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By D. Van Dyk

Horizontal rotating mills are being used all over the world in different mineral and power generation industries. David Brown South Africa, with over 140 years of experience in gear manufacture and design, has been supplying these industries with innovative designs at exceptional quality. The gearing systems associated with these industries are challenged daily with operating conditions that are not always fully understood. Failures are therefore experienced, over time in the industry, which cannot always be fully explained. David Brown South Africa has developed a gear monitoring system, the Intelligent Gearing System, in association with Transmission Dynamics (UK), in order to monitor and analyse these operating conditions in real time. The system has been designed on the principles of Six Sigma, incorporating Design for Six Sigma. The purpose with this system design is to monitor the operating conditions on the pinion, record the information and analyse the data in relation to the rate of fatigue damage to the girth gear and pinion. This is done in real time and unattended. The output from the Intelligent Gearing System can be fed back into the operating system of the mill user, in order to display an alarm for operating conditions exceeding the design criteria as well as information on the rate of fatigue damage due to these operating conditions. When the mill operating and the effect on the fatigue life of the mill gearing components, conditions are better understood, mill users can forecast critical spare holding levels with an increased accuracy. The Intelligent Gearing System also allows early actions to remove reasons for system overloads.

Jan 1, 2006

1. Book reviews A report by the Monopolies and Mergers Commission on the efficiency and. costs in the development, production and supply of coal by the NCB (Chairman G. Le Quesne). London, Her Majesty's Stationery Office, Jun. 1983. £20 for report and appendices (2 vols). Reviewer: M. J. Martinson Canadian mines handbook 1983-84, edited by M. R. Brown. Toronto, Northern Miner Press Ltd, 1983. 444 pp. $22. Reviewer: Northern Miner Review Editor 2. New publications Developments in geophysical exploration methods-5, edited by A. A. Fitch. Barking. Applied Science Publishers Ltd (Ripple Road, Barking, Essex IG II OSA, England), 1983. 255 pp. £35.75. High-pressure researches in geoscience--behaviour and properties of earth materials at high pressures and temperatures, edited by W. Schreyer. Stuttgart, E. Schweizerbart'sche Verlagsbuchhandlung, 1983. 545 pp. DM 188. Dynamics of oil and gas accumulations, by Alain Perrodon. Pau, Elf Aquitaine (Documentation Centre Micoulau, 64018 Pau, France), 1983. 368 pp. 240 FF. New paths to mineral exploration, edited by F. Bender. Stuttgart, E. Schweizerbart'sche Verlagsbuchhandlung, 1983. 169 pp. DM 58. Results of the First Workshop on Standards in Geothermics, edited by R. Haenel and M. Gupta. Stuttgart, E. Schweizerbart'sche Verlagsbuchhandlung, 1983. DM 98. E&MJ book of jlowsheets edited by Paul C. Merritt. New York, McGraw-Hill, 1983. 214 pp. $42. 1983 E&MJ international directory of mining. New York, McGraw-Hill, 1983. 808 pp. $70. The future of heavy crude and tar sands - volume 11. New York, McGraw-Hill, 1983. 1300 pp. $1l0. 3. Mineral Policy and Energy publications Aluminium, by A. Johnston. 12 pp. . Arsenic, by J. J. Hogan. 4 pp. Cobalt, by D. G. Fong. 6 pp. Selenium and tellurium, by A. G. Johnston. 7 pp. Stone, by D. H. Stonehouse. 13 pp. Uranium, by R. T. Whillans. 16 pp. 4. Mintek publications Report M88 'l'he recovery of platinum-group metals and gold by the lead-collectionstep of thefire-assay procedure. Report MI04 The preparation and analysis of reference materials, and the provision of recommended values. Progress report no. 5. Report Mll1 The determination, by flow-injection analysis, of iron, sulphate, silver, and cadmium. Special publication 3 A guide to the presentation of papers.

Jan 1, 1983

By Ernst-Ulrich Reuther, Alexander Donmen

Mine ventilation in the German coal mining industry is concerned mainly with problems of thermal environment arising from greater depths and with increasing emission of methane gas. The development of computer techniques over the past ten years for solving these and ancillary problems is reviewed. The emphasis from a planning and control point of view falls mainly on ventilation network calculations, temperature predictions and advance estimates of methane emission.

