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By R. E. Wilmot

This paper is based on the experiences, over many years, of numerous authors in the South African mining industry and of the hot dip galvanizing process and its application as a corrosion protection system. The paper sets out the extensive development, financial resources and stringent operating requirements of the South African mining industry. After many years of research and operational experiences, hot dip galvanizing and, when necessary, duplex systems, have been found to meet the demanding requirements of this particular industry. The paper sets out the requirements from the standpoint of corrosion criteria and is followed with a case where the corrosion protection properties of hot dip galvanizing are demonstrated. This case history traces the early investigation of the expected corrosive conditions in a new mining operation and concludes with two follow-up visits to the mine in order to examine actual performance of the corrosion protection system after ten years in service.

Jan 1, 2007

By P Knight, P A. Walker, H E. Speight

Pushback 8 South is the final cut back on the south wall of the East Pit at BHPBilliton?s Mt Whaleback iron ore mine in the Pilbara region of Western Australia. Development of the cutback commenced in 1999 and is now nearing completion with ultimate pit walls up to 300m high. This paper describes the geotechnical, structural and hydrogeological setting of PB8S, reconciliation between design and slope performance and the slope engineering techniques used to effectively manage the risks associated with the slope. These techniques include slope buttressing and sequential mining with waste backfilling, as well as a detailed program of displacement and hydrogeological monitoring, structural mapping and slope stability assessment. During the course of slope formation recent developments in remote slope displacement monitoring using radar and remote structural mapping using terrestrial photogrammetry have also been applied. Aspects of the PB8S slope management plan are relevant to many large scale open pit slopes. This paper provides geotechnical practitioners with information which may be helpful in managing geotechnical risk in similar environments.

Jan 1, 2006

With increasing demand for real-time monitoring of mine parameters, the requirement for appropriate data management in many mining applications is also increasing. This includes atmospheric monitoring in underground coal and metal mines. Although a number of different (real-time) monitoring systems have been installed in underground mines, they all typically share the same systems or sub-systems, where each sub-system may include both custom hardware and / or software components. In addition, monitoring components installed in underground coal mines in the USA should also be intrinsically safe and approved by the US Mine Safety and Health Administration. Real-time analysis adds complexity to the system since data validation and storage should be completed independently of filtering, data reduction operations, or visualization. Real-time processing may include statistical evaluation, trending, cross-correlation, and real-time alarm or warning generation. This paper presents the concept and design of an integrated system under development for atmospheric monitoring in US coal mines.

Jan 1, 2014

By J. Böhlke, B. Friedrich, E. Hecker

The legislation for the disposal of heavy metals contaminated substances is still going to be tightened up in the future. The main criteria for the utilization or deposition of these residues are the content and the water solubility of these metals. Through this, the use of slags from the lead-and zinc-industry in road building may become limited or even not possible at all. From an economic point of view this would lead to Pb/Zn losses and costs for safe dumping. This paper investigates the feeding of the reducing agent via hollow electrode DC smelting and the yield of metal reduction. After carrying out thermodynamic calculations, the process window conditions for electric-arc furnace tests were determined. Doing this, the zinc could be reduced, evaporated and recovered as an oxidic intermediate product flue dust, while the lead was present either in flue dust or in metallic form. The zinc content in the final slag could be reduced by up to 90%. The slag product has undergone an eluation test which allows it to be used as building materials. Keywords: zinc reduction, lead reduction, hollow electrode, slag treatment, electric arc furnace

By R. E. Wilmot

The problem of corrosion of reinforcement in concrete structures is internationally recognized and represents the single biggest expenditure in the preservation of steel reinforced concrete structures. While the corrosion protection of the reinforcing steel is no substitute for design and the placement of good quality concrete, it does provide for a viable and economical extension of structural integrity and service life in the day-to-day and practical environment in which concrete structures are constructed. The mechanism of corrosion attack and consequent deterioration of reinforced concrete structures is well understood and documented. New structures can be designed and built to withstand corrosion. However, due to short-term economic restraints, many new reinforced concrete structures continue to suffer as a result of corrosion damage, which results from the corrosion of the steel reinforcing. This paper explores the economic and practical benefits offered by the application of hot dip galvanizing as a viable means of protecting reinforcing steel concrete structures. The paper also discusses technical misconceptions that exist about application and performance provided by the use of hot dip galvanized reinforcing steel.

