Electronic Theses and Dissertations (Masters)

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Benefits of using Internet of Things technology for fuel management at a mechanised underground platinum bord and pillar mine: A Bathopele mine case study
(University of the Witwatersrand, Johannesburg, 2024-01) Thema, Sephela Makete; Cawood, Frederick; Feroze, Tariq
The advent of the fourth industrial revolution, Environmental Social and Governance (ESG), and push for green energy transition has propelled mining companies to reconsider their strategies. Over the past two decades, mining companies along the Bushveld Igneous complex in South Africa have been shifting towards mechanized mining methods which are generally safer and provide for the generation of greater volumes of output. Sibanye Stillwater’s Bathopele mine, which has a fleet of over two hundred and fifty (250) trackless mobile machinery (TMM) and a daily fuel consumption of approximately ten thousand (10 000) liters per day. The introduction of Internet of Things (IOT) technology in the fuel management system at Bathopele mine achieved benefits such as fuel consumption tracking, effective inventory management, prevention of fuel theft, detection of fuel leaks, determination of maintenance requirements and readily available access to fuel use data. This access to data enabled the mine to effectively apply for fuel use rebates from the South African Revenue Services (SARS) with ease. To determine the impact of the increased distance to underground working places on the refueling of TMM, the Theory of Constraints (TOC) method, qualitative and quantitative techniques were applied. A bivariate analysis conducted indicated a linear relationship between fuel consumption and production output at Bathopele mine, which suggests that an effective fuel management system had a positive impact on production output at the mine. A real-time or near real time model for fuel management in underground trackless bord and pillar mines in proposed.
A comparison of various modelling techniques to optimise production rate on a platinum mining project
(2021) Dreyer, Jaco
Every business aims to create an optimal economic value for its shareholders. The production rate is one of the critical drivers of value in the mining business. Several approaches have been developed to determine the production rate for mining operations. This study applied three approaches for determining production rate, namely the tonnage-based, microeconomic and marginal-analysis modelling methods. These methods were applied on a platinum project, and the production rate results from the three methods were used to determine the life of mine (LOM) production profiles, capital expenditure (CAPEX) and operational expenditure (OPEX). These results were then used as inputs into a discounted cash flow (DCF) model. The DCF model results were compared and analysed to determine a production rate determination method that results in an optimum production output rate for the project. The study revealed that the tonnage-based modelling technique resulted in the highest production rate of 410-kilo tonnes per month (ktpm), the highest CAPEX of USD957.24 million, the lowest OPEX of USD75.37 per mined tonne, the highest net present value (NPV) of USD63.12 million and the highest internal rate of return (IRR) of 12.85% over a 40-year LOM. The microeconomic modelling technique ranked second with a production rate of 270 ktpm, CAPEX of USD 726.24 million, OPEX of USD 76.68 per mined tonne, NPV of USD 3.46 million and IRR of 10.17%. The marginal-analysis modelling technique ranked last with a production rate of 230 ktpm, CAPEX of USD 658.76 million, OPEX of USD 77.83 per mined tonne, NPV of USD -10.69 million and the lowest IRR of 9.47%. Mineral Resource tonnage-based modelling may be further investigated in other commodities other than platinum or other multi-element/polymetallic mineral deposits in line with the South African mining industry. This will result in the formulation of industry-specific calibration in the South African mining industry
Geometallurgical influence of clays on the Jwaneng kimberlite value chain
(2024) Nkgakile, Naomi
Geometallurgy is a cross- disciplinary function that provides a better understanding of the ore characteristics impacting the treatability of the material. Optimal treatment of the material is enabled by understanding variability in the ore body. Having this understanding leads to flexibility when planning mining mixes. The present investigation of the Jwaneng DK2 deposit’s geometallurgical responses demonstrate that various rock lithologies impact the treatability of the Jwaneng kimberlites. The plan t is therefore hindered from achieving design capacity as a result of its treatability constraints. The volcaniclastic kimberlite, which is a majority- treated lithology at Jwaneng Mine, contains the highest volumes of smectite clays. These clays cause settling challenges resulting in higher consumption of processing materials. To allow for informed strategic planning, all vital treatability information on the clayrich kimberlites needs to be collected. The clay occurrence can then be incorporated into the creation of the geometallurgy model. Then the completed geometallurgical model can be utilised as a predictive tool for planning
Improving open pit mine economics through ultimate pit slope optimization: case study of Pickstone-Peerless mine
(2024) Nyamande, Pardon
