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By G. Swan, E. Nordlund, P. Zhang

"SynopsisThe most widely used support design damage criterion for rockburst-prone mines is based upon kinetic energy, which is proportional to the square of the ejection velocity and is commonly expressed in terms of peak particle velocity (PPV). Field monitoring and back-analyses have shown that ejection velocities of the order of 10 m/s and higher can result from seismic events of moderate magnitude. Such velocities are much higher than those predicted using PPV obtained from scaling laws. It has also been found that the peak ground motion (i.e. PPV) on the surface of an excavation is preferentially amplified (by four- to tenfold) compared to the motion in solid rock at a similar distance from the source. However, the wave propagation and interaction processes involved within the fractured rock in generating high ground motion are very complex and are not well understood at this time.In this paper, velocity amplification was investigated by modelling the dynamic interaction between fractured rock and a free surface using a 2D discontinuum-based numerical program, UDEC (Universal Distinct Element Code). A 1D model with a fractured zone was used to represent the fractured rock. Velocity amplification, quantified by PPV, predicted at the free end of the model was 2.0–3.6 times higher than the input velocity. It was found that the wave frequency, fracture stiffness, fracture spacing, and thickness of fractured zone are the main factors that affect the velocity amplification. The results have proved that the interaction of the seismic wave and multiple fractures near the free surface strongly influences the ground motion.IntroductionSince mining-induced seismicity is almost inevitable in deep mines, ground support is generally employed to mitigate the risk of seismically-induced damage. The most widely used support design criterion for seismicallyprone mines is one that seeks to maximize the absorption of the kinetic energy (plus potential energy if a gravity component is considered) of key rock blocks. Based on this criterion, design methods for rock support were first proposed by Wagner (1984) in South Africa and later improved, among others, by Roberts and Brummer (1988) and Kaiser et al. (1996)."

Jan 1, 2015

The May General Meeting of the Institute was held in Kelvin House, Johannesburg on 20th May, at 4.30 p.m. Mr V. C. Robinson (Vice-President) was in the Chair in the absence, overseas, of the President, Mr J. K. E. Douglas. There were also present 16 Fellows: Messrs J. A. Adamson, R. S. J. du Toit, J. A. Drummond, D. F. A. Grave, T. L. Gibbs, G. H. Grange, D. V. Howat, P. H. Kitto, Dr P. J. LIoyd, Messrs B. H. L. Leach, J. de V. Lambrechts, Dr J. T. McIntyre, Messrs C. S. MacPhail, P. W. van Rensburg, S. G. Taussig, W. S. Rapson. Six Members: Messrs E. L. Atkinson, R. Hemp, Dr J. Martinson, Messrs A. H. Munro, G. J. van Jaarsveld and J. H. Qwilliam. Two Associate Members: Messrs B. H. van Rensburg and H. Triiter. Four Visitors: Prof J. E. Kerrich, Dr G. K. Sluis-Cremer, Messrs D. Kisbey-Green and L. W. Isserow. For Secretariat: Mrs S. de Gersigny. Total present: 27. OBITUARY The Vice-President: "It is my sad duty to announce the death of Stephen Ring, a member who joined the Institute in ]961, and passed away on the 31st of December, 1969. I would ask you all to rise and observe a moment's silence. Thank you." MINUTES The Vice-President: "May we confirm the minutes of the Special General Meeting and Monthly General Meeting, held on 20th February, 1970, as published in the April issue of the Journal?" MEMBERSHIP The Vice-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: Fellows: Denis Ian Field, Arthur Cecil Waiter Comyn, John Hall, Leon VercueiI. Members: Jan McLellan Vosloo, Jan van Velze. Graduates: Richard Darnley Beck, John Edward Andrews, Roderick Nowell Randell. Associates: Alexander Duncan Ross, Ian James Terrill. Students: Hendrik Jacobus Oostenwald Prins Smith, Graham Peter Gooding, Rudannes Raath Homan. "I welcome the newly, elected members to the Institute." GENERAL BUSINESS The Vice-President: "Are there any matters which you wish to raise under 'General'? There being no matters to raise under 'General', we will proceed to the next item on the Agenda." PAPER FOR PRESENTATION The Vice-President: "It is my pleasant duty to call on Dr du Toit to deliver his paper, entitled, 'The functional relationship between dust hazard and the rate of collecting funds to pay compensation for pneumoconiosis'." After the presentation of the paper (published in the March Journal) the Vice-President said: "This paper is a very important addition to the considerable volume of work applications on this subject of pneumoconiosis. The disease, in all its various forms, has received attention from many, many great men, both in the medical world, and engineers. The fact that there is this big volume of publications of literature on it still doesn't mean that we can get anywhere beyond the old, simple injunction, that the prevention of pneumoconiosis does not depend on compensation, levies or anything else. It simply depends on allaying dust as quickly as possible. "This paper, however, is another scientific landmark and I think, in a cold and dispassionate way, it sets out some important points in this whole subject of the relationship of the levy - the money of compensation to the dust which causes it. "I have, personally, very little to criticise in this paper but when I listened to Dr du Toit's final conclusions, I wondered whether the words, 'Within the data available', aren't the key to this whole situation. I agree that he has demonstrated a workable relationship between the current industries for levy and dustiness, but among the factors which he lists as being important, I know that there is one which is missing. This is extremely difficult to evaluate. It's a factor which has destroyed, on so many occasions, the work which has been done by so many genuine, intent, honest people working in this field, and this is this unknown factor, this hidden factor of political opportunism, which has so often played a very important part in pneumoconiosis compensation. "How many of us have seen the grubby, grasping fingers of power-mad demagogues, and I can name them for you - but I won't - and also the blatant vote-catching of certain politicians interfering in this field. How, at the end of all that, the poor scientist, the poor dedicated man in the Mines' Department, who has to write the law of compensation, can operate, I do not know. "From this picture the ordinary layman recoils in horror. Among the casualties in this particular war, which has been fought over so many years, I am perfectly certain, are some of the criteria of certification, especially in '56/,57, when that extraordinary condition, known as 'pulmonary disability' was introduced. I am sure there were casualties then, in the criteria of certification. "Nevertheless, this paper is a worthy addition to the long list of scientific work done on this so-important

