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The major proportion of South African coal is extracted by the bord-and-pillar mining method which requires that the overlying strata be supported by pillars of coal. The stability of the pillars is a major safety concern. One of the factors which affects the strength of coal pillars is the intensity and nature of discontinuities in the coal seams. Current design methods for pillars assume that al the coal seams have equal strength and are equally disturbed by natural discontinuities, resulting in over-designed pillars in some cases and potentially unstable pillars in others. Research was carried out to determine the nature of discontinuities in coal seams and to assess their potential effect on pillar strength. It was found that large variations exist in the intensity of discontinuities in the different coal seams being mined. In addition, numerical model studies showed that the discontinuities could significantly reduce pillar strength if the width-to-height ratio of the pillars is small, but the effect decreases as the width-to-height ratio increases.

Jan 1, 1997

By R. J. Fruehan

Slags have many useful functions in iron and steel making. In particular, slags are used to remove impurities such as sulphur, phosphorus and inclusions from the metal, and a large amount of research has been done in this area. Slags also insulate the metal thermally and form reactions with the atmosphere such as reoxidation and nitrogen pick-up. However, slags serve other more unique functions, several of which are reviewed in this paper. The role of slags in new iron smelting processes with regards to reduction of ore and gaseous desulphurization are discussed. In iron smelting processes, much of the reduction occurs by the reaction of carbon in the char and the metal suspended in the slag with iron oxide dissolved in slags. The slags also react with the gas resulting in sulphur removal from the process. The mechanisms of these reactions and pilot plant data for these processes are given in this paper. Slag formation within ferrous burden materials affects the cohesive zone and the performance of the blast furnace. Recent theoretical and experimental findings on this topic are presented. In the electric arc furnace, foamed slags are used to allow for higher power operation and productivity. Of particular interest, foaming in stainless steel production is more difficult than for normal steels. The foam index, or the ability of the slag to foam, for stainless steelmaking is similar to that for carbon steelmaking slags. The poor foaming is due to the lack of gas generation for the foam. Methods to increase foaming in stainless steelmaking are discussed.

Jan 1, 2004

By W. C. Joughin

Problems with the stability and performance of rockpasses in deep-level mines are common. This paper presents the results of an investigation into the recorded performance of rockpasses in deep-level gold mines. Records relevant to the geological environment in which the passes are excavated, their excavation details, and their historical performance are not at all well documented on mines. In general, the quality of data available from mines is poor. The investigation showed that very large spans frequently developed in passes during use, and that rock mass quality, the orientation of the pass with respect to the dip of the strata, and the magnitude of the stress acting normal to the axis of the pass were the main factors of influence. From the historical information obtained, the risks of instability in rockpasses are identified.

Jan 1, 2005

By M Lipalile, A B. Tunono, A W. Naismith

Konkola No 3 shaft experienced severe mining induced stress and time related deterioration in ground conditions in an area where an over-cut and bench (OCB) mining method was used to extract a shallow dipping wide orebody. This caused an unacceptable risk for safe mining operations to sustain the required levels of production. After a review of the conditions it was decided to change the mining method to CASCADE to recover ore in the affected area and modify the OCB method and use a modified over-cut and bench method (MOCB) for new mining sections. This paper describes the geotechnical criteria included to derive the mining standards for the MOCB. The geotechnical risks are identified and taken into account to develop stope design parameters, stoping sequences and support requirements. A monitoring programme to assess conditions as mining progresses is also discussed.

Jan 1, 2005

Like it or not, CPD is upon us. As from 1 January 2006, all registered engineering professionals, i.e. professional engineers, professional engineering technologists, professional certificated engineers and professional engineering technicians, were required to undertake CPD in order to keep their professional registration current. The rules regarding CPD have been gazetted under Government Gazette No. 28328, Board Notice 131 on 23 December 2005, and they also appear on the ECSA website?www.ecsa.co.za. For the convenience of our members they are reproduced in full in this issue of the SAIMM Journal.

