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By M. Shapiro, L. A. le Grange, B. Henning

Effective pyrometallurgical process vessel design requires accurate assessment of the heat fluxes through the walls of the furnace. This is particularly important for freeze lining operation which is designed to protect refractory materials exposed to chemically corrosive molten contents, or facilitate high temperature operation when the refractory materials are used at conditions close to their service limits. Numerical modelling of fluid flow and heat transfer in process vessels is often used to aid in the design of process vessels. Sophisticated models are used to analyse the three dimensional flow and heat transfer predicting the effects of electrical heating, magnetic stirring, buoyancy, shear forces, various cooling effects and ultimately heat fluxes at the walls of the furnace and refractory. Traditionally these models are applied to the separate single fluid systems in a vessel such as the freeboard region including the arc, the slag region and the metal bath. Boundary conditions such as shear forces and heat fluxes between connecting regions such as the slag and metal bath are either estimated or carried over from separate solutions. Shortcomings in these traditional approaches include the estimation of sometimes critical boundary conditions leading to unreliable heat flux calculations. Also when boundary conditions are carried over between solutions, the process is difficult to set up, time-consuming and finally not fully coupled. In this paper the definition and results of a fully integrated numerical model of a complete arc furnace are presented. The most important mechanisms acting in an arc furnace were considered, including the fields of electrical potential, current, magnetism, momentum, heat transfer and radiation. Temperature dependant properties included electrical conductivity, density, viscosity, and thermal conductivity. The geometry consists of the freeboard, the arc, slag, metal baths and different refractory regions. Although the combined model of air, slag and metal would be defined as a multi-phase problem it is not solved as such. Instead the different fluids are separated by sets of special solid baffles. These baffles allow the implicit transfer of current, magnetism, heat transfer and shear forces between the different fluids and disallow mixing of the separate fluids. The strengths of the integrated model are threefold: Firstly, it provides robustness in defining the geometry and boundary conditions for the overall model. Secondly, it provides the capability to switch on and off individual mechanisms such as buoyancy, magnetic stirring and shear forces in order to observe their individual importance. Finally, it provides a useful tool in the design process through its ability to obtain results of parameter changes in short time scales.

Jan 1, 2004

By D. R. Hardman, J. W. Oberholzer

Based on information supplied by South African collieries to the Coal Mining Laboratory of the Chamber of Mines since 1978, the paper outlines the general performance of the continuous miners used and gives the results more-detailed studies of the cutting, loading, and transportation processes. On average, the continuous miners produced coal at a rate of 76 t per operating hour, which, at an average machine availability of 67 per cent, resulted in a production of 51 t per total hour. The cutting rates varied between and 250 t/h but, owing to machine and system inefficiencies, the overall production rate varied between 92 and 48 It is concluded that, if the collieries concentrated on improving their machine utilization procedures and operating practices, they could increase the overall production from their continuous-miner sections.

Jan 1, 1987

By Q. G. Reynolds

The presence of dust and fume suspended in the freeboard region is a common feature of the operation of direct current (DC) plasma smelting furnaces. This occurs primarily as a result of the use of fine feed materials together with the open-arc, open-bath operation of such smelters, and is exacerbated by the high velocities and turbulent mixing of the gas in the vicinity of the arc jet. Dust and fume losses into the furnace off-gas system can be significant in some cases and may have economic, operational, and environmental impacts on the process. A computational modelling study is presented in which the concentration of dust material was considered as a continuous field subject to a governing partial differential equation. Settling behaviour was calculated as a function of particle size, local gas/plasma temperature, and other physical properties. Development of the coupling between the concentration field and a magnetohydrodynamic description of the arc is shown, and the resulting models were used to compute various aspects of the behaviour of the concentration field in the arc region for a variety of furnace conditions. Time-averaged as well as transient models of the arc were used to generate the results presented. Qualitative case studies produced several practical suggestions for furnace operation, including increased dust capture by the bath when feed ports are located closer to the electrode, and the possible effects of feed segregation in the furnace freeboard based on dust particle size and density.

Jan 1, 2015

By G. Smith

This paper describes the allure of diamonds over time and highlights the magic and mystery of famous diamonds. Consideration is given to the effectiveness of marketing in the diamond industry. It is concluded that diamonds are held as cherished possessions, valued far above their real market price, retained as valued heirlooms, and widely used as a form of highly liquid currency. In order to sustain value, both from an investment and jewellery perspective, demand has been stimulated to keep pace with growing global supply while the illusion that ?diamonds are forever? has been fostered to ensure that most diamonds, once sold, do not re-enter the market.

