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By D. A. Spencer, L. J. Gardner

In light of the apparent productivity benefits provided by mechanised stoping, Impala Platinum Limited commissioned a study to investigate its possible implementation for mining reserves located 1200 – 1700 m below surface. This paper records the methodology employed for designing a support system for such mechanised mining, as well as initial conclusions of the work done. Preliminary results show the concept to be technically feasible; work was however stopped due to financial non-viability. En considération des bénéfices de production apparents que donne l’exploitation par gradins mécanisée, Impala Platinum Limited a commissionné une étude visant à examiner sa mise en œuvre possible pour des réserves minières situées à 1200 – 1700 m sous la surface. L’étude présente rapporte la méthodologie employée pour créer un système de support pour ce genre d’exploitation mécanisée, ainsi que les conclusions initiales de ce projet. Les résultats préliminaires montrent que le concept est techniquement faisable ; cependant le travail fut arrêté à cause de difficultés de rentabilité. Im Licht des offensichtlichen Produktivitätsnutzens auf Grund mechanisierten Stossbaus, kommissionierte Impala Platinum Limited eine Studie, die dessen mögliche Implementierung für den Abbau von Reserven 1200 - 1700 m unterhalb der Oberfläche untersuchen soll. Dieses Elaborat dokumentiert sowohl die Methode die für das Design eines Unterstützungssystems für eine derartige mechanisierte Abbauweise angewendet wird als auch die anfänglichen Konklusionen der geleisteten Arbeit. Anfängliche Resultate zeigen daß das Konzept technisch durchführbar ist; die Arbeit wurde jedoch wegen der finanziellen Nichtrealisierarkeit gestoppt.

Jan 1, 2003

By K. Osburn

South Deep Gold Mine, owned by Gold Fields Ltd., is situated near Westonaria in the Gauteng Province of South Africa and mines the conglomerate bands of the Upper Elsburg reefs (Mondeor Conglomerate Formation) of the Witwatersrand Supergroup and the Ventersdorp Contact Reef (VCR) of the Ventersdorp Supergroup. The stoping and underground developments are mechanized. The Upper Elsburg reefs are mined by a variety of mining methods, including mechanized drift and fill, modified drift and bench, longhole stoping, and low-profile mining. Optimal mine design and scheduling for deep-level mechanized mining are complex, and success is highly dependent on detailed, robust, and accurate geological and geostatistical models. Geological structures significantly influence the sedimentological characteristics, distribution, and preservation of the Upper Elsburg reefs and VCR. Accordingly, particular emphasis is placed on the generation of a mine-scale structural model that accommodates the relationships between the older north-trending fault systems (West Rand and Panvlakte faults) and younger east-trending dextral wrench faults. Results from underground mapping, borehole intersections, and highresolution three-dimensional seismic data have been integrated to produce coherent three-dimensional geological models. The Upper Elsburg reefs suboutcrop against the VCR and comprise an easterly diverging clastic wedge, thickening from the suboutcrop position, to approximately 130 m at the mine?s eastern boundary. The Upper Elsburg reefs are characterized by conglomerate and quartzite bands forming multiple, stacked, upward-fining unconformity-bounded couplets. Palaeocurrent directions are dominantly from west-northwest to east-southeast, indicating that the more proximal deposits are preserved close to the suboutcrop, with distal facies to the east. Sedimentological modelling is applied to individual stratigraphic units and caters for facies definition. This is achieved through channel width (CW) kriging and fitting of type sections to borehole and mapping data. Homogenous geological geozones for each stratigraphic unit are thus defined within individual structural blocks on the basis of those sedimentological parameters that have been found to have a positive spatial correlation to gold concentration. These geozones then serve as constraints to the evaluation of the orebody. This contribution presents a summary of the modelling processes that are currently applied in the development of high-confidence, timeously produced geological models that are essential input for mineral resource estimation and mechanized mine planning and scheduling.

