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By L. Hansen

Sulphuric acid plants now and then see unexpected increases in SO2 emissions. Our experience is that it is not always easy for the acid plants to pinpoint the exact reason for the SO2 increase. Sometimes a catalyst bed is sacrificed even though reliable temperature readings and gas analyses could have verified satisfactory activity. Hence the leaking heat exchanger is never discovered and after the shutdown the SO2 emissions are still too high. This paper will look into some basic catalyst management tools: good record keeping is a necessity for collection of representative catalyst samples; reliable operating data is an inevitable starting point for all analysis; and trending of operating data is a must for plant optimization and troubleshooting. In addition, these catalyst management tools will give continuous updated knowledge of the catalyst status in each bed, providing the basis for a more effective replacement strategy. The most typical reasons for increasing SO2 emissions will be presented together with easy guidelines for cross-checking operating data, temperature optimization and good record keeping.

Jan 1, 2009

By M. S. Raseroka

An experimental rig has been constructed to produce chloride stress corrosion cracks in Type 304L stainless steel tube samples. The samples are to be used to test possible in situ repair methods in future work. The factor which influences the time to failure most strongly is the sample temperature; the distribution of cracks within the sample is affected by local temperature variations and by the position of the water line. Low-frequency oscillations in stress, caused by the on-off temperature controller, did not appear to influence cracking in these tests.

Jan 1, 2009

By Peter Townsend, Sergei Diachenko, Allan Moss

The Palabora Mining Company has successfully extended the life of its operation by developing a 30,000tpd block cave underground mine below the now closed open pit. The process of transitioning from surface to underground mining has been technically, operationally and managerially challenging. This has been due to a number of factors; in particular, the development of a block cave in a very competent rock mass. The competence of the rock mass is clearly demonstrated in the open pit that preceded the block cave, one of the steepest deep open pit excavations in the world. With cave breakthrough, however, the pit was ?instantaneously? deepened by 400m causing a major failure of the northwest wall involving close to 100Mt of waste material.

Jan 1, 2006

By R. Boom, L. Holappa

In the present paper, microstructure changes of solid-state reduction of industrial chromite pellets and lumpy ore were investigated with SEM/EPMA. To simulate the reactions in the packed bed zone of the Submerged Arc Furnace (SAF), carbon monoxide was used as the reducing agent, with the presence of graphite in proximity to chromite. The experiments were carried out at 1500 °C. Scanning electron microscopy was used to observe and analyse the structure and composition changes of the chromite samples. It was found that reduction of lumpy ore generally took place slower than that of pellet. In all samples, chromite reduction proceeded faster in the outer part of the sample than in the centre part. The reaction mechanism is discussed on the basis of experimental results and earlier investigations. The possibilities to optimize the FeCr production process are also discussed.

Jan 1, 2007

An effective electrowinning process in hydrometallurgical industry requires fluoride levels in the base metal solution to be less than 10 mg/l. Selective removal of the fluoride ions from base solution is thus desired, if fluoride was added to control calcium and magnesium in the circuit. Consequently, adsorption of fluoride onto activated alumina was studied in a batch and a column set-up. The effects of base metal solution pH, temperature, initial concentration and flow rate on activated alumina performance were investigated in either a batch or column configuration. A two-level factorial experimental design was implemented in studying column dynamics. Results demonstrate that activated alumina is an effective adsorbent for selective removal of fluoride from base solution. In the batch operation, fluoride was removed to values below the maximum allowable concentration (10 mg/[l]) when pH was = 8. In the column adsorption step at 55°C and 600mg/[l] initial concentration, up to 16 bed volumes were processed before breakthrough level was reached. Desorption step using 1% sodium hydroxide solution achieved an elution of 8 bed volumes. The activated alumina (AA) had a capacity of 8.65 gF/[l]AA at the 10mgF/[l] fluoride breakthrough level during the column adsorption test. Keywords: Fluoride; activated alumina; adsorption; recovery; regeneration.

Jan 1, 2009

By P. C. Carrasco

Knowing the origin of the relevant and irrelevant components of the nugget effect is essential to optimize the process under study. This paper describes the causes of the nugget effect and, its dependency on the sample support, sampling density, and on the QA/QC procedures. Several examples of natural and ?human? nugget effect are given. A method to estimate the magnitude of the relevant and irrelevant components is suggested. Finally, the economic consequences of misunderstanding the nugget effect are analysed.

