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By M. J. Little

Potgietersrust Platinums Ltd (PPRust) is Anglo Platinum?s only open pit operation. The major slope stability concern at PPRust is rapid, small-scale brittle failure on the west wall of Sandsloot open pit. In order to improve safety and mine more economically, a comprehensive slope monitoring strategy has been implemented. In the last 3 years four new state-of-the-art monitoring systems have been installed namely an ISSI microseismic monitoring system, a GeoMoS automated prism monitoring system, prismless Riegl laser scanners and a GroundProbe slope stability radar (SSR). Groundwater monitoring and visual monitoring have also been improved over the same time period. To complement the visual inspections, SiroVision digital photogrammetry is now used for predicting where future failures may occur. All these monitoring tools provide primary monitoring which is used to identify high risk areas. The SSR is then set up in that area to provide early warning of failure so evacuation can be successfully done. Fault tree analysis has proved that with this comprehensive slope monitoring strategy the geotechnical risk at PPRust is greatly reduced, allowing mining to continue safely and economically in challenging conditions.

Jan 1, 2006

By P. J. D. Lloyd

The widely employed IPCC models for the release of methane from underground coalmining operations are reviewed, and put in the context of the South African National Communication on greenhouse gas emissions. Then attempts to calibrate the model via measurements on South African coalmines are described. These attempts failed because it rapidly became clear that the IPCC model, involving methane adsorbed by the coal and released (a) by the depressurization of the strata caused by mining, (b) from the broken coal and (c) from coal remaining in roof, floor, pillars or goaf after mining, was not valid. Instead, measurements showed that the methane release was very variable, sporadically falling to zero. Carbon dioxide concentrations were monitored at the same time as methane, and followed methane concentrations. An alternative model was developed, in which methane was largely displaced from the coal and held in fissures, cleats and pores, which, when intersected by mining, released methane into the ventilation stream. In a key test of this hypothesis, methane concentrations around a continuous miner were monitored both during operation and after shutdown. Even during operation, methane became undetectable. It is hypothesized that heating of the South African coal-seams during the emplacement of the igneous dykes that cut so many of the seams caused displacement of the methane from the coal into the pores. This fissure-held methane, or free methane, is released rapidly once a pathway through the coal into the mine atmosphere is established. In contrast, methane adsorbed in the coal, and measured as the seam gas, desorbs relatively slowly. Measurements suggest that on average about 50%of the adsorbed methane is lost one day after mining. By that time, the coal will have left the mine, so that the remaining seam gas will be released to the atmosphere outside the mine. Attempts to measure methane emissions from surface coal-mining operations showed very little detectable methane. Coal from surface operations, which was milled and exposed to atmosphere, adsorbed gas from the air. It is concluded that methane release from surface operations is probably less than 3Gg/a. It is estimated that the total methane release from the coalmining industry amounts to about 72 Gg/a, as opposed to the National Communication estimates of 323 Gg/a in 1990 and 317 Gg/a in 1994. However, there are large errors associated with these estimates, and it is recommended that the methodology outlined in this report be extended to as many mines as possible to reduce the errors that are inherent in the physical processes underlying the release of methane from South African coalmines.

Jan 1, 2005

By Philippe Dumont

?Lay out of the tunnel section ?General ?Geology ?Tunnels methods ?Stations constraints ?Impacts on tunnels ?Design ?Programs

