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By W. J. Theron

The purpose of the paper is to give an introduction to the concept of fatigue and its causes in the mining industry. By knowing the fundamental role it plays, together with its dynamics, can positively contribute to a mine?s safety management system. The difference between physical and psychological fatigue will be addressed with a possible range of causes that could trigger fatigue. There are two main sources of fatigue: firstly, work-related fatigue which is associated with activities at the workplace; and secondly non-work-related fatigue. The shared responsibility between the employer and employee is also discussed as it involves factors that occur both in and outside the workplace. Employers have the responsibility to manage fatigue through using a risk management approach. Employees have the responsibility to ensure they get enough sleep, take sufficient and regular nutrition, are healthy and physically fit and come to work fresh and alert. The impact of the implementation of a fatigue management plan and procedures has the potential to eliminate employee fatigue or its causes, reduce the likelihood of fatigue occurring in the workplace, and counteract the effects of fatigue when it occurs. Factors considered when implementing a fatigue management system include: extended hours of work, shift work, time of day and work design. Fatigue is one of the major role players (either causal or contributory) when it comes to causes of fatalities in the mining industry. Our main challenge in identifying whether fatigue played a role is the fact that it cannot be tested in post-mortems like drug or alcohol abuse. It is an aspect worth understanding and getting an organization sensitive to managing it properly to benefit both organizational as well as employee needs. Keywords Signs of fatigue: Causes of fatigue, circadian rhythms, the fatigue equation, fatigue management, fatigue affecting safety, fatigue fighting tips, lifestyle suggestions.

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 J. N. Van der Merwe

In the process of pillar extraction, pillars are seldom if ever extracted completely. The pillar remnants, or snooks, play an important role in the extraction process. At the working face, they need to be stable to provide a measure of support in the immediate area. Further back, they have to fail in a controlled manner to prevent undue load build-up on the pillars that have not yet been extracted. The stability condition at the working area is the result of interaction between the stability of the pillar and that of the roof rock. It is shown that the primary mode of roof layer failure is by bending induced tension. Direct tension can be excluded in most practical conditions, and only in exceptional cases will the first failure be in shear mode. Panel spans required to cause the first goaf to be formed, predicted using analytical considerations, are of the same order as has been observed in practice. Once the first goaf has formed, the horizontal stress is reduced and failure will occur at more frequent intervals. It is shown that bending induced tension is the most likely mode of failure in an unjointed roof layer. In roof layers with a high frequency of weak or uncemented jointing, failure can be expected to occur at spans equal to the joint spacing. In this context, failure will occur at the smallest of the spans required to induce tensile roof failure and the joint spacing. A fundamental procedure to evaluate the likely roof layer failure in a stacked beam system is developed. This can to be used to estimate the loading condition on snooks. It is shown that snooks assist in stabilizing the immediate roof beam. The sizes and positions of the snooks relative to the position of the next pillar to be stooped, control the magnitude of the contribution to stability. The further the snook is from the next pillar, and the larger it is, the greater the contribution to the stability of the immediate roof. Under the condition of loading by the immediate, continuous roof beam, the position and size of a single snook controls the load acting on it. The closer it is to the nearest solid, provided that the roof overhang extends beyond the snook, the greater the load on it. However, once the immediate roof beam fails, the loading conditions change. The snook is then loaded by the tributary area load. A procedure is developed to assess the condition of snooks for different situations. Using the fundamental considerations developed in this paper, snooks can be designed to be stable during the active mining phase in their immediate vicinity, but to fail once the next line of pillars has been extracted.

Jan 1, 2005

By R. L. Pienaar

Paper written on project work carried out in partial fulfilment of B Eng (Min. Eng.) degree A study was conducted to investigated and compare the feasibility of two single level extraction layouts for an intact part of theorebody of the De Beers diamond mine, Koffiefontein. Two layouts were chosen and the tonnage profile, development schedule and production ring blast layouts were calculated by applying the information acquired through a literature study. Current principles used on the mine were also applied. The first layout chosen is described as a simple straightforward layout with 6 production tunnels spaced 15 m apart, and is referred to as Layout A. The second layout, named Layout B, is described as a complex chevron layout with 9 production tunnels spaced 15 m apart. This layout has a rim tunnel situated in the kimberlite ground, which is called a chevron and this made the layout more complex than Layout A. By comparing the financial results of the two layouts, it was found that Layout B is a more feasible option than Layout A. Sensitivity analyses show that both layouts are extremely sensitive to the revenue of the projects. Therefore it is recommended that Layout B can prove to be a source of additional tonnage to add to the total tonnage profile of the mine and to extend the life of mine by 20 months, only if certain financial/economic factors improve. There is, however, still some areas of the project that need to be investigated.

