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By F. Enslin

Heavy metals and sulphates in acid mine drainage (AMD) can beadsorbed onto bentonite clay, leaving clean water and a heavy metal loaded clay precipitate as products. Due to the toxicity of heavy metals, the clay could not be disposed of safely in the past. A method was thus required to remove the heavy metal content from the clay. Acid leaching was proposed to liberate the heavy metals from the loaded clay. Sulphuric, nitric and hydrochloric acid were considered as lixiviants. Loaded clay samples were leached over a range of pH values from 1 to 3.5 to identify an optimum leaching condition. From the results it was found that metals can berecovered from loaded bentonite clay by means of acid leaching and the optimum pH for heavy metal liberation was found to be 2.5, with uranium as an exception, being optimally leached at a pH of 3. This allows for the possibility of selective leaching. Furthermore, X-ray diffraction analyses indicated that the clay structure did not deteriorate significantly during acid leaching, suggesting that the bentonite could be reused. The treatment of AMD with bentonite clay, and subsequent acid leaching of the clay, is a sustainable solution, and current outcomes could possibly lead to industrial implementation of the process during water purifying and metal recovery from waste streams. Keywords: Acid mine drainage, bentonite, heavy metals.

Jan 1, 2010

By M. Kumral

The efficiency of an ore-processing unit depends on the consistency of the characteristics of raw material entering the plant. When the mined ore is highly variable in quality, the only way to ensure consistency is to homogenize the ore prior to feeding to the processing plant. The homogenization can generally be achieved by the bed blending operation. Given that the stockpiling and reclamation processes are very expensive, it is necessary to design the process in such a way as to minimize variabilities of specified properties of raw material. In this paper, for alternative stacking types, optimal stockpile geometry is found in three stages: First, stockpile input is simulated by sequential Gaussian simulation, and then the variance reduction ratios (VRR) as a criterion of stockpile efficiency are calculated for various stockpile geometry scenarios by a stockpile simulator written in FORTRAN. Second, multiple regression analysis is performed to model the VRR by the use of stockpile length, the number of layers and stacker speed as the independent variables. Finally, the model is an optimization problem. Decision variables are the stockpile length, the number of layers, stacker speed and stacking type. The genetic algorithms (GA) are used to minimize the VRR. The approach was demonstrated on data from an iron orebody. The problem was to reduce fluctuations of iron, silica, alumina and lime contents in the stockpile output. The results showed that the approach could be used for the bed blending design efficiently. Keywords: bed blending design, multiple regression analysis, genetic algorithms, iron ore, content fluctuation

Jan 1, 2006

By C. J. Liebenberg

This paper focuses on the application of ion exchange technology for the recovery of copper from a leach solution originating from a heap bioleach in which base metals are leached from a low-grade ore that bears platinum group metals. Screening tests indicated that Dow XUS43605 has high selectivity for copper over the other metals in the solution, namely nickel, iron, cobalt, zinc, manganese, and aluminium. Batch adsorption kinetic experiments showed that copper adsorption equilibrium is attained at a fast rate. The kinetics of adsorption increased as the temperature was increased from 25°C to 60°C due to the decrease in solution viscosity and the subsequent improved intra-particle mass diffusion. Single-component Langmuir and Freundlich isotherm models were fitted to the batch copper adsorption equilibrium data, and a maximum copper capacity of 26 g/l was observed for Dow XUS43605. The effects of flow rate, temperature, pH, and initial metal concentration on the dynamic recovery of copper were investigated in fixed-bed columns, and it was determined that temperature and flow rate had the most significant impacts on the loading of copper on the resin at copper breakthrough. A 36% increase in copper loading at breakthrough was observed when the temperature was increased from 25°C to 60°C. Finally, it was determined that a split elution is possible by using different concentrations of H2S04 to first elute co-loaded nickel from the resin, followed by the elution of copper.