In most open pit mining operations the need to create stable pit slopes and the influence of the overall pit slope on the economics of such an operation is highly appreciated. Despite such knowledge many open pit mines are designed with little or no geotechnical investigations being carried out so as to come up with an optimized pit slope in line with site specific conditions. This can lead to under or over estimating pit slope angles. Conservative (too gentle) slopes result in high stripping ratios therefore a high operating cost. Slopes too steep may result in slope failures, which may lead to high operating costs or premature mine closure. This project emphasises the importance of geotechnical investigations not only for safety reasons but for economic reasons as well. A case study of Pickstone Peerless mine was used. Geotechnical data was gathered through core logging and face mapping of the existing pit. The data gathered was then used for stability analysis employing empirical, kinematics, limit equilibrium and numerical modelling. Rocscience software packages were used for numerical based analysis. From the results obtained it was concluded that it is possible to steepen the current 52o overall pit slope angle of the Peerless pit by 1o without compromising stability at both bench and regional scales. This will be possible provided adequate slope management practices are put in place and adhered to. The steeper slope would have saved the mine more than 2,681,110 m3 of waste stripping, translating to in excess of $12,064,995.00 (USD) in financial savings for the existing pit. The steeper angle applicable to the current pit may not be appropriate to the pit extensions. Further geotechnical evaluations should be done on suitably positioned and spaced boreholes in the area of the extension, to verify the stability of steeper slopes in that area. The analysis done as part of this project was used to show that the current pit can be deepened by 5 m without a push back.
Optimisation of fragmentation at south deep gold fields mine: a case study
(2020) Nong, Matsobane
A fundamental aspect of an efficient mining operation is the steady movement of material throughout the mine system; particularly the flow of ore from the upstream excavation point to the downstream processing or stockpile site(s). This can be achieved by attaining an optimal fragmentation size from drilling and blasting suitable for subsequent mining process such as loading, hauling and crushing. Drilling and blasting are the first fragmentation process and is currently the most economical technique of fragmenting hard and competent rock especially for deep-level mines where operational costs are high. The aim of this research is to analyse and optimise fragmentation to improve the oreflow efficiency at South Deep Mine in South Africa. The mine experiences coarse fragmentation that cannot pass through 300mm by 300mm grizzlies. As such, secondary blasting is often done to reduce the size of boulders either in the stopes or on top of the grizzly which leads to a reduction in productivity. Although coarse fragmentation is reported in the stopes and on top of grizzlies, the plant is reporting fine fragmentation that is not suitable for the ball mill. This results in reduced gold recoveries. To get a better understanding of the fragmentation size distribution achieved, fifty-one images of the muckpile from five stopes were analysed using the Split-Desktop software. The analysis showed an overall F80 passing of 287.48mm, which is less than the 300mm grizzly size implying that the fragmentation size achieved is adequate. However, looking at the overall particle size, the Rosin-Rammler distribution was found to be 0.80. This infers an inconsistent fragmentation where the mine produces both coarse and fine fragmentation size. The AEGIS Underground drill and blast software was used to analyse the drill and blast design patterns. The analysis showed that the design toe spacing varies from about 0.5m to 7.5m in the same blast. Due to the software’s limitations, the break model analysis was only run for toe spacing between 2m and 7.5m. This showed that there is no overlap between blastholes which may be the source of the coarse fragmentation size. Fine fragment size may be as a result of blastholes which are close together, i.e. 0.5m. Although not tested, the impact of blasting stresses emanating from primary stopes may result in fractures in secondary stopes which will have a greater impact on the propagation of the shock wave and high-pressure gases between the blastholes and consequently the fragmentation distribution size. It is recommended that the mine change their drill and blast pattern. The mine must change from 76mm blasthole diameters and introduce a larger blasthole diameter of 89mm blasthole diameter. Not only will this diameter improve drilling accuracies but will reduce the fragmentation size distribution. It is also recommended that the mine maintains a ring burden of 2m throughout despite an increase in the blasthole diameter. For the first design, the toe spacing must also be 2m followed by increments of 0.5m per blast until a suitable fragmentation distribution size is achieved. After which, the toe spacing must be kept constant. It is important that South Deep Mine continually evaluate the fragmentation size distribution achieved from each blast for optimisation purposes. Therefore, a blast management system is important.
