope grooves is necessary to meet this objective. Early analysis of the change of rope loads for ropes in grooves that are mismatched in depth treated the grooves as rigid. Groove depth tolerances deduced from this analysis are stringent and difficult to achieve in practice. Test work indicated that the inherent flexibility of groove lining materials alleviates the load-sharing problem. However, no analysis of rope load changes due to mismatched flexible grooves has been published. In this paper we develop new equations for the rope load variation for flexible grooves. By allowing flexibility to reduce to zero, the corresponding rigid rope groove equations are obtained. New criteria for tolerable groove depth variations are developed from this analysis, which depend on the flexibility of the groove lining material.

Sep 1, 2021

By S. O. Bada

Coal samples taken from the No. 2 Seam and No. 4 Seam in a South African colliery were tested in a rotary triboelectrostatic separator. The two-stage triboelectrostatic separation results using the -177 µm size fraction reduced No. 2 Seam coal containing about 30.4 per cent ash to a clean product of 8.9 per cent and 13.1 per cent ash with combustible recoveries of 9.6 per cent and 30.7 per cent respectively. The same separation approach on No. 4 seam feed coal, which contained 36 per cent ash, produced a clean coal product with 10.8 per cent ash at a combustible recovery of 6.0 per cent. Petrographic tests show a significant improvement in the vitrinite content and a reduction in visible minerals encountered when using the triboelectrostatic separator, with about 53 per cent vitrinite reporting to the clean fraction for No. 2 Seam compared to the feed content of 21 per cent, and a 54 per cent vitrinite in the clean No. 4 Seam from a feed content of 21 per cent. Significant sulphur reductions were also observed after separation in both coal samples, with a better separation in the second-stage coal products.

Jan 1, 2012

By F. T. Cawood

Monitoring of the slopes of surface mines can prevent loss of life, loss of equipment, loss of production and possibly the loss of the mine. The effectiveness of such monitoring depends on the extent to which slopes give adequate advanced warning before failing, and on the ability of the monitoring system to detect such warning. In this paper an overview is given of slope monitoring requirements, from both the geotechnical and survey points of view, as well as the types of equipment and instrumentation that are available. Legal issues relevant to slope monitoring are also dealt with. It is concluded that conventional geotechnical and survey instrumentation will continue to have their place in slope monitoring. However, the slope monitoring scene has changed substantially in recent years. A real and volume-based monitoring equipment is now available and this has provided, and will continue to provide, the means to improve safety, and to enhance productivity in mining. Its benefit to slope management is substantial. In the near future it is expected that data obtained from such equipment will add a much needed new dimension to slope engineering, and be used to improve slope designs and to optimize slope angles.

Jan 1, 2006

By R. R. Mankowski

The work described here attempts to underscore the importance of the time lag between the end of a loading phase and the instant a winding drum begins its acceleration phase. Traces generated from a computer-simulation model show that the amplitude of the stress oscillations occurring in mine hoisting cable during the constant velocity-of-ascent phase is a direct result of the temporal sequence employed between the loading and the raising phases. While current and early literature indicates that extensive work has been undertaken on the isolated effects of these two independent sequences, the literature does not appear to contain any documented evidence to suggest an optimal control or interfacing between these two dynamic regimes.

Jan 1, 1995

By Org de Wet

This paper summarises the strategy for selection between a two module coal plant incorporating large, but less equipment, and a three module coal plant with more but smaller equipment. The two options were evaluated in terms of three main categories: ? Size ? size of the equipment and the effect on the process efficiency as well as the difference in physical dimensions of the plant to accommodate the larger equipment; ? Cost ? capital savings between a two and a three module plant, processing the same ROM (run-of-mine) tons per hour (t/hr); and ? Practicality ? in terms of constructability of the plant, safety of using larger equipment and maintainability of the equipment. Decisions that were taken to reduce the risk associated with size, cost and practicality on the chosen option of a two module plant will be highlighted.

Jan 1, 2006

By K. G. Lomberg

The integration of various highly sophisticated IT applications has been implemented at Bafokeng Rasimone Platinum Mine, a new platinum mine in the Anglo Platinum Group. This system is required to assist with compiling the necessary geological and grade information together with safety, environmental, ventilation, rock engineering and logistical constraints, to allow the design of the appropriate mining layout, to schedule this design, provide the necessary output for technical review and costing as well as budgeting to allow medium- and long-term business planning. In addition the production management and short-term planning needs must be met. This includes the plotting of all underground and surface infrastructure and excavations, giving the necessary mining and best cut instructions, daily production management, ore reserve and grade management as well as assisting with budgetary management. In addition all safety, health, environment and risk assessment requirements and legal requirements have to be met. The system at Bafokeng Rasimone Platinum Mine has met these criteria. Keywords: Platinum, Bushveld Complex, Mine Planning, Production Management

Jan 1, 2003

By B. van Beek, J. H. Zietsman, A. Lexmond, N. J. Andrew

"In platinum group metals (PGMs) smelting, the slag-to-matte ratios are very high (approximately 4:1 to 9:1). The slag temperature therefore has a strong influence on matte temperature, which is a continual concern due to the low matte melting temperature and its resultant high superheat. Maintaining a stable slag temperature is therefore a critical safety and operational issue. This project aims to improve the understanding of the slag bath temperature drivers so that a more effective slag bath temperature control strategy can be implemented.With the aim of developing a multiphysics model of the furnace, extensive data analysis was performed to develop an in-depth understanding of the process before the start of modelling work. In this work, the effect of fluctuating furnace feed composition on slag temperature was examined. The results are based on equilibrium calculations using FactSage, implemented with ChemApp.A method was developed, using an equilibrium calculation at 25°C, to convert the available chemical assays to approximate mineralogical assays in order to determine the feed enthalpies. Actual 2013 furnace feed data was used and the average specific energy requirement to produce slag and matte at 1600°C was calculated to be 671 kWh/t concentrate. The furnace energy input was then kept constant, and it was found that the slag temperature varies significantly as a function of the feed composition. These results were compared to actual slag temperatures measured on site. It was found that close management of the furnace energy balance is important for maintaining a stable slag temperature."

