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By M. Viljoen

South Africa has produced more than a third of the total gold mined throughout history and remains a major although, until recently, no longer the largest producer of gold. South African gold production peaked in 1970 with an output of 1 000 t, a major component of the western world?s gold production, with the development of the country?s economy having been based largely on this mineral wealth. The costs and difficulties of increasingly deep-level mining, coupled with increasing labour costs and the low gold price until relatively recently, have seen production fall steadily since then, with the closure of many mines including those of the Central Rand Goldfield in the mid seventies. Thus in 1998, only 464 t were produced, with 342 tons being produced in 2004. In 2006, 275 tons of gold were produced and after more than 100 years was the last year as the world?s largest gold producer. In 2008 gold production was 221 tons, making South Africa the third largest gold producer after China (292 t) and the USA (234 t). Gold production would have been lower if it had not been for massive tailings dam retreatment operations that started in the late seventies, including in the Central Rand Goldfield. Mining of a remaining deep and lower grade shallow resources has now also become a major focus and has recently lead to a rebirth of reef mining on the Central Rand Goldfield.

Jan 1, 2009

By George Kayesa

[ ] A multiple-bench slope failure occurred at Letlhakane mine on 14th July 2005. No injuries or damage to equipment was suffered and mining production was not affected. Slope failure was preceded by the precursors of tension crack formation, crack widening and extension as well as slope monitoring targets movement. It was predicted that slope failure was imminent using the Geomos slope monitoring system, though the timing was not certain. The area to be affected by the slope failure was also known before hand as was the slope failure mode. As a result, measures were taken to avoid exposing personnel and mining equipment to the slope failure risk. This paper discusses how the prediction of the slope failure of 14th July 2005 using the Geomos slope monitoring system resulted into avoiding potentially fatal injury, damage to mining equipment and loss of mining production.

Jan 1, 2006

By D. C. Krige

The estimation of the tonnage and grade of payable ore in a mine and the correct policy of selective mining based on such estimates, is of vital importance to the mining engineer it is surprising, therefore, that more attention has not been devoted on the Witwatersrand to the scientific improvement of mine valuation methods. At present these methods consist almost entirely of the application of simple arithmetic and empirical formulae guided by practical experience, and ignore the many advantages to be gained from a careful statistical analysis of the behaviour of the gold values. The science of statistics has expanded rapidly during the last two decades and its value as a powerful and indispensable tool is now recognized not only by research workers and scientists but also, ever-increasingly, by the commercial and industrial world. This being the case it is noteworthy that in a mining field such as the Rand with its highly developed and advanced mining methods, singularly little attention has been paid to the analysis of mine valuation problems on a modern statistical basis. This omission is even more striking when cognizance is taken of the wealth of sampling data concerning the gold ore which is available and of the far-reaching decisions and deductions constantly being based on such data. Some contributions have however been made from time to time towards the application of statistics to mine valuation on the Rand (References Nos. 7, 8, 9, 11, and 12), but none of these have been generally applied in practice and a systematic practical approach based on clearly deemed fundamental concepts still appears to be lacking. The object of this paper is, therefore, to define these statistical concepts and to indicate briefly the lines along which statistical methods can be applied profitability in solving some of the existing problems and in improving the general standard of mine valuation on the Rand For this purpose a knowledge of mathematical statistics is essential, but as this paper is primarily intended to provide the mine valuator with a practical introduction to statistical application in his field, the mathematics is confined to a short annexure, together with references from which details can be obtained.

Jan 1, 1994

By Bosman

Medium suspensions play an integral part in the successful application of dense medium separation for both static and dynamic separators. Although models exist to predict particle movement as a function of medium density and viscosity, these models have been derived on the assumption of Newtonian rheology. Viscosity measurements of medium suspensions have shown that they are non-Newtonian, with a yield stress, and as such cannot be used in the existing models. As a result, medium selection remains an art based upon practical experience and indirect measurements of viscosity such as stability and cyclone differentials.

