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By M. Åstrand, M. Johansson

"Advanced planning and automation are increasingly important in modern mines. Sophisticated methods for long-term mine planning are often used, and the advent of autonomous machines makes the actual operation more predictable. However, the interface between these two timescales, i.e. the scheduling of the mobile production fleet, often limits the ability to operate mines at maximum profitability. We show how scheduling the production fleet in an underground mine can be modelled as a flow shop. A flow shop is a general abstract process formulation that captures the key properties of a scheduling problem without going into specific details. Thus, the flow shop enables mine scheduling to reap the benefits of scheduling research from other industries. We review recent results from the mining community and the flow shop community, and introduce scheduling methods used in these two fields. This work aims at providing value to researchers from the mining community who want to leverage their skill set, as well as to theoretical researchers by presenting the mining process as a potential application area. Lastly, we discuss the results, and outline some future challenges and opportunities facing the industry. IntroductionThe margins in underground mining are constantly under pressure since costs increase as the mine becomes deeper. One major component influencing the operational performance, and thus the profitability of an underground mine, is how the mobile machinery and staff are coordinated. Today, the coordination of the underground fleet, i.e. scheduling of the machines, is mostly done manually, with methods that are stretched to their limit and with no guarantees on performance. According to a survey of more than 200 high-level executives in mining companies around the world (Mincom, 2011), the top challenge for modern mines is to maximize production effectiveness, rather than improving the reliability of individual items of equipment. This highlights the importance of coordination on a system level.The effectiveness of mine production can be increased by introducing supportive algorithms in the scheduling process. These algorithms enable mines to construct optimized schedules with respect to custom metrics. Additionally, manual scheduling is a tedious and error-prone task where the performance is heavily dependent on the scheduler. To reduce the staff dependency, supportive algorithms can help to achieve more uniform outcomes, resulting in a more predictable process. In turn, this increases the transparency of the mining process through the entire production chain. It is worth noting that automatic scheduling has proved beneficial in many other industries, such as chemicals and metals (Floudas and Lin, 2004; Tang et al., 2001)."

Dec 1, 2018

By C. Chongo, F. X. Paquot, C. Ngulube

"Over the last six years, the Kansanshi copper/gold mine has continued to process significant quantities of complex transitional mixed ores. The effect of the complex mineralogy on the flotation performance is depicted. Initially, ore treated came predominantly from accumulated stockpiles. In the ensuing years, ore treated shifted to primarily freshly mined ore that generally showed less tarnish with better float kinetics but with the downside of producing lower concentrate grades. A number of changes were made to improve the efficiency of the roughing circuit and quality of concentrate produced. These changes were as a result of initial mineralogical studies and laboratory float test work done and discussed at length in a previous paper. Salient among the adopted recommendations from previous work were increasing circuit capacity and modifying configuration to increase the residence time and the number of sulphidisation stages. These modifications were completed and commissioned in 2011. This, however, resulted in significantly low rougher concentrate grades and subsequently below-specification final concentrate product. This was primarily due to higher mass pulls resulting from the extended rougher bank with multiple concentrate discharge streams. This necessitated the need for an enlarged cleaning capability to offset this. The extra cleaning capacity came on-stream in 2014. Of note was the development of a recovery model, based on the strong correlation between the total copper and acid-soluble copper ratio, as a tool for monitoring plant performance. INTRODUCTION The Kansanshi mine, the largest copper mine in Africa, is 80% owned by Kansanshi Mining PLC, a First Quantum subsidiary. The remaining 20% is owned by the state through the parastatal ZCCM. The mine is located approximately 10 km north of the town of Solwezi and 180 km to the northwest of the Copperbelt town of Chingola. The mine has been in commercial operation since 2005. Prior to June 2009, Kansanshi mine treated only two ore types: oxide and sulphide. All transitional ores mined during the period leading up to 2009 were stockpiled. The treatment of the minerologically complex, transitional ores through a third train commenced in June 2009 but with numerous metallurgical challenges. This transitional ore (called mixed ores) could not be previously treated economically due to high gangue acid consumption (GAC) minerals association (making it unsuitable for the oxide float–leach circuit) and poor flotation response ruling out the conventional sulphide float circuit. The new novel circuit involved a conventional sulphide pre-float followed by flotation involving staged controlled potential sulphidisation (CPS)."