By G B. Gnoinski

The Skorpion Zinc Mine and Refinery is situated approximately 25 km north of Rosh Pinah, south-western Namibia. The supergene zinc oxide deposit at Skorpion is hosted in a volcano-sedimentary succession within the para-autochthonous Port Nolloth Zone of the Gariep Belt. Rock types hosting the ore deposit include altered and metamorphosed volcaniclastic and clastic sediments, limestone and rhyolite. At Skorpion, the metallurgical process is unique and the plant design requires minimal fluctuations within a selected feed grade. In addition, the presence of limestone inter-fingered with ore in some areas of the deposit results in dilution problems which may increase gangue acid consumption and therefore processing costs. Hence, selective mining is necessary to ensure the delivery of suitable ore to the processing plant, in order to keep the overall operating costs at a minimum. A complex control system is in place and is capable of a high degree of selectivity. The paper describes the grade control system in place at Skorpion Mine which ensures that the qualities of the blocks planned for mining and the material being mined meet the stringent process requirements of the refinery, i.e zinc grade, gangue acid consumption and deleterious elements that may impact on the efficiency and costs of the metallurgical process. Keywords: Skorpion zinc, zinc oxide, supergene, volcano-sedimentary, grade control

Jan 1, 2007

By X. Yu

Although many investigations of the deformation behaviour of rocks have been carried out, most of them are carried out in compression. In all rock engineering practice it is usually assumed that the deformation of rocks in tension is the same as that in compression. However, data from numerous researchers have shown that this assumption is not correct for some rocks. A new loading frame for testing rocks in compression and direct tension has recently been developed by the authors, with the capacity to conduct both compression and tensile tests on the same rock sample. The results obtained show that the ratios between the average Young?s modulus in compression (ECA) and in direct tension (ETA) are 1, 1.16, 2 and 6 respectively in four rock types tested. For Poisson?s ratios, analogous relations were obtained. It was observed that, in all cases, the tangent Young?s modulus intension reduces with an increase in the applied tensile stress, while the behaviour of Poisson?s ratio is similar, but shows greater variability. The difference between the Young?s modulus of rocks in tension and that in compression could lead, large errors in calculating induced stresses around underground openings, as well as in determining the Brazilian tensile strength of rocks. This may have a significant influence in rock engineering and therefore more investigation is necessary into the tensile deformation behaviour of rocks and its influence.

Jan 1, 2005

A wide range of materials are used in hydraulic backfilling operations and the pipeline flow behaviour of these mixtures varies considerably. It is shown that despite the large differences in constituent materials and flow behaviour, a common approach can be applied to analysing the flow of all hydraulic backfills. This is extended to include a rational design approach for backfill distribution systems. The use and limitations of pipe loop tests as a design aid is discussed. Backfill quality control is identified as a key area where improvement needs to be made to enhance the reliability of backfill system operation.

Jan 1, 2001

By J. D. Steenkamp

"In July of 2016 and June 2017, major tap-hole repairs were carried out during the annual shutdown of two 63 MVA submerged arc furnaces producing ferrochromium in South Africa. The hot excavations of the tap-holes allowed for a study of the wear profiles. Subsequent thermodynamic calculations allowed for the quantification of the potential for chemical reaction between refractory and slag or alloy contributing to wear in the tap-hole area. Results from both wear profiling and thermodynamic calculations are reported here. IntroductionFerrochrome (FeCr) is an essential alloy in the production of stainless steel (Gasik, 2013). In 2017, 11.7 Mt of FeCr was produced (Pariser et al., 2018.). The main producers were China (39%), South Africa (29%), Kazakstan (12%), and India (8%).A number of grades of FeCr are available to producers of stainless steel, including high-carbon ferrochrome (HCFeCr) (Gasik, 2013). HCFeCr typically contains 60–70% Cr and 4–6% C (Basson and Daavittila, 2013). When the chromium content is lower (50–55% Cr) and the carbon content higher (6–8% C), it is referred to as charge chrome. Charge chrome is typically produced in South Africa due to the grades of ore available.FeCr is produced in submerged arc furnaces (SAFs) and in open arc furnaces (Mc Dougall, 2013) by carbothermic reduction of oxide raw materials. In a SAF the electrode tips are submerged in a porous charge mix. In FeCr production, the electrical energy is mainly liberated by resistive heating of the wet coke bed (Barker et al., 2007; Steenkamp et al., 2017). Thermally conductive lining design philosophies are typically applied in SAFs producing FeCr (Steenkamp, Denton, and Hayman, 2017; Coetzee, Duncanson, and Sylven, 2010; Coetzee et al., 2010).In July of 2016 and June of 2017, major tap-hole repairs were carried out during the annual shutdown of two 63 MVA SAFs producing FeCr in South Africa. The hot excavations of the tap-holes allowed for a study of the wear profiles. Both SAFs were operated on the same site, by two different operating crews, using the same raw materials. The major difference between them was that the SAF excavated in 2016 was an open SAF (referred to as Furnace A) and the one excavated in 2017 was a closed SAF (referred to as Furnace B). In an open SAF, a gap exists between the top of the steel shell and the roof, with the top of the burden being open to the atmosphere and the CO-rich off-gas being combusted as it escapes. In a closed SAF, the roof is attached to the steel shell and the CO-rich off-gas is collected from an offtake on the roof for further treatment and used in downstream processes.The paper presented here reports the macro-scale observations on refractory wear for the two SAFs, and studies the potential for chemical wear of refractory by slag and alloy as a potential contributing factor to the tap-hole wear observed."

