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By J. T. Jordaan

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree This paper addresses the critical parameters that need to be considered when designing a mechanized bord-and-pillar mining layout for a narrow tabular steep dipping orebody. These parameters are : ?Reef dip ?Reef width ?Geological structures within the orebody ?Physical dimensions of the selection of machines ?Gradeability of the selection of machines. The main objective in designing such a layout is to maximize machine efficiencies whilst minimizing dilution. This methodology was then applied in the design of a mechanized bord-and-pillar mining layout for a given piece of ground (Vlakpoort and Moddergat) using a given selection of machines. This piece of ground contains the PGM bearing UG2 Reef with an average thickness of 124 cm and dipping at 18°withadverse strike and dip changes. Two bord-and-pillar layouts were designed for this area. Layout 1 is characterized by the use of strike conveyors to convey ore on strike with an average LHD hauling distance of 35 m. Layout2 uses LHDs for all on strike conveyance of ore with an average hauling distance of 75 m. These two layouts were then technically and financially compared. It was concluded that layout 1 is theoretically superior but layout 2 was chosen due to its greater flexibility and probability of operational success. Layout 2 was also compared to conventional mining and it was concluded to be more economically feasible. However the latter is a proven mining method in these conditions and has a lower risk operational failure. Bord-and-pillar mining has some favourable promises such as improving labour difficulties, lowering operating costs and providing safer working conditions. The success of mechanized bord-and-pillar mining in narrow tabular steep dipping orebodies will depend on the extent of the research and development efforts which need to create and innovate technologies to overcome some of the current limitations stated in the above-mentioned parameters.

Jan 1, 2003

By M. du Toit

Cromanite?is a new high-strength austenitic stainless steel developed by Columbus Stainless. It contains approximately 19 percent chromium, 10 per cent manganese and 0,5 per cent nitrogen. Cromanite can be welded successfully, but due to the high nitrogen content of the base metal, certain precautions have to be taken to ensure sound welds with the desired combination of properties. Although no matching filler metals are currently available, Cromanite can be welded using a range of commercially available stainless steel welding consumables. Welds produced using E309L, E307, E307Si and E312 filler wires are resistant to hot cracking and the formation of nitrogen-induced porosity, but the hardness, strength, ductility and toughness of the welds are generally inferior to those of the base metal. In applications where full use is made of Cromanite?s high strength, welds with matching strength levels would be required. In wear applications, where Cromanite is used primarily for its work-hardening properties and corrosion resistance, lower strength welds would probably be acceptable. Welds produced using E307 filler metal demonstrate the best combination of properties for use in wear applications. The welds display high rates of work-hardening that would result in increases in hardness and strength when subjected to abrasive or high impact environments.

Jan 1, 1999

By P. Roy

Smelting or converting of sulphide concentrates and mattes in a batch operation presents a challenge when directing the off- gas to a conventional acid plant. The Hindustan Zinc Ltd. (a division of the Vedanta Group of companies) Chanderia Lead Zinc smelter was presented with such a challenge that was met with the adoption of the Cansolv® SO2 Scrubbing System. The Ausmelt top submerged lance technology used at Hindustan Zinc generates a furnace gas stream that contains between 0.1 vol% and 12 vol% SO2 during the three stages of batch smelting. Cansolv® SO2 Scrubbing Technology captures the SO2 to ensure that treated flue gas exits the facility at a concentration below 100 ppmv SO2 and it releases SO2 in a controlled fashion, to more closely match the needs of the existing acid plant. The application of a regenerable scrubbing system to capture SO2 from a batch-operated furnace and convert it to acid in a conventional acid plant was a first of its kind in the world. This paper provides an update on the design and operation of the Hindustan Zinc SO2 recovery system and suggests two improvements to the basic flow sheet that optimize the cost of SO2 scrubbing further.