Jan 1, 2006

By W. V. Mutler

Present day capital costs are analysed for a 2 000 metric tonne per day (MTPD) pyrite burning plant and compared with a sulphur burning plant of the same capacity. Power, raw material and steam production rates are then compared for the two facility types. A sensitivity analysis is conducted to highlight the impact changing sulphur, pyrite, capital and operating costs have on the relative economics of these feeds. Technological improvement effects on capital cost and energy recovery are also discussed. Besides the steam produced from the burning of pure sulphur or pyrite, plants using an advanced form of heat recovery can produce up to 10 bar steam using heat from acid formation. The quantity depends on the overall water balance which is influenced by such factors as gas strength and product acid concentration. Modern materials and innovative process design also improve the ability to increase the high pressure steam from the roaster boiler in pyrite plants above the traditional 1.25 kg of superheated steam per kg of acid produced.

Jan 1, 2009

By D. S. F. Silva

A survey of 120 recent NI 43-101 technical reports was conducted to evaluate the current state of practice regarding resource classification techniques. The most common classification techniques are based on search neighbourhoods (50% of recent reports), drill-hole spacing (30% of recent reports), and/or kriging variance (6% of recent reports). Two new techniques are proposed. The first is based on kriging variance and involves removing one or more drill-holes with the highest weights while performing kriging and using the resultant kriging variance for classification. This technique has the advantages of variance-based techniques and reduces artifacts. The second technique is based on conditional simulation and uses a moving window approach for classification at the desired selective mining unit resolution based on larger production volume criteria. This technique has the advantage of accounting for heteroscedasticity, which is a common characteristic in mineral deposits, and also reduces artifacts since a production volume scale is considered for the actual classification. The drill-hole spacing, search neighborhood, kriging variance, and simulation-based techniques are described and compared for 2D and 3D examples with regular and irregular drilling patterns to highlight the advantages and disadvantages of each method.

Jan 1, 2014

By P. Share

As part of JAGUARS (JApanese-German Underground Acoustic emission Research in South Africa), high-resolution tiltmeters were installed during 2007 at Mponeng gold mine, South Africa, in an attempt to study and understand the risks posed by in-mine seismic events and to subsequently use the knowledge gained to mitigate these risks. In December 2007, an M2.2 event occurred at Mponeng and was detected by the tiltmeters installed. The tilt expected for the M2.2 event is modelled through the use of numerical and analytical tools and utilizing, as input parameters, characteristics of the event such as the rupture area, the amount of slip, elastic properties of the rock, the state of stress before the event occurred, and frictional parameters of the rupture. The calculated tilt values are correlated and compared with the recorded data, and are found to be of the same order. Certain input parameters, such as the initial rupture point, are further constrained by varying them, during modelling, until the calculated and observed tilt values are approximately equal. From modelling, it can be concluded that the rupture point had to be closer to the location of the tiltmeters. In addition, possible locations acting as source areas for the observed aftertilt are determined. Further modelling still needs to be done to quantify the effects of the tunnel close to the tiltmeters and plastic deformation of the rock mass. Keywords high-resolution tilt data, Mponeng gold mine, M 2.2 seismic event, analytical modeling, numerical modeling, rupture plane.

Oct 1, 2013

The aim of this investigation was to study the influence that varying production rates have on iron sinter quality. This was done by performing sinter pot tests at different pressure drops over the sinter bed, namely 11 kPa and 15 kPa (for 500 mm total bed depths). During each of the sintering processes temperature-time profiles were recorded of the top, middle and bottom layers of the sinter bed. On completion of the sinter process the sinter cakes were divided into top, middle and bottom layers. The physical properties of each layer were subsequently characterized by performing a tumbler test and a sieve analysis. A comprehensive mineralogical study was also conducted on each layer. This study revealed that sinters of similar cold strength could be produced under the examined production rates. However, a higher production rate was accompanied by an increased amount of fines. The cold strengths of both sinters significantly increased from the top layer to the bottom layer of the sinter bed. This strength variation is not related in any simple way to the phase composition. Keywords: Sinter, sinter bed, production rate, phase composition, cold strength, tumbler index, sieve analysis, temperature-time profile