Jun 1, 2019

By J. A. Ryder

A high proportion of damaging rockbursts are thought to be underlain by seismic events that represent shear or rupture along planes of weakness (faults, joints, dyke contacts). Such events are controlled by shear stresses and friction properties along the plane. Excess shear stress (ESS) is a measure that can be evaluated numerically and that, in principle, can be used in an assessment of the possible magnitude and relative likelihood of seismic activity. Methods for the calculation of ESS in practical mining contexts, and for the estimation of the magnitudes of possible seismic event progressions, are briefly reviewed. The effects of variables such as depth, stoping width and, in particular, virgin horizontal stresses on general shear-type seismic hazards are investigated. Attempted back-analyses of two large rockbursts are described.

Jan 1, 1988

By A. van den Berg

Mining of sand in South Africa is rapidly growing to sustain an increasing demand for sand for building purposes. Although mining of sand is regulated by environmental legislation, such as the National Environmental Management Act 107 of 19981, previous bad mining practices have left areas of land degraded and vulnerable to erosion. This study was conducted in the Seringveld Conservancy, where mining of sand has left the landscape with a degraded and unsightly appearance, and where little rehabilitation of the original vegetation has taken place. The aim of the study was to develop rehabilitation techniques for the degraded mined soils on two sand mines, Boekenhout Sand and Krokodil Sand, and to develop an overall strategy of revegetation by regenerating key plant species. Techniques for regenerating indigenous tree species cover, using modified mined sludge if topsoil is not available, were used to develop a practical and cost-effective strategy to be used in revegetation. A comparative trial was used to cultivate indigenous tree species in different soil mixtures. The study is important as it provides new information on the rehabilitation and revegetation of sand mined areas in the Seringveld Conservancy. This study will determine if alternatives could be used to replace topsoil on mined areas where none is available. The study is needed to determine whether revegetation of the mined areas would be possible using indigenous plant species that are difficult to grow. The overall results indicate that replacing topsoil was successful for various modified soil mixtures that could sustain the growth of indigenous vegetation on the sand mines. Different indigenous tree species require different modified soil mixtures for successful propagation. A revegetation strategy was developed to complement and enable the rehabilitation of the mined areas in the Seringveld Conservancy. Keywords Rehabilitation, revegetation, Seringveld, sand mines, Burkea africana, topsoil, germination trials.

