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By S. W. Jacobsz, Y. Narainsamy

Several high-impact tailings dam failures around the world in recent years have placed a renewed focus on the stability of tailings dams and pointed to potential shortcomings in traditional drained design and safety evaluation procedures. A need to consider undrained shear strength in the design of tailings facilities has become apparent. However, there are specific requirements that need to be met before undrained shearing occurs. In South Africa, the last major failure was likely the Merriespruit disaster in 1994, which leads to the question of whether the conditions required for undrained shearing are readily applicable to South African tailings dams. This paper describes research at the University of Pretoria that has recently commenced to further investigate the conditions required for undrained failure to occur. The research includes laboratory and field testing to replicate these conditions in the laboratory and relate them to those found in an active tailings dam.

Jun 2, 2022

By B. Hayen

The principal advantages of fibre optics as compared to copper wire are well known and include almost perfect electromagnetic isolation, light weight, small size, excellent transmission security and substantially better bandwidth/distance performance. The decreasing cost of the optical fibre technology (both fibre cable and equipment) has led to another generation of private networks, which provide much larger bandwidths, very high reliability and an increase of the maximum geographical coverage. The larger bandwidth allows to transport all types of information on a single network. Typical communication requirements are speech (audio), computer data, LAN info, control information, video, etc. OTN or ‘Open Transport Network’ is a transmission system based on the latest available technology in fibre optics. It is characterized by the dual ring approach, resulting in high network availability, and the integration of different types of services in one network. As such, it can fulfil almost all transmission requirements for voice, data, LAN, video and any special service required.

Sep 1, 2001

By T. Bui, T. Wallmach, S. B. Blancher, A. Back, M. Pierre, V. Delarue, A. Kanzari

This study investigates nickel laterite porosity and its impact on geometallurgical modelling. We performed a detailed mineralogical study on a set of Ni-laterite samples originating from New Caledonia. Samples were analysed after heavy liquid separation by automated SEM (QEMSCAN®). Laboratory and QEMSCAN® modelling results do not correlate well. Ideal physical mineral properties such as mineral densities used in QEMSCAN® modelling do not match the actual physical densities of minerals. The presence of empty or water-filled pores can represent important amounts in minerals and change the overall density of a particle. An adequate modelling of real density separation of minerals and particles should consider the water-filled pores. The first step towards a better simulation was to integrate pores larger than 10 μm in diameter filled with water (density of 1 g/cm3) in the QEMSCAN® database. The results approached, but did not match the physical laboratory results. The second step was to identify nanometer to micrometer sized pores, which could not be identified by QEMSCAN®. It was possible to identify nanometric pores in enstatite, Fe-oxides, serpentine, talc and quartz, and radial aggregates of fibrous Fe-oxyhydroxides with high resolution SEM (HR-SEM). The quantification of those micro-sized pores was performed on 2D HR-SEM images using image-processing techniques developed in Python to calculate the nanometer to micrometer scale pores in each mineral. Despite the limitation of converting 2D imaging into 3D objects, in our case pore sizes and porosities, we were able to calculate a mean value of porosity for each mineral. The integration of this porosity in the calculation of particle densities yielded a good match between the QEMSCAN® model and the laboratory experiment results. Despite the complexity of a strongly weathered material, such as Ni-laterites, a good knowledge of the ore makes it possible to build reliable processing models. Keywords: Mineralogy, geometallurgy, nickel laterites, SEM, QEMSCAN®, porosity, density

