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By A. M. Hearn, J. G. Roos

Energy consumption, being a large proportion of the input of the ferroalloy production process, can be measured in terms of the efficiency with which the energy is utilized and the effectiveness with which it is used. The efficiency of the usage of energy revolves around the specific consumption of the energy for the production of the alloy, which encompasses the thermodynamic aspects of the process and is more of a metallurgical function that will not be addressed further in this paper. The effectiveness with which the energy is utilized is determined by the optimisation of the electricity supply from the utility (in this case Eskom). The South African electricity supply industry is on the brink of considerable restructuring, implying changes in ownership, structure and regulation. In other countries, however, restructuring has often seen higher prices. Owing to the diversity of growth prospects in South African markets, Eskom is turning to new market management and generation strategies. In future, Eskom will develop pricing strategies to increase demand from attractive customer segments such as paper & pulp, iron & steel, aluminium, and other metallurgical industries. There will be a broader spectrum of product offerings, including dynamic pricing options and demand-side management incentives. In a future electricity market that will become more dynamic and demanding, it will become increasingly important for electricity consumers to optimise their electricity supply. There are many facets in optimising the electricity supply, which include optimal utilisation of the tariff, integrating energy cost management into the production planning process, implementation of demand-side management actions, modelling, scenario planning (.what-ifs?.), optimisation, maintenance scheduling coordinated with the tariff periods, etc. This paper gives consideration to the status of the development of technology at the manganese alloy works of Samancor at Meyerton, South Africa in order to increase the effectiveness with which energy is utilized.

Jan 1, 2004

By D. Limpitlaw

As coal mining often results in the generation of acid mine drainage (AMD), careful planning and management of the water on such mines is required. A colliery in Mpumalanga recently sponsored independent research into the pollution-ameliorating potential of a natural wetland that has been receiving AMD for at least two decades. Samples of the sediment collected in the wetland were subjected to nine stages of sequential extraction in a determination of the distribution of the metal species present. The samples were then analysed for aluminium, iron, and manganese. The concentrations of sulphate-reducing bacteria (SRB) were also determined. The SRB concentration was found to increase with distance downstream (away from the source of pollution). An analysis of the sediment speciation data indicated that metal immobilization may be optimal in areas where the organic adsorption of metals is at its greatest. The analysis also provided evidence of the biogeochemical improvement of the water quality as the AMD passed through the wetland environment. The metal species present did not correlate strongly with the SRB populations; nor did the soluble species correlate with the species formed over long periods of time.

Jan 1, 1996

By A. S. Macfarlane

Western Deep Levels (North) is a deeplevel, longwall gold mine. Severe strata control problems and high rates of elastic closure, resulting in high rates of energy release, are associated with mining at depths of up to 3 500 metres. To assist in controlling these aspects of mine design and safety, a waste backfilling system has been designed and commissioned. The integration of such a system into an existing, producing longwall brings many problems of logistics, organization, planning and control. It is the purpose of this paper to examine these aspects of fill management, and to describe some of the practical problems involved with the integration of this project into the mining environment. Although many of the rock mechanics and soil mechanics aspects of backfilling systems are common there are specific problems involved which apply to longwall systems. Very strict guidelines are required for planning personnel to design their backfilling systems for a particular situation. These aspects are examined, and basic models developed which can be used without the necessity of comprehensive input from rock mechanics. A summary of the financial implications is included, and these are examined with regard to possible future applications and expansion of waste filling.

Jan 1, 1988

1. Book review The geology of some northern Nigerian anorogenic ring complexes, by J.N. Bennet, D.C. Turner, E.C. Ike, and P. Bowden. The British Geological Survey: Overseas Geology and Mineral Resources, no. 61. London, HMSO, 1984. 66 pp. Reviewer: R.H. Ingram 2. Mintek reports Report M226 The separation of tungsten and molybdenum by the formation of sulphide complexes and extraction into a weak-base resin. Report M228 The solvent extraction of zinc, iron, and indium from chloride solutions by neutral organophosphorus compounds. Report M230 Shear flocculation of fines for improved flotation. Report M239 A mineralogical study of residue from the column leaching of a low-grade nickel-copper sulphide ore.3. Recent publication Driger Review, special edition, act. 1985. 48 pp. (Copies obtainable from Roly Nyman, HAMPO PMIE Division, P.O. Box 170, Joham1esburg 2000.) Black Mountain's achievement The 13 689 t consignment of metal concentrate that was loaded aboard the bulk carrier 'George' and shipped out of Saldanha Bay early in December brought the number of tons exported from Black Mountain via the Sishen-Saldanha railway and harbour system to one million.

