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By M. Jele

? Sulphuric acid plant in umbogintwini. ? Double absorption plant, capacity of 550MTPD. ? Build by simon curve during the year 1973. ? Side stream plants such as: ? Liquid SO2 Plant, ? Liquid SO3 and ? Oleum plant

Jan 1, 2009

By R. Dippenaar

The emergence of new steel grades is largely driven by the need to produce high quality steel at a competitive price. The principal aims are to attain ultra-high purity, (especially low interstitial elements) and ultra-cleanliness (by the control of the inclusion content and size). Whereas the steel used to build the Titanic contained 650 ppm sulphur, resulting in MnS stringer-inclusions 25 mm in length, modern quality requirements for arctic pipelines would only allow 10 ppm of sulphur and inclusions in ball-bearing steels must be smaller than 5µm. Most developments are aimed at hot-metal treatment before refining and ladle treatment after decarburisation. Because ferroalloys are added during or after the refining step, it is the secondary (ladle) refining production technologies that are of specific interest to the ferroalloy producer. Through ladle treatment, hydrogen and nitrogen contents are reduced, ultra-low levels of solute impurities are attained and the shapes as well as the composition of inclusions are modified. Steelmakers are concerned about the cost effectiveness of the use of ferroalloys such as consistent product analysis and delivery, improved financing arrangements and technical support. Minimal variation in product sizing is vital because it impacts on handling problems and because particle size determines the rate of particle dissolution. The required ferroalloy product quality depends on the specific use but in general sulphur, phosphorous and nitrogen contents are of concern. Apart from the presence of trace and impurity elements, ferroalloys also contain inclusions. For example, ferromanganese may contain MnO-MnS-SiO2 inclusions while high-carbon ferro-chrome may contain different kinds of Cr-Mn-spinels. The presence of these impurities and inclusions has a significant impact on steel production techniques and cost and hence, on the selection and use of ferroalloys. The interrelationship between ferroalloy quality and steel production technology is plant and product specific and hence, effective communication between ferroalloy suppliers and steel producers is essential.

Jan 1, 2004

By B. Genc

"The risk of spontaneous combustion is well known in the South African coal mining industry. In the coming years it is very possible that the incidence of spontaneous combustion will increase from current levels, due to factors such as an increased rate of mining, re-working of previously mined seams, more stooping and total extraction for underground mines, and higher stripping ratios for surface mines, leading to more spoils. It is also fairly certain that coal mining will face tougher environmental emissions legislation in the near future. To determine the areas where the risks of spontaneous combustion are high, it is necessary to improve on our current laboratory procedures for testing and evaluating coal samples, combining the results with site and field data, and if necessary revising the laboratory rating system to refine our understanding of South African conditions.Currently, laboratory tests are conducted in order to determine both the Wits-EHAC index and the crossing-point temperature which, when combined, give an indication of the spontaneous combustion propensities of the coal samples. This procedure has enabled the establishment of a database of results to review and evaluate South African coal seams. Using this database, the high-risk areas in terms of spontaneous combustion are identified. Tests have been undertaken for five consecutive years, between 2008 and 2012. In total, 119 coal samples from different coal seams and production coalfields have been analysed and classified through a series of laboratory tests. A comprehensive database of these results is available, and is continually being updated as new test results are added. This database will continue to expand, and to provide the basis for an improved risk evaluation methodology for spontaneous combustion"

Jan 1, 2015

By G. de B. van Niekerk

This paper briefly outlines some mining technology that is used with success in Australia but is not yet fully utilized in South Africa. The following aspects are discussed: improved rotary-drill bit performance, use of trucks and load haul- dump units underground, long-hole raising, blasting techniques, and the use of butterfly roofbolt plates for support.

