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By M. B. Shongwe, G. Freemantle, M. Botha, S. Brill, J. D. Steenkamp

During steelmaking, one important factor for production efficiency is the free opening of the ladle nozzle during continuous casting. Free opening occurs when the well filler sand and the steel flow freely when the slide gate is opened. Well filler sands are used for the slide gate of a ladle to separate the slide gate refractory and the molten steel. The well filler sand is partially sintered by the heat of the molten metal, which can result in the ladle nozzle failing to open if the sand is not sintered to an appropriate extent. It is therefore of great importance that the sintering behaviour of well filler sand is understood. We studied the effect of the well filler sand chemistry on its sintering properties. Samples of well filler sand with various chemical compositions were sintered in a high-temperature chamber furnace. Quantitative X-ray diffraction (XRD), inductively coupled plasma optical emission spectrometry (ICPOES), and wavelength dispersive spectrometry (WDS) by electron microprobe analysis (EMPA) were used to analyse the various well filler sand mixes. Points of analysis were indicated on backscattered electron (BSE) micrographs. Quantitative element mapping was undertaken by energy dispersive spectrometry (EDS). Thermodynamic calculations in FactSage predicted the percentage liquid phase present for the various well filler sand compositions at equilibrium conditions. The results of this work show that the degree of sintering of chromite-silica well filler sand depends strongly on the silica content. The amount of liquid phase formed increases with increasing silica content.

Feb 2, 2022

By E. Emami, J. Valencia, J. Sattarvand

The knowledge of the final location of a drillhole is critical in obtaining the expected blasting results. This paper proposes a new methodology to control the drilling accuracy in open-pit mines using aerial images and machine learning. Specifically, it investigates how support vector machines (SVM) and convolutional neural networks (CNN) are useful for automatically detecting blastholes over drone images captured in blasting patterns. Several datasets were obtained from different mines in Nevada (USA) and were used to train and test models. We then processed those images to create orthomosaic and digital elevation representations of the patterns. Thousands of patches were then extracted and augmented to develop SVM and CNN models. The results demonstrate that machine learning is useful for drillhole detection and, in this way, to control the drilling accuracy and use the explosive energy more efficiently.

Sep 1, 2021

By J. R. L. Read, A. N. Ogden

This paper describes mining industry funded research that is being undertaken to address the critical gaps and uncertainties in our knowledge so that we can develop new approaches and create more effective ways for predicting the reliability of rock slopes in large open pit mines. It is envisaged that this research will not only lead to more effective pit slope design but further reduce the potential for unforseen geotechnical risks by enabling the geotechnician to communicate the risks more effectively with management and to optimise site specific control measures. To achieve this, several research tasks are in hand. The first is to accurately represent the structured rock mass with a 3D computer model (Siromodel) that creates polyhedral blocks from structural distribution data characterised by position, orientation and persistence. Siromodel is being coupled with particle flow and other numerical codes to evaluate how the structured rock mass deforms in the stress environment of an open pit and how a candidate failure surface may propagate through the dilating rock mass along the path of the least shear and/or tension resistance. A beta version of the Siromodel software has been distributed to 20 Sponsor mine sites for technical evaluation. The end state is to develop methods of analysis that characterise the reliability of a described candidate surface, and the probability of the candidate surface propagating to failure, recognising that the rock mass strength may well be defined in a different way than before.

Jan 1, 2006

By L. H. Lindstad

The paper reviews the tapping process and the major wear mechanisms on the tap-hole, including wear from tapping tools. Measured temperatures in different tap-holes are related to choice of binder and material for repair pastes. The strength and disadvantage of carbon and silicon carbide materials are compared. Normal daily and weekly maintenance of tapholes is described, together with the major repairs that are done during longer furnace shutdowns. The objective is to show that the type of repair and repair material needs to be adapted to each individual furnace.

