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By A. Mabentsela

A furnace freeze lining is necessary for safety and economic reasons in several smelting operations. The integrity of the freeze lining is put at risk by furnace power imbalances. Although numerous models have been derived to model the growth and depletion of the freeze lining due to power imbalances, no model exists for thermomechanical damage to the freeze lining. This study provides an initial pathway for modelling thermomechanical damage to the freeze lining in an ilmenite smelting furnace using information from the literature and experimental work. A methodology under the framework of continuum damage mechanics is proposed to model mechanical damage to the freeze lining due to phase changes, thermophysical changes, and constrained thermal expansion. Drill cores of solidified slag ingots were used to represent the freeze lining. The modified power law proved to be the best predictor of the softening response of the drill cores. Damage driving parameters were extracted from the raw data, and governing equations of the parameters with respect to temperature were derived for use in a finite element method (FEM) code.

Jan 26, 2023

By H. Ogasawara

To study the preparation process of an earthquake, we should get closer to the hypocentre. In co-operation with ISS International, we had an experimental field (~200 m x~200 m) without dykes and faults in a South African deep gold mine. We have monitored more than 20,000 seismic events (M<2) with borehole tri-axial accelerometers. We used a data acquisition system with 15 kHz sampling and 120-dB dynamic range. In a remnant area at a distance of 100?200 m, an earthquake sequence associated with an M~2 event occurred. Significant changes in seismic parameters such as stress drop, b-value, energy index were observed associated with the sequence. We installed Ishii?s borehole strain meters and could monitor as large a strain change as 10-4associated with mining. However, sampling was only 4 times per hour and 12 bit A/D. A distance from the M2 sequence was ~100 m, being not close enough. Therefore, we found another field with several crosscut tunnels excavated across a fault where an M=2-3 event is expected. We installed the strain meter within several metres of the fault to monitor both shear and normal strains on the fault. The strains are continuously digitized with a 24-bit 25-Hz A/D conversion. The Earth Tide (10-8)is clearly detected. Seismicity induced by longwall mining can be compared to earthquake swarm induced by fluid intrusion to vertical dykes. We also found a decrease in energy index in the source area of M>5events a few days before the major events. Keywords: seismic monitoring, strain monitoring, seismic parameters, preparation process of an earthquake, South African gold mine.

Jan 1, 2002

By P. Sharma

Longwall panels facing wind blasts have been investigated at both Newstan and Moonee Collieries in the Newcastle Coalfield under the Wind Blast Project of the School of Mining Engineering, The University of New South Wales. The fluid mechanics involved in the compression and expulsion of air during wind blasts have been defined and the overpressure and air velocity time histories utilized to determine the wind blast parameters and define the relationship between them. The characteristics of wind blasts pressure pulses in mine roadways show some similarity with transient phenomenon like air blasts from explosives and shock waves from the failure of pressurized vessels. The peak wind velocities in roadways, however, exhibit marked deviations from theoretical predictions based on compressible fluid flow and Rankine-Hugoniot relationships applied to goaf air displacement and panel geometry. Peak overpressures and wind velocities have shown a positive correlation with the areas of goaf falls, with the values peaking off for larger areas. The field investigations have helped the mine management in risk assessment and in evaluating the success of induced caving by hydrofracturing to mitigate the hazard.

Jan 1, 2004

By P. Valicek, M. Farren, R. G. B. Pickering, G. Harrison, P. van Dorssen, W. Joubert, H. J. van Rensburg