By C. J. Van Niekerk

The study comprised of the investigation into the sensitization characteristics of AISI 409 titanium stabilized ferritic stainless steel during low heat input welding. AISI 409 is a fully ferritic stainless steel used in catalytic converters and tubing for automotive exhaust systems due to the supposition that sensitization does not occur during low heat input welding. Two plates of 2 and 4 mm were tested for sensitization during low heat input welding. The study confirmed that chromium carbide (M23C6) precipitation occurs on the grain boundaries in the heat-affected zone with consequent depletion of Cr adjacent to the grain boundaries during welding. In the 2 mm plate sensitization occurred in the heat input range of 0.1 kJ/mm to above 0.25 kJ/mm and in the 4 mm plate sensitization occurred in the heat input range of 0.2 to 0.9 kJ/mm. Ti stabilization is ineffective at the heat inputs used in this investigation due to the rapid cooling rate through the temperature region where TiC precipitates. The presence of N was found to be detrimental since it consumes Ti on cooling, forming TiN, effectively lowering the amount of Ti available for TiC formation during rapid cooling after welding. Annealing for 5 minutes at 725°C does not improve the sensitization characteristics of the welded plate. There is a linear increase in grain size as heat input increases. The resistance to pitting corrosion decreases in the sensitized, welded plate in theheat-affected zone adjacent to the fusion line of welding. Keywords AISI 409 ferritic stainless steel, sensitization, grain growth, resistance to pitting corrosion, low heat input welding.

Jan 1, 2011

By J. H. Zietsman, M. W. Erwee, P. J. A. Bezuidenhout, Q. G. Reynolds

"Pyrometallurgical furnaces are tapped through tap-holes that are opened with drills and oxygen lances. The lance is often used on its own or as the last step of opening the tap-hole. Interaction of oxygen with molten material inside the tap-hole can occur, and is a phenomenon that is not well understood. As part of a study that focuses on the effect of lancing on flow inside and around the furnace tap-hole, a cold-model validation was done. The validation study focuses on validating the MULTIPHASEINTERFOAM multiphase flow solver in OpenFOAM® for the problem involved. The sensitivity of the model to different materials properties (viscosity and density in particular) is presented with both cold models and the results from flow simulations in OpenFOAM®. IntroductionMany pyrometallurgical operations are carried out in furnaces where molten material accumulates continuously. Once enough material has accumulated and is ready to be removed from the furnace, material is tapped through one or more tap-holes in the furnace. Tap-holes differ significantly in both geometry and materials of construction, depending on the process involved – examples of different types of tap-hole configurations can be found in, for example, Nelson and Hundermark (2014). Tapholes all share one common feature: they are high, wear areas of the furnace. Molten material at high temperature flows through these areas, after which the tap-hole is sealed, usually using tap-hole clay. The purpose of the tap-hole clay is to harden inside the tap-hole and seal it until the next tap.Once ready to tap, a pneumatic drill and/or oxygen lance is used to open the tap-hole. The extent of lancing a furnace tap-hole depends strongly on the type of furnace. In, for example, many blast furnace operations lancing is limited as much as possible, and done only if drilling was not effective. In other operations, such as on small-scale pilot furnaces with short tap-holes, only lancing is used to open the tap-hole."