Jan 1, 2014

By H. Ramazi, A. Amini

"This article is devoted to the introduction of a new technique of electrical resistivity data processing called residual resistivity (RR). We define RR as measured resistivity minus background resistivity. To determine the background resistivity, the data acquired from electrical resistivity measurements along a given survey line is evaluated, and then an equation is fitted to the data corresponding to a chosen measurement station as a function of current electrode spacing (or array length). The RR technique was applied to several synthetic models to compare the conventional resistivity inversion of each model with its RR-based inversion. A case study was carried out in a karstic area in Zarrinabad, Lorestan Province, western Iran, to detect the location and geometry of probable cavities by conventional resistivity inversion and RR-based inversion. The results showed that the anomalous zones are better highlighted in the RR-based inversion images in comparison with the conventional inversion images. In some cases, anomalies detected by the RR-based images were hidden in the conventional method. IntroductionThe geoelectrical resistivity method has been widely used since the early 20th century, and plays an important role in several fields such as groundwater and subsurface mineral exploration, geotechnical and environmental investigations, and archeological studies (Bayrak and Senel, 2012; Candansayar and Basokur, 2001; Fehdi et al., 2011; Hee et al., 2010; Osella et al., 2003; Wilkinson et al., 2010). The goal of geoelectrical resistivity surveys is to determine the distribution of subsurface resistivity by measuring the current-potential difference on the ground surface (Aizebeokhai et al., 2010). In the electrical resistivity method, an electrical current is injected into the ground by two electrodes, called current electrodes (AB), and the potential difference is measured between another pair of electrodes, the potential electrodes (MN). Several methods of interpretation are available for application to electrical resistivity data, the simplest being the graphical interpretation of the apparent electrical resistivity pseudo-sections along each survey line. A second method, electrical resistivity inversion, has been developed to create relatively accurate two- and threedimensional computational resistivity models of subsurface sections (Loke and Barker, 1996; Niwas and Mehrotra, 1997; Nordiana et al., 2014; Oldenburg and Li, 1994; Papadopoulos et al., 2009; Yilmaz and Narman, 2014). In the inversion method, models of subsurface objectives are mathematically inverted to reach optimal solutions subject to prescribed objective functions, constrains, and convergence criteria. A common problem when using the electrical resistivity inversion method is that the inversion model of an electrical resistivity profile may be non-unique because different inhomogeneities in the investigation media can result in the same electrical response (Smith and Vozzof, 1984)."

Jan 1, 2016

By Q. Li, B. Ricks

Over the last several decades mineral concentrate long distance slurry pipelines have been installed and successfully operated. Nearly all were installed via the buried construction method. Their record of depend ability and economy has been well proven. However, these systems operate in regions where seasonal soil frost penetration is shallow or non-existent. In recent years interest in long distance mineral concentrate pipelines in northern cold regions has been increasing. For cold regions one must consider seasonal temperatures and soil frost penetration in order to ensure reliable operations through the year. Herein a case study is developed where heat balance and temperatures for small and large diameter long distance slurry pipelines are compared. The study development is as follows: ?Rheological properties are analysed over range of temperatures from near freezing (4ºC; 39ºF) to relatively very warm (40ºC; 104ºF). ?Then assuming similar climatic conditions, soil properties, and pipeline length, a study is carried out for two pipeline diameters, namely: a small diameter (nominal8 inch; 219.1 mm) and a large diameter (22 inch; 558.8 mm). ?The study focus is on maintaining slurry temperature above freezing throughout the pipeline length by illustrating a decision based on burial depth versus coating the pipeline with insulation.