Jan 1, 2020

By J. P. T. Kapusta

"The copper smelting industry faces increasingly stringent environmental regulations and must continue driving innovation to reduce energy usage in its production chain. With the coming of age of ‘bottom-blowing’ copper technologies in China over the last decade, much renewed attention has been brought to tuyere bath smelting for clean copper-making. Since bottom-blowing sonic injection was originally developed and implemented in steelmaking in the 1970s and lead smelting in the 1990s, the time seems appropriate to revisit the sonic injection concepts and dispel some myths. After reviewing the trends in the copper industry and providing a brief historical context of research and development related to sonic injection, the author presents a comparison of the main submerged tuyere bath smelting technologies, namely the Noranda Reactor (NR), the Teniente Converter (TC), and the Chinese Bottom-Blowing Smelting Furnace (SKS/BBS) for copper, and the Queneau-Schuhmann-Lurgi Reactor (QSL) for lead. The core of this article, however, consists of a brief description of the fundamental theories for sonic injection (jetting regime) and ‘sonic flow mapping’ to illustrate the relationship between the minimum tuyere back-pressure required to achieve sonic flow and the tuyere internal diameter. The article also offers a comparison between side- and bottom-blowing in jetting regime before concluding with the author’s vision of the new trend in submerged tuyere bath smelting. IntroductionIn the last decade, developments in the copper smelting industry have been driven by two key concepts: (1) increasing cleaner smelting capacity to meet the world’s growing copper demand, as illustrated in Figure 1, and (2) increasing process off-gas capture to comply with more stringent environmental regulations and abide by a corporate social responsibility ethic of a clean work environment (for smelter employees) and clean air (for families living around smelters). The copper smelting industry has also faced some major challenges in the last few decades, including (1) low treatment and refining charges (TC/RC or processing fees) impacting custom smelters, (2) lower concentrate quality and grades with higher levels of impurities (e.g. As and Hg), (3) higher processing and transportation costs due to the rising cost of energy, (4) restrictions in process intensification (tonnage oxygen usage) due to furnace integrity limits, and (5) scarcity of educated and trained personnel due to fewer metallurgists graduating from pyrometallurgical school programmes combined with a high retirement rate of skilled workers."

Nov 1, 2018

By R. H. Matjie, J. R. Bunt, A. C. Collins, J. C. van Dyk, C. A. Strydom

South African coal discards derived from feed coal for thermoprocesses pose human health and environmental problems and incur high disposal costs. These issues need to be resolved. Coal fines and a coal fines/ K2CO3 blend were combusted at 700°C in a laboratory rotary kiln to produce ashes containing metakaolinite (Al2O3.2SiO2) and illite/muscovite/orthoclase amorphous materials. The blend ash and coal fines ash, containing 18% K2O and <1% K2O respectively, were leached with water and with 1 M and 8 M NaOH at 80°C for 4 hours using a solid to liquid ratio of 1:5. The 8 M NaOH leach yielded 17% sodalite (Na8Si6Al6O24(OH)2) formation through SiO32-, Al(OH)4-, and Na+ precipitation in the leached ashes. The 1 M NaOH leach yielded no sodalite. X-ray fluorescence analysis of the original ashes and leached ashes showed low Al and Si dissolution efficiencies due to the sodalite formation. Sequential NaOH leaching resulted in the highest potassium dissolution efficiency of 89% for the ashes of fines/K2CO3 blend and 59% for the fines. It may be possible to increase the ash-derived zeolite concentration by using even higher NaOH concentrations (12–20 M NaOH) during leaching. Sodalite derived from coal ash could possibly be utilized for water purification in industrial applications, or as molecule separators. The potassium-containing liquid could be used in fertilizer manufacture.

Mar 30, 2023

By O. S. Tinkler, K. C. Sole

Approximately 20% of current world copper cathode output is produced using a hydrometallurgical process route, generally referred to as the leach–solvent extraction–electrowinning flowsheet. Since its commercialization in the late 1960s, steady improvements in the performance and efficiency of the solvent-extraction reagents and equipment, combined with significant developments in leaching and electrowinning, have made an ever-widening range of ore types amenable to this technology. Following successful implementation on all major continents, a large proportion of growth in recent years derives from the re-emergence of copper solvent extraction in the Central African Copperbelt. This review provides a brief history of the development and evolution of copper solvent extractants and mixer-settler contactors, and the significance of the Copperbelt region in achieving commercialization and acceptance of the technology. The opportunities and challenges presented by the abundant high-grade oxide ores of the Copperbelt are contrasted with the processing of solutions derived from the low-grade mixed oxide–sulfide ore bodies that are prevalent in other geological regions. The current status of hydrometallurgical copper production in the African Copperbelt, within a global context, and a medium-term outlook for the technology are discussed.