Jun 1, 2019

By L. Arnberg, E. Ott

The microstructure of ferrosilicon is important since it controls the disintegration of the material during crushing and thus the generation of fines. Therefore a study of the microstructure formation during solidification of pure FeSi(75wt%Si) and FeSi(75wt%Si) containing 1.2wt%Al and 0.2wt%Ca has been initiated. The material has been cast into rods of 8mm diameter, which have been remolten by induction heating and directionally solidified in a Bridgman apparatus. This allows the temperature gradient and the growth rate to be controlled independently. The temperature history during solidification has been recorded by a thermocouple in the melt. Growth rates have been varied between 5 and 400µms-1 and temperature gradients between 3 and 14°Kmm-1. The microstructures show a large dependence on the solidification conditions. The crack formation in the alloys has been studied and found to be strongly related to the microstructure.

Jan 1, 2004

By B. Salt, R. Sullivan, E. Roos, M. de Vries, K. McKenna, L. R. Nelson, M. J. N. Uys, P. Jacobs, E. Munnik, P. Lewarne

A review is presented of the furnace cooling system design and operating developments since the initial furnace start up in January 2001 of the Chambishi DC-arc furnace to produce ferrocobalt alloy. The furnace operating conditions present a number of challenges to the furnace designers and operators in particular to provide a sustainable lining that can withstand the highly corrosive siliceous slag (roughly 50% SiO2). This is exacerbated by the dual requirement to operate this slag in a relatively highly superheated state (?T ? 400°C when tapped at 1550°C) to ensure that the ferroalloy can be tapped (estimated 1370°C alloy liquidus temperature) prior to atomisation. The core design challenge occurs at the alloy-slag interface, where a single refractory type cannot simultaneously meet the dual requirement of both adequate alloy and slag corrosion compatibility. Progression by the fourth furnace campaign to involve a retrofit of the bath sidewall to Hatch high-intensity, water-cooled, copper Waffle coolers and tapblocks is described. This involves operation of the entire slag bath, the slag-alloy interface and a portion of the alloy within a more chemically compatible refractory/slag (and possibly at times even an alloy) freeze-lining. Due to the high furnace power density employed (up to 500 kW/m2 hearth area) coupled with the large slag superheat needed, the resulting imposed peak bath sidewall heat fluxes are substantial, especially in the alloy (typically averaging 170 kW/m2), and on occasion have exceeded 1000 kW/m2. The performance of the Hatch Copper Waffle coolers under such aggressive process pyrometallurgical conditions is described. Aspects of the design and especially operating strategies to effect sustained production at up to 38 MW power input are also discussed.

Jan 1, 2004

By I. Mitov, A. Stoilova, D. Krastev, B. Yordanov

We present three technological scenarios for the recovery of valuable components from gangue, stored in the tailings dam at Kremikovtzi metallurgical plant in Bulgaria, into marketable iron-containing pellets. In the first approach the iron concentrate was recovered through a two-stage flotation process, desliming, and magnetic separation. In the second proposed process, the iron concentrate was subjected to four sequential stages of magnetic separation coupled with selective magnetic flocculation. The third route entails the not very common practice of magnetizing roasting, followed by selective magnetic flocculation, desliming, and magnetic separation. The iron concentrate was pelletized in a laboratoryscale pelletizer. Each technology has been assessed with regard to the mass yield of iron concentrate, the iron recovery. and the iron, lead, and zinc content in order to identify the most effective route.

May 1, 2021

By W. Mbhalati

"Conzal Mine was not meeting production targets in 2013, and it was established that this was caused by the inability of the load haul dump machines (LHDs) to tram the required tonnages. An investigation of the LHD productivity was therefore conducted to identify the inhibiting factors. This was accomplished by carrying out a literature review on LHD operations to gain in-depth knowledge and conducting observations in the working environment. The relevant information and data on the LHD type used at Conzal was also acquired.The major inhibitor was found to be excessively long tramming distances in all the sections of the mine. The one-way tramming distances were all significantly greater than the 90 m set in the mine’s code of practice (COP), with the Main Shafts section having the longest average one-way tramming distance of 260 m. The other inhibitor was LHD utilization, which in 2013 was only 47% against a target of 70%. Simulation of the LHD operation, taking these two factors into account, showed that production could be increased by more than 100%. As a result, it was recommended that conveyor belts should be extended regularly in order to keep tramming distances within the recommended one-way distance of 90 m. In addition, utilization can be improved by minimizing employee absenteeism as well as by modifying the travelling routes such that LHDs do not encounter unnecessary delays.Paper written on project work carried out in partial fulfilment of BSc. (Mining Engineering)"

