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By S. Curry

The Objana Cement Plant is located in central Nigeria, approximately 200km south of capital city Abuja (figure 1). It is the second largest cement plant in Africa, and the fifth largest in the world [1]. The selected mining location is unique as it has all the major raw materials (except gypsum) in close proximity. This includes limestone, clay, marl, laterite soil, and laterite iron. [ ] The plant has a capacity of 5 million metric tones per year (~15,000 tones per day). A 135 megawatt gas-fired power plant, with 90 km of natural gas pipeline, was constructed to power the plant. The total project cost is approximately 1.2 billion US dollars. The lifeline of the plant is two overland conveys totalling 7.7km in length. The first 800m conveyor is relatively mundane. The second conveyor however, is unlike any other troughed belt conveyor in the world. It 6.9km length transports 2,400 T/H and operates at 5.0 m/s. Its ?snake? profile consists of 11 vertical cuvees, and four horizontal curves. The last of which is 2,000m in radius, has a length of 2.2km, and is located at the high tension head end of the conveyor. Although these specifications are noteworthy, the unique feature of this system is that it is entirely elevated from head to tail using a triangulated truss gantry structure (figure 2).

Jan 1, 2008

The development of 3D multi-parametric models facilitate the provision of resource information well in advance of the mining face. Using the model, one can evaluate mining areas not only for grade and tonnage predictions but also for predictions of rock mass quality. Blast design and milling requirements can be derived from the rock mass quality predictions. This information can be used for overall mine planning and evaluation, costing, production optimization and slope design. This allows the full range of mining activities and costs to be interconnected, there by lowering costs and improving efficiencies through the application of the multi-parametric model. Feasibility studies for new projects require an expected budget expenditure estimate to within5% of actual costs. This level of accuracy is expected by mining companies and investors but cannot be achieved without a sound knowledge of the rock mass variability. By developing a 3Dmulti-parametric model as part of the feasibility study and using the same geological model exploration boreholes, a significantly better understanding of the rock mass conditions can be obtained. This rock mass information can be used for equipment selection, economic pit layouts, processing plant design, underground mining layouts and support requirements, to name but a few design parameters that depend on rock mass conditions. The initiative at Anglo Platinums, Potgietersrust Platinum Ltd.?s (PPRust) operation, has delivered significant results showing improvements across the mine to mill value chain. These include increased loading rates, reduced electricity and crushing consumables, as well as higher plant throughput. The ore reserve model has gained international acceptance as an invaluable tool for a mining operation. Certainly most financial organizations will not invest in a mining project that does not have an ore reserve model. There is the potential for multi-parametric models to be recognized as vital tools in the mining process, as is the case with ore reserve models.

Jan 1, 2006

By J. A. Maree

After the South Deep complex was purchased by Goldfields in 2006a re-feasibility study was done and the life of mine (LOM) was extended to 52 years. This also implied that the mine?s infrastructure would have to be enhanced. One of the changes was the proposal of five new main orepass systems to be excavated before the mine reaches full production in 2013. Excavations started to show signs of scaling, and in some cases, whole new excavations were lost. This particular area was exposed to very high stresses and the geology was prone to body delimination rendering the relevant areas unstable. This paper investigates the conditions at the location of one of the proposed orepass systems, and the best possible orientation was suggested to ensure that the orepass system would be stable and have a practical life. It was, however, found that the fourth leg of the orepass system would require further support to be classified as stable by the chief rock engineer and the section geologist of South Deep. Several support methods and orepass system linings would then be analysed and evaluated to give calculated recommendations on how to productively and practically support an orepass system. Keywords Main orepass system, stresses, body delamination, impact and abrasion, rock support, concrete lining.

Jan 1, 2011

By N. K. Singh

The calculation of resource volumes for large mineral sands deposits is the process of systematically compiling all known data in order to define the volume of ore contained and its intrinsic economic value. Traditionally, this process has been highly speculative in nature, as the variability of the layer thickness, even between closely spaced, boreholes can be highly variable. The issue of horizon continuity is of critical importance in mine modelling and resource definition. Accurate volume estimates are difficult to derive from drilling data alone, as the borehole spacing of an economically viable drilling programme is often greater than the spatial frequency of the variations in profile thickness. The limitations associated with this inferential approach to resource estimation can be mitigated through the use of newly developed ground penetrating radar (GPR) methods, thereby maximizing orebody optimization by reducing contamination and orebody loss. The use of GPR in the mining industry has historically been limited to shallow, high-resolution applications, such as the location of voids in limestone or the mapping of paleo channels for alluvial gold and diamonds (Francke and Yelf, 2003). These limitations have not been technology based, but rather market based, as the vast majority of GPR systems were originally designed for civil engineering applications. A new generation of GPR technology, designed specifically for maximum penetration in sand environments, is now being developed. This technology has been trialled extensively at the Richards Bay Minerals heavy mineral sand deposit in South Africa with optimistic results. The clay base of the mineral sands has been imaged to some 120 metres. Further equipment refinements are expected to yield even deeper profiling and higher resolution. The resolution offered by this technology is unique, allowing individual depositional sequences to be imaged and modelled in three dimensions. This paper will discuss the advances in GPR technology relevant to the mineral sands industry, as well as methods to optimize and integrate GPR data into existing mine models. Also addressed will be approaches to three-dimensional modelling of high-resolution GPR data and subsequent volume estimations.