Jan 1, 2014

Physical testing of rock support for rockbursting conditions has been carried out for over 40 years. A review of this testing shows that it has been mostly component?based, rather than actually testing support systems. Further, it is concluded that none of the testing is truly representative of rockburst loading in a similitude sense. Similitude conditions are not achievable, mainly because the real conditions in a rockburst event, such as seismic source location and magnitude, wave frequencies, amplitudes, and interactions, are not all known. Because such information is not available, and because the results of all testing carried out to date have not been able to define, for support design purposes, the capacity of support systems, ongoing physical testing of rockburst support systems is essential. It is essential that the test should simulate, or actually take place in, a supported rock excavation. A rock support system is a combination of individual support components that work together to retain and contain the rock. In doing this, the components are subjected to loading by the rock and to interactive loading between one component and another. It is necessary to prove the capacity of such rockburst support systems by subjecting them to severe loading, as in direct blasting. The direct blasting approach, pioneered more than 40 years ago, probably still provides the greatest validity as a significant test of rockburst support capabilities, even though it does not simulate a rockburst. Direct blast testing of rockburst support systems in a surface environment, such as in a quarry or on exposed rock cutting surfaces, could represent a practical development of the approach, facilitating the execution and monitoring of tests.

Jan 1, 2012

By D. F. Malan, Y. Jooste

"SynopsisScattered mining was practised on Kusasalethu Mine (previously Elandsrand Gold Mine) prior to 1998, but at deeper mining levels it was no longer feasible, since it would have resulted in unacceptably high stress levels and energy release rates. Longwall mining was not adopted at these depths as the mine required a more flexible mining method owing to the highly variable grade and the presence of geological structures. A mining method was developed that consisted of dip stabilizing pillars for regional support, as well as bracket pillars to clamp geological structures. A strict sequence of extraction was followed and this, together with the particular layout, was called the ‘sequential grid mining method’. This method addressed two key problems, namely negotiating adverse geology and the erratic grade of the Ventersdorp Contact Reef (VCR) orebody. However, a significant drop in production rates resulted in the need for alternatives and improvements to the original mine design. Modifications to the design were proposed in order to increase production rates, and an investigation to consider the rock engineering implications of these modifications was conducted. The study indicated that the modified method, called the ‘multi-raise mining method’, appears to be feasible and might address some of the production problems that were experienced with the original sequential grid design. An analysis of actual seismic data showed no significant differences between the original sequential grid mining and the implemented multi-raise mining. The numerical modelling of the mining layouts showed slightly higher interim energy release rates (ERRs) and average pillar stress (APS) levels during the extraction process. The final values are nevertheless identical to that of the original sequence. The study also investigated the use of a modelled moment method to analyse future seismic trends. The study illustrated that the expected seismic trends will be very similar for the multi-raise method compared to the original sequential grid mining method. This study is nevertheless considered of a preliminary nature and ongoing monitoring and analysis of seismic data at the mine is required to verify the response of the rock mass to the modified sequence and increased extraction rate. In particular, future work needs to investigate the effect of mining rate (advance rates in individual panels as well as volume of mining in particular raise lines) on the level of seismicity."

Jan 1, 2015

Utilizing a very large database from a mined-out area on a South African gold mine, the relative efficacy of a method to mitigate the smoothing effect introduced by the algorithmic constraints imposed by kriging was investigated. Smoothing effects arising from limited data availability are differentiated from the smoothing arising from the application of estimation algorithms. Very little can be done to ameliorate smoothing of estimates because of too little data, barring additional drilling or sampling. However, the smoothing effects resulting from the kriging process are shown to be mitigated by use of an alternative algorithm. The primary criterion in the development of the new algorithm was to avoid re-introducing conditional bias. This paper examines firstly the smoothing effects introduced into estimates via the kriging covariance matrix, secondly the process for ameliorating the smoothing effect, and finally it uses a case study to demonstrate the effectiveness of the new algorithm on a very large database. The database was used to introduce a 60 m by 60 m drilling pattern which in turn was used to model the semi-variogram and produce 30 m by 30 m kriged block estimates. The follow-up database was then re-introduced (roughly 5 m by 5 m grid spacing) and averaged into 30 m by 30 m blocks to provide a direct comparison with the initial estimates. In this way the extent of smoothing and accuracy of the estimates before and after the corrections was tested.