Jan 1, 2010

By P. J. D. Lloyd

The widely employed IPCC models for the release of methane from underground coalmining operations are reviewed, and put in the context of the South African National Communication on greenhouse gas emissions. Then attempts to calibrate the model via measurements on South African coalmines are described. These attempts failed because it rapidly became clear that the IPCC model, involving methane adsorbed by the coal and released (a) by the depressurization of the strata caused by mining, (b) from the broken coal and (c) from coal remaining in roof, floor, pillars or goaf after mining, was not valid. Instead, measurements showed that the methane release was very variable, sporadically falling to zero. Carbon dioxide concentrations were monitored at the same time as methane, and followed methane concentrations. An alternative model was developed, in which methane was largely displaced from the coal and held in fissures, cleats and pores, which, when intersected by mining, released methane into the ventilation stream. In a key test of this hypothesis, methane concentrations around a continuous miner were monitored both during operation and after shutdown. Even during operation, methane became undetectable. It is hypothesized that heating of the South African coal-seams during the emplacement of the igneous dykes that cut so many of the seams caused displacement of the methane from the coal into the pores. This fissure-held methane, or free methane, is released rapidly once a pathway through the coal into the mine atmosphere is established. In contrast, methane adsorbed in the coal, and measured as the seam gas, desorbs relatively slowly. Measurements suggest that on average about 50%of the adsorbed methane is lost one day after mining. By that time, the coal will have left the mine, so that the remaining seam gas will be released to the atmosphere outside the mine. Attempts to measure methane emissions from surface coal-mining operations showed very little detectable methane. Coal from surface operations, which was milled and exposed to atmosphere, adsorbed gas from the air. It is concluded that methane release from surface operations is probably less than 3Gg/a. It is estimated that the total methane release from the coalmining industry amounts to about 72 Gg/a, as opposed to the National Communication estimates of 323 Gg/a in 1990 and 317 Gg/a in 1994. However, there are large errors associated with these estimates, and it is recommended that the methodology outlined in this report be extended to as many mines as possible to reduce the errors that are inherent in the physical processes underlying the release of methane from South African coalmines.

Jan 1, 2005

Beatrix Gold Mine, a deep-level gold mine in the Free State province of South Africa, has the highest methane emission rate of any gold mine in the country. Methane is emitted from underground sources intersected during mining operations and is liberated into the general mine atmosphere. The total methane emission rate for the mine is of the order of 16001/s and the South section of the mine emits approximately 10001/s of methane gas. The mine has a history of gas accumulations which have led to a number of underground explosions. Following the last explosion in 2001 and the subsequent investigation, a number of recommendations were made. Two of these were to consider extracting the underground mine methane to render the mine atmosphere safe, and to declare hazardous locations that require special operating procedures. A number of such workplaces have now been declared at the South section of the mine. Methane gas is a potent, explosive greenhouse gas whose contribution to global warming and climate change is 21 times higher than that of carbon dioxide. To reduce its inherent danger and to mitigate its global warming impact, a carbon credit project under the Clean Development Mechanism (CDM) of the Kyoto Protocol has been developed and implemented, the aim being to capture and destroy the methane at Beatrix mine. The mine has constructed an extraction system to capture and extract 400 (Is of the methane. Percentage methane (per volume) of the gas intersected at source is 85%, with negligible concentrations of other hydrocarbons and water associated. The mine contracted the services of Group Five to design and construct the flare and ancillary equipment on surface, and Promethium Carbon was contracted to assist with the carbon¬-related aspects, approval framework, and administration of the project. A number of design and construction challenges had to be faced to extract and transport the gas effectively to the surface of the mine as the emitters are approximately 3 600 m away from the mine shaft at a depth of 860 m. Further considerations were the requirements for the type of column to be used to transport the methane gas, the pressure loss over the system, the safety systems needed to address the risk factors involved in the transport of the methane gas, and a suitable pumping system to extract the gas to the surface. The system operates under negative pressure provided by two blowers on surface delivering the emissions to a flare capable of burning off 450 8/s of methane gas. In this paper a number of benefits for the mine are discussed. These include, but are not limited to, the removal of approximately 55% of the total volume of methane gas from the general body of the air in the geographical areas of the mine where the methane gas is emitted into the atmosphere, and reducing the risk of methane-related incidents. A further benefit of this project is the mitigation of the global warming impact of the methane gas and the reduction of the mine's carbon footprint by approximately 25%. This project could also assist in alleviating the energy shortage being experienced in South Africa by means of the planned generation of 4 MW of electrical power, utilizing the methane gas, as a second phase of the project.

