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By M. J. Gouws, T. P. Knoetze

The spontaneous combustion of coal and the explosion of coal dust are two phenomena that were identified by the South African mining industry as requiring investigation. Research contracts were awarded to the G.P. Badenhorst Research Facility of the CSIR and the Department of Mining Engineering of the university of the Witwatersrand by the now defunct National Energy Council. Both projects entailed tests on numerous coal samples in specially designed apparatus. Since the completion of the project, attempts have been made to predict experimental results without incurring the cost of performing experiments. This paper describes predictive indices, based on routine laboratory tests, that were developed by the different research teams for their particular projects. A comparison of the results obtained by applying the spontaneous combustion liability index and the explosibility index to common coal samples indicates that, in general, propensity to spontaneous combustion and explosibility exhibit an inverse relationship. A brief overview is given of some major South African coal-mine disasters.

Jan 1, 1995

By M. Kamali

In this research, in order to predict the peak particle velocity (PPV)(as vibration indicator) caused by blasting projects in the excavations of the Karoun III power plant and dam, three techniques including statistical, empirical, and neural network were used and their results were interpreted and compared. First, multivariate regression analysis (MVRA) was used as statistical approach. Next, PPV was predicted using some widely used empirical models. Lastly, an artificial neural network was used. In the ANN model, maximum charge per delay, total charge per round, distance from blast site, direction of firing, blasthole length, number of blastholes, total delay in milliseconds, number of delay intervals, and average specific charge were taken into consideration as input parameters and consequently the PPV as output parameter. The results of the techniques were interpreted from two points of view. Firstly, the correlation between the observed data and predicted ones, secondly the total error between observed data and predicted ones. The MVRA had a satisfactory correlation but its error of estimation was comparatively very high. The empirical model had reliable correlation and a small error of estimation; in total the results of empirical method were more reliable than those of MVRA. Generally, the ANN approach showed very high correlation and a very small error. The results of this research indicated that the ANN model is the best predicting model for PPV in comparison with other approaches.

Jan 1, 2010

By D. Burrows

Traditionally, characterisation of the mineralogy and textures of ore and rock samples were based on observations of hand specimens and thin sections using an optical microscope. The extent of the data collection was limited by the available tools and thus variations in mineralogy and texture were generally not described by quantitative data. These qualitative to semi-quantitative approaches, even though well established over the years, resulted in variable observations and data sets. The data were unlikely to be representative of a sample and limited statistical validity meant the results could not be reliably used in modern digital mining design and planning. With recently developed SEM based quantitative mineralogy tools and the corresponding methodologies, ore textures can be quantified and compared numerically. The numerical data can not only enhance the understanding of an orebody in geological terms, but can also be used in the creation of metallurgical models for mine and mineral processing design and simulation. These capabilities provide valuable inputs to risk assessment studies and the evaluation of mineral projects.

Jan 1, 2007

By T. Bohmer, L. Auret, N. Pillay, Z. Horn, P. Rambalee, A. Haasbroek

As part of a broader digital technology-enabled transformation programme, a major mining company is systematically implementing Advanced Process Control (APC) solutions and associated instrumentation throughout their operations. This paper highlights the approach and benefits of this holistic approach for a specific instrumentation installation, and APC installation at a South African coal processing plant. For the coal processing plant under consideration, a systematic approach was followed. Process sections/units are considered from upstream to downstream processing. APC solutions are designed for each process section and each process section is interrogated in terms of availability of sufficient process measurements to ensure stable, capable, and ultimately, optimised performance. Where insufficient process measurements are available, instrumentation upgrades are implemented. Finally, APC solutions are implemented, and evaluated in terms of productivity, safety, health, and environmental benefits. For the flotation section, an opportunity was identified to install froth sensors. The installed froth sensors provide measurements on froth velocity, bubble size, height, colour, and stability. The improved visibility that the froth sensors provided on the flotation process resulted in quick gains in terms of productivity: for example, instability in the feed to the flotation section could be quantified. This resulted in targeted process troubleshooting in an upstream thickener, and subsequent improvement of process stability, and reduced feed variance. The measurements from the froth sensors were further integrated in an APC solution. Proportional mass pull contributions per cell and per line can be inferred from the froth sensors, serving as controlled variables, while pulp level set points serve as the manipulated variables. On-off tests indicated that the advanced process control solution provided increases in yield and product quality.