Jan 1, 2014

By J. B. Oosthuizen

Mechanical rock breakers are used in block caving operations to reduce the size of ore fragments which are too large to pass through grizzlys at the load-haul-dumper tipping points. Several layouts of grizzly, rock breaker and ore pass are possible. The authors evaluated three different layouts at the Premier Mine Division of De Beers Consolidated Mines. The first layout consisted of a 15m surge bin before the breaker, which was located 15 m below the production level. The second layout had a 43 m longs urge bin, with the breaker located 43 m below the production level. The third layout did not have a surge bin, the breaker was located on the production level and operated at the tip. The ore throughput, availability and utilisation, delays, costs and operational experience with each system are discussed. It was found that the rock breakers did not represent a bottleneck in the ore transfer system and a surge bin did not significantly improve the production capacity. The mine has decided to make use of rock breakers situated on the production level, breaking rocks at the tip.

Jan 1, 1997

By J. L. Havenga, L. J. van der Walt, J. T. Nel, H. Bissett

"SynopsisNew technologies used to manufacture high-quality components, such as direct laser sintering, require spherical powders of a narrow particle size distribution as this affects the packing density and sintering mechanism. The powder also has to be chemically pure as impurities such as H, O, C, N, and S causes brittleness, influence metal properties such as tensile strength, hardness, and ductility, and also increase surface tension during processing.Two new metal powder processes have been developed over the past few years. Necsa produces zirconium powders via a plasma process for use in the nuclear industry, and the CSIR produces titanium particles for use in the aerospace industry.Spheroidization and densification of these metal powders require remelting of irregular shaped particles at high temperature and solidifying the resulting droplets by rapid quenching. Spherical metal powders can be obtained by various energy-intensive methods such as atomization of molten metal at high temperatures or rotating electrode methods. Rapid heating and cooling, which prevents contamination of the powder by impurities, is, however, difficult when using these methods for highmelting- point metals. For this reason plasma methods should be considered.Thermal plasmas, characterized by their extremely high temperatures (3000–10 000 K) and rapid heating and cooling rates (approx. 106 K/s) under oxidizing, reducing, or inert conditions, are suitable for spheroidization of metal powders with relatively high melting points. Thermal plasmas for this purpose can be produced by direct current (DC) plasma arc torches or radio frequency (RF) inductively coupled discharges. In order to obtain chemically pure spheroidized powder, plasma gases such as N2, H2, O2, and CH4 cannot be considered, while Ar, Ne, and He are suitable. Neon is, however, expensive, while helium ionizes easily and it is therefore difficult to obtain a thermal helium plasma at temperatures higher than 3000 K. Therefore argon should be used as plasma gas. Residence times of particles in the plasma region range from 5–20 ms, but this is usually sufficient as 7–8 ms is required for heating and melting of titanium or zirconium metal particles in the 30 µm size range at 3500 K. In this study the melting and spheriodization of titanium powders was investigated by DC non-transferred arc and RF induction plasma methods. The powders were characterized before and after plasma treatment by optical microscopy and scanning electron microscopy (SEM) to observe if any melting or spheroidization had occurred."

