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By P. A. Corbeil, C. Swart, F. Miller, V. Falmagne

Automation technologies are increasingly adopted in different mines worldwide. This paper presents the technical aspects of vehicle automation applications at two Noranda operating mines. Teleoperation of 5 LHD’s at Noranda’s Bell Allard mine is used in order to meet aggressive mining requirements under difficult conditions. The equipment is performing under high demand for reliability and performance. In order to further increase performance, automated loading has been commissioned on one of the LHD’s and is being tested. Results to date indicate improved performance with respect to an operator through better filling of the bucket, fewer passes at the muck pile and shorter cycles. Noranda’s Brunswick mine is currently commissioning an automated haulage zone where two optically guided trucks transport ore from a remotely operated chute to two ore passes. Expected operational advantages include increased system capacity and enhanced safety and comfort for the operator. Monitoring to date indicates that the trucks can operate reliably under the conditions imposed by mine production.

Sep 1, 2001

By E. A. Brinkmann

A kinetic model framework for single particle kinetics in combined diffusion and adsorption processes is presented. The framework applies to the general case in which both diffusion and the adsorption reaction play important roles in determining the overall rate in processes where the migrating species can both adsorb and accumulate. The technique, which should be applicable to a wide range of reaction mechanisms, consists of an iterative integration procedure for the coupled diffusion and reaction equations. The case of a reversible linear adsorption reaction rate is developed. In order to verify the technique as a legitimate method of model development, an analytical solution for the identical case is derived and compared to the numerical solution. Excellent agreement exists between the two solutions.

Jan 1, 1987

By A. Cáceres, L. Navarro, N. Altmann, R. Betinol

Copper concentrate is produced in Chile in the high Andes and transported to the coast for shipping through long distance pipelines. The pipeline and fittings installed have to withstand the high abrasion and corrosion environment of the copper concentrate. To protect the inside tube wall against corrosion, high density polyethylene (HDPE) liner is used. While HDPE liners can protect the steel wall against corrosion, it has also been assumed that the low surface roughness of the HDPE liner also inhibited incrustation caused by calcium carbonate and sulphate deposition. Recent events have indicated otherwise in a couple of concentrate pipelines for which BRASS has provided consultant service. This paper delivers a case study which includes (i) formation of incrustation and adhesion to HDPE liner, (ii) the detection of the incrustation through hydraulic analysis, (iii) the mechanism of removal of incrustation, and (iv) the catastrophic effects of their presence in an emergency situation.

Jan 1, 2007

By M. Kilfoil

Many minerals processing operations result in crushed rock being mixed with a liquid. Sometimes, the rock particles have to be dried before the next process begins and there may be a considerable distance between the equipment carrying out these processes. Bateman Engineered Technologies (BET) developed, patented and commercialized a method of simultaneous pneumatic conveying and drying. A joint project to assist with optimizing the process is under-way. Part of it is a numerical simulation of the process. The simulation is done using a dedicated program written in MATLAB, (commercial software which is widely used in engineering). It accounts for heat and mass transfer as well as particle transport. The main part of the program consists of a loop containing a series of equations which are evaluated sequentially. During any particular iteration, the properties are changed one at a time. Since the properties are changing relatively slowly, this method gives good results. The outputs of the simulation are consistent with the operational experience of BET’s engineers. The output is very comprehensive and all numerical. Since the program is currently being used for research purposes, flexibility is very important. Thus the output is converted into a spreadsheet file. Variations in the output quantities are displayed graphically using MS Excel. Some simulation could have been done using computational fluid dynamics (CFD) software. The advantages and disadvantages (technical, financial and skills requirements) of the two approaches for this particular type of simulation are compared briefly. Keywords: Pneumatic conveying, Heat and mass transfer, Computer model

Jan 1, 2003

By W. C. Joughin

A risk evaluation model has been developed that enables the quantification of expected injuries and economic losses resulting from rockfalls associated with a support system in a given geotechnical environment, which is described in Part I (Joughin et al., 2011b). Part II presents the validation of the risk evaluation model. Underground mapping of joints and rockfalls was carried out to provide data for field calibration of the model. This survey was limited to small rockfalls, due to the relatively short period of mapping. Therefore the model was also correlated with rockfall and rockfall injury data collected by mine personnel. The analyses showed that the model provides a reasonable estimate of the expected frequency and size of rockfalls and the frequency of rockfall injuries, but further work is required to enhance the model. Three case studies are presented, which show the benefits of improved support systems from both economic and safety perspectives. This work has demonstrated that the risk evaluation model and the software developed are immediately useful, but further work is required to develop and improve the tools.