Jan 1, 2015

By E. R. Davis, R. J. Knott

The paper discusses some of the tools of management in the field of project control, especially in engineering. Project control includes planning and cost engineering, and involves various phases: the conceptual Design and Planning Phase, the Definitive Design and Capital Budgeting Phase, and the Implementation Phase. Each of these phases is discussed in in, together with the use that can be made of data banks, progress reports, and computer systems.

Jan 1, 1982

By M. J. Kanda, T. R. Stacey

Thin spray-on liners (TSLs) have been used as sealants and rock support in tunnels for over 25 years. Laboratory tests have indicated satisfactory properties that can provide adequate strength, adhesion, toughness, and elasticity as part of rock support systems in mining excavations. These characteristics are, however, not always demonstrated in practice, when mine environmental conditions do not correspond with laboratory environmental conditions. The shortcomings of TSLs experienced in the mining industry have raised concerns, resulting in scepticism from some operators regarding their utilization. The research described in this paper aims to investigate TSL performance in environmental conditions similar to those experienced in mines. Brazilian indirect tensile (BIT) specimens were prepared from precast shotcrete and coated with TSLs. The specimens were then exposed to different environmental conditions for up to 112 days before BIT testing under various conditions: laboratory room temperature and humidity; saturated room temperature; and combined saturated and high temperature (50°C). Additional uncoated shotcrete and TSL BIT specimens were prepared for comparison purposes. The results of the BIT tests showed that environmental conditions have a significant influence on the tensile strength enhancement of shotcrete by TSLs. Water-based TSLs are most likely to be suitable for high humidity environments, although their performance decreases at higher temperatures. Numerical modelling of TSL-coated BIT samples confirms the potential limitations of designing TSL support based only on laboratory testing carried out under room conditions.

Jul 1, 2021

By T. Nyakudarika

The Unki Platinum Mines concentrator, employing an MF2 circuit configuration which includes fully-autogenous primary milling of run-of-mine (ROM) ore, was commissioned in November 2010. The project was Anglo American Platinum?s first PGM concentrator in Zimbabwe and would form a significant contribution to the group?s platinum production. The project financials demonstrated that the project was operating-cost sensitive. After reviewing the metallurgical testwork, mineralogical examinations, and the history of similar operations, it became apparent that the Unki ore characteristics rendered it amenable to autogenous milling. The primary ball mill, structurally designed for 30 per cent steel load, could be operated at the required initial phase throughput with fully-autogenous primary milling, realizing savings in both power requirements and grinding media consumption. The original mill sizing had been done with fully-autogenous milling in mind, but allowing for flexibility and mitigation in case of varied mining fragmentation. Since attaining steady state, target grinds have been achieved. This paper looks at the Unki ore characterization programme, design considerations, and the operational and control philosophy for a successful comminution circuit, and discusses the design to produce a flexible, low opex, mitigated comminution and overall MF2 flowsheet that is easily expanded in line with the potential for optimum exploitation of the orebody.

Jan 1, 2012

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 J. P. Gous, M. Tangstad, J. D. Steenkamp

In April of 2013 a 48 MVA submerged arc furnace producing silicomanganese was excavated in South Africa. One of the areas excavated systematically was the furnace taphole. The aim was to obtain a refractory wear profile of the tap-hole area, together with affected hearth and sidewall refractory. Subsequently, thermodynamic modelling was applied to quantify the potential for chemical reaction between refractory and slag and refractory and metal in the tap-hole area.