Sep 1, 2021

By J. B. A. Solar Menéndez, M. A. Martínez Fidalgo, L. A. Alvarez-Santullano

1. ANTECEDENTS This present communication refers to the results of the research project entitled "Training in the correct use of chemical oxygen self rescue apparatus and also an analysis of apparatus autonomy", carried out under the auspices of the Specific Collaboration Agreement signed between the Industry Council of the Principality of Asturias (Spain) and INSALUD (National Silicosis Institute, Spain). The antecedents of this project lie in work undertaken by the National Silicosis Institute aimed at optimising efficiency in the use of chemical oxygen self rescuers through improvements in worker training. To be precise, by means of Agreements drawn up between the above-mentioned parties, a simulator was designed and incorporated as the basis of a training station within the " Fundación Barredo" of the Industry Council of the Principality of Asturias. This has been operative since the year 2001 and, up to the present, 2300 Asturian coal mine workers have been trained there. What prompted this activity was the observation of various errors in the use of the self rescuers, deriving from their innate characteristics, especially with respect to the sensation of discomfort - the high temperature and humidity of the breathed oxygen, resistance and inconvenience - and limited autonomy. It was precisely this insight that, in critical situations, lack of familiarity with the conditions of discomfort likely to be experienced during the evacuation process might lead to rejection of the equipment, with fatal consequences, that has justified the setting up of this training and simulation centre. The centre is able to provide all mine workers with the necessary training, and experience of the characteristic sensations experienced when using such equipment (Fig.. 1).

Jan 1, 2003

By N. Mulaudzi

The use of SO2/air gas mixtures as an oxidant to precipitate Mn from Co(II) leach liquors was investigated. The effects of SO2/air ratio, pH and temperature on Mn precipitation were evaluated. It was found that the use of SO2/air gas mixtures resulted in significantly higher Mn precipitation kinetics compared to using air or pure O2 alone. The SO2/air ratio was varied from 0% to 6% SO2(v/v) in air and similar Mn removals were achieved at 0.75% to 3% SO2 at pH 3. The solution pH was varied from pH 2 to pH 4; Mn precipitation did not increase considerably from pH 2 to pH 3, but increased significantly at pH values higher than pH 3. Cobalt co-precipitation also increased as pH increased, with 1% Co co-precipitation at pH 3. An increase in temperature from 30°C to 60°C also increased Mn precipitation and 100% Mn precipitated at 50°C. Cobalt co-precipitation also increased significantly with an increase in temperature. An activation energy of 25 kJ/mol was calculated from the Arrhenius plot, which is an indication that the precipitation reactions were both chemically and diffusion controlled. XRD analysis showed that Mn precipitated in the form of Mn2O3 instead of MnO2 that was predicted from thermodynamic data. SEM and XRD analysis also revealed that the precipitate consisted mainly of gypsum or bassanite (99%), with the Mn containing phase (< 1%) distributed within the gypsum phase. The co-precipitated Co reported to the Mn phase. Keywords: manganese precipitation; SO2/O2 gas mixtures; cobalt solutions.