Jan 1, 2015

By S. Lohmeier, D. Gallhofer, B. G. Lottermoser, T. Schirmer

At a time of resource consumption, it is important to study the chemical composition of mining and metallurgical wastes to prevent the dissipative loss of metals and metalloids from the mining value chain. In particular, the recovery of critical elements from wastes is an option to increase the resources of such materials that are economically significant and have an overall supply risk. In this paper we report on the chemical composition, in particular the critical element content, of granulated slag originating from historical smelting activities in the Tsumeb area, Namibia. Laboratory-based inductively coupled plasma–mass spectrometry (ICP-MS) and X-ray fluorescence (XRF) analyses as well as portable X-ray fluorescence (pXRF) demonstrate that the slags are on average enriched in base metals (Cu 0.7 wt%, Pb 2.7 wt%, Zn 4.7 wt%), trace metals and metalloids (Cd approx. 50 mg/kg, Mo approx. 910 mg/kg) as well as critical elements (As approx. 6300 mg/kg, Bi approx. 3 mg/kg, Co approx. 200 mg/kg, Ga approx. 100 mg/kg, In approx. 9 mg/kg, Sb approx. 470 mg/kg). While metals and metalloids such as As, Mo and Pb can be determined reliably using pXRF instruments, the technique has inherent limitations in evaluating the contents of certain critical elements (Ga, Sb). However, there are positive correlations between the As, Mo, and Pb contents determined by pXRF and the Ga and Sb contents obtained through ICP-MS and XRF. Thus, quantitative pXRF analysis for As, Mo, and Pb allows calculation of Ga and Sb abundances in the slags. This work demonstrates that pXRF analysers are a valuable tool to screen smelting slags for their chemical composition and to predict the likely contents of critical elements.

Mar 1, 2021

By R. J. Durrheim, Y. Yabe, M. S. D. Manzi, DSeis team, N. Z. Nkosi, S. B. Mngadi, Jr. H. Ogasawara

On 5 August 2014, the Orkney M5.5 earthquake, the largest in South African gold mining districts, occurred with an unusual strike-slip mechanism at great depth of 4.78 km below the surface. In a rare case, the ML 5.5 earthquake occurred within the area covered by the legacy 2D and 3D reflection seismic data acquired in the 1990s and 2000s for gold exploration and mine development. In addition, the earthquake ML 5.5 rupture plane was recorded and accurately delineated by the underground in-mine seismic network near the source region. The integration of the legacy 2D reflection seismic data and mine seismicity data allowed us to identify a near-vertical structure, striking northnorthwest-south southeast (NNW-SSE). The ICDP-DSeis team drilled three holes (Hole A, Hole B, and Hole C), and two holes (Hole B and Hole C), intersected the upper edges of the ML 5.5 rupture. These holes recovered metasediments, metabasalts, intrusive rocks including dolerite sills and lamprophyre dykes adjacent to the fault zone, and the fault gouge. Late Prof. Tullis Onstott and geomicrobiologists installed a packer in Hole A and successfully recovered saline water and detected gas (~10 MPa). Slip weakening and rupture propagation are significantly influenced by the existence of fault gouges and the production of wear material between two sliding rock surfaces. Using the fault gouge material recovered from Hole C, we conducted friction experiments under dry and room temperature conditions at high slip velocity of ~100 mm/s and normal stress of 2 MPa. The resulting steady-state frictional strength was ~0.66 over a slip weakening distance of ~9.1 m. The steady-state frictional strength was high, which may be caused by large gouge thickness, and the rate of wear generation. As a result, it is proposed that the Moab Khotsong ML 5.5 seismogenic zone is complex and could be controlled by three main processes: a) the complex structural architecture of the seismogenic zone (e.g., intersection of fault, lamprophyre dykes, and dolerite sills); b) the mechanical process induced by tectonic and/or mining related stresses; and c) the mechanical and chemical processes caused by the water and rock interaction.

Jan 12, 2025

By M. Bueno, T. Chavez Matus, M. S. Powell, S. Michaux, S. Luukkanen

Comminution tests are an essential element in the design of ore beneficiation plants. Many methods have been developed to assess the breakage characteristics of rocks to generate parameters for modelling. However, most of the existing methods are laborious, expensive and require large samples. Consequently, test work has been traditionally conducted with a few representative reference samples. On the other hand, geometallurgical modelling programs require an extensive amount of test work to allow understanding the variability of ore properties within the deposit and establish spatial geometallurgical domains that show the differential responses to mineral processing. Therefore, comminution tests for geometallurgy need to be more efficient in terms of time, cost and sample size. This paper introduces a new testing device (Geopyörä) which is capable of measuring forces and energy applied to rock particles during the breakage process. The new testing method uses smaller samples and can be up to 50 times faster than other commonly used tests in the industry. This paper presents the concept prototype and the preliminary test work results, which have been benchmarked against some of the industry standard tests, such as the JK Drop Weight Test (JKDWT), the SMC Test® and the Bond ball mill test. Keywords: Geometallurgy, comminution, ore breakage characterization, variability.

