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By I. J. Geldenhuys

South Africa’s mining and metals industries have an illustrious history dating back to the Late Iron Age. We live in a complex and data-intensive world that has already fundamentally changed how we work and live. The outbreak of the global COVID-19 pandemic in 2020 resulted in immeasurable suffering worldwide, but the crisis also accelerated many technological developments and altered the way we think about, and experience, technology and work. Problem-solving requires new and rapidly changing skills to manage the data tsunami. Whether at the rock face or on the processing plant, the fundamentals have not changed, although how we interact with minerals and their properties has changed dramatically. Sustainable processing and design are non-negotiable if we genuinely want to achieve the aim of the cradle-to-cradle principle. As we venture forth, what can scientists, engineers, technologists, and mathematicians learn from history? History is data presented in a context; sometimes, the context is also important. We exist in an age of data, with most of the world’s data created in only the past two years. History can enhance our understanding of the present and enhance our future outcomes. Lessons from history can help provide insights into making ethical and sustainable choices related to technology or engineering in the mining and metallurgical industry. Shifting the perspective of mining and metallurgy professionals from a narrow focus on complex technical solutions towards a broader context for problem-solving and designs that includes the entire ecosystem is crucial. In other words, using or reflecting on historical process development is, at its core, systems thinking.

Sep 1, 2021

By Brian W. Mackenzie

The mineral exploration environment has observable economic characteristics, the assessment of which provides guidelines for exploration planning in the mining company. The long-term survival of the mining company is directly dependent on successful exploration. Exploration planning contributes to successful exploration through the development of exploration strategies. The objective of exploration planning is to select exploration environments which will enable the mining company to realize best possible profit and corporate risk conditions. Thus, the formulation of exploration strategies is based on profit and corporate risk criteria. Strategic considerations include the selection of commodities as exploration targets, geographic concentration of exploration effort, the realization of acceptable survival conditions, and the structuring of an exploration programme to optimize the economic benefits of the exploration investment process.

Jan 1, 2014

By F. Mwaura

"The aim of the audit was to determine whether the mining project environmental impact assessments (EIAs) in Kenya are undertaken according to international best practice. A sample of 50 EIA reports for the 2007–2016 period was evaluated using 18 criteria in the Environmental Law Alliance Worldwide (ELAW) guidelines. The findings showed that only two criteria were considered ‘excellent’ according to the ELAW guidelines, namely baseline environmental assessment and prediction of physical impacts. Six criteria were found to be ‘satisfactory’, including prediction of social impacts, analysis of alternative options, and impact mitigation. The reports were quite weak in terms of: consideration of all phases in the mining cycle, environmental regulatory framework, prediction of biological impacts, stakeholder consultation and engagement, integration of human right issues, and integration of climate change and cost-benefit analysis. It is therefore recommended that the Kenyan National Environment Management Authority (NEMA) should consider tightening the EIA terms and conditions in the approval of statutory terms of reference (ToR) for full-scale mining EIAs to ensure improved performance of EIA as a tool for environmental protection. IntroductionThe nexus between society and the environment has continued to generate interest because the environment is the source of goods and services that sustain the various needs of human beings as outlined in the UN sustainable development goals (SDGs) (Armstrong and Peart, 2000; Sutton 2004; Chakrabarti 2007; Strange and Bayley 2008). All the five generic categories of societal needs, namely physiological needs (food, water, clothing, medicines, etc.), residential and occupational needs (shelter, transport, energy, etc.), economic needs (tradeable goods and services), leisure and recreational needs (tourism), and cultural and spiritual needs (e.g. sacred resources and ecosystems) (Mwaura et al. 2016) are addressed by the environment. Consequently, a wide range of development sectors have been established around the world in order to address the above needs (Lederer, Galtung, and Antal, 1980; Rammelsberg et al., 2006; Noonan, 2014). All these development sectors rely entirely on the environment for their proper functioning, as shown in Table I."

