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By L. Hekkala, J. Ollila, J. Keihäs, P. Mäkelä

The Outokumpu Steel Belt Sintering (SBS) Technology is used for manufacturing chromite pellets that are charged into a smelting furnace for ferrochromium production. One of the main elements in successful furnace operation is the control of gas flows inside the furnace, giving improved temperature distribution in the bed during the process. Computational Fluid Dynamics (CFD) gives excellent opportunities for studying these phenomena. An investigation using CFD can be performed relatively fast. For example, implications of different configurations can be studied within a day and an optimum design chosen. Therefore, Outokumpu Technology has developed a Steel Belt Sintering Model (SBSM), which takes advantage of a commercial CFD code. Each main physicochemical event occurring in a steel belt sintering furnace is incorporated independently in the SBS model as a sub-model, enabling every event to be studied separately. The commercial CFD code solves mass, momentum, species and energy equations for determination of the gas flow, composition and temperature. In addition, the Outokumpu SBSM takes into account the moving pellet bed, drying of pellets interms of water content, coke combustion, oxidation and reduction of chromite and the decomposition of carbonates and silicates. During the development of the model, numerous laboratory-scale tests were performed. The sub-models were validated against the laboratory tests. The reliability of the Outokumpu Steel Belt Sintering Model was validated against a pilot-scale batch-sintering furnace by comparing the modelling results against measurements. The aim of this paper is to give a brief presentation of the Outokumpu steel belt sintering model by showing some general modelling examples. Emphasis has been placed on demonstrating some of the main features of the model.

Jan 1, 2007

By S. G. Hardcastle, C. K. Kocsis

In Canada’s metal mines, ventilation, which requires electricity to operate the fans and fossil fuel for heating, accounts for a significant portion of the overall mine’s underground power consumption. Mine ventilation systems are usually designed near the end of the mine design process and often designed for the ‘worst-case-scenario’ with respect to ventilation demand. In Canada’s metal mines this is commonly dictated by either diesel equipment usage or heat management considerations. Once designed, mine ventilation systems tend to operate at this peak level throughout the operating life of the mine. This is despite there being significant periods when this quantity is not required this is done mainly due to lack of appropriate ventilation controls. Consequently, such systems are inefficient and wasteful and this must be changed if mining operations are to remain competitive while meeting increasingly more stringent regulations of underground environmental conditions. The advances in computing power and modelling software now make it possible to design, model and schedule a mine from opening to closure. The tools used for this include several disparate types of software. A developing trend is to design and plan the mine using orebody modelling software, followed by using discrete event simulation to predict production and evaluate various operating scenarios. It seems that again ventilation design is not being integrated into this process. Although, several modelling packages exist for ventilation design, little work has been done on integrating ventilation modelling into the overall life cycle plan of the mine. This paper will present a discussion of the work where the authors are attempting to integrate discrete event simulation for mine planning with ventilation modelling to predict the ventilation requirements for the operating life of the mine.

Jan 1, 2003

By M. L. Baharani

Looking for an idyllic paradise that has investment and business potential as spectacular as the stunning views of mountains, the rich Ganesh Himal zinc-lead deposit exposed between 4,050 m and 5,000 m is the answer. Arising from the sea floor in a span of 55 million years, the enchanting Himalayas had remained one of the most potent factors influencing the Asian region. The challenges of the mighty Himalayas notwithstanding, it continues to provide opportunities for the humankind in optimum usage of the natural resources and sustainable development. Optimal management of natural resources in mountain areas through decision support tools offered by remote sensing will go a long way in realization of the Ganesh Himal Zinc-Lead Project. The authors have a real life endeavor spanning over 37 years in developing a mining industry in a mountainous region of Nepal and an attempt to integrate with the development of other natural attributes of the region. With rapid acceleration of science and technology, humankind has acquired power to transform his environment countless ways and on an unprecedented scale. While mineral resources are the pillars on which we have built industry and infrastructure, industrial countries in the North have been in the forefront of technological advancements, the developed countries of the South have been at the receiving end of exploitation of mineral resources worldwide. A relationship with natural environment, re-crafted by the civilizing impulse, to meet human demands are upcoming challenges for management of natural resource in sustainable manner for a livable world.

