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By M. Gous

Namakwa Sands is a heavy minerals mining and beneficiation business in the Anglo Base Metals Division, and operates along the West Coast of South Africa. The business encompasses mining, mineral concentration, separation, and smelting operations. The smelting process comprises the carbonaceous reduction of ilmenite to produce titania slag with a TiO2 content of 86%, and iron with a carbon content of 2.5%. The Namakwa Sands smelter, situated near the Saldanha Bay harbour, commenced smelting operations in 1994, when a 25 MW DC-arc furnace was commissioned. The smelting operations were expanded in 1999, with the commissioning of a second 35 MW DC-arc furnace. Despite the fact that ilmenite smelting poses a technical challenge in terms of the high temperatures required, the physical characteristics of the slag, the constraints placed on the feedstock, and the tight product specifications, Namakwa Sands has continually increased slag production since 1995. High furnace feed-on utilization and furnace stability, complemented by continuous improvement drives, will be thevehicle to drive performance in the short-term, with longer-term performance enhancements due to strategic process development. Keywords: Pyrometallurgy, Namakwa Sands, ilmenite, DC-arc furnace, titania slag, pig iron

Jan 1, 2006

By R. Rampersadh

Paper written on project work carried out in partial fulfilment of B Eng (Metallurgical Engineering) degree Steel was sampled after calcium treatment, to follow changes in inclusion composition during the processing of alumium-killed steel into continuously-cast billets, at Mittal Vereeniging. There is some shift in the distribution of inclusion compositions towards alumina, as the liquid steel moves from the ladle to the tundish. This shift may reflect some reoxidation. However, the effect on inclusion modification is small, since only a small fraction of the tundish oxide inclusions is fully solid?which agrees with the plant observation that these heats cast without clogging. Magnesium oxide in the inclusions contributes to liquid formation, substantially increasing the range of lime: alumina ratios over which the inclusions are partially or fully liquid.

Jan 1, 2006

By Paul Hughes

This paper summarizes current underhand paste backfill mining as applied to Goldcorp Inc?s Red Lake Mine, Newcrest Mining Ltd?s Kencana Mine and the Lanfranchi Nickel Mine as well as ongoing research at the University of British Columbia?s Norman B. Keevil Institute of Mining Engineering. The Red Lake Mine utilises a 6 m wide undercut with a 2 MPa unconfined strength paste in order to selectively mine its high grade, high-stress orebody. Kencana?s orebody is located in a poor rock mass environment. An 8 m wide, 2 MPa unconfined strength paste sill allows a safe working condition for its high grade orebody. The Lanfranchi Nickel Mine utilises a cable-supported, 2 MPa paste, with 12 m span sills, to optimize the mining of the squeezing rock mass. This paper details the rock mechanic hazards, ground support techniques, paste practices and unique conditions for each mine. Further, an update of ongoing research at the University of British Columbia, focussing on the optimization of safe mining in underhand cut-and-fill mining in high-stress/weak rock masses, is presented.

May 1, 2011

By R L. Langak, R A. Heins

The use of differences in specific gravity between minerals to separate them has long been utilized in the extractive industries. The environmental and cost benefits of the commercialized forms of these processes are well understood and widely used. Gravity concentration is used inter alia in the primary beneficiation of gold, diamonds, coal, tin, ferrous metal ores and andalusite. The potential for economic loss due to poor performance of these gravity processes is significant, but diverse in manifestation and regular process monitoring can prevent or at least reduce these losses. The measurement of performance of gravity processes has always presented a challenge, due primarily to the masses of material involved and the physical nature of the processes, generally typified by long reporting time, and hazardous materials (such as Tetrabromoethane) for float and sink type tests. The development of density tracers has improved this situation, however recovery of these tracers from the process streams created the next set of challenges, requiring significant manpower to physically remove tracers from product dewatering screens. Additions to these tracers (magnetic or x-ray fluorescent) eased the recovery mechanism issues but made them much more expensive to produce, hence operators became concerned about losses during process testing. In addition, magnetic recovery of smaller size tracers by a magnet suspended above a loaded screen panel is still problematic. The development of new low cost magnetic tracers has improved statistical significance of tracer tests, as the tracers themselves can be bought and used in much larger quantities, whilst still remaining economically viable. Coupled with the development of effective magnetic recovery technology, such as the Gekko MagScreen, for even fine sized tracers, on-line, continuous tracer testing is now becoming a reality. Whilst the development of high technology radio frequency detection tracer systems continues, enabling the real time measurement of the process and interpretation of results, miniaturization and recovery of these tracers, which is critical given their costs at present, remains an issue. Keywords: Gravity, process measurement, tracers, magnetic recovery