Jan 1, 2014

The proper understanding of the functioning of ground support under dynamic loading and the current approaches to designing of dynamic support are plagued by a great deal of uncertainty and lack of knowledge. This applies equally to the understanding of the support capacity as well as the demand placed onto the support due to dynamic loading. This lack of understanding currently leads to a case of design indeterminacy. This paper does not aim to solve this problem of design indeterminacy but to explore some of the issues that need consideration to obtain a better understanding of the dynamic demand on ground support systems. Keywords ground support, dynamic loading.

Dec 1, 2013

By K. H. Berget, V. Andersen, H. Tveit, R. Jensen

This paper presents some of the work carried out in order to improve the tapping process in silicon production, with special focus on the environmental and the safety standards. Some of the modelling work that has been done to improve the understanding of the process is described, together with the resulting implementation to improve tapping standards.

Jan 1, 2014

By D. Burrows

Traditionally, characterisation of the mineralogy and textures of ore and rock samples were based on observations of hand specimens and thin sections using an optical microscope. The extent of the data collection was limited by the available tools and thus variations in mineralogy and texture were generally not described by quantitative data. These qualitative to semi-quantitative approaches, even though well established over the years, resulted in variable observations and data sets. The data were unlikely to be representative of a sample and limited statistical validity meant the results could not be reliably used in modern digital mining design and planning. With recently developed SEM based quantitative mineralogy tools and the corresponding methodologies, ore textures can be quantified and compared numerically. The numerical data can not only enhance the understanding of an orebody in geological terms, but can also be used in the creation of metallurgical models for mine and mineral processing design and simulation. These capabilities provide valuable inputs to risk assessment studies and the evaluation of mineral projects.

Jan 1, 2007

By Keith Rowley, Neal Harries, David Noon

The management of risks associated with slope instability is an essential process in the safe and economic operation of open cut mines. The ?slope stability radar? (SSR) has been developed to better manage those risks. The SSR remotely scans rock slopes to continuously measure any surface movement and can be used to detect and alert users of wall movements with sub-millimetre precision. The high level of movement precision and broad area coverage of the rock face can allow for a better understanding of the geomechanics of slope deformation, including magnitude of potential failures and additional warning time of impending instability. Additionally, radar waves adequately penetrate through rain, dust and smoke to give reliable measurements, 24 hours a day. SSR systems have been deployed in many mines in Australia, Indonesia, South Africa, Zambia, Chile and the United States. Greater than 70 rock falls and waste dump failures (from several to millions of tonnes) have been monitored, and on every occasion precursor ?warning? movements were recorded by the SSR. This technology enables a radical change in the management of risks in open cut mining. This paper will present recent case studies of the SSR operation in coal and metalliferous mines.

Jan 1, 2006

By K. A. Moxham

The ARM 1100 was described in a paper presented at the 6th International Symposium on Mine Mechanization and Automation in September 2001. It started operation underground at Rowland Shaft in early 2002. This paper covers the results of those trials that resulted in more than 1 100square metres of UG2 being mined.

Jan 1, 2004

By J. O. Marsden

The copper industry is cyclical with the price determined by market forces (i.e. the balance between supply and demand for the metal.) The period of each cycle typically varies between 6 to 9 years. These cycles drive decision making for exploration, new project and mine development, mine closures, process improvement, research and development, and technological innovation. The gold industry is fundamentally different from copper in that supply and demand do not, alone, determine metal price and many other factors play a key role, including global and regional financial conditions, political stability, and the global future economic outlook. However, the gold price experiences trends and longer term cycles that similarly drive business decision making. This paper examines developments in the copper industry that have occurred over the past few price cycles (approximately 20 years) and explores how the lessons learned can be applied to gold extraction. A number of specific examples and opportunities are discussed in detail, including; technology development and innovation, cost control and business improvement, material characterization, comminution equipment, biological heap leaching, and concentrate pressure leaching.