Jan 1, 2008

By Grant Loveday, Vincent Dieudonné, Andrew Jonkers

Bateman Minerals & Metals supplies the APIC Technologies which include the under-bed air-pulsed APIC jig and related technologies such as the JigScan controller and advanced mathematical models of the jig process. Bateman have developed a methodology for predicting process performance for jigs from simplified testing and modelling, based on batch equipment matched to industrial designs. Batch tests conducted on laboratory scale air-pulsed jigs can process small batches of material, such as those obtained from drill core samples. The novelty comes from using an advanced jig process model, ASTRAD, to link the results of batch and continuous jigs. The batch jig presented as a novelty in this paper has been designed to be hydraulically equivalent to the full-scale APIC Jig, allowing the generation of equivalent pulse shapes and using JigScan controller. Lump and fine ferrous ore material have been separated in this unit and any feed >1mm can be tested and extracted. The global test procedure and further modelling focus on the stratification of material, with emphasis on key aspects such as pulse shape, feed characteristics and residence time. The splitting of rejects from concentrates is itself more difficult to reproduce in batch jigging, however the ASTRAD model includes a separation imperfection module, and the APIC Technologies have extraction systems adapted to each type of material. Air pulsed batch jigs are available in several locations and are relocatable. They have been used to treat samples from Australia, South Africa and India as part of studies into ore processing using jigs. Each test layer is available for various physical testing procedures (density and chemical analyses). Test-work is performed on a case by case basis, and analysed using an advanced model ?now available over the internet. Some fundamentals of air-pulsed jigging are recapped along with some of the features of APIC jigs. The process of designing a ?hydraulically equivalent? batch jig test is then described. Some results from jigging tests are presented plus the results of the ASTRAD advanced jig model, which was first developed at the JKMRC with ferrous ores and coal and is now being supported and further developed and utilised by Bateman.

Jan 1, 2006

By D. Boshoff

The ability of an explosive to break rock is influenced considerably by the extent of confinement in the blasthole. It is believed that confinement is improved by the use of adequate stemming. The aim of this paper is to present the results of the first and second stages of developing a stemming performance testing rig for small diameter boreholes. The rig was used to compare and contrast the performance of different designs of products. The results showed that different stemming products have differences in terms of their functionality, which can have a major impact on the efficiency of rock breaking. Two test procedures were used, one through the exclusive use of compressed air and the second using a purpose-built high pressure test rig with small quantities of explosives. Both tests were used to identify and evaluate the ability of various stemming products to resist the escape of explosive gas through the collar of a blasthole. An investigation was done to determine the types of stemming products most commonly used in South African underground hard rock mines, and these products were used during the tests. The first stage of tests using compressed air only did not prove adequate to predict with certainty the pressure behaviour in the borehole of a particular product under high pressure conditions. The purpose-built high pressure test rig also did not prove to be a very effective tool to test stemming products under high pressure conditions. The test rig incorporated only the effect of gas pressure on the stemming product, and excluded the effect of the shock wave. This study therefore proved that to take into account only the gas pressure generated in the blasthole is not sufficient to effectively test stemming product performance.

Jan 1, 2011

By E. V. Lilford

Equity investors and project sponsors have divergent views about expected or minimum returns that should be generated by a mineral project. Irrespective of their views, the fundamental estimation of the corporate cost of capital remains singularly determinable, with additive components of risk and uncertainty often incorporated in the final analysis. This paper discusses and details the fundamental, numerical determination of the corporate cost of capital.