Introduction In South African metalliferous mines, stoping operations are largely confined to narrow, tabular orebodies making mechanization extremely difficult. Limited flexibility in terms of stope width has necessitated drilling by means of hand held, pneumatic rock drills at most of our operations. As the largest producer of platinum in the world, we drill in excess of forty million stope blast holes per annum. Cleaning of the broken ore is also done by conventional means—utilizing scrapers and scraper winches. Conventional methods such as these carry high costs in terms of risk exposure as well as labour intensity. The purpose of this paper is to describe the development of a long hole stoping system suitable for the narrow platinum reefs. The new system had to be substantially safer and more cost effective than conventional mining. We selected a site that was conducive to mechanized mining and set out the parameters that we considered would meet our requirements. We then conducted a feasibility study to evaluate the conceptualized long hole stoping system in terms of specific goals. An analysis of the proposed system identified the Key Performance Indicators (KPIs). One of the most critical goals was to be able to create a man-freestope. This would mitigate the safety risk associated with normal stoping operations, as well as the inefficiency cost previously referred to. Other challenges included setting targets for long hole accuracy, stoping width reduction and specific blasting system performance for long hole stoping. We also modelled a critical span that we considered to be inherently safe and to ensure hangingwall stability, throw-blastcleaning and overall system productivity. Anglo Platinum Research and Development and Sandvik Tamrock entered into an agreement for the supply of a specialized long hole-drilling machine. The system was implemented and tested by the mine with the support of the other participants. The results achieved met our expectations. It was demonstrated that with this method of mining it is possible to have a man-free/support-free stope face and to achieve a reduction in shaft head cost per ton whilst reducing dilution. Key performance indicators assessed during the trial •Safety targets •Mining layout •Drill rig •Production targets •Support requirement •Explosives requirement •Services requirement •Ore removal and cleaning requirement •Training requirement Safety targets All persons involved with the project had to adhere to the mine’s safety programme including the zero-tolerance campaign, and were required to report all hazards observed immediately. Mine personnel and Tamrock carried out a full risk assessment on the drill rig before transporting underground. A further risk assessment was carried out when the machine was in position underground. Mining layout See Figure 1 and Figure 2 for a detailed description. Drill rig The drill rig was a combination of a Secoma P-Low LC 10long hole feed and an Axera low profile carrier. The choice of this equipment was made through consultation with Tamrock Sandvik. All relevant design perimeters of the area to be mined were taken into consideration. Production targets

Sep 1, 2001

By T. Watanabe, S. Hayashi, M. Hayashi, K. Nagata, H. Fukuyama

Chemical states of fluorine in CaO-SiO2-CaF2glasses in a composition range of CaO/SiO2=0.5?1.3 and 5?25 mol%CaF2have been investigated by 19F solid-state NMR with and without MAS. The isotropic chemical shifts of the glasses are close to those of cuspidine crystal (59.4 and64.3 ppm with respect to C6F6) and CaF2crystal (58.6 ppm). The fluoride ions are coordinated with four or less than four calcium ions in this composition range. The chemical shifts move to the lower frequency with an increase in the CaF2content, whereas those are not affected by theCaO/SiO2ratio. The ionic distance between calcium and fluoride ions increases with an increase in the CaF2content. The chemical state of fluorine is not disturbed by the degree of polymerization of the silicate network. Comparing the MAS and static NMR spectra, the second moment attributed to 19F-19F dipole-dipole interaction has been estimated. The values of the glasses range over 3.1?7.3107Hz2andthose are larger than the calculated value of cuspidine crystal. This indicates that fluoride ions form Ca-F clusters in the glasses and that the size of clusters increases with increasing the CaF2content. Keywords: chemical state of fluoride ion, CaO-SiO2-CaF2glass, solid state 19F NMR spectroscopy

Jan 1, 2004

By M. Q. W. Jones

This paper presents a compilation of physical properties of rocks from the Bushveld Complex. The database consists of more than 900 measurements each of thermal conductivity and density. The data are well distributed from localities around the Complex and most rock types are well represented. Thermal conductivity and density are shown to vary widely in the ranges 1.8-4.2 W m-1K-1and 2600-4200 kg m-3respectively. Although only 190 heat capacity measurements are available, this parameter is quite uniform for most rock types present, 800-900 J kg-1K-1, except for chromitite, which has a lower average, 750 J kg-1K-1. Rocks encountered in deep platinum mines are particularly well characterized and this has important implications for prediction of mine refrigeration requirements. The heat flux into a semi-infinite region with properties typical of the Bushveld Complex as a function of time is substantially lower than an equivalent model for the Witwatersrand Basin.