Jan 1, 2007

By P. Roy

Smelting or converting of sulphide concentrates and mattes in a batch operation presents a challenge when directing the off- gas to a conventional acid plant. The Hindustan Zinc Ltd. (a division of the Vedanta Group of companies) Chanderia Lead Zinc smelter was presented with such a challenge that was met with the adoption of the Cansolv® SO2 Scrubbing System. The Ausmelt top submerged lance technology used at Hindustan Zinc generates a furnace gas stream that containsbetween 0.1 vol% and 12 vol% SO2 during the three stages of batch smelting. Cansolv® SO2 Scrubbing Technology captures the SO2 to ensure that treated flue gas exits the facility at a concentration below 100 ppmv SO2 and it releases SO2 in a controlled fashion, to more closely match the needs of the existing acid plant. The application of a regenerable scrubbing system to capture SO2 from a batch-operated furnace and convert it to acid in a conventional acid plant was a first of its kind in the world. This paper provides an update on the design and operation of the Hindustan Zinc SO2 recovery system and suggests two improvements to the basic flow sheet that optimize the cost of SO2 scrubbing further.

Jan 1, 2007

By G. Tranell, L. Kolbeinsen, S. Gaal, J. Safarian

The effect of carbon material properties on the rate of MnO reduction from ferromanganese slag by solid graphite was investigated. A sessile drop technique was used to study the reduction rate of a synthetic slag containing 45 wt% MnO at 1500 and 1600 ºC. Different types of graphite substrates were used and the con-tact angle between slag droplets and substrate were measured in-situ. Moreover, the slag droplet volume during the interaction with the graphite substrates was calculated and normalised. The mathematical relationship between the slag density during the reduction and the normalised slag droplet volumes during the reduction were derived and the MnO reduction curves were then calculated. A method for measuring the slag reactivity of solid carbon was defined and used to qualify the propensity of the different graphites to react with the liquid slag. Some supplementary studies such as manganese evaporation measurement and EPMA analysis for determining the extent of MnO reduction were also carried out. It was observed that there is nota significant difference in the wetting angle of the graphite substrates by the slag, and the wetting is not changed within the temperature range of 1500-1600ºC. However, the changes in the contact angle during the slag reduction at 1600ºC are more than at 1500ºC. The kinetics of MnO reduction is dependent on the type of graphite and it is more dependent on the graphite properties at lower temperatures. On the other hand, the dominant properties of graphite on the reduction rate vary with temperature. A multivariate analysis on the graphite properties and the parameters related to the slag reactivity indicated that the kinetics of MnO reduction is mainly dependent on the temperature, and then on the graphite properties. It was also found that at1500 ºC the surface area and the CO2 reactivity are the most important graphite properties for the slag reduction, suggesting that the reactivity of carbon is rate controlling at 1500 ºC. However, the porosity related parameters are the most important graphite properties at 1600 ºC, suggesting that CO gas desorption is rate controlling at high temperatures.

Jan 1, 2007

By A. Schippers, S. Hedrich

Chalcopyrite represents the most important copper resource and is currently mainly exploited using pyrometallurgy. Bioleaching is an environmental-friendly and economic alternative to conventional mineral processing technologies. The technical feasibility of stirred tank reactor bioleaching of copper ore concentrates using acidophilic iron-/sulfur-oxidising bacteria is proven, however, often incomplete due to inefficient chalcopyrite dissolution. A decoupling of bacterial growth from bioleaching activity in one bioreactor by adjusting appropriate temperatures for both process steps allows for almost complete chalcopyrite dissolution. Separation of copper and recovery of other metals from the PLS was possible by implementation of different biological and chemical techniques. The Ferredox process has been proposed to treat limonitic laterite ores for cobalt and nickel recovery by means of anaerobic reductive dissolution with autotrophic, acidophilic bacteria. As a modification, aerobic reductive dissolution of laterites with acidophilic bacteria has shown economic and environmental advantages over anaerobic reductive dissolution. The reductive bioleaching technology has the potential to increase metal recovery in existing mines, and transform unexploited ores and limonite stockpiles into valuable resources. Keywords: Biomining, bioleaching, chalcopyrite, laterite, Ferredox process

