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By O. A. Olaseinde

The 2101 lean duplex stainless steel has wide potential application in storage, heat exchangers, and in the oil and gas industries. This work investigates the electrochemical behaviour of 2101 duplex stainless steel with an addition of 0.15 wt% ruthenium, using potentiodynamic techniques in 1M H2SO4 at 25º, 40º, 60º, and 80ºC. The microstructures of samples were characterized using optical metallography and scanning electron microscopy. The results showed that the ruthenium addition moved the corrosion potential of alloy 2101 to a more positive potential. All samples containing ruthenium displayed longer passive regions at 25°C and 80°C compared to those without ruthenium. Alloys without ruthenium had higher critical current density (icrit) values when compared to the alloys with ruthenium. Ruthenium additions decreased the passive current densities and inhibited anodic dissolution. At room temperature the corrosion rate of alloys with ruthenium was lower than these without ruthenium.

Jan 1, 2012

A South African gold mining rock-related fatal accident database has been analysed in order to determine rock-related fatality trends in the gold mining industry over the period 1990 to 1998. This analysis was extended further to include some of the individual reefs mined and focused particularly on the Carbon Leader Reef, the Ventersdorp Contact Reef, the Vaal Reef and the Basal Reef. Rock-related accident locations are also presented. A stope rock-related risk is proposed, where the fatality rate in terms of rock-related fatalities per million square metres mined for the gold mining industry as a whole is compared to individual reefs, allowing a stope rock-related risk to be attributed to the individual reef. This comparison is extended further by removing the contribution by the reef being evaluated from the industry data, thereby allowing this reef to be directly compared to the rest of the industry with respect to a stope rock-related risk.

Jan 1, 2001

By A. Whillier

The decisive action taken by mine managements in recent years has been the main factor in bringing about the present downward trend in mine fires. A better understanding of the fundamental factors that govern the ignition and spread of fires. obtained as a result of investigations into mine fires, has provided useful guidance to production personnel. Similar investigations into fire-fighting techniques have assisted the Rescue Training Service and mines to institute more effective fire-fighting techniques. Some of the more important findings of recent investigations in these areas are outlined.

Jan 1, 1981

By I. Matsunaga, K. Aoki, W. -j. Jung

Blasting is widely used in mining and basic construction because of its speed and economy to destroy the rocks. Blasting has the advantages of reduced excavation costs and shorted construction time when compared to the use of heavy machinery for excavation and cutting such as that with a tunnel boring machine. There are numerous problems with blasting, including the noise, vibration and fly rock. So it is necessary to accurately evaluate fracture mechanics of rocks on the dynamic loading condition to control the fracture process of the blasting. The tests using Hopkinson's effect for the dynamic condition using the precise detonators were performed for various strain rates on three different kinds of rocks. In the tests using Hopkinson's effect for the dynamic condition, the high-speed camera was used to observe the fracture process of the test sample rocks. As the results of experiments there was an increase in the tensile strength of rock with an increase in the strain rate for three kinds of rock on the dynamic loading. The tensile strength of rocks with high porosity on the water saturation condition was decreased on the both static and dynamic condition. It is clear that the strain rate and water saturation were influenced to the tensile strength of the rocks.

Jan 1, 2003

By C. Balci

Specific energy is defined as the amount of work required to break a unit volume of rock and is used to predict the performance of mechanical miners. It is obtained from full-scale rock cutting experiments, which require large block samples, experienced personnel and expensive equipment found in only a few research centres in the world. Estimation of the optimum specific energy, at which a given geological formation is excavated at optimum cutting geometry in the most energy efficient manner, from mechanical rock properties to predict the performance/efficiency of roadheaders is the basic aim of this study. The mechanical rock property tests require only core samples, which are easier to obtain and to test. In this context, full-scale rock cutting tests are performed on 23 different rock, mineral and ore samples including sandstone, claystone, tuffite, chromite, trona and copper collected from some operating mines in Turkey. The optimum specific energy values are obtained for each sample. Physical and mechanical property tests are performed on the core samples obtained from the same samples to determine uniaxial compressive strength, indirect (Brazilian) tensile strength, static and dynamic elasticity moduli, Schmidt hammer rebound values, density, and Cerchar abrasivity index. The relationships between the optimum specific energy and the mechanical rock properties are analysed using statistical methods. The results indicate strong relationships between the optimum specific energy and the mechanical rock properties. The strongest relationships are found by using uniaxial compressive strength and tensile strength. The performance models developed in this study are in good agreement with the empirical models previously developed for roadheaders and can be used reliably for prediction purposes. Keywords: Mechanical excavation, roadheader, performance prediction, rock cutting, optimum specific energy, mechanical properties of rocks.