Jan 1, 1989

By Arun Vathavooran, Adrian Singh, Michael Fletcher, Rainer Imhof

The Imhoflot G-Cell, a new development in the pneumatic flotation technology (which incorporates centrifugal forces in the separating vessel) is a recent innovation in the mineral processing world. The G-Cell was invented by Dr Rainer Imhof and commercialised by Maelgwyn Mineral Services Ltd. In a short time span a number of plants and units have been successfully commissioned in the mineral processing industry. In addition, a number of industrial G-Cell flotation plants are in the process of construction for the purpose of coal preparation and environmental remediation. In this paper two industrial installations have been highlighted together with a pilot plant test programme investigating ultra fine flotation recovery for a base metal operation.

Jan 1, 2007

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 J. A. Bakken, T. Magnusson, G. Sævarsdottir

This paper describes measurements of current and voltage done on submerged arc furnaces. The aim is to focus on and attempt to separate from one another the electric arc current and the current bypassing the arc through the charge. Toward this goal two measurement campaigns on AC-arcs burning on coke beds are ac-counted for. The first was done on a 150 kVA pilot furnace at SINTEF in Trondheim Norway, and the second one was done on a 48 MVA industrial furnace run by Icelandic Alloys in Iceland. The measurements were compared to simulations employing an advanced MFD arc model. The main results are that a coke bed does not necessarily behave as a linear conductor. However the warmer chemically transformed part of an operating Si-metal or FeSi furnace probably exhibits linear behaviour and passes a considerable fraction of the phase current, perhaps on some operating conditions, as much as 50%.

Jan 1, 2007

By M. Dworzanowski

Beneficiation, in the context of this paper, has two distinct definitions. From an economic perspective, beneficiation relates to adding value to a mined raw material. From a metallurgy perspective, beneficiation relates to processes used to upgrade the mined raw material. Clearly then, ?economic beneficiation? is dependent on ?metallurgical beneficiation?. South Africa possesses the world?s largest mineral resources by value and is a significant global producer of many mined commodities. Significant metallurgical beneficiation of ores does occur in South Africa. The role of metallurgy in economic beneficiation will be examined in terms of current practice and the potential for expansion. South Africa?s main mining commodities will be covered ? namely gold, platinum, coal, iron ore, manganese, chromium, vanadium, copper, nickel, titanium, zirconium, uranium, and diamonds.

Sep 1, 2013

Electricity supply constraints in SA are increasingly challenging mines to operate more energy efficiently without reducing production output. Mining compressed air systems are well known to be operated inefficiently and are also a major power consumer. Two available and proven technologies can be applied on new and existing mines to replace or and optimise available compressed air facilities and achieve meaningful reductions in electrical power consumption; ? Hydro powered drilling and mining is significantly more energy efficient than compressed air and provides drilling rates that are twice as fast. ? Stope drilling systems using compressed-air or water drills allow further energy savings. The technologies are discussed and a broad strategy to selectively apply these them together is presented.

Jan 1, 2008

By Chris D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900?s. This versatile product displaced the expensive and easily-poisoned platinum-based catalyst in nearly all applications by the 1930?s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has world-wide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development program dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and pre-heater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

By Chris D. Winkler

Vanadium-based sulphuric acid catalyst has been utilized to oxidize SO2 to SO3 since the early 1900?s. This versatile product displaced the expensive and easily-poisoned platinum-based catalyst in nearly all applications by the 1930?s. MECS has been manufacturing the vanadium-based catalyst since 1925 and today is the leading supplier in the world of sulphuric acid catalysts in a variety of forms. Currently, MECS has world-wide customer/technical support for the catalyst as well as a dedicated catalyst manufacturing plant in Martinez, California. MECS also has a strong technical and research and development program dedicated to creating new and improved products and services. This paper will describe some of the technical details of vanadium-based sulphuric acid catalysts as well as offering a unique look into how caesium-promoted MECS catalysts can be used in single and double absorption acid plants, and off-gas plants running on irregular gas feeds, to reduce emissions and pre-heater run times. An update on MECS technical services extended for use in characterizing converter performance is also presented.

