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By L. du Preez, J. D. Steenkamp

This paper introduces the concept of clean steel production from a pyrometallurgist’s perspective to the broader metallurgical community. A simplistic overview of the steelmaking process from iron ore to car body manufacturing is followed by an introduction to the South African steel industry and the technologies that it utilizes. The process is illustrated by an overview of the flow sheet and technologies for the production of clean steel at Saldanha Steel, South Africa.

Jan 1, 2015

By C. L. E. Swartz, I. J. Barker, J. H. Schubert

A dynamic simulator of the leaching and adsorption cascades of a gold plant was developed and used to compare the effect of various disturbances on the overall efficiency of the plant. These comparisons show which disturbances most critically need to be controlled to optimize plant performance. The simulator was based on an existing gold plant. Dynamic and steady-state data were collected on the plant and were used in the modeling of the process. Simple dual-rate models are used to describe the leaching and adsorption processes. Mole-balances of various species take into account the changes of concentrations in the leach, and also the movement of pulp and carbon up and down the adsorption cascade. Fluctuations in the flow rate, density, and cyanide concentration of the feed to the leach have a negative effect on the efficiency of the leach, while carbon attrition was found to be an important factor in decreasing the efficiency of the carbon-in-pulp (GIP) section. Badly regulated transfers contribute towards the decreased efficiency of the GIP section, but overflows and carbon leakage have only a limited long-term effect. Various carbon profiles and transfer schemes were studied, and the results indicated that a slightly heavier loading at the bottom of the cascade is beneficial, while the type of transfer is relatively unimportant.

Jan 1, 1993

By J. H. Lazarus

The evolution of backfill-distribution systems for deep gold mines is examined. The status of current technology for the design of backfill-distribution systems is considered with reference to pipeline pressure gradients, pipeline wear rates, and slurry flow regimes. The effect of an increase in the relative density of the slurry on the performance of backfill-distribution systems is illustrated. Future trends regarding the design of backfill-distribution systems are discussed.

Jan 1, 1993

By F. T. Cawood

The new mineral royalty regime for South Africa was signed into law in November 2008, with its main objective being to compensate the State for the depletion of public minerals through a royalty charge payable from 1 March 2010. The aims of this paper are to establish the potential impact of mining royalties on State revenues, industry affordability, and explore whether the dual formula system is likely to encourage miners to become refiners. It also measures the royalty dispensation against economists? tax standards in an attempt to make a judgement on the ?equity? of the new system. This paper argues that most stakeholders should be comfortable with most of the requirements of the Act for most of the time. However, the new regime is unlikely to motivate miners to become refiners, as the benefit of the reduced rate on refined minerals appears to be insufficient to justify the additional costs to refine the mineral resource to the prescribed states of beneficiation.

