ETD Collection

Permanent URI for this collectionhttps://wiredspace.wits.ac.za/handle/10539/104


Please note: Digitised content is made available at the best possible quality range, taking into consideration file size and the condition of the original item. These restrictions may sometimes affect the quality of the final published item. For queries regarding content of ETD collection please contact IR specialists by email : IR specialists or Tel : 011 717 4652 / 1954

Follow the link below for important information about Electronic Theses and Dissertations (ETD)

Library Guide about ETD

Browse

Has files: YesSubject: search.filters.subject.Coal mines and mining

Search Results

Now showing 1 - 7 of 7
  • No Thumbnail Available
    Item
    Validation of a dynamic simulation of an opencast coal mine
    (2019) Muniappen, Kesavan
    A dynamic simulation study is a critical deliverable of a mine project feasibility study. Mining houses rely on simulation to confirm that complex, integrated systems can achieve design capacity before investment decisions are made. Dynamic simulations are powerful tools, but only if they are developed using the right methodology, and with information that has been verified. The importance of work in the field of mine dynamic simulation validation was made clear during the early stages of this research report when it was identified that there is limited information available on the subject. Work conducted in the realm of validation can make an invaluable contribution to the success of future projects undertaken around the world. The last few years have been difficult for employees of some mining companies because of looming job cuts due to high production costs, high overheads, and decreasing product demand. For many mining companies, it was a case of survival which gave rise to the development of new strategies and innovative thinking. Coal Mine A Life of Mine (LOM) extension project is a prime example of innovative thinking. In this case, the project was approved for implementation when export coal prices were on the low end of the price cycle. The dynamic simulation of the full materials handling value chain conducted during the project was of utmost importance, and provided assurance to the project review team that annual production targets can be achieved. The simulation development methodology was based on a unique approach that reduced time spent on the simulation through the integration of different, independent models that represented sub-systems in the materials handling value chain. There was, therefore, a strong need to validate the simulation, which could lead to the adoption of this approach on future projects. In this research report, the LOM extension project scope and the mining activities conducted by Coal Mine A are explained, and a brief, but interesting history of Modelling and Simulation (M&S) is provided. The subject of M&S is vast and has evolved into its own separate discipline. M&S is an invaluable tool, and the importance of verification, validation and credibility is elaborated on. The development of the simulation and the inputs and outputs of the simulation are discussed before the validation effort. The work conducted on the validation aimed to confirm the accuracy of the simulation unequivocally. Although the production target was not achieved as predicted by the dynamic simulation during the period of validation, there was an indication that the materials handling value chain could perform as predicted as each of the individual sub-systems had achieved the design capacity. Problem areas were identified which could be attributed to the poor performance, and if these areas are addressed, the system could perform as predicted by the simulation. This confirms that dynamic simulation can add value to predictions about mining system performance such that informed decisions can be made.
  • No Thumbnail Available
    Item
    A new blueprint for new digital technology adoption in the mining industry using a systems thinking approach
    (2019) Fan, Xiang
    Successful adoption of new technologies is critical for the improvement of efficiency and the enhancement of health and safety in South African mining industry operations. However, the process of new digital technology adoption in the South African mining industry has been slow and difficult. This research is aimed at addressing some of the problems associated with the process. As part of this research, a new blueprint has been developed to guide the commissioning entity through the entire process of new digital technology adoption and installation. The new blueprint will provide capability to monitor the quality of the work during adoption, as well as assessment of the outcome of the adoption by