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By D. Strachan

Installation of support in known poor ground intersections during reaming operations requires rapid access to stabilize the shaft wall and thus to prevent the loss of the shaft through scaling. This is especially relevant to shafts of long dimension where the duration from time of exposure to time of support installation is lengthy This paper deals with the innovative methodology employed at Harmony?s No. 8 Shaft 17/24 level sub ventilation shaft to rapidly support a shale intersection between 23 and 24 Level by employing a single deck stage suspended from the reamer head by means of Skyjack winches.

Jan 1, 2009

By R. B. Ngenda

The ?Kolwezi Zinc Plant?, in French ?Usines à Zinc de Kolwezi? (UZK), has produced about 910 000 dry metric tons of residues during the hydrometallurgical treatment of calcines from sulphide zinc concentrates. The zinc hydro plant residues contain on average 19.47% Zn, 2.7% Cu, 2.1% Pb, 26.6% Fe, 0.12% Cd, 0.39% As, 157ppm Ag, 447.8 ppm Ga, 475.4 ppm Ge, etc. This material was dumped in five ponds in the vicinity of the plant. The high Fe content in the ore concentrates induced important conversion of some of zinc and copper into ferrites during the roasting process. Those ferrites are very stable compounds, which are difficult to leach with dilute sulphuric acid solution. Therefore, they mainly report to the leaching residues. Hot leaching has been successfully applied to the treatment of zinc hydro plant residues. The method, however, presents the disadvantage of simultaneously dissolving iron(Fe). It is then necessary to remove an important iron quantity from solution prior to zinc and other metals recovery.

Jan 1, 2009

By J. L. Fuentes-Cantillana, Á. Rodríguez, P. Morillo

Evacuation operations from work places in the case of an emergency are the key to minimising the effects of catastrophic type accidents such as fires, explosions, cave-ins, floods, etc. The correct planning of these operations, having the necessary means for sounding alarms and communicating and suitable training of personnel are the key factors for guaranteeing successful evacuation. The article gives an analysis of the problem in the case of subterranean mining and various types of work developed by AITEMIN in this field, including the development of new alarm and communication means specially adapted to the characteristics of mining operations, development of tools for help in the preparation of emergency plans and experiences in the education and training of personnel.

Jan 1, 2003

By M. Abdellatif

Keywords: Magnesium, pyrometallurgy, Mintek Samples of crude magnesium produced by the Mintek Thermal Magnesium Process were refined in two stages. The first stage consisted of co-melting of batches of the crude metal and MgCl2-KCl flux (cleaning), followed by stirring at 30 rpm for 30 minutes and settling of the sludge (mixture of molten salt and solid impurities) from the magnesium melt. The operating temperature was 680?730°C. Most of the contained calcium and significant proportions of iron and silicon were transferred into the sludge phase, which left a metal containing, on average, 950 ppm Si, 470 ppm Fe, and 230 ppm Ca. In the second stage, small-scale refining tests were conducted on cleaned samples from the first stage, as well as on crude magnesium. FeCl3 was used as the refining agent. These tests were carried out at 715?760°C with various amounts of the refining agent. The refined metal was suitable for the production of various magnesium alloys, particularly AZ91D.

Jan 1, 2006

By M. A. Kujoana

Following on the design of good mining layouts and regional support systems, and the implementation of sound strata control practices, stope support is the ultimate strategy to combat the hazards of rockfalls and rockbursts. The primary function of stope support in intermediate and deep level mines is to stabilize the rock mass immediately surrounding stoping excavations, that is, the zone of fractured rock which behaves in elastically around stopes. Support design is a process resulting in a support system which is both practical and meets or exceeds by a factor of safety the requirements for a particular geotechnical environment. The aim of this project was to design a support system, which accommodates the factors of rockfalls and rockbursts. The pack support unit must be easily handled, less costly and can be used in stopes without any significant convergence. The project tested the structural stability of packs to their expected deformation, in order to design a height to width ratio for stopes where little convergence is expected.