Jan 1, 2007

By G. Humphries, E. Wolmarans

The PPRust North project is an expansion of existing operations on the ?Platreef? orebody in the Limpopo Province of South Africa. Anglo Platinum has been mining and processing the Platreef since 1993 at the adjacent Sandsloot and Zwartfontein South open pits at a current rate of approximately 4.5 million tons per annum. This paper describes the origin of the proposed process flow sheet. A comprehensive test work programme has been conducted evaluating the best process flow sheet for the very hard and variable ore in the proposed mining area. The selection of the comminution circuit is discussed where conventional crushing and SABC options were analysed based on both extensive test work and analyses of current operational data at the existing concentrator. The application of the high pressure grinding roll technology has significant advantages?it replaces the 3rd and 4th stage crushing stages in a conventional circuit. This programme has been conducted over several years and has involved work done at site at pilot scale, internally at the company?s research facilities and externally at various sites. The on-site pilot work was completed over a 7-month period at the existing concentrator facility using a ThyssenKrupp-Polysius, ?Polycom?, 950 mm by 350 mm, high pressure grinding rolls (HPGR) machine. In excess of 185 000 tons of ore was processed through the unit during the trial period. This paper describes the test work programme and particularly the proposed application of high pressure grinding technology and its potential for further application in the platinum industry.

Jan 1, 2006

By M. J. Kanda

"The design of rock slopes in the planning and operation of open pit mines and for road and rail cuttings requires the evaluation of their stability. This is commonly done using two well-established methods – limit equilibrium and numerical modelling. The research described in this paper compares the outputs of analyses using these two methods with regard to factor of safety and probability of failure, taking into account technical factors associated with each method and other factors such as material parameters and their variabilities. Results show that technical factors such as number of slices and slip circles, number and type of finite elements, and the stress reduction factor can all affect the results of stability analyses. Factors not taken into account in limit equilibrium analyses, such as dilation, in situ stress, and locked-in stresses can affect the outputs significantly. The research has focused particularly on the predicted location of the failure surface, the resulting volume of failure and, most significantly dependent on this volume, the predicted risk associated with slope failure. The results presented show that there is good agreement between the outputs of the two methods regarding factor of safety and probability of failure. However, the same is not the case with regard to volume of failure and hence risk, which can be very dependent on the methods of analysis and their input parameters. The research is not exhaustive, and there are many other factors that could affect the results of slope stability analyses that were not investigated. Some such factors are mentioned in the paper.IntroductionThe design of rock slopes in the planning and operation of open pit mines and for road and rail cuttings requires the evaluation of their stability. The traditional method of stability analysis used limit equilibrium (LE) methods, and this approach continues to be used. Numerical modelling (NM) packages are now also commonly used in slope stability analyses. The outputs from these analyses provide the factor of safety (FOS) and probability of failure (POF) of the slope. Since the capabilities of the two approaches are different, there can be some variations in FOS and POF outputs and in the predicted location of the failure surface. These variations can affect the predicted volume of failure, and this could in turn have a significant effect on the risk associated with the potential failure (Read and Stacey, 2009). Researchers such as Chiwaye and Stacey (2010) have found that LE analyses underestimate the predicted failure volume, unlike NM methods."

Jan 1, 2016

By F. A. G. M. Camisani-Calzolari

Approximately 850 groundwater samples were collected over a 29 300 km2 region of the semi-arid Northwestern Cape during the site selection phase of the South African radioactive waste disposal project. The purpose of the geostatistical investigation was primarily to delineate metallogenic occurrences and provinces which might exist below the thin veneer of surficial material and could thus interfere with the suitability of the site, and to quantify the distribution patterns of groundwater parameters in order to establish a relationship to local and regional geology. Up to 34 variables were analysed for each sample. Structural analysis revealed that the study area is statistically uniform. The variables have low correlation coefficients, with the exception of major ions, indicating a general poor degree of interrelationship between the spatial distribution patterns of the different variables. On the other hand, the long semivariogram range of the majority of variables, which reaches 70 km in cases, demonstrates their continuity on a regional scale. Kriging, which was repeated for each parameter, reveals that most variables, particularly trace metals, have distribution trends which are not influenced by local geomorphology or surface lithology. A 50 km wide, 220 km long metallogenic province, defined by kriging, could possibly reflect a broad metallogenic imprint on the basement and could represent a target area for prospecting. Kriging also reveals the possible existence of a wrench faulting system which may well have influenced the Namaqualand coastal graben and the western boundary of the Karoo.