Jan 1, 2007

By D. S. van Vuuren

Industrial production of titanium occurs via the batch-wise reduction of titanium tetrachloride (TiCl4) with a reducing metal, being magnesium in the Kroll process, or sodium in the Hunter process. In the search for low cost titanium, the CSIR is developing a continuous process to produce titanium powder directly via metallothermic reduction of TiCl4 in molten salt, dubbed the CSIR-Ti process. The move to a continuous process has been attempted by a number of organizations, but was until now always met with failure, due in no small part to challenges inherent in the process chemistry. The reaction between TiCl4 and the reducing metal can occur directly, when TiCl4 or any titanium sub-chlorides present, comes into contact with suspended or dissolved reducing metal. The reaction can also occur indirectly, without any physical contact between the reacting species, via an electronically mediated mechanism. The reaction mechanism via electronic mediation can cause TiCl4 to react at the outlet of the feed port, rapidly causing blockages of the TiCl4 feed line. The electrical conductivity of the metal reactor can also cause the electronically mediated reaction to favour the formation of titanium sponge on the reactor walls and internals, rather than titanium powder. Various methods were investigated to overcome the problem of blockages in the TiCl4 feed line, e.g. mechanical removal, sonic velocities, dilution of the TiCl4 and the use of ceramic feed lines. This article discusses problems experienced with the continuous feeding of reagents, and various methods attempted are shown and discussed. Information is also given on the morphology, chemical composition and suitability of the final titanium powder for powder metallurgical application as presently produced by the CSIR-Ti process. Keywords Titanium dioxide, titanium nitride, carbo-thermic reduction, ilmenite, slag, tunnel kiln, residence time.

Jan 1, 2011

1. OPLEIDING IN INGENIEURSWERK VIR IN G ENIEURS- IN -OPLEID IN G 1.1 llegistrasie as Ingenieur-in-opleiding 'n Gegradueerde ingenieur wat in 'n eksamen geslaag het wat die Raad erkenl, is registreerpaar as 'n ingenieur-in-opleiding kragtens die Wet op Professionele Ingenieurs2. Aansoekvorms kan van die Registrateur verkry word. Mineral processing congress The XIIIth International Mineral Processing Congress is to be held in Warsaw from 4th to 9th June, 1979. Seeing that by products and co-products are becoming of increasing importance in mineral processing operations, the theme of the Congress is to be the 'Treatment of Raw Materials with Total Utilization of All Constituents'.

Jan 1, 1979

By P. Pięta, A. Surowiak, T. Niedoba

In a flotation process of copper ore three factors were measured: copper grade in concentrate (β), copper grade in tailings (J) and recovery of copper in concentrate (e). The experiment was conducted by means of the Jameson cell. The factors influencing the quality of the process were particle size (d), time of separation (t), type of the collector (k) and dosage of the collector (s). The considered vector function was then [β(d, t, k, s), J(d, t, k, s), e(d, t, k, s)]. Optimisation achieved was based on determining the values of the adjustable factors (d, t, k, s). The goal was to obtain the highest possible values of functions β and e (maximum) and the lowest possible values of function J (minimum). To this purpose the taxonomic methods were applied. Keywords: Flotation, copper ore, lithology, flotation agents, particle size distribution, taxonomic methods

Jan 1, 2020

In China, thin coal seams are rich in resources but are technically challenging. The mineable reserves in these seams account for 20.4% of the total coal resources, while the current production accounts for only 10.4% of the total annual production. Characteristics such as narrow mining space, low level of mechanization, poor working environment, and high cost of mining, restrict the development of mining safety and efficiency. Recently, fully mechanized mining technology has developed rapidly for thin coal seams, the level of yield and efficiency has reached or exceeded the international standard, and some state-owned key coal mines are considering automation of their mining process. In thin coal seams with hard stone bands that contain concentrations of pyrite, a specialized software, LS-DYNA, is used to calculate the rational blasting parameters that are used in the deep-hole pre-splitting blasting. Using this method the hard stone bands are fractured effectively, and hence increasing the coal productivity. In addition, mining advance rate were increased by enhancing the level of fully mechanized equipment and safety improved by increasing gas drainage from the gas outburst prone seam located some 7 m below the coal horizon. At present, thin coal seam mining technology faces many challenges, including the low level of equipment automation, the low advance rate in mixed coal-rock ground, and the large number of the mine personnel underground. By lowering the labour intensity and improving efficiency through automation and other measures, more efficient working faces can be implemented in thin coal seams.