Jan 1, 2006

By J. -Y. Jia, G. -B. Qiu, C. -G. Bai, D. -F. Chen

Due to the great importance of the smelting process, it is essential to establish a calculation model on the viscosity of the slag system containing titania. In this paper, the calculation models of mass action concentrations and viscosity for the CaO-SiO2-TiO2slag system have been established according to the coexistence theory of the slag structure, as well as the referenced viscosities ofCaO-SiO2-TiO2at different temperatures and TiO2compositions. With the two models, corresponding calculated programs are made by means of programming language Matlab5.3, and the curves of viscosity of the TiO2concentration (?TiO2/%) at 1400°C, (R=0.9~1.0) are plotted. The results show that mass action concentrations of TiO2increases with increasing percentage ofTiO2, while the viscosity of CaO-SiO2-TiO2system is decreased. The results show that the models are in good agreement with the experimental and referenced data. They also shows that the models are reasonable for the CaO-SiO2-TiO2slag system. Keywords: coexistence theory; CaO-SiO2-TiO2slag system; viscosity ; calculation models.

Jan 1, 2004

The slags produced by the Imperial Smelting Process (ISP) are based on the system ZnO-?FeO?-Al2O3-CaO-SiO2. The slag chemistry is important to the process since it determines the fluxing practice and the operating temperature of the furnace required to produce fluid slag. The paper presents the results of the first systematic experimental investigation of these ZnO-containing slags in equilibrium with metallic iron, and provides information on the primary phase fields and liquidus temperatures in these slags over the range of compositions used in ISP practice. A feature of the slags is the presence of alumina, which has a major influence instabilizing the spinel phase. This information presented in the form of pseudo-ternary sections ZnO-?FeO?-(Al2O3+CaO+SiO2) enabling the data to be readily used by plant engineers. Keywords: liquidus temperature, ISP, EPMA, ZnO-?FeO?-Al2O3-CaO-SiO2, phase equilibria.

Jan 1, 2004

By C. J. Cutler

Metallurgical accounting for toll treatment smelters pose a number of challenges. Multiple feed stockpiles have to be accounted for as part of the monthly recovery estimation. Moreover, multiple metallurgical intermediates make up part of the in-process inventory, which also influence the monthly recovery calculation. Errors propagate from the measurements of volumes, assays, moisture fractions and bulk densities in the various material types through multiple steps up to the point where the final recovery is calculated. These errors contribute non-linearly to the variance in the final recovery estimate. This paper develops the mathematical formulation for variance propagation in toll smelting operations, including the effect of in-process inventory, assuming measurement biases have been eliminated beforehand. Operational data from a Southern African copper smelter is used for a case study. The method of propagation of variance showed that uncertainties in stockpile assays were the main contributors to variance in the recovery estimate. Variance in the volume and bulk density uncertainties contributed a secondary, yet significant, proportion to the overall recovery variance. It was determined, for the given case study, that the recovery variance depended on the calculation method used and that variance propagation via the two-product formula was smaller than recovery variances calculated via the standard recovery formula. However, the probability that the two product formula will give inaccurate (versus imprecise) results is significantly more due to the practical difficulty of equiprobable sampling of tailings streams from smelter plants (which includes materials such as slags and flue dust). Recommendations are made on how to achieve a reduction in overall uncertainty for toll treatment smelters. Keywords: metallurgical accounting, copper smelters, pyrometallurgy, variance propagation, errors, precision, sampling

Jan 1, 2006

By R. C. W. Webber

Mining up to depths of 5 000 m would be a world first and, accordingly, no previous experience in the determination of acceptable heat stress limits, criteria or indices is wholly applicable. However, some South African gold mines are already operating at depths beyond 3000 m and much of the knowledge gained in reaching and working at such depths will be helpful in making adequate provision for acceptable environmental control at the greater depths being contemplated. Accordingly, it is necessary to take cognisance of the industry?s experience in deep-level mining and of standards and regulations already established in South Africa and elsewhere in order to ensure acceptable working conditions and control standards, that compare favourably and defensibly with those in other mining industries. The local and international use of heat stress limits, criteria and indices were investigated as it was necessary to determine to what extent any other indices, limits or criteria would be applicable to South African deep mine conditions. In addition, it was necessary to establish whether there was a single heat stress index that could be used for South African ultra deep mining conditions. It was found that an appropriate combination of heat stress indices would be required in planning for and ultimately controlling thermal conditions in ultra-deep mining. The depths being contemplated and the concomitant potential heat hazard present too great a risk for reliance on a single environmental component of heat stress, such as wet-bulb temperature at present in common use locally. The study recommends that a heat stress index, preferably Air Cooling Power (ACP), be used to design an ultra deep mine?s ventilation system and that wet-bulb temperature be used to monitor and control the system once it is implemented.