Jan 1, 2014

By Elizma Ford, Vincent Sithole

"Two shortened test procedures for estimating the Bond ball work index are compared for suitability of use on Zambian/DRC-type copper–cobalt ores. The first procedure is based on a batch milling test while the second procedure is based on a limited locked-cycle test. Both procedures were conducted using a standard Bond test mill. INTRODUCTION The Bond ball work index is widely used in the field of minerals processing as an indicator of ore grindability. The work index is determined by means of a locked-cycle test procedure that typically requires seven to eight cycles to stabilise at a re-circulating load of 250%. A typical test requires between three to four kilogram of ore sample and around eight hours of operator time. For geometallurgical test work applications, where a large number of variability samples are to be tested, it would be highly beneficial to use a test procedure that requires less sample mass and operator time. Certain test work laboratories, for example SGS and JK Tech, are already offering various types of shortened test procedures for estimating the Bond ball work index. This paper discusses a comparison of two shortened test procedures that were evaluated for suitability of use on Zambian/DRC-type copper–cobalt ores. EXPERIMENTAL Test Procedure 1 – Batch Milling The first test procedure is derived from a batch milling approach proposed by the University of Hacettepe (Aksani, 2000). Some modifications were, however, made to the data analysis method from that originally proposed. During this test procedure, a 700 mL volume of sample is milled in a standard Bond test mill for a pre-determined number of revolutions. The feed and product particle size distributions are measured for each test. These results are then used to back-calculate a cumulative breakage rate parameter (k) for each particle size, according to the following formula:"

Jan 1, 2015

By Masanobu Masukawa, Toshio Shiota

The shaft-type ferromanganese smelting furnace (SF) at Mizushima Ferroalloy Co., Ltd. has been in operation since startup in 1985 and is continuing to perform smoothly. Production has been increased from the original design capacity of 270t/d to 350t/d by various operational improvements. As a productivity index of the shaft-type furnace, production of 350t/d is equivalent to productivity of 0.9t/m3/d (daily production/cubic capacity of furnace). Recently, various operational improvements were implemented to achieve productivity of 1.0t/m3/d or higher, including oxygen enrichment operation, increased tapping frequency, maintenance of the throat profile, and operation with small lump coke. The target productivity of 1.0 t/m3/d was achieved in January 2005. This report describes the improvements introduced as part of this high productivity technology.

Jan 1, 2007

By H. Krogerus, P. Jokinen, T. Lintumaa

The energy consumption and recovery of chromium are important economic factors in ferrochrome production. Outokumpu has a lot of experience of the reduction behavior of the sintered pellets in industrial-scale furnaces and also on the grounds of numerous laboratory and pilot-scale investigations. Sintered pellets have shown a superiority over lumpy ore and briquettes made of the same chromite grade. The good performance of the pellets has also resulted in investigations on the reasons for such a performance. In this study, the factors affecting pellet behavior in smelting furnace were investigated. This study is divided into two sections, i.e. the investigations were on the factors affecting solid state reduction and on the factors affecting reduction under melting. These tests were performed by means of thermo gravimetry and by smelting tests. The correlation between the pellet characteristics and reduction behavior was shown and its influence on industrial-scale furnaces was discussed. Factors worth of consideration are for instance, the extent of oxidation during sintering, slag formation and chemistry in respect of molten state reduction, and the grain size of the chromite mineral in the raw material in respect of kinetic reasons (retention time in smelting).

Jan 1, 2007

By Swapan Ghosh, Amitava Sengupta, Proloy Das

Ferro-alloys are very important ingredients used for making of quality steel with desired composition. In view of high demand in various types of ferro-alloys, it has become necessary to produce the same efficiently, safely and cost-effectively with consistent quality maintaining the anti-pollution norms. To achieve this goal, it is necessary to adopt latest process/equipment with the state-of-the-art instrumentation and automation system. A Programmable Logic Controller (PLC) based automation system with suitable Human Machine Interface(HMI) terminals along with intelligent field mounted sensing/control devices allows to monitor and control the complete plant effectively with optimum deployment of man-power. In association with this, use of process optimization controllers enables to achieve specialised functionalities of the submerged arc furnaces like material management, lining management, electrode management, power management, overall production management etc.