Jan 1, 2004

By E. H. Myrhaug, K. Aasly, T. Malvik

Six different types of quartz and quartzites used as raw materials by ferroalloy plants have been investigated with respect to their thermo mechanical properties. In order to investigate the effect of the thermal shock caused by the rapid heating of quartz when it enters the furnace, the following techniques have been used for both in situ investigations and investigations of pre-heated quartz: -Heating stage microscopy for in situ observation of heating effects. -Shock heating of quartz in an induction furnace An optical microscope-mounted heating stage was used for in situ observations of the microscopic effects of heating up to 1300 ºC. The effects of heating were observed at different temperature intervals in different samples. The main temperature intervals were below 573 ºC and above 1000 ºC. The cause of the observed effects is interpreted as fluid inclusion decrepitation for T<573 °C and structural implications (micro cracks, grain boundaries and remaining fluid inclusions) at T>1200 °C. Shock heating of the samples was carried out in an induction furnace to 1300 ºC for ten minutes. The effects of the heating were studied with different techniques such as direct observation during and directly after heating, optical microscopy and XRD. Combined transmitted and fluorescence light microscopy shows that the heated quartz show an opening of the grain boundaries and evenly distributed micro cracks that were not present in the unheated reference samples. In some of the heated samples, weak generation of cristobalite was detected by XRD.

Jan 1, 2007

By P G. Gaylard

The minerals Industry carries out over US$ 2 billion of R&D annually. The R&D is performed at three levels ? in house research facilities; on a one-on-one basis with a research provider; as syndicated (collaborative) research. The key to a successful R&D programme is project selection. It is suggested that at this time of ?bounty? for the minerals industry the research portfolio should contain some ?blue sky? but potentially long term significantly beneficial projects. This said, the projects should align the technical concepts with the business imperatives. AMIRA has found the ?Road Map? concept has assisted in defining areas for R&D. Examples of this methodology using a Copper Road Map developed by AMIRA for the copper producers operating in South America is presented. The benefits derived from syndicated research are also discussed.

Jan 1, 2007

By E. Munnik

The Chambishi Metals Cobalt Plant in Zambia has recently installed a novel oxidation/precipitation pressure leach process as part of the COSAC (CObalt from Slag And Copper as by-product) Project. Aniron-cobalt-copper alloy, produced by the carbothermic reduction of slag, is atomized and pumped to the COSAC Leach Plant, where cobalt and copper are recovered as dissolved sulphate salts, andiron is rejected primarily as hematite. Cobalt and copper are subsequently recovered as cathode metal in the existing Chambish ioperation by conventional electrowinning. This paper examines the challenges faced during the design and subsequent successful commissioning of the COSAC Leach Plant. The challenges discussed include alloy handling, autoclave design, autoclave cooler design, residue liquor recovery and the water balance design. Keywords: Chambishi, Avmin, COSAC, Zambia, Copperbelt, cobalt, copper, alloy handling, pressure leach, autoclaves, cooling, filtration.

Jan 1, 2003

By R. M. Lamya

The leaching behaviour of nickel?copper matte in an acidic?copper sulphate solution during the repulping stage at Impala Platinum Refineries has been studied. The base metal recovery process consists of a matte repulping stage prior to a series of pressure leach stages. Therefore, the repulping stage is basically an atmospheric leach stage in which the matte containing mostly Niand Cu is leached in copper-spent electrolyte from the tank house, resulting in dissolution of nickel and precipitation of almost all the copper. To understand the nature of the leaching process during this stage of the operation, the effects of temperature stirring rate and matte particle size on the rate and extent of base metal dissolution and copper rejection from the solution have been investigated. The leaching mechanism of the matte in the investigated system is alsoproposed.

Jan 1, 2006

By I. Jauhari, F. Stober, D. Fowler, B. O. Wasmund, T. Miraza, C. Nichols, A. Taofik Hidyat, K. Said