Jan 1, 2009

The additive property of dispersion variances was found experimentally by D.G. Krige using data from the gold deposits of the Witwatersrand. In this property, called ?Krige?s relationship?, the dispersion of a small unit, v, within the deposit is equal to the sum of the dispersion of v within a bigger unit, V, and the dispersion of these units, V, within the deposit, D. It is known that the variance of the grades decreases as the support increases, the so-called volume-variance relationship. To analyse volume-variance and Krige?s relationship, the methodology herein proposed combines blending piles and geostatistical simulation to simulate the in situ and the pile grade variability. Variability reduction in large piles is based on the volume-variance relationship, i.e. the larger the support, the smaller the variability (assuming perfect mix). Based on a pre-defined mining sequence to select the blocks that will form each pile for each simulated block model, the statistical fluctuation of the grades derived from real piles can be simulated. Using this methodology, one can evaluate within a certain time period the expected grade variability for various pile sizes, and also calculate the Krige?s relationship between the small blocks and the piles of different sizes. A real case study using a large Brazilian iron ore deposit illustrates the methodology and demonstrates the validity of the results.

Jan 1, 2014

By C. -T. Mutale, A. S. Tuling

Titanium can exist in three different oxidation states. Its oxides are numerous and in presence of iron and oxygen, iron-titanium oxide compounds can also form. Some of the oxides are non-stoichiometric, making the determination of the thermodynamic properties of titanium and its oxides in molten steel and in slag difficult. Therefore, for the assessment of titanium activity in molten steel using the electrochemical measurements of oxygen partial pressure, the identification of oxides in equilibrium with titanium is important. This paper reports on an investigation of solid titanium oxide inclusions, which have been identified by combining different methods of analysis on quenched samples. These samples were taken from a Fe-Ti-melt at 1600°C, quenched in cold water then mounted and polished for optical microscopy. The oxide inclusions were analysed using transmission electron microscopy (TEM) with energy dispersive spectroscopy (EDS). Both single crystal and polycrystalline diffraction patterns were used to identify the oxides by comparing the d spacings with those in the ICDD X-Ray Diffraction (XRD) database. XRD was used to analyse the oxide particles on the top of slow cooled samples. It was found in the TEM study that the similarity of the diffraction patterns of the various phases meant that unique identification was difficult to achieve in some of the diffraction patterns. However, TiO, Ti2O3, Ti3O5, Ti4O7were identified in quenched samples, while TiO2, FeO.TiO2and iron oxides were seen in slow cooled samples. It was also confirmed that the type of oxides is related to titanium content of the samples. Keywords: Titanium, Titanium Oxides, Iron, TEM, XRD, thermodynamic.

Jan 1, 2004

By W. Mackenzie

The development of a resource project inevitably requires the investigation of a vast range of issues across most engineering disciplines - mining, metallurgical, chemical, civil, electrical, mechanical and environmental - as well as the geosciences. It is also a characteristic feature of the resource industry that no two orebodies - and hence no two development projects - are the same. So these technical issues have to be addressed to a greater or lesser extent in evaluating any resource project's development potential. Not surprisingly then, technical issues tend to predominate when assessing the development potential of a project in the process typically referred to as `doing a feasibility study'. But the principal purpose of a `feasibility study' is to determine whether a development opportunity makes good business sense, not just whether it is technically possible. Resolution of technical issues is often seen as the primary focus of a feasibility study, whereas in reality, these technical issues are the basis upon which an asset delivery and business plan is built. This is not to say that technical issues are unimportant - they are a prerequisite to the demonstration of a project's viability. The feasibility study process must therefore demonstrate that not only have the technical issues been satisfactorily addressed, but also that the broader commercial, economic and social issues have been considered in the development of a comprehensive business plan, which includes an assessment of the risk-reward profile of the proposed development. This paper will present a framework for the conduct of `feasibility studies' and provide guidance to minimum standards and best practice.