Jan 1, 1987

By T. G. Maepa

"The creation of mine excavations alters the stress distribution in the surrounding rock mass. In modern mining, resin-grouted rockbolts are used as a means of support in order to redistribute stresses and reestablish equilibrium in the rock mass. The success of resin-grouted rockbolting depends on the design of the system and the correct installation of the support units.The support design and rockbolt installation procedure at a platinum mine in the Bushveld Complex were investigated. A number of issues that resulted in poor installation were identified, including resin admixture, incorrect length and orientation of support holes, over- or under-spinning of the resin, and incorrect rockbolt tensioning. The support design used at the mine was reviewed and its limitations identified. A number of recommendations were made for optimizing the support design by reducing the diameter of the drill bit and reducing the length of the support holes. These changes will enable the mine to use different combinations of resin capsules. Implementation of the proposed changes will lead to a significant reduction in the cost of installation per support hole, as well as improve productivity and safety.IntroductionThe creation of any mine excavation disturbs the virgin state of stress in the Earth’s crust. This results in stress concentrations that interfere with the stability of the rock mass surrounding the excavation. It is essential to modify the internal behaviour of the rock mass surrounding excavations in order to reinforce the ground and stabilize excavations. Resin-grouted rockbolts are extensively used for this purpose. Esterhuizen (2014) stated that when effectively installed, the rockbolt exerts a clamping force and a bonding strength that keeps the rock mass together. This increases the cohesive strength of all discontinuities in the rock mass and enhances the stability of the excavation. Poorly designed and installed ground support is ineffective and constitutes a safety hazard. It is therefore crucial for every mine to ensure that any form of ground support is designed and installed correctly. This research evaluates the installation of resign-grouted rockbolts and identifies challenges and solutions for improved safety as observed at an operating hard rock mine. The support design used at the mine was reviewed and the design parameters optimized. The outcomes will enhance the efficiency of support and minimize the costs associated with the installation of resingrouted rockbolts."

Jan 1, 2017

By A. Pytlik, W. Masny

"Underground mining is subject to various natural hazards such as seismic events, rockbursts, fire, and gas (methane). In general, an increase in the extraction depth causes an increase in the likelihood of these hazards, especially seismic activity and rockbursts. Dynamic phenomena such as rockbursts and tremors have been recorded on six continents: Europe (Poland, Russia, Czech Republic, Germany, and Slovenia), Asia (India, and China), North and South America (USA, Canada, and Chile), Africa (South Africa), and Australia. To select appropriate mine working supports for such dynamic phenomena, the performance characteristics of such support types must be determined under both static and dynamic load conditions.This article presents information regarding the application of rockbolts in Polish underground hard-coal mines. Dynamic phenomena occurring in the mines from 2004–2013 are also characterized. A methodology developed at the Central Mining Institute (GIG) for the laboratory testing of rockbolts is presented. In this methodology, the bolts are loaded by the direct impact of a free-moving mass (up to 20 000 kg) at speeds of up to 1.2 m/s. The facilities at GIG used to test the support under static and dynamic load conditions are characterized, and the results of laboratory tests on yielding bolts with a nominal capacity of 420 kN are presented. These types of bolts are commonly used for reinforcing steel arches and the surrounding rock mass in Polish coal mines. The results of the laboratory testing of yielding bolts are discussed.IntroductionSeismic events such as rock bumps and tremors occur with great frequency during underground mining. These phenomena have been reported in such countries as Poland, Czech Republic, Germany, France, Slovenia, Russia, India, China, the USA, Canada, Chile, South Africa, and Australia (Brauner, 1991; Potvin, Hudyma, and Jewell, 2000; Kidybin??ski, 2003; Driad-Lebeau et al., 2005; Li, Cai, and Cai, 2007; Whyatt and Loken, 2009; Durrheim and Riemer, 2012; Holub, Rušajova, and Holec?ko, 2011). Descriptions of the dynamic events and their effects in the form of damage to or destruction of supports have been presented in many publications, both for hardrock mines as well as for coal mines (Brauner, 1991; Dubin??ski and Konopko, 2000; Heal, 2010; Heal and Potvin, 2007; Simser, Joughin, and Ortlepp, 2002; Kaiser and Cai, 2012; Cai 2013; Nierobisz, 2013; Mark, 2014; Masny and Prusek, 2015). One of the main goals of the research has been to develop methods, criteria, and guidelines for the selection of an optimal and safe support for mine workings located in areas of rock bumps or tremors. Example of such studies include the Canadian Rockburst Support Handbook (Kaiser, McCreath, and Tannant, 1996), or the principles presented in the literature (Li, 2010; Cai, 2013)."