Jan 1, 2020

By G. R. Lane

A large opencast gold mining company in Africa had just completed a feasibility study for an expansion of the operations. A traditional net present value project valuation methodology had been used that showed a very positive net present value (NPV). The project team had conducted a qualitative risk assessment that identified and logged all potential project risks and had subjectively incorporated 'risk' via the discount rate and other assumption contingencies around gold price expectations, operating parameters, etc. Management requested that an independent quantitative risk modelling approach be adopted to obtain a better understanding of the impact of risk on the overall project valuation and confidence level in the final valuation. A detailed project valuation model was configured in the Cyest Carbon Modelling Technology platform, and the stochastic modelling module used to perform the Monte Carlo simulations. Analysis of historical operational performance data relating to actual achievements versus planned and budget determined the historical variability of the underlying parameters as well as variance to budget. This was done at a detailed level for mining rates and costs, processing rate, costs and recovery, and other operational efficiency measures. External market assumptions relating to gold price, exchange rate, and inflation were modelled and the dependency between them modelled using a copula. This case study will demonstrate the approach taken to building and populating the quantitative risk model and the overall results of the Monte Carlo simulation. The final valuation demonstrated that the project had a 44 percent probability of an NPV less than zero i.e. a 44 percent chance of project finance loss.

Jan 1, 2013

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree The stability of a ferrosilicon dense medium suspension is one of the most important parameters to keep under control since it determines the density gradient of the medium in the separation zone and thus directly influences separation sharpness. The stability of ferrosilicon suspensions were characterized using settling tests employing a differential pressure method. Particles smaller than 45 µm and especially the ore fines played an important role in the settling behaviour of the solids. High medium stability is favoured by ore fines, fine medium particles, and high medium densities. Keywords: dense media, ferrosilicon, dense medium stability, ore fines

Jan 1, 2002

By C. Wade, A. Swart, M. Dworzanowski

AngloGold Ashanti operate a pyrite flotation plant at their East Gold Plant, Acid Plant and Flotation Plant (EGAF) metallurgical complex within their Vaal River operations in the North West province in South Africa. The flotation plant feed is reclaimed pyrite rich tailings and the concentrate produced is used as the source of sulphur for the EGAF acid plant. The sulphuric acid produced is in turn used for the recovery of uranium at the Vaal River South uranium plant. The original flotation plant built in 1960 was based on the use of many small volume flotation cells and was becoming very expensive to operate and its age severely limited further operation. A decision was taken in 2005 to replace this plant with a new one based on fewer, larger volume flotation cells. This paper describes the benefits of using larger volume flotation cells in this new flotation plant when compared to the smaller volume flotation cells in the old plant. The benefits of the new plant include a smaller plant footprint, fewer flotation cells, fewer pumps, no distribution boxes, simpler piping, a greater flotation volume and a reduction in installed power. The saving in capital cost could not be quantified because of the age of the old plant. The savings in operating cost will arise from fewer operators, less maintenance and reduced power consumption. The new plant has not been in operation long enough to quantify the benefits in operating cost and metallurgical performance. However, recovery improvements can be expected given the greater flotation volume (increased residence time) and the installation of larger, more efficient flotation cells.

Jan 1, 2007

Stope support systems, typically consisting of props and packs, are used extensively in the gold and platinum mining industry to stabilize the rock mass in the excavation vicinity and to reduce the hazard associated with rockfalls and rockbursts. The design of stope support systems was historically based predominantly on past experience and practices, and cost considerations. The recent development of a new and improved support design methodology, has led to the potential for significant increases in worker safety and support cost savings. This paper reviews some of the fundamental rock mass and support criteria that form the basis of the improved support design methodology. The considered design criteria are the height of potential fall; quasi-static stope closure rates; dynamic stope closure rates; compressive hangingwall stresses; discontinuity spacing, orientation and interface properties; effect of support length (stoping width); effect of compression rate; consistency of support performance; a real coverage; support spacing; and zone of support influence. The proposed support design methodology combines both the zone of influence and key block stability theories, resulting in optimized support systems for rockfall and rockburst conditions. The site-specific methodology consists of two stages: (i) a tributary area analysis, and (ii) a zone of support influence and a stability analysis, considering hangingwall failure due to buckling, shear and block rotation, which gives maximum safe spacing of individual support units. The methodology is suitable for designing support systems for both blocky hangingwalls and hangingwalls fragmented by face-parallel extension and shear fractures.