Jan 1, 2015

By Y. I. Yang, Y. -B. Tang, D. -J. Ma

Chlorine-containing minerals are commonly present in coal. Associated minerals such as pyrite can undergo exothermic reactions. Consequently, it is of great significance to study the effect of inorganic chloride on the spontaneous combustion of coal. In this study, the effects of five inorganic chlorides (sodium chloride, magnesium chloride, potassium chloride, calcium chloride, and zinc chloride) on the spontaneous oxidation of coal were investigated. Analysis of the gaseous products of coal oxidization at low temperatures (323K to 453K) showed that the presence of inorganic chlorine in coal markedly decreases O2 consumption and the generation of CO and CO2. Samples of raw coal and chlorine-loaded coal were oxidized for 36 hours under the same experimental conditions. Infrared diffuse reflectance spectroscopy results showed that inorganic chloride can inhibit the oxidative decomposition of some functional structure components (methyl, methylene, methine, and hydroxy) in the coal. The influence of inorganic chloride on the oxidation characteristics of the functional groups in coal during spontaneous combustion was investigated using benzyl alcohol and 1-phenylpropanol as model compounds, which were tested under the same experimental conditions as the coal samples. The oxygen consumption of model compounds with and without the addition of inorganic chloride further suggested that inorganic chloride may hinder the oxygenolysis of these structures during low-temperature oxidation. This phenomenon can be attributed to the radical reaction from the perspective of radical chemistry. It can therefore be concluded that inorganic chlorides play an inhibitory role in the spontaneous combustion of coal.

Jan 1, 2015

By J. K. Williams, M. P. Wells

"As part of the planning system at each division of Nchanga Consolidated Copper Mines, Limited, the Mine Planning Department is required to produce a detailed production schedule for each shaft.Because of the difficulties in producing a schedule which satisfies all the mining constraints, and because of the large clerical effort involved, the full range of possible schedules can never be considered.It has been found possible to produce a schedule using linear programming which satisfies the majority of the many varied mining constraints. Computer programs have been written to enable the mine planning department to use this mathematical system without assistance.The system has a large degree of flexibility to enable the planner to include conditions which cannot be incorporated readily in the linear program. This system permits the more efficient production and evaluation of schedules and reduces the amount of clerical effort."

Jan 1, 2014

By P. Ramsaywok, S Ndanduleni, G. Legodi

The objective of this paper is to share the optimisation journey of a pilot Reflux classifier (RC) circuit in the Exxaro GG1 plant, at Grootegeluk beneficiation complex in Lephalale, South Africa. The RC circuit was commissioned in 2016 to produce semi-soft coking coal at its fines circuit; however the stability of operation as well as the quality control of the coal product was not fully achieved. Various test campaigns and optimisation studies were conducted to understand and optimise the RC circuit at GG1. The studies revealed circuit design inefficiencies; provided an improved technical understanding of the current pilot circuit and the parameters required for the circuit to reach a stable operation. The operation was stabilised with its current inefficiencies to produce an average 12.5% ash semi-soft coking coal product for sustained periods, above the initial target of 10.3% ash. Keywords: Reflux classifier, coal

Jan 1, 2020

By M. Kumral

A mining system consists of many sub-systems such as drilling, blasting, loading, hauling, ventilation, hoisting and supporting. During mining operation, these sub-systems may experience various problems that stop the operation because of possible environmental equipment and safety issues. In order to ensure delivery contracts in the required quality and safe mining medium, the operation should be, at least, performed in the specified reliability level of the system. If the system reliability decreases below the specified level, there will be safety and financial losses for the mining company. Therefore, the mine should be maintained by a reconstruction procedure to guarantee the operation continuity. Given that each sub-system has a different reliability function and maintenance cost, the determination of reconstruction time will be a complicated decision making problem. In this paper, the determination of reconstruction time is formulated as a nonlinear optimization problem and solved by genetic algorithms (GA). A case study was conducted to demonstrate the performance of the approach for an underground operation. The results showed that the approach could be used to determine the best action time. Keywords: mining system; genetic algorithms; reconstruction time; reliability analysis

Jan 1, 2009

By M. H. Marsden, R. A. Laybourne, J. D. Flint

Operations of the strip mine at Arnot Colliery are described, and the improved volumetric extraction of the in situ coal reserves that has been obtained by the application of strip-mining techniques is highlighted. An account is given of the major problems encountered during the early stages of the operation with particular reference to overburden removal. coal and parting handling, and transportation. The techniques used in dealing with the problems and the current degree of success in overcoming them are outlined.