May 1, 2019

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 L. J. Olivier

The possible closure and subsequent flooding of South Deep Gold Mine?s (SD) neighbouring Randfontein Estates Limited No. 4 Shaft (REL 4) necessitated the construction of five concrete plugs in the connecting tunnels to prevent the ingress of groundwater into REL4 from flooding SD. This paper describes the proposed controlled flooding of REL 4, the planned in-service monitoring of the five plugs and the water barrier between REL 4 and South Deep Mine, and the long-term maintenance of the plugs and rock mass in the immediate vicinity of the plugs.

Jan 1, 2006

By E. V. Lilford

A number of countries have introduced codes governing the valuation of mineral assets and securities. The African continent will follow suit in due course considering the importance of the global minerals industry as it relates to the attraction of foreign investment. South Africa is to introduce the Petroleum and Minerals Development Bill legislating the involvement of previously disadvantaged individuals and communities in the country?s minerals industry. One of the challenges facing the successful implementation of such codes and bills lies with the abilities of independent valuators to value mineral properties and projects on a consistent basis. Certain valuation principles and methodologies are applicable in all jurisdictions in the minerals industry. These valuation tools and principles are considered and developed in this report. They have been discussed and developed to encourage minerals valuators to consider and consistently apply the most applicable valuation methodologies.

Jan 1, 2002

By R. Mumbi, M. Peart, E. Arinaitwe, B. Mbao, J. Zulu

Since 1925, xanthates have been widely used in sulfide flotation due to their low cost, ease of manufacture, and ability to float most value species. However, the industry's increasing need for safer and more selective alternatives, driven by low head grades, poor-quality, difficult-to-process ore with complex mineralogy, and stricter environmental regulations, has led to the development of Solvay's AERO® XR series of collectors. These custom-formulated products are based on greener chemistries and offer metallurgical benefits that are similar to or better than those of xanthates, without the safety concerns. Developed through Solvay's Flotation Matrix (FM) 100 approach, the XR series collectors are suitable for a wide range of applications, including the processing of Cu, Zn, and Cu-Ni, as well as the flotation of precious metals. This paper will highlight the differences between xanthates and XR series collectors, and present case studies of their successful commercial application at various global operations.

Jan 1, 2023

By R. G. B. Pickering

The hard rock gold and platinum mines in South Africa have seen little development in the technology of mining. Holes are still drilled in the rock?though the latest water hydraulic rockdrills will complete that task in two minutes compared with the eight hours for hand drilling. Charging up is with far safer explosives and with available initiation systems it is no longer necessary to run up the face lighting each fuse. Movement of rock in the stope is predominately by means of scraper buckets and scraper winches?these were first introduced in the 1920s. Support is still mainly rock, either in situ pillars or backfill, or alternatively wood. Just as the mining process has changed very little it is hardly surprising that the productivity of mining is also relatively unchanged. Major efforts have been made to mechanize the mining process. However, most of the narrow reef mines where ?trackless mechanized mining? was introduced in the early1980s have reverted to conventional mining. In the wider reefs mechanized mining is the option of choice, unfortunately most of the gold and platinum mines have very narrow reefs that are not suitable to ?off the shelf? equipment. The move to introduce room-and-pillar mining into the narrow UG2 reefs is at the expense of mining more waste with the reef, fortunately it appears that appropriate waste and reef separation processes are available. Room-and-pillar mining followed by long hole drilling and blasting of a narrow slot of reef out of the pillars currently appears to offer the best of both worlds?maximum reef recovery with minimum waste dilution.