Jan 1, 2006

By Glen Mc Gavigan

The roof of the Sishen cave is being mined in order to exploit 6.8Mt of high grade ore. The cavity is filled with quartzite backfill in order to support the roof in the event of collapse. The cave dips at approximately 37o, is 260m along dip and 70m along strike and has a total volume of 261,391m3. GPS and optical monitoring techniques were attempted to detect subsidence but proved to be impractical. The GroundProbe Slope Stability Radar (SSR) uses differential interferometry to measure sub millimetre movement in a rock face. The SSR was applied in a non production situation and detected subsidences of 38mm/day before visual signs of instability were detected. The rate of deformation detected was slowing as a result of the roof coming to rest on underlying backfill. Monitoring during production drilling detected a sudden subsidence of 18.6mm/hour which resulted in the evacuation of personnel from the area. Further inspection of data showed that the rate of deformation was slowing and production was allowed to continue without further incident. The SSR has helped dispel the fears of workers and has proven that subsidence can be accurately measured and delineated with the SSR.

Jan 1, 2006

CSIRO Mineral has recently developed a new electron microprobe based system for characterizing zircon grains from heavy minerals sand deposits. The system acquires cathodoluminescence (CL) spectra, X-ray and backscattered electron (BSE) signals in parallel. By scanning over a specified target area, CL wavelength and X-ray element distribution maps of polished zircon grains can be acquired. Post-inspection of the combined dataset using in-house developed software enables correlations between chemistry and structure to be investigated. The new method offers significant benefits over traditional CL and BSE techniques in that direct comparison with the elemental concentrations over the same region is now achievable. By combining the electron microprobe results with data for the same mapped region obtained via a nuclear microprobe, significantly better detection limits (~ 1ppb) for elements with atomic numbers greater than iron are possible. The ability to measure spatially related analytical data and then investigate the correlation of the CL spectra with chemical data is an important advancement in the characterization of zircons. Key words: zircon, characterization, cathodoluminescence, backscattered electron, electron microprobe, nuclear microprobe, chimage, proton induced x-ray emission.

Jan 1, 2003

The newly implemented mineral law framework exacerbated the need to clarify the roles and responsibilities of mine and land surveyors in the preparation and registration of plans and diagrams. The main concern is that survey tasks may be performed by persons who are not considered competent under the different laws. The methodology used was to analyse historic and present legislation on the issue in order to formulate a narrow interpretation of the current requirements. The major findings are tabulated to present a summary of who is responsible for which areas of survey.

Jan 1, 2010

By C. F. Vos, J. D. Miller, J. C. Davidtz

Small replacements of C12-trithiocarbonate (C12-TTC) for dithiocarbonate (DTC)/dithiophosphate(DTP) in a reagent suite for the flotation of platinum group metals (PGM) have significantly improved the rejection of gangue. Coupled to this is an improvement in kinetics, grade and recovery of PGMs. In a pilot-plant trial, after a 5 mole per cent replacement of the current DTC/DTP collector combination by C12-TTC, large opaque bubbles were replaced by small clear ones. In addition, a similar flotation response was realized with one-third of the current depressant dosage. During a preliminary plant trial on underground UG2 ore, the initial rougher concentrates were characterized by higher PGM concentrate grades and this was in part due to improved chromite rejection. The concentrate produced from the TTC trial also exhibited a much finer particle size distribution. The overall circuit performance, which included secondary regrind and flotation, showed an increase in concentrate grade of approximately 44% while the tailings grade remained unchanged

Jan 1, 2006

By H. Hu, T. S. Golosinski

The paper reports on use of neural network algorithms to model performance and condition of mining trucks. The model inputs are selected digital data streams collected by truck Vital Information Management System, VIMS, during its operation in a mine. The models built as the result of this work allow for projection of truck condition and performance into future. As such they facilitate more efficient management of mine truck fleets. Keywords: Modelling, modeling, neural networks, mining equipment, Vital Information Management System, Intelligent Miner, mining truck