Jan 1, 2001

"Exploitation of an ore deposit can be optimized by adapting the beneficiation processes to the properties of individual ore blocks. This can involve switching in and out certain treatment steps, or setting their controlling parameters. Optimizing this set of decisions requires the full conditional distribution of all relevant physical parameters and chemical attributes of the feed, including concentration of value elements and abundance of penalty elements. As a first step towards adaptive processing, the mapping of adaptive decisions is explored based on the composition, in value and penalty elements, of the selective mining units.Conditional distributions at block support are derived from cokriging and geostatistical simulation of log-ratios. A one-to-one log-ratio transformation is applied to the data, followed by modelling via classical multivariate geostatistical tools, and subsequent back-transforming of predictions and simulations. Back-transformed point-support simulations can then be averaged to obtain block averages that are fed into the process chain model.The approach is illustrated with a ‘toy’ example where a fourcomponent system (a value element, two penalty elements, and some liberable material) is beneficiated through a chain of technical processes. The results show that a gain function based on full distributions outperforms the more traditional approach of using unbiased estimates."

Jan 1, 2015

By L. Andrews

Nickel is recovered as a by-product of the platinum-producing process operated by Anglo Platinum. The metal is mined mainly as sulphide minerals contained in platinum ores. These pass through the concentrating, smelting and converting process route and nickel is finally recovered by electrowinning. Smelting of the concentrated ore in the electric furnace produces a melt with a high slag to matte ratio. The resulting furnace slag is granulated and later milled and floated to recover matte. A project was initiated to investigate the distribution of nickel in the slag in order to improve recovery. Slag samples were examined using a combination of chemical and mineralogical techniques. The granulated slag was found to consist mainly of a silicate glass phase, which reflects the composition of the molten slag in the furnace. Nickel occurs as free matte granules, as matte phases locked inside the glass, and in the glass phase itself. Whereas nickel in the matte is as sulphide, most of the nickel in the glass phase appears to be oxide- bound(i.e. in solid solution). Milled slag as flotation feed showed recovery-limiting features such as free matte with oxidized surfaces and unliberated matte inclusions in the slag. The biggest nickel losses, assuming no tapping problems, are in the glass phase solid solution. Only around 40% of nickel would be recovered from the slag, even under ideal conditions. Spoon and pot slag samples were also examined to see if casting and crushing would improve recovery. Although larger and therefore more easily recovered matte phases formed, nickel partitioned into crystalline silicate phases, limiting the maximum theoretical nickel recovery to 70%.

Jan 1, 2004

By M. H. Solomon

After the global financial crisis of 2008, African mining is entering anew phase of development. The rapid withdrawal of emerging market funding from the critical exploration and development industries provided a hiatus in funding, a gap which was quickly filled by Chinese and other Asian investors. While the continent is still economically dependent on its extractive industries, the prevalence of Dutch Disease has undermined Africa?s ability to benefit fully from its mining, oil, and gas industries. While the extractive industries are closely related to many of the more fragile and failed states in Africa, it is equally true that the strongest states in Africa have mining-based economies. This paper explores the possible linkages between mining, strong and weak political economies, and poverty in Africa. It draws the conclusion that neither Dutch Disease nor Resource Course is a given in resource-endowed countries, and that it can be avoided if the mining economies in these countries are actively integrated into their respective broader economies and used to foster economic diversification. The author asserts that given the capacity constraints of many African governments, it is contingent on mining companies to become integrally involved in catalysing diversification around their infrastructure and supply chains.