Jan 1, 2014

By C. J. Badenhorst

Oxides of sulphur are corrosive and are produced when sulphur-containing fuels are burned. Sulphur dioxide (SO2) is a colourless gas with a characteristic, irritating, pungent odour. Exposure routes to the human body are mainly through inhalation and skin and/or eye contact. Symptoms of exposure to SO2 may include irritation of the eyes, nose, and throat; rhinorrhea (discharge of thin nasal mucous); choking; cough; and reflex bronchoconstriction. To protect employees against the ill health effects of SO2 exposure, they are often required to make use of respiratory protection whenever entering areas were the SO2 levels exceed the statutory limits. The use of respiratory protective equipment should always be a last resort and should be considered only after other control measures have failed to reduce occupational exposure levels to below the occupational exposure limit or whilst other control measures are being investigated or implemented. Whenever the use of respiratory protection equipment is considered, it should always be used as part of a comprehensive respiratory protection plan. It is also extremely important that all potentially exposed persons are adequately and comprehensively informed and trained.

Jan 1, 2007

By J. E. Davidsen, M. Honstad

"A well-maintained tap-hole channel is important in order to achieve good and stable furnace operation over time. A worn or short tap-hole channel can lead to more violent flow, significantly increasing the fume emissions during tapping and leading to more metal being mixed with and lost to the slag. Over time, a worn tapping channel might cause side channels and damage to the lining around the tap-hole area. This can result in a burn-through which is a considerable safety risk and will cause significant production losses. At Eramet Norway Porsgrunn, tap-hole maintenance has been done regularly with electrode paste for over three decades with good results. This article summarizes some of the experiences obtained from this practice on a 33 MW SiMn furnace, as well as a change to a coal tar pitch-free binder. IntroductionA well-maintained tap-hole channel is important in order to achieve good and stable furnace operation over time. Metal and slag are regularly tapped from the furnace and may cause a lot of wear on the tapping channel, increasing the risk of lining damage and ultimately leading to a burn-through. On furnace 10 at Eramet Norway Porsgrunn, the tap-hole area is the part of the lining that has been by far the most prone to burn-through since the startup of the furnace.Experience shows that almost all lining problems have started with burn-through in the tap-hole area or in close proximity to the tap-hole. During tap-hole repairs, side channels with metal and slag have also been observed emanating from the main tapping channel. In addition, a shorter tapping channel will cause more violent flow. This can lead to more metal droplets being entrained in the slag, and increase the risk of the furnace not being closed properly at the end of the tap.As a burn-through is a considerable safety risk, and also causes significant production losses, systematic work has been performed over the years to maintain the tapping channel in order to prevent burn-through."

Jun 1, 2019

By X. Goso

Laboratory-scale tests were conducted at Mintek for the production of titanium powder from particulate Kroll sponge by the hydrogenation-dehydrogenation (HDH) process. The aim of this work was to produce titanium powder for powder metallurgical consolidations. The work involved the production of titanium powder at optimized conditions, which included hydrogenation in a horizontal tube furnace at 600°C for 2 hours, milling using planetary and roller mills, and dehydrogenation in a vacuumed retort fitted in a muffle furnace running at 700°C for 36 hours. The titanium powder produced in this project matched the elemental specifications of commercially available titanium powder, except for high carbon content. Nevertheless, the powder has been tested further in mechanical alloying and has been found suitable for the production of powder metallurgical compacts. Keywords Powder metallurgy, titanium components, HDH process, ball milling.