Jan 1, 2002

In surface mining operations, ultra-heavy trucks operate on haul road networks which are typically from 10?40 km in length. These road networks are often not optimally designed and maintained and as a result, identifying and remediating road functional defects is problematic. Most surface mine operators agree good roads are desirable, but find it difficult to translate this into an effective road maintenance system. This paper presents a haul road maintenance management system which utilizes an assessment of rolling resistance based on a functional performance evaluation of a haul road, together with mine haul truck operating cost models to derive the optimal frequency of road maintenance. A typical application is presented which illustrates the potential of the technique to manage maintenance as and where needed with resultant reduction in total road user costs and an improvement in service provided for the road user. Keywords: Haul road, surface mining, road maintenance, transportation, pavement design

Jan 1, 2003

By R. E. Wilmot

The problem of corrosion of reinforcement in concrete structures is internationally recognised and represents the single biggest expenditure in the preservation of steel reinforced concrete structures. While the corrosion protection of the reinforcing steel is no substitute for design and the placement of good quality concrete, it does provide for a viable and economical extension of structural integrity and service life in the day-to-day and practical environment in which concrete structures are constructed. The mechanism of corrosion attack and consequent deterioration of reinforced concrete structures is well understood and documented. New structures can be designed and built to withstand corrosion. However, due to short-term economical restraints, many new reinforced concrete structures continue to suffer as a result of corrosion damage, which results from the corrosion of the steel reinforcing. This paper explores the economic and practical benefits offered by the application of hot dip galvanizing as a viable means of protecting reinforcing steel concrete structures. The paper also discusses technical misconceptions that exist with respect to the application and performance provided by the use of hot dip galvanized reinforcing steel.

Jan 1, 2006

By R. J. Hundermark

Keywords: Anglo American, Anglo Platinum Ltd, Waterval, Mortimer, Polokwane, ACP, pyrometallurgy, platinum, PGMs Anglo Platinum Ltd is the largest primary platinum producer in the world and operates three smelters in South Africa: Waterval, Mortimer and Polokwane. The operational details of the smelters are covered in previous reviews, thus only unit operations that have been upgraded are discussed. The most significant of the upgrades include the installation of a second ACP converter at Waterval Smelter in 2006 and the anticipated upgrade of Mortimer Smelter to 38MW in 2011. Several advances have been made in the smelting operations to improve the furnace stability and longevity. Control of the chromium input to each of the smelters has substantially allowed continued operations at levels below the spinel saturation point in slag, which results in lowered matte and slag temperatures. Mogalakwena concentrate, arising from the Platreef ore, is used to dilute high chromium-containing concentrates. In addition, furnace controls have improved in terms of crucible temperature and condition monitoring, improved feeding control, management of alarms and trips and having the quality of instrumentation and operational rigour required to support this. Advances have been made on the ACP converter in terms of good converter matte quality, and increased intensity and efficiency of operation. Combined with improvements to both the conventional and tower sulfuric acid plants, the emissions from Waterval Smelter have been reduced substantially since the introduction of the ACP. This is in spite of increasing metal throughput. The Anglo Platinum Ltd smelting operations have made significant progress since 2006 and further advances are envisaged to further improve on safety, reduce costs, increase efficiencies and throughput, while reducing emissions.

Jan 1, 2011

By L. Rojas Mendoza, F. J. Hrach, A. Gupta, K. P. Flynn

ST Equipment & Technology (STET)’s tribo-electrostatic belt separator technology allows for the beneficiation of fine mineral powders by means of an entirely water-free technology with high throughput and low energy consumption. The STET separator is suited for separation of very fine (<1 μm) to moderately coarse (500 μm) particles, in contrast to other electrostatic processes that are typically limited to particles >75 μm in size. STET has performed exploratory studies with several iron ores including tailings and experimental results to date have demonstrated that low-grade iron fines can be upgraded by means of STET tribo-electrostatic separator to commercial grades (58-65%Fe). Experimental results together with high-level economic evaluations indicate that scavenging processes involving low drying costs, DSO operations and tailings beneficiation offer a commercially viable processing method to recover fine iron that would otherwise be lost by traditional processing. Dry electrostatic processing of iron ore presents a clean, low-energy opportunity for iron producers to reduce costs and wet tailings generation associated with traditional gravimetric, flotation and wet magnetic separation circuits. Moreover, STET technology allows for mining waste utilisation and resource recovery from iron ore fines and tailings, therefore offering processors a novel method to recover fines that would otherwise be difficult to process to sellable grades with existing technologies. Keywords: Iron fines, industrial minerals, dry separation, calcium carbonate, talc, barite, quartz, tribo-electrostatic charging, belt separator, fly ash