Jan 1, 2012

By J. Abdollahisharif

Optimal cut-off grade is one of the most critical parameters in open-pit mine design because it defines the ore and waste and thus determines the maximum net present value possible from the mining operation. Although the algorithm presented by Lane (Choosing the optimum cut-off grade. Colorado school of Mines Quarterly, vol. 59, no. 4, 1964. pp. 811-829) is the most common one in the literature, it does assume constant capacities of the mine, processing, and refinery. In this paper, Lane's original algorithm has been modified to consider variable processing capacities in order to determine the optimal cut-off grade in open-pit mines. The new algorithm proposed here is compared to both Lane's original algorithm and to a previous modification that incorporated rehabilitation costs into the cut-off grade estimation. The algorithm proposed here that permits variable processing capacities is shown to be superior for the determination of optimal cut-off grade to both these previous versions. In addition, a computer-based program was developed in Microsoft Office Excel© to calculate the optimal cut-off grade as proposed here.

Jan 1, 2012

By G. R. Sawyer

Although backfilling has been in operation for many years, the methods for selecting appropriate slurry dewatering aids have, in some cases, been rather unsophisticated. This has led to many misconceptions regarding the role of the dewatering aid and its various means of application. Testing procedures employed in the correct selection of any practically applied dewatering aid must mirror the actual working processes in which they are to be used. This constraint necessitates the development of complex testing methods when applied to backfilling. The current testing procedures were scrutinized and their various merits noted. From this study a series of testing methods was evolved which incorporate the best aspects of these testing procedures with novel ideas which would eventually result in the correct selection of the dewatering aid. A major consideration in the application of any of these methods is the modus operandi of the backfilling process, and the relevance of the tests to the process. This work attempts to consolidate the testwork performed in the past and suggest new approaches in the correct selection of acceptable dewatering aids for backfilling.

Jan 1, 1988

By T. Marsden

The demand for continuous improvement in the industrial world is an ongoing process. Some sectors, where the competitive forces are well established, have led the development of new and reliable technological innovations. Although the metallurgical industry can rightfully be proud of its process improvements, there is still work to be done in materials and in material handling. In some cases, the improvements will be as simple as adopting technologies that have been perfected in other processing or manufacturing industries. This paper discusses the next design generation for copper tankhouses which will yield: ?Improved copper quality ?Improved equipment availability ?Lower life cycle costs ?Safer operations. These benefits will be realized through new developments and design improvements in: ?Permanent cathodes ?Cathode washing ?Cathode stripping machines ?Anode preparation machines ?Improved lead anode design ?Recycling of lead anodes and refurbishment of cathodes. The demand for base metals, and in particular copper, has led to more research into improving efficiencies in electrowinning and refinery plants around the world. One of the areas previously taken as a matter of course was the production of lead anodes and stainless steel cathodes. In South America alone there are over 600 000 cathodes and anodes in circulation?a very significant figure.

Jan 1, 2009

By More-O&apos, R. C. Ferrall, J. W. Wilson

SYNOPSIS The theory of elasticity has been shown to provide a means of determining the stresses and displacements induced by mining in deep level hard rock mines. This theory has been incorporated into an electrical resistance analogue on which the plane of a reef or ore-body can be modelled to enable the rapid determination of stresses and displacements at points in the plane of the reef. This electrical analogue has been used to determine energy release rates caused by scattered mining, which, to some extent, is a measure of the degree of hangingwall fracture. A correlation between predicted energy release rates and actual underground conditions in stopes in the O.F.S. goldfields has been encouraging enough to define parameters on which future stoping layouts can be based. The use of the elastic theory through the analogue has been extended to the assessment of the influence of stoping operations on off-reef excavations. Underground conditions at damaged and undamaged areas have been compared with predicted elastic stresses at the positions under review, resulting in the derivation of design parameters for use in siting off-reef excavations in the prevailing geological conditions in the O.F.S. and Klerksdorp goldfields. The analogue has also been used to assess the vulnerability of certain un mined dykes to bursting. Correlations between stresses induced on dykes by stoping and dyke behaviour underground has enabled critical stress levels to be determined for several persistent dykes occurring in the O.F.S. and Klerksdorp goldfields. A number of long and short term planning projects at mines operating in the Anglo American Corporation and General Mining and Finance Groups are described, where the data derived from the electrical resistance analogue is processed by computer programmes and assessed on the strength of the design factors derived from the correlation of field work and the elastic theory.

Jan 1, 1970

By O. G. Motlogelwa

Any company operating a fleet of trucks will be greatly advantaged if the associated fuel costs can be decreased. The optimal tonnage that trucks should be hauling to ensure minimum consumption of diesel fuel has been investigated. The fuel consumption in litres per ton for a fleet of trucks hauling different tonnages of iron ore was recorded in a time-motion study and the optimal tonnage was determined. The following points emerged as a result of the research: > The diesel fuel consumption in litres per ton decreased with increasing tonnage, which means that in order to improve fuel efficiency, the trucks should carry 21 t > As a result of queuing, Africa Truck Hire (one of the two equipment contractors) loses R282.57 per day to diesel that the trucks burn when they are left idling. It is thus advisable that the company adopt a policy of requiring the drivers to switch their engines off while queuing at the stockpile > Filling up the trucks during each shift or rationing the quantity of diesel to 200 litres each shift has a negligible impact on the trucks' fuel efficiency > For the company to spend 35% of their revenue on fuel, the diesel price would have to be between R8.14 and R8.78 per litre.