Jan 1, 2009

By P. Ramphisa

In South Africa reprocessing used oil into industrial fuel is commercially attractive. The reprocessed product is sold as a substitute for heavy fuel oil that is derived from crude oil (Rose Foundation, 2008). The objective of this investigation is to evaluate the use of petroleum products such as oil, petrol and diesel in Driefontein Gold Mine. The recovery of oil through recycling has costs implications to the mine while the release of petroleum hydrocarbons due to the poor management of the use of petroleum products has potential to cause pollution and negatively affect soil and water. Environmental legislation such as the Minerals and Petroleum Resources Development Act (Act 28, 2002) requires that such negative impacts to the environment be rehabilitated. The rehabilitation cost of pollution caused by petroleum products to the environment increases operational costs in business. Field assessment is conducted to identify the main sources of petroleum product contamination such as leaks in piping, overfills and petroleum spills. The areas that require mitigation would be mapped in the study. Recommendations for mitigation measures will focus on using the best practicable environmental option (BPEO) as well as the best available technology not exceeding excessive cost (BATNEEC). The recovery of oil from the mining industry is generally low and very poor. In this study, the effect of proper management of petroleum products to the mine?s operational costs is investigated and compared to there mediation costs of the impacts caused due to poor management of these products. The study investigates the financial benefit that could be obtained from proper environmental practices and efficient usage of petroleum products in the mining.

Jan 1, 2009

By H. Edinger

China?s engagement with the African continent has increased impressively in the past decade. Even though China is not the African continent?s largest stakeholder, the rapidly increasing engagement is evident in the huge number of Chinese migrants that have come to Africa in the wake of unprecedented trade and investment levels, as well as in increasing diplomatic and political interactions, which has taken most other commercial partners by surprise. All but four countries in Africa have adopted the ?One China?1 policy stance; and in so doing opened the door for new or strengthened commercial dealings with China, including increasing investments into Africa?s extractive industries. This has been particularly evident since the turn of the century, with a clear shift in China?s policy towards Africa elevating the continent in China?s foreign policy objectives. As such, Africa has become a strategic focus2 for Chinese outward bound and internationalizing companies, especially in the extractive industries. This planned shift in focus is based largely on geo-strategic and commercial needs and interests, rather than previous ideological ones.3

Jan 1, 2011

By C. D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900s. This versatile product displaced the expensive and easily poisoned platinum-based catalyst in nearly all applications by the 1930s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has worldwide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development programme dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and preheater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

By M. Verri

The paper describes the design options available for the simultaneous production of liquid sulphur dioxide, via cryogenic condensation, and sulphuric acid in a sulphur-burning sulphuric acid plant. The impact of the operating conditions of the cryogenic condensation on plant capital and operating costs are discussed, with the main focus on the optimization of the most important economic and operative drivers of the non-ferrous mining industry, such as energy efficiency, reliability, and availability. A case history relevant to an integrated sulphurburning plant producing liquid sulphur dioxide and sulphuric acid, recently started up in the Democratic Republic of Congo, is described. Keywords sulphur burning, sulphuric acid, liquid SO2, cryogenic SO2 condensation, liquid sulphur dioxide, sulphur dioxide.

Aug 1, 2013

By L. I. Boshoff, S. Gracie

This paper discusses pilot and laboratory-scale metallurgical test work conducted on bulk samples from a low grade heavy mineral deposit and provides an overview of basic practical metallurgical techniques applied to ascertain the suitability of existing production plants to process material from this orebody. Previous investigations have shown this specific orebody to be more challenging in terms of mineral beneficiation as it has a high gangue mineral content. Test work was conducted on targeted stratigraphic units based on lithology and assay results to enable identification of the stratigraphic units portraying quality issues. Unit specific metallurgical pilot work has never been conducted on any of the RBM orebodies and is a new field currently being explored. During this investigation focus was placed on potential quality and yield issues for ilmenite product, with particular reference to CaO quality. A basic evaluation of zircon and rutile separability was also conducted. The test work was conducted using a comparative baseline methodology with metallurgical test work methods specifically aiming at mimicking the existing production plant as closely as possible. This enabled not only the likely metallurgical performance to be assessed but also indicated whether current plant design would be suitable to process the low grade ore types into products of acceptable quality at acceptable yields. The methods and findings discussed in this paper indicate that although there is considerable variation between different units, a blended feed can be successfully processed. With unit specific metallurgical data applied to the existing geological block model, expected yields and recoveries using current plant designs could be predicted.