Jan 1, 1980

By D. I. Hoyer, M. F. Dawson

The results obtained from the operation of a batch centrifugal ball mill are reported, together with the development of a model for the behaviour of a particle in free flight within the mill, and the introduction of a cumulative breakage rate function. Schumann and Rosin-Rammler plots show the change in particle-size distribution with time at various configurations of the mill. Graphs showing the rate of production of fines and the rate of breakage of coarse particles are included.

Jan 1, 1982

By J. W. Joubert, R. C. W. Webber-Youngman, M. D. Budeba

"SynopsisCost estimation for surface coal mines is a critical practice that affects both profitability and competitiveness. New mines require these costs to be estimated using available information before a project begins. The competitive advantage of a new mine depends on it being both efficient and cost-effective. Low-cost producing mines have a higher chance of survival in a low-price environment than do high-cost producers. The competitiveness and profitability of a coal mine is based on the costs of production and the supply position on the cost curve. There is no single method of cost estimation, and the available methods consider only one or a few variables, leaving out multiple variables that could significantly affect the estimation of mine costs. Mining companies are thus searching extensively for a method that will increase accuracy in the estimation and evaluation of mining projectsThis paper highlights the shortcomings of the available approaches and proposes a data envelopment analysis method to develop a frontier for effective surface coal mines, and the use of a parametric method for modelling the costs and productivity of new mines to ensure effective competitiveness. The models will extend the capability of estimation and the accuracy of estimates using the efficient decision-making units, by considering the optimal mine-specific and external variables affecting costs.IntroductionCoal contributes 25% of the world’s primary energy needs, after fuel oil, which contributes 35%. The world energy demand, estimated over the period 1990 to 2030, is expanding at a cumulative annual growth rate (CAGR) of 1.7% (Schernikau, 2010, p. 14). This emphasizes the need for enhancing the production of existing mines, as well as opening new mines in order to increase the supply of coal."

Jan 1, 2015

By D. W. de Vos

A school on the principles and practices of ladle metallurgy, organized by the Technical Committee: Metals Technology of The South African Institute of Mining and Metallurgy, was held at the University of Pretoria from 13th to 16th November, 1989. The course leader, Professor R.J. Fruehan from the Carnegie Melon University, Pittsburgh, Pennsylvania, presented the main part of the course. Three papers were read by local steelmakers on the experience gained in the field of ladle metallurgy in South Africa. The School also included a special half day seminar on new and innovative steelmaking and casting processes presented by Professor Fruehan.

Jan 1, 1990

To B. K. Martus I discussed several points raised by Mr Martus in my reply to Professor Krige*. Mr Martus discusses several possible interpretations of optimum South African sales, but in my paper these sales refer to the sales level that maximized the working profit of the whole South African gold-mining industry over the past eleven years. Mr Martus also seems to be under the impression that the paper deals with the future. While there may be references to the future, and some implications for the future may be obvious, the paper deals essentially with the past eleven years.

Jan 1, 1984

This paper considers the probability of the occurrence of potential rockfals in deep-level gold mines where there is point support (props, pipesticks, and timber sticks). The investigation described gave rise to the following implications: natural joints subparalel to the direction of strike have a controlling influence on the potential occurrence of rockfals; with discrete types of support such as props at typical sparings, there is a significant probability of the occurence of potential rockfals; the use of headboards oriented in the direction of strike reduces the probability; and loss of support from a prop increases the probability.

Jan 1, 1989

By A. W. S. Schumann

SYNOPSIS The most economic exploitation of South African coal resources requires sustained study of the balance between known resources and the predicted rate of consumption, against the background of the development of other sources of energy in South Africa and relevant developments elsewhere in the world. A number of the major issues which would arise in such a study are discussed, including the need for a standardized South African definition for coal resources, the merits of sectoral forecasts of consumption compared with global forecasts, the encouragement of a higher recovery from reserves, and the development of an export market for South African coal.

By P. Henning

Rock fall accidents continue to be the main cause of fatal and serious injuries in the mining industry. Although there has been an improvement in the FOG (falls of ground) related fatal and serious injuries over the past few years, the rate is still too high. New technology has made it possible to reduce this rate significantly. FOG accidents imply failure of the support system or the design of the support system in use. In this paper we deal with the latest technology available to assist the mines to reduce the rates of FOG related injuries and fatalities.

Jan 1, 2010