Jul 5, 2023

By B. F. Giyani, A. Salama

Tanzania is a country with a variety of mineral deposits, including metallic minerals, gemstones, mineral fuels, industrial minerals, and critical minerals. This study provides an overview of mining legal framework, mineral occurrence and production, challenges in the mining sector, and government initiatives. The aim is to demonstrate the development of the mining sector in Tanzania and explore the potential for further mining investment in the country. The mineral production data showed generally increasing trends over the years, for example, gold production increased from 42 tonnes in 2018/2019 to around 50 tonnes in 2023/2024. Despite the growth, the mining sector encounters several challenges, including a lack of detailed geological information on mineral deposits, inadequate infrastructures in some remote mining sites, the existence of informal artisanal miners, and mineral smuggling. The Tanzanian government has introduced several initiatives to address these challenges, including carrying out the highresolution airborne geophysical survey to increase geological information in some areas, the formalisation of artisanal and small-scale mining, establishing mineral markets to combat mineral smuggling, and encouraging mineral value addition within the country.

Oct 24, 2025

By S. T. Johansen, B. T. Løvfall, T. Rodriguez Duran, J. Zoric

A methodology for building pragmatic physics-based models is here adapted to predict the erosion of ladle linings in the steel industry, in order to support operators when deciding whether the lining can be used safely for another heat. A defective lining may allow 140 t of molten steel to spill, with disastrous consequences for workers and plant. The adopted work flow for the development, challenges faced, and some model results are presented. One key learning outcome is that model development should allow time for maturing the process understanding, as well as for many iterations by ‘questions-responses and actions’ at various stages in the model development. Good interaction between the development team and industry case owner is an important success factor. Combining or extending the model with the use of machine learning and cognition-related methods, such as knowledge graphs and self-adaptive algorithms, is discussed.

Apr 16, 2024

By D Olivier

De Beers&apos; Finsch Mine is situated in the Northern Cape province, 170 km northwest of Kimberley. The concentrator facility, designed and constructed by Bateman Engineering, was commissioned in 1967 and upgraded in 1979 using diamond liberation and extraction technology available at the time of design. Since then significant advances in diamond processing and technology have been made and these -have been incorporated into the new main treatment plant and recovery plant flowsheets, making diamond liberation and recovery from the Pre-1979 dumps a viable economic option at Finsch."

Jan 1, 2010

By J. W. van der Merwe, K. G. Moloko

Furnace wall tubes from 600 MW subcritical boilers at three coal-fired power stations were sampled and the fireside deposits examined to determine the mechanism of fireside corrosion. This involved an indepth investigation into the morphology and composition of the fireside deposits and the conditions of the furnace that enable this type of attack. SEM-EDS analysis revealed high concentrations of oxygen, iron, and sulphur, QEMSCAN and XRD analyses identified the presence of Fe3O4, Fe2O3, FeS, and FeS2. Differential thermal analysis showed thermal activities at temperatures of 500–600°C, 900–1100°C, and 1100–1250°C, which are associated, respectively, with FeS2 oxidation to FeS and Fe2O3, at 475–525°C, formation of aluminosilicates at 925–1100°C, and melting of FeS around 1190°C. The absence of sodium and potassium eliminates the contribution of molten alkali sulphates to the corrosion. The consistent coexistence of iron sulphide and iron oxide is indicative of the substoichiometric conditions in the furnace, while the detection of pyrite suggests that the coal is not completely combusted, which points to a poor combustion process. These observations were affirmed by gas analysis at one of the stations, where very high levels of carbon monoxide were measured at the furnace wall (≥ 14 000 ppm) and furnace exit (≥ 3500 ppm). The high CO concentrations are indicative of limited combustion caused by limited O2. These reducing conditions promote the formation of FeS-rich deposit, which is the corrosive species responsible for degradation.