Jan 1, 2006

By G. Wendel

Uranium is a naturally occurring radioactive material in the earth?s crust. Geological processes have resulted in concentration of uranium into ore mined for its gold content in South Africa. This uranium is present in the form of discrete particles of uranium minerals, generally oxides, which are normally insoluble. Chemical and physical processes during gold mining and extraction, particularly when carried out in conjunction with uranium extraction and sulphuric acid manufacture, act on the uranium minerals and the radioactive decay products of uranium. This may result insignificant accumulations of radioactive materials in certain parts of the process. There are a number of naturally occurring radioactive materials in the earth?s crust, such as Uranium-235, Thorium-232, andPotassium-40. This paper focuses on Uranium-238, together with its decay products, and how they affect the gold mines. Water plays a significant role in the redistribution of radionuclides, both as a physical transport medium, and as a solvent in which chemical reactions take place.

Jan 1, 1998

Mining companies in order to compete and succeed in being viable business propositions must look to the future and select mining methods which guarantee improved efficiency and productivity as well as lower costs. A mining company in adopting a method of mining must now select the equipment most compatible. To some mines compatible equipment may mean the use of drilling jumbos to replace hand held rock drills or the use of load haul dump units to replace scrapers. To other more mechanised mines compatible equipment may mean the use of raise borers and road heading machines. The right decision will be where equipment compliments method in such a way that the working environment is improved, productivity is maximised, cost if reduced and all profit opportunities are optimised. An example of such is where the use of improved mining techniques in underground operations may see cut off grades reduced. By selectively mining these lower grade orebodies, smaller operation's ore reserves improve and the capacity for continued growth is enhanced.

Jan 1, 1990

By J. Sikamo, A. Mwanza, C. Mweemba

"The Zambian copper mining industry as we know it today had its genesis in the 1920s. Consistent private sector-driven investment in the industry over a period of over 50 years in exploration, mine development and operation, development of minerals processing facilities, building of infrastructure for pyrometallurgical and hydrometallurgical processing, with attendant support facilities, including building of whole new towns, resulted in copper production rising to a peak of 769 000 t in 1969, providingover 62 000 direct jobs. The industry was nationalized in 1973 and remained in government hands for just over 24 years. During this period, the industry experienced a serious decline in production levels, reaching the lowest level in the year 2000 when production was 250 000 t. An average of just under 2000 jobs were lost every year in the 24-year period, reaching just over 22 000 direct jobs in 2000.Following the return of Zambian politics to pluralism and liberalized economic policies, the government decided to privatize the mining industry. The process started in 1996 and by the year 2000 all the mining assets had been privatized. The new investors embarked on serious investment to upgrade the assets and to develop greenfield mining projects. Fourteen years later and after more than US$12 billion investment, production levels increased year-on-year to a peak of 763 000 t in 2013 with direct jobs reaching 90 000.This paper discusses the impact of the mining industry in Zambia on the economy in areas such as employment, support for other industries, direct contribution to the national gross domestic product (GDP), foreign exchange earnings, and social amenities. The paper also focuses on the performance of the mines during these periods vis-à-vis mineral availability, mineral grades and complexity, new technologies, and human capital. This is looked at particularly in the light of current challenges the industry is facing. Suggestions are proposed on how the industry can be nurtured to continue being a major driver for the Zambian economy and a major player in the international copper mining business."

Jan 1, 2016

By N E. Whitehead

An application to mine an ilmenite-rich sand deposit in Westland led to public concern about potential radioactive hazards should the ore be further processed to recover zircon or monazite. A review recommended that any material involved in the heavy mineral sand industry containing more than 0.05% thorium, uranium or their mixture should be considered a radioactive substance and, for mining purposes, a notifiable product. Safeguards for those occupationally exposed would operate via the Radiation Protection Regulations. The major safety requirement would be the minimisation of dust in certain operations.