Jan 1, 2011

By T. Feroze, B. Genc

"The effect of some of the system variables in forcing and exhausting ducted fan systems on ventilation in an empty heading was investigated using computational fluid dynamics(CFD) and comparative analyses. The diameter of the duct, duct mouth to face distance, and the power of the fan (quantity delivered by the fan) were varied and their effect on ventilation determined through a comparative analysis of the flow rates calculated close to the face of the heading. Estimation models were developed, which can be used to calculate the flow rate close to the face of the empty heading for different settings of the system variables studied.The study showed that recirculation for a forcing ducted fan system can be reduced by increasing the duct diameter or increasing the duct mouth to face distance. For the exhausting ducted fan system, higher flow rates were achieved by reducing the duct mouth to face distance, andincreasing the fan design flow rate and duct diameter.The outcomes of this investigation will help ventilation engineers in deciding the optimum duct fan system required for sufficient ventilation.IntroductionThe ventilation of underground mines, irrespective of the type of mine and mining method, is divided into two broad branches, the primary ventilation and secondary or auxiliary ventilation. The primary ventilation is responsible for the total volumetric flow through the mine and the auxiliary ventilation is responsible for the ventilation of the development ends, production areas, and facilities disconnected from the main circuit with no through-ventilation connections. Auxiliary ventilation is the more difficult to achieve (Bise, 1996), and the disruption of this ventilation system is considered to be one of the primary factors contributing to methane and coal dust explosions (Creedy, 1996). A number of causalities have been recorded by many authors due to these explosions (Phillips and Brandt, 1995; Dubinski et al., 2011; Phillips, 2015). The ventilation of short headings, less than 10 m in depth, can be carried out without the use of any auxiliary equipment (Feroze and Phillips, 2015). However, for headings deeper than 10 m, auxiliary ventilation systems are required. These are generally classified into the three basic types, namely line brattice (LB) ventilation systems, ducted fan systems, and jet fans (Figures 1 through Figure 3 respectively)."

Jan 1, 2017

By J. Kerr

The first stage of the development of a new modified 201-type low nickel austenitic stainless steel is described in this paper. The alloy is intended for use as a structural alloy, and so requires a yield strength >400MPa as well as acceptable weldability and toughness. The low nickel content will give a lower material cost in comparison to more conventional austenitic grades, and the processing route is required to be similar to that of Type 304 to keep the processing cost low. The base alloy was designed using empirical methods developed for stainless steel, and the properties of the base alloy were verified using a range of small-scale melts. The base alloy had a 0.2% proof strength of ~320-400MPa, and so it is planned to use V additions of ~0.15% to bring about precipitation strengthening in the hot rolled condition, so raising the alloy?s proof strength above the 400MPa minimum.

Jan 1, 2004

By M. Kumral

The efficiency of an ore-processing unit depends on the consistency of the characteristics of raw material entering the plant. When the mined ore is highly variable in quality, the only way to ensure consistency is to homogenize the ore prior to feeding to the processing plant. The homogenization can generally be achieved by the bed blending operation. Given that the stockpiling and reclamation processes are very expensive, it is necessary to design the process in such a way as to minimize variabilities of specified properties of raw material. In this paper, for alternative stacking types, optimal stockpile geometry is found in three stages: First, stockpile input is simulated by sequential Gaussian simulation, and then the variance reduction ratios (VRR) as a criterion of stockpile efficiency are calculated for various stockpile geometry scenarios by a stockpile simulator written in FORTRAN. Second, multiple regression analysis is performed to model the VRR by the use of stockpile length, the number of layers and stacker speed as the independent variables. Finally, the model is an optimization problem. Decision variables are the stockpile length, the number of layers, stacker speed and stacking type. The genetic algorithms (GA) are used to minimize the VRR. The approach was demonstrated on data from an iron orebody. The problem was to reduce fluctuations of iron, silica, alumina and lime contents in the stockpile output. The results showed that the approach could be used for the bed blending design efficiently. Keywords: bed blending design, multiple regression analysis, genetic algorithms, iron ore, content fluctuation