Jan 1, 2011

By K. Basaure, S. Palma, R. L. Castro

"Mud rushes are sudden inflows of fine wet ore within underground mines; they can harm people and equipment as well as cause production delays. Block and panel caving mines are prone to mud rushes in their production levels, with mud flowing from the drawpoints. Different mines have developed methods to control drawpoint conditions and thus perform safe ore extraction. The aim of this study is to develop a decision matrix and apply it to samples from drawpoints for the Diablo Regimiento mine, Codelco, El Teniente Division (Chile). The Abrams’s Cone was used to perform slump tests on mud samples and characterize their consistency by setting the saturation degree and packing. The unconfined strength for different saturation degrees and packing was then evaluated. The results show that conditions for fluid response in slump tests correspond to conditions for low strength in unconfined compression tests. We also found the water content value at which the flowing consistency changes from plastic to soft behaviour according to the slump test classification for each sample. This value varied between 12.2% and 16.9%, depending on the sample tested. Finally, a fluid security factor was defined in order to design an extraction pattern for the samples tested, based on the water content. We conclude that a very densely packed ore is not prone to flowing. The flow properties depend strongly on the specific properties of the ore tested, and consequently a specific criterion should be developed for different types of ore at a particular mine. The criterion developed for Diablo Regimiento ore provides critical water content values from 11% to 15%, depending on the ore type. IntroductionBlock/panel caving has the lowest cost and the highest production rates of all underground methods (Heslop, 2000; Hubert et al., 2000). Good management of the risks is important to ensure the security of personnel and infrastructure. Operational risks for the method include rockbursts, air blasts, and mud rushes (Hubert et al. 2000). A mud rush is defined as a sudden inflow of mud from a drawpoint or other underground opening into the mine (Butcher, Joughin, and Stacey, 2000; Butcher, Stacey, and Joughin, 2005). Mud rushes can cause dilution, production delays, and damage to equipment as well as injuries and fatalities. The elements necessary for mud rushes are mud-forming material, disturbances, a discharge point, and water (Butcher, Joughin, and Stacey, 2000). All these elements are present in block/panel caving mines. Mud-forming material comes from ore milled by the caving process; water comes from underground and surface sources. Drawpoints in the production level are discharge points for the mud. Finally, several types of disturbance could trigger the mud rush phenomena: blasting, earthquakes, operation of equipment (Call & Nicholas, Freeport McMoRan, and Hydrologic Consultants, 1998; Jakubec, Clayton, and Guest, 2012), arch collapse above drawbells (Butcher, Joughin, and Stacey, 2000; Butcher, Stacey, and Joughin, 2005; Jakubec, Clayton, and Guest, 2012) and ore drawing (Butcher, Joughin, and Stacey, 2000; Butcher, Stacey, and Joughin, 2005; Call & Nicholas, Freeport McMoRan, and Hydrologic Consultants, 1998; Jakubec, Clayton, and Guest, 2012)."

Jan 1, 2017

By A. L. Hinde, P. J. D. Lloyd, D. Hebden

The philosophy behind the design of a rougher cell for the handling of coarse feed and for the maximization of recovery within a given time is presented. The application of this philosophy in cells of 22-litre, 320-litre, and 3 m3 capacity is outlined, and the results of the process testing of these cells are given. In this testing, particular accent was placed on the recovery of water as a guide to the recovery of the finest size of particles, and the rate of recovery of various mineral species. It is concluded that a promising concept has been identified, but that further testing is needed for the firmer establishment of optimal operational parameters in a production environment.

Jan 1, 1983

By A. V. Z. Brink

This paper describes the development of a monitoring architecture that allows for continuous monitoring of the process of mining, the underground environment, the state of the rockmass and its response to mining. The system is based on an open standard and is non-propriety. It allows for dense sensor arrays in the workplace, wire less communication to the closest power line, and TCP/IP communication to a central server. Continuous monitoring and quantification of the appropriate parameters allows a mine to optimise its mine process; to dynamically access the safety and health risk to people and equipment; and to quantify exposure to potential heath hazards such as dust, gas or noise. Current application examples of continuous monitoring include an application to optimise drilling and blasting thought fragmentation monitoring; an application of wireless sensor network-based monitoring in to provide early detection of potential rockfalls; and a trail to continuously assess the gold grade at the shaft through correlation with radioactivity. It is unlikely that a single monitored parameter will provide adequate knowledge of the assessed risk or even an optimisation approach. Multiple parameters are being combined using cognitive science tools such as Bayesian theory and other statistical methods to improve the accuracy and relevance of, for example, risk quantification. The decision maker is not confronted with massive amounts of raw data but rather with a single knowledge statement such a probability of failure, a human physiological strain index or an optimisation index.