Jan 1, 2011

By H. Yilmaz

A testing method for assessing the shear-bond strength of thin spray-on liner (TSL) on rock substrate was developed at Wits University Rock Mechanics Laboratories. The gap between a 20 mm thick steel ring and a rock core is filled with TSL along the depth of the ring. After the curing of the TSL for a predetermined period, the sample is placed on a base, which offers support to the steel ring and the TSL but not to the rock core. A compressive load is applied on the rock core displacing the core on TSL contact and punching it towards the void in the support base. Shear-bond strengths for different TSL products as well as shotcrete were measured. This paper describes the test set-up and points out the important aspects and procedures during sample preparation and test execution. The test results are also presented and discussed.

Jan 1, 2007

By B. J. Kloppers, J. V. Z. Visser, C. J. Horn

"The long-term plan (LTP) in a mineral resource company is defined by the quality of the mineral resource and represents the result of a series of trade-offs to fulfil internal organizational as well as external business and legislative requirements, ensuring ultimate delivery on the defined organizational strategy.The LTP should as a whole align to a coherent and well-defined organizational strategy, working towards a clearly defined objective while still allowing a tactical response to short-term requirements of the organization. The ability to respond tactically to changes in environment, like the unprecedented five-month strike in 2014 on the platinum belt following the 2012 Marikana incident, is a measure of the flexibility of the plan given the agreed strategy.This paper describes the Lonmin process of linking company strategy with long-term planning, tactical planning, and the execution of the plan through an annual planning cycle to maximize organizational flexibility. This flexibility enables mining companies to respond to the many internal and external forces that impact on both strategy formulation and delivery of results that meet shareholder expectations."

Jan 1, 2015

By G. M. J. van Heerden

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree The Union Section of Anglo Platinum is situated ±18 km west of the town of Northam on the north-western rim of the Bushveld Igneous Complex. Both the Merensky and UG2 reefs are mined. Support of the Merensky stoping areas with rock bolts is specifically problematic due to the stoping width restrictions varying around 90 cm. The installation equipment of in-stope rock bolts and the effectiveness thereof in the Merensky stoping areas was critically evaluated. In order to do this a background research on the need for better on-the-face support had to be conducted. The need for improving the rock bolt drilling and the equipment had to be investigated and the financial implications and justifications for the improved equipment examined. To conduct the search an overall study was done on the rockfalls and safety aspects throughout the platinum industry in South Africa and specifically Union Section. It was found that most of the rock falls in the Merensky stoping areas of which ± 70% are less than 1.2 m in thickness generally occurs within 4 m from the face and causes ± 60% of the in-stope injuries. Serious shortcomings had been identified with respect to the airleg, rock drill machine and the drill steels used in the drilling of the rock bolt holes. Through experimentation, using a testing frame built for this purpose on surface and with the co-operation of mine staff and suppliers, a number of possible modifications were identified and tested. This resulted in the final product with which it was possible to drill a 1.2 m hole in the hangingwall of the stopes ranging with an angle to the hanging from 90° for a 90 cm stoping width and 67° for a 80 cm stoping width. It is confidently concluded that this system will effectively improve the total face support and result in a substantial reduction of rock falls and consequently the occurrence of injuries and fatalities in the Merensky stoping areas. The installation of rock bolts on the face with the modified drilling equipment will increase the direct support, but the system has a potential of a substantial reduction in the profile stick support density and an increase in productivity in the stoping areas due to fewer occurrences of rock falls. It was finally concluded that effective modifications to the drilling equipment for rock bolt in-hole drilling could be made and the installation thereof in the stope face is adequately justified.