Jan 1, 2003

By B. C. Viljoen

"SynopsisCommencement of the next phase of the Lesotho Highlands Water Project is a year or so away from becoming reality. Some 50 km of tunnels in the form of access adits, shafts, diversion tunnels, and main waterways will be constructed. Sprayed concrete will form an integral part of the temporary and permanent rock support systems that will be installed. Furthermore, the use of sprayed concrete as a final tunnel lining solution was proposed as a viable alternative to concrete linings in the feasibility studies that preceded the forthcoming implementation phase.The aim of this paper is to make the reader aware of all the sprayed concrete related issues that engineers tend to grapple with during the design and construction of tunnel projects and other underground works. Primarily, these issues would include selection of applicable design parameters, technical specifications, construction application methods, quality control and, most importantly in the context of final or permanent linings, the durability of sprayed concrete.The International Tunnelling Association (ITA) Working Group (WG) 12 has been tasked specifically to publish a set of recommendations on the Quality and Control of the Application of Sprayed Concrete and the Testing of Sprayed Concrete for Durability. These tasks were also further explored at the recent World Tunnel Congress (WTC 2015) that was held in Dubrovnik, Croatia at the end of May 2015.IntroductionSprayed concrete is presented in a variety of shapes, designs, forms, application methods and accompanying terminologies including shotcrete, gunite, pneumatically applied concrete, and the like. The International Tunnelling Association (ITA) decided to standardize on a single terminology, namely ‘sprayed concrete’, in order to simplify specification, interpretation of guidelines, and codes of practice."

Jan 1, 2015

By J. N. Van der Merwe

The research described in the paper was aimed at providing standardized information of cases of failed and intact coal pillars in the form of databases to researchers. It also offered the opportunity to take stock of the pillar stability situation in coalmining and to review the impact of the application of the safety factor formula for pillar design. It was found that the physical parameters of coalmining have not changed substantially over the last four decades. However, changes in the controllable parameters like pillar width, pillar width-to-height ratio and percentage extraction have all moved toward the more conservative side. Scrutiny of the database indicates that of all the failures recorded, only 23 occurred in panels that were mined after 1969, when one can assume that the safety factor formula was fully applied. If the pre-1969 practices had been continued, at least 144 collapses would have been expected. There has thus been a substantial reduction of pillar collapse cases, justifying the cost paid for the formula, which has shown to be in the region of 600 million tons of coal. It is evident that that are distinct differences in the natures of the failures among different coalfields. This justifies the attempts to derive seam or coal field specific strength formulae and is a topic that should be pursued.

Jan 1, 2006

By S W. Robertson, A Vercuil, P Craven

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

Jan 1, 2005

By 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 R. Poisel, C. Scavia, Preh A., W. Roth, M. Pirulli

ABSTRACT: Two methodologies for the three-dimensional simulation of the run out of rock avalanches are presented: one based on a granular approach and the other based on a continuum equivalent approach. An evaluation of the possible run out area of the Oselitzenbach landslide (Carnic Alps, Austria) has been carried out applying the two methodologies. The combined use of these two approaches makes it possible a comprehensive assessment of the run out area. RESUME: Deux méthodologies pour la simulation tridimensionnelle de la propagation des avalanches rocheuses sont présentées: la première est basée sur un modèle de type granulaire et la deuxième sur un modèle du continu équivalent. Une évaluation de la propagation éventuelle de l’avalanche de Oselitzenbach (Alpes Carniche, Autriche) a été réalisée en utilisant les deux méthodologies. Les résultats obtenus montrent que la combinaison des deux approches rend possible une analyse plus complète de la phase de propagation. KURZFASSUNG: Für die dreidimensionale Modellierung eines Felsmassensturzes (sturzstrom) werden zwei Methoden, eine granulare und eine kontinuumsmechanische Methode, vorgestellt. Beide Methoden wurden zur Abschätzung der Ausbreitung (runout) der Massenbewegung Oselitzenbach (Karnische Alpen, Österreich) herangezogen. Die kombinierte Anwendung beider Methoden ermöglichte eine umfassende Beurteilung des möglichen Ausbreitungsbereichs.