Pit Optimisation of Vondeling Quarry by Understanding Geotechnical Parameters Determined at Zoutkloof Quarry
(University of the Witwatersrand, Johannesburg, 2023-11) Mukwevho, Tshinanne Matty; Pillay, Ohveshlan
The purpose of the study was to investigate the geotechnical parameters at Zoutkloof quarry and how they affect stability and the mine planning process. The geological features of Zoutkloof and Vondeling are similar, hence the lessons learned while mining Zoutkloof quarry can be used when mining Vondeling quarry. Zoutkloof quarry has already reached its limits and is no longer operational. It is important that mine planning considers the critical geotechnical parameters. The main reason for this consideration is to keep slope walls stable, employees and equipment safe, and to continue mining the ore in an economical manner. The methodology of the research incorporated highlighting the literature in the public domain on geotechnical considerations in open pit mining. Evaluating geotechnical parameters such as groundwater, rock mass strength, slope angle and monitoring; and additionally, showed scheduling of mining blocks from 2007 to 2008 formed part of methodology in the research. The results analysis indicated that the strategies implemented to control groundwater were successful to keep the production benches dry and walls stable. Good understanding of the discontinuities and the rock mass strength enabled the quarry to be divided into ground control districts. Kinematics analysis for possible failures was done and the results showed that there was no probability of failure on planar mode. However, there were minor possibility that failure can occur on wedge and toppling mode. Yearly mining scheduling was completed, focusing on tonnage and quality requirements. During this period, Zoutkloof had minimum waste mined and the quarry had narrowed significantly which required the operational team to work within mine design specifications to maintain safety and slope angles. Some resources had to be compromised as it was not practical to exploit them safely. The research concluded its findings as successful because Zoutkloof quarry was mined completely with approximately 10 slope failures that resulted with no injuries to employees or damage to equipment. The factors of safety (FOS) were evaluated to be well above one and slopes remained stable until mining ceased. The research also made recommendations that can be implemented while the Pretoria Portland Cement (PPC) continue to mine Vondeling quarry to aid same success as Zoutkloof while being cost effective.
Selection of an Optimal Tunnel Development Method for an Underground Mine Travelling Way Using an Analytic Hierarchy Process
(University of the Witwatersrand, Johannesburg, 2024-01) Meyer, Berto; Musingwini, Cuthbert; Tholana, Tinashe; Sihesenkosi, Nhleko
This research study was conducted at the Marikana Operations (Marikana) which are situated within the Western Limb of the Bushveld Complex (BC) located in the North West province of South Africa. The Marikana Operations mine platinum group metals (PGM) using conventional underground mining methods. The Marikana Operations are owned by Sibanye-Stillwater. The PGM conventional underground mining entails extracting a shallow-dipping narrow reef horizon which is accessed via a network of development workings. Within this layout, a travelling way is an inclined tunnel that connects lateral development workings with the workings on the reef horizon. At Marikana the conventional hand-held mining method is used to excavate travelling ways. However, there was a trial process completed that proved the viability of the inverse drop raising method of excavating travelling ways at Marikana. With more than one viable tunnelling method being available for travelling way development, the need arose to select an optimal travelling way development method for Marikana. The selection is a multi-criteria decision making (MCDM) process because it requires the simultaneous consideration of several factors when evaluating the different alternatives or options. Commonly applied tunnelling techniques were reviewed leading to the selection of both the hand-held drill and blasting method and the inverse drop raising method as applicable to the conventional underground mining environment and specifically to travelling way development. Thereafter, Multi Criteria Decision Analysis (MCDA) techniques were reviewed, and the Analytic Hierarchy Process (AHP) was selected as the MCDA technique to be used as the selection tool for the research, due to its several advantages such as the ability to detect inconsistencies in judgements and provision to remedy the inconsistencies. After the application of AHP, the inverse drop raising method scored 7.2% higher than the hand-held method with a 53.6% versus 46.4% score. The inverse drop raising method was therefore selected as the optimal method to develop travelling ways at Marikana. With the approach that both these methods are currently being executed at Marikana, the inverse drop raising method is nearly twice as expensive as the conventional hand-held method. If PGM prices become a constraint, the method might not be sustainable if executed the way that it is done at the Marikana Operations from a cost perspective. It is suggested that further research should be done to see how the method can be executed more cost-effectively.