Jan 1, 2020

By J. Pelders, G. Nelson

"Fatigue is a significant concern in the mining industry as it is a causal or contributing factor in many incidents and accidents. Fatigue can be caused by work- and non-work-related factors. There is a lack of information about associations between demographic and other non-work factors, and fatigue. This study aimed to assess associations between demographic, work, living, and socioeconomic conditions, and lifestyle characteristics, and fatigue at a platinum smelter in South Africa. Eight interviews with management and two focus groups with production workers were conducted, and 75 questionnaires were completed by production and other workers. Both work- and non-work-related factors were considered to be causes of fatigue. These factors included overtime, shift work, high workloads, activities performed outside of work, age, race, housing tenure, diet, sleep disorders, stress, and job satisfaction. In general, higher levels of fatigue were reported by younger participants, those who rented accommodation, ate less healthily, had a sleep disorder, and those with high levels of stress and low job satisfaction. As various demographic, lifestyle, and wellness-related factors were associated with fatigue, both work and non-work contributors should be addressed in fatigue management plans. BackgroundFatigue may be defined as ‘a state of impaired mental and/or physical performance and lowered alertness arising as a result of, or a combination of, hard physical and mental work, health and psychosocial factors or inadequate restorative sleep’ (BHP Billiton, 2005). Williamson et al. (2011) define fatigue as a biological drive for recuperative rest. Sleepiness and fatigue are related, and the terms are often used interchangeably. However, sleepiness, more specifically, can be defined as sleep propensity, or a person’s tendency to fall asleep (Hossain et al., 2003; Shen, Barbera, and Shapiro, 2006).Increasing levels of fatigue and sleepiness are associated with lapses in attention, errors, response slowing, fluctuations in alertness and effort, and impaired attention, working memory, long-term memory, decision-making, and creativity (Alhola and Polo-Kantola, 2007; van Dongen and Dinges, 2000). Fatigue is also associated with adverse effects on mood and impulsive behaviours (Alhola and Polo- Kantola, 2007; Minkel et al., 2011; Schwarz et al., 2013). It is a significant concern in the mining industry as it is commonly identified as a causal or contributing factor in many accidents and injuries (Schutte, 2009). Fatigue can also lead to long-term health problems, including digestive problems, heart disease, stress, and mental illness (Shaw, 2003)."

Mar 1, 2019

A wide range of drill holes and process streams are sampled for resource estimation, grade control, and contractual purposes in the minerals industry. However, despite the availability of training courses, conferences and both national and international standards on correct sampling practices, it is still surprising how often little attention is given to ensuring that representative samples are collected for analysis. The reason for this is that the responsibility for sampling is often entrusted to personnel who do not appreciate the significance and importance of sampling, with cost being the main driving force rather than whether the sample is representative of the material from which it was extracted. This seriously undermines the precision and accuracy of the analyses subsequently generated and can render the analysis process a total waste of time and money and expose mining companies to serious, potential, financial losses. Company management needs to reverse this situation and ensure that sampling is given the attention it deserves to generate representative samples for analysis.