Jan 1, 2009

By P. S. G. Leon

One of the most difficult areas in concession contracts in resource-rich developing countries is achieving an equitable balance between the interests of investors, host states and, increasingly, mine and near mine communities. While some countries in the Andean region have resorted to outright or creeping expropriation of natural resource contracts under the guise of resource nationalism, others such as the Democratic Republic of the Congo (DRC), have claimed international best practice in the review (and setting aside) of important concession contracts.

Jan 1, 2011

By D. H. Diering

The paper takes the reader into the depths of a modern ultra-deep South African gold mine and gives a perspective on the vertical and horizontal extent of the tunnel networks in such a mine. Depending on the mine design layout employed, tunnels once excavated are subjected to various levels of stress change over their life time, and the support requirements are explained. It is suggested that shotcreting is the only viable ultra-deep level support medium, and after looking at the latest developments, the logistical problems are put forward. In an effort to overcome most of these problems, the South African ultra-deep mining industry embarked on a collaborative research programme in 1998. The importance of tunnelling and in particular tunnel support as a critical technology for future successful ultra-deep level mining is stressed. While not yet fully ?on top of? these problems and challenges, our industry is now fully addressing them and we expect to make significant progress during the next 4 to 5 years.

Jan 1, 2000

By T. H. Yang, K. K. Lee, Z. Z. Liang, C. A. Tang, L. C. Li, Y. Tsui, L. G. Tham

Abstract: A series of numerical tests of hydraulic fracturing in heterogeneous rocks were performed to investigate the influence of pore pressure magnitude and gradient on initiation and propagation of tensile fractures. The numerical tests were run with a Rock Failure Process Analysis code, F-RFPA2D, incorporated with a Flow-Stress-Damage coupling model (FSD). To investigate the influence of pore pressure magnitude on fracture behaviour, “pinch-off” breaking tests, originally employed by Bridgeman to investigate the effective stress law for tensile fracture in a uniform pore pressure field, were numerically modelled. In another numerical test, a double-notched sample, with fluid pressure in one notch while keeping the other one open to the atmosphere, is numerically extended to investigate how the fluid flow direction or the pore pressure gradient will influence the fracture behaviour. The simulation results show that fracture is strongly influenced by both pore pressure magnitude and pore pressure gradient. Keywords: seepage mechanics; heterogeneous; pore pressure; numerical simulation; failure process ZUSAMMENFASSUNG: Um den Einfluss der Wasserdruckgroesse der Oeffnung und der Porisitaet auf den Bruchentstanden und Verbreiten der Tension von Gebirgen zu beurteilen, wurde viele nummerische Pruefungen auf den hydraulischen Bruch in dem Gebirgen aufgenommen. Diese Pruefungen wurden mittels der Analyse- Software F-RFPA2D und Flow-stress-Damage Coupling model ( FSD) durchgefuehrt. Um den Einfluess der Wasserdruckgroesse der Oeffnung auf den Bruch zu beurteilen, wurden auch Bruchpruefung und nummerische Analogexperimenten gemacht, und dadurch wurde die ganze Phase der Bruchentstanden und Verbreiten wiedergezeigt, und die Ergebnissen ergeben sich, dass die Wasserdruckgroesse der Oeffnung und der Porisitaet sehr viel auf den Bruchentstanden und Verbreiten der Tension von Gebirgen beeinfluessen. Schluesselwoerter: Durchlaessigkeit , ungeleichmaessig, Wasserdruck der Oeffnung, nummerische Analog, Zerstoerungspahse Résumé : Une série de simulations numériques a été ménée pour analyser l’influence de la grandeur de la pression de pore et du gradient sur la naissance et la propagation des fractures de tensions par le biais de la simulation numérique des fractures hydroliques dans des rochers hétérogènes . Le logiciel F-RFPA (Rock Failure Process Analysis code ) intégrant FSD ( Flow-Stress-Damage coupling model ) y a été employé. Les résultats des simultations montrent tout le processus de la naissance et de la propagation des fractures sous la pression de pore. Ces résultats nous ont permis de constater que la grandeur de la pression de pore et le gradient exercent une influence importante sur la naissance des fractures dans les rochers et sur leur mode de propagation . Mots de clé : le mécanisme de transfusion ; l’hétéogénéité ; la pression de pore ; la simultation numérique ; le processus destructif