Jan 1, 2020

By P. C. Schutte

The objective of ergonomics is to enhance the effectiveness and efficiency with which human tasks are carried out. Furthermore, the objective is to improve desirable human values. This can be achieved by enhancing safety, reducing fatigue and stress, increasing comfort, increasing job satisfaction, having greater user acceptance and thereby improving the quality of life. Mechanization has influenced the prevalence of injury, mainly due to the application of human physical effort as the power source. With mechanization, the operator?s function is now essentially one of control rather than being an energy source, however, the risk of injury has not diminished. Mechanization in itself has introduced inefficiencies, health risks and physiological stress. The major objectives of ergonomics are discussed through examples of acceptable and less successful implementation of ergonomics within mechanized mining. The influence of the machine system on the human is addressed and practical solutions to improve and optimize the interaction of the human and the machine are outlined. Furthermore, practical examples of control and display integration, anthropometric and biomechanic influences on design, orientation, posture and stereotypes are used to accentuate the advantages of the application of sound ergonomics principles to the specialized area of mechanized mining.

Jan 1, 2002

By S. Kauchali

"Underground coal gasification (UCG) is recognized as an efficient mining technique capable of chemically converting the coal from deep coal seams into synthesis gas. Depending on the main constituents of the synthesis gas, chemicals, electricity, or heat can be produced at the surface. This paper provides a high-level graphical method to assist practitioners in developing preliminary gasification processes and experimental programmes prior to detailed designs or field trials. The graphical method identifies theoretical limits of operation for sensible gasification within a thermally balanced region, based primarily on the basic coal chemistry. The analyses of the theoretical outputs are compared to actual field trials from sites in the USA and Australia, with very favourable results. A South African coal is studied to determine the possible synthesis gas outputs achievable using various UCG techniques: controlled retractable injection point (CRIP) and linked vertical wells (LVW). For CRIP techniques, an important result suggests that pyrolysis, and subsequent char production, are important intermediate phenomena allowing for increased thermal efficiencies of UCG. The conclusion is that South African coals need to be studied for pyrolysis-char behaviour as part of any future UCG programme. The results also suggest that UCG with CRIP would be a preferred technology choice for Bosjesspruit coal where pyrolysis dynamics are important. Lastly, the use of CO2 as oxidant in the gasification process is shown to produce syngas with significant higher heating value. Introduction and literature surveyCoal is a commonly utilized fossil fuel, providing over 40% of global electricity demand and about 90% of South Africa’s primary energy needs. However, less than 20% of the known world resources are suitable for possible extraction using conventional surface and underground mining techniques (Andrianopolous,, Korre, and Durucan, 2015). Underground coal gasification (UCG) has the potential to recover the energy stored in coal in an environmentally responsible manner by exploiting seams that are deemed unmineable by traditional methods. The UCG process, if successfully developed, can increase coal reserves substantially. For example, in the Limpopo region of South Africa alone, the estimated potential for UCG gas, based on existing geological records, is over 400 trillion cubic feet (TCF) natural gas equivalent – this is about a hundred times more gas than the existing 4-TCF Pande-Temane natural gas field reserve in Mozambique (de Pontes, Mocumbi, and Sangweni, 2014)."