Jan 1, 2013

By A. Fredriksson, R. Christiansson, I. Staub

A theoretical model based on DFN models and 2D DEM numerical modelling has been developed for evaluating the rock mass mechanical properties. The description of the methodology is non-site related and can be applied in any site for this type of characterisation. The methodology was developed in the frame of the Site Investigation programmes for a Deep Repository for spent fuel in Sweden, and validated on sets of data coming from the Äspö Hard Rock Laboratory. Un modèle théorique base sur des modèles probabilistiques de réseaux de fractures et sur un modèle numérique DEM 2D a été développé dans le but de déterminer les propriétés mécaniques de la masse rocheuse. La méthodologie développée peut être appliquée à tout type de site pour ce genre de caractérisation. Le modèle a été élaboré dans le cadre des programmes de recherche d’un site d’enfouissement des déchets nucléaires en Suède, et validé par une application au laboratoire de recherche souterrain à Äspö. Ausgehend von DFN-Modellen und 2D DEM numerischen Modellierungen wurde ein theoretisches Modell für die Auswertung von mechanischen Eigenschaften von Fels entwickelt. Die Methodikbeschreibung ist nicht standortspecifisch sondern kan überall für diesen Typ von Standordkarakteriserung angewendet werden. Die Methodik wurde in Schweden im Rahmen der Standortuntersuchungsprogramme für die Endlagerung von verbrauchten Brennelementen entwickelt und ist mit Hilfe von Daten des Äspö Hard Rock Laboratory validiert worden

Jan 1, 2003

By A. P. N. Sutherland

Pipelines for transporting high concentration slurries are often designed using methods applicable to homogeneous non-Newtonian laminar flow. Many industrial slurries though comprise coarse particles in a non-Newtonian carrier fluid, and existing experimental evidence from tests with such slurries demonstrates that they are not homogeneous. Under laminar shear conditions the coarse particles settle, even in statically stable carrier fluids. To understand this better, the Institute of Materials Science and Technology (IMST) at Cape Peninsula University of Technology (CPUT) is conducting ongoing research into the flow of these high concentration non-Newtonian settling slurries. Since pressure gradient and flow rate measurements alone are insufficient to adequately model the flows, an electrical resistance tomography (ERT) instrument developed by the University of Cape Town (UCT)was incorporated into the pipe test loop to determine pipe cross-section concentration and velocity profiles. The software developed to do this is modular and allows different image reconstruction and cross-correlation algorithms to be implemented and tested without significantly changing the rest of the application. At a total frame capture rate of 566 frames/sec a 2.67 GHz Intel Celeron processor with 500 MB of RAM is fast enough to calculate and display velocity profiles in ?real-time? at an update rate of one profile every two seconds. Examples of experimental concentration and velocity profiles obtained using the system are shown and some proposed improvements/extensions to the system are listed.

Jan 1, 2008

By Pekka Taskinen

Advanced optimizing control of the fluidised bed zinc roaster has been in use for an extended period at Boliden Kokkola and the implications are seen as extended bed stability, increased throughput and far better on-line availability. The roaster furnace control system developed is based on a dynamic and predictive furnace model, with parameters determined experimentally at the site. The controller maximises the concentrate feed and keeps the furnace operational parameters inside limits given by raw material mix and equipment constraints. The products of a zinc roaster, calcine, sulphur dioxide and the side products, such as mercury, meet gradually more stringent requirements, in particular as to their assays and total recoveries in the process chain. The end users of sulphuric acid in northern Europe, among others in the pulp and paper industry, require mercury levels much less than the conventional 0.2-0.4 ppm Hg. Therefore, secondary de-mercurising circuits have been used over the last five years for further cleaning the SO2 stream allowing production acid grades with less than 0.08 ppm Hg.

Jan 1, 2008

By T. Gerritsen, R. C. Delgado, J. Janzen, E. R. Veloza

The paper describes the components of an Integrated Furnace Control system for covered-arc (shielded arc) smelting with results from the recently started 75 MW Cerro Matoso Line 2 Furnace. The paper starts with a review of the mechanisms of power and feed input and heat losses in the shielded-arc smelting process, and describes how the details of the control system are tailored to the process. The control modules of a covered-arc smelting furnace are described including measured results and screen captures. This paper focuses on Integrated Furnace Controls tailored to shielded-arc smelting, but similar approaches have been recently applied to other furnace processes including immersed-arc smelting.

Jan 1, 2004

By M. A. van Nierop

Load behaviour in an industrial mill has been measured directly by inserting probes through liner bolts. The data from conductivity probes have indicated the presence of premature centrifuging during manipulation of the load mass. Overloading conditions were also encountered. Overloading and premature centrifuging both reduce the power drawn by the mill. These effects have been successfully modelled.

Jan 1, 1997

By M. du Plessis, D. F. Malan

"The aim of any mine design is to ensure that the excavations remain stable for the period they will be in use. Various pillar systems are used to ensure that underground stopes remain stable and that mining activities do not affect the surface infrastructure through either surface subsidence or seismicity. Intermediate-depth platinum mines make use of in-stope pillars designed to fail while the pillars are being cut at the mining face. The pillar stress exceeds the loading capacity and the pillars crush as a result. The aim of the paper is to provide an overview of in-stope crush pillars. This will include the application, behaviour, function, mechanism, impact, and design of a crush pillar system."