Jan 1, 1986

By R. J. Forzatti

The production of sulphuric acid from sulphur generates heat. The majority of this heat is recovered as steam and is often used to generate electricity. Heat not recovered as steam is rejected to cooling water systems. The design of the turbine, condenser, and cooling water systems impacts the overall water, energy, and environmental footprint of the plant. This review considers a conceptual 2000 t/d sulphuric acid plant with several alternative cooling water systems. The review utilizes Hatch?s 4 Quadrant sustainable design tool to compare the alternatives on both an economic and a weighted sustainability scale.

Jan 1, 2014

By E. Pothas, P. R. Jochens, L. B. McRae, D. D. Howat

SYNOPSIS The phase equilibria, viscosities and sulphur capacities of titaniferous slags were determined in the composition range of CaO = 30 to 0 per cent, MgO = 0 to 30 per cent, SiO2 = 19.69 per cent, AI.O. = 13.12 per cent and TiO2 = 37.19 per cent. The phase equilibria were determined by high temperature microscopy, the viscosities were measured using a rotating outer cylinder viscometer and the sulphur capacities were evaluated from the results obtained by equilibrating the slag in a gas stream of CO, CO2 and SO2. The behaviour of these titaniferous slags under reducing conditions was examined. Possible use of the slags for aggregate, or slag-cement, and the possibility of extracting the TiO2 are discussed. CONTENTS INTRODUCTION PHASE EQUILIBRIA VISCOSITIES DISCUSSION OF THE PHASE EQUILlBRIA AND THE VISCOSITY VALUES EFFECT OF REDUCING CONDITIONS SULPHUR CAPACITY DISCUSSION OF THE SULPHUR CAPACITY VALUES POSSIBLE USES CONCLUSIONS ACKNOWLEDGEMENTS REFERENCES INTRODUCTION The latest phase in the exploitation of the mineral wealth of the Bushveld Igneous Complex is the erection of a plant by the Highveld Steel and Vanadium Corporation Limited near Witbank to produce steel and vanadium-rich slag from the titaniferous magnetites occurring in this rock formation. These titaniferous magnetites occur as segregations in the gabbro body and the TiO2 is mainly present within the structure of other constituent minerals but also occurs in smaller amounts as ilmenite and ulvospinel. The vanadium is thought to be present in the iron oxide phase due to isomorphous replacement of the iron. Until very recently, it was feared that the high titania content of these titaniferous magnetites would militate against their value as useful iron ores. However, the design of an integrated plant to produce both steel and vanadium-rich slag, and in which the iron-making process is conducted in submerged arc furnaces instead of in

By M. D. G. Salamon

If a transition from one equilibrium state to another occurs during the course of mining, energy transfer takes place in the rock mass, which is assumed to be an elastic continuum. The energy components are defined as follows: the work done by external and body forces, W; the increase in stored energy in the mass, Uc; the strain energy in the rock mined during the transition, Urn; the work done on mine support or backfill, Ws; and the released energy, Wr. The energy balance is defined as (W + Urn) - (Uc + Ws) = Wr> 0, where the first set of components in parentheses represents the sources of energy, while that of the second corresponds to the known modes of energy expenditure and the component on the right is the unaccounted-for energy surplus, which must be released and dissipated in some form. The inequality Wr ~ Urn> 0 applies. Expressions for the energy components are derived first for the general case and then for the 'slit' modal used to simulate tabular excavations. Through specific examples, the importance of the progressive nature of mining is emphasized. The size of the steps used to enlarge the excavations appears to play a significant role in the mode of energy transfer. This observation forms the basis of the second paper in this series of two papers.

Jan 1, 1984

By R. E. Gundersen

Hydro-power-the use of high-pressure water as an energy source-offers tremendous benefits for environmental control in deep, hot mines. The extent of these benefits depends on the mining method, the selection of equipment to be hydro-powered, and the efficiency with which the coolth is extracted from the water and into the working environment. The engineering of hydro-power systems continues to receive much attention. However, this paper considers the environmental implications of using hydro-powered equipment, particularly with regard to positional efficiency. The integration of hydro-power with developments such as backfill, mechanization, and higher face-advance rates is discussed. Layouts are proposed that attempt to minimize the quantity of water in circulation by extracting the maximum coolth from the water.