The existing PT Aneka Tambang (Antam) ferronickel smelter located at Pomalaa, Indonesia consists of two RKEF lines with reduction furnaces nominally rated at 17 MW and 18 MW, respectively. The low power densities and heat fluxes allowed both furnaces to operate with falling water film shell cooling systems. The furnace campaigns comprised a 5-yearly cold shut -down for metal taphole area rebuild and a 10-yearlysidewall and hearth perimeter repair. Towards the end of these campaigns the furnaces would typically be operated at below nominal power due to excessive sidewall temperatures. In January 2001 Hatch performed a smelter study which proposed options which indicated the possibility of a single furnace operation for the smelter, elimination of lime addition and transition to shielded-arc operation with associated efficiency and throughput gains. This paper discusses the process of uprating the second?line furnace capability from 18 MW to 32MW following the decision by Antam to implement the recommendations proposed by Hatch. It will cover the development of scaled-up furnace design basis by Hatch and Antam with the enabling application of Hatch cooling and binding technology. To optimise the capital cost and maximise Indonesian supply content and post installation support, the scope was carefully and clearly divided between Hatch and Antam. The challenges, set backs and valuable learning experiences gained during the implementation of the retrofit include; ?The support and re-use of existing roof system and challenges presented in re-use of existing crucible support steel. ?Training and technical assistance for Antam operators to perform refractory and copper cooler installation and maintenance of crucible integrity technologies. ?Hearth integrity during start-up and development of an initial charge and start-up procedure to achieve planned thermal expansion of the hearth prior to bath formation ?Implementation of a sidewall hold-down system within the refractory sidewall due to space constraints ?Existing furnace foundation reinforcement to overcome lateral forces on furnace piers during crucible support steel expansion ?Conversion of an open-loop gravity feed cooling water system to a closed loop pressurised system with integrated emergency gravity feed and backup system ?Existing water treatment system and pumping system improvement and modification to meet copper cooling system requirements ?Integration of the new instrumentation control system designed by Hatch to increase performance of the furnace monitoring system and operation ?Uprate transformer capacity from 25 MVA to 40 MVA to meet with requirement of Shielded- Arc Furnace Operation.

Jan 1, 2007

By J. J. Swanepoel

Titanium nitride in upgraded nitrided ilmenite (bulk of iron removed) can selectively be chlorinated to produce titanium tetrachloride. Except for iron, most other components present during this low temperature (ca. 200°C) chlorination reaction will not react with chlorine. It is therefore necessary to remove as much iron as possible from the nitrided ilmenite. Hydrochloric acid leaching is a possible process route to remove metallic iron from nitrided ilmenite without excessive dissolution of species like titanium nitride and calcium oxide. Calcium oxide dissolution results in unrecoverable acid consumption. The leachability of nitrided ilmenite in hydrochloric acid was evaluated by determining the dissolution of species like aluminium, calcium, titanium and magnesium in a batch leach reactor for 60 minutes at 90°C under reflux conditions. The hydrochloric acid concentration (11%, 18% and 25%), initial acid-to-iron mole ratio (2:1, 2.5:1 and 3.3:1), and solid-to-liquid mass ratio (1:8.33 to 1:2.13) were varied. The results indicate that a hydrochloric acid concentration of 25 wt% supplied in a 2:1 acid-to-iron mole ratio would produce the most favourable upgraded nitrided ilmenite product. The dissolution of iron in this solution reached 97 per cent after only 60 minutes. The total dissolution of calcium and titanium species was 0.01 and 0.11 wt% respectively. Hydrochloric acid can therefore be used as lixiviant to remove metallic iron from nitrided ilmenite. Keywords Titanium nitride, upgraded nitrided ilmenite, hydrochloric acid leaching, metallic iron dissolution.

Jan 1, 2011

By X. Q. Cao, D. S. Zhang, L. Q. Ma

To solve the support stability control problem for a coal face with large angles along both strike and dip (CLSD), the ’support-surrounding rock’ mechanical model has been developed, which takes into account the impact of the dip angle of the seam on the stability of the support in the strike direction. The mechanical relationships of the critical topple angle and critical slip angle of the support along the strike of the coal face with large dip angle and the support height, support resistance, friction coefficient, and other factors have been derived through the mechanical analysis of support stability in the strike direction of CLSDs in the free state, the operating state, and the special state. The research findings were applied to a fully mechanized CLSD in Xinji Coal Mine. The maximum underhand angle and overhand angle in strike are 42° and 25° respectively, and the maximum dip is 39°. It is calculated that during underhand mining and overhand mining, the critical support resistances for avoiding support toppling are 3723 kN and 1714 kN respectively, and the critical support resistances for avoiding slipping of the support are 7405 kN and 6606 kN respectively. Thus, the selection of type ZZ7600/18/38 hydraulic roof support for the coal face is justified. Measures to prevent sliding of the support and the installation of a limiting stop maintain the support runs in good condition and ensure safe and efficient mining of CLSD.