Jan 1, 2010

By J. Daraisme

Société le Nickel (SLN) exploits the Dôme lateritic nickel orebody at its Tiébaghi operations in New Caledonia. The site geology has an obvious bearing on recovery and metallurgical performance, and the controls are extremely complex at all scales: lithology, oxidation-reduction conditions, mineralogy, and multivariate geochemistry. In that context, establishing an adapted recoverable resource estimation method that is efficient and transparent proves an interesting challenge. The method must address the key notions of: ? Support effect: the exploration data-set can only warrant the estimation of large panels 20×20×3 m3, which are much larger than the selective mining units (SMUs) of 5×5×3 m3 ? Information effect: the selection at production stage uses estimates based on information much denser than that available for mine planning. The problem is rendered more complex in this type of deposit by the fact that the additive variables used for any estimation process (metal accumulation and ore tonnage) are not the ones used to establish the selection at mining stage (i.e. the nickel grade of SMUs, which is the ratio of accumulation on tonnage). Eventually, the selection criteria involve not only Ni grades but also other constituents such as Al2O3, Fe2O3, MgO, and SiO2. The solution presented in this paper is the construction of a platform of SMU multivariate simulations in the saprolitic horizon, together with efficient post-processing aimed at producing the multivariate recoverable resource estimates. The efficiency constraints imposed by the number of blocks to be simulated (1.5 million) lead to resorting to direct block simulations. The underlying multivariate discrete Gaussian model (DGM), the validity of which is tested beforehand, is put to good use to mimic the selection process at the mining stage, by offering the ability to simulate in each block a composite value located at random within the block. Finally, the paper presents the application of a scenario reduction algorithm to pick a representative subset of a few simulations to help appraise the risk attached to the downstream phases (reserve optimization, mine sequencing) of the project. The implementation presented here is for the first generation of the Scenario Reduction plugin built in Isatis software, where measuring the distance between the initial set of scenarios and the reduced set is based on Ni quantities only. Research is under way to adapt the measure to the true multivariate nature of the problem.

Jan 1, 2014

By K. Y. Lee, J. M. Park, C. W. Park

Laboratory-scale experiments were carried out to investigate the effect of ladle slag composition on the decreasing behaviour of aluminum content in steel, i.e., reoxidation of molten steel in contact with slag, using a vertical tube furnace. The steel composition and the slag system chosen were for ultra low carbon and CaO-Al2O3-FeO-MnO-MgO based to simulate ULC steel grades. It has been observed that the reoxidation rate shows a good relationship with (T. Fe) content in slag. In case of (T. Fe) content higher than 1.5 weight per cent, the reoxidation rate increases linearly with increasing (T. Fe) content. For a given (T. Fe) content, it decreases with the increasing (CaO)/(Al2O3) ratio of the slag. However, in the case of (T. Fe) content lower than 1.5 weight percent, no particular relationships are observed between the reoxidation rate and (T. Fe) content or the (CaO)/(Al2O3) ratio of the slag. These results were used to propose for an aim a slag composition for the ULC steel grades in a steelmaking plant. Keywords: slag deoxidation, slag killing, slag composition control, IF steel, ULC steel grade

Jan 1, 2004

"Coal seam gas problems can adversely affect the safety and productivity of underground coal mines, leading to fatalities and financial losses. Conventional gas management technologies using ventilation and gas drainage are unable to deal with the high and irregular gas emissions associated with high-production longwall mining. New technologies need to be developed to supplement the traditional gas management techniques to minimize the hazard of coal seam gas. Thin spray-on liners (TSLs) have gained some success for rock surface support since their introduction to the mining industry. Due to their relatively low permeability and appropriate mechanical properties, TSLs also show potential to be used as a gas management tool in underground coal mines.In this paper we review the current gas management challenges and discuss the potential use of TSLs as a gas management tool in underground coal mines. This may involve reducing gas migration into the excavations/roadways, enhancing in-seam gas drainage, and preventing spontaneous combustion. Some potential areas for future research work are identified. IntroductionWhen a coal seam is influenced by mining activities, gas stored inside is liberated into the underground ventilation system. Gas emissions have created serious difficulties for the coal mining industry around the world. Therefore, coal mines have to develop effective strategies to control the gas concentration below the threshold value to meet statutory requirements. Ventilation has been the first solution in gas management for underground coal mining. When the emitted gas cannot be effectively diluted by ventilated air, gas drainage using pre- and/or post-drainage has to be introduced. However, even with ventilation and gas drainage, irregular gas emissions usually increase the gas concentration in roadways and slow down the development rate, thus causing significant economic loss to the coal mining industry (Thakur, 2006). Therefore, new technologies need to be developed to address this issue and mitigate the explosion risk."