Jan 1, 2003

By K. Ding

The thermodynamic activity of MnO was measured in MnO-CaO-MgO-SiO2slags that are typically encountered in the production of manganese containing stainless steels. Gas equilibration-quenching technique was employed in measuring the activities. Activity of Mn in Pt-Mn alloys were redetermined at 1600°C which reconfirmed earlier results of strong negative deviations. MnO activities were then measured by equilibrating slags of various compositions based on a statistical experimental design procedure with Pt-Mn alloys under controlled partial pressure of oxygen in MnO saturated platinum crucibles at 1600°C. Activities of MnO were found to increase with increasing concentration of MnO, basicity and CaO to MgO ratio. Two multi-coefficient repression models were developed to predict the activities and activity coefficients of MnO in slags at 1600°C. Keywords: activity, MnO, slag.

Jan 1, 2004

By P. Foster

Over the past decade there has been a great deal of research into the use of virtual reality (VR) and computer graphics in the mining industry. Much of this has led to developed applications including training simulators and accident reconstruction. One other area where there is considerable potential for virtual reality is that of mining ergonomics. This paper identifies those common ergonomic limitations associated with mining equipment that can be effectively modelled using VR techniques. From this, two simple models have been developed, namely (i) remote control continuous miner operation and (ii) free steered vehicle sight-lines, which demonstrate the practical use of VR in this area.

Jan 1, 2004

By M. Shapiro, L. A. le Grange, B. Henning

Effective pyrometallurgical process vessel design requires accurate assessment of the heat fluxes through the walls of the furnace. This is particularly important for freeze lining operation which is designed to protect refractory materials exposed to chemically corrosive molten contents, or facilitate high temperature operation when the refractory materials are used at conditions close to their service limits. Numerical modelling of fluid flow and heat transfer in process vessels is often used to aid in the design of process vessels. Sophisticated models are used to analyse the three dimensional flow and heat transfer predicting the effects of electrical heating, magnetic stirring, buoyancy, shear forces, various cooling effects and ultimately heat fluxes at the walls of the furnace and refractory. Traditionally these models are applied to the separate single fluid systems in a vessel such as the freeboard region including the arc, the slag region and the metal bath. Boundary conditions such as shear forces and heat fluxes between connecting regions such as the slag and metal bath are either estimated or carried over from separate solutions. Shortcomings in these traditional approaches include the estimation of sometimes critical boundary conditions leading to unreliable heat flux calculations. Also when boundary conditions are carried over between solutions, the process is difficult to set up, time-consuming and finally not fully coupled. In this paper the definition and results of a fully integrated numerical model of a complete arc furnace are presented. The most important mechanisms acting in an arc furnace were considered, including the fields of electrical potential, current, magnetism, momentum, heat transfer and radiation. Temperature dependant properties included electrical conductivity, density, viscosity, and thermal conductivity. The geometry consists of the freeboard, the arc, slag, metal baths and different refractory regions. Although the combined model of air, slag and metal would be defined as a multi-phase problem it is not solved as such. Instead the different fluids are separated by sets of special solid baffles. These baffles allow the implicit transfer of current, magnetism, heat transfer and shear forces between the different fluids and disallow mixing of the separate fluids. The strengths of the integrated model are threefold: Firstly, it provides robustness in defining the geometry and boundary conditions for the overall model. Secondly, it provides the capability to switch on and off individual mechanisms such as buoyancy, magnetic stirring and shear forces in order to observe their individual importance. Finally, it provides a useful tool in the design process through its ability to obtain results of parameter changes in short time scales.