Jan 1, 1993

By Randall M. Wheeler

The purpose of this workshop is to illustrate how computer software can be used to evaluate blast design timing and simulate probable vibration characteristics. The workshop will be presented in two parts. Part I will cover the COMPU-BLAST Blast Design and Timing Analysis Program. Part II will focus on the ALPHA-BUST Vibration Analysis and Waveform Simulation Program. The information presented in the workshop will show how these two programs can be used together to help plan blast designs and aid in the control of vibration effects.

Jan 1, 1991

By Peter A. Oshust

The EKATI Diamond Mine has successfully completed the development and commissioning of the Panda Underground Project to extract the ore below the Panda open pit. The dominant kimberlite domain of the Panda Underground, intermixed olivine-rich and mud-rich resedimented volcaniclastic kimberlite (RVK), is very similar to the kimberlite domain characterizing the open pit portion of the pipe. A sublevel retreat mining method is in operation underground at Panda; near-vertical blast rings are drilled and blasted into an open void. Broken ore is mucked with load, haul and dump trucks (LHD?s), sized underground then moved to surface through a conveyor system to the process plant. An advanced feasibility study is in progress at the Koala Underground Project. The Koala pipe is geologically more complex than Panda. The pipe below the open pit is comprised of at least five distinct kimberlite domains. There is a 100 m thick zone of incompetent low-grade mud-rich RVK between the open pit and the stable high-grade olivine-rich primary volcaniclastic kimberlite where mining will be initiated. As a result, it is proposed that Koala will employ sublevel caving; each blast ring shot would be confined and mucked in sequence to maintain the cave of the over-lying low-grade RVK ore. The sublevel cave method seeks to safely defer the mucking of the low grade ore to the latter part of the mine life.

May 1, 2006

By J. N. Van der Merwe

The current state of the South African mining industry is briefly reviewed from the point of view of an engineer not schooled in the finer details of predictive economics. Based on the assumption that current world exploration targets are indicative of which commodities the world will want in the future, it is concluded that the South African mining industry will continue to be viable and growing well into the future. South Africa holds the minerals the world wants and needs, and as long as the world has people, the demand for those, including gold, will continue to grow. There still is a growing demand for vanity commodities' and even the demand for platinum as a jewellery material displays significant growth. Mine safety still needs to improve, but significant improvement has already been made although the industry is not always acknowledged for the effort in this field. The safety target set for 2013 is within reach but will require sustained effort. The physical mining conditions for the main revenue earners, coal, platinum, and gold, will change substantially in the near future. Research in mining has declined alarmingly and it is urgently necessary for that to be revitalized to generate the knowledge that will be required. In order to streamline the transfer of knowledge to the mining engineers of the future, research needs to be conducted with the full involvement of the universities. It will also be necessary for the universities to continually review curricula to incorporate the latest knowledge and to embark on a campaign of knowledge transfer to the older generation of mining engineers. The mining industry is well supported by the universities, who have done their duty with regard to societal transformation, and the universities are in turn supported by the industry through vehicles like the METE Industry is also strongly supported by a number of professional and vocational societies. The SAIMM will continue to play its vital role as the meeting point of the mining technical sciences, and will continue to disseminate knowledge via the journal, schools, and conferences. In the future, it will review its modus operandi to support the needs of growing membership in the remote branches. It will enter the research arena in an appropriate manner and give effect to the developing integration of mining and society. The most important threat to the future of the mining industry is the recurrent mention of nationalization. While interaction between the mining industry and political and economic development of South Africa has always been characteristic, the current debate is emotional more than rational, and engineers are not well equipped to participate. This matter needs to be finalized before it becomes a popular force that politicians cannot control.