Jan 1, 2003

By L. Joncourt, N. Touchard, G. Pochart, C. Perdon

Worldwide, the major Manganese ores can be separated into three different types: ?Oxidized ores (MnO2): in Australia, Gabon, Brazil,?. ?Semi-oxidized ores (Mn2O3): in South-Africa, Australia,?. ?Carbonated ore (MnCO3): in Ghana, South Africa, Kazhakstan?. The other Manganese ores are less rich but can be used locally or in the neighbour countries (China, Ukraina, India?). Since the beginning of the 20th Century, Manganese has played a big role in the steel industry process average usage ratio: 9,5 kg/mt of steel). The recent grow-up of this industry has led to an increase of Manganese ores demand. In parallel, several companies have increased their Manganese ore producing capacity. In this presentation, we explain the link between the main Manganese ores characteristics and the key different factors for an effective and low cost Mn alloys production (HCFeMn and SiMn): ?Chemistry ?Size ?Reactivity Then we will point out the advantages of Comilog ore and Sintec ® usages in various Manganese alloy metallurgical process compared with the other main ores and with the local ores. Some advised formulations for the different kinds of furnaces and alloys will be also discussed.

Jan 1, 2007

Gullies are the vital in-stope excavations that provide access for mining personnel and material to, and mined ore from, the producing faces in the tabular hard rock mines. They pose a serious problem in most mines because they induce stress orientations, which, combined with blast damage, produce adverse rock fracture patterns that contribute to the loss of hangingwall and sidewall integrity. Rock-related injury statistics confirm this by highlighting gullies as the second-highest risk area in South African hard rock mines. Inappropriate gully geometries, poor blasting practice, and non-adherence to accepted standards worsen the problem. The aim of this work is, firstly, to provide guidelines to select the correct gully geometry and appropriate support for a particular geotechnical environment and, secondly, to review the practical issues behind gully safety and stability. In order to meet these aims, this paper reviews the available literature on gullies and their history, and reports on an industry-wide survey of practices and opinions. Then it covers observations from underground visits to 107 gullies situated in the respective geotechnical environments of the Basal Reef, Beatrix Reef, Vaal Reef, Carbon Leader Reef, Ventersdorp Contact Reef, Kimberley Reef, Kalkoenkrans Reef, Merensky Reef, and UG2 Reef. Despite the differing geotechnical conditions and gully geometries, common problems are experienced with geological structure, stress, and fracturing. Results from numerical modelling are also presented to help analyse the underground observations and to quantify the merits of the different gully layouts. It is concluded that there are no new techniques available to improve gully stability, but that significant improvements in safety are attainable by employing the correct gully geometry for the geotechnical environment, good blasting practice, and appropriate support.

Jan 1, 2002

By N. Mulaudzi, S. Archer

"Direct cobalt electrowinning was developed to produce unrefined cobalt metal as an alternative to producing a mixed hydroxide product (MHP), which is the common cobalt intermediate product in African Copperbelt operations. MHP is preferred due to the high cost of producing high-grade cobalt cathode. Direct cobalt electrowinning test work results have shown that the purity of the unrefined cobalt metal produced from a low-grade copper solvent-extraction raffinate stream was ~97% (w/w), which is significantly higher than the MHP purity (up to 45% (w/w) Co). The current study investigates whether direct cobalt electrowinning would increase the profitability of African Copperbelt copper–cobalt oxide operations, when compared with the MHP flowsheet. An order-of-magnitude economic evaluation was conducted using dynamic differential discounted cash flow models on a “bare-bones” basis, using a 10% discount rate. Three variables were evaluated, namely; reagent utilisation extents, precipitation extents and filter-press wash efficiency. Multivariable risk analysis was also conducted using the Monte Carlo simulation technique to understand the impact of key project drivers. The financial study results indicated that a direct cobalt electrowinning flowsheet could potentially result in a higher mean net present value (NPV) compared with the MHP flowsheet. Cobalt recovery was found to have the most significant impact on the NPV. In addition to increased profitability of African Copperbelt operations, direct cobalt electrowinning has the potential to reduce the environmental footprint of operations as well as addressing the Democratic Republic of Congo government’s drive towards export of higher value metal products instead of low-grade intermediates."