Jan 1, 2004

By M. Maleki

Variogram analysis and kriging lack robustness in the presence of outliers and data with long-tailed distributions, which often arises when estimating grades in precious metal deposits. The capping technique, consisting of truncating the data to some top-cut grade, is widely used in order to mitigate the influence of the values in the upper tail of the distribution. However, this procedure omits part of the grade variability and is likely to provoke a bias in the estimates. To avoid these issues, a recently proposed approach is to decompose the grade of interest into three components (the truncated grade, a weighted indicator above the top-cut grade, and a zero-mean residual) and jointly estimate the truncated grade and the indicator by cokriging. This approach is attractive as it provides unbiased grade estimates, allows choosing the ?optimal? top-cut value, and essentially works with truncated and indicator data, thus avoiding the use of outlying values for calculating sample variograms and performing spatial interpolation. This work presents an application of this approach to a disseminated gold deposit that has been identified through exploration drilling. The effect of using an indicator covariate is assessed through leave-one-out cross-validation, by comparing the grade estimates with the true grades and with the grade estimates obtained with the conventional capping approach, which considers only the truncated grade as the variable of interest. As a result, cokriging the truncated grade and the indicator above top-cut grade outperforms the conventional capping approach, yielding significantly more accurate estimates. A few complementary guidelines are provided for validating the model hypotheses and for the implementation of cokriging.

Jan 1, 2014

By P. C. Schutte

The objective of ergonomics is to enhance the effectiveness and efficiency with which human tasks are carried out. Furthermore, the objective is to improve desirable human values. This can be achieved by enhancing safety, reducing fatigue and stress, increasing comfort, increasing job satisfaction, having greater user acceptance and thereby improving the quality of life. Mechanization has influenced the prevalence of injury, mainly due to the application of human physical effort as the power source. With mechanization, the operator?s function is now essentially one of control rather than being an energy source, however, the risk of injury has not diminished. Mechanization in itself has introduced inefficiencies, health risks and physiological stress. The major objectives of ergonomics are discussed through examples of acceptable and less successful implementation of ergonomics within mechanized mining. The influence of the machine system on the human is addressed and practical solutions to improve and optimize the interaction of the human and the machine are outlined. Furthermore, practical examples of control and display integration, anthropometric and biomechanic influences on design, orientation, posture and stereotypes are used to accentuate the advantages of the application of sound ergonomics principles to the specialized area of mechanized mining.

Jan 1, 2002

By H. Kotzé

Ticor SA began with a detailed feasibility study in 1995. The Hillendale mine (situated between Richards Bay and Empangeni) and mineral separation plant were approved in 2000. The smelter, just outside Empangeni, consists of two 36 MW DC arc furnaces that were commissioned in 2003. Experiences gained during the initial commissioning of the furnaces proved valuable in later commissioning work, as shown by the increase in ramp-up rates. The capacity of the plant is 250 kt/a TiO2slag and 145 kt/a of pig iron.

Jan 1, 2006

By A. More, J. M. Míguez, J. Bullón

In 2000 Ferroatlantica started a project with the aim to develop a new casting machine for silicon and other ferroalloys. Until now, it has been cast more than 25.000 tons of silicon for the chemical and metallurgical market. This system has improved the process yield, productivity and product quality which place?s Ferroatlantica at the top of technology development in this field. After the first presentation of the Ferroatlantica?s casting machine at Infacon X, we would like to show the improvements in the control which have permitted us to increase the lifetime of the copper and to obtain, at the end of the machine, the right product size for the customer avoiding the current necessity of crushing and sizing the lumpy metal. Furthermore, we have improved the system in relation to the obtaining of smaller granulometries at the end of casting machine. Not only is this kind of machine cost competitive for special silicon applications but also for other normal ferroalloys with different specifications of size and thickness.