Jan 1, 2009

By A. W. Sundström

This paper reviews the development and suitability of various important thermophysical and electrical properties with respect to base metal mattes. Areas of focus include the critical validation of measurements of viscosity, density, surface and interfacial tension, electrical conductivity, and an overview of the various experimental methods used to determine these properties. Accurate physical property data of mattes are critical in process modelling and computational fluid dynamic modelling of smelting and converting operations employed in the extraction of copper, nickel, cobalt and platinum group metals.

Jan 1, 2008

By W. J. Kempson

As a result of the rising electrical energy costs in South Africa, a method was sought to reduce the overall electrical consumption of typical shaft systems. A typical shaft configuration was analysed and the primary energy consumers were identified. The ventilation fans for this system were found to consume 15% of the total energy of the shaft system. It was calculated that more than 50% of this energy is consumed by the shaft itself, more specifically, by the pressure losses that occur in the shaft as the ventilation air passes through it. In order to ensure that the theory being used for the evaluation of these shaft systems is accurate, a total of five shafts were instrumented and the actual pressure losses over the shafts plotted against time. These shafts were then analysed from a theoretical perspective. Finally, in order to ensure a thorough understanding of the behaviour of the ventilation air in shaft systems, the systems were simulated using computational fluid dynamics (CFD) techniques. There were significant discrepancies between the theoretical analysis and the CFD simulation during the initial comparisons. This discrepancy lessened as the complexity of the CFD models increased, until when the complete shaft was modelled using the full bunton sets, the pipes, and the flanges, the difference between the theoretical evaluation and the CFD simulation was small. This result demonstrates that the theory is insufficient and that the interrelated effect of the buntons and fittings has not been fully appreciated by current theory. The final phase of the work presented here was to evaluate the costeffectiveness of using different bunton shapes and shaft configurations. It is shown that the increase in the pressure losses and therefore the direct operating costs of the shaft can vary by as much as 80%, depending on the bunton configuration chosen. The placement of the piping in the shaft can increase the pressure losses, and therefore the direct operating costs of the shaft, by as much as 12%, depending on the placement of the piping in the shaft; this effect includes the use of flanges. The use of fairings on a large cage can reduce the resistance that the cage offers to the ventilation flow by as much as 30%. This, however, does not translate into a direct saving because as the cage moves through the shaft, the overall effect is transitory. These savings can be significant when the items highlighted in this work are applied correctly. Keywords shaft design, ventilation, energy consumption, modelling, CFD.

Dec 1, 2013

By M. Verri

The paper describes the design options available for the simultaneous production of liquid sulphur dioxide, via cryogenic condensation, and sulphuric acid in a sulphur-burning sulphuric acid plant. The impact of the operating conditions of the cryogenic condensation on plant capital and operating costs are discussed, with the main focus on the optimization of the most important economic and operative drivers of the non-ferrous mining industry, such as energy efficiency, reliability, and availability. A case history relevant to an integrated sulphurburning plant producing liquid sulphur dioxide and sulphuric acid, recently started up in the Democratic Republic of Congo, is described. Keywords sulphur burning, sulphuric acid, liquid SO2, cryogenic SO2 condensation, liquid sulphur dioxide, sulphur dioxide.

Aug 1, 2013

By H. Moslemi

Metal sulphides are usually semiconductor and their electrical conductivity is low; therefore they are sources of electrons and promote electrochemical reactions. This phenomenon is of significant importance in sulphide flotation. The formation of a hydrophobic surface on the sulphide minerals is the result of various electrochemical reactions. Potential difference in the mineral-liquid interface plays an important role in the kinetics of the reactions, and consequently, on the flotation behaviour of sulphides. The value of the potential difference is influenced by different oxidation-reduction reactions at the interface area, and is measured by a two-electrode system in which an electrode is applied as reference electrode. In this study, we attempted to measure open-circuit potentials of pyrite, pyrrhotite, and steel electrodes with respect to the reference electrode. To verify the results, two reference electrodes, saturated calomel and gold, were used. Time-potential relations with respect to both reference electrodes show that the potential of both pyrite and pyrrhotite increases with time; however, this trend decreases for steel except when at pH 12. The results show a potential drop by an increase in pH value, except for steel, for which the opposite holds. This paper discusses galvanic interactions between minerals and grinding media in the grinding circuits, as well as among other minerals in the flotation processes.