Jan 1, 2014

By J. Loubser

The concept of caring is in most cases confused with material needs and not psychological needs. By giving employees a job, most managers think that employees should be grateful and return the favour by being loyal, productive and working safely. Other managers hold the view that employees can be lucky to have a job. To show and demonstrate that management are caring for the safety of the workforce requires involvement, dedication and commitment. Obtaining the trust and respect of the workforce should be the main thrust of any organization because within trust and respect lie the secret of optimal safety performance. In the last 70 years, all the fatalities and serious injuries that occurred in the mining industry can be traced back to one thing, non-caring. The same safety non-compliances are still observed, reported and planned against as 70 years ago, and strange as it may sound, the same injuries occur the same way. The question could be asked: Does the mining industry need more risk assessments? More codes of conduct? More engineering. Or does the mining industry need more caring?

Jan 1, 2010

By M. Andersson, R. Elsrud

The quality and the production rate for the mining operations in the Garpenberg mine has been much improved due to a new system, that presents the latest exploratory and planning data for the driller at the moment he deploys the drill rig at the face. Other components in this improvement work are better planning procedure, large-scale production system with longer rounds and introduction of new drill rigs in the mine. The new Rig Control System (RCS) for the new series Atlas Copco Boomers L2C has made it possible to develop this system for production drilling in the Garpenberg mine. The ABC Regular has been extended with map navigation and drill plan generator. The driller will have the best estimate of the orebody in front of him and the best drill plan for that orebody. The customer’s specific system will also become a standard Atlas Copco product for the Boomer ABC drill rig family.

Sep 1, 2001

By M. Fener, S. Kahraman, O. Gunaydin, M. Alber

Falling into the weak rocks category, fault breccias have extremely poor engineering properties. These pebbles typically cause issues with slopes, subterranean construction, and building projects. Professionals will benefit from the creation of some predictive models for fault breccia triaxial strength, as smooth specimen preparation is typically challenging and timeconsuming. The purpose of this study is to develop some predictive models for the differential stress (Δσ) based on physical and textural properties. Artificial neural networks were used to analyse data related to Misis fault breccia. Initially, models with moderate (noticeable, but not good) correlation coefficients were created using multiple regression analysis. After that, the regression models and three distinct artificial neuron network models were contrasted. Regression models are weaker and less trustworthy than artificial neuron network models, as demonstrated by this comparison. Pointed out is the practicality and ease of use of the artificial neuron network model with S-wave velocity and volumetric block proportion. Ultimately, it can be concluded that artificial neuron networks analysis provides a reliable indirect method for predicting the differential stress of Misis fault breccia.

Sep 1, 2025

By M. Saghaeian, R. Hejazi, V. Sheikhzadeha, A. H. Baladastian, A. Dehghani Ahmadabadi

This paper describes research done to remove apatite (phosphorus) from hematite ultrafine (70% finer than 25 micron) concentrate, recovered by electromagnetic separators at the FST Tailing Recovery Plant located in Chadormalu Iron Ore Complex through reverse froth flotation. As a result, iron and phosphorus content in magnetic concentrate (flotation feed) were 53.52% and 0.58%, respectively. Therefore, to increase the Fe content and decrease the P content of the sample, reverse flotation tests were applied. Chemical reagents used in this research consisted of sodium silicate as a depressant, sodium hydroxide and sodium carbonate as pH regulators, Alke & Dirol as fatty acid collectors and MIBC as frother. Process parameters including dosages of collectors, depressant and frother, preparation times of depressant and collectors, steps and time of frothing and pH range were selected. After doing flotation tests, in optimum condition, dosages of collectors were 1200 g/t, depressant 1200 g/t, pH in the range of 9.5 to 10, preparation time of collectors in the first step was eight minutes and at the other steps, four minutes; the number of frothing steps 4 and frothing time in each stage was three minutes. In this case, it was observed that the amount of phosphorus in the final concentrate was reduced to 0.05%, the Fe content increased from 53.52% to 61.66% and the Fe recovery achieved was 82.21%. Keywords: Iron ore, hematite ultrafine concentrate, iron and phosphorus content

Jan 1, 2020

By P. A. P. Fouché

Processing confidence for a bankable feasibility study on a green field heavy mineral deposit is inmost cases achieved only through bulk sample processing. Bulk sample is classified as a large enough concentrate sample that is processed into final products to satisfy market sample demand as well as further processing demands such as smelting. In this case study the demand was to produce 500 tons of heavy mineral concentrate from more than 5 000 tons run-of-mine on are mote location with limited to no infrastructure. The various challenges faced and lessons learned are documented as an outcome of the success of this mission.

Jan 1, 2007