Jan 1, 2007

Comminution is a vital part of minerals extraction, and therefore of the South African economy. The high cost and throughput-limiting nature of comminution forms a strong motivation for research directed at improving the efficiency of the process. Building on a ten year background of fundamental charge motion research, a new formal UCT flotation and communication group has been formed. The group is also moving strongly into the field of milling circuit modelling and simulation, based on close links formed with the Julius Kruttschnitt Mineral Research Centre (JKMRC) of Australia, and an international collaborative research programme.

Jan 1, 1998

Gravity-driven rock falls account for a large proportion of all fatalities and injuries in underground mines. Potentially unstable blocks of rock are found in the hanging wall of excavations, which may be delineated by natural joints or stress fractures. These blocks, referred to as keyblocks, will fail if their weight exceeds the support capacity or if they are located between support units. This paper describes a computer program which simulates blocks in the hanging wall of an excavation based on measured properties of fractures and joints. Keyblocks are identified and placed at random locations in a predefined excavation. The keyblocks are tested against the support to determine whether they fail the support, drop out between the support or are stable. By repeating the procedure several thousand times, statistics of the probability of failure of the keyblocks are obtained. This approach allows the relative hazard associated with different types of support or excavation orientations to be obtained. It is concluded that a probabilistic approach is suitable for the evaluation of supports effectiveness in situations where large numbers of discontinuities or stress fractures are exposed in excavations.

Jan 1, 1998

By T. Ertekin, X. Dong

This paper identifies the need for the development of specialized inverse solution techniques for the analysis of pressure transient data for the characterization of the transport and sorption properties of coal seams. Central to the proposed inverse solution technique is a specially structured artificial neural network (ANN). The most important transport and sorption characteristics of coal seams are butt and face cleat permeabilities, macropore porosity, Langmuir volume constant, Langmuir pressure constant, and sorption time constant. Conventional methods, such as type curve matching techniques and laboratory-derived measurements are handicapped in terms of being representative over the entire domain of interest. In this paper, we utilize analytical forward solution techniques for various combinations of characteristics of coal seams to generate training and testing patterns. These training patterns are shown to an ANN structured to learn the ubiquitous non-linear relationships that exist between coal seam properties, input conditions and the pressure transients measured. The trained networks are then extensively tested to ensure that they have effectively learned the training patterns. In the final stage of the development, the networks are run in the prediction mode. The responses of the networks are found to be in agreement with the input data. The developed networks are able to generate results generally within 5% error margin for permeability and porosity and 20% error margin for the sorption characteristics of coal seams. A number of examples highlighting the capabilities and degree of effectiveness of the network in characterizing the coal seams areincluded. Keywords: artificial neural networks (ANNs); coal seam characteristics; pressure transient analysis

Jan 1, 2003

By I. Bock

Selective Blast Mining (SBM) makes use of milli-second sequential blasting technology to separate the valuable reef material from waste rock in the blasting operation at stope faces in the mining of tabular ore bodies such as exist in the gold and platinum mines in South Africa. The waste rock is cast blast to the back of the stoping area, and the reef material is fractured and deposited close to the stope face. Only the reef material is transported to the surface. A simplified economic model is presented to evaluate the economic benefits of SBM. Although premature, in that adequate experimental demonstration of the validity of the model has not yet been possible, the model is presented since it indicates substantial benefits in the case of narrow reef gold mines. It is suggested that many marginal mines should seriously consider SBM. Benefits can also be realised in platinum mines, but a lot more experimental work is necessary to establish cost parameters more reliably. Some practical experience in the use of SBM in the mining of the UG2 reef is presented.