Jan 1, 2003

The unpaved road network on a surface mine is extensive, comprising numerous roads of varying construction and material qualities with highly variable traffic volumes. Existing haul road maintenance management systems (MMS) work well for predictable traffic volumes, but for complex mine road networks, the MMS becomes onerous. This results in sub-optimal road maintenance strategies with the attendant increase in total road-user costs and reduction in service. A real-time maintenance management system was thus sought to overcome the deficiencies of existing MMS for mine roads. Since most large mines operate trucks with on-board diagnostic data collation, linked through a centralized communication and GPS backbone, it was proposed that road condition could be monitored on a real-time basis through on-board vibration signature analysis. The aim of this paper is to present the development of a real-time mine haul road maintenance management system. Following are view of mine road maintenance practices, the real-time system architecture is introduced and the results of a field trial of on-board vibration signature assessment is presented. The trial results are discussed in the light of road defect signature recognition, analysis, signature repeatability and system limitations. This approach has applicability to other situations such as a network of district roads, subject to an analysis of the economic feasibility. The paper concludes that modern technology has the potential to apply maintenance as and where needed with possible reductions in authority cost and an improvement in service provided for the road user.

Jan 1, 2003

By R. Katzenbach, M. Vogler, U. Adamietz

Abstract The design of deep excavation pits in rock mass is dependent as well on the mechanical properties of the rock mass as for example the orientation and the type of discontinuities like bedding planes, joints and fissures, the length of the discontinuities (persistence), the grade of weathering, the strength of rock mass, and the shear strength in the discontinuities, etc., and also on the respective boundary conditions specific for the project, and here especially the geometrical boundary conditions. The basic mutual influences and interactions between these boundary conditions are explained and exemplary presented at an excavation pit with a depth of 18,5 m, situated at a slope with a surface near groundwater table. Résumé La planification des excavations profondes dépend aussi bien de la qualité mécanique du roc, par exemple la location de la texture de la surface de moindre résistance, le degré de rupture, le degré de décomposition, la dureté du roc et la résistance limitée au cisaillement de la texture de la surface de moindre résistance que des conditions limitées spécifiques pour le projet, ici en particulier des conditions limitées géométriques. Les influences et interactions essentielles et mutuelles entre les conditions limitées isolées seront expliquées et présentées à l’aide d’une excavation 18,5 m de profondeur, située sur une pente où le niveau des eaux souterraines est près de la surface. Kurzfassung Die Planung tiefer Baugruben im Fels hängt sowohl von den mechanischen Eigenschaften des Fels wie z.B. der räumlichen Lage des Trennflächengefüges, dem Durchtrennungsgrad, dem Verwitterungsgrad, der Gesteinsfestigkeit sowie der Scherfestigkeit des Trennflächengefüges als auch von den projektspezifischen Randbedingungen hier insbesondere von den geometrischen Randbedingungen ab. Die wesentlichen gegenseitigen Einflüsse und Interaktionen zwischen den einzelnen Randbedingungen werden aufgezeigt und an einer 18,5 m tiefen Baugrube in Hanglage mit oberflächennahem Grundwasser vorgestellt.

Jan 1, 2003

By L. du Plessis

The name FISH (Fully Integrated Sort House) refers to a class of technology deployed at Jwaneng Mine final diamond recovery. The FISH concept is based on three pillars, namely: ?Improved sorting efficiency FISH is based on laser technology, which is more efficient than hand sorting for certain product categories. Laser sorting is based on measuring in-elastically scattered light from molecules and this is referred to as Raman spectroscopy. The Raman scattered light occurs at wavelengths that are shifted from the incident light by the energies of molecular vibrations ?Availability of production information Roller gap diamond size distribution information is generated on line for upstream process optimization ?Improved product security A ?hands-off? philosophy reduces security risk during operation and maintenance of the plant. In addition, a number of lessons were learnt about the application of new technologies in the industry: ?The required human competency profile demanded by new technology should match the available competencies of the operational staff ?An integrated information management system should be fully functional for both production management and diamond control purposes ?Operational feedback must be correctly evaluated to identify design, maintenance, training and operational issues so as to accelerate the maturity of the new technology within the time span of the sustainable operations project ?Project execution and technology maturity risks have to be evaluated and married to ensure risk mitigation by means of suitable project resource and contracting model selection.