Jan 1, 2011

By R. Owen, T. Canty, C. Marks

The industrial vision system provides on-line 2D particle size analysis for aggregate slurries in both the overflow and underflow of hydrocyclones. This paper covers required vision system features allowing CCD cameras to function in the harsh environment of a mine milling area. The study conducted demonstrates the system’s capacity to obtain particle size distributions for controlling hydrocyclonic separators. The particle size distribution is obtained within seconds and immediately updated to allow for process adjustments. Results are then provided as a graphical computer generated display or output as a 4-20mA current loop for process control. The primary use of the vision system is in classifying particles in cyclone overflows which are often a few microns in size. Typical size information for actual mine slurry samples are presented and possible control schemes discussed.

Jan 1, 2002

By Kazuyuki Matsuzawa

A series of plate loading tests were carried out on a loam ground in order to investigate the influences of the plate size and the loading rate on the observed load-settlement relations. Two circular plates having diameters of 0.3 m and 1.0 m were used. Three types of loading methods were employed; 1) static cyclic maintained load test, 2) static continuous load test, and 3) rapid (dynamic) plate load test. An interpretation method called non-linear damping method was used to estimate a static load-settlement relation from the rapid plate load test signals. The derived static load-settlement relations match well with the measured results from the static load tests.

Jan 1, 2006

By R. R. Sayers

The increasing use of hydrogen fluoride (annual consumption now exceeds 500,000 pounds (1)4/) directly and its occurrence as a byproduct of the utilization of fluorine compounds in the mineral industries, especially in metallurgical processes and in the refining of petroleum products, has aroused interest in its toxicity, and a brief review of the literature, with special reference to the hazard of poisoning in the mineral industries, seems to be opportune. Recently, residents in the vicinity of aluminum plants have been complaining of injury to livestock and vegetation as well as to their own health from the gases discharged into the air during operation of the plants, hydrofluoric acid gas apparently being the offender. The comparatively recent utilization of hydrofluoric acid in the alkylation process for the production of high-octane gasoline has raised the question of the hazard of poisoning in the petroleum Industry. In addition, the use of fluorine-containing refrigerants has extended the potential al exposure outside of industry (2).

Jan 1, 1945

By Xiang-yang Zhou

Keywords: Low-Grade Dolomite, Low CaO Content, High Specific Surface Area, MgO. A low energy consumption preparation technology of magnesium oxide with low calcium oxide content and high specific surface area from low-grade dolomite has been investigated. The optimum technical conditions for the preparation of magnesium oxide are the followings: dolomite is partially calcined at 750-800° for 2 h; the optimum solid-liquid ratio range in calcined dolomite slurry is 20-30 g?l?1; carbonation temperature, carbon dioxide pressure and end point pH value of carbonation are less than 40°, 0.4-0.6 MPa and 7 respectively during carbonation process; decomposition temperature of Mg(HCO3)2 solution is near 100°; calcination temperature of the precursor (i.e. precipitated basic magnesium carbonate) is less than 850°. More than 90% of magnesium can be extracted by the technology. The MgO product (CaO < 0.38%) with a specific surface area of near 50 m2?g?1 also can be obtained by the technology.

Jan 1, 2005

By Ali Kahriman, Alper Celtikc, Serdar Celik, Tuncer Gungor

This paper presents the results of ground vibration measurements carried out in Gülyali Hisarcik Basalt open pit mine located on the north side of the Anatolia near Ordu province in Turkey. Within the scope of this study in order to predict peak particle velocity level for this site, ground vibration components were measured for 5 shots during bench blasting. In blasting operations; ANFO (blasting agent), gelatin dynamite (priming) and delay electric detonators (firing) were used as explosives. Parameters of scaled distance (charge quantity per delay and the distance between the source and the station) were recorded carefully and the ground vibration components were measured for all blast events using 5 different vibration monitors (4 White Mini-Seis and 1 Instantel Minimate Plus Models). The absolute distances between shot points and monitor stations were determined using GPS. The equation of square root scaled distance extensively used in the literature was taken into consideration for the prediction of peak particle velocity.