Jan 1, 2003

By F. T. Cawood, M. A. Jooste

This paper describes the survey monitoring processes at Venetia, which are discussed under visual inspections, ad hoc investigations, system monitoring and slope stability radar monitoring. This is followed by a description of the main survey monitoring methods. The next section briefly states typical problems, i.e. the atmospheric corrections required to adjust total station distances, maintenance of the system and management of the monitoring process. The paper ends with some important lessons that could be applied to similar monitoring programmes. These lessons are firstly, communication is most important, process a vital part of the system, a champion must take responsibility for the programme and system planning ensures that the monitoring results are needs driven.

Jan 1, 2006

By L. Munsamy, B. J. Madden

OpenRisk, an open cast risk rating system, takes into account relative differences in the importance of hazards, as experienced on each mine as a result of different combinations of geotechnical factors and mining conditions. The system is based on critical geotechnical and operational parameters that have been identified by mining personnel and rock engineers. The primary advantage of this risk rating system is that all the strip mines would use an identical system, which enables the user to compare their risk to the risk at neighbouring mines and/or other open cast mines. The system can be adjusted to meet local, mine specific requirements. This system has been made practical and easy to use. Therefore, this tool can be used by personnel from other disciplines not directly related to rock engineering. OpenRisk system has been in operation at nine Anglo Coal and other open cast mines. It adequately detects areas of high risk and generates adequate remedial solutions to reduce the risks. Awareness of the personnel has been higher at the sites that use OpenRisk. The proactive approach of OpenRisk ensures that all personnel are aware of risks in the pits and how to deal with potential risky areas.

Jan 1, 2006

By M. B. Shongwe

Pt-based alloys are being developed for high-temperature applications with the aim of replacing some of the currently used Ni-based superalloys (NBSAs) in the highest temperature applications. The Pt-based alloys have a similar structure to the NBSAs, and since Pt is more chemically inert than nickel and has a higher melting point, they can potentially be used at higher temperatures, up to 1300°C, and in more aggressive environments. Several experimental Pt-based alloys were studied at Mintek, and an optimum composition was found to be Pt84:Ahi:Ru2:Cr3 (at.%). On the basis of hardness and microstructure, a later study identified a new optimum: Ptr8:A111:Ru5:Cr6 (at.%). There are at least two Pt3A1 allotropes, and the high-temperature cubic structure has better properties than the lower temperature tetragonal form, and so needs to be stabilized. This work describes the latest results obtained in transmission electron microscopy (TEM) studies of the quaternary Pt-based superalloys. These results are both interesting and important, because the samples have a higher precipitate density compared to those from earlier work. The precipitate morphology is mainly cubic, with minor areas having irregular-shaped precipitates. The high volume fraction of the precipitates is a major breakthrough, since the objective of this work is to improve the alloys. A prior disadvantage was that the proportion of the precipitates was too low in samples before this work, especially compared with the work from Germany on Pt-Al-Cr-Ni¬based alloys as well as the NBSAs. TEM -Pt3A1 diffraction patterns were studied, and for each diffraction pattern, many possible lattice point combinations were tried, with the angle between the lattice spots as well as interplanar spacings being calculated for each phase (cubic or tetragonal) to match the measured results. An overall analysis of the diffraction results indicates that the cubic phase fitted the experimental lattice points with much lower errors compared to the tetragonal phase. Thus, with the close match achieved with the cubic structure, the structure of -Pt3A1 precipitates is likely to be cubic. X-ray diffraction has been carried out on selected samples, and the results confirmed the presence of cubic -Pt3A1 and (Pt). Different X-ray diffractometers were used to further verify the results, and the results were also compared with those from TEM.

Jan 1, 2012

The relationship between neural network (NN) performance and the parameters that form the architecture of the neural network is complicated. This paper studies an issue that is still controversial—the effect of the number of neurons and number of hidden layers on NN performance. This paper tests if the above parameters affect network performance when the NN is trained according to the quick stop strategy. It was determined that the number of neurons did not have any effect on the NN performance for a single layer or a double layer network. It was also found that the training error and calibration error could be poor indicators of the prediction correlation coefficient.

Jan 1, 2003