Jan 1, 2007

By F. T. Cawood

This paper reviews the Mineral and Petroleum Resources Royalty Bill of 2006, identifies potential areas that require further consideration by the National Treasury and, where appropriate, offers alternatives. At its basic level a royalty regime consists of two elements: the base and the rate that must be applied to the base. Deciding on an acceptable royalty rate is a complex matter and can be done only after extensive analysis of all variables affecting the competitiveness of the regime. The proposed royalty rates are in the range of zero to five per cent and are based on sales revenue. It is argued that future investment patterns are more likely to be influenced by market cycles and commodity prices than policy events. Inevitably the current boom in the minerals sector will come to an end and the success of the proposed regime will be known only when profit margins are under pressure. Policy makers must therefore have the long run in mind when developing policies that affect the ability of industry to do business, without the need to renegotiate each time there is a change in the market. A long-run policy must be sufficiently flexible to allow for consistently fair sharing ratios and splitting of revenues between government and industry. Although broadly in line with international practice, the current version cannot be regarded as internationally competitive and efficient. In order for the royalty bill to become internationally competitive, promote beneficiation of mineral production and adequately compensate the State for the loss of a national resource, the National Treasury should heed the following main recommendations in this review: 1. Abandon the notion that each mineral product must have its own royalty rate; 2. Introduce an NSR type royalty that allows for value-addition costs to be deducted from the base; and 3. Provide for automatic relief through the use of a sliding-scale mechanism based on ability to pay, e.g. the X-Factor used in the gold mining tax formula.

Jan 1, 2007

By N. D. L. Burger, S. Thorley

In engineering design of operators? compartments, in underground mining equipment, ergonomics principles are often neglected or not given the full recognition they deserve. This paper defines ergonomics, applies it to machinery in an underground mining environment, and describes the ergonomics analysis undertaken during the design phase of an EJC extra low-profile mining loader. Encompassing the design of the operator?s compartment of this new loader, this paper illustrates the importance of ergonomic principles within the collective design process ensuring that it is fully integrated into the design approach. An ultimate aim of this study is to ensure that all future designs follow this route to guarantee not only the outcome of a highly efficient, cost effective and productive machine but that it is also takes the human factor into account, not only in maintenance but also in operation. Maximizing comfort will have the ultimate outcome of actually increasing productivity beyond expectations.

Jan 1, 2004

By M. Helm

Over the last 40 years, numerous investigations have focussed on the preg-robbing capacity of carbonaceous material during gold ore processing. Various techniques have been applied to characterize the physical and chemical properties of the carbonaceous material in efforts to predict its preg-robbing capacity. The present study, which forms part of an ongoing investigation, is specifically designed to increase the understanding of preg-robbing in ores containing carbonaceous material. In excess of 100 samples from 13 gold mines located in major gold provinces of the world have been incorporated into the present study. These samples were characterized using industry standard metallurgical techniques and were shown to have gold adsorption capacities ranging from a few grams to many hundreds of grams of gold per ton of ore. Further analysis showed that the crystalline nature of the carbonaceous material, which is related to its geological history, is important in determining the preg-robbing capacity of an ore. This finding builds on the common understanding that the preg-robbing behaviour of an ore is related to the amount (or abundance) of carbonaceous material present in that ore. In this study, Raman spectroscopy was used to evaluate the physical nature of carbonaceous material. This is a tool which has been successfully applied by researchers for the characterisation of carbon materials, with respect to crystallite size and lattice defects. Raman analysis of the samples included in this study showed varying degrees of disorder in the carbonaceous materials from the different deposits. Comparison of the Raman spectra with the gold loading capacities of the samples indicated a direct relationship between the structure of the carbonaceous material and its capacity to preg-rob gold. From this, a simple and robust method has been developed based on the Raman spectra of the sample and carbonaceous material content to predict the preg-robbing capacity of an ore. The potential exists to develop a predictive tool using Raman spectroscopy for characterising the preg-robbing capacity of an ore. Such a tool would have potential application in projects ranging from the early stage of exploration through to more detailed feasibility studies and mining operations. The result of applying the predictive method outlined in this paper would be the effective and proactive management of the deleterious influence of carbonaceous material on gold recovery in mining operations.