Oct 1, 2018

By Chris D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900?s. This versatile product displaced the expensive and easily-poisoned platinum-based catalyst in nearly all applications by the 1930?s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has world-wide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development program dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and pre-heater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

By N. Coulson, P. F. Stewart

The Mine Health and Safety Act No. 29 of 1996, as amended, embeds an occupational health and safety management system that facilitates communication between representatives of the state, capital, and labour. In underground mines, two communication loops between these role players serve to separate the production chain of command from the political tripartite relations. Worker-elected health and safety representatives are involved in both communication loops, but are severely constrained in escalating their occupational health and safety concerns to the legalpolitical level. This has a direct bearing on the exercise of the Right to Refuse Dangerous Work (RRDW). As previously reported, health and safety representatives were found to primarily consult their production supervisors in preference to their trade-union representatives. This follow-up article presents production supervisor perspectives on the RRDW. The study demonstrates how, for mineworkers, the two distinct communication subsystems constrain, rather than facilitate, implementation of the RRDW.

Apr 14, 2024

By D. G. Krige

D. G. Krige: The stimulating contributions from Messrs Cooke, Curtis, Martus, Johnston, Van Wyk, Van Rensburg and Wroth are appreciated by the author and provide clear evidence of the importance not only of the principle of assistance to gold mines, but also of its scope and form. In general all the arguments, raised by Messrs Cooke, Martus and Johnston in favour of extending the scope of the new assistance scheme can be accepted as sound.

By D. W. Dean, J. A. Ryder

"A computer system designed to assist in maintenance scheduling and costing, and in monitoring the performance of equipment, is described. The emphasis is on the information retrieval and implementation aspects of the system.INTRODUCTIONThe cost of the maintenance of equipment can account for a substantial proportion of the total costs of any large industry. These costs are made up of the following elements:(i) capital expenditure,(ii) maintenance labour,(iii) maintenance spares,(iv) maintenance overheads,(v) production losses.Control of these cost elements cannot be achieved without a system which maintains and retrieves the necessary infor¬mation efficiently.The system should provide engineering management with the information necessary to:(i) establish the cost of maintaining items of equipment,(ii)establish the economic life of equipment,(iii) determine breakdown patterns for the establishment of optimum inspection, service and overhaul frequencies,(iv) establish work schedules for those responsible for the maintenance of equipment,(v) establish the optimum maintenance labour complement,(vi) establish the optimum stockholding of maintenance stores items,(vii) improve the performance of equipment,(viii) justify the selection of a particular type and make of equipment,(ix) establish the reasons for any abnormal usage of materials and labour, and to(x)reduce the dependence on the human element for the control of equipment maintenance activities.Many industries have comprehensive and numerous equipment maintenance records but they experience great difficulty in retrieving the required information in the time available and with the labour available. Many industries do not bother to maintain meaningful records, because of this difficulty."

Jan 1, 2014

By Donald Sir Tebbit

To have been invited to deliver this second CMMI lecture is an honour that I deeply appreciate. But, when I contrast my qualifications for delivering it, with those of Sir Alistair Framet, who delivered the inaugural lecturet in the series, or with those of other members of the Council, I feel rather an imposter. Far from having been a miner al my life, I have been associated with the mining industry on a part-time basis for a mere eight years. However, I encourage myself with two recollections. The first is the admission of the great Sherlock Holmes that he was often guided to the truth by the erroneous opinions expressed to him by Dr Watson. I may be able to perform a similar service for you. Secondly, I recall that, when I was a member of the Diplomatic Service, I was quite often asked to address representative gatherings of such professional people as the police, architects, dress designers, teachers, doctors, funeral directors, bird fanciers, and so on. Since it would have been pointless to pretend that I was expert in any of their businesses, I used to resort to the technique of announcing as my theme' A diplomat looks at the police' or whatever profession it was. They fortunately took it as a compliment that their profession was apparently one that diplomats spent a lot of time brooding over. They could also afford to laugh of any criticism that I might make because it could be ascribed to ignorance rather than informed malice. I hope that you will do the same.