Jan 1, 2006

By D. E. Ng?andu

The experience of Mufulira concentrator, of the Zambia Consolidated Copper Mines Limited, with underground mine drainage water, which is used in milling operations is discussed. It is shown that the underground mine water has a deleterious effect on flotation performance. The adverse effect of the underground water was successfully negated by adding lime into the primary ball mills and increasing the pH of the slurry, from a ?natural? pH of 8 to the flotation pH of 10.5. Traditionally, the pH modifier, quicklime, had been added downstream of the milling. Changing the lime addition point further reduced lime consumption by 50%,?a key issue as lime accounted for over 60% of the Mufulira flotation reagent costs. The nature of the effect of the underground water at Mufulira, particularly the sensitivity of the flotation to the pH at which the milling was conducted, characterized galvanic interaction. A large-scale plant situation is presented in which the desired electro-chemical response in the flotation was achieved, by a deliberate manipulation of the milling environment. The experience provides practical testimony of a more fundamental role for the milling process, other than the mere physical preparation, i.e. size reduction and liberation, of mineral particles prior to flotation.

Jan 1, 2001

The effect of composition on electrical conductivity (resistivity), viscosity and liquidus temperature of the slags encountered in electric smelting of PGM containing suphide concentrates is reviewed, along with the relationsip between slag composition, slag-matte separation and metal losses to slag. Optimization of slag composition at furnace temperature is attempted on the basis of opposite and parabolic trends of the viscosity-conductivity relationships of the slags. The importance of surface tension of slags is emphasized using available and estimated information which are grouped into a useful correlation. These values are coupled with or incorporated into slag viscosity plots to illustrate the correlation between the two factors, which influence slag-matte separation as well as refractory attack. The electrode in the slag-resistance furnace is the central factor in the design and operation of the furnace by its role of conveying the smelting power. The obvious parameters are the size and positioning in the slag bath, which are defined by slag resistively, furnace resistance, cell constant and power input. The flow of heat generated by the electrode current determines the energy distribution and furnace dimensions creating viscosity profiles, which in turn affect flow conditions. Thus the flow of slag and matte are discussed in conjunction with the furnace geometry, stirring action of the electrodes, buoyancy and electromagnetic effects. The action of the electric furnace as a settler is discussed. The rectangular furnace is considered as a channel reactor in this analysis, and the action of the electrodes is described to indicate a balanced settling rate in the area of electrode action. Discussion of the design and production capacity of the electric furnace, with reference too perating current, power input, furnace dimensions and electrode size, are based on considerations derived mainly from slag properties such as its resistively, viscosity and liquidus temperature.

Jan 1, 2004

By S. Rolseth, J. Thonstad

The traditional electrolyte for aluminium electrolysis is based on molten cryolite (Na3AlF6), acting as solvent for the raw material, alumina (Al2O3). Over the years there has been a trend to increase the content of excess aluminium fluoride (AlF3) to the cryolite-based electrolyte, in order to enhance the current efficiency of the process. In most cases one has ended up at 11?13 wt% excess AlF3because higher contents makes it difficult to control the heat balance of the process. This problem may be overcome if sensors are developed that will allow online control of electrolyte temperature and composition, and we may then see a surge towards still higher AlF3contents. In the development of new anode materials to replace the carbon anode with inert, oxygen-evolving anodes, focus is on anode corrosion, and a low electrolyte temperature is then highly desirable. While the conventional process operates at around 960°C, electrolyte temperatures as low as 750°C are being tested. This is achieved by having large excess contents of AlF3(40 wt%). The consequences of using such electrolyte compositions are discussed.

Jan 1, 2004

By Y. Nakata, K. Nagata

Plasma is partially ionized gas composed of ions, electrons and activated elements at high temperature. Some flying ash from incinerated municipal waste is melted to become glass by a transfer-type arc plasma furnace. As the glass is ionic silicate, when an electric current passes through anode to cathode, ions in molten slag electrochemically react with electron in plasma at the surface of molten slag. In case of molten Na2O-SiO2, sodium ions in the molten slag carry electric current and SiO2are reduced to evaporate as SiO gas by electron in plasma. The cases of Ag+in NaNO3-KNO3molten salt and Fe2+in FeO-SiO2slag were examined. The amount of cathodic reaction is larger than that of anodic reaction and not apparently according to the Faraday?s law on the electrochemical reactions.