Jan 1, 2011

By O. Leuangthong, M. Nowak

"The impact of high-grade data on resource estimation has been a longstanding topic of interest in the mining industry. Concerns related to possible over-estimation of resources in such cases have led many investigators to develop possible solutions to limit the influence of highgrade data. It is interesting to note that the risk associated with including high-grade data in estimation appears to be one of the most broadly appreciated concepts understood by the general public, and not only professionals in the resource modelling sector. Many consider grade capping or cutting as the primary approach to dealing with high-grade data; however, other methods and potentially better solutions have been proposed for different stages throughout the resource modelling workflow.This paper reviews the various methods that geomodellers have used to mitigate the impact of high-grade data on resource estimation. In particular, the methods are organized into three categories depending on the stage of the estimation workflow when they may be invoked: (1) domain determination; (2) grade capping; and (3) estimation methods and implementation. It will be emphasized in this paper that any treatment of high-grade data should not lead to undue lowering of the estimated grades, and that limiting the influence of high grades by grade capping should be considered as a last resort. A much better approach is related to domain design or invoking a proper estimation methodology. An example data-set from a gold deposit in Ontario, Canada is used to illustrate the impact of controlling high-grade data in each phase of a study. We note that the case study is by no means comprehensive; it is used to illustrate the place of each method and the manner in which it is possible to mitigate the impact of high-grade data at various stages in resource estimation."

Jan 1, 2015

By I. W. van der Merwe

Recently, a new kind of filtration has emerged, namely nano-filtration (NF). It is a membrane-based process which exhibits totally unique separation characteristics for dissolved salts as well as for many non-charged species. By exploiting the particular separation characteristics of this new membrane type, many unique and novel separations have been made possible. The basis for separation by nanofiltration is the negative surface charge of the membrane. This results in rejection of multivalent anions, whilst associated cations are also rejected to maintain electro-neutrality. This peculiar property enables separation of dissolved ions such as sulphate and copper from acid, whilst the acid may be purified for reuse. This paper aims at providing an overview of the principles of nanofiltration, illustrated by particular examples.

Jan 1, 1998

By T. Z. Mugodi, D. R. Fleming

Information and Communications Technology (ICT) is defined as ‘The goods and services that support the electronic display, processing, storage and transmission of information’. Early in 2002 the South African Department of Trade and Industry (DTI) commissioned a study into the diffusion and adoption of ICT in eight sectors of the economy. The platinum mining Sector was one of these. The key findings presented in this paper are based on the platinum sector component of that study. The paper examines the theoretical basis behind technology transfer and innovation diffusion and presents the results of an ICT diffusion survey carried out in the South African platinum mining sector. ICT is shown as the modern day technological tool which is an accelerator of economic development. The current state of ICT diffusion in the platinum mining sector is defined and projections for the near future are given. Recommendations which will ensure smooth and full adoption are presented and justified.

Jan 1, 2003

By B. P. Watson

The Bushveld platinum group metal deposits are two distinct, shallow-dipping stratiform tabular orebodies and strike for many hundreds of kilometres. Mining is extensive, with depths ranging from close-to-surface to 2 000 m. The mining method is a variation of planar open stoping. Pillars are widely used to support the openstopes. Little work has been done in the past to determine pillar strength and pillars have been designed using experience and formulae developed for other hard-rock mines. This has led to oversize pillars with consequential loss of ore or undersize pillars resulting in potential collapses or pillar bursts. This paper describes a back-analysis of pillar failures at Impala Platinum, just north of Rustenburg, and provides insights into pillar behaviour. Strength formulae are presented for Merensky Reef pillars at Impala. These formulae may be used cautiously on other platinum mines with similar geotechnical and geomechanical conditions.