Jan 1, 2016

By M. Timusk

"The working environment for ground support installation in mines has improved during the last 20–30 years, with more mechanized equipment for installation of ground support elements such as bolts, cable bolts, and screens. Ground support installation productivity has, however, not followed the same development curve, remaining more or less constant. In some cases, for example the mechanized installation of bolts, productivity has even dropped. One reason for this is that modern mechanized bolt rigs are complex. In this paper we evaluate manual and mechanized ground support systems, propose a way to measure the productivity of bolt rigs, and make relevant comparisons between different mines and equipment. Some productivity measures for rock reinforcement are suggested, using productivity results from eight case study mines.IntroductionTo improve safety for operators and equipment underground, ground support systems (bolts, screens, etc.) are installed in mines to stabilize the rock mass (Hoek, Kaiser, and Bawden, 1995). Important questions to ask when selecting a ground support system include where ground stability problems are located, why they have occurred, how problems should be addressed, and when and how the ground support system should be installed (Hadjigeorgiou and Potvin, 2011). The performance of bolting and screening operations in underground mines is important for both safety and productivity reasons. With greater mine depths and an increasing focus on safety, ground support has become a significant bottleneck in the production process of many mines.Many factors play a role in establishing safe and stable underground structures. Equally, there are several factors to consider in productivity, including the mining method, organization, logistics, mechanization level, and procedures. Today, most mines in Scandinavia have changed from manual to mechanized bolting, as this improves operator safety and arguably boosts net capacity. Internationally, however, manual installation of bolts remains common, with some claiming that manual installation is more productive (Bawden, 2011)."

Jan 1, 2016

By R. A. Govender, A. Mudau

"Rockbursts continue to be a major contributor to mine accidents and cause of damage to mine excavations, particularly at great depth. The problem of rockbursts has also escalated in civil engineering tunnels driven at depth, due to high levels of in situ stress at such depths. Attempts have been made in the past to mitigate the impact of rockbursts, with rock support remaining the ultimate method for providing stability in rockbursting environments. However, records show that, on many occasions, conventional support elements such as rockbolts, wire mesh, shotcrete, and lacing fail to withstand severe rockburst events.Recently, a support method termed ‘sacrificial’ support was proposed as a potential additional method to prevent rockburst damage, based on observations made after rockburst events in a mine. The philosophy behind a sacrificial support system is that, under dynamic loading conditions, support in the form of a liner must fail; leaving behind, undamaged, what was previously supported rock mass. The sacrificial support concept reported herein is applicable in situations where the source (i.e. seismic event) of the rockburst is located remote from where rockburst damage is likely to occur.Spalling tests based on the split Hopkinson pressure bar (SHPB) technique were conducted to study some aspects of dynamic rock fracturing in tension at high strain rates and the role a sacrificial layer plays in combating dynamic rock failure. A single Hopkinson pressure bar, with a long cylindrical intact rock specimen attached at the bar free end, was impacted by a striker on the opposite free end in order to generate a dynamic stress pulse responsible for spall failure upon reflection from the specimen free end. Different liners and liner combinations were then introduced at the specimen free end as support. Such a simple, yet robust, experimental set-up allowed the potential benefits and failure mechanisms associated with sacrificial support under dynamic loading to be demonstrated and compared with ‘sacrificial support’ behaviour observed in real rockburst events in a mine. Analysis of the results revealed that varying liner thickness and mechanical impedance between rock and support liner play a significant role in limiting rockburst damage."

Jan 1, 2016

By K. -C. Han, S. -Y. Kim

This study was carried out in a bid to survey Ganboke gold mine in Pala, Mayo-Kebbi Province, southwestern Chad. The Ganboke mine is now being prepared for investigation and development, and the research sought to perform rock properties tests of relevant rocks through its geological survey, rock mass evaluation, and in-situ and laboratory tests and analyze the stability by the means of limit equilibrium method, thereby suggest appropriate methods to design the pit slope and individual benches in Ganboke mine. Targenting GS1-GS1' section with the depth of 180 m and GS2-GS2' section with the depth of 150 m in the survey area, we set the height of the bench at 10 m and 15 m, and the angle of bench at 60o and 70o, respectively, and then reviewed the stability for dried condition and saturated condition. The result of examination indicated that it would be appropriate to set the bench height at 10m and the bench angle at 60o in developing the mine slopes concerned. Cette étude est réalisé dans le but de faire des recherches sur Ganboke mine d'or dans Pala, Mayo-Kebbi Provence, Tchad sud-ouest. La Ganboke mine est actuellement en train de étre disposé à la investigation et le développement, et la recherche a cherché à accomplir les tests de la propriétè des roches par l'intermédiaire de la étude géologique, la évaluation de la masse rocheuse, et in-situ et les tests de laboratoire et à faire l'analyse de la stabilité au moyen de la méthode d'équilibre limite, de ce fait à proposer le methodes propres à faire le plan de la pente et les gradins individuels dans la Ganboke mine. Concernant la section de GS1-GS1' avec la profondeur de 180 m et la section de GS2-GS2' avec la profondeur de 150 m dans l'aire d'étude, nous mîmes l'hauteur du gradin à 10 m et 15 m, et l'angle du gradin à 60o and 70o, respectivement, et alors nous avon reconsidéré la stabilité pour la condition sèche et la condition saturé. Le résultat d'examen a indiqué que il pourrait être propre de mettre l'hauteur du gradin à 10m et l'angle du gradin à 60o en développant les pentes de la mine concerné. Diese Forschung wurde um das Gold Bergwerk zu überschauen in Pala, Mayo-Kebbi Provinz, der Südwesten Chad ausgeführen. Das Ganboke Bergwerk ist jetzt zur Erforschung und Entwicklung vorgebereiten worden, und die Forschung suchte zu ausführen die Prüfungen der Felseigenschaft durch geologischen Überblick, Felsmassewertbestimmung, und In-situ und Lavorversuch auf, und analysieren die Stabilität mittelst der Grenzegleichgewichtsmethode, da-durch schlug die angemes-sen Methoden zu entwerfen die Böschungen und die einzelnen Bänke im Ganboke Bergwerk vor. Für den Abschnitt GS1-GS1' mit der Tiefe von 180 m und GS2-GS2' mit der Tiefe von 150 m in der Überblickfläche, wir setzten die Bankhöhe an 10 m und 15 m, und das Bankwinkel an 60o und 70o, beziehungsweise, und dann zurückblickten die Stabilität für die getrockneten Bedingungen und die gesättigten Bedingungen. Das Ergebnis der Untersuchung anzeigte daß es würde angemessen sein zu setzen die Bqnkhöhe an 10m und das Bankwinkel an 60o in der Entwickelungen vom Bergwerk be-teiligt.