Jan 1, 1998

By F. R. Camisani-Calzolari

Surface defects on continuously cast slabs require treatment by grinding. This extra phase in the process causes lower throughput of final product and extra energy costs. The elimination of slab treatment after casting implies that slabs can be direct rolled or hot charged, resulting in higher throughput and lower energy costs. To increase the number of slabs that can be direct rolled or hot charged, defects have to be predicted before a slab has completed the casting process. Transversal and longitudinal cracking, casting powder entrapment and other inclusions, bleeders, deep and uneven oscillation marks, stop marks and depressions are the defects thatare considered for prediction. A structure with two models is proposed. The first model describes the effect of mould level, water inlet temperature and casting speed (MV?manipulated variables) on 38 thermocouple temperatures (IV?intermediate variable). Casting speed is a manipulated variable while mould level and water inlet temperature are treated as measured disturbances. This model is known as the MV to IV model, and is used to control the occurrence of defects. The second model describes the effect of the thermocouple temperatures on the defects at different positions and locations on the slabs (OV?output variables). This model is known as the IV to OV model and is the predictor of defects. The models are determined using time-series methods in the form of auto regression with exogenous input using data of approximately 500 slabs cast over a period of 6 months. The models are validated using plant data from 44 slabs gathered three years later, with good results. As an example, published results give a sensitivity and specificity of 61.5 per cent and 75 per cent respectively for longitudinal cracks on validation data, while the presented method gives 63.6 per cent and 93.5 percent, respectively. The IV to OV model is used in an inversion to determine the optimal thermocouple temperatures for each slab width. Keywords: Continuous casting, model, defect, prediction, direct rolling, hot charging, goodness-of-fit, correlation, time-series, soft sensor, ARX.

Jan 1, 2003

By J. N. Van der Merwe, M. Mathey

"The South African squat coal pillar strength formula, developed by researchers from the Chamber of Mines Research Organization in the 1980s, predicts an exponential increase in coal pillar strength once a critical width-to-height ratio of 5 is exceeded. The arguments that have been proposed in favour of this formula are discussed critically in this paper.Field experience with squat pillars in the USA and evidence from published physical, analytical, and numerical model pillar studies corroborate the fact that a squat effect is unlikely to occur in coal pillars at width-to-height ratios less than 10. Furthermore, an exponential increase in peak strength of coal pillars does not exist. An alternative design criterion for squat pillars in South Africa is therefore suggested. IntroductionFive decades of coal pillar research in South Africa have produced a wealth of information on the mechanisms contributing to the strength and failure of in-situ coal pillars and accompanying phenomena. The relevant knowledge was sourced from, and for, a South African coal mining environment that remained largely unchanged in the second half of the 20th century. The depth of mining seldom exceeded 250 m, with mined seam thicknesses averaging 3 m and typical pillar width-to-height ratios (w/h) of 3–4.It is therefore not surprising that comparatively little research has been directed at the prediction of coal pillar performance in deeper deposits, where squat pillars of larger width-to-height ratios will be required to support the overlying strata. However, a thorough understanding of squat pillar performance will be necessary should the remaining deep coal deposits of the country be extracted in future, for instance in the Waterberg or Ermelo coalfields.A squat coal pillar strength formula has already been proposed in South Africa. The origin of this formula will be discussed in some detail in the following sections and its appropriateness will be critically reviewed against a great amount of evidence from relevant squat coal pillar research conducted internationally."

Jan 1, 2016

By A. Krause

Shovel-truck systems for loading and hauling material in open pit mines are now routinely analysed using simulation models or off-the-shelf simulation software packages, which can be very expensive for once-off or occasional use. The simulation models invariably produce different estimations of fleet sizes due to their differing estimations of cycle time. No single model or package can accurately estimate the required fleet size because the fleet operating parameters are characteristically random and dynamic. In order to improve confidence in sizing the fleet for a mining project, at least two estimation models should be used. This paper demonstrates that the Machine Repair Model can be modified and used as a model for estimating truck fleet size in an open pit shovel-truck system. The modified Machine Repair Model is first applied to a virtual open pit mine case study. The results compare favourably to output from other estimation models using the same input parameters for the virtual mine. The modified Machine Repair Model is further applied to an existing open pit coal operation, the Kwagga Section of Optimum Colliery as a case study. Again the results confirm those obtained from the virtual mine case study. It is concluded that the Machine Repair Model can be an affordable model compared to off-the-shelf generic software because it is easily modelled in Microsoft Excel, a software platform that most mines already use. This paper reports part of the work of a MSc research study submitted to the University of Witwatersrand, Johannesburg, South Africa. Keywords: simulation, bunching, probability distributions, cycle time, queuing, matching, shovel-truck, OEM.