Jan 1, 2012

By H. Rosen

The pump is the heart of most industrial and mining plants, providing the energy to separate valuable minerals from process feed. The actual effect of the pump, both in terms of production costs and overall process efficiency, is often assumed or misunderstood by engineers due to insufficient pump performance data. Pump performance can be understood and corrected, where required, through continuous performance monitoring, leading to dramatic improvements in both pump life cycle costs and system efficiencies. The performance of every pumping application is subject to variation and the main contributing factors are as follows: ?Unavoidable deviations from pump supplier curves ?Pump wear ?Pump curve derating factors for slurry pumping ?System curve variation ?Deviation from basic principles of centrifugal pump operation. These are discussed in detail through case studies and the author?s personal experiences. This paper shows ways to minimize the effect of these variations, thereby reducing performance loss and preventing damage to the pump. The paper discusses the benefits of efficient pump operation, the requirements of pump performance monitoring, and its practical application to pump operation in the slurry and water environments. The cost of remedial actions is explored and compared against the savings in both power and plant reliability, resulting in a reduced life cycle cost of the pump.

Jan 1, 2010

By R. Kuyvenhoven, A. Parbhakar-Fox, X. Prieto, J. Quevedo, L. V. Danyushevsky

This paper presents the results of a study focussed on determining the distribution of cobalt in different types of pyrite of the La Estrella IOCG deposit in Chile. In the IOCG mineral deposits, where copper is the main product, the quantification and distribution of cobalt is required to correctly define the technical and economic viability of recovering cobalt as a by-product. In the La Estrella mineral deposit, seven alteration and mineralisation events were recognised through both optical and automated electronic mineralogical analysis. Of these seven events, five different types of pyrites were identified, each with unique characteristics of the pyrite crystals. Through advanced elemental analysis of these five types of pyrites, it was determined that the concentration and distribution of cobalt within the pyrite crystal is dependent on the mineralisation event. The results indicate high cobalt concentrations in the early pyrite mineralisation events, associated with relatively fine pyrite grains, and cobalt generally occurring in a solid form in the pyrite core. The late pyrite mineralisation event exhibits the lowest concentrations of cobalt, with cobalt predominantly present along the outer periphery of the pyrite. These results are relevant from a metallurgical point of view because the preferential location of cobalt within the pyrite crystal will influence the maximum metallurgical recovery of cobalt. For this, a cobaltiferous pyrite concentrate must be formed which, according to the characteristics of pyrite, must be processed with the optimal solubilisation method. The overall objective is to ensure both good cobalt recovery and a high concentration of cobalt in the leach solution resulting from pyrite leaching. Keywords: Cobalt, pyrite, IOCG, copper, metallurgical recovery, solubilisation, Chile

Jan 1, 2020

This list of corrosion-related terms was compiled to encourage the use of the correct terminology, and to serve as a handy reference for students. It Is based on a similar list compiled by the National Association of Corrosion Engineers (NACE). To promote bilingualism, the Afrikaans terminology is included (in italics at the end of each entry).

Jan 1, 1991

By Karl-H. Daum

Over many decades, numerous feasibility studies have demonstrated, that the production of sulphuric acid remains the most viable option of sulphur recovery from smelter off gas and abatement of SO2 emissions to the atmosphere. This is particularly more pronounced as smaller but more concentrated off-gas flows are to be treated from smelters, and enhanced sulphuric acid processes be-come available. Off-gas handling systems represent a significant capital and operating cost burden to the metallurgical operation. Modern pyrometallurgical smelter processes for sulphide ores based on the use of oxygen-enriched air, produce relatively small off-gas flows with high SO2 concentrations in the smelter gas of 30?60 %-vol. of SO2. This is a prerequisite for substantial cost reductions in the smelter off-gas handling and treatment system. As an alternative to sulphuric acid production, numerous scrubbing concepts with alkali or dual-alkali combinations as well as organic absorbents have been proposed. Also the reduction of the SO2 to elemental sulphur has frequently been studied. Very few of those alternative processes have been built in industrial scale, but all were generally characterized by none sustainable operation due to cost reasons, problems with issues related to chemicals used and by-products or poor availability. Thus the traditional concept of converting the SO2 to sulphuric acid is most common, although regarded as un-economic, but is at least a proven, environmentally sustainable and reliable way of sulphur gas processing. With the high acid price levels these days, operating companies are even able to generate significant revenue with their otherwise ?fatal? acid.