Jan 1, 2007

By D. Chetty

Process mineralogy forms an integral part of geometallurgy, with ore body characterisation being but one piece of the puzzle in optimising value derived from ore. This value is not only financial, but importantly speaks to sustainability from environmental and social standpoints. The reactive approach of traditional process mineralogy is increasingly being replaced by predictive methods in the geometallurgical sphere, for which mineralogical information must be timeously acquired on judiciously selected sample sets to understand ore variability and its impact on orebody processing. Such processes are not only metallurgical, but must incorporate mining and waste management protocols. Dwindling resources like water and energy also demand innovative approaches for lowering consumption and/or promoting recycling along the value chain. Addressing such challenges relies on appropriate characterisation of ore behaviour under different process regimes. Coupled with this, emerging characterisation tools are increasingly applied to understand the mineralogy of unconventionallypresented and difficult-to-process ores to meet societal and technology demands. Such tools are often accompanied by the generation of large, computationally intensive datasets, for which data management and storage are key requirements, particularly when deciphering temporal trends in ore and process variability. This paper will elaborate on these themes with examples that highlight the importance of process mineralogy throughout the minerals value chain. Keywords: Process mineralogy, ore characterisation, geometallurgy

Jan 1, 2020

By M. L. Bakker

Keywords: Pyrometallurgy, top submerged lance (TSL), nickel, PGM, calcium ferrite, lime ferrite The ISASMELT? top submerged lance (TSL) bath smelting process was developed in Mount Isa, Australia by Mount Isa Mines Limited (now a subsidiary of Xstrata plc) during the 1980s. By the end of 2011, the total installed capacity of the ISASMELT? technology will exceed 9 000 000 metric tons per year of feed materials in copper and lead smelters around the world. Commercial plants, operating in Belgium and Germany, are also batch converting copper materials in ISASMELT? furnaces. This TSL technology is equally effective for continuous converting processes, whereupon it is called ISACONVERT?. This paper presents the recently patented ISACONVERT? process for the continuous converting of nickel and Platinum Group Metal (PGM) containing mattes using the calcium ferrite slag system. The paper focuses on the potential application of the ISACONVERT? technology to existing nickel and PGM smelting complexes.

Jan 1, 2011

By M. Hopf, E. Rossouw

Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able to consistently identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed). Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa.

Jan 1, 2006

By T. Struminski

The paper is aimed to assess the possibilities of usage of pyrometers and thermal cameras to study ventilation and environmental conditions in underground mines. Surface and underground thermovision tests were carried out in the Rudna mine and included channels and diffusers of some selected fan stations, shaft crest closures, engines of central fans and their instrumentation. The thermovision underground tests in the Rudna mine consisted of ventilation barriers, underground fans, temperature of rocks, ventilation machines, parts of belt-conveyors and electric machinery.

Jan 1, 2003

By M. C. Bhulose

Paper written on project work carried out in partial fulfilment of B. Eng (Mining Engineering) degree The purpose of this project was to identify constraints that could occur in the current sub-decline shaft at Turffontein Shaft should an increase in production take place. Particular attention was to be paid to the transportation of men and materials and to the broken rock and ventilation capacity of the shaft. This project is an in-depth evaluation of the logistic capacity of the sub-decline system at Turffontein Shaft in order to determine by how much production can be increased in this area to replace tonnages from the vertical shaft area, where ore reserves are rapidly becoming depleted.

Jan 1, 2004

By O. Rondon

Localized uniform conditioning is a technique developed to spatially locate selective mining unit grades that have been derived using uniform conditioning for the assessment of recoverable resources. The technique has the advantage of producing selective mining unit estimates conforming to the uniform conditioning panel-specific grade-tonnage curve while introducing spatial information at the scale of the selective mining units. This paper describes an alternative technique to localized uniform conditioning which does not explicitly require the uniform conditioning panel-specific grade-tonnage curve to localize the selective mining unit estimates. The technique can therefore be implemented in mining software where uniform conditioning is not available.