Jan 1, 2007

By Godofredo F. Barrios

For years urethane screen surfaces have been used in a wide range of wet screening applications where openings from as fine as 100 microns and coarser have been used. The purpose of this paper is to expose the reader to new developments in both screen surface and screening equipment technologies which allow an end user to consider urethane screen surfaces for fine screening applications. These technologies allow an end user to use the inherent advantages of urethane with regards to wear resistance while also realizing the benefits that a high oper area urethane screen surface can bring. These benefits include non blinding characteristics and feed capacities that which rival that of traditional stainless steel surfaces. The paper will highlight the features of this patented urethane screen surface technology and the screening machines they are used in conjunction with. There will also be a presentation of case studies of commercial installations where these technologies are utilized. These case studies are from the base metals industry therefore relevance to the conference is direct and not inferred. Included in the paper will also be constraints which must be taken into account when considering urethane screen surfaces such as temperature and chemical attacks. This paper will expose potential end users to a possibility of using screens to achieve extremely accurate size separations in applications where screens were previously not considered. The paper will explain and demonstrate that prior concerns of screen surface blinding, high screen surface consumption rates and large screen surface area requirements can be eliminated by proper utilization of high open area urethane screen surfaces.

Jan 1, 2007

By V. Arslan

In this study, effects of the inert constituents, such as ash, and the effect of blending coals with differing rank and composition on the plasticity of coal blends were investigated. The reference coal originated from the Zonguldak region, in the north-west part of Turkey. Firstly, the effect of coal ash on the plasticity of Zonguldak coal was determined. Secondly, the relationship between the plastic properties of the individual coals and those of the blended coals were identified. Some important relations were found, related to the characteristics of the individual coals. Ultimately, the manner in which the plasticity of Zonguldak coal was affected by blending with low volatile coals was investigated. Keywords: coal blending, coal plasticity, coke, fluidity, rank.

Jan 1, 2006

By H. Aykul

The choice of which mining method to use at many large surface coal mines is often dicated by what machinery is available or what experience the mine management can offer. One of the most significant surface coal mines in Turkey is owned and operated by the Turkish National Coal Board, located to the west of the city of Kütahya. The Seyitömer Lignite Enterprise (SLE) extracts low quality coal, the majority of which is supplied to an adjacent power station. The coal seems at SLE contain bands of ash which under normal mining conditions are extracted with the coal. This increases the ash content of the run of mine coal and results in lower efficiency at the power station and financial penalties for SLE. In this paper, therefore, selection of the best possible equipment and production method was identified to achieve high selective mining at SLE. The research found that two different high selective mining methods were suitable for selective excavation of the B3 seam, which were hydraulic excavator and truck and surface miner and truck combinations. It was also found that high selective excavation could provide the desired coal quality at 52% lower costs when the whole process (excavation, transportation, processing, etc.) was considered. Keywords: coal mining, surface mining, selective mining.