Jan 1, 2009

By A. F. Khan

The CSense advanced process control (APC) solution?s main objective was to improve the stability of the pH in the first stage leach process thereby improving nickel and iron extraction efficiencies and reducing the base metal (BM) content in the platinum group metals (PGM) concentrate. By improving the stability of the control of the pH on the first stage leach it had the corresponding effect of improving the Ni extraction efficiency by 0.5% and the Fe extraction efficiency by 3.3%. The system relieved the operators of many decisions that were virtually impossible to make given the complex, variable and real-time nature of the processes in their charge. On the operational side, the operators understand the APC system and they trust it. Another benefit is the reduction in pH peaks in the autoclave, which can oxidize certain elements whereby they become difficult, if not impossible, to leach. These elements go right through the process and end up contaminating the PGM solids, with the result that the entire batch has to be recycled through a lengthy and costly processing pipeline.

Jan 1, 2009

By Kedikilwe Oageng

Effective perimeter control during drilling and blasting is critical not only to blasting results but also to the overall stability of the pit over its entire life span. A pit where perimeter control is not given enough attention when conducting drilling and blasting operations, often experiences over-break or back break beyond final pit wall limits, and therefore has a relatively high probability of failure. Such a pit also becomes unsafe, sometimes not easily accessible, has increased loading costs due to production of oversize, longer cycle times and often problems are encountered when blasting subsequent benches. All these are undesirable consequences, which have negative cost implications. Specialised blasting techniques such as trim blasting and pre-splitting have over the years proved to be effective perimeter control measures. However, the success of these techniques is directly attributable to the time and effort given to the processes. This paper presents results of a project undertaken to monitor, review and optimize the trim blasting and pre-splitting processes at Orapa Diamond Mine in Botswana. The project was specifically incepted to improve the final wall conditions, which continued to deteriorate due to persistent over-break during blasting. The paper also analyses the results obtained against a benchmark of results taken prior to project implementation. Specific blast design parameters which are critical to blasting results were identified as problem areas after auditing of the pre-implementation drilling and blasting practices. These include drill-hole depth, spacing, splitting factor for pre-splits and timing of trim blasts. The impact of different rock types on the results was also studied, and recommendations were made at different phases of the project and results obtained after implementation analysed until optimum results were achieved.

Jan 1, 2008

Grains are subject to contamination by mycotoxins which are metabolic by-products of various fungi. The fungal infestations produce local concentrations of the mycotoxins thousands of times higher than the average. These facts make the sampling of the grain for assessment of the mean mycotoxin levels potentially very difficult. In the context of sampling theory, this morphology of the infestations creates a very high distributional and intrinsic heterogeneity of the grain shipment. The distributions of mycotoxin concentrations in seaborne shipments that exist at loading and the number and intensity of infestations that develop under shipping conditions are unknown. All grain shipments carry spores that may give rise to mycotoxin-producing colonies; moisture and temperature determine the final extent of the problem. This paper develops the value of the sampling constant with respect to intrinsic heterogeneity based on data on observed Ochratoxin A (OTA) concentrations in individual wheat kernels. A useful relationship between the distribution of mycotoxin concentrations on a kernel to kernel basis and the distribution of concentration over subsamples is developed.

Jan 1, 2009

By J. Gholamnejad

Determination of the optimum production schedules over the life of a mine is a critical mechanism in open pit mine planning procedures. Long-term production scheduling is used to maximize the net present value of the project under technical, financial, and environmental constraints. Mathematical programming models are well suited for optimizing long-term production schedules of open pit mines. There are two approaches to solving long-term production problems: deterministic- and uncertainty- based approaches. Deterministic-based models are unable to deal with grade and geological uncertainties, which are two important sources of risk in mining industries. This may lead to discrepancies between actual production obtained by these algorithms and planning expectations. In this paper, a new binary integer programming model was developed for long-term production scheduling that incorporates geological uncertainty within the orebody. Then, traditional and uncertainty-based models are applied to an iron ore deposit. Results showed that the uncertainty-based approach yields more practical schedules than traditional approaches in terms of production targets.