Jan 1, 2015

By J. M. Richards

For most of the 20th century optical petrography has been the primary petrological and mineralogical tool used to characterize coal. The development of quantitative SEM-based techniques, e.g. QEMSCAN®, for coal began only about a decade ago. The application of these techniques for coal lagged behind other commodities, but they are currently being developed with the aim to provide ?one complete analysis? for coal. Quantitative SEM-based techniques are supplemented by quantitative X-ray diffraction (XRD). Recent indications are that these more modern techniques cannot replace the ?standard? petrographic and chemical evaluations, but rather complement them where and when required. The great advantage of quantitative SEM-based techniques is that they are very rapid, with the result that large volumes of samples can be processed on a routine basis. This is ideal for coal type identification, since the results can be used in the creation of ?intelligent? composites. This can lead to the more speedy evaluation of coal deposits by reducing the number of samples on which detailed metallurgical and characterization test work is required, without an increase in the overall statistical error of the resource model. Coal petrography, however, remains important for the prediction of the coking characteristics of certain coals and coal products. As a consequence it is therefore important that any coal laboratory be able to produce data with confidence. This requires strict quality control and assurance protocols that adhere to international standards. Keywords coal petrography, coking strength, scanning electron microscopy, QEMSCAN®.

Nov 1, 2013

The risk associated with mining induced seismicity is one of the major threats to the safety and sustainability of deep underground mines. This paper describes techniques that allow site practitioners to efficiently control such risks in mines. The proposed approaches rely on ground support to strategically control seismic risk and re-entry time to tactically control this risk. The strategic approach is based on the detailed understanding of past seismicity to as certain the seismic hazard of individual sources throughout the mine. This approach also relies on assessing the potential damage that these sources can induce on nearby excavations using the excavation vulnerability potential (EVP) and rockburst damage potential (RDP) concepts proposed by Heal et al. (2006). It is then possible to investigate how to reduce the risk of experiencing damaging seismicity in mine drives by locally enhancing the ground support system. The tactical approach relies on a proposed methodology to estimate reliable re-entry times or exclusion periods based on the seismic decay following blasting. Some examples of how these techniques have been applied in Australian mines are given.

Jan 1, 2009

By R. Sullivan, K. Joiner, B. Emery, M. de Vries, F. A. Stober, L. R. Nelson, J. M. A. Geldenhuis

Keywords: Pyrometallurgy, smelting, converting, furnace design, furnace retrofit, high-intensity smelting, copper coolers, plate coolers, waffle coolers, tap-blocks, lower sidewall air-cooling, wall hold-down system, platinum group metals, ferroalloys, ferrochrome, ferrocobalt, ilmenite smelting, ironmaking, operational readiness, operational support The paper describes the development of furnace designs by Hatch in conjunction with the smelting plants in Africa to meet the intense process requirements in certain applications; continued improvement in operating efficiency through increased throughput from existing crucibles; and improvement in campaign life and furnace integrity. The era of Hatch in Africa has seen the doubling of furnace power in retrofit projects using existing crucibles to developing the highest intensity immersed electrode operations in the world. This has resulted in minimized OPEX and CAPEX per unit of production. Through the continued development of its cooling, binding and furnace power supply technologies and working with the experienced and knowledgeable personnel at the smelting facilities in Africa, Hatch has managed to meet the challenges of ever increasing furnace process requirements associated with increased power density and superheats prevalent in the operations. In addition to developing furnace crucible designs, Hatch has also intensified its ?after sales service and support? with the construction, commissioning and start-up technical assistance and operational readiness and operational support for ramp-up to nameplate capacity and beyond. The key areas of furnace risk associated with high superheat molten material tapping has also seen the development of diagnostic systems to mitigate risks and produce early warning signals for the operators.

Jan 1, 2006

By P. Kluge

Mining engineers frequently encounter complex design problems for which the critical components of the design are difficult to quantify or compare. Teams of people typically work on these designs and human perceptions and judgments play a strong role. To assist with this process, the analytical hierarchical process (AHP) as a decisionmaking tool is described in this paper. Although the technique is used in many other disciplines, it is currently not widely used in mining engineering in South Africa. To use the AHP process, the problem should be treated as a hierarchy that defines the goal, the alternatives to reach it, and the criteria for evaluation of these alternatives. Pair wise comparisons are conducted on the criteria of the hierarchy to establish priorities. The value of the technique is that it is simple to test for consistency amongst the pair wise comparisons to ensure that the answer obtained is better than that provided by a random selection. To illustrate the technique, the use of a backfill support system in a platinum mining project was investigated. Ten design parameters, which will be impacted by the use of backfill, were identified and weighted according to their relative importance. The result of the AHP evaluation was that the use of a backfill support system should be preferred to a conventional support system at the mine.