Jan 1, 2008

By S. Rupprecht, G. Rapson

Long blast hole drilling has been successfully implemented since the 1950s in caving operations, steeply dipping wide reefs and boxhole/raise developments worldwide. However, when applying long hole drilling to narrow tabular reefs, the challenges of achieving high economic drilling rates, combined with acceptable accuracy and appropriate powder factors have yet to be overcome. The focus in this paper is the selection, application and optimization of long hole drilling equipment at mining operations shallower than 2 000 meters. The drilling, blasting and cleaning operations have to be optimized as a process if maximum production at minimum per unit cost is to be achieved. For this to be possible, it is essential that the mine design and layout match the mining process being implemented. The critical parameters affecting the sustainable implementation of long hole drilling in stoping applications for platinum mines are improved safety and higher production rates compared to conventional methods. In terms of drilling, both top hammer and down-the hole hammer configurations have been considered. For economic drilling, the benefits of monitoring and optimizing performance (i.e. drill bit rotation, thrust, and percussive power) for specific rock types are discussed. While the drive is for longer, more accurate, smaller diameter holes to reduce drilling costs, the design of appropriate blast hole patterns and the corresponding charging and initiation systems is crucial for success. The effect of hole diameter and pattern on the powder factor, when comparing small diameter, shorter holes versus large diameter, longer holes, is a major factor in achieving good blasting results. Once appropriate drilling and blasting have been implemented, the cleaning process becomes a potentially critical operation to ensure the production, cost and safety goals are met. Hence, the blast hole pattern and charge have to be integrated for optimal fragmentation to suit the cleaning cycle for maximum production output. Providing that long blast hole drilling is applied as a process in a planned, committed and well-managed manner, the benefits in safety, production and cost over conventional methods should be achievable. However, if the implementation process is not planned and supported by all parties concerned, it will not be possible to succeed in the new operation. Hence, an implementation or roll-out plan of new technology is crucial for success.

Jan 1, 2004

By P M. Bradbury

The nature of aggressive process chemical requirements typically in the Platinum Refinery Industries, lend themselves to the use of Polymer Composite Glass Reinforced plastics for pipework and other associated equipment in these types of Plants. This paper discusses the basic characteristics of a Polymer Composite glass reinforced piping system and gives sample examples of applications in current present day use.

Jan 1, 2006

By P. J. Brereton-Stiles, C. J. Hockaday, I. J. Barker, M. S. Rennie

This paper reports on studies that have been done on the electrical conduction in silicon, ferro silicon, and charge chrome furnaces. A system has been developed that can distinguish between normal resistive conduction and arcing, and this was used to quantify in particular the relative amount of arcing that takes place in these furnaces. It was found that silicon and ferro silicon behave similarly and exhibit a relatively large amount of arcing. Charge chrome on the other hand exhibits considerably less arcing, and the extent of this arcing is highly correlated with the tapping of the furnace. The arcing measurements can also be used online in the control of the furnace, both for the electrodes and electrical circuit, and for the raw materials.

Jan 1, 2007

By S. R. Dindarloo

Although blasting is one of the most widely used methods for rock fragmentation, it has a major disadvantage in that it causes adjacent ground vibrations. Excessive ground vibrations can cause a wide range of problems, from nearby residents complaining to ecological damage. Prediction of blast-induced ground vibration is essential for evaluating and controlling the many adverse consequences of surface blasting. Since there are several effective variables with highly nonlinear interactions, no comprehensive model of blast-induced vibrations is available. In this study, the support vector machine (SMV) algorithm was employed for prediction of the peak particle velocity (PPV) induced by blasting at a surface mine. Twelve input variables in three categories of rock mass, blast pattern, and explosives were used for prediction of the PPV at different distances from the blast face. The results of 100 experiments were used for model-building, and 20 for testing. A high coefficient of determination with low mean absolute percentage error (MAPE) was achieved, which demonstrates the suitability of the algorithm in this case. The very high accuracy of prediction and fast computation are the two major advantages of the method. Although the case study was for a large surface mining operation, the methodology is applicable to all other surface blasting projects that involve a similar procedure.

Jan 1, 2015

By M. Olper

The change in regulations and the strong attention to the environment have suggested some changes in the traditional processes for the recycling of lead acid batteries. Engitec Technologies, marketing the Integrated CX® System, is continuously updating and improving its technology to fulfil the technical, economical and ecological requirements coming from the market and from the environmental authorities. In this paper Engitec Technologies will present the latest technical innovations introduced in the Integrated CX® System.