Jan 1, 2011

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 J. A. Luckmann

"SynopsisThe purpose of this paper is to introduce an innovative approach to risk management in surface mining operations, namely, positive risk. Traditionally, risk management focused on mitigating losses (negative). Positive risk, on the contrary, reverses the approach and focuses on exploiting a project’s inherent benefits (positive).The inability to accurately determine project objectives during the project planning phase and the failure to achieve those objectives during the execution phase is a major problem for any project management in the mining environment.The advance of computer aided design models for mine planning enables mining engineers to examine various options within a very short time. Employing positive risk management combined with drivers-based risk management when evaluating these options provides an ideal opportunity to investigate areas for improving the mining project’s profits. Furthermore, harnessing positive risk returns during the planning phase contributes immensely to the successful achievement of project objectives.Mining has inherent business risks, which can appear overwhelming when considering the risks associated with a mining project schedule, cost, and safety or resources, etc. The question is – how to manage risks in a surface mining environment, and what process methodologies, work methods, processes, and standards should be used when considering the surface mining risks. Applying the principles of positive risk management to manage surface mining risks is not only relevant, but definitely beneficial to mining projects and to the mining industry as a whole.It would be beneficial for risk managers and risk professionals to understand the roles of positive risk ‘drivers’, also known as ‘propitious attractors’. Identifying, analysing, estimating, and understanding the propitious attractors, their behaviour and their influence on project risk events helps considerably during the planning and execution phases. The theoretical and practical knowledge of both sides of the risk – the downside risk (negative risk) and upside risk (positive risk) – can add substantial value to any organization when downside risk is adequately mitigated and upside risk is beneficially exploited."

Jan 1, 2015

A shortage of technical skills in all areas of the mining industry is being experienced worldwide. This has significant consequences for design, operations, productivity and safety and, therefore, needs to be seriously addressed, both in the short and longer term. It is therefore both a strategic and a tactical issue. Importantly, however, since mining is a long-term business, the shortage of skills must be dealt with from a strategic point of view to ensure the supply of the necessary skills for future mining. This paper will deal specifically with the provision of high level technical skills, that is, university graduates in mining engineering, and the outlook for the institutions that are currently producing such graduates.

Jan 1, 2008

By R. Armstrong

Due to limited available level ground, Nkomati Nickel Mine cut a weathered rock slope at the base of a mountain spur in order to create a platform for construction of the primary crusher plant and run-of-mine stockpiles. As space is limited around the mining area, ore processing at Nkomati is based on a high reliability of flow of material through the crusher plant, with minimal usage of other and larger designed stockpiles. Evidently, any crusher plant shutdown will render the mine as a whole unproductive and put excessive strain on the medium- to long-term large ore stockpiles, the deposition rates for which are restricted by founding material consolidation requirements. At the onset of the 2012 rainy season, movement was identified on the slope monitoring system and cracks developed on the slope. After a minor failure on the crusher slope an assessment of the slope stability was conducted and a slope management plan recommended, which included deployment of real-time monitoring. An evaluation of the conditions leading to instability was conducted and the likely causes for the failure identified. A full evaluation of the slope monitoring, rainfall, and mining conditions was undertaken and movement triggers were determined. This paper describes the events leading to the development of the failure and the evaluation of the monitoring data to determine a management plan for the failure that allowed for minimal shutdowns of the primary crusher.

Jan 1, 2014

By D. P. Roberts

This paper reviews the use of crush pillars on mines in the Bushveld Complex and the Witwatersrand Supergroup. Stress measurements were undertaken in order to determine the residual strength of these crush pillars. The results from these stress measurements are compared with previous attempts to determine the residual strength of crush pillars using back analysis. It is concluded that the residual strength of such crush pillars lies in a band between 13 MPa and 25MPa. Using the data from the stress measurements, as well as published and unpublished data, a stress-strain curve for a crush pillar with a width-to-height ratio of 2:1 is proposed. Where further work is required, this is indicated in the text.