Jan 1, 2013

By K. C. Corin, M. S. Manono

The drive to reduce water usage globally has led to the mining industry reassessing its water usage - owing to past environmental degradation due to effluent discharge, tailings disposal and process water seepage into the water-table (Haggard et al., 2015). Factors such as water scarcity and environmental restrictions have created the necessity for recycling of process water in mining and other industries. Water recycling, however, causes an accumulation of ions in the process water, which may affect the strength of reagent action on the target mineral and in turn critical aspects of flotation may be impacted. Prior studies have shown that certain ions have specific effects on flotation: for example, calcium and copper have been found to enhance the adsorption of depressant onto gangue (Feng et al., 2013, Wang et al., 2016). Calcium and sulfate ions have been seen to give a higher concentrate grade than other ions present in process water (Manono et al., 2012). An increase in ion concentration will increase the mineral grade due to a decrease in entrainment (Corin et al., 2011). This study considers the impact of ion accumulation on reagent action and flotation response. Keywords: Flotation chemistry, water quality, ionic strength

Jan 1, 2020

By Oaitse Medupe

The feed to the BCL concentrator is made of the ore from Phikwe No3 shaft, Selebi shaft and Selebi North shaft. The receiving bin of the concentrator has daily throughput of 7869mt live capacity of ore with feed grade from underground operation of 0.70%Ni, 0.75% Cu and 0.05% Co. The valuable minerals in the ore are Pentlandite, Chalcopyrite. Cobalt is present mainly in the solid solution in pentlandite. The common non-sulphides minerals are Amphibolites, quartz, micas, and Feldspar while pyrite and pyrrhotite are the major gangue sulphides. Pyrrhotite contains between 0.1% and 1% Ni in solid solution. From the mineralogical investigation, it was found that approximately 65% of the pentlandite in the ore occurs as exsolutions in the pyrrhotite and the grain sizes ranges from 8 to 38µm. about 25% of the nickel bearing pentlandite is medium grained and subhedral. This kind of pentlandite occurs along the cracks of pyrrhotite or as inclusions in pyrrhotite. The rest of pentlandite present is disseminated in the gangue matrix. Because of the fine occurrence of pentlandite, fine grinding was conducted in order to improve the recovery as well as the concentrate quality. A series of subsequent flotation test were performed in order to evaluate grinds of 35, 40, 45, 50, 60 and 80% passing 75µm. It was observed that ? The mass pull increased together with increasing fineness of grind ? Similar nickel recoveries were obtained at 35 and 40% passing 75µm but from 50% and 60% the grind was seen to adversely affect the nickel recovery. At 80% passing 75µm the recovery increased by small amount. ? Flotation kinetics showed higher initial nickel recoveries but these did not translate into higher final recoveries. ? Grinding finer than 80% passing 75µm yield very high grades of the concentrate in the first minute of the flotation test, and the grade is dramatically reduced in the fifth minute of the test. It was concluded that the current grind of approximately 48% passing 75µm is close to the optimum and no significant benefit were found to be associated with finer primary grinds. The inconsistence of the grade and recovery as well as the pentlandite losses will be discussed. Keywords: Pentlandite, Nickel losses, Grain size, Flotation

Jan 1, 2007

By B. Mulcahy, M. Valenta

"The purpose of executing a project in a stagewise fashion is to evaluate all potential options in a cost-effective manner and develop an understanding of the project drivers, thereby minimizing overall project risk to the client. Among the more valuable tools for this exercise are production and financial models that can be used to quantify the sensitivity of the project to the critical parameters.The mine and concentrator used in this case study are located on the Kalahari Copper Belt, which extends from Zambia through northern Botswana into Namibia. This area of Africa has seen very little industrial development and the project will create much-needed employment and development in the region.The success of this project thus far can be attributed to the close cooperation between the geological, mining, and metallurgical disciplines. Regular updates of projected capital and operating cost estimates coupled with project outputs guided the teams in optimizing their various discipline models, ultimately delivering a compelling argument for the execution of the project. Key to the success was the development of a geometallurgical model for the prediction of concentrate tonnage, grade, and recovery for the life of the mine from the mining plan.This paper summarizes the metallurgical findings and the outcome of the various project stages. The development of the model is discussed, as are the challenges faced in developing a suitable metallurgical process route. IntroductionThe Kalahari Copper BeltThe Kalahari Copperbelt, which extends from Zambia across northwest Botswana into Namibia, is considered to be a broad time equivalent of the Central African Copperbelt, with a similar style of mineralization. However, at shallower depths (<25 m), chrysocolla and malachite exist in significant proportions in certain geological areas. As illustrated in Figure 1, the project is located in the Ghanzi-Chobe Fold Belt which forms part of the Kalahari Copper Belt. The Ghanzi Group, which overlies the lowest stratigraphic unit (the Kwebe Formation), consists of three formations, namely the Ngwako Pan, the D’Kar, and the Mamuno Formation (Hall, 2012)."