Jan 1, 1990

By R. L. Castro

Block caving methods, when operated under favourable rock mass conditions, can achieve higher production rates and lower operating costs than other various existing underground mining applications. For this reason, it has been considered the preferred method for the mining of deep and large orebodies in current and future operations around the world. One of the key aspects in the design of block caves is the selection of the production level layout, which, among other parameters, is based on the gravity flow characteristics of the caved rock. This is because gravity flow has a large impact on total ore recovery and the amount of dilution in a caving operation. Today, there are a number of computer based methods which aim to emulate the gravity flow pattern of the caved rock. In this paper, the authors present the development of FlowSiman improved model of gravity flow based on the cellular automaton approach, to estimate dilution entry, mixing and ore recovery. As part of the model development, flow simulations were conducted and subsequently compared to full-scale data collected at two mine sectors operated by Codelco Chile. The results indicate that by using proper calibrated parameters, good correlations between simulated and measured grades as well as dilution entry are obtained. The potential use of the numerical tool to evaluate drawpoint spacing in terms of recovery and dilution for block/panel caving operations is also presented.

Jan 1, 2009

Paper written on project work carried out in partial fulfilment of M.Sc. (Chemical Engineering)degree Identification of non-linear systems can be a daunting task and in the process industries the problem is complicated considerably by the presence of noise from various sources, non-stationarity of the data and intermittence, such as observed in particulate flows. Traditional methods, such as frequency analysis and linear model-ling do not handle these systems well. Similar problems arise with the application of non-linear theory developed over the last few decades, where much of the analysis depends on embedding of the data in a phase space or pseudophase space, since these methods were not originally designed to deal with noisy systems. In contrast, singular spectrum analysis is a method which can be used to identify structure and distinguish noise from important information in multivariate data, such as the trajectory matrices of time series measurements. It provides an orthogonal basis onto which the data can be transformed, so that components of the time series can be investigated individually. With Monte Carlo methods, the components can be compared with those from linear surrogate data in order to identify possibly non-linearities in the data. In this paper, this versatile technique is briefly explained and illustrated by means of case studies.

Jan 1, 2003

By Li-ming Qi

During mining, the stress in the coal face varies, and, at the same time, the gas flows from the coal body into the excavation, which will cause the gas pressure to change continuously. Assuming the coal gas content of the coal to be constant, and applying the law of energy conservation, the influence of stress concentration on the gas pressure was analysed. It was found that the stress is proportional to the gas pressure. Finally, as a result of analysis and the law of gas flow, the gas pressure dynamic distribution ahead of tunnelling was modelled, and the mechanism by which blasting induces outburst was explained by making use of the model. Keywords: gas pressure, stress concentration, excavation, tunnel.

Jan 1, 2007

By A. Fouchee, N. Naudé, K. Schommarz

"This article presents laboratory test work conducted on an African haematite ore to determine the influence of the flotation pulp pH on the final iron grade and recovery. Results show that a combination of an isodecyl ether propylene amine/amino acetate and 1,3-propanediamine, N-(3-(C10-C16-alkyloxy)propyl)-derivatives collector is suitable for separating haematite from quartz. Higher iron grades were obtained at pH levels between neutral and pH 9. This underlines the importance of the surface charge effect of the ore on its flotation characteristics. The results serve as good baseline conditions for further optimization. IntroductionBeneficiation of iron ore by flotation is widely used in Brazil, India and China. In Africa, however, this practice is not yet commercially developed.The aim of this test work is to serve as a starting point by establishing suitable pH conditions for the development of a practically implementable reagent suite, which will then be included in a larger beneficiation circuit for producing high-grade iron ore sinter feed.In the literature, African iron ore types are graded as low-grade (60.0–62.9% Fe; 8.6– 12.5% SiO2 and insolubles), high-grade (66.0– 69.9% Fe; 0.8–4.5% SiO2 and insolubles), and meduim-grade as the remaining portion (Astrup et al., 1998). The low-grade ore used in this work contains less than 60% Fe.For Brazilian ores consisting of a combination of haematite and quartz, it is common to use corn starch as a depressant and ether amine blends as collectors with additional frothing characteristic (Araujo et al., 2005). Work by Turrer and Peres (2010) shows the possibility of using other depressants successfully as well.The main mechanism of the reverse flotation of quartz from iron ore is based on the electrostatic theory of flotation. This is due to the strong pH dependence of the zeta potential of the mineral edge planes on silicate particles (Fuerstenau and Pradip. 2005)."