Jan 1, 1988

By V. Sheikhzadeh, S. M. H. Haddad, M. Saghaeian, N. Esmaeili, R. Hejazi

One of the most significant features of iron ore concentrate (pelletising feed) is the specific surface area (SSA) that affects the achievement of desirable pellet properties. There are various methods to determine this parameters and currently, the most common is the Blaine air permeability method. However, due to the simplified assumptions including spherical and identical particles and 50% bed porosity, the Blain test does not provide accurate results. In fact, these two suppositions are far from reality. In this research, comparison of SSA measurement ways are investigated, containing laser diffraction testing and Blaine air permeability, on samples with different SSA, obtained from Ball mill and high pressure grinding rolls (HPGR). The output data showed that the calculated amounts of SSA by means of laser analysis were far greater than any other one. Furthermore, in the same results of Blaine air permeability tests on samples comminuted by different grinding methods, it was observed that the SSA figures from the laser diffraction method for HPGR products were almost 800 units greater than Ball mill ones. Keywords: Pelletising feed, specific surface area, Blaine air permeability, laser diffraction testing

Jan 1, 2020

Assuming that a gold ore has been effectively ground to ensure maximum economic liberation of gold, the circuits that will have the most effect on the successful operation of a gold plant will be that of the leaching and carbon-in-pulp circuit (CIP). The reagent and utilities operating costs associated with leaching, adsorption, elution and regeneration would typically make up some 15% of total operating cost, whilst the capital costs associated with these areas is about 16% of the total. Although not largest (capital and operating costs associated with comminution are generally dominant) these items represent a significant proportion of capital and operating cost. Much more importantly, these plant areas represent the primary gold recovery process and their technical and operational efficiencies will have a significant impact on overall plant efficiency. The objective during process design of these sections is thus to develop a design which provides maximum technical and economic efficiency and which is robust to potential changes in ore throughput, mineralogical characteristics and head-grade. Experience has shown that, particularly for longer life and higher-grade projects typical of the South African underground gold mining industry, small changes in recovery and efficiency have a significant value over the life of the project.

Jan 1, 1999

By N. Duda, P. Śliwiński, P. Stefaniak, B. Jachnik

Ventilation and air-conditioning are some of the most energy-consuming processes in deep underground mining. Additionally, the energy consumption of these processes systematically increases along with the expansion of the mine. Therefore, proper energy efficiency assessment and consumption forecasts of these systems are particularly important in modern mines for ongoing tracking and planning of the likely costs. In the article, a short-term prediction model for surface air–conditioning stations is described. This model takes into account dependencies that were identified, based on the data from the supervisory control and data acquisition (SCADA) systems. These dependencies between the response value and the external conditions are then incorporated into the model. This way, for example, the ambient temperature or the total number of specific days of the week (with sometimes significantly lower or higher than the weekly average energy consumption levels) are included. Taking into account these dependencies, and e.g. forecasted average monthly temperatures allow us to include the seasonality of energy consumption in the presented model. In the article, a sample energy efficiency analysis of the A/C system based on an example of the KGHM Polish Copper Polkowice-Sieroszowice mine is performed. The results of the solution proposed in the article are then evaluated, and compared to the currently functioning, more basic forecasting methods. However, given the general nature of the dependencies used in the model, similar solutions could be used in other case studies.

Sep 1, 2021

By C. Ntsele

Stirred milling technologies have firmly established themselves in concentrator circuits as energy-efficient alternatives to tumbling ball mills. High and continued increases in electricity costs, coupled with the ever-increasing power consumption by primary grinding circuits due to declining head grades of ore-bodies, provides a compelling case for these technologies. Additionally, the ability to successfully deploy stirred milling in coarse grinding applications extends the range of use in concentrators, thus increasing the opportunity matrix for energy optimization in a flowsheet. This paper therefore details methodologies and strategies that can be applied to evaluate the optimum stirred milling solution for different concentrator applications. These methods and strategies will focus specifically on the two major stirred mill machine types; namely, gravity-induced (VERTIMILL? grinding mill and Nippion-Eirich tower mill) and fluidized (SMD, Isamill?, Knelson-Deswik mill, etc. ). Finally, case studies from circuits across industry and laboratory tests will be used to illustrate the energy benefit from the use of stirred mills.

Jan 1, 2012