Jan 1, 2003

By G. Dhakal, J. -I. Kodama, K. Neaupane, T. Yoneda

ABSTRACT Durability tests and evaluation of sub-zero temperature effects to some argillaceous clastic rocks were carried out. Welded tuff, limestone, sandstone and schist samples collected from different parts of Japan were tested and results are presented. Schist and dolomite from Ganesh Himal area along the higher Himalayas of Nepal were also tested, and the results are compared. The slaking tests were performed on all samples in pure water. The results reveal that the slaking index of schist from Japan is lower than that of schist from Nepal. Regarding carbonate rocks, the slaking index of limestone from Japan is higher than that of dolomite from Nepal. A tendency of decrease in slake durability with an increase in porosity is also observed. Freezing and thawing experiments conducted on welded tuff and schist reveal that crack initiates earlier but extends slower in schist than in welded tuff. It is also observed from the freeze-thaw experiment that the welded tuff deteriorates and wears faster than the schist. However, sandstone remains relatively intact for a long run of freeze-thaw cycles. Zusammenfassung Beständigkeitstests sowie die Bewertung der Auswirkungen von Minusgraden auf Tonschiefer Trümmergestein wurden durchgeführt. Dabei wurden geschweißter Tuff, Kalkstein, Sandstein und Schiefer aus verschiedenen Gebieten Japans sowie Schiefer und Dolomitgestein aus dem Ganesh Himal Gebiet, dem höheren Himalaya Nepals, untersucht und die Resultate verglichen. Für alle diese Gesteine wurden Slaking-Tests in reinem Wasser vorgenommen. Die Resultate zeigen, dass das Slaking von Schiefer aus Japan höher als das von Schiefer aus Nepal war, wohingegen bei kalkhaltigem Gestein das Slaking von Kalkstein aus Japan niedriger als das von Dolomitgestein aus Nepal ausfiel. Es wurde dabei auch eine Tendenz zur Löschbeständigkeitsverringerung bei gleichzeitig erhöhter Porosität beobachtet. Gefrier- und Tautests an geschweißtem Tuff und japanischem Schiefer zeigten, dass Risse in Schiefer schneller auftraten, aber sich langsamer ausweiteten als in geschweißtem Tuff. Bei Gefrier- und Tautests wurde ebenfalls beobachtet, dass geschweißter Tuff schneller verfällt und verschleißt als Schiefer. Sandstein hingegen blieb über lange Tau- und Gefrierzyklen intakt Résumé Des tests de solidités et l’évaluation de l’effet des températures en dessous de zéro sur les rocs argileux ont été effectués. Les rocs d’origine volcanique (cendre), les rocs calcaires, sableux et les schistes de différentes régions du Japon, ont été étudiés. Les schistes et les dolomites de la région de Ganesh Himal le long du haut Himalaya (Népal) ont été étudiés et comparés à ceux du Japon. Les tests de désintégration sur les rocs ont été effectués dans l’eau pure. Les résultats montrent que l’index de désintégration des schistes du Japon est inférieur aux schistes du Népal. En ce qui concerne les rocs carbonyles, l’index de désintégration des rocs calcaires du Japon est supérieur à ceux des dolomites du Népal. Une décroissance de la résistance à la durabilité est observée avec une plus grande porosité des rocs. Les tests de congélation-décongelation sur les schistes et les rocs d’origine volcanique (cendre) du Japon montrent une apparition précoce des fissures mais l’expansion des fissures est plus rapide dans les rocs volcaniques. Des tests similaires montrent que les rocs volcaniques (cendre) se désagrégent plus rapidement que les schistes. Cependant, les rocs sableux restent intacts après plusieurs cycles de congélation-décongélation.