Jan 1, 2007

Novel flotation reagents were developed to improve the flotation of coarse particles. Laboratory tests conducted on an anthracite coal sample from Kyung-Dong Coal Company, Korea, showed that the reagents can successfully clean 2?3 mm top-size materials. Pilot-scale tests conducted on a 1.41 mm x0 coal gave substantially better results than those obtained using kerosene as collector. The pilot-scale test results were used to develop a flowsheet, in which the 1.41 mm x0 fraction is cleaned by flotation and the 4 x1.41 mm coal is cleaned by single-stage spirals. The performance of this circuit was compared with another flowsheet, in which the 0.5 mm x0coal is floated using the conventional flotation reagent, with the 4 x0.5 mm material being cleaned using two separate spiral circuits. The performance of the two flowsheets was compared by computer simulation. The results showed that the flowsheet consisting of the coarse particle flotation circuit can give substantially higher yield sat a given product grade. Keywords: coal flotation, coarse particle flotation, collector, spirals, computer simulation.

Jan 1, 2002

Viscosity measurements were carried out on slags in the CaO-Cu2O-CuO-MgO-SiO2systemcontaining ~ 63 wt% SiO2in air. The experimental work was carried out over a range of temperatures where the slags were completely liquid. Initial measurements were on a binary CaO-SiO2slag to which incremental additions of CuxO-MgO-SiO2slag with the same silica mole fraction were made. The viscosity-temperature relationship was measured for slags with‘Cu2O’contents of 0.02, 0.19, 0.38, 0.79, 1.69, 2.47, 3.01, 5.31 and 10.0 wt%. The proportions of Cu+and Cu2+in the slags were determined. The oxidation state of Cushifted from predominantly Cu+to Cu2+, with the Cu+/Cu2+ratio of approximately 0.3 for slag with a Cu content above 2 wt%. This is equivalent to Cu1.13O. The trends observed for changes of Cu2+/Cu+redox ratio with slag chemistry were consistent with the literature. Decreasing the CaO content by substituting copper oxide resulted in a decrease in the Cu+/Cu2+redox ratio. The change in ratio corresponded to a shift of the value of x in CuxO from an initial value of 1.8 to 1.1,when the slags contained 10% ‘Cu2O’. In this study, the SiO2content of the slags varied between 64 and 60 wt% as the Cu content increased. The viscosity of the slag containing 10 wt% CuxO was nearly 4.5 times lower than the binary CaO-SiO2slag. As the silica mole fraction (xSiO2) actually stayed constant (0.61±0.009),the results show that CuxO acted as a network breaker. Comparison with other ternary slags with similar silica mole fractions suggest that that addition of CuxO to silicate slags has a stronger effect on lowering the viscosity than FeO or MnO has on a molar basis. Keywords: viscosity, copper, silicate, slags