Jan 1, 2009

By L. Thomson

"The smelter at Sudbury Integrated Nickel Operations, located in Sudbury, Ontario, operates a single electric AC furnace. This furnace treats nickel sulphide concentrates produced by Glencore and third-party feeds and as such its performance is key to the company’s nickel supply chain. Currently the plant has two shutdowns per year in order to carry out significant repairs on matte tap-holes.Improved monitoring systems that enable better prediction of tap-hole wear have been a continued focus. The electric furnace is an essential piece of the smelter flow sheet requiring the need for planned tap-hole maintenance along with robust systems for management according to to this plan.The ability to meet our goal of zero harm is ensuring that safe practices are in place. Detailed procedures and cool-down practices have been implemented to ensure that required matte chemistry and temperature criteria can be met during the period leading into a shutdown for tapblock maintenance.A significant repair of the electric furnace will take place in 2015. During this rebuild, the sidewalls and matte endwall will be replaced. There is work underway to improve wall and matte end performance in an attempt to extend the time between rebuilds. This paper will review the approach taken towards this end."

Jan 1, 2014

"Chairman: Mr W. S. GALLAGHERRapporteur: Professor A. M. STARFIELDPapers:Long-term mine production scheduling by G. C. S. BurneAn application of linear programming to investment analysis by A. ErlandssonOptimizing medium-term operational plans for a group of copper mines by M. Splaine, D. C. Atkinson, W. Davison and L. SmithThe simulation of underground stoping and transport operations in gold mining by F. H. Touwen and N. C. JoughinProduction planning is a subject that lies at the interface between the computing centre and mine management. Discus¬sion during this session was thus largely concerned, directly or indirectly, with communication between computing and mining personnel, and as such was relevant to the symposium as a whole.Mr A. Weiss set the tone of this discussion by referring to `user-orientated systems&apos;. He congratulated Mr Burne in this regard, pointing out that his long-term production scheduling program, as a computer system, was similar in approach to the manual system it replaced, and was therefore easily understood by planning engineers. He asked whether the schedule engineer had his &apos;hands on&apos; the system, to which Mr Burne replied that the engineer did in fact spend several days running alternative schemes through the computer. Mr Weiss commented on the advantage of having terminals on site for this sort of engineer-computer interaction. He also commented on the flexibility of Mr Burne&apos;s approach to scheduling and how preferable this was to a one-step optimization package. This was brought home by a question from Mr H. D. Small: Mr Burne&apos;s program sometimes found it necessary to temporarily halt an advancing face, and he asked whether the logic of the program could be altered to avoid this (e.g. by suitably slowing down the rate of face advance). Mr Burne replied that it was in fact easier for the planning engineer to sort this problem out manually. The way in which the computer results were presented made it particularly simple for the production engineer to see how to avoid or remedy a stopped face.On the technical side, both Mr Weiss and Mr H. M. Wells questioned Mr Burne on the handling of grade control by his program. From answers by Mr Burne and his colleague Mr K. H. Thomson it emerged that a spot-check on grade every now and then was all that was necessary at Mufulira, and that the idea of actual grade control was more a question of short-term than of long-term planning."