Jan 1, 2016

By M. G. Senyur

This study aims at investigating the structural characteristics of backfilling material. In this regard, spatial arrangement of solid particles and associated voids in a unit mass of coal mine refuse as backfilling material were tested. The materials were produced from coal mine refuse of Zonguldak Colliery, Turkey. The experimental procedures were developed to determine their void ratio (or its equivalent porosity), bulk density and the shape properties of constituent particles. The orientation fabric and the co-ordination number were the other two fabric elements determined. The filling materials were sieved and their particle size distributions were found. The results obtained by experiments were related to the particle size distribution parameters, namely, the coefficient of uniformity and the effective size. It was concluded that mean value of void ratio is correlated with coefficient of uniformity. The standard deviation of porosity as an index of fabric heterogeneity is clearly correlated to effective size. By an original experiment, the frequency distribution of coordination number was observed as binomial in uniformly graded materials. Also, the co-ordination numbers of test mixtures were calculated by the Marsal method and results obtained showed a good correlation between the minimum particle size and number of contacts per unit area.

Jan 1, 1998

By W. Mackenzie

The development of a resource project inevitably requires the investigation of a vast range of issues across most engineering disciplines - mining, metallurgical, chemical, civil, electrical, mechanical and environmental - as well as the geosciences. It is also a characteristic feature of the resource industry that no two orebodies - and hence no two development projects - are the same. So these technical issues have to be addressed to a greater or lesser extent in evaluating any resource project&apos;s development potential. Not surprisingly then, technical issues tend to predominate when assessing the development potential of a project in the process typically referred to as `doing a feasibility study&apos;. But the principal purpose of a `feasibility study&apos; is to determine whether a development opportunity makes good business sense, not just whether it is technically possible. Resolution of technical issues is often seen as the primary focus of a feasibility study, whereas in reality, these technical issues are the basis upon which an asset delivery and business plan is built. This is not to say that technical issues are unimportant - they are a prerequisite to the demonstration of a project&apos;s viability. The feasibility study process must therefore demonstrate that not only have the technical issues been satisfactorily addressed, but also that the broader commercial, economic and social issues have been considered in the development of a comprehensive business plan, which includes an assessment of the risk-reward profile of the proposed development. This paper will present a framework for the conduct of `feasibility studies&apos; and provide guidance to minimum standards and best practice.

Jan 1, 2007

By K. C. Naidoo

There are two main types of densifying cyclones currently available in the market, namely polyeurethane (PU) and ceramic. The PU densifying cyclones are currently used throughout the Grootegeluk complex and coal beneficiation in general. It has been identified that PU densifiers wear relatively fast depending on the operating pressure and need to be replaced frequently as a result. The motivation for this paper is to achieve an increase in the densifying cyclone lifetime through less wear and an increase in efficiency resulting in the ability to build higher relative densities (RD) more quickly. This will allow for a reduction in downtimes due to replacing densifying cyclones as well as building RD and a reduction in the operating costs associated with replacing worn densifying cyclones. Some of the major findings of the study indicated that the ceramic cyclone theoretically undergoes less wear than the PU cyclone, but since wear is application-specific and was evaluated, the wear on the polyurethane cyclone was found to be minimal. The RD differential is higher on the PU cyclones than the ceramic cyclones, showing that the PU cyclones perform better in a densifying application. This is the first test conducted on this application and type of cyclones. It should therefore be noted that having the PU cyclone significantly outperform the ceramic cyclone was not expected, due to the only change being the material of construction. This is an indication to take the material of construction into account when selecting cyclones as it can have a significant impact on the cyclone performance in specific applications. Keywords: Ceramic, cyclone, densifying, density, dense medium, polyurethane, wear

Jan 1, 2020