Jan 1, 2005

Novel flotation reagents were developed to improve the flotation of coarse particles. Laboratory tests conducted on an anthracite coal sample from Kyung-Dong Coal Company, Korea, showed that the reagents can successfully clean 2?3 mm top-size materials. Pilot-scale tests conducted on a 1.41 mm x0 coal gave substantially better results than those obtained using kerosene as collector. The pilot-scale test results were used to develop a flowsheet, in which the 1.41 mm x0 fraction is cleaned by flotation and the 4 x1.41 mm coal is cleaned by single-stage spirals. The performance of this circuit was compared with another flowsheet, in which the 0.5 mm x0coal is floated using the conventional flotation reagent, with the 4 x0.5 mm material being cleaned using two separate spiral circuits. The performance of the two flowsheets was compared by computer simulation. The results showed that the flowsheet consisting of the coarse particle flotation circuit can give substantially higher yield sat a given product grade. Keywords: coal flotation, coarse particle flotation, collector, spirals, computer simulation.

Jan 1, 2002

By Q. G. Reynolds

DC arc furnaces are widely used for steel scrap melting, and are increasingly being used for smelting applications as well. The electrical resistivity of slags varies widely, from highly conductive slags in ilmenite smelting, to highly resistive slags in applications such as cobalt recovery from non-ferrous slags, and nickel laterite smelting. Models have been developed to predict the electrical behaviour of the DC open plasma arc and the molten slag bath. These models allow the voltage and current ranges of furnace power supplies to be specified.

Jan 1, 2004

By I. Ewart, E. Roux

Skorpion Zinc operates a solvent extraction/electrowinning zinc plant producing over 150 000 t/a of special high grade (SHG) zinc (>99.995% Zn). In the current flow sheet copper and cadmium are cemented from the neutral leach solution using zinc powder, to prevent galvanic corrosion of plant equipment and build-up of copper in plant solutions. This process is effective but unfortunately consumes expensive zinc dust and produces a low value copper product. The EMEW® (Electrometals electrowinning) technology of Electrometals Technologies Ltd. uses a rapid flow of electrolyte through a cylindrical cell to deposit copper or other metals from dilute solution (less than 1 g/L) [1]. The copper can be deposited as powder or may be harvested as a tubular cathode product. The advantage of the use of EMEW® technology at Skorpion Zinc will be to eliminate the use of expensive zinc dust and to produce a high value copper product for sale. Following extensive bench test work, a piloting campaign was carried out at Skorpion Zinc. The tests demonstrated the ability of the EMEW® cell to effectively remove copper from solution through direct electrowinning at lower operating cost than cementation. Keywords: Skorpion Zinc, copper, cementation, direct electrowinning, EMEW®

Jan 1, 2007

By A. A. Debrah

Artisanal and small-scale mining (ASM) plays a fundamental role in the national and local economies of resource-rich countries in Africa. As such, more effort must be geared towards fostering this type of economic activity to sustain livelihoods in rural communities. Across Africa, efforts to operationalize ASM based on a sustainable development framework have been quite tedious and often ineffective. This is because most of these frameworks lacked context and an understanding of the continuum from the artisanal through small-scale and up to the junior miner, grouped under the general term ?ASM?. Driven by the need to contextualize some of the definitional issues in this niche sector, and gain a clearer understanding of their peculiar challenges, this paper aims to contribute to the debate on ASM by considering two of Africa?s resource-rich countries ? Ghana and South Africa. Since South Africa has made greater inroads in protecting the interests of small-scale miners, we thus draw comparisons from both countries? approach to ASM, outline the lessons learnt, and provide recommendations regarding the ways forward.