Jan 1, 2003

Gullies are the vital in-stope excavations that provide access for mining personnel and material to, and mined ore from, the producing faces in the tabular hard rock mines. They pose a serious problem in most mines because they induce stress orientations, which, combined with blast damage, produce adverse rock fracture patterns that contribute to the loss of hangingwall and sidewall integrity. Rock-related injury statistics confirm this by highlighting gullies as the second-highest risk area in South African hard rock mines. Inappropriate gully geometries, poor blasting practice, and non-adherence to accepted standards worsen the problem. The aim of this work is, firstly, to provide guidelines to select the correct gully geometry and appropriate support for a particular geotechnical environment and, secondly, to review the practical issues behind gully safety and stability. In order to meet these aims, this paper reviews the available literature on gullies and their history, and reports on an industry-wide survey of practices and opinions. Then it covers observations from underground visits to 107 gullies situated in the respective geotechnical environments of the Basal Reef, Beatrix Reef, Vaal Reef, Carbon Leader Reef, Ventersdorp Contact Reef, Kimberley Reef, Kalkoenkrans Reef, Merensky Reef, and UG2 Reef. Despite the differing geotechnical conditions and gully geometries, common problems are experienced with geological structure, stress, and fracturing. Results from numerical modelling are also presented to help analyse the underground observations and to quantify the merits of the different gully layouts. It is concluded that there are no new techniques available to improve gully stability, but that significant improvements in safety are attainable by employing the correct gully geometry for the geotechnical environment, good blasting practice, and appropriate support.

Jan 1, 2002

By J. -W. Kim, Y. -B. Kang, H. -G. Lee

The effect of SiO2addition on the decomposition of Li2CO3was investigated at temperatures up to 1000ºC. It was found that addition of SiO2greatly enhanced the decomposition of Li2CO3. The main decomposition reaction started at around 600ºC, and completed just above the melting point of Li2CO3. The major decomposition product was Li2O?SiO2irrespective of the Li2CO3to SiO2mixing ratio while both reactants were available. It was ascertained that a liquid layer betweenLi2CO3and SiO2particles formed and facilitated the decomposition reaction. The governing reaction of the decomposition was the one between the dissolved Li2CO3and SiO2in the liquid layer to form Li2O?SiO2. The decomposition rate was independent of the Li2CO3/SiO2mixingratio until either one had been completely exhausted. When excess Li2CO3existed, it further reacted with the initial product of Li2O?SiO2to form 2Li2O?SiO2. When SiO2was found in excess, on the other hand, no further reaction took place. This is attributed to the fact that uponLi2CO3exhaustion there is no liquid phase available to facilitate further reaction. The apparent activation energy of the decomposition of Li2CO3in existence with SiO2is 198 kJ mol-1.

Jan 1, 2004

Recently, work was carried out by the Shotcrete Working Group to study anisotropy in steel fibre reinforced shotcrete using strain-controlled, compressive strength testing methods. The shotcrete materials used and specimen preparation procedures as well as testing methods are described. The test results are discussed and it is concluded that, because of the anisotropic nature of fibre reinforced shotcrete, it may be worthwhile investigating the degree of such anisotropy in practice using strain-controlled, strength testing techniques.

Jan 1, 2001

By J. M. Lottering

Paper written on project work carried out in partial fulfilment of B Eng (Chem) degree Operational factors influencing the electrostatic separation of mineral sands were investigated in a laboratory separator. Measurements were collected online by means of an optical sensor using diffused reflectance spectroscopy to determine the mineralogical composition. The results have shown that the roll speed and potential were the dominant operating variables, collectively explaining more than 83% and 68% of the product grade and yield, respectively. In contrast, the feed rate, temperature and position of the plate did not affect separation. The effect of the ambient relative humidity, ranging from 10% to 45%, could not be assessed conclusively and at best appeared to have a weakly beneficial effect on the product grade. Keywords: process modelling, high tension roll separator, mineral sands

Jan 1, 2006

By R. M. Goktan

Point-attack picks are one of the most widely used tools for the mechanical excavation of rock and coal. In the literature, some practical formulas have been developed to estimate their performances under varying cutting conditions such as the pick geometry, cutting depth and cutting geometry. In this study, it is shown that Evans?s theoretical model, the most cited in the literature, has serious limitations concerning the changes in the cutting geometry. Analysis of the two independent full-scale linear rock cutting experimental data reveals that both his theory and its recent modification can not fully explain the mechanism of rock breakage under asymmetrical attack. The cutting force predictions made by employing such models are shown to be too significantly weak to be of any service in practice. In this study, a semi-empirical approach was followed by means of which cutting forces under varying cutting geometries could be made. By analysing the full-scale rock cutting test data, prediction equations of the peak cutting force and mean cutting force have been developed. Comparisons of laboratory determined and predicted force values indicate that the suggested prediction equations are applicable to quite different rock materialsm which have uniaxial compressive strength in the range of about 30?170MPa, and valid for different cutting geometries. It is also shown by regression analysis that the established prediction equations are statistically significant.