Jan 1, 2011

By Mark Coleman

Pnuematic Conveying and Process Injection Technologies have been implimented in the metals markets for the last 40 years and have consideribly improved the productivity and the performance of many processes. There have been many steps forward in handling technology and this paper seeks to consider those now offered by Clyde Materials Handling who as an established customer-driven solutions provider, which has turned its attention to supporting the Metals Market. Clyde seek to utilises its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries. With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets. Operators within the metals market have developed and deployed pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustain-able solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes. Operators, such as Codelco in Chile, Corus Steel in the UK, and many others across the World have seen pneumatic injection solutions transform their process and costs. To inject a consistent, pulseless and accurate flow of material to a copper concentrate bath smelter, or injecting granular or pulverized coal as a coke substitute in to a blast furnace via the Tuyeres helps to increase the operational capacity, availability and productivity and reduce the cost of the operation. This paper will discuss and highlight the ways in which pneumatic conveying and injection technologies, created by Clyde Materials Handling, and applied in partnership with the customer, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Lead and Zinc Industries. With examples from Zinc Fuming in Australia, Zinc Calcine and Powder Handling in Korea, Precision coal injection to QSL and TSL Furnaces, and metered distribution of Zinc Calcine to Reactors.

Jan 1, 2008

The 107th Annual General Meeting of The South African Institute of Mining and Metallurgy was held at The Country Club, Johannesburg, Napier Road, Auckland Park on Wednesday, 11 August, 2004. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations, also to recipients of awards, senior members of industry, Honorary Life Fellows, past-presidents, our members and other guests, among them the following: Ralph Bagirathi, Executive Member, African Mining Association Rudi Rudolph, President, Association of Mine Managers of South Africa Andrew Whibley, President, Association of Mine Resident Engineers of South Africa Dr Con Fauconnier, President, Chamber of Mines of South Africa Nxolisi Diliza, Chief Executive Officer, Chamber of Mines of South Africa

Jan 1, 2004

Analysis for pillar extraction potential (A-PEP) is an intelligent tool, which could be used as a preliminary output indicator when considering the secondary extraction of regional support pillars in the Witbank and Highveld coalfields of South Africa. The safe and economic extraction of underground coal pillars is of paramount significance and importance to the South African coalmining industry to ensure continuity of supply of this fossil fuel. Pillar extraction practices in South Africa have been responsible a significant proportion of safety and fatality statistics in relation to its relative output (less than 5 per cent of total South African coal production) and, as a result, research was undertaken in local pillar extraction operations and extended to similar operations in New South Wales, Australia to assess a way forward for pillar extraction in South Africa. It was found that, although little in the way of new technologies has emerged in this field in the recent past, significant contributions could be made in the field of risk analysis to obtain a generic design methodology for pillar extraction in South Africa. The resultant A-PEP tool to assess pillar extraction potential is based on certain physical, risk and economic factors, which combine to indicate operational success in terms of economic, health and safety attributes. At the time of A-PEP?s development there was alack of operating underground coal pillar extraction operations, which made it difficult to validate its applicability. Since then, however, A-PEP has been successfully tested and validated against two unique underground coal pillar operations, which is the discussion of this paper. One operation is situated in the Witbank coalfield and is extracting pillars, which are 20 years old and at a depth of 80 metres below surface, while the other operation is situated in the Highveld coalfield-which is extracting 6 month-old-pillars underneath a massive dolerite sill at a depth of 220 metres. A-PEP has shown that its predictive nature is consistent the workings at both operations, irrespective of their unique conditions, and as such it can be successfully used as a mine planning tool. The A-PEP mine planning tool thus represents a positive step toward an integrated approach to underground coal pillar extraction when considering legal and operational aspects, which could form the basis for legislative guidelines when considering the future of pillar extraction in South Africa.