Jan 1, 2008

The term geostatistics was introduced by Matheron (1960) to cover the development and application of mathematical and statistical models which take specific account of the spatial structure of a 'regionalised' variable. In ore valuation the relative positions of available ore values within an ore body or portion thereof, can only be ignored in the unlikely case where there is no significant pattern of association or correlation between them - that is, if they do not disclose any significant spatial structure. A structure might not be evident in the available data, e.g. where the spacing of the available values is relatively wide such as in surface drilling on a new deep gold mine. However, practical selective mining considerations could dictate the need for eventual underground valuation on a scale much smaller than that represented by this spacing and the possibility of a significant structure on such a smaller scale cannot then be ignored. Some spatial structure must be present wherever the average variability among the values of check ore samples from the same, adjacent or nearby grooves or of borehole cores from the deflections in the same borehole, is lower than the overall variability for ore values within the whole ore body. Another practical check on the presence of a spatial structure is where it is evident that there is or will be a significant variation in the ore grades for individual ore blocks. Any correlation between peripheral and follow-up internal ore block values also provides evidence of a spatial structure, and hence the regression techniques covered in §1.16-1.2 1 can be accepted as the first application of the geostatistical procedures. The spatial structure of a regionalised variable can be studied and measured by the pattern, usually a decreasing function, in the level of correlation or of the covariance between pairs of values as the distance or lag between the values increases, that is, by the correlogram or covariogram (Krige, 1968, 1969, 1976; and Fig. 18). In geostatistics, for various practical and theoretical reasons (Matheron, 1960, 1971), the measure most commonly used is the semivario- gram, which increases as the lag increases. The semivariogram and covariance values are interrelated and for the lognormal- de Wijsian pattern used extensively for gold ore valuation both measures as well as their relationship can be defined on a fairly straightforward basis. Provided the underlying as- sumptions are realistic, the choice of measure - correlogram, covariogram or semivariogram - will be dictated mainly by convenience. Paragraph 2.2 will cover some general geostatistical terms and $2.3-2.12 will deal mainly with the theoretical side of the lognormal-de Wijsian model for spatial structures. Wherever the relevant variable lends itself to normalisation via the 3-parameter lognormal distribution (see 51.9) the de Wijsian semivariogram model is also likely to be suitable and will provide substantial advantages in application. Various practical applications will be covered in Section 3. Although confined to the lognormal-de Wijsian model, much of the theory covered and the general approach is applicable to all spatial structures. [ ]

Jan 1, 1981

By K. Morita, N. Sano

Thermodynamic properties of chromium oxides in molten slags are very important for optimization of stainless steel refining processes as well as reduction processes of chromium ores. The solubility of chromite into molten slags has been found to vary considerably with oxygen partial pressure and slag composition in former studies by the authors. In the present study, activity data and redox equilibria of chromium oxides measured under moderately reducing conditions, PO2= 6.95x10–11atm, at 1873 K are summarized. For the CaO-SiO2-CrOXsystem, the activity coefficient of chromium oxide increased with increasing basicity, and the optimized slag composition for stainless steel refining is assessed as that saturated with CaCr2O4and Cr2O3usingthe phase relations determined. On the other hand, the presence of MgO and Al2O3brings about different behaviour of chromium oxide activity and redox equilibiria and the 44 mass per centCaO-39 mass per cent SiO2-11 mass per cent Al2O3-6 mass per cent MgO slag is recommended toreduce the chromium oxidation loss in the practical stainless steel refining process at 1873 K. Keywords: chromium, activity, stainless steel, AOD, VOD, oxidation loss, redox, CaO-SiO2-Al2O3-MgO slag

Jan 1, 2004

By M. J. U. T. Van Wijngaarden

SYNOPSIS The corrosion characteristics of a new steel, 14Cr, which is a modification of the well-known 3CR12, in aqueous sulphate solution were studied through polarization diagrams and a computer analysis based on the polarization¬resistance technique. It was found that the corrosion rate of 14Cr steel is independent of pH for pH values above 6, but, below a pH value of 4, the corrosion rate increases sharply with decreasing pH. In air-saturated solutions of neutral and mildly alkaline pH, the corrosion rate is approximately 60 µm per year. The 14Cr steel shows a twentyfold improvement in corrosion resistance over that of 3CR12 in sulphate solutions at pH 2,0. This is considered to be due to the beneficial effect of its higher chromium and nickel contents.

Jan 1, 1985

By M. C. van Blerck

This paper outlines the tax provisions that became defective in January 1992, which allow a working mine to make tax-deductible contributions to a dedicated environmental body that is itself not subject to tax. Such a body will then provide a source of funding for the mine's future environmental expenditures. It is concluded that the establishment of such environmental bodies is a financially sound, tax-effective route, allowing mines, prospectors, and quarry operators to provide for future environmental rehabilitation.