Jan 1, 2013

By M. J. Mullikin, J. B. Conway

Equations capable of representing combined first -and second-stage creep behavior include the Andrade, Cottrell-Aytekin, Garofalo, and de Lacombe equations along with a third-degree polynomial in t1/3. Employing some recent high- temperature creep data for arc-cast tungsten the effectiveness of these expressions was evaluated. It was found that, in this instance, the most accurate representations were afforded by the third-degree polynomial in t1/3 and the de Lacombe equation. Also noted was the fact that the Andrade equation gave results just slightly inferior to those obtained with the third-degree polynomial, definitely better than those due to the Cottrell-Aytekin equation, and slightly superior to those furnished by the Garofalo equation. EXPRESSIONS designed to describe combined first -and second-stage creep behavior must possess certain specific characteristics. At time zero the equation must reduce to a strain value corresponding to the instantaneous deformation on loading. Then in the early moments following load application transient-creep behavior must be described to reflect a creep rate which constantly decreases with time. And finally at larger time values linear (or at least nearly linear) strain-time behavior must be accounted for to yield the steady state or minimum creep rate. Some equations, such as the one based on the parabolic creep law, yield fairly satisfactory results in transient analyses but are not effective at all when combined first- and second-stage data are to be analyzed. Other equations give equally accurate results in both instances although in general the complexity of the equation is slightly increased. For example the Andrade1 equation: has found fairly general application in expressing first-stage creep behavior. Furthermore the contribution of the exponential term becomes more and more prominent as the time increases and causes this equation to exhibit a point of inflection at large values of time. With a proper selection of equation constants the curve can be made fairly flat in the region of the inflection point indicating a desirable equation form for combined first- and second-stage creep analysis. Another equation form with the proper characteristic is that of Cottrell and Aytekin:2 e =a +bt1/3 +ct [2] Obviously as time increases the first derivative of this expression approaches a constant value to suggest application to combined first- and second-stage creep analysis. Similarly a third-degree polynomial in t1/3: e -a + bt1/3 + ct2/3 +dt [3] has the same characteristics. Expressions of this type have been shown3 to be very effective in the analysis of transient-creep behavior and the fact that the first derivative has the same characteristic as Eq. [2] suggests use in the combined analysis.

Jan 1, 1967

The common approach of designing blasts on a trial and error basis is quickly coming to an end. When utilizing the full scale blast environment, trial and error can quickly become cost prohibitive and leaves much to be desired in terms of true blast diagnostics. In these situations testing is usually only continued until a perceived improvement is achieved and when the gross undesirables in blast results are removed. This does does not preclude, however, that further improvements of up to 100% or more can not be obtained.

Jan 1, 1991

By J. M. Krese

This paper gives an overview of the National REAP program emphasizing the program&apos;s current status and future plans. A brief historical review of the program will be given containing roof-fall accident trends and statistics. The latest developments in roof control technology and training as it affects the REAP program will be presented. A brief discussion concerning some effects of the implementation of the amendments to Part 75, CFR, concerning roof support is included.

Jan 1, 1988

By A. M. Milev

A simulated rockburst was conducted underground at Kopanang Mine, previously called Vaal Reefs No. 9 Shaft. The rockburst was simulated by means of a large blast detonated in solid rock close to a crosscut sidewall. The simulated rockburst involved the design of the seismic source, seismic observations in the near and far field, high-speed video filming, a study of rock mass conditions such as fractures, joints, rock strength etc. Knowledge of the site conditions before and after the simulated rockburst was also gained. Some of the important findings are listed below: ?Two areas of damage were identified on the blasting wall: (i) an area of high-intensity damage in which ground velocities of 3.3 m/s were recorded by an accelerometer, which was subsequently ejected in a block of rock, (ii) an area of low-intensity damage where ground velocities of 1.6 m/s were recorded by an accelerometer which remained on the tunnel wall. ?High-speed filming revealed rock fragments being ejected from the wall at velocities in the range of 0.6 m/s to 2.5 m/s. The measurements were taken in the area of low-intensity damage. As planned, no gas pressure was directly involved in damaging the wall of the tunnel. ?The attenuation of peak particle velocities for the main blast in the near field (6 m to 30 m), as a function of distance R, was found to be proportional to R-1.7. ?The simulated rockburst was recorded as a local magnitude ML= 1.3 by the Klerksdorp regional seismic network. ?Peak particle velocities from nearby blasting, recorded on the tunnel wall after the simulated rockburst, were about six times greater then peak particle velocities recorded from the same source area before the simulated rockburst.

Jan 1, 2001