Slope Failure Prediction at Husab Open Pit Mine in Namibia
(University of the Witwatersrand, Johannesburg, 2023-12) Thikusho, Christine Runguro; Watson, Bryan P.
The study is focused on Domain D at Husab Mine in Namibia. The purpose of the study was to improve prediction of pending slope failures for planar and wedge configurations. Planar and wedge failures are similar in that little strain is required to initiate failure. Slope monitoring systems such as ground based radars, interferometric synthetic aperture radar and prisms were reviewed from the available literature. The data from the mine’s satellite monitoring data and the ground-based radar instruments was analysed. Slope prediction methods were used to back-analyse the failures, to determine if failure prediction times were possible. A case study was incorporated from the neighbouring Rössing Uranium mine, to supplement the data. The data utilised for the study was downloaded from the slope monitoring instruments on the mine i.e., the interferometric synthetic aperture radar, ground-based radar and tension crack data. The following slope failure predictive tools were investigated; the strain deformation approach; the inverse velocity method; the slope gradient method; the acceleration and velocity approach; and Displacement/Time plots. The back-analysis work done proves that the following slope failure predictive methods were able to predict failure at least 3 days before failure: velocity, cumulative displacement and inverse velocity. It appears that the Husab mine failure mechanism is not as brittle as previously assumed and failures are not necessarily instantaneous. Therefore, failures should be identified early, and the necessary risk mitigation measures implemented proactively. The ability of back analysing large volumes of stored data is important in the study of failure prediction.
Support Design Approach for Crusher Chambers: A Case Study of Palabora Mining Company
(University of the Witwatersrand, Johannesburg, 2023-01) Masole, Nyeleti Venus; Stacey, T.R.
This report project aimed to design a support system for crusher chambers at Palabora. The research project focused mainly on the two crusher chambers (12m wide by 25m high and 61m long) planned for the Lift 2 project as part of the ore handling system. The main research questions that the researcher sought to answer were; what are the differences between Lift 1 & Lift 2 in rock mass characterisation, classification and the ground control district?; how suitable is the Lift 1 crusher chamber support system for Lift 2?; what could be support requirements for Lift 2 crusher chambers in terms of empirical, analytical and numerical design methods and what are the recommended support design approaches for Lift 2 crusher chambers? The methodology used to design support for the Lift 2 crusher chambers was based on determining the expected failure mode first and then selecting suitable design methods to cater for the extent of failure. This study combined empirical and analytical methods to determine the failure mode and required support system. The results were then validated using Finite Element Method numerical modelling software called RS2 (Phase 2) from RocScience. Research findings revealed that the ground control district, classification and characterisation of rock masses differ slightly between Lift 1 and Lift 2. Jointing in dolerite dykes (DOL) was slightly dense in Lift 2 compared to Lift 1 and was associated with increased mining depth. Furthermore, the Lift 1 crusher chamber support system was found to be suitable for Lift 2 but must incorporate dynamic support. Unwedge (RocScience) analysis simulated wedge type of failure in the crusher chamber walls. The empirical and analytical design approach proposed cable bolt lengths of between 6m and 9 m and 3-4 m for roof bolts with bolt spacing of 1.4 m and 1.0 m respectively. The simulation results using RS2 confirmed that the cable bolt length and spacing were appropriate. The recommended support system was expected to provide sufficient support to the crusher chamber in terms of controlling rock mass deformation and yielding. The general conclusion was that the design approach selected for crusher chambers must be able to adequately represent rock mass behaviour and the support required to maintain long-term stability.