Jan 1, 1994

The Annual General Meeting of the Institute was held in Kelvin House, Johannesburg, on Wednesday, 26th August, 1970, at 4.15 p.m. Mr. J. K. E. Douglas (President) was in the Chair. There were also present sixty-three Fellows, thirty-five Members, one Graduate, eight Associates, five Students and nineteen Visitors, making a total of one hundred and thirty-two. The President declared the meeting open at 4.20 p.m. OBITUARIES The President: 'It is my sad duty to announce the deaths of the following members of the Institute. Dr J. A. Papenfus, Fellow, who joined the Institute in 1942 and passed away on the 28th of May, 1970. Mr D. G. Beadle, Fellow, who joined the Institute in 1946 and passed away on the 17th of June, 1970. Gentlemen, Derek Beadle was very well known in this Institute. His papers on dust will be remembered and, at the time of his untimely death, he was one of our assistant editors. As a mark of respect to the memory of the deceased and in sympathy with the bereaved, I would ask you to rise and observe a few moments' silence.' MINUTES The President: 'May we confirm the minutes of the General Meeting held on 15th April, 1970, as published in the July, 1970, issue of the Journal'. Agreed. WELCOME TO VISITORS The President: 'Ladies and Gentlemen, we are honoured this afternoon by the presence of many distinguished guests and I extend to you all a most cordial welcome. We are happy to have with us Dr A. A. von Maltitz, President of the Chamber of Mines of South Africa, who is also Honorary President of this Institute. We also have one of our Honorary Vice-Presidents, Mr T. L. Gibbs, the Government Mining Engineer; Mr D. E. Hamm, President, Institution of Certificated Mechanical and Electrical Engineers, S.A.; Mr S. C. M. Naude, Director, Witwatersrand Technical College; Mr I. R. G. Stephen, Senior Vice-President, The S.A. Institute of Electrical Engineers; Mr G. M. Tompkins, President, The S.A. Institution of Mechanical Engineers; Professor P. B. Ackermann, President of the Geological Society of S.A.; Mr A. S. Robinson, Vice-President of the S.A. Institute of Civil Engineers; Professor W. Mare, President of the Institute of Land Surveyors of the Transvaal; Mr B. D. Charlton, President of the S.A. Institute of Assayers and Analysts; Mr R. Hemp, The President, The Mine Ventilation Society of S.A.; Mr L. J. Prince, The President, The S.A. Association of Mine Managers; Mr J. Botha, The President, The S.A. Institute of Foundrymen; Mr G. Niterl, The President, The Institute of Welding; Mr M. R. Gericke, President, S.A. Council of Professional Engineers; Mr N. A. Honnet, Chairman, Orange Free State Branch; Mr P. R. C. Cooke, Chairman. The South African Chemical Institute (S. Tvl. Section). Gentlemen, we are very honoured indeed, to have these distinguished gentlemen with us this afternoon, as our honoured guests. We are also pleased to have with us, one of our Honorary Fellows, Mr F. G. Hill, and several Past-Presidents. I also extend a very warm welcome to all our lady guests and to all our other visitors.' MEMBERSHIP The President: 'I have pleasure in announcing that the names of the following candidates, having been published in accordance with By-Law 5.2.2, Council has elected them to membership in the following grades: NEW APPLICATIONS Fellows: Herbert Dalton-Brown, Stephen William Morel. Members: Clive Lester Workman-Davies, Basil James Russell Botha. Students: Timothy Nigel Watson, John William Hair-bottle. I wish to welcome the new members to the Institute and to congratulate those members who have been transferred to a higher grade.' ANNUAL REPORTOFTHE COUNCILAND ACCOUNTS FOR THE YEAR ENDED 30th JUNE, 1970 The President: 'I now have pleasure in presenting to you, the Annual Report and Statement of Accounts for the year ended June, 1970. These have been handed to you this afternoon and, as is customary, I propose they be taken as read. Before moving their adoption, however, I would like to refer to some of the salient features, leaving as is usual, the task of dealing with the finances, to our Honorary Treasurer. It is encouraging that membership has continued to grow, and now stands at 1,613, an increase of 61 over last year's total. Your Council, however, is aware that there are still people in our mining and metallurgical industries, who could qualify for membership, but who have not yet joined the Institute. A drive to increase membership was accordingly organised, and members of Council were given the responsibility for campaigning in sections of industry, and for publicising the objectives and advantages of belonging to the Institute. Up to now there has not been much reaction to this campaign, but I hope we will see results in the coming year. At the same time, Council has recognised the need for change in the conduct of the Institute's affairs in order to meet the changing needs of our membership. Our members, both mining and metallurgical, are in the first place, geographically more widely dispersed than they used to be, and secondly, with the growth of the metallurgical industry, their technical interests are now more diversified. The Institute must cope with these changing needs if we are to continue to perform a useful function. The