Jan 1, 2014

By G. Lyman

The cross-belt sampler is a device that is very widely used even though it has not been ratified by the Standards associations. This paper is concerned with the bias testing of two cross-belt sampler designs against stopped belt samples and a cross-stream cutter at the belt end. The bias analysis is carried out using size distribution as the analyte and conventional t-testing and the Hotelling T squared test, which are compared for their effectiveness. The paper considers the issue of detectable bias and the statistical planning of bias tests.

Jan 1, 2010

By G. D. Buson

Driefontein Consolidated Limited has a proud history in the South African gold mining industry dating back to March 1945 with the formation of the West Driefontein Gold Mining Company. The reclamation gold plant at West Driefontein was originally built as a uranium recovery plant in 1970. With the collapse of the uranium oxide yellow cake market, the uranium plant was closed in 1988and successfully converted into a gold plant, recovering gold from repulped tailings dams1. The West Driefontein Reclaim plant utilized milling, leaching, conventional rotary vacuum filtration and cementation to recover the gold at a rate of 200,000 dry tons per month. The No. 1 tailings dam (at a head grade of 0.8 Au g/t) began to near the end of its life during 1996, and the next slimes dams to be treated, the No. 2tailings dam (at a lower head grade of 0.56 Au g/t) was found too marginal for reprocessing using the filtration technology. Alternate technologies were investigated, particularly the carbon-in-pulp (CIP) plant based on the Anglo-American Corporation (AAC) pump-cell technology at the Vaal Reefs Exploration and Mining Company?s East gold plant which was operating profitably at lower head grades2. The AAC pump-cell technology is based on the carousel mode of operation2. The suitability of CIP technology for the West Driefontein Reclaim plant was investigated using a pilot plant pump-cell supplied by Kemix The data gathered were utilized in sizing a full scale AAC pump-cell plant. This plant was motivated, built and commissioned on the 22nd of November 1996. Incorporating 6 eighty cubic metre AAC pump-cells. The West Driefontein Reclaim plant initially treated repulped slimes dam material. A subsequent change of feed material to current arisings (from the main gold plant) occurred in1997 in order to convert mills for waste rock treatment. Currently the reclaim plant treats a combination of current arisings and waste rock (milled at the reclaim site). The new CIP plant replaced twenty-seven rotary vacuum filters. A comparison between the filters and CIP in terms of operating costs was undertaken, as well as a performance analysis of the CIP plant to determine its flexibility in terms of variation of the throughput, pulp density, gold input, leaching efficiency prior to CIP, and the rate of carbon movement.

Jan 1, 1999

By R. T. Jones

Keywords: Pyrometallurgy, DC arc furnace, myths, history, hollow electrode, radiation, resistance, flicker, AC DC arc furnaces are widely used for steel scrap melting as well as for reductive smelting of ore fines. Industrial smelting applications include the smelting of chromite to produce ferrochromium, the smelting of ilmenite to produce titania slag and pig iron, and the recovery of cobalt from non-ferrous smelter slags. A number of myths and misconceptions are widely held, especially regarding: the age of the technology, the use of a hollow electrode, arc stability and shape, arc and bath radiation, interaction between the arc and molten slag, electrical behaviour of arcs and slags, a comparison between AC and DC furnaces, DC reactors, the lifespan of bottom electrodes, and the applicability of DC arc furnaces to various metallurgical systems.

Jan 1, 2011

By M. R. Samis

The great variability of mineral and energy prices has motivated some governments to incorporate a windfall profits tax into their mineral taxation regimes. Windfall profits taxes are a means for governments to capture additional mineral revenue when mineral prices are considered higher than some historic level. Governments need to be aware of the effects of such contingent taxes on the exploration, development and operating decisions of mining companies. Mining companies need to be able to calculate the full impact of windfall profits taxes on the economics of their projects. This paper examines the valuation of a multi-phase copper-gold project in the presence of a windfall profits tax. Real options Monte Carlo simulation is used to characterise the different exposures of the mine owner and of the government to the risky cash flow streams that they receive from the project. The results highlight that Monte Carlo simulation paired with the real option valuation method is able to account appropriately for the differing risk exposures, while the traditional discounted cash flow valuation model is not. Our key conclusion for governments and mining companies is that the impact of contingent tax and royalty terms can and should be assessed using advanced valuation techniques, and the results used to improve contract designs under the constraint of actual and perceived fiscal system stability.