Jan 1, 2003

The peak in Sulphur price late 2008 caused again intensified investigation into the decomposition of sulphates and spend acid. One option is the recycling of sulphur from spend acid, which already started more than 40 years ago in the field of spend acid from organic processes in refineries and acrylic glass manufacturing. Since this acid couldn't be neutralized and discarded due to high organic contents, another source of SO2 to produce sulfuric acid is the decomposition of metal sulfates. The decomposition of metal sulfates was investigated at the next peak in Sulphur price in the 80?s. The first major scale pilot tests and studies of gypsum decomposition were carried out for clients in Florida. The decomposition of gypsum was quite often mainly influenced by the strategic decision of some countries to get own and independent acid production. In other cases the industry doesn?t have enough space to dump the gypsum. Therefore the company was also forced to convert the gypsum into ?saleable? products to avoid these residues. Other projects were made for the recycling of iron-sulfates from the pigment industry. The motivations for these projects were not only given by acid price. For the German pigment industry it was no longer permitted in the 80?s to dump the iron sulphate residues into the sea. These regulations forced the industry to develop new technology, which allows converting of the FeSO4-residues into iron oxide and acid. Therefore economical and mainly environmental factors influenced the decision of the companies to develop and to build these plants. Beside the above mention iron- and calcium-sulphates many other process exist, which produce metal sulphates as an intermediate product. These cases are not forced by environmental or strategic factors. In cases like Ni, Co or Mn-decomposition the main product of the plant is treated in the decomposition plant and later on used as ferrous-alloys. These final products are higher in price compared to e.g. CaO, which exclude the high-energy consumption for the endothermic chemical decomposition reaction. The reaction of SO2 generation based on acid or sulfate decomposition takes place in the range of 1000°C. The energy demand of the endothermic reaction is considerable and leads due to the high fuel-combustion off-gas stream to a diluted SO2 gas. Energy prices are usually increasing at the same time like sulphur. Sulphuric Acid based on decomposition is therefore more expensive than as acid based on sulphur combustion. The paper describes fluid bed technology and possible process concepts for decomposition plants. Additionally the thermodynamic background of the decomposition process and the main influence factors are provided to receive a better understanding of this technology.

Jan 1, 2009

By M. D. Raganya

The Kriel Colliery is an Anglo Coal mine which is contracted with Eskom to produce No. 4 seam for Kriel power station. The mine previously found it uneconomical to mine No. 5 seam due to the low qualities and tonnages of the seam, both at the opencast and underground sections. An area has been encountered for the first time at Kriel Colliery opencast pit 5, where the tonnage and qualities of No. 5 seam warrant further investigation. The primary reason for the investi¬gation of No. 5 seam by Kriel Colliery is because of the advantage of the high selling price (R450/t) that the market is currently prepared to pay for the No. 5 seam. The aim of this project is to mine No. 5 seam economically without interrupting No. 4 seam mining operations. The problem is that the equipments that are currently being used at the mine belong to Eskom and are dedicated to mining No. 4 seam only, not No. 5 seam. Through geology investigation, it is found that the whole No. 5 seam (No. 5 seam upper and lower) has an average thickness of 1.8 m. It also contains a parting of carbonaceous shale which divides the seam into two parts. No. 5 seam upper contains less tonnage compared to No. 5 seam lower. The calorific value and ash content of No. 5 seam lower is far better than No. 5 seam upper, but would still require washing the coal. This makes No. 5 seam lower the preferred seam to mine because it meets the requirements of the customer which is Highveld Steel. It is a coincidence that the area containing No. 5 seam under investigation encounters high overburden problems. The problem of drilling to No. 4 seam was going to be encountered because the thickness of the overburden ranges from 35 to 39 m. The Gardner Denver at the mine can drill blastholes only to a depth of 34.5 m, meaning the full overburden will not be drilled at once. This means the mining of No. 5 seam will do favours for Eskom because the overburden thickness will be minimized. This then led to an agreement between Anglo Coal and Eskom to mine No. 5 seam because both companies benefit from the project. In order to identify a suitable mining method for No. 5 seam lower, literature studies took place. It is found that San Juan mine from the USA has similar geological features to Kriel Colliery's No. 5 seam. Through comparisons, it is found that truck and shovel mining would suit the geology of Kriel Colliery's No. 5 seam since San Juan mine is using it. The sequence of mining No. 5 seam lower allows for a clearance of two cuts between the truck and shovel operation and the dragline. The mining sequence of No. 5 and 4 seam will be in the order of top soil removal; soft overburden pre-stripping; pre-strip drilling; pre-strip hard overburden; No. 5 seam lower coaling; interburden drilling and blasting; interburden stripping and No. 4 seam coaling. Financial evaluation of the project shows that a contractor will charge Kriel Colliery (Anglo Coal) approximately R 102.2 million to mine No. 5 seam successfully. The sales of No. 5 seam lower will provide a profit of R99.4 million at a yield of 70% from the washing plant. The project is beneficial to both Eskom and Anglo Coal because Eskom will have eliminated the problem of pre-stripping and Anglo Coal will generate additional profit. Through investigation and analyses of the project, it is proven to be viable and should take place. This is after looking at the advantages that the project has for Anglo Coal and Eskom. Keywords No. 5 seam, truck and shovel mining, Kriel Colliery, No. 5 seam mining at Kriel Colliery opencast, Anglo Coal and Eskom, No. 5 seam upper and lower, top soil removal, soft overburden pre-stripping, pre-strip drilling, pre-strip hard overburden, No. 5 seam lower coaling, interburden drilling and blasting, interburden stripping, No. 4 seam coaling.