Jan 1, 2014

By A. Pytlik, W. Masny

"Underground mining is subject to various natural hazards such as seismic events, rockbursts, fire, and gas (methane). In general, an increase in the extraction depth causes an increase in the likelihood of these hazards, especially seismic activity and rockbursts. Dynamic phenomena such as rockbursts and tremors have been recorded on six continents: Europe (Poland, Russia, Czech Republic, Germany, and Slovenia), Asia (India, and China), North and South America (USA, Canada, and Chile), Africa (South Africa), and Australia. To select appropriate mine working supports for such dynamic phenomena, the performance characteristics of such support types must be determined under both static and dynamic load conditions.This article presents information regarding the application of rockbolts in Polish underground hard-coal mines. Dynamic phenomena occurring in the mines from 2004–2013 are also characterized. A methodology developed at the Central Mining Institute (GIG) for the laboratory testing of rockbolts is presented. In this methodology, the bolts are loaded by the direct impact of a free-moving mass (up to 20 000 kg) at speeds of up to 1.2 m/s. The facilities at GIG used to test the support under static and dynamic load conditions are characterized, and the results of laboratory tests on yielding bolts with a nominal capacity of 420 kN are presented. These types of bolts are commonly used for reinforcing steel arches and the surrounding rock mass in Polish coal mines. The results of the laboratory testing of yielding bolts are discussed.IntroductionSeismic events such as rock bumps and tremors occur with great frequency during underground mining. These phenomena have been reported in such countries as Poland, Czech Republic, Germany, France, Slovenia, Russia, India, China, the USA, Canada, Chile, South Africa, and Australia (Brauner, 1991; Potvin, Hudyma, and Jewell, 2000; Kidybin??ski, 2003; Driad-Lebeau et al., 2005; Li, Cai, and Cai, 2007; Whyatt and Loken, 2009; Durrheim and Riemer, 2012; Holub, Rušajova, and Holec?ko, 2011). Descriptions of the dynamic events and their effects in the form of damage to or destruction of supports have been presented in many publications, both for hardrock mines as well as for coal mines (Brauner, 1991; Dubin??ski and Konopko, 2000; Heal, 2010; Heal and Potvin, 2007; Simser, Joughin, and Ortlepp, 2002; Kaiser and Cai, 2012; Cai 2013; Nierobisz, 2013; Mark, 2014; Masny and Prusek, 2015). One of the main goals of the research has been to develop methods, criteria, and guidelines for the selection of an optimal and safe support for mine workings located in areas of rock bumps or tremors. Example of such studies include the Canadian Rockburst Support Handbook (Kaiser, McCreath, and Tannant, 1996), or the principles presented in the literature (Li, 2010; Cai, 2013)."

Jan 1, 2016

By H. L. Monro

Contribution by B. K. Martust I congratulate the author on his interesting paper. In my view, the establishment of the level at which South African gold output is at some kind of optimum is an interesting though somewhat academic exercise. Contribution by D. M. Hawkins* The thesis of the paper is a very interesting one, but, before it is used as the basis of any firm proposals to restructure the mining industry, which changes may be irreversible, one should be very sure that the basis of the calculations is sound. Contribution by P. J. Niewenhuizen* The hypothesis advanced by Mr Monro that the demonetization of gold in August 1971 introduced a major new policy variable, namely the supply-pricejdemand-price relationships, into the decision making process touches on a matter that has never really been given serious thought by the industry. Contribution by B. G. Kingsman* As a co-worker on the development of an econometric model for supply and demand in the world gold market with Mr H. L. Monro, it would perhaps be useful for me to make some comments on the various points raised in the discussions on his paper.

Jan 1, 1984

By R. L. Robinson

An analytical framework is formulated to assist mining companies in assessing the relative merits of mineral exploration and acquisition strategies. The anticipated costs, risks, and returns of each strategy are conceptualised using decision trees. Economic criteria - expected net present value, expected return per unit of investment, and the probability of success - for each strategy are derived(from the appropriate decision tree network. Application of the analytical framework is illustrated using the example of a medium-size company in the Canadian base metal sector.

Jan 1, 1987

Good blasting practices based on the careful application of explosive energy lead to significantly safer mining operations. Case studies demonstrate how the selection of the correct charge mass, explosive type and round design are vital for extracting the exact amount of rock required and preventing spurious damage to the remaining rock mass. In other cases the explosives are applied to precondition the rock mass, design rockburst resistant support, prevent damage to important excavations and reduce the exposure of miners to unsafe conditions. The Hybrid Stress Blasting Model is used to understand the explosive rock interaction and to illustrate and contrast good and bad blasting practices. In all cases, good supervision is required to continue safe mining according to the design. Keywords Blasting, safety, production, preconditioning, explosives, numerical modelling, drop raising, vibrations, and presplitting.

Jan 1, 2011