Jan 1, 2012

By T. Orupold

This paper covers the commercial development of gravity separation of fine particles using a Lamella High Shear Rate REFLUX? Classifier (REFLUX? Classifier), focusing primarily on coal applications. The REFLUX? Classifier is a fluidized bed device that incorporates a system of closely spaced parallel inclined channels located above the fluidized bed. These channels make it possible to achieve a significant suppression of the effects of particle size, resulting in a highly effective separation on the basis of density. The improved gravity separation performance is shown to be remarkably high, with a significant reduction in the variation of separation density with particle size, and a significant reduction in the change in Ecart probable error (Ep) with size. The first full commercial-sized units of the REFLUX? Classifier were field-tested in late 2009 in coal applications. More recently, the technology has been applied in fine particle separation in minerals applications and there are a number of full-sized units operating in chrome applications in South Africa. Initially, pilot-scaled units (typically the RC?300) were trialled in iron ore, mineral sands, and manganese plants amongst other minerals, typically after other technologies failed to achieve the desired results. Currently a number of laboratories globally are carrying out more testing in minerals applications. More than 50 RC? units are now operating in coal and minerals applications. This paper introduces the REFLUX? Classifier technology, identifies commercial applications, and gives some commercial results.

Jan 1, 2014

By C. Musingwini, T. C. Sebutsoe

"The primary objective of any mining business unit is to make profit by extracting, processing, and selling minerals from a particular mineral deposit. It is important to optimize extraction of the mineral resource given time, capital, and space constraints. Mineral extraction is often associated with uncertainty due to variable technical and human factors. Technical factors such as grade distribution, ground conditions, and equipment reliability influence the performance of a mining production system (MPS). The performance of the MPS is also impacted by human factors such as employee skills, health, and attendance. Uncertainty associated with technical and human factors often leads to actual output differing from what was planned. Therefore an in-depth analysis of the significant causes of deviations from the planned outcomes is relevant.In this paper we investigate the empirical relationships between inputs and outputs in a MPS in order to assist management in directing efforts at key production drivers. Once a MPS has been empirically characterized, more effort and resources can be focused on the key decision-making variables (DMVs) in order to meet the planned outcomes.For a typical underground, tabular, narrow-reef conventional drill-andblast platinum mine the face advance, face length mined, number of teams, team efficiencies, and team size have a statistically significant relationship with the centares (m²) produced, which is a key performance indicator (KPI). The production function derived in this study can be used to align the physical, technical, and human factors together to predict the optimal output level. The most significant production lever of the MPS is the face advance. IntroductionA mining production system (MPS) is a result of an iterative process of design, planning, and optimization of mining input variables and decision-making variables (DMVs). The MPS exists within the mineral extraction link of the complete mining value chain. It represents the stage where mining companies have the opportunity, through production, to start generating returns on the investments undertaken. Returns on shareholders’ investments can be realized at this stage."

Jan 1, 2017

By J. L. Porter

This paper takes a personal look, through the author?s own experiences, at the implementation of innovations in the narrow-seam, hard-rock mining environment of South Africa?s mining industry over the past 40 years. A number of examples are used to illustrate some of the successes and failures over this period. More importantly, the examples are used to illustrate that the bulk of the investment for these projects should have been applied in a manner that could have achieved more sustainable results. The use of the word ?technology? in this context is also examined, as it is the author?s contention that only measuring the performance of machinery fails to encapsulate the potential of the entire system describing the scope of the innovation being implemented. These experiences and observations are projected onto the current backdrop of upheaval in the relationship between key industry stakeholders and the sustainability challenges facing areas of the mining sector in the South African economy. The paper concludes with some opinions on where attention can be focused in order to develop new thinking that can be applied for the safe and economic extraction of the nation?s mineral wealth.