Jan 1, 2011

By I. Beukes, H. Kotze, B. Krause, R. P. Hattingh

Hillendale Mine is operated by Exxaro KZN Sands, and is situated on the north coast of KwaZulu-Natal in South Africa near the towns of Empangeni and Richards Bay, some 200 km north of Durban. During the mining operation the heavy minerals rutile, ilmenite, zircon and leucoxene are extracted for further beneficiation at a processing complex near the town of Empangeni. The deposit contains approximately 25% slimes (defined as the sub-45 micron fraction), and is mined using hydraulic monitoring. Run of mine is gravity fed down launders to pump stations, which deliver the material to a primary wet plant. Slimes is separated from the run of mine prior to the heavy minerals being separated from the sand. Sand tails containing approximately 2-5% slimes is pumped to the mining void. The slimes is thickened to a density of approximately 1.2, and most of the resultant material is pumped to a sub-aerial deposition site (residue dam). The area is characterized by an annual rainfall of approximately 1300 mm, which is relatively high by South African standards. From an agricultural perspective the soils are deep and well weathered. Dryland agriculture has been practised on an extensive scale in the area for the past 70 years. Sugar cane in particular is cultivated on and around the mine area. In terms of environmental approvals, the post-mining land use and objectives are defined as economically viable and sustainable sugar cane cultivation in the mined areas. During mining the soil profile is destroyed. In this paper the establishment of a reconstituted soil profile is discussed, with specific reference to the methodology that is being followed to achieve the homogeneous blending of sand and slimes. Defining the rehabilitation strategy and soil specification Strategically Exxaro KZN Sands divided rehabilitation into four aspects, comprising physical rehabilitation (restoration of soil structure), vegetative rehabilitation (restoration of vegetative cover), ecological rehabilitation (restoration of sustainable ecological communities), and sustainability (sustainable man/environment interface) (Hattingh and Viljoen, 2006). It is believed that the key to successful rehabilitation lies in achieving a substrate (soil) suitable for the establishment of the target vegetation. During the development of the rehabilitation strategy the key factor in the establishment of a suitable soil profile was shown to be the soil water retention of this material. Since dryland agriculture is practised, this aspect becomes critically important in ensuring that the post-mining land use is sustainable (Hattingh et al., in prep.). From a financial perspective, a closure certificate being issued implies that the state takes over financial liability for the rehabilitated land. This has significant implications for the state-the default position will be that all possible latent and residual impacts must be identified and known prior to a closure certificate being issued. From the mine's perspective this precautionary approach by the state implies that post-operational costs cannot be quantified exactly, and our approach is therefore to mitigate the risk of a long post-closure care and maintenance phase by means of addressing all potential latent defects during the operational rehabilitation phase. The financial viability of the soil reconstitution process itself is therefore not measured against other rehabilitation methods, but against the risk of not achieving closure. During a series of technical workshops comprising experts in the various disciplines in the rehabilitation of the soil profile were identified. These aspects include the re-establishment of a functional soil profile, soil physical characteristics, soil chemistry, soil biota, salinization potential, erodibility and soil weathering. The natural soils in the Hillendale area have been classified in terms of the South African soil classification system (MacVicar and co-workers, 1991) and consist of Hutton (orthic topsoils on red apedal subsoils) and Clovelly (orthic top soils on yellow apedal subsoils) soil forms. The topsoils consistently comprise medium to fine grained sand overlying heavier textured sandy clay loam to clayey subsoils. The topsoil structure consists of a single grain structure, whereas subsoils are apedal. These soils are typically deeply weathered and do not show secondary structures. During the mining process a layer of topsoil (300 mm) is stripped off, and the balance of the material down to the footwall is processed. Sand with 2-5% slimes (defined as the sub-45 micron fraction) is returned as backfill in order to re-establish the dune to approximate the previous landform. From an agricultural perspective this material is not suitable for the dryland cultivation of sugar cane. A capping of more suitable material therefore has to be provided. The most significant difference between the premining soil form and the backfill material is the percentage slimes, consequently a mixture of the sand and slimes is required as a capping over the backfilled sand. The required thickness of the cap is a function of specifically plant growth requirements, erodibility, weathering and runoff (Hattingh, et al.; in prep.). The percentage slimes required in the cap is a function of mainly soil water requirements (Hattingh and Viljoen, 2006). The conservative indications to date show that the reconstituted soil profile should consist of a homogeneously blended mixture of 70%-80% sand and 30%-20% slimes up to a maximum of 2 metres thick. This will be sufficient to ensure growth during dry periods.