Jan 1, 2015

By S. C. Gouws

"SynopsisSustainable infrastructure development has long been identified as a key enabler for socio-economic growth and poverty reduction in societies globally. Twenty-one years into the young South African democracy, economic prospects are fragile and unemployment statistics are high. According to Trading Economics (2015) the GDP growth rate in South Africa averaged 3.07% from 1993 until 2015.Through the National Development Plan 2030, the government has responded by instituting the Presidential Infrastructure Coordinating Commission (PICC) to direct national growth and drive job creation by effecting a long-term infrastructure investment programme. The Commission is mandated by Cabinet to coordinate, integrate, and accelerate implementation of more than 150 individual social and economic infrastructure plans.In the civil infrastructure development sector, increased urbanization is compelling governments and the public sector to expand safe and reliable public amenities, but the availability of real estate for construction in congested cities is a challenge. Within the mining infrastructure construction industry safe, rapid, and efficient mine extraction strategies are imperative to realize increased production, business hurdle rates, and stakeholder expectations.Asset owners and stakeholders are obliged to consider advanced mechanized underground excavation and support technologies in order to present feasible solutions timeously. From an engineering design, procurement, and construction management (EPCM) perspective tunnelling technology and boring applications have a distinct advantage over conventional excavation techniques. These solutions may enhance commerce and transportation by expanding infrastructure in concentrations of national economic activity, providing crucial linkages with rural areas, between cities, and across international borders.This paper explores the contribution by mechanized tunnelling technology and boring applications applied in conjunction with digital and automation technologies compared with conventional methodologies. The technological expertise, combined with a paradigm shift in delivery of project objectives, will promote economic growth, aid recovery from the economic downturn, and improve social development."

Jan 1, 2015

By F. T. Cawood

One of the consequences of globalizing mine finance is a necessity to apply uniform accountancy and valuation standards that are clearly understood and consistently applied by the global investment community. However, each country has unique circumstances, which sometimes make it difficult to align domestic practice with international requirements. South Africa is no exception and issues such as its political history, a taxation regime enforcing different rules on different mineral producers and a unique mineral rights ownership distribution, are barriers to internationalization. The economy is in a transitional phase as a result of the many and diverse policy documents following the change in political dispensation in 1994. Many of these documents have recently been implemented through new legislation and, in the case of mining, negotiations are continuing in order to ensure an acceptable outcome. This paper discusses the challenges that the South African minerals industry faces in the field of mineral property valuation. It draws on international experience and includes a discussion on the unique considerations that the South African mineral property market must take into account in establishing a code for this purpose, as such a code could later be aligned with international practice.

Jan 1, 2004

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

Paper written on project work carried out in partial fulfilment of M.Sc. (Chemical Engineering)degree Identification of non-linear systems can be a daunting task and in the process industries the problem is complicated considerably by the presence of noise from various sources, non-stationarity of the data and intermittence, such as observed in particulate flows. Traditional methods, such as frequency analysis and linear model-ling do not handle these systems well. Similar problems arise with the application of non-linear theory developed over the last few decades, where much of the analysis depends on embedding of the data in a phase space or pseudophase space, since these methods were not originally designed to deal with noisy systems. In contrast, singular spectrum analysis is a method which can be used to identify structure and distinguish noise from important information in multivariate data, such as the trajectory matrices of time series measurements. It provides an orthogonal basis onto which the data can be transformed, so that components of the time series can be investigated individually. With Monte Carlo methods, the components can be compared with those from linear surrogate data in order to identify possibly non-linearities in the data. In this paper, this versatile technique is briefly explained and illustrated by means of case studies.

Jan 1, 2003

By T. Markus, K. Hilpert

Discharge vessels of advanced light sources are made of translucent polycrystalline Al2O3(PCA).These tubes contain salt mixtures, which essentially consist of metal halides. The salt mixture is present as a melt at the coldest spot of the vessel under operating conditions and vaporizes partly. The temperatures of the coldest spot range between 1200 K and 1300 K, depending on the lamp performance. The maximum wall temperatures range up to 1500 K and for special purposes up to1700 K. Important constituents of the melt are alkali halides AX (A = Na, Cs, X= Br, I) and rare earth metal halides LnX3(Ln = Dy, Ho, Tm). Severe corrosion attack on the wall material is observed in the PCA discharge vessels. The aim of this work is to elucidate the corrosion mechanism. Annealing experiments under well defined temperatures were carried out in order to understand the complex chemical corrosion processes. Two different annealing vessels were used, one for experiments under isothermal conditions with a temperature of 1473 K and one for experiments with a linear temperature gradient from 1450 K to 1600 K. The vessels were filled with salt mixtures of different compositions and annealed for 1000 h. The corrosion attack was characterised by XRD, analytical electron microscopy, high temperature mass spectrometry, and chemical analysis of the salt melts. The results of our investigations show that the corrosion attack is caused by vapour species and by the salt melt. The most severe corrosion is observed in vessels filled with mixtures of alkali halides and rare earth metal halides. No corrosion of the alumina is practically observed if pure alkali halides or pure rare earth metal halides are present in the annealing vessel. Keywords: thermodynamic, corrosion, lamps, metal halide salt