Jan 1, 2015

By J. Gholamnejad

In open pit mine planning and design, push back mine sequencing is widely used for long-term production planning. In push back design, a series of nested pits is generated and then considered as possible push backs with regard to the minimum push back width requirements. These nested pits are produced by parameterizing on one economic parameter like commodity price, mining or processing cost, stripping ratio, etc. The most important characterization of these push backs is that the innermost push back has the highest value per ton, the second innermost push back has the second highest value per ton, and so on. These nested pits are generated based on the best estimates of grade within a representation of the orebody in a three-dimensional matrix form. Therefore, the inherent uncertainty associated with reserve estimation (for our discussion, grade uncertainty) is not taken into account when push backs are designed. These methods do not attempt to establish which part of the deposit is likely to be worth most. This paper introduces a new algorithm that incorporates ore grade uncertainty during the pushback design process. The suggested strategy tries to seek to schedule risky blocks later in the extraction sequence. Keywords: open pit mine, push back, ore grade uncertainty.

Jan 1, 2007

By A. J. Geldenhuys

This paper will focus on two topics, namely (1) an innovative process for the neutralization and partial sulphate removal of acid streams produced during coal mining and processing and (2)optimization of this integrated neutralization process by adding small amounts of synthetic organic polymers. The integrated lime and limestone process has been developed to neutralize acid mine water and to remove sulphate (to less than1 200 mg/l), magnesium and metals. Limestone and lime treatment is the most cost-effective technology for neutralization and partial sulphate removal of acidic/sulphate-rich water to sulphate levels of less than 1 500 mg/l due to precipitation of magnesium and removal of the associated sulphate fraction (through gypsum crystallization). Neutralized mine water of this quality may be suitable for irrigation. The process consists of the following stages: 1. Limestone (CaCO3) neutralization to raise the pH to 7 and CO2-production. 2. Lime (Ca(OH)2) treatment to pH 12 for Mg(OH)2precipi-tation and gypsum (CaSO4.2H2O) crystallization. 3. pH adjustment with CO2recovered from stage 1 and CaCO3 precipitation. Retention times of 1 hour, 4 hours and 1/2an hour were required by stages 1, 2, and 3 respectively. The sulphate level was reduced to 1 094 mg/l, which is less than the original aim of 1 200mg/l. Chemical costs associated with neutralization, using limestone instead of lime, are reduced by 69% in the integrated limestone/lime process. The overflow water from the clarifier of each of the above stages generally contains a wide variety of colloidal impurities that may cause the water to appear turbid or may impart colour. This results in very slow sludge settling rates that cause overflow water with a high degree of turbidity and colour. There are a number of successive or simultaneous stages involved in the agglomeration of particles. To get optimum neutralisation of the acid water and partial sulphate removal to below the saturation level of gypsum (i.e. 1 500mg/l), maximum sludge recovery is needed. The higher the concentration of seed crystals, the larger the surface area. Therefore, effective removal of suspended and colloidal matter from the overflow of each stage is required and can be achieved by coagulation and flocculation. The polymers PAC6 and 3095 were effectively used as coagulant and flocculant respectively. The addition of these polymers resulted in a clear overflow in each of the above stages with a very low turbidity.

Jan 1, 2003

Abrasivity and wear resistance are not intrinsic properties of materials, but rather parameters describing the interaction between the wear part and the material exerting the wearing action. Moreover, wear or, at least, that part of the wear which is due to the cumulative effect of minute scratches, is linked to the hardness disparity concept. Abrasivity, in this context, is a relative concept, pertaining to a metal-rock pair, rather than to a rock. Based on this assumption, a methodology has been developed and checked against actual cases, enabling description of the abrasiveness of a rock or the abrasion resistance of a metal through the ratio of comparable quantitative indicators. The paper describes the methods and provides examples of applications to practical cases (namely: rock cutting, excavation by means of tunnel boring machines (TBMs), rock crushing, and hydro-mill cutting).

Jan 1, 2012

By R. Webster

"Daniel Krige’s influence on soil science, and on soil survey in particular, has been profound. From the 1920s onwards soil surveyors made their maps by classifying the soils and drawing boundaries between the classes they recognized. By the 1960s many influential pedologists were convinced that if one knew to which class of soil a site belonged then one would be able to predict the soil’s properties there. At the same time, engineers began to realize that prediction from such maps was essentially a statistical matter and to apply classical sampling theory. Such methods, though sound, proved inefficient because they failed to take account of the spatial dependence within the classes.Matters changed dramatically in the 1970s when soil scientists learned of the work of Daniel Krige and Georges Matheron’s theory of regionalized variables. Statistical pedologists (pedometricians) first linked R.A. Fisher’s analysis of variance to regionalized variables via spatial hierarchical designs to estimate spatial components of variance. They then applied the mainstream geostatistical methods of spatial analysis and kriging to map plant nutrients, trace elements, pollutants, salt, and agricultural pests in soil, which has led to advances in modern precision agriculture. They were among the first Earth scientists to use nonlinear statistical estimation for modelling variograms and to make the programmed algorithms publicly available. More recently, pedometricians have turned to likelihood methods, specifically residual maximum likelihood (REML), to combine fixed effects, such as trend and external variables, with spatially correlated variables in linear mixed models for spatial prediction. They have also explored non stationary variances with wavelets and by spectral tempering, although it is not clear how the results should be used for prediction. This paper illustrates the most significant advances, with results from research projects."