Jan 1, 2005

By A. Andrews

Paper written on project work carried out in partial fulfilment of MSc (Eng) degree Solid state sintered silicon carbide ceramics are used in aggressive environments as sealings. There exist data concerning corrosion, but there are only few data concerning their electrocorrosion behaviour. Therefore the electrochemical corrosion of solid state sintered silicon carbide (SSiC) ceramics has been studied at room temperature in acidic and alkaline environments by using potentiodynamic polarization measurements. The investigation showed a pronounced electrochemical corrosion in bases and acids. In HCl andHNO3pseudo-passivity features due to the formation of a thin layer of SiO2on the surface were observed, whereas in NaOH soluble silicate ions were observed, resulting in more pronounced corrosion. The microstructural observations of initial and corroded samples reveal that the residual carbon found in the microstructure do not dissolve preferentially. Keywords: Corrosion; SEM; SSiC; polarization test.

Jan 1, 2006

A new method, localized uniform conditioning (LUC), was proposed in 2006 for modelling grades of small blocks of ore when data spacing is too broad for their accurate modelling by the linear regression based techniques, such as kriging (Abzalov, 2006). It represents a modified uniform conditioning (UC) technique that calculates the grade distribution functions for the large panels. LUC uses partitioning of the panels onto the small blocks and then ranks them in increasing order of grade. Based on the block ranks, a single grade value can be deduced for each block from the UC model of the gradetonnage relationships of the corresponding panel. After being first presented in 2006, the LUC method has been implemented in ISATIS© (commercial software) and became one of the common approaches for grade estimation when data spacing is broad in comparison with the estimated block size. Several years of study on the LUC method and its application to different geological environments, have allowed identification of the strengths and weaknesses of the method, which are as follows: ? The method produces accurate grade-tonnage functions, which are in a good accordance with a volume-variance relationship principles ? An initial ranking of the selective mining unit (SMU) blocks can be made by direct kriging from the sparse data grid. Therefore, the LUC method can be particularly useful at the early stages of exploration and mining project evaluations when sparsely distributed data is often the only available information ? Accuracy of the local estimation depends on the SMU ranking techniques. When ranking performed by direct kriging of the SMU blocks their spatial distribution is approximate. When the variogram of the studied variable is characterized by a large nugget effect, the block ranks produced by kriging can significantly differ from their ?true? distribution ? Block ranking can be improved using auxiliary data, either geophysical or geochemical. This allows use of the LUC method for integrating different data sets. In particular, LUC can be used for grade control in open pits by integrating resource definition data (e.g. drill-hole assays) and blast-hole assays. The latter are used for the block ranking.

Jan 1, 2014

By M. F. Handley

Sequential grid mining has been employed as the primary mining strategy at the AngloGold West Wits Elandsrand Mine since the inception of stoping operations from the sub-vertical shaft system in 1988. Little has been published on sequential grid mining as a mining strategy since, and the purpose of this paper is to describe sequential grid mining, its history, its implementation at Elandsrand, and the outcome to date. The results obtained using sequential grid mining have been evaluated from seismic data, productivity statistics, and rock related accident statistics. Comparisons with neighbouring mines namely Western Deep Levels and Deelkraal, have been made to substantiate the improved conditions observed at Elandsrand, and to compare sequential grid mining directly with longwall mining in similar conditions and at similar depths. Sequential grid mMining is shown to be cost-effective, more flexible, and safer than long wall mining in similar conditions, at least on the Ventersdorp Contact Reef in the western part of the Carletonville Goldfield. More work is necessary to establish it as the favoured mining strategy at depths exceeding 3000 metres, and for reefs other than the Ventersdorp Contact Reef.

Jan 1, 2000

By N. Sano

The chromium oxide in stainless steel slags usually exists as Cr2O3. However, there is a possibility that it is oxidized to hazardous CrO3 after disposal or during use. Therefore, some technical developments to reduce chromium oxide by using a smelting reduction technique have been reported recently. This paper describes the fundamentals of the technique which have been applied to ferrochromium production and reviews the recent results in literature.

Jan 1, 2004