Jan 1, 2004

By D. Peatfield

The design and operation of coal preparation plants are governed by the inherent quality of the raw coal to be processed, market specifications and the saleable tonnage requirements. Topography influences the layout of the plant but does not affect the process design. The coal market comprises many sectors, each having specific requirements with respect to both size and quality. In turn, these have led to different levels of preparation and the development of specific types of coal preparation plant design. Developments in processing techniques and processing equipment have also influenced the design and now give the preparation engineer numerous permutations in process and equipment selection. This paper gives an overview of the coal industry in general and summarizes some of the developments in the design of plants and technical developments in the areas of dense medium processing, fine coal treatment and equipment design.

Jan 1, 2003

By Grant Loveday, Vincent Dieudonné, Andrew Jonkers

Bateman Minerals & Metals supplies the APIC Technologies which include the under-bed air-pulsed APIC jig and related technologies such as the JigScan controller and advanced mathematical models of the jig process. Bateman have developed a methodology for predicting process performance for jigs from simplified testing and modelling, based on batch equipment matched to industrial designs. Batch tests conducted on laboratory scale air-pulsed jigs can process small batches of material, such as those obtained from drill core samples. The novelty comes from using an advanced jig process model, ASTRAD, to link the results of batch and continuous jigs. The batch jig presented as a novelty in this paper has been designed to be hydraulically equivalent to the full-scale APIC Jig, allowing the generation of equivalent pulse shapes and using JigScan controller. Lump and fine ferrous ore material have been separated in this unit and any feed >1mm can be tested and extracted. The global test procedure and further modelling focus on the stratification of material, with emphasis on key aspects such as pulse shape, feed characteristics and residence time. The splitting of rejects from concentrates is itself more difficult to reproduce in batch jigging, however the ASTRAD model includes a separation imperfection module, and the APIC Technologies have extraction systems adapted to each type of material. Air pulsed batch jigs are available in several locations and are relocatable. They have been used to treat samples from Australia, South Africa and India as part of studies into ore processing using jigs. Each test layer is available for various physical testing procedures (density and chemical analyses). Test-work is performed on a case by case basis, and analysed using an advanced model ?now available over the internet. Some fundamentals of air-pulsed jigging are recapped along with some of the features of APIC jigs. The process of designing a ?hydraulically equivalent? batch jig test is then described. Some results from jigging tests are presented plus the results of the ASTRAD advanced jig model, which was first developed at the JKMRC with ferrous ores and coal and is now being supported and further developed and utilised by Bateman.

Jan 1, 2006

By L. J. Gardner

Ore pass systems play a critical role in moving broken rock from the workplace to surface, and the integrity of the ore pass excavations is crucial. Over the life of the mine, ore pass integrity deteriorates, which may eventually result in the ore pass no longer being fit for purpose. This paper presents several case studies of successful ore pass rehabilitation exercises.

Jan 1, 2006

By M. Q. W. Jones

This paper summarizes important features of a compilation of thermal properties of stratified rocks from Witwatersrand gold mining areas. The database consists of more than 1000 thermal conductivity measurements, more than 700 density measurements, and nearly 100 heat capacity measurements. Most important rock types and stratigraphic units are well represented. Heat capacity does not differ significantly from one rock type to another, and density is relatively uniform although particular rock types are characterized by distinct average values. Different rock types also have distinct thermal conductivities, but this parameter varies by a factor of four to five. Primary factors controlling the thermal properties are mineral composition, degree of metamorphism, and porosity. In addition, the temperature dependence of thermal conductivity and heat capacity of quartzite may significantly decrease the thermal diffusivity of this rock at deep mining levels.

Jan 1, 2003

By I. H. Clark

A variety of backfills is presently being placed in different gold mines. The backfills are pumped as slurries to stopes where they are discharged into some form of retaining paddock. The effectiveness of fill as a support medium will depend on a number of factors. These can largely include (i) inherent properties of the material, e.g. particle size, shape, distribution and com- position, and (ii) conditions of placement. The terminology required for describing backfills is introduced, and the various laboratory-measured properties are presented for a variety of fills. Finally, the properties of the fills as they are placed underground are discussed.