Jan 1, 2007

By T. Lindstad, J. Kaczorowski

The Boudouard reactivity of single cokes produced from selected bituminous coals and commercial cokes has been investigated in a thermo gravimetric furnace. The effect of potassium as a catalyst for this reaction was studied, as it is known to accumulate in ferromanganese furnaces. A gaseous impregnation technique using K2CO3 as the potassium source was applied to impregnate the coke samples. The reactivity experiments were designed to simulate conditions occurring in an industrial furnace, as used for production of Mn-alloys. The coke particle size varied from 3.35 to 6.63 mm, while the temperature was maintained between 800- 1100oC with a gas composition from 50 to 75% CO2 in a CO/CO2 mixture. To determine the catalytic effect of potassium, the concentration varied from a fraction of a percent up to 15%wt. The results show that single chars vary significantly in reactivity, depending on the properties of the parent coal, while commercial cokes exhibit similar reaction rates. Temperature and partial pressure of CO2 have the strongest influence on the reactivity, while the influence of gas flow rate and coke particle size were found to be negligible. The catalytic studies revealed that the relative reactivity of non-impregnated samples are preserved after the impregnation, so the least reactive coke is still the least reactive after the impregnation for the whole range of potassium loads. Also, it has been confirmed that the Boudouard reactivity reaches a plateau at potassium concentration of 4%wt.

Jan 1, 2007

By S. Chai

Waste dumps are widely used to discharge stripped mine wastes in open pit mining methods. As mining progresses, the height of the waste dumps will increase gradually, which may induce sliding failure once the height exceeds a critical value. Therefore, estimation of the maximum dumping height is crucial to the life-cycle use of a waste dump. However, published information about the maximum height of mine waste dumps are extremely rare. In this study, the maximum dumping height is estimated based on the strength-reduction technique by numerical simulations. The influences of dump geometry and properties on the maximum height are investigated. The results show that the maximum dump height decreases as the dump slope inclination angle α or the unit weight of dump materials γ increases, but decreases when the shear parameters of dump materials (cohesion c and internal friction angle ϕ) increase. The maximum height starts to increase with the ground inclination β when shear failure occurs at the interface between the dump and the base. Furthermore the effects of the dump width B, Young’s modulus E, and Poisson’s ratio μ of dump materials on the maximum height are almost insignificant. Good agreement was found between numerical results available in the literature and those obtained in this study.

Oct 1, 2022

By O. Dahl, B. Musuku, N. Schreithofer

Recovery of fine pentlandite is proving to be a challenging task in the Kevitsa sequential flotation operations, with over 60% of the nickel losses reporting into the -25μm size fraction. Since commissioning, the Kevitsa process has undergone major changes to address throughput and flotation performance. Major changes were implemented in the configuration of the milling and flotation circuits as well as in the operating conditions and reagent regime. Some of these changes improved nickel flotation while others deteriorated flotation performance. Most of the changes have had a direct impact on nickel flotation. This paper reviews the systematic analysis, laboratory testing and salient changes done to the process with special focus on the impact on the fine pentlandite flotation. Keywords: Blending, Flotation, Chalcopyrite, Pentlandite, Fines

Jan 1, 2020

By B. E. Ydstie, B. F. Lund, K. R. Løvåsen, B. A. Foss

The paper presents sensitivity analysis for a dynamic model of submerged arc silicon furnaces. The model we study, called ?Simod?, was developed by Elkem in cooperation with NTNU and Sintef. It is today a much used tool in Elkem for operator training and analysis of the dynamic behaviour of the silicon production process. The aim of our work is to bring the simulator tool closer to industrial practice, and construct a mechanism to adapt the model to the behaviour of a running process, online. The paper presents the results of the sensitivity analysis that has been undertaken for important parameters in the Simod model. The parameters associated with the process inputs are electric power loss, loss of fixed C and reactivity of carbon. The output signals that have been investigated are fed quartz, tapped silicon and silica. The paper also interprets the results of the sensitivity analysis in a process operation context.