By J. Markgraaff

Because composites offer new solutions to materials problems, they are currently the focus of intense research and development worldwide. However, the natural tendency of users is to remain with tried materials in every situation of material selection. This approach ignores the tremendous advances that have been made in composite materials and their application. These advances enable engineers to tailor composites to suit specific applications such as the demanding needs of mining and industry in South Africa. However, the application of composites, where new and improved components and products are needed or are being developed is often hampered by the limited knowledge and experience of the engineers concerned. This paper presents some of the basic information needed for an appreciation of the terminology, definitions, and properties of various types of composites. It also reviews recent developments in manufacturing technology and product development that may find application in local industries and mining.

Jan 1, 1996

By C. van Loggerenbergt, P. E. Ventert

A strong incentive exists for the coal-preparation engineer to improve plant efficiency by modifying circuits and upgrading process equipment, since these result in lower production costs and more valuable plant products. At the Grootegeluk Coal Mine, it was found that the overall plant efficiency could be improved by modifications to the dense-medium circuits, the installation of additional process equipment for the recovery of fine coal, and improvement of the fine-material processing circuit. Apart from these modifications, there is still potential to increase the plant efficiency, particularly in the utilization of plant waste, the recovery of slimes, and even the improvement of cycloning performance as a result of new cyclone design. This paper points to the potential wealth locked up in existing coal-preparation plants, and shows how the coal-preparation engineer, with new technology at his disposal, can unlock this wealth.

Jan 1, 1992

By G. Song, S. Yang

"SynopsisThe development of techniques and equipment for single-pass high-seam longwall mining in China is reviewed. Some methods used to obtain the fractured zone height are discussed. The boundary between the caved and fractured zones is generally not clear, but one important difference that distinguishes the two zones is that horizontal compressional forces exist only between blocks of fractured zone. Based on this, a theoretical method is presented to investigate the destabilizing modes of the main roof (by sliding or rotation) and is used to determine if the main roof is in the caved or fractured zone. This method considers the mining height, immediate roof thickness, bulking factor, main roof thickness, main roof strength, main roof periodic weighting interval, and vertical stress in the overlying strata. To verify the method, a representative physical model of Wangzhuang coal mine is developed. The movement of overlying strata and fractured zone height are thus obtained. According to the results, the total collapsed height of the strata reaches about 70 m above the coal floor; the first main roof bending interval is 45 m and periodic bending distance is 10–15 m; the maximum strata subsidence is around 62 mm; and the presence of a three-hinged arch causes the fluctuation of subsidence in the same stratum level. Based on the theoretical and experimental analysis, the middle of the main roof is considered the boundary between caved and fractured zone; the caved and fractured zone heights are about 21 and 49 m respectively.IntroductionThick coal seams (>3.5 m) account for about 44% of the coal rescource/reserves and more than 40% of the total annual production in China (Zhao 2004; Wang 2009). Three mining methods – slice mining, top coal caving, and single-pass high-seam longwall mining – are frequently used in underground thick-seam operations. Compared with slice mining and top coal caving, high-seam single-pass longwall mining significantly simplifies the mining processes, reduces roadway excavation, and improves coal production, productivity, and recovery. The favourable economics, high production, and technical simplicity make high-seam single-pass longwall mining one of the most popular underground mining methods for thick coal seams in China."

Jan 1, 2015