Jan 1, 2014

By A. Nhasengo

Paper written on project work carried out in partial fulfilment of B. sc. Eng (Mining Engineering) The purpose of this investigation was to assess the mining strategy for steep reefs at Mine A mine in 2005 and 2006. Reefs steeper than 35° were discovered when production commenced at the mine. At that time reefs steeper than 35° were not popular in South African tabular gold mines, therefore new techniques of mining them had to be developed. The underhand mining method was chosen for this purpose. The project was about assessing ventilation, support costs, local support cycles, adherence to the mine?s support standards, mine planning and efficiencies of the underhand mining method. The project work was covered by doing a literature research for underhand mining methods and performing a literature review of the mining methods, support methods, ventilation standards at Mine A. Underground visits were conducted at Mine A mine for data collection, and Mine B was visited to obtain information on support costs and efficiencies. During the investigation it was realized that the underhand mining method was an appropriate method for mining steep reefs; however, there were some challenges related to ventilation and support installation. Efficiencies could be realized with the underhand mining method and planning and scheduling were not different from breast mining.

Jan 1, 2007

By K. Andres

This paper presents the vibrating mill technology and summarizes the grinding principle of ultra fine grinding. In addition, a variety of operations is described and the benefits of these different operating modes? product size and efficiency are specified. A case study of an industrial application is presented to show the integration of vibrating mills into grinding circuits. The primary focus is the overall process scheme of this technology, the installation and operating costs, as well as the design parameters required for best performance. The vibrating mill can be used in a wide range of applications for process engineering duties. For a wide range of applications, from soft to extremely hard products, which require ultra fine grinding, surface activation or homogenization, the vibrating mill is well proven. Due to its easy operation, versatility and operation efficiency, the PALLA? vibrating mill gains in importance in the mineral processing industry. Keywords: Coal, comminution, grinding, mineral processing

Jan 1, 2010

By C. M. Rule

High pressure grinding rolls (HPGR) technology has come a long way in its application for comminution duty in hard rock mineral processing in the last three years. Several major projects in copper, nickel, gold, molybdenum, platinum, and iron ore have opted for this technology. Advances in wear abatement technology have established the HPGR as a reliable machine with the required high utilization and availability. The HPGR captures the imagination as the next step change improvement in ore processing, based on the following benefits: ?Energy efficiency (potentially 10?30% more efficient)?very topical in an increasingly ?green? society, and in times of rapidly increasing energy costs and availability concerns. 2008 has shown this to be especially important in Southern Africa ?High (and stable) throughput with a relatively small footprint ?Lower operation cost ?Liberation benefits ?Creative ?mine-to-metal? system improvements made possible by HPGR. The platinum industry, renowned for its historically conservative approach, has not been left behind with two significant new HPGR installations, one in Platreef application and one in UG2 application, commissioned in 2008. While the decision for the Platreef application was driven primarily by comminution circuit capacity and design imperatives, the UG2 application seeks to develop a flowsheet that will have a significant recovery benefit in addition to capacity increase and reduced operating cost. The Platreef application of HPGR also provides the opportunity to introduce a novel comminution flowsheet and to demonstrate exceptionally low wear rates treating very hard, abrasive and variable ore types. The HPGR lends itself for inclusion in existing SABC circuits to increase the capacity of the plant and mills. With current PGM prices many operations are attracted to the HPGR technology benefits. The HPGR clearly has the potential to transform entrenched opinion and provide decision makers with significant alternative comminution options. This paper aims to provide an overview of the current applications and to speculate on the transforming stimulus that the HPGR exerts on industry.

Jan 1, 2009