The Impact of Digital Technology in South African Coal Mining: A Financial Performance Analysis of Anglo Coal American, Bhp Billiton and Glencore
(University of the Witwatersrand, Johannesburg, 2023-10-27) Maluleke, Reply; Neingo, Paskalia; Marshall, Tania R.
Digital technology, typically, refers to electronic tools, resources, devices and systems that store, generate and process information rapidly. Digital technology and innovation are among the initiatives that can assist mining companies to realise productive, efficient, profitable and sustainable mines. As such, the mining industry is taking steps towards digital technology and innovations that have evolved in recent years. The objective of this report was to discuss the financial impact of digital technology of the selected South African thermal coal mining companies namely Anglo American Coal Division now operating as Thungela Resources, Glencore, and South32, previously spun out of BHP Billiton and now operating as Seriti Resources. Coal mines were selected for analysis, due to their importance with respect to energy generation in South Africa. Industry cost curves over the period 2013-2019 were constructed as part of the financial analyses to show the trend of the selected companies’ unit costs. The research also used other financial analysis methods such as operating profit, profitability ratios, Economic Value Add and Du Pont analysis to analyse the performance of these companies. There appeared to be no production and unit cost improvement directly linked with investment in digital technology, as breakdowns, commodity prices, depletion of reserves, selling of operations, mine closures, high contracting prices, inflations and other factors also affected these parameters. Results for Anglo Coal and South32 did not indicate consistent good or improved financial results in all the financial analysis methods post the investment years in digital technology, in contrast to Glencore’s results which did. Glencore also invested more capital in digital technology as compared to Anglo Coal and South32. It is suggested that this may be one reason for its success. Consequently, it is recommended that companies looking to invest in digital technology follow the example of Glencore and invest as much capital as possible in this venture in order to maximise its potential.
The incorporation of unmanned aerial vehicles in a slope stability monitoring system: a Rössing uranium mine case study
(2024) Shanyengana, Olga Ndapewoshali
Slope stability monitoring is a safety critical input in the Slope and Dump Management Plan (SDMP) at Rössing Uranium Limited (RUL) mine. The SDMP was adopted to satisfy the requirements of the D3 standard – management of slope geotechnical hazard at the operation. Through this standard, RUL aims to provide an injury-free and safe working environment for the operation. This is achieved by proactive identification and management of slope risks and instabilities onsite. This research is a case study of the incorporation of unmanned aerial vehicle (UAV) technology into the slope stability monitoring system (SSM) at RUL, towards conformance to the D3 standard. The study highlights the safety benefits gained by removing personnel from hazardous areas and substituting them with UAVs. The utilisation of UAV data in geotechnical processes such as; the final wall assessment, crack detection and monitoring, as well as dump advancement rate calculations are also discussed. The study further investigated the use of UAVs for SSM prism inspections and proposes the incorporation of UAVs into the trigger action response plan (TARP). A concept of UAV modification for prism-cleaning operations has been developed through this research, to alleviate the challenges of prism loss in inaccessible areas due to dust accumulation on the prism surfaces.