Jan 1, 2015

By A. M. Bryukhanov, A. G. Mnukhin

The report states accident rates for gassy/dusty coal mines represented as an ergatic system "man – machine - environment" with further analysis by the method of conditional probabilities. A coal mine has been analyzed with allowance for the attending personnel, equipment and environment as a sequence of events and states. Probabilities of operational states have been determined and prediction of mine behavior has been made on the basis of investigation findings for equipment and the personnel states, and analysis of the environment (i.e. mine and mining conditions). Utilization of expert estimation methods has been considered for determining major operational parameters of gassy/dusty mines. The importance of standardized values of permissible occupational risks (permissible probability of accident, PA) is demonstrated. It is also stated that a procedure is essential to determine these values, involving regular check-ups of the integral safety criterion at all mines and further development of customized recommendations for individual mines on efficient improvement of accident situations. Methodology to determine the assessment criteria has been developed and scientifically substantiated for permissible accident rates in hazardous industries.

Jan 1, 2003

By M. S. Raseroka

An experimental rig has been constructed to produce chloride stress corrosion cracks in Type 304L stainless steel tube samples. The samples are to be used to test possible in situ repair methods in future work. The factor which influences the time to failure most strongly is the sample temperature; the distribution of cracks within the sample is affected by local temperature variations and by the position of the water line. Low-frequency oscillations in stress, caused by the on-off temperature controller, did not appear to influence cracking in these tests.

Jan 1, 2009

By M. Dworzanowski

The beneficiation of fine iron ore will increase in importance in the future because most new iron ore resources will be in the form of lower grade ore deposits that will require liberation of iron ore minerals at finer sizes. Generally this fine iron ore will be beneficiated to produce a pelletizing concentrate with very strict chemical and physical specifications. In addition, because of the increasing demand for iron ore there are now more opportunities to produce by-product iron ore from mining operations producing other commodities. In the past the associated iron ore minerals would report to final tailings but now there is potential value to be realised from by-product revenue. These by-product iron ore opportunities are almost all centred on producing pelletizing concentrate. Currently pelletizing concentrates are produced mainly by various combinations of flotation and magnetic separation. The selection of the beneficiation route will depend on ore mineralogy and considerations around plant capacity and final concentrate quality. The main economic iron minerals are magnetic, haematite being paramagnetic and magnetite being ferromagnetic. This, therefore, means that magnetic separation can be applied, in principle, to all fine iron-ore beneficiation plants. While flotation has a considerable capacity advantage over magnetic separation, the real advantage of magnetic separation over flotation in fine iron-ore beneficiation is that treatment of -10 µm iron ore is possible-in flotation, the feed is deslimed at 10 µm and the -10 µm stream is considered to be final tailings, even though there is often a significant amount of contained iron ore. This paper describes a study around the recovery of fine magnetite in the form of a pelletizing concentrate. The study is based on an evaluation of an iron ore by-product opportunity from an iron oxide copper-gold (IOCG) deposit. Experiments were conducted to quantify the differences in magnetic separation performance with decrease in particle size treated. A mineralogical evaluation of all the test work products was undertaken to facilitate the interpretation of the test work results. These results were then used to propose an economically viable flowsheet for maximizing fine magnetite recovery using magnetic separation.

Jan 1, 2012