Jan 1, 2015

Abrasivity and wear resistance are not intrinsic properties of materials, but rather parameters describing the interaction between the wear part and the material exerting the wearing action. Moreover, wear or, at least, that part of the wear which is due to the cumulative effect of minute scratches, is linked to the hardness disparity concept. Abrasivity, in this context, is a relative concept, pertaining to a metal-rock pair, rather than to a rock. Based on this assumption, a methodology has been developed and checked against actual cases, enabling description of the abrasiveness of arock or the abrasion resistance of a metal through the ratio of comparable quantitative indicators. The paper describes the methods and provides examples of applications to practical cases(namely: rock cutting, excavation by means of tunnel boring machines (TBMs), rock crushing, and hydro-mill cutting).

Jan 1, 2012

By M. Royker

Gold has been demonstrated as a possible catalyst for oxidation reactions. Some evidence for a possible promotion effect of platinum has also been recorded. The influence of platinum as promoter for Au/?-Al2O3 prepared via anionic ion-exchange for the oxidation of glycerol was investigated in a batch reactor at 60°C. It is inferred that the addition of platinum reduces the catalytic activity and therate of deactivation, resulting in an overall higher final conversion of glycerol with increasing platinum loading. The addition of platinum to the catalyst favours the formation of the desired product, glyceric acid.

Jan 1, 2012

By J. L. van Niekerk

The proposed Gautrain Rapid Rail Link (GRRL) will require approximately 15 km of double or twin high-speed rail track tunnels located for the greater part beneath the northern suburbs of Johannesburg, including Houghton, Rosebank and Sandton. During the Environmental Impact Assessment (EIA) it became clear that potential surface vibration above and in the vicinity of the tunnels was a matter of serious concern to the residents of the affected properties and that the impact required assessment. The general method proposed is based on a US Department of Transportation, 1998, publication in which abase vibration curve derived for typical high-speed passenger trains is adjusted for the topological, geological and other features to predict the surface vibration and the associated ground-borne noise. The predictions indicate that some isolated areas might be impacted but that the impact will likely be limited, and it is possible to mitigate the impact using suitable track construction methods and track support systems.

Jan 1, 2004

By P. Sun

Abstract: From the viewpoint of interaction mechanics of solid and gas, a coupled mathematical model is presented for coal/rock mass deformation and gas leak flow in parallel deformable coal seams. Numerical simulations for the prediction of the safety range of mining of protection layer are performed with experimental data from a mine with potential danger of coal/gas outbursts. Analyses show that the numerical simulation results are consistent with the measured data on the spot. Therefore, the coupled model shows a positive future for applications in a wide range. ZUSAMMENFASSUNG:Von der Veranschaulichung der Abhängigkeit Mechaniker für Körper und Gas, wird ein verbundenes mathematisches Modell für festen coal/rock Deformation und Gasleckstelle Fluß in parallele deformable Kohlenähte dargestellt. Numerische Simulationen für die Vorhersage der Sicherheit Strecke, die Schutzschichtbergbau verwendet, werden mit experimentellen Daten von einer Grube mit möglicher Gefahr der coal/gas Ausbrüche durchgeführt. Analysen zeigen, daß die numerischen Simulation Resultate mit den gemessenen Daten bezüglich des Punktes gleichbleibend sind. Folglich zeigt das verbundene Modell eine positive Zukunft für Anwendungen in einer breiten Strecke. RÉSUMÉ: Du point de vue de la mécanique d&apos;interaction pour le solide et le gaz, un modèle mathématique couplé est présenté pour l&apos;écoulement plein de déformation de coal/rock et de fuite de gaz dans les filons houillers deformable parallèles. Des simulations numériques pour la prévision de la gamme de sûreté employant l&apos;exploitation de couche de protection sont effectuées avec des données expérimentales d&apos;une mine avec le danger potentiel des accès de coal/gas. Les analyses prouvent que les résultats numériques de simulation sont conformés aux données mesurées sur place. Par conséquent, le modèle couplé montre un futur positif pour des applications dans un éventail.

Jan 1, 2003