Jan 1, 2014

By C. Sawmliana

Deep-hole blasting operations in opencast mines are always associated with some annoyance to the surrounding areas in terms of ground vibration, noise, flyrock, etc. These become more severe when underground mines run parallel to them. Blasting in opencast mines may pose danger to the underground mines in terms of roof/side failures, damage of water dams, isolation/ventilation stoppings and other underground installations. The paper discusses a case study in India on the impact of deep-hole blasting in Ramagundam Opencast Project ? III on the stability of various water dams of GDK-6B Incline coal mine operating in close proximity. The stability of underground water dams of GDK-6B Incline mine was endangered due to deep-hole blasting at OCP-III. There were 15 water dams in seam 3 and 16 dams in seam 4 of the underground mine. The physical strength tests using a Schmidt Hammer instrument were carried out in all the 15 water dams of No. 3 seam and 16 water dams of No. 4 seam. The test revealed that there is a decrease in compressive strength values of three dams of seam 3, namely 6A, 6B and 7. Theose three dams were also directly connected to the water source. Water seepage was also observed from the surfaces of the three dams. However, they were found to be stable in accordance with their design parameters and damage point of view while considering a threshold value of ground vibration as 25 mm/s. It was found that the value of tensile stress generated by a vibration of 25 mm/s was much lower (i.e. 0.171N/mm2) than the tensile strength of the two weakest concrete dams (1.85 N/mm2). Ten experimental blasts were conducted at different working benches of the opencast mine and the ground vibration data were recorded in roof and pillars near various underground water dams. The maximum value of vibration data recorded was 5.9 mm/s in roof near dam no. 1 in seam 3 with the dominant peak frequency of 22 Hz. No adverse effect on either of the dams was observed after that blast. During the period of study, no deterioration/adverse impact was found in any dam of the mine. Based on the results of the study and the analyses of the data, optimized blast design parameters and explosives weight per delay were suggested for the opencast mine to maintain the safety of the underground water dams. Keywords: Opencast blasting, damage, water dams, underground mine, ground vibration

Jan 1, 2009

By C. F. Vos

Small replacements of C12-trithiocarbonate (C12-TTC) for dithiocarbonate (DTC)/dithiophosphate (DTP) in a reagent suite for the flotation of platinum group metals (PGM) have significantly improved the rejection of gangue. Coupled to this is an improvement in kinetics, grade and recovery of PGMs. In a pilot-plant trial, after a 5 mole per cent replacement of the current DTC/DTP collector combination by C12-TTC, large opaque bubbles were replaced by small clear ones. In addition, a similar flotation response was realized with one-third of the current depressant dosage. During a preliminary plant trial on underground UG2 ore, the initial rougher concentrates were characterized by higher PGM concentrate grades and this was in part due to improved chromiter ejection. The concentrate produced from the TTC trial also exhibited a much finer particle size distribution. The overall circuit performance, which included secondary regrind and flotation, showed an increase in concentrate grade of approximately 44% while the tailings grade remained unchanged

Jan 1, 2007

By B. Matsetela, S. Amos, V. Nkuna

"The Kamoa-Kakula copper project—a joint venture between Ivanhoe Mines, Zijin Mining Group Co. Ltd, and the government of the Democratic Republic of Congo—has been independently ranked as the world's largest undeveloped high-grade copper discovery by international mining consultant Wood Mackenzie. It is a very large, near-surface stratiform copper deposit with adjacent prospective exploration areas within the Central African Copperbelt, approximately 25 km west of the town of Kolwezi and about 270 km west of the provincial capital of Lubumbashi. A phased development approach is currently envisaged. The first phase of the project involves the development of a 6 Mt/a underground mine and surface processing complex (dual stream concentrator) at the Kakula deposit, a discovery announced in early 2016. The second phase involves an integrated 12 Mt/a two-stage development, beginning with initial production from the Kakula mine, to be followed by a subsequent, separate underground mining operation at the nearby Kansoko mine, along with the construction of a smelter. Project description and locationThe Kamoa–Kakula project comprises a newly discovered, very large stratiform copper deposit with adjacent prospective exploration areas, located within the Central African Copperbelt in Lualaba Province, Democratic Republic of Congo (DRC). The Kamoa–Kakula project lies approximately 25 km west of the town of Kolwezi and about 270 km west of Lubumbashi. Ivanhoe owns a 49.5% share interest in Kamoa Holding, an Ivanhoe subsidiary that currently owns 80% of the project. Zijin Mining owns a 49.5% share interest in Kamoa Holding, which it acquired from Ivanhoe in December 2015 for an aggregate cash consideration of US$412 million. The remaining 1% interest in Kamoa Holding is held by privately-owned Crystal River.The Kamoa–Kakula project consists of the Kamoa exploitation licences (exploitation permits 12873, 13025, and 13026, which cover an area of 397.4 km2) and one exploration licence (exploration permit 703 covering an area of 12.74 km2). The Kamoa exploitation licences, approved 20 August 2012, grant Kamoa Copper the right to explore for, develop, and exploit copper and other minerals, for an initial 30-year term, expiring on 19 August 2042. The permits can then be extended for 15-year periods until the end of the mine’s life."

Nov 1, 2018