Jun 1, 2021

The key aspects of process metallurgy that distinguish platinum group metal (PGM) concentrate smelting from that of other base metal sulphide concentrates are presented. These differences include considerably higher input chrome and magnesia contents that directly raise the slag liquidus temperature and have the potential to increase accumulations of refractory spinels. Most importantly, the higher processing temperature required for PGM smelting, and the resulting very high matte superheat lead to considerably more onerous smelting conditions than those typical of other smelting operations. This has presented challenges to furnace design and integrity, especially when coupled with the progressive intensification of smelting, involving doubling, and then redoubling, of furnace power input over the past 20 years. These power increases have been enabled by increasingly more advanced furnace cooling and structural technologies. Key technologies include strong constant-force spring-loaded bindings acting in three dimensions to minimize infiltration of superheated matte into brick joints, and robust well-cooled tapholes for reliably tapping the superheated matte. The result has been substantially improved productivity, and reduced smelting capital cost outlay per unit of production. A significant challenge that was not anticipated, presented itself in the form of insidious corrosion of the furnace lining, and especially high-intensity copper cooling elements. Investigation of corrosion in related industries eventually identified &apos;chloride-accelerated sulphidation&apos;, and this term has been retained as it generically describes the most pertinent aspects of the accelerated low-temperature wear of copper coolers observed in PGM smelting. In addition to discussing the corrosion mechanism, this paper describes a number of solutions that were developed jointly by Anglo American Platinum and Hatch to address the copper corrosion problem. First, new monitoring technologies allowed furnaces to be operated more safely for a longer period of time. Second, a system for replacing corroded coolers from outside the furnace during a fast &apos;hot&apos; shutdown minimized the impact on furnace operating factor and hearth life. Finally, a corrosion-resistant graphite-protected cooler design significantly improved furnace campaign life, and heralds a more lasting solution to cooler corrosion in PGM furnaces.

Jan 1, 2012

"Chairman: Dr W. S. RAPSON Rapporteur: Mr J. W. WILSONPapers:Computer applications in rock mechanics by F. H. Deist, E. Georgiadis and J. P. E. Moris Rock mechanics in the design of mine layouts by K. Hodgson and N. G. W. Cook Automated regulation of mine ventilation by P. NiskanenThe rock mechanics papers, because of their complementary nature, were presented in succession and discussion on both followed directly. The paper on automated ventilation control at a mine in Finland was then presented and the session was closed with several contributions to this paper.By and large the papers and discussions which followed in this session showed how a classic tie-up had developed between the use of computing techniques in important fields of mining, and their practical application. In fact, the dis-cussion following the rock mechanics papers showed clearly that without the aid of high-speed digital computers the rate of progress in applied research in deep-level hard-rock mines, would have been severely hindered. Furthermore, it became apparent from the comments made by several contributors that the rock mechanics techniques and computer progress described in Deist&apos;s and Cook&apos;s papers could be used to provide useful data in the solving of rock mechanics and design problems on mines other than flat dipping deep tabular deposits.The paper by Niskanen, which described an automated ventilation control system at a mine in Finland, showed how effective computers could be in areas where the reversal of mine ventilation occurs due to severe seasonal temperature ranges. Although the system described in the paper could not be introduced easily in complex underground mines, several contributors gave examples of similar ventilation problems that could be solved mechanically,In introducing his paper, Dr Deist said that the purpose of the paper was to give a brief account of some of the programs designed by himself and his co-authors to aid in the solution of rock mechanics problems,The first system presented by Dr Deist was known as MINSIM in the South African mining circles. This system was designed specifically to aid in the solution of rock mechanics problems in the South African gold mining industry. It was particularly designed to handle tabular deposits at great depth but it has been used satisfactorily on a number of occasions to obtain at least approximate solutions in other mining situations. Dr Deist said that the principles embodied in the programs were easily extended and, in fact, there was a project in progress at that time which was aimed to do this. He said that the principles could easily be extended to shallow-depth mining at steep or very steep inclinations."