Jan 1, 2007

By C. C. Pretorius

3D seismic surveys have become a well-accepted method of imaging sub-surface geology in the Bushveld Basin. Because both the seismic sources and receivers are placed at surface, most surveys are limited to imaging faults with >=7 m throw. However, some areas such as shaft infrastructure can benefit from the ability to detect smaller structures prior to shaft sinking. Borehole radar and logs such as the acoustic televiewer can identify these structures in the shaft barrel, but not within -200 m from the shaft. Therefore, Anglo Platinum has developed the method of high-resolution 3D vertical seismic profiles (VSPs) for structural sterilization of shaft sites prior to shaft sinking. VSPs utilize a surface source and sub-surface receivers deployed down a borehole. This means that seismic energy goes through the near surface only once, and therefore suffers less frequency loss than when both source and receivers are on surface. Furthermore, VSPs can record 3 component (3C) data which comprises P wave, Sh (horizontal) and Sv (vertical) wavemodes. Because S waves travel at about 0.6 of the velocity of a P wave, shorter wavelengths and therefore higher resolutions are possible using S wave data. VSPs were first used in their one dimensional, zero offset, mode to correlate borehole geology with seismic stratigraphy within seismic surveys. This showed that VSPs record -30% higher frequencies than surface seismic surveys. The program then applied two dimensional VSPs to the problem of imaging geological structure close to a borehole. 2D VSPs confirmed that high frequency results could be achieved, and that this enabled a more accurate image of the Merensky Reef than could be achieved by surface seismic data. Finally, the program has achieved the successful recording and processing of 3D VSP data, with both compressional and shear wavemodes giving a high resolution structural result. Although P wave data gives -30% frequency improvement over surface seismic surveys, S wave data can give as much as 80% improvement, further improving the structural image achieved. The high fixed costs of VSP surveys mean that they should ideally be run in multi-client batches, which can reduce the per borehole cost by up to 50%. Their application is anticipated to be on high value capital infrastructure with a geological risk from faults which are not imaged by surface seismics-generally in the sub-7 m range. Keywords VSP, 3D seismic, bushveld, platinum, resolution, imaging, shear waves, shaft sinking.

Jan 1, 2011

By M. Mostert

Mining companies sponsor a range of non-core, corporate social responsibility projects to adhere to social and labour plans and environmental management prerequisites that form part of a mining licence application. Some companies go above and beyond such projects, sponsoring initiatives that generate renewable energy through solar power, wind energy, natural gas, etc. The challenge for these companies is to choose between a variety of projects to ensure maximum value, especially in times when the economic climate might be less favourable for such projects. The focus of this research was to analyse the concept of sustainability as it exists today, and to apply that to the triple bottom line accounting method in an attempt to quantify the sustainability of a project. Research was done on the methane burn-off project at Sibanye Gold?s Beatrix Mine to establish how such projects are planned and financed, and what impact they have on the triple bottom line of a company. The financial bottom line is, by definition, one that executives understand. This paper also proposes a quantitative method for defining the social and environmental bottom lines as well. By considering the financial, social, and environmental values, the study attempts to determine a monetary value for a sustainable renewable energy project. This monetary value can be compared to similar values obtained for other sustainable renewable energy projects under consideration. The research suggests that monetary value alone is not enough to base a sustainable decision on, and qualitative measures are suggested for use in conjunction with quantitative methods. The selection method proposed should assist the board of a mining company to choose the most sustainable option and the project that will add the greatest value to the company across all three bottom lines. It will also provide increased justification for such renewable energy projects, even in periods of harsh or uncertain economic climates.

Jan 1, 2014