Jan 1, 2002

By G. L. Smith

This paper introduces and defines the concept of a linkage between long-term planning parameters (?global assumptions?) and possible future world views as conceived in scenario planning. Scenario planning, the tool that is used to arrive at plausible future worldviews, is described in the context of the platinum industry. The interpretation of the scenarios into long-term planning parameters is made, followed by an illustration of how the long-term planning process has been adapted at Anglo Platinum to include the notion of uncertainty.

Jan 1, 2008

Viscosity measurements were carried out on slags in the CaO-Cu2O-CuO-MgO-SiO2systemcontaining ~ 63 wt% SiO2in air. The experimental work was carried out over a range of temperatures where the slags were completely liquid. Initial measurements were on a binary CaO-SiO2slag to which incremental additions of CuxO-MgO-SiO2slag with the same silica mole fraction were made. The viscosity-temperature relationship was measured for slags with‘Cu2O’contents of 0.02, 0.19, 0.38, 0.79, 1.69, 2.47, 3.01, 5.31 and 10.0 wt%. The proportions of Cu+and Cu2+in the slags were determined. The oxidation state of Cushifted from predominantly Cu+to Cu2+, with the Cu+/Cu2+ratio of approximately 0.3 for slag with a Cu content above 2 wt%. This is equivalent to Cu1.13O. The trends observed for changes of Cu2+/Cu+redox ratio with slag chemistry were consistent with the literature. Decreasing the CaO content by substituting copper oxide resulted in a decrease in the Cu+/Cu2+redox ratio. The change in ratio corresponded to a shift of the value of x in CuxO from an initial value of 1.8 to 1.1,when the slags contained 10% ‘Cu2O’. In this study, the SiO2content of the slags varied between 64 and 60 wt% as the Cu content increased. The viscosity of the slag containing 10 wt% CuxO was nearly 4.5 times lower than the binary CaO-SiO2slag. As the silica mole fraction (xSiO2) actually stayed constant (0.61±0.009),the results show that CuxO acted as a network breaker. Comparison with other ternary slags with similar silica mole fractions suggest that that addition of CuxO to silicate slags has a stronger effect on lowering the viscosity than FeO or MnO has on a molar basis. Keywords: viscosity, copper, silicate, slags

Jan 1, 2004

By W. M. Jansen

In many mineral processing operations, the reported production figures for an accounting period may not make the best use of available data. While most of the mathematical approaches, such as check-in/check-out, mass balancing, used in effective metallurgical accounting strategies are well understood, the sources and magnitude of measurement errors generally are not. As part of the 'AMIRA P754-Metal Accounting and Reconciliation' project, a study was undertaken at the Northparkes copper/gold concentrator near Parkes, New South Wales to examine the data used in their concentrator metallurgical accounting system. This paper summarises the results of a detailed examination of the mass measurement systems around the concentrator as well as the primary sampling system used for grade estimation. The goal of this work was to develop practical techniques to quantify the error (ie both accuracy and precision) of the measured metal accounting information. With this information, statistical confidence levels for this data can then be calculated. If the errors are small, the effect of error in each piece of measured data can then be propagated to other calculated production figures such as recovery and feed grade using a statistical technique called `the propagation of error'.

Jan 1, 2007

By R. C. Urquhart, D. D. Howat, R. I. L. Guthrie

Heat losses from ladles during teeming by R. C. URQUHART, M.Eng. (McGiII), Ph.D. (Visitor). R. I. L. GUTHRIE, B.Sc. (Eng.) (London), A.R.S.M., Ph.D., D.I.C. (Visitor), and D. D. HOWAT, B.Sc. (Glas.), Ph.D. (Fellow) In an investigation of the loss of temperature by liquid steel during a teeming operation, a numerical technique was used to calculate the heat flows and the rate of temperature drop over the entire teeming operation. The calculations show that, before teeming, approximately 50 per cent of the heat loss is into the ladle wall at the level of the metal. As teeming progresses, the amount of heat lost by radiation to the wall above the metalline increases. The effect of variables, such as initial metal temperature, the preheat of the ladle and ladle cover, and delays, on the rate of temperature loss by the metal were determined.

Jan 11, 1973