Jan 1, 2004

By S. Badr, R. Mendoza, M. U. Ozbay, M. D. G. Salamon

ABSTRACT: The use of coal pillars at depth is fraught with problems due roof control difficulties and the possible occurrence of coal or pillar bumps. In the USA the largest and most important application of pillars at depth is in longwalling, where chain pillars are the customary supports of the multiple entry developments. At first, the chain pillars were designed using conventional approaches, where the principle is that the strength of the pillar should exceed the load imposed on it. Such approach to design led to larger and larger pillars at great depths, but instead of eliminating, it tended to aggravate the roof control problems. Eventually the idea was born that small sized yielding pillars, which have proved to be successful elsewhere, might provide the answer to this pressing problem as well. The aim of this paper is to study the modes of pillar failure at great depths, using two solution methods. The first of these comprises some elementary solutions obtained with the aid of a simplified conceptualization of the rock mass. This model consists of a strain-softening coal seam sandwiched between two stratified masses. The second approach utilizes FLAC3D, which is a commercially available three-dimensional numerical modeling software package. To gain a better insight, both the strain-softening and ideally plastic Mohr-Coulomb constitutive laws embodied in FLAC3D were exploited. As expected, the width to height ratio of the pillar has proved to be the primary factor that determined the behavior of the pillars. Narrow pillars fail in a stable manner without the occurrence of instabilities. Intermediate w/h ratio pillars under the appropriate loading conditions, may fail suddenly and may even collapse totally. Squat pillars do show the potential for sudden, coal bump like side failure, but because the remaining large width of the inner core, the ruble around the pillar provides sufficient confinement so as to reestablish stability. Finally, the study revealed that the traditional Mohr-Coulomb law does not provide a useful insight into the failure of coal pillars. RESUME: L’utilisation des piliers de charbon dans les mines souterraines de grande profondeur occasionne des problèmes due aux difficultés de control de plafond et possibles fracture ou explosions au niveau des piliers. Aux Etats-Unies d’Amérique, l’utilisation des piliers dans les mines souterraines de charbon comme moyen de support est considèrees comme étant la plus grande et la plus importantes des méthodes utilisée dans le ‘’ longwalling method’’ ou une série des piliers sont disposé de manière à supporter les multiple entrées d’exploitation de charbon. En premier lieu, cette série des piliers étaient construit de manière conventionnelle avec un principe basé sur le fait que le poids exerce sur les piliers doit être inférieur a la force que ces piliers exerce sur le plafond. Ce principe a conduit a ce que le volume des piliers augmente au fur et à mesure que la profondeur au de la mine augmente. Malheureusement, au lieu de résoudre le problème de support, ce principe n’a fait qu’aggraver le problème de contrôle de plafond. Eventuellement une idée s’est dégagé allant du fait que les piliers endommagés de taille moyenne qui se sont avérés être efficaces ailleurs, pourraient fournir un indice à ce particulier problème. Le but de cette recherche est celui d’étudier les différent types de ruptures qu’un pilier peut occasionner lorsqu’il est utilisé a grande profondeur, tout en utilisant deux possible méthodes. La première d’entre elle comprend quelques solutions élémentaires obtenues avec l’aide d’une méthode simplifié et conceptuelle de la masse de la roche. Ce modèle consiste à prendre en sandwich la bande de minerais de charbon entre deux masses stratigraphiques sans pour autant endommager le plafond. La seconde méthode nécessite l’utilisation du ‘’ FLAC3D’’, qui est un logiciel commercialisé disposant d’un modèle numérique en 3 dimensions. Dans le but d’obtenir

Jan 1, 2003

By Ike Madingoana, Stephan van Zyl, Antoine F. Mulaba-Bafubiandi

"The study presents a control strategy implemented at the Nkomati nickel mine flotation plant for process stabilization and improvement. The control strategy involves flotation concentrate volumetric flow rate stabilization and the flotation cell mass pull control. The flotation concentrate volumetric flow rate is operated at a fixed set point. The initial control strategy involved varying the flow rate to maintain the concentrate tank level thereby reducing pump cavitation. The flotation cells mass pull control comprises air rate manipulation into the cells with the exception of the recleaners. The air rate into cells is automated to adjust based on the concentrate tank level variation. The control strategy was implemented on the roughers, cleaners and the recleaner circuit. The recleaner cells air flow rate is adjusted based on the MgO content in the concentrate. The stabilization of the flotation concentrate volumetric flow rate and the mass pull by aerate automation will increase the scope of optimization for further process improvement. The immediate benefit of the control strategy implementation was plant stability. Disturbance to the flotation cells downstream was minimized due to stable flow rate, and the air addition manipulation ensured that the concentrate tank levels are maintained, minimizing pump cavitation. INTRODUCTION Froth flotation is a challenging process because it is influenced by a large number of factors, including the flotation feed characteristics. One of the ore types mined at Nkomati nickel mine is the main mineralized zone (MMZ). The MMZ ore is hosted in the Uikomst complex, a Ni-Cu-PGE-Cr- mineralized, layered basic to ultra-basic intrusion which hosts commercially viable magmatic base-metal sulphides (De Waal et al., 2001). The MMZ ore is a heterogeneous sulphide mineral resource with a varying sulphide mode of occurrence and texture. The beneficiation of the complex sulphide ore is challenging due to the presence of impurities in the ore. The impurities report to the flotation final concentrate and penalties are levied if the impurities are beyond the contractual limits."

Jan 1, 2015