Jan 1, 2012

By J. P. Gouvea, W. Geel

Resin bolting in South Africa has been developed and refined in underground coal mines (i.e., soft rock) since the late 1940s. The extension of resin bolting to hard rock mines started in 2003 and has required significant adaptations, challenging the status quo from both a supplier and applicator perspective. As far as resin bolting is concerned, the most affected aspect in coal mining and hard rock mining environments, is the rock drills or machinery used for installation. Hard rock mines mostly use hand-held airlegs with limited thrust, low torque, and rotation speed, relative to coal mine mechanised bolters. Resin bolt development for hard rock mines was, and still is today, predominantly focussed on compensating for the ‘shortfalls’ of using hand-held airlegs. At face value, hydro-powered rock drills, which are more powerful than traditional handheld equipment, provided hard rock mines with a means to attain more consistent and reliable resin bolt installations. This paper assesses the quality and performance of hydro-powered resin bolting at an intermediate to deep level platinum mine in South Africa and its potential contribution to rock-related instabilities when applied erroneously. The findings of this paper necessitate a revision of current quality control and quality assurance measures related to resin bolting for underground support.

Nov 24, 2025

By P. R. Jochens

South Africa depends to a considerable measure on the exploitation of mineral reserves and the processing of these minerals. One of the prime requirements for the mining and metallurgical industry to continue in this vital role is access to sufficient energy in a suitable form. Hence, four important questions are discussed: Does South Africa have sufficient energy for the processing of its minerals and metals! Will the cost of energy allow South Africa's minerals and metals to compete on world markets? Can mining and metallurgical processes become more energy-efficiency Can mining and metallurgical processes be adapted to the various forms of energy that may have to be utilized in the future? It is concluded that about 26 per cent of the extractable reserves of coal would be required in the mining and processing of 50 per cent of South Africa's reserves of gold, platinum-group metals, copper, iron, ferrochromium, and ferromanganese. However, the reducing agents required exceed the extractable reserves but not the total estimates of mineable in situ resources of metallurgical coal and anthracitic coal. Even under the severe constraint that coal could become virtually the sole source of energy, only about three-quarters of the extractable reserves of coal would have been consumed by the year 2025. The reasonably assured resources of uranium metal that can be recovered at less than $80 per kilogram are considerable and, at current conversion efficiencies to electricity, are equivalent to one-fifth of the extractable reserves of coal. The rate of exportation of energy in the form of U30. was about five times that of coal in 1978. It is pointed out that the price of energy has a direct effect on the competitiveness of metals, and, although constituting only a small proportion of the selling price of precious metals, it represents a significant proportion of the selling price of copper and metals recovered from oxide ores. The scope for the conservation of energy appears to be greater in the extraction and conversion of primary energy-carriers to electrical energy than in other mining or metallurgical fields. Provided that alternative sources of energy can be converted to electrical energy, they can be applied to the mining and metallurgical industries. The decision as to which type of energy should be used in specific mining and metallurgical situations is complicated, and is likely to be subjected to closer scrutiny than in the past. The hope is expressed that the tentative conclusions reached will give rise to more-quantitative analyses from those qualified to undertake such an exercise. Inevitably, the questions asked at the outset give rise to more questions, and the more interesting ones are posed in the context of each conclusion.

Jan 1, 1980

By D. F. Malan, T. E. Oates

A recent experimental pillar extraction project at a UG2 bord-and-pillar mine presented a unique opportunity to compile a new pillar database. Currently, the South African hard rock bordand- pillar mines are designed using the Hedley and Grant formula with a modified K-value. This empirically derived formula was developed for uranium mines in the Elliot Lake district of Canada. The use of this formula for the design of pillars in South Africa is questionable. Very few pillar failures have nevertheless been observed and its current calibrations for the various reef types are possibly too conservative. A new UG2 pillar database of 66 pillars, of which seven are classified as failed, was compiled by the authors. This enabled a revised ‘first-order’ calibration of the K-value for the Hedley and Grant formula. The new estimated value for the UG2 is K = 75 MPa. This gives a pillar strength that is more conservative than the PlatMine formula. This work should nevertheless be considered as only a preliminary calibration as the database was small. Further work is also required to determine whether the exponents in the formula for the width and height parameters are appropriate for UG2 pillars.

May 3, 2023