Jan 1, 2007

By B. McFadzean, M. Tadie, T. Dzingai, M. Becker

Ores from a single deposit may exhibit extensive variability in their mineralogy and texture. The ability to quantify this variability and link it to mineral processing performance is one of the primary goals of process mineralogy. This study focuses on the effect of alteration in three platinum group element ore samples from the Great Dyke in Zimbabwe – two of which were more pristine compared to the third, which was locally classified as ‘oxidized’ ore. These ores are known to be characterized by varying degrees of alteration, resulting in numerous challenges in flotation and affecting both grade and recovery. Alteration, by near-surface oxidation, of the valuable base metal sulphides and platinum group minerals resulted in lower flotation recoveries of Cu, Ni, Pt, and Pd. Evidence of incipient oxidation was more readily observed in the base metal sulphide assemblage than the platinum group mineral assemblage, even though the loss in recovery (because of oxidation) was most significant for Pd. Alteration through hydration resulted in a significant increase in mass pull and dilution of concentrate grade through the inadvertent recovery of naturally floating gangue comprising composite orthopyroxene and talc particles. In this study, the amount of naturally floating gangue was more strongly correlated with the talc grain size distribution than the grade of talc in the flotation feed. The oxidation and hydration alteration reactions are not necessarily mutually exclusive, although one may be more dominant than the other, giving rise to ore variability.

Sep 1, 2021

By T. R. Marshall

SAMREC (The South African Code for the Reporting of Exploration Results, Mineral Resources and Mineral Reserves) Clause 7 notes that ‘Documentation detailing Exploration Results, Mineral Resources and Mineral Reserves from which a Public Report is prepared must be prepared by, or under the direction of, and signed by a Competent Person.’ Similar statements with respect to Competent Valuators (CVs) and Qualified Reserves Evaluators (QREs) are contained in the SAMVAL (South African Code for the Reporting of Mineral Asset Valuations) and SAMOG (South African Code for the Reporting of Oil & Gas Resources) codes respectively. What does it mean to be a Competent Person (CP) in the context of compiling/signing-off on SAMCODE (South African Mineral Code) compliant documents? What do the registration and experience requirements mean? Who is ultimately responsible for the report and what does such responsibility prescribe?

Sep 1, 2021

By G B. Gnoinski

The Skorpion Zinc Mine and Refinery is situated approximately 25 km north of Rosh Pinah, south-western Namibia. The supergene zinc oxide deposit at Skorpion is hosted in a volcano-sedimentary succession within the para-autochthonous Port Nolloth Zone of the Gariep Belt. Rock types hosting the ore deposit include altered and metamorphosed volcaniclastic and clastic sediments, limestone and rhyolite. At Skorpion, the metallurgical process is unique and the plant design requires minimal fluctuations within a selected feed grade. In addition, the presence of limestone inter-fingered with ore in some areas of the deposit results in dilution problems which may increase gangue acid consumption and therefore processing costs. Hence, selective mining is necessary to ensure the delivery of suitable ore to the processing plant, in order to keep the overall operating costs at a minimum. A complex control system is in place and is capable of a high degree of selectivity. The paper describes the grade control system in place at Skorpion Mine which ensures that the qualities of the blocks planned for mining and the material being mined meet the stringent process requirements of the refinery, i.e zinc grade, gangue acid consumption and deleterious elements that may impact on the efficiency and costs of the metallurgical process. Keywords: Skorpion zinc, zinc oxide, supergene, volcano-sedimentary, grade control

Jan 1, 2007

By S. Zhang, Z. Hua, D. Feng, X. Tong, X. Xie

The separation and beneficiation of low grade collophanite has long been a technical challenge in phosphorous production. It requires the joint efforts of process design, reagents optimisation and operational control. In this study, the statistical response surface method was applied for determining the optimum reagent dosing in the flocculate flotation of a low grade (18.59%) collophanite ore. The dosage of three reagents, including a pH regulator (Na2CO3), depressant (Na2SiO3) and flocculant (modified starch), were input parameters of the modelling design. Two quadratic mathematical models were derived for prediction of grade and recovery based on the statistical design. Statistical analysis of the experimental results validates the reliability of the models. Through further calculation, the optimum dosage of the three reagents were found to be 3,020g/t Na2CO3, 1,990g/t Na2SiO3 and 880g/t modified starch, with which a maximum recovery of 75.81% and P2O5 grade of 30.08% was obtained from flocculate flotation test. Keywords: Process optimisation, modelling, froth flotation, collophanite ore, response surface methodology

Jan 1, 2020

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

Jan 1, 2014