Jan 1, 2008

By F. P. Hassani

Today, mine backfilling has become an integral part of mining operations, both from a local and overall ground control point of view, and as regards mining techniques and environmental considerations. During the past decade, substantial research has been carried out to contribute to the better understanding of the mechanisms involved in mine backfill behaviour. This work involved analytical, experimental and numerical studies at different scales. Accordingly, this work has been aimed at developing backfill design guidelines for actual working conditions. Backfill design for deep mining conditions is complex and requires understanding of various elements. The most important of these elements are: backfill inherent strength parameters, backfill placement method, stope geometry and interaction between backfill and host rock. The mobilization of backfill strength parameters controls the backfill behaviour and thus, its failure mode. It is believed that the governing boundary conditions and backfill-rock interaction influence the backfill strength mobilization significantly. Accordingly, the interaction between backfill and host rock is an influential factor in overall backfill behaviour under applied loads. The focus of this research is to investigate the backfill-rock interaction, considering a nonlinear behaviour for both backfill and rock mass. Assuming typical stope geometry, the FLAC code was used to model the complex boundary condition associated with narrow vein mining conditions and to simulate the backfill behaviour. A comprehensive numerical study was conducted and the results obtained were compared against field observations. The analysis of findings provides qualitative results, which can be used for backfill design. Keywords: Numerical modelling, backfill, deep mining, non-linear behaviour, rock mechanics, backfill behaviour, narrow vein mining.

Jan 1, 2008

By R. T. Jones

Technical publications in the field of mining and metallurgy have existed for a long time. Recent developments in electronic publishing on websites make it possible to disseminate information more widely and cost-effectively than before. Professional societies have an opportunity to serve their members and their industry by publishing high-quality peer-reviewed papers on their websites as well as in printed form. Older publications can be scanned, and optical character recognition used to provide searchable text. Various business models exist around this process. This paper outlines the approach used by the Southern African Institute of Mining and Metallurgy (SAIMM) to provide free open access to their journal papers and conference proceedings, as well as the work being done by OneMine.org to collect technical papers from a number of international societies and make them available to subscribers via a large database. An approach is outlined that should be of benefit to authors, readers, and society at large.

Jan 1, 2012

By J. M. Benson

Titanium is an exciting structural material that can offer significant strength-to-weight advantages over currently used alloys. However, its Achilles? heel is its costly, energy-intensive production process that effectively eliminates it from competing with aluminium and high-strength steels, apart from critical applications where titanium forms only a small component of the total cost. Current attempts are being made to reduce the cost of titanium products and these recognize the importance of minimizing the costs over the total production chain. Powder metallurgy (PM) technologies play a crucial role within this, as the output of the existing and potential primary metal production methods is in the form of sponge or powder. By using PM, costly remelting and forming operations can then be avoided, except in the manufacture of large components. Metal injection moulding (MIM) is an effective process for producing complex net-shape components in large volumes from metal powders. Nevertheless, the commercial use of titanium powders in this process is still in its infancy. The only major supplier of feedstock utilizes a polyacetal-based binder. This gives good green strength but requires a catalytic nitric acid process to remove most of the binder prior to thermal treatment. As this involves additional and expensive equipment and is a potentially hazardous process, there is interest in finding an alternative binder system that can be debound either purely thermally or that involves a less hazardous, more environmentally friendly solvent. This paper describes the use of capillary rheometry to characterize the influence of temperature and shear rates on the flow behaviour of potential binder systems for titanium MIM feedstock. Keywords Titanium, metal injection moulding, capillary rheology, feedstocks, powder loading.