Jan 1, 2016

By D. K. Weatherley, T. P. Oladele, L. B. Bbosa

Comminution is a critical stage of mineral processing which aims to reduce the size of ore particles through breakage, consequently increasing the likelihood of liberation of valuable minerals. Several factors, such as pre-existing cracks, mineralogical composition and particle size, are known to affect ore breakage behaviour. While investigating the contributing role of each factor is essential to improve understanding of breakage, isolating individual factors by experiment is typically impractical. Numerical techniques such as the Bonded Particle Model-Discrete Element Method (BPM-DEM) have been developed as a means of studying closely controlled breakage conditions. This study evaluates this technique in modelling the effect of pre-existing cracks breakage behaviour for synthetic ore specimens during impact breakage in a short impact load cell (SILC). Synthetic ore was modelled as a collection of discrete entities connected by brittle-elastic beams. Model parameters were calibrated against macroscopic material properties of a conventional homogenous synthetic ore. The extent of pre-existing cracks within specimens was prescribed by varying discontinuities between the connecting entities. An approach with the insertion of seed points was used to model the mineralogy of the specimens. Results showed that pre-existing cracks resulted in a decrease in the fracture force as the crack density increased. Additionally, the irregularity of fracture patterns within rock specimens after impact became more apparent as the crack density increased. The findings were used to emphasise some of the attributable causes of the variation observed between ore hardness characterisation tests and in situ ore behaviour. Keywords: Element Method; Bonded Particle Model, synthetic rock sample; rock fracture, preexisting cracks

Jan 1, 2020

By M. C. van Eeden, R. Vermeulen, K. B. Le Bron

This paper presents the lessons learnt during the transition from an open pit method to a sub-level open stoping method at the Koidu Limited kimberlite pipe. These learnings may assist other mines with planning, both from a practical implementation perspective (layout, charging up challenges), and a method for estimating potential dilution and stability challenges associated with the interaction between the surface and underground excavations. Predictive geotechnical stability modelling was successfully applied to highlight potential failure zones, which allowed modification and enhancement of the mining layouts and quantification of the potential dilution of the kimberlite from indicative instabilities.

Sep 1, 2025

By A. J. Dickson, A. M. Starfield

This paper reviews the progress made to date in the development of computer models of heat and moisture transfer from rock surfaces to the ventilating air in deep-level mines. The application of these programs to ventilation planning and design is discussed.

Jan 1, 2014

By H. Karabulut, S. Gündüz, K. Karacif, M. A. Erden

The corrosion properties of iron-based composite materials containing graphite and silicon carbide (SiC) reinforcement were investigated. The effects of silicon carbide reinforcement were investigated by adding 0.5% graphite and 1%, 2%, and 4% SiC. A powder metallurgy method was used to produce the composite samples. Iron, graphite, and silicon carbide powders were blended for one hour with a threeaxis mixer and then unidirectionally pressed under a pressure of 750 MPa. After pressing, the composite materials were sintered at 1100°C for one hour. The corrosion properties and microstructure, density, and hardness properties of the composite materials that can affect the corrosion properties were also investigated. It was determined that the pore ratio and hardness of the composite material increased, and corrosion resistance decreased, with increasing silicon carbide content.

Jun 2, 2022

By A. Nicotra, E. H. Roux, J. H. du Plooy, D. H. de Jagger, P. De Waal, G. J. van der Linde

This paper reviews the geology, history, current beneficiation practices, uses, marketing, and future outlook of phosphate in South Africa. The vastness of the reserves, and the industry&apos;s efficiency and competitiveness in world terms, are highlighted.

Jan 1, 1989

By B. Rainier

This paper discusses the preparation of material for backfilling operations using hydrocyclones. Aspects dealt with include the advantages and disadvantages, material requirements, process constraints, operating systems and equipment of the backfill plant.

Jan 1, 1988

By W. J. Van Den Berg, J. G. Taylor

The paper discusses the introduction of blindhole boring on the South African gold mines of Anglo American Corporation. It covers the boring trials conducted, and outlines the progress made in the development of blindhole borers. The operating costs, and performances, of the latest 1,52 m diameter borer are given. Future trends and requirements In the application and design of blindhole borers are discussed, as well as factors that are of importance in the design of future machines.

Jan 1, 1978