Jan 1, 2014

Bateman Engineering managed the establishment of a second diamond treatment plant at the Letseng Mine in the Mokhotlong District of northern Lesotho, about 100 km from the town of Buthe Buthe. Letseng Diamonds Proprietary Limited, is owned 70 % by Gem Diamonds and 30 % by the Government of the Kingdom of Lesotho. The second plant, which commenced construction in late 2006, doubled Letseng Mines&apos; hard rock processing capacity from 2.6 million t/yr to 5.2 million t/yr, making it the worlds&apos; seventh largest diamond mine by throughput. Bateman Engineering provided the engineering design, procurement and construction management of the new plant.

Jan 1, 2010

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 D. F. Malan, W. J. Theron

Practical mining aspects should be considered when conducting pillar designs for bord-and-pillar layouts. The current methodology for pillar design will result in increasing pillar sizes with depth. This affects the extraction ratio and will result in onerous ventilation requirements when cutting large pillars. A holistic approach, including all mining engineering requirements, is required to ensure that the rock engineering designs are optimized to ensure efficient mining operations and sustainable production. Bord widths should not only be a function of the rock mass ratings, but should also be selected to fit the specifications of the mechanized equipment. The use of a ‘squat pillar’ formula for hard rock is discussed in the paper and the formula based on the exponents of the Hedley and Grant pillar formula, is explored. The effect of abutments and geological losses on average pillar stress is also explored. These factors must be considered when designing layouts at increasing depths.

Nov 27, 2024

By E. Kumar, L. A. Kumar

"A methodology is proposed to develop an optimization model to understand the impact of transporting minerals, from mines to the final destination, on air quality. Recently, there has been increasing concern about the combined effects of multiple activities over many years, and the regional environmental changes brought about by a single project. Environmental issues in the iron ore industry have highlighted the need to broaden the cumulative impact assessment. In this study, we simulated the optimal routes and quantity of materials needed to meet the destination plant demand based upon environment constraints (level of air pollution), as well as the cost of transportation and availability of materials. Multiple scenarios were developed to analyse the effects of changes in routes, alternative transport system (or multi-modal split), traffic congestion, and the cumulative impacts on air quality. The air quality impact zones of the study area were demarcated using a GIS technique. The expected outcome of the study is the selection of a suitable transport system for a particular site with the least impact on air quality, including the transportation route, relative to the minimum cost of transportation of the minerals from the mines to their final destination. The proposed methodology is evaluated with a case study. IntroductionIn India, the process of environmental impact assessment (EIA) has been focused primarily on the local impacts of projects, without considering regional environmental effects. Environmental clearances for proposed projects are based on reports of local impacts. However, any developmental project poses a potential risk to the environment as a whole, and not just in the immediate vicinity of the project. Recently, there has been increased concern about the combined effects of multiple activities over many years—the regional environmental changes due to development of a single project (Dutta, Mahatha, and De, 2004). Environmental issues throughout the country, particularly in the iron ore industry, have emphasized the need to broaden the analysis to include the combined impacts, or those forecast for a proposed region, on an existing environment. The most significant adverse environmental consequences of iron ore transportation are the deterioration of biodiversity and air quality (Kumar and Ajay, 2015)."