Jan 1, 2011

By Chandrakala Kari, S. Mohan Rao, Gajanan Kapure, K. S. Raju

High carbon ferrochrome production process is energy intensive, consumes approximately 3300-3400 kWh per ton of metal produced. This amounts to ~ 34% of the total ferrochrome production cost. The power costs in India are almost 4 times greater than the leading ferrochrome producing countries like South Africa. Hence there is a need to look for alternative sources of energy. In ferrochrome making process large volumes of high concentration CO gas (~ 85%V) is developed at ~400-5000C, which if combusted within furnace represents high potential for significant electrical energy savings. In a typical heat in the state-of-the-art submerged arc furnace, about 34 kmol of CO gas is generated per ton of ferrochrome metal, which, if post combusted to CO2, represents 7620 MJ of energy. Post combustion of the evolving CO (and H2) gas to CO2 can be achieved by providing additional oxygen before the generated CO gas leaves the furnace. In this paper, a concept of post combustion in submerged arc furnace as potential source of significant electrical energy saving in ferro-chrome making process has been explored. The prospects and limitations of the same are discussed. The value of this paper lies in its attempt to explore the post combustion application to submerged arc furnace with an objective of significant reduction in electrical energy consumption in ferrochrome production process.

Jan 1, 2007

By H. T. Chiwaye

Risk analysis is an important step in the design of rock slopes in open pit mining. Risk is defined as the product of the probability of slope failure and the consequences of the failure, and is generally evaluated in terms of safety and economic risk. Most of the risk analysis done at present is based on the use of limit equilibrium (LE) techniques in evaluating the probability of failure (POF) of the slopes. The approach typically makes use of full Monte Carlo simulations of the limit equilibrium models, with all uncertain variables randomly varied. The number of required simulations is generally over a thousand, at times as high as 20 000, in order to produce statistically valid results of the POF. Such an approach is clearly not practical when using numerical modelling programs dueto the high computational effort required. This paper explores the impact of using numerical modelling instead of the traditional LE techniques in evaluating the probability of slope failure. The difference in the overall assessed risk, in terms of economic impact, for the mining operation is then evaluated. With numerical models, approximate methods are used in the calculation of the probability of failure instead of full Monte Carlo simulations. This paper will use a method called the response surface methodology (RSM) for estimating the POF from numerical analyses. Simple slope models were used to verify the accuracy of the RSM method by comparing the results with those obtained from full Monte Carlo simulations. It is shown that there is good agreement between the POF values computed using full Monte Carlo simulation and those obtained using the RSM method. Finally, the use of numerical modelling in the assessment of risk is shown to bring a significant difference in the result compared with that from LE methods. One of the reasons for the difference is that LE models tend to underestimate the failure volumes and hence the consequences of slope failure.

Jan 1, 2010

By W. P. Erasmus

This paper will focus on the use of the ?wet-mix? steel fibre re-in forced shotcrete as a permanent lining in deep shafts, assessing gold bearing reef. It will cover all aspects relating to the choice of this material covering the geological conditions through to the final quality control. All procedures are in line with ISO 9001,as JCI projects who manage the project, are an approved company therof.

Jan 1, 2001

By K. Richardson

Although the De Beers group has a long history of placer mining on land, the group only became actively involved in deep water marine diamond exploration and mining in 1983 with the formation of DeBeers Marine. Full-scale commercial mining commenced around1991. Since then, the group marine mining capability has grown into a formidable fleet of 8 large deep water (>70 m) mining vessels, as well as other special purpose geosurvey platforms. Marine diamond production by the group is expected to be just short of 1 million carats in 2006. De Beers operates across the entire value-chain spectrum from geology and geosurvey, through sampling to mining, and finally ore processing into high value concentrate. Supporting these operations involves significant service activities such as maintenance, security, logistics and environmental management. Specific challenges exist in terms of developing or acquiring appropriate technology for marine mining. These challenges have resulted in De Beers operating extensive in-house R&D and projects departments, as well as drawing extensively from technology partners. An array of computational and test facilities is also available to support R&D and projects activities. Hydrotransport in various guises is key to the current approaches to marine mining and ore processing. Use is made of airlift and centrifugal pumping for hydraulic hoisting of very coarse gravel, while splitters, launders, dewatering, elutriators, jet pumps, centrifugal pumps, dense medium circuits, pipeline systems, and instrumentation for coarse abrasive particles are used extensively in the ore processing plant.

Jan 1, 2007

By M. Hopf, E. Rossouw

Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able to consistently identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed). Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa.

Jan 1, 2006