Jan 1, 2004

By N. Andersen

During the preliminary design phases and feasibility study of a proposed vertical shaft, a vertical diamond drill-hole is normally drilled on the site. This paper outlines how rock mass characteristics, in-situ rock stress, rock strength, hydrological characteristics, and structural parameters can be determined using wireline logging of this borehole. In addition, a rock mass classification scheme is developed, based on published work, and in particular the Q-factor is adapted to assess the stability of raise-bored shafts. The ‘stick plot’ is introduced, which combines all geotechnical parameters applicable to the stability of a vertical shaft into a colourcoded format where cross-correlations can readily be made on a day-today basis during the shaft-sinking process.

Jan 1, 2015

By H. F. Fuls

The quality of Pregnant Leach Solution (PLS) at Skorpion Zinc is of utmost importance for efficient operation of the Solvent Extraction (SX) Plant. Suspended solids in the PLS forms CRUD in the settlers, resulting in reduced zinc transfer capacity and increased impurity carry over to Electrowinning. The Ishigaki Fibre-Wakishimizu filter (fibre media rapid filtration equipment) has been identified as polishing filter that potentially could remove solids from the PLS of Skorpion Zinc. A pilot unit with 20m³/h capacity was tested on site over a period of 9 months under plant operating conditions in the refinery. The FW filter produces a clear filtrate, acceptable for the Solvent Extraction. Turbidity is improved by 72%. Gravimetric analysis indicates a 47% removal of solids. However, the gravimetric method is biased by a co-precipitation of saturated salts during the analysis. Filter media is blinded by the Skorpion Zinc PLS solution, as result of suspended solids and process chemistry. The media could not be regenerated to acceptable conditions. Further testwork to investigate the impact of process solution chemistry modification on blinding is undertaken. Based on the outcome of this investigation a final decision on the FW filter can be taken.

Jan 1, 2008

By D. Fray

Electrochemical processing using molten electrolytes is undergoing a considerable renaissance due to several innovative ideas being explored both in the laboratory and also at the pilot scale. Several of these new ideas are related to developments in energy generation and storage and involve solid electrolytes. Sodium has been prepared by the electrolysis of sodium carbonate or sodium hydroxide with the transfer of sodium ions through a sodium beta" alumina membrane and magnesium oxide dissociated by the removal of the oxygen through a stabilized zirconiaelectrolyte incorporating a fuel cell electrode. By using halides with highly electropositive cations, such as molten calcium chloride, it has been found that the favoured cathodic reaction, when oxygen is present, is the ionization of oxygen and not the deposition of calcium. This approach has been applied to the reduction of many metal oxides including titanium, zirconium, niobium and rare earth oxides and, by using a mixture of oxides as the cathode, homogeneous alloys are produced. This concept can also be applied to deoxidation of solid and liquid metals. Refining of metals is possible using intercalation compounds and, in a completely different application, it has-been found that, by intercalating alkali metals by electrolysis of alkali halides into graphite, it is possible to produce carbon nanotubes and nanoparticles. The technological opportunities of these various concepts will be discussed.

Jan 1, 2004

By S. Sarac

In this study, graphical and mathematical methods used to determine operating points in single or multiple fan ventilation systems are summarized. The problem is mathematically formulized for parallel connected fans in which analytical solutions are not possible. For n number of parallel connected fans, a non-linear equation system that consists of n number of non-linear equation sis derived. The Newton-Raphson method, which is a numerical analysis method, is adapted to solve this non-linear equation system and the solution steps are given as an algorithm. A computer program based on this algorithm is written and its applicability is proved.

Jan 1, 2000