Jan 1, 2007

By E. E. Almási, G. Mucsi, G. Rákhely, Á. Rácz, B. Csőke, Zs. Pap, K. Bohács, N. Halyag

Wet stirred media milling is a widely applied grinding process in the field of mineral processing to produce <10 μm ground materials. In this paper, the results of wet stirred media milling of different Ti, Fe and Cu-oxide and phosphate minerals are presented. During the experimental work, grinding of ilmenite, vivianite, hematite and cuprite was carried out in a continuous operation wet stirred media mill. During the experiments, the particle size distribution and specific surface area of the ground materials were determined after a certain grinding time, as well as measuring the specific grinding energy, thereby determining the grinding kinetics of the different minerals. The measurement results showed the differences and similarities in the grindability of the individual minerals. Nano particulate vivianite, hematite and ilmenite was successfully manufactured in a stirred media mill; however cuprite was characterised as the coarsest final product for the same grinding circumstances. Keywords: Wet stirred media mill, cuprite, vivianite, ilmenite, hematite

Jan 1, 2020

By А. V. Aksenov, S. G. Rybkin, А. Y. Senchenko

Recovered activated carbon fines result from processing of ore and concentrates via cyanide leaching and sorption of valuable metals on carbon at gold-mining plants. This intermediate product is characterised by the particles sized smaller than 0.6 mm and gold grade up to 300-500 g/t. Processing of carbon fines with recovery of valuable metals is not available at many plants due to the lack of optimal technology. The paper describes the testwork and development of an efficient technology to process carbon fines with the recovery of valuable metals into the target gold alloy. This innovative technology involves pelletising of fine activated carbon particles using an organic binder, drying and further firing of pellets in a grate fired furnace at 800-900 °С. The produced ash is subject to sintering with sodium nitrate and hydroxide at 600-700°С. The sintered ash is then leached in water. The insoluble residue containing gold and silver is removed by filtration, dried and smelted to produce gold alloy. Water solution containing sulphur and arsenic is subject to detoxification. Processing of recovered carbon fines according to the developed technology implies the use of standard full-scale equipment. The offered method to treat gold-bearing carbon fines was patented by the Eurasian Patent Office. Key words: Fine activated carbon particles, valuable metals, pelletizing, firing, ash, sintering, leaching, smelting

Jan 1, 2020

By K. C. Corin, M. Tadie, N. Ndamase

Fresh water conservation efforts and strict environmental regulations have forced the mining industry to reduce freshwater consumption and effluent discharge. This is achieved by recycling process water back to mining processes. The performance of flotation circuits depends on the pulp chemistry. When process water is recycled to flotation cells, organic and inorganic species that have accumulated over time alter the pulp chemistry. The presence of accumulating ionic species such as SO4 2- and S2O3 2- has been found to hinder the adsorption of collector ions onto mineral surfaces. Sulphide minerals are semi-conductors; electrochemical reactions take place on their surfaces. The adsorption of collectors onto mineral surfaces takes place via electrochemical reactions. This study, therefore, aims to investigate how the presence of accumulating ionic species at varying ionic strengths affects the adsorption of sodium ethyl xanthate onto chalcopyrite from an electrochemical perspective. Synthetic plant water comprised of single salts with varying ionic strengths was used. Rest potential measurements were conducted to investigate collector-mineral interactions in the presence of these ionic species. Microflotation tests were performed to determine whether the presence of these ionic species affects mineral floatability. Higher chalcopyrite recoveries were achieved in the presence of SO4 2- than in the presence of S2O3 2-. Rest potential measurements were found to successfully predict microflotation performance in the presence of the ions of interest. Keywords: Flotation water quality, electrochemical adsorption; xanthate collectors

Jan 1, 2020

It is widely accepted that the type of grinding media has an impact on the grinding chemistry and subsequent flotation behaviour of the sulphide minerals being separated. There are countless laboratory investigations demonstrating that inert grinding media produces more oxidizing pulp potentials, reduced levels of grinding media corrosion products, and superior concentrate grades and valuable metal recoveries. However, taking these results to industrial scale has proved difficult. This paper provides details of the protocol developed and used during a high-chrome grinding media plant trial. It describes the test regime employed to measure changes in pulp chemistry as well as concentrate grades and recoveries to produce a statistically meaningful result. The work also highlighted the need for close cooperation between the metallurgists on site and the researchers conducting the trial. To demonstrate the protocol, data gathered during a plant trail in a PGM concentrate will be presented describing the changes in pulp chemistry and metallurgical response observed.

Jan 1, 2012