Jan 1, 2003

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

A running facebreak ahead of the powered support units occurred on the number 4 seam at Matla Coal’s number 3 shaft (Matla 3) in April and May 2002.Very difficult mining conditions were experienced for a distance of some 150 m in the tailgate and to a lesser extent on the face itself. The paper analyses the main causes for the high stress conditions leading to the facebreak, namely, the existence of a >20 m dolerite sill close to surface and the effect of stopping longwalling on the overlying 5 seam. Difficulties experienced during the facebreak are discussed, including, pillar and roof collapses in the tailgate, high stress areas ahead of the face causing roof and sidewall stability problems, flushing of broken rock into the face area at the tailgate, secondary mid-face breaks, and the availability of critical support units. Successful rock engineering interventions and learning points were that, a goaf angle of 14.6° was found to be more realistic than the previously used 20 to 25° in predicting dolerite sill behaviour in this area, pre-split blasting of the sill significantly reduced stress on the face and tailgate allowing re-support work to proceed, varying pillar support types were analysed and rated, the need to always have a ground control “First Aid” kit available was recognised and a strategy for subsequent panels beneath the sill was developed. Numerous support units were used and the performance of the more suitable types is briefly discussed. A running facebreak ahead of the powered support units occurred on the number 4 seam at Matla Coal’s number 3 shaft (Matla 3) in April and May 2002.Very difficult mining conditions were experienced for a distance of some 150 m in the tailgate and to a lesser extent on the face itself. The paper analyses the main causes for the high stress conditions leading to the facebreak, namely, the existence of a >20 m dolerite sill close to surface and the effect of stopping longwalling on the overlying 5 seam. Difficulties experienced during the facebreak are discussed, including, pillar and roof collapses in the tailgate, high stress areas ahead of the face causing roof and sidewall stability problems, flushing of broken rock into the face area at the tailgate, secondary mid-face breaks, and the availability of critical support units. Successful rock engineering interventions and learning points were that, a goaf angle of 14.6° was found to be more realistic than the previously used 20 to 25° in predicting dolerite sill behaviour in this area, pre-split blasting of the sill significantly reduced stress on the face and tailgate allowing re-support work to proceed, varying pillar support types were analysed and rated, the need to always have a ground control “First Aid” kit available was recognised and a strategy for subsequent panels beneath the sill was developed. Numerous support units were used and the performance of the more suitable types is briefly discussed. Une cassure de taille en avant des unités de soutènement s’est produise sur la veine numéro 4 dans le puits numéro 3 (Matla 3) de la mine Matla Coal en avril et mai 2002. Les conditions d’extraction étaient extrêmement difficiles sur une distance d’environ 150 m dans la voie de tête et, en moindre mesure, sur le front de taille lui-même. L’étude présente analyse les raison majeures pour les conditions de grandes contraintes qui ont conduit à la cassure de taille, à savoir l’existence d’un mur de dolérite de >20m proche de la surface et l’effet d’arrêter la longue taille sur la veine 5 superposée. Les difficultés rencontrées pendant la cassure de taille sont rapportées, y compris les effondrements de piliers et toit dans la voie de tête, les aires de grandes contraintes en avant du front de taille causant des problèmes de stabilité pour le toit et les parois latérales, l’injection de roches cassées dans la taille en voie de tête, les cassures secondaires à mi-taille, et la disponibilité d’unités de soutènement critiques. Interventions minières réussies et leçons apprises furent : un angle de remblai de 14.6° était plus réaliste que celui de 20 à 25° utilisé auparavant pour prédire la conduite du mur de dolérite dans cet endroit ; tir à deux temps du mur a réduit considérablement les contraintes sur la taille et la voie de tête, ce qui a permis un travail de support complémentaire ; des types variés de support de piliers furent analysés et évalués ; la nécessité d’avoir toujours une trousse de première urgence disponible fut reconnue ; et finalement une stratégie pour les panneaux en dessous du mur fut

Jan 1, 2003

By C. S. Chenga

Sustainable development is currently an extremely relevant concept worldwide, especially in developing countries like South Africa. Mining and metals companies are also directly affected by the sustainable development agenda. The Mining Charter?s requirements as well as new legislation (Mineral and Petroleum Resources Development Act) expect, among others, for mines to support infrastructure and poverty eradication projects in the communities surrounding the mines. The aim of this paper is to, against the background of a qualitative study of mining communities in the North-West Province of South Africa, put forward some critical factors for the sustainability of social development projects in the mining sector.

Jan 1, 2006

By John V. Simmons, Peter J. Simpson

Excavated slopes in open pit coal mines are designed to be as steep as possible consistent with stability and safety requirements. Slope failures occur for many reasons, including oversteepening. This paper is concerned with slope design and excavation experience in the Bowen Basin coalfields of central Queensland (Figure 1), [ ]

Jan 1, 2006

By N. Steven

Published parameters from the Mufulira copper in situ leach (ISL) in Zambia are used for order-of-magnitude flow-rate calculations for an envisaged gold ISL in back-filled Witwatersrand stopes. A successful leach operation requires that the porous medium, usually a sand, has a hydraulic conductivity in excess of 5 x10-7m/second (i.e. a permeability >50 millidarcies).Empirical evidence suggests that average linear velocities would be of the order of 60 m/day if the backfill has the grain size of a fine sand. The proposed gold lixiviant would probably be an alkaline or ammonium thiosulphate, not cyanide. The resultant sulphate-rich ground and drainage waters could probably be processed using existing purification techniques to produce gypsum and magnesium/calcium carbonate. Within the next 100 years it is inevitable that solution mining will find widespread application on the Witwatersrand, if not for gold extraction, then certainly for water remediation purposes.

Jan 1, 2009

By R. Sullivan, K. Joiner, B. Emery, M. de Vries, F. A. Stober, L. R. Nelson, J. M. A. Geldenhuis

Keywords: Pyrometallurgy, smelting, converting, furnace design, furnace retrofit, high-intensity smelting, copper coolers, plate coolers, waffle coolers, tap-blocks, lower sidewall air-cooling, wall hold-down system, platinum group metals, ferroalloys, ferrochrome, ferrocobalt, ilmenite smelting, ironmaking, operational readiness, operational support The paper describes the development of furnace designs by Hatch in conjunction with the smelting plants in Africa to meet the intense process requirements in certain applications; continued improvement in operating efficiency through increased throughput from existing crucibles; and improvement in campaign life and furnace integrity. The era of Hatch in Africa has seen the doubling of furnace power in retrofit projects using existing crucibles to developing the highest intensity immersed electrode operations in the world. This has resulted in minimized OPEX and CAPEX per unit of production. Through the continued development of its cooling, binding and furnace power supply technologies and working with the experienced and knowledgeable personnel at the smelting facilities in Africa, Hatch has managed to meet the challenges of ever increasing furnace process requirements associated with increased power density and superheats prevalent in the operations. In addition to developing furnace crucible designs, Hatch has also intensified its ?after sales service and support? with the construction, commissioning and start-up technical assistance and operational readiness and operational support for ramp-up to nameplate capacity and beyond. The key areas of furnace risk associated with high superheat molten material tapping has also seen the development of diagnostic systems to mitigate risks and produce early warning signals for the operators.

Jan 1, 2006

By N. K. Singh

The calculation of resource volumes for large mineral sands deposits is the process of systematically compiling all known data in order to define the volume of ore contained and its intrinsic economic value. Traditionally, this process has been highly speculative in nature, as the variability of the layer thickness, even between closely spaced, boreholes can be highly variable. The issue of horizon continuity is of critical importance in mine modelling and resource definition. Accurate volume estimates are difficult to derive from drilling data alone, as the borehole spacing of an economically viable drilling programme is often greater than the spatial frequency of the variations in profile thickness. The limitations associated with this inferential approach to resource estimation can be mitigated through the use of newly developed ground penetrating radar (GPR) methods, thereby maximizing orebody optimization by reducing contamination and orebody loss. The use of GPR in the mining industry has historically been limited to shallow, high-resolution applications, such as the location of voids in limestone or the mapping of paleo channels for alluvial gold and diamonds (Francke and Yelf, 2003). These limitations have not been technology based, but rather market based, as the vast majority of GPR systems were originally designed for civil engineering applications. A new generation of GPR technology, designed specifically for maximum penetration in sand environments, is now being developed. This technology has been trialled extensively at the Richards Bay Minerals heavy mineral sand deposit in South Africa with optimistic results. The clay base of the mineral sands has been imaged to some 120 metres. Further equipment refinements are expected to yield even deeper profiling and higher resolution. The resolution offered by this technology is unique, allowing individual depositional sequences to be imaged and modelled in three dimensions. This paper will discuss the advances in GPR technology relevant to the mineral sands industry, as well as methods to optimize and integrate GPR data into existing mine models. Also addressed will be approaches to three-dimensional modelling of high-resolution GPR data and subsequent volume estimations.

Jan 1, 2007

By P. M. Swash

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

Jan 1, 1988

I am a partner in a minerals' development company called A.B.F. Limited, that does minerals development in Africa and Asia. I have read your very fine magazine often at the Colorado School of Mines Library in Golden, Colorado. I would like to ask your assistance in trying to locate a South African smelter; preferably on the coast, but not totally necessary for the project, that can separate the first four metals (Au, Ag, Cu, and Pb).

Jan 1, 1980

By B. R. Broekman, J. P. W. Bennie, P. D. K. Robinson, R. P. Viljoen

The theme of the Congress was 'Resources and Technology', the intention being to highlight those basic technical aspects in the disciplines of geology, mining, extractive metallurgy, and metals technology that are required for successful mineral-based operations. The technical programme covered a fairly broad field, as is appropriate for the CMMI Congress, and was generally considered to be of a high professional standard; informative and, with the exception of some minor hitches, well-run. Parallel sessions were held in the four disciplines. All were well attended, and despite tight presentation schedules, certain valuable discussions developed.

Jan 1, 1994

By T. Wallmach

Heavy mineral deposits are a source of the economic important element titanium, which is contained in minerals such as ilmenite, pseudorutile and rutile. In the Ranobe heavy minerals deposit these minerals occur not only as primary unaltered minerals but also display various degrees of alteration resulting in an increased titanium content of the deposit. The presence of the various FeTi-oxide minerals? textural relations is a reflection of geological processes and may ultimately be used to unravel the geological history of the deposit. These minerals have different chemical and physical properties that influence metallurgical tests and the quality of products produced from various mineral beneficiation streams. It is therefore of metallurgical importance that the minerals are well characterized, defined and monitored during preliminary beneficiation tests.

Jan 1, 2007

By L. Woollacott, R. P. King

This paper presents data collected from full-scale plants in order to verify the predictions of a new simulator of CIP or CL operations. Good agreement was found between the experimental data and the simulator predictions. The simulator is able to predict the effects of many of the complex operating phenomena in GIP and CL plants that previous simulation techniques could not describe. This is illustrated by predictions of how factors, such as the manner of carbon transfer, concurrent leaching, and gold loading on eluted carbon, can affect the performance of an adsorption plant.

Jan 1, 1990

By K. Richardson

Although the De Beers group has a long history of placer mining on land, the group only became actively involved in deep water marine diamond exploration and mining in 1983 with the formation of DeBeers Marine. Full-scale commercial mining commenced around1991. Since then, the group marine mining capability has grown into a formidable fleet of 8 large deep water (>70 m) mining vessels, as well as other special purpose geosurvey platforms. Marine diamond production by the group is expected to be just short of 1 million carats in 2006. De Beers operates across the entire value-chain spectrum from geology and geosurvey, through sampling to mining, and finally ore processing into high value concentrate. Supporting these operations involves significant service activities such as maintenance, security, logistics and environmental management. Specific challenges exist in terms of developing or acquiring appropriate technology for marine mining. These challenges have resulted in De Beers operating extensive in-house R&D and projects departments, as well as drawing extensively from technology partners. An array of computational and test facilities is also available to support R&D and projects activities. Hydrotransport in various guises is key to the current approaches to marine mining and ore processing. Use is made of airlift and centrifugal pumping for hydraulic hoisting of very coarse gravel, while splitters, launders, dewatering, elutriators, jet pumps, centrifugal pumps, dense medium circuits, pipeline systems, and instrumentation for coarse abrasive particles are used extensively in the ore processing plant.

Jan 1, 2007

By R. G. Cawthorn

The vertical distribution of platinum-group elements (PGE) in the Merensky and UG2 chromitite Reefs is highly variable, but does follow certain general patterns that allow the testing of geological models. In the Merensky reef, historically popular geological representations and interpretations have suggested that the mineralization occurs in a pegmatitic pyroxenite bounded by two chromitite layers. However, there are now enough published exceptions to this relationship to expose its fallacy. The vertical distribution of the PGE depends largely upon the separation between these two chromitite layers or the absence of one chromitite layer. Where separation is small or only one chromitite layer is present, there is considerable PGE mineralization in the footwall below the pyroxenite and lower chromitite layer. With increasing separation between the two chromitites, the mineral¬ization occurs progressively higher in the succession, and tends to track the upper chromitite layer. The view presented here is that the entire Merensky package is comprised of three events of magma emplacement, in which each has produced variable reaction with, and erosion of, the footwall, causing recrystallization of pyroxenite into pegmatitic pyroxenite. The magma then produced a chromitite layer followed by pyroxenite. Each chromitite layer is associated with some mineralization, which was extensively complemented by the subsequent formation of a sulphide liquid carrying PGE that trickled down through about 1 m of permeable crystal pile. The sulphide liquid formed after, not coincident with, the pyroxenite layers. The distribution of PGE in the UG2 chromitite shows up to three upward depletion sequences of PGE, also suggesting three events. The PGE are associated only with the chromite. The contribution from a sulphide liquid is considered to have been minimal for two reasons. Cu and Ni are extremely low in the UG2 which would not be expected if sulphides had been present. Also, by analogy with the Merensky, downward trickling of sulphides would have caused some PGE to be present in the footwall. There are some PGE in the footwall, but only where remnants of chromitite occur, and the hanging wall is lacking in PGE. In the northeastern Bushveld the UG2 chromitite is thinner than elsewhere, and there is a UG3 chromitite layer, not present elsewhere, that has a high Pt/Pd ratio. It is surmized that in the rest of the Bushveld the UG3 only appears to be absent because it has merged with the UG2 to produce the high Pt concentration at the top of the composite UG2. The non-accumulation of the package of pyroxenite-norite-anorthosite between the UG2 and UG3 in the northeastern Bushveld, which is not seen elsewhere, creates an interesting challenge to the formation of silicate layering in the complex. The mineralization in the Platreef is not addressed here. Keywords Bushveld complex, Merensky Reef, UG2 chromitite, geological evolution.

Jan 1, 2011

By D. R. Hack

The complexity of commercial mining software has gained rapidly over the past decade as hardware developments have surpassed software capabilities at a staggering rate. Software users, recognizing the limitations of off-the-shelf applications, have adapted embedded scripting languages. Custom programming has always had a vital role in mine computing innovations, yielding a dynamic research environment in industry and academia. Fields such as industrial minerals can benefit from customization of existing software, since the majority of mine planning software was designed for large metal mines. Different customization approaches utilizing embedded scripting languages are presented, with examples of sand and gravel applications in development. Following implementation by Surpac and development of the Surpac Command Language, Tcl has been widely applied. Mintec introduced Python, also extensible and portable amongst various operating systems, for use in their MineSight products. In early 2000, Gemcom introduced the use of Microsoft Visual Basic for Applications, widely used customization tools for a decade. Datamine implemented a flexible multi-language approach, with all program commands and processes available through the COM Server Interface. This extends customization from the existing macro language to scripting in HTML, JavaScript, or any language that supports COM.

Jan 1, 2003

It is shown that, when a flat-bottomed indentor is pressed into the surface of a strong rock, the normal force necessary to cause failure of the rock is reduced substantially if a shear force is applied to the indentor. A mathematical analysis is described, which shows that higher stresses are induced in an elastic material close to the free surface of the material ahead of a punch when a shear force together with a normal force is applied to the punch. Therefore, failure of the material would occur with lower forces applied to the punch. Stress trajectories show that fractures develop in the rock along lines of maximum principal stresses.

Jan 1, 1978

By A. v. E. Conradie, I. Nieuwoudt

Comminution and flotation circuits are frequently perturbed by disturbances, such as feed particle size variations, ore hardness and varying mineral liberation, which can have a significant impact on the recoveries and grades. Although advanced control strategies can neutralize many of these disturbances, few such systems have been implemented at present. One reason is that it is only recently that the requisite sensor systems have been developed and used to control froth flotation systems. Another is owed to the complexity of these non-linear interactive systems. In this paper, a plant-wide control strategy is considered, wherein both unit operations have a single overall control objective. The automated design of the controller is based on an advanced evolutionary algorithm viz., Symbiotic, Memetic Neuro-Evolution (SMNE), for developing neural network controllers in a reinforcement learning framework. A rigorous phenomenological comminution and flotation model was used to develop suitable neurocontrollers, which used all possible sensor inputs and available manipulated variables. The neurocontroller managed to identify optimal or near-optimal operating conditions consistently and showed robust performance in the presence of significant disturbances. The results suggest that evolutionary reinforcement learning offers a very competitive approach towards the development of integrated non-linear controllers for mineral processing plants. Keywords: neural networks, control, flotation, comminution, evolutionary reinforcement learning

Jan 1, 2003