Jan 1, 2005

By A. Patri, D. S. Nimaje

Wireless sensor networks and wireless communication systems have become indispensable in underground mines. Wireless sensor networks are being used for better real-time data acquisition from ground monitoring devices, gas sensors, and mining equipment, whereas wireless communication systems are needed for locating and communicating with workers. Conventional methods like wireline communication have proved to be ineffective in the event of mine hazards such as roof falls, fires etc. Before implementation of any wireless system, the variable path loss indices for different workplaces should be determined. This helps in better signal reception and sensor node localization, and also improves the method by which miners carrying the wireless devices are tracked. This paper proposes a novel method for determining the parameters of a suitable radio propagation model, which is illustrated with the results of a practical experiment carried out in an underground coal mine in southern India. The path loss indices, along with other essential parameters for accurate localization, have been determined using the XBee modules and ZigBee protocol at 2.4 GHz frequency.

Jan 1, 2015

By A. M. Hearn, J. R. Henning, A. S. J. Van Rensburg

The lining, together with the electrodes, forms the heart of the operation of a submerged arc furnace. Subsequent to a lining failure on M12 furnace during the early 1980s, Metalloys was active in investigating the concept of thermally efficient ?freeze? linings for its furnaces. The theory revolved around that, not only would, thermally efficient linings result in significant cost savings, but they would also last longer as a result of being subjected to less harsh operational conditions. After having proved the concept on the .smaller. furnaces, Metalloys decided to implement the concept on its largest submerged arc furnace, M12 Subsequent to having recovered from an impending failure of a lining installed in 1981 in M12 in the mid 1980s, Metalloys managed, through rigid lining management, to extend the life of this lining to 1999. At the end of 1999 the decision to replace the lining in the furnace with a ?freeze? lining was made and planning and design proceeded in earnest. This paper discusses the options considered in making the final decision. The features of the design of the lining are also discussed. Consideration is given to the furnace shell cooling system as a result of its importance in maintaining the thermal equilibrium in the lining. Note is made of the fact that the purchase of a .freeze. lining is an expensive exercise but that the time savings in the installation of the lining and the efficiency improvements during operation far outweigh the additional capital cost. The experience on M12 has been that the payback period of the marginal capital expenditure is less than three years. As a result of the opportunity to reline a furnace the size of M12 not presenting itself very often, the learning points from the installation of the lining and the operational advantages and disadvantages are significant. Finally, the point is made that the project had its pros and cons but overall the success of the project has been evident and, as such, the ?freeze? lining is likely to become the norm at Metalloys.

Jan 1, 2004

By Z. Saw, C. Poveda, N. L. Mai

Optimising the throughput of a mining network comprising all equipment from shovels to semi-autogenous grinding (SAG) mills is a complicated task, yet the potential benefits can be significant. Key modelling challenges stem from the sheer number of possible routes which material can travel, different equipment operating under different constraints, and the rate of SAG mills being calculated through a nonlinear function of the blended materials’ rock attributes. Nevertheless, this is an ideal onapplication area of mathematical programming, a branch of operations research. This paper describes an application of mixed integer linear programming (MILP) to optimise the mining equipment network of one of the world’s largest copper mines.The model takes as input a year-long monthly mine schedule of shovels in different pits, pushbacks, sequences and faces which produce material to be moved through a network of crushers, conveyors, silos, distributors, stockpiles and SAG mills, ultimately outputting a daily operational plan for all equipment that maximises the throughput of the network. All operational constraints and business rules are considered, including three quality attributes of copper ore. Comparing model results with actual data shows an improvement of 4.47% in network throughput tonnage. Additionally, although the model is solved using a free, open-source solver, optimal solutions are still achieved within a practical timeframe.

Sep 1, 2021

An effective electrowinning process in hydrometallurgical industry requires fluoride levels in the base metal solution to be less than 10 mg/l. Selective removal of the fluoride ions from base solution is thus desired, if fluoride was added to control calcium and magnesium in the circuit. Consequently, adsorption of fluoride onto activated alumina was studied in a batch and a column set-up. The effects of base metal solution pH, temperature, initial concentration and flow rate on activated alumina performance were investigated in either a batch or column configuration. A two-level factorial experimental design was implemented in studying column dynamics. Results demonstrate that activated alumina is an effective adsorbent for selective removal of fluoride from base solution. In the batch operation, fluoride was removed to values below the maximum allowable concentration (10 mg/[l]) when pH was = 8. In the column adsorption step at 55°C and 600mg/[l] initial concentration, up to 16 bed volumes were processed before breakthrough level was reached. Desorption step using 1% sodium hydroxide solution achieved an elution of 8 bed volumes. The activated alumina (AA) had a capacity of 8.65 gF/[l]AA at the 10mgF/[l] fluoride breakthrough level during the column adsorption test. Keywords: Fluoride; activated alumina; adsorption; recovery; regeneration.

Jan 1, 2009