Jan 1, 2017

By L. Forbes, G. Forbes, J. Wang

Bubble size measurement is a vital part of flotation system analysis and diagnostics. Over the years, a great many different bubble size analysis tools have been developed. However, all of them rely on ex-situ measurement and in-pulp sampling techniques. This paper evaluates the Mettler Toledo ParticleView™ Measurement probe as a novel method for in-situ bubble size measurement. This device is then compared to the conventional Anglo Platinum Bubble Sizer (StoneThree). It was found that the in-situ bubble size analysis technology appears to be a more user-friendly and reliable option for determining bubble size in flotation. However, the current instrument design is not suited to industrial applications. Keywords: Bubble size measurement, bubble coalescence, PVM probe

Jan 1, 2020

By F. C. Harris, S. J. Gaab, J. Sattarvand, S. Duzgun

Underground mines are inherently dangerous due to potential hazards such as fires, explosions, and caving of rock. Although these events are rare, once they occur a speedy and safe egress of mineworkers is critical to survival. Static evacuation systems use exit signs or directional lines but can get obstructed or be hardly visible in smoky or dusty conditions. This paper presents the investigation of the effectiveness of a smart evacuation technology in underground mining, where a real-time guidance system leads individuals on an optimised path to the egress while avoiding danger zones, compared to conventional practices. Participants simulated an evacuation from a virtual reality mine, using the conventional system and the smart evacuation system with real-time guidance. The highest reduction in evacuation time using the smart method amounted to nearly 40% on average. Moreover, 83% of participants preferred the smart guidance system, and agreed that it could enhance safety.

Sep 1, 2021

By W. R. Matizamhuka

"The consolidation of nano-sized composite materials presents a challenge using conventional hot pressing methods. Spark plasma sintering (SPS) technology has shown great promise in the successful sintering of nanoreinforced composite materials. This qualitative review seeks to impart knowledge gathered, and progress made over the years on the consolidation of nanocomposite materials using SPS technology. The review is aimed at introducing this technology to the South African science and engineering community. Emphasis is on improving the mechanical properties of structural ceramic nanocomposite materials, which over the years have shown great promise in a wide range of applications, including transport, energy, mining, and the environment. Although success has been achieved within the laboratory for research purposes, there are still great opportunities to commercialize the technology for the production of larger components with more complex shapes.IntroductionSince the pioneering work of Niihara and Nakahira (1991) over a decade ago there have been extensive attempts to harness the potential of nanostructural metals, ceramics, and composites in a number of applications (Niihara and Nakahira, 1991; Selaho et al., 1997; Sekino and Niihara, 1995; Khalil, 2012; Aalund, 2008). It is generally realized that reducing the grain size of materials to nanoscale offers a significant improvement in properties. Attempts to synthesize nanostructured compacts by conventional sintering methods have not succeeded owing to the uncontrollable high rates of grain growth driven by long dwelling times at the sintering temperatures and large powder surface areas (Sergueeva et al., 2009; Gua, Khora, and Chieng, 2004; Tang et al., 2009). Following the development of spark plasma sintering (SPS) technology, it is now possible to process nanocrystalline materials with controlled grain growth. SPS, also referred to as the field-assisted sintering technique (FAST) or pulsed electric current sintering (PECS), was developed with the aim of improving on the well-established hot pressing (HP) technology (Kessel and Hennicke, 2007;"

Jan 1, 2016

By M. Onifade, O. S. Otuogbai, A. F. Mulaba-Bafubiandi, O. D. Eniowo, H. Grobler

Artisanal and small-scale miners in Nigeria struggle to attract formal financing to upgrade their operations to a more sustainable form of small-scale mining operation. Literature shows that for an investment to attract formal sources of financing; the business must be considered creditworthy by potential lenders. This means that the credit risks associated with the investment must be bearable for the potential lender. This study looks at how artisanal and small-scale miners can attract formal funding, which will help them take the leap from artisanal state to a form of sustainable small-scale mining operation. This study evaluates the creditworthiness of artisanal and small-scale mining operators using key credit risk parameters identified in the literature and through primary investigation. A quantitative study is conducted on a sample of 100 artisanal and small-scale miner establishments in Nigeria to evaluate the effect of these identified credit risk parameters on creditworthiness. It is shown in this study that being a member of a mining cooperative society, which is a form of social collateral, best improves the chances of access to formal financing for miners within the sample group. This underpins the role of social collateral, in both the formal and informal economy, and its influence in improving the creditworthiness of a typical artisanal and small-scale miner.

Jul 23, 2025