The underrepresentation of technical women in executive and board of directors’ roles in the ten largest listed mining companies in South Africa
(2022) Zulu, Noluthando
As with many technical industries, mining is dominated by men. It is well established that the industry has struggled with the attraction and retention of female talent. While women have made significant inroads in the industry, technical women (defined here as women who come from a geology, engineering, metallurgical, etc background) are underrepresented in the most senior decision-making roles of major mining companies. The purpose of the study was to explore this phenomenon, examining the executive committee and board composition of the 10 largest mining companies listed on the Johannesburg Stock Exchange and interviewing 30 technical women who have worked for, or currently work for, these organisations. The results demonstrate that technical women seldom advance from operations to the boardroom and, typically, play a support function while men make core mining and technical decisions. The study also finds that many technical women move into nontechnical roles for a number of reasons. Further, while attraction of women to the industry continues to rise, the studied companies are struggling to retain technical female talent. The study further highlights the significance of government intervention concerning the inclusion and advancement of women in mining. It also emphasises the need for continued policy development and concludes with recommendations on how mining companies can drive both the inclusion of women in mining as well as their corporate advancement.
Utilising interferometric synthetic aperture radar and ground-based radar data to predict time to failure and to calibrate numerical models on an opencast coal mine
(2024) Strydom, Jacques
Accurate time failure predictions and improved geotechnical certainty in an opencast mine will lead to tremendous safety and economic benefits. This study utilises interferometric synthetic aperture radar and ground-based radar data to conduct a back analysis on slope failures that have occurred in an opencast coal mine in South Africa. Time to failure predictions was done utilising the inverse velocity technique, while the effect of different data smoothing techniques on the accuracy of the failure predictions was evaluated. Additionally, ground-based radar data was used to calibrate a finite element numerical model to improve geotechnical certainty. Time to failure predictions based on satellite monitoring data was less accurate than predicted in the literature, but satisfactory results were obtained from ground-based radar data. This study confirms that displacement measurement from ground-based radars may be used to optimise the strength parameters of finite element numerical models. To improve the accuracy of time to failure predictions from satellite monitoring data, it was proposed that a satellite constellation with a shorter data acquisition time must be utilised. By having access to more frequent data acquisitions and by identifying the most active points within the failure zone of a slope, it is expected that the accuracy of the time to failure predictions can be improved.
Verifying the Quality and Performance of Grout Using Sensor Technology
(University of the Witwatersrand, Johannesburg, 2023-10) Hadebe, Menzi Bright; Mitra, Rudrajit
Underground mines systematically install ground support to stabilize excavations and provide safe working environments. Support units, such as rock bolts and cables, are commonly filled with cementitious grout to effectively prevent corrosion, maintain bonding behaviour between the support unit and grout, and enhance the load transfer between the grout and surrounding rock mass. The grouting process is however time consuming and labour-intensive, which leads to haphazard installations. These substandard grout installations are only observed after rock fall instabilities occur when the quality and extent of grouting inside a support hole are exposed and can be observed. The need to monitor grout installations increased (provide assurance) but remained a challenge due to the invisibility of grout inside the support hole. The invisibility of the grout column inside the support hole renders the routine quality control inspections of installed support units ineffective. This ineffectiveness of quality control inspections has led to a growing need to monitor grout installations with smart technologies to provide quality assurance of full-column grouting. In its current state, grout technology in the mining industry can only measure the extent of grout inside a support hole directly after installation (limited battery life). It cannot measure the loss of grouting material into near borehole fractures, shrinkage, quality of grout inside the support hole or its impact on support performance. These factors are critical to the success of an effective support system and pose a significant safety risk when overlooked. This research report will describe how grout sensor technology data was recorded and used to verify the extent and quality of cementitious grout inside support hole installations at laboratory and deep-level mine study sites. Grout sensor technology, in practice, utilizes several grout sensors placed at predetermined positions along a support unit with a receiver attached to the collar of the support hole. Electrical resistivity data from each sensor is collected using a grout detector. Depending on the position of each grout sensor, the extent of grout inside a support hole can be confirmed, hence eliminating the need for speculative and ineffective visual observations. The non-destructive verification and prediction of the quality and performance of grout inside support holes using sensor technology forms an invaluable strata control tool that can be used to identify sub-standard grouting operations and significantly improve safety at underground mines. This novel and innovative technology is a mining industry first.

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