Jan 1, 1988

By I. A. Mwamba

Titanium aluminide of composition Ti-47.5 at.% Al was prepared by melting titanium and aluminium of commercial purity with additions of precious metals of 0, 0.2, 1, 1.5 and 2 at.% content. The microstructure, hardness and oxidation properties were assessed. It was found that at 47.5 at.% Al, the microstructure of plain TiAl alloys was duplex, consisting of duplex lamellar grains and ? grains. The lamellar grains consisted of alternating lamellae of ? (TiAl) and a2 (Ti3Al), with overall aluminium content in the range of 43?47 at.%. The ? grains had a aluminium content above 50 at.%. The addition of precious metals to the TiAl alloy resulted in the formation of a new phase, with a high precious metal content, occurring mostly in the ? phase, without any major change to the microstructure. Increasing the amount of precious metals resulted in an increase of the new phase amount, at the expense of the ? phase. The hardness of the different alloys was around 300HV10. Overall, the research has shown that addition of precious metals to TiAl resulted in a slight increase in hardness and a significant improvement of the oxidation resistance. This shows that alloying TiAl with precious metals, at the addition levels investigated, does not alter the mechanical properties very much, but improves oxidation resistance.

Jan 1, 2012

By J. W. van der Merwe, K. G. Moloko

Furnace wall tubes from 600 MW subcritical boilers at three coal-fired power stations were sampled and the fireside deposits examined to determine the mechanism of fireside corrosion. This involved an indepth investigation into the morphology and composition of the fireside deposits and the conditions of the furnace that enable this type of attack. SEM-EDS analysis revealed high concentrations of oxygen, iron, and sulphur, QEMSCAN and XRD analyses identified the presence of Fe3O4, Fe2O3, FeS, and FeS2. Differential thermal analysis showed thermal activities at temperatures of 500–600°C, 900–1100°C, and 1100–1250°C, which are associated, respectively, with FeS2 oxidation to FeS and Fe2O3, at 475–525°C, formation of aluminosilicates at 925–1100°C, and melting of FeS around 1190°C. The absence of sodium and potassium eliminates the contribution of molten alkali sulphates to the corrosion. The consistent coexistence of iron sulphide and iron oxide is indicative of the substoichiometric conditions in the furnace, while the detection of pyrite suggests that the coal is not completely combusted, which points to a poor combustion process. These observations were affirmed by gas analysis at one of the stations, where very high levels of carbon monoxide were measured at the furnace wall (≥ 14 000 ppm) and furnace exit (≥ 3500 ppm). The high CO concentrations are indicative of limited combustion caused by limited O2. These reducing conditions promote the formation of FeS-rich deposit, which is the corrosive species responsible for degradation.

Jun 1, 2021

By F. Peer

This Technical Note was presented as a poster at the Western Cape Mineral Processing Symposium held in August 2001 The cleaning of fine coal (-1000 µm) in today?s coal preparation plants is an economically important factor. Coals with high ash contents are, in general, commercially undesirable. Current well-known techniques for treating fine coal include froth flotation and spirals. The primary critical factor with regards to spirals is the efficiency of the process whereas that of flotation, is the cost of there agents used. Research into enhanced gravity separation techniques has resulted in several commercially available enhanced gravity separators. This project was based on a preliminary investigation into the feasibility of one such separator, to effectively treat fine (-500 µm) coal. Experimental variables included particle size and speed of rotation of the said instrument. The performance of the separator was compared to the results obtained from liquid density separations done for the two coal fractions evaluated. From the results obtained in this preliminary study it appears that the piece of equipment investigated does not measure up to expectations. Recommendations for further investigation include the evaluation of the instrument on other South African coals to obtain conclusive results.

Jan 1, 2002

By M. K. Elmouttie, G. V. Poropat

Mapping of exposed rock walls provides data on geological features such as joints, bedding planes, faults etc critical to the economics and the safety of mine operations. Traditional, manual methods of mapping can be time consuming, error prone and limited in their coverage. New methods have been developed to map exposed faces remotely and safely however the benefits of these methods are only fully realised when exposed structures can be quickly and easily mapped using automated methods. This paper describes the application of an automated method of analysis of 3D images that provides users with the capacity to map exposed structures automatically. The method is based on the use of vector classification methods used in some neural network systems and provides rapid and reliable identification of exposed planes. CSIRO Exploration and Mining is applying these methods to 3D images for a range of applications from pit mapping to machine automation.

Jan 1, 2006