Jan 1, 2004

By M. Buchmann, T. Mütze, F. Heinicke

Dry air classification is a well-known technique used for decades in the cement industry to separate material in the size range of 0.01-1.0 mm. Additionally, in corresponding dry grinding circuits with effective machines such as High Pressure Grinding Rolls (HPGR), the energy consumption can be reduced compared to wet applications. These dry systems are not state of the art in minerals processing plants, but first prototypes have been installed and an increasing number of projects are starting to evaluate this option. One challenge in this field is the mineral composition of ores, which have, by far, a higher variety in density and size than those of cement. High density particles such as iron- containing ones have higher settling rates than low density silica particles of the same size. The main question to answer in this paper is how to evaluate this effect, so a quantitative method using Mineral Liberation Analyses was developed to calculate two-dimensional partition curves. Additional statistical analyses allow for isolation and quantifying the interaction of density and size, enabling engineers to consider this effect for the sizing of process plants. The paper will present the method and selective results for a compounded ore of iron and silica. Keywords: HPGR, air classification, partition curve, MLA

Jan 1, 2020

By D. F. Malan, J. A. L. Napier

This paper describes some important aspects associated with historical underground measurements in South African gold and coal mines. Deformation measurements were used to confirm the use of elastic theory to simulate the rock mass behaviour in the Witwatersrand gold mines in the 1960s. Although a prominent time-dependent component of stope closure was measured as early as the 1930s, it was ignored owing to the benefit of adopting elastic theory. Neglecting the time-dependent response of the rock for many decades resulted in important aspects such as the effect of mining rate, the effect of advance per blast, and the need for enhanced design criteria not being explored. Recent work is only now starting to address this gap in knowledge. In-situ measurements of large coal specimens in the 1960s and 1970s indicated that a linear formula may possibly be a better approximation of coal pillar strengths. This alternative formulation was never adopted, however, as the power law strength formula was already deeply entrenched in the industry at that stage. In spite of these apparent failures to continuously generate and adopt new knowledge, a key lesson learnt is that major advances in rock mechanics will not be possible without careful monitoring of the rock mass behaviour in experimental sites. Areas requiring further research, such as pillar strength formulae for the Bushveld Complex and enhanced design criteria for the gold mines, can only be developed using extensive undergroundmonitoring programmes.

May 1, 2021

The first annual student prizegiving function of the South African Institute of Mining and Metallurgy was held in the Dorothy Susskind Auditorium, University of the Witwatersrand, on Thursday, 26th May, 1977. The address (see opposite page) was given by Dr M. G. Atmore, a director of Anglo American Corporation and Vice-President of the Institute.

Jan 1, 1977

By M. A. Jensen, J. J. Bettencourt

SYNOPSIS An analysis was made of records of accidents involving Bantu mineworkers and which resulted in either minor injuries or hospitalizations to determine patterns in underground accidents from which to formulate priorities in accident prevention in gold mines. The results showed that: (i) specific labour categories, such as inexperienced men, are exposed to certain types of hazards the extent of which warrant the separate design of safety programmes to meet their specific needs; (ii) the systematic study of minor accidents provides a dependable source of. information of which safety departments could make greater use in their efforts to control and prevent mining accidents.

By L. Archambeault

This paper describes preliminary research on the application of Markov Decision Processes (MDP) to Real Option Valuation (ROV) and the optimisation of mine scheduling. The MDP framework is a novel approach to option valuation and scheduling in mining operations. A learning agent is introduced into the valuation process of an open pit, where prices and block ore grades have probabilistic values. The prices are modelled using a mean reverting diffusion process and the block grades using sequential Gaussian simulation. The agent is asked to learn which production parameters should be used in order to maximise the overall value of the project. The introduction of the agent permits a real option approach to mine valuation, such that the value associated with the robustness of a design to uncertainty can be measured. A simulated example is used in which there are ten blocks to be extracted under conditions of grade and price uncertainty. Using policy iteration, an optimal policy is generated and the value of production options is found. The potential financial gains from applying MDPs to mine valuation and optimisation are substantial and warrant further investigation.

Jan 1, 2007