Jan 1, 2016

By F. van Heerden

The paper sketches the. management of the various phases in a cost-reimbursable, plus-fee contract. which is claimed to be the most flexible of all contracts. In this type of contract, the contractor is reimbursed for all the direct costs Incurred, plus a percentage fee to cover his profit (or overheads and profit). The client usually reserves the right to approve all drawings, equipment purchases. contract awards, technical specifications. project cheques and change orders.

Jan 1, 1982

By R. A. Harris

In this study Pt-Al thin films were prepared via electron beam physical vapour deposition (EB-PVD) with an atomic concentration ratio of Pt25:Al75. These films were heat treated at temperatures ranging from 150°C to 650°C for annealing times from 4 to 60 minutes. The resulting microstructure of these thin films were obtained via secondary electron imaging used in conjunction with depth profiling with the aid of scanning auger microscopy (PHI 700).Elemental maps of the micrographs were obtained. Simulations, based on a chemical potential Monte Carlo method1, were run for various interaction parameters. From these simulations theoretical depth-profiles and proposed microstructures were obtained. These were compared to the experimentally measured depth profiles and elemental maps. Keywords Monte Carlo, chemical potential, depth profile, Pt-Al thin films.

Jan 1, 2011

The November General Meeting of the Institute was held in Kelvin House, Johannesburg, on Wednesday, 18th November, 1970, at 4.00 p.m. V. C. Robinson (President) was in the Chair. There were also present 30 Fellows, including J. K. E. Douglas, R. C. J. Goode, Dr J. P. Hugo, Prof J. de V. Lambrechts, D. G. Maxwell, Prof R. P. Plewman, Dr M. D. G. Salamon, P. W. J. van Rensburg, L. W. P. van den Bosch (Council Members), R. E. Burnton, S. Craib, D. de Villiers Oxford, J. C. Fritz, G. W. Gray, G. H. Henderson, S. D. Hill, C. H. Kruger, B. Leach, C. S. MacPhail, D. J. Molony, W. G. Fyne Mercier, R. A. Scott, M. v. R. Steyn, I. E. van Aswegan, A. D. Vos, J. M. Vosloo and N. Zolezzi. Four Members, including I. G. Evans, R. W. Shearer, W. Wilson. One Associate: P. M. C. Wilson. Four Students: H. G. Albertyn, J. T. Davies, P. G. Henderson and P. J. Pretorius. Fourteen Visitors, including S. R. Barker, F. H. Deist, Dr de Jager, L. F. Duvel, P. du P. Kruger, B. D. Maree, B. R. Meyer, R. Redmond, J. Rietief, A. W. S. Schumann, Mrs A. W. S. Schumann, T. S. Stoffberg, C. A. Visser and R. van der Wait. Secretary, D. C. Visser. Total present 55. The President: "Gentlemen, I would like to welcome all members of the Institute who are present, and visitors, and I would like specially to welcome any members of the Suid-Afrikaanse Akademie who are present this afternoon." OBITUARIES The President: "Before starting on the agenda the first item, of course, is unfortunately obituaries and it is my sad duty to announce the death of the following: I would like to start with a person who is not actually a member of the Institute but who, in his capacity as President of the Chamber of Mines, was Honorary President of this Institute three times and I refer, of course, to Mr Herman Calderwood Koch who passed away last Saturday. Then I would refer to Richard Beaumont Tasker, Life Fellow, who joined this Institute in 1932, and who died on the 22nd of October, 1970. Then, lastly, Mr Jean Francois du Plessis, a student, who joined the Institute on the 19th June, 1968, and passed away on the 11th of November, 1970, as the result of an accident. Mr du Plessis was to have received a Student Prize today for his paper entitled, Displacements and stresses in the vicinity of a horizontal long-wall'. We were all most upset to learn of his death last week, and we are now going to make arrangements to hand his prize to his widow on a suitable special occasion. As a mark of respect to the memory of the deceased, and in sympathy with the bereaved, I would ask you all to stand and observe a few moments' silence. Thank you." CONFIRMATION OF MINUTES The President: "May we confirm the minutes of the monthly general meeting which was held on 16th September, 1970, as published in the November Journal?" Agreed. MEMBERSHIP The President: "I have much pleasure in announcing that the names of the undermentioned candidates having been published in accordance with By-Law 5.2.2, Council has elected them to membership of the Institute in the following grades: Fellow: Ronald White Ballantine. Members: Jan Johannes Hertzog Viljoen, Agge Petrus Rutgerus van der Meer, Peter Anthony Reynolds, Ernest Esdaile Leyde Hans Lutz Klingmann, Ronald Archer.' Graduates: Trevor Stanley Schultz, Thomas Cochrane Meiklejohn, Leslie Harold Heyman, Dennis William Bosch, Sydney Stuart Absolom. Associates:Roderick James.Vermaak, Theodorus Daniel van Wyk, Michael Osmond Savignac Stedman, Leslie Owen Raymer, Bryan Arthur McKay, Leon Ellis Finlay Leask, Dudley Graham Lovedren Hall, John Arthur Gibbon, Richard Reginald de Villiers, Carel Frederik Boshoff. Students: Frederik Wilhelm Christian Coetzer, Phillippus Johannes de Wit, Jan van der Merwe Grimes, Davood Khareghani, Jan Wolvaardt Oberholzer, Johannes Lodewikus Pretorius Pieter Jacobus Strobos, Herbert Gerald Waldeck.' MEMBERS TRANSFERRED TO A HIGHER GRADE From Associate to Fellow: Howard Mitchell Wells. From Associate to Member: Ernest John Dominy. "I welcome the newly elected members to the Institute and congratulate the members who have been transferred to a higher grade." AWARDS The President: "It is with very great pleasure that I can announce that Council has agreed to make the following awards for papers presented to the Institute during the year ended July, 1970. Gold Medals to Prof Plewman and W. D. Ortlepp for their paper entitled 'The development and application of a digital computer method for the solution of strata control problems' written jointly with F. H. Deist (Visitor) and presented in September, 1969. A Silver Medal to Dr Finkelstein for his paper entitled 'The Influence of sulphydryl and cationic flotation reagents on cyanidation of native gold' written jointly with Dr K. G. Ashurst (Visitor), and presented in June 1969 at the Symposium on the Recovery of Pyrite. ' May I congratulate these gentlemen on the high honour they have won with their papers. As new medals are in the process of being designed the actual awards will be made at a later date to be announced to members.

By D. Janicijevic

This paper describes the process of scraper winch pull force measurement and shows the results of the actual winch pull force in extreme stall situations as well as during the face and gulley cleaning. It was found that by slowing down the motor and causing it to slip, torque up to 3.5 times higher than the nominal can be developed, resulting in the same increase of winch pull force. On the other hand, measurements of the actual force needed for cleaning of the face and the gully have shown that the currently used winches are too powerful. The extra torque that can be developed by the already too powerful winch motor poses a significant danger and necessitates the implementation of measures that will eliminate this risk.

Jan 1, 2008

By M. Keevy, K. Hackney

Centrifugal slurry pump station and deposition sites are a common feature of many mines and mineral processing plants. Yanacocha Mine has completed the design of a pump station consisting of two trains of four pumps each. A number of trade-off studies was conducted to optimize the pump station design. The most significant of these was determining the drive types for the slurry pumps. The pump station duty can vary considerably due to the number of deposition points round the disposal site. The standard solution to this problem on a multi-stage pump train is to install one pump with a variable speed drive to control the pump station output by varying the speed of this pump and stopping and starting other stages. However, there are a number of negative impacts associated with this approach. These include head losses through pumps that are stationary or ?wind-milling?, different wear life on pumps that are running and pumps that are stationary, and slower response to the control system with the possibility of hunting. The use of variable speed drives on all the pumps was considered as an alternative to the standard solution. The factors considered in comparing these options were the control and operational differences, the pump efficiencies and absorbed power, the expected pump wear life, the impact on pump maintenance and the cost of the drive options. For this project the option of using all variable speed drives was selected. The paper presents the following aspects of the study: ?Description of the various options investigated. This includes a discussion on the required duty and the drive options. ?Technical comparison between the options. ?Description of the factors influencing pump performance and life.

Jan 1, 2007

By D. D. Munro

Finsch Mine is a kimberlite diamond mine located at Lime Acres in the Northern Cape Province of South Africa. The mine was founded in 1961 and started surface mining in 1964. Underground production commenced in 1990 using a modified blast-hole open stoping method for the mining of Blocks 1, 2 and 3. Block 4 is currently being mined as a block cave. The process of identifying and optimizing a method to mine the Block 5 orebody started in 1991, and in 2006 incline caving was identified as being technically feasible. This paper aims to document the process employed in developing this method by the Block 5 prefeasibility team as well as discuss the technical challenges encountered during this process. The paper commences with a history of Finsch Mine and highlights the complex geology and threat of sidewall failure that prompted the decision to use block caving as the mining method for Block 4. A literature study of mines that implemented mining methods upon which the incline cave was conceptualized is then presented. These practices were then used to form the basis for the designs on which the initial geotechnical modelling was done and built upon through an iterative process of modelling and design changes. The ventilation of the mining area, initial productivity simulation results, and the applicability of automation and comminution processes in the incline cave are also presented. The paper concludes with an investigation into some of the challenges of the mining method, and shows that that incline caving is a technical option available for further investigation in determining the optimal mining method to be employed at Block 5, Finsch Diamond Mine. Keywords massive mining, incline caving, geotechnical modelling.

Jul 1, 2013

By Marek Dworzanowski

Dense medium separation (DMS) is critical to the operation of coal and diamond beneficiation plants. It is also utilised in iron ore, manganese, chromite and andalusite beneficiation as well as pre-concentration for platinum-bearing UG2 ore. Gravity concentration plays an important role in the processing of diamonds, coal, gold, platinum, titanium minerals, zircon, chromite, iron ore and manganese. The DMS and Gravity Concentration operations and technology in South Africa conference will focus on the operation of DMS and Gravity Concentration circuits in the South African Mining Industry. The current status of the technologies and equipment employed will be presented as well as future developments. The conference was set up to showcase South African DMS and Gravity Concentration operations and provide a forum where operators, technology and equipment suppliers can engage in knowledge sharing. The papers cover a wide spectrum of topics, including descriptions of operations, optimisation projects, new capital projects, equipment applications, process monitoring and process selection. Most commodities and unit processes associated with DMS and Gravity Concentration are covered. The conference venue was selected to be the CSIR Convention Centre in Pretoria. The CSIR has contributed to DMS research in South Africa and it is located not far from many coal, diamond, gold, platinum and chrome mines that extensively utilise DMS and Gravity Concentration in their beneficiation plants. I believe that the papers and presentations submitted for this conference will provide a valuable future reference for DMS and Gravity Concentration, thus making the work of all the contributors to this conference highly rewarding and worthwhile.

Jan 1, 2006

By K. Goshtasbi

In this paper a genetic algorithm is used in a heavily jointed rock mass in order to investigate the critical circular slip surface and modification of slope surface. This method was applied to the southern wall of the 6th Golbini Jajarm bauxite mine. The mine is the largest bauxite deposit in Iran, located to the northeast of the town of Jajarm in the Khorasan province. Estimated reserve of bauxite in this deposit is about 160 million tonnes. Field and laboratory investigations were conducted in order to determine rock mass behaviour. A genetic algorithm code that uses the Simplified Bishop method as an objective function was developed for findingt he safety factor of circular slip surfaces. Sensitivity analysis was applied to determine the optimum values of the genetic algorithm variables, such as population size, selection method, crossover and mutation rates. After finding the critical circular slip surface, slope modification is carried out by removing unstable sections from marked critical slip surfaces, and this process is repeated until the last unsafe section is removed. Based on this code, modification occurred during 7 steps, by reaching a safety factor of 1.3 in the last step. Finally, the modified slope angle of the southern wall of the 6th Golbini Jajarm bauxite mine was determined to be 48.44 degrees. Keywords: Genetic algorithm, slope modification, circular slips surface, 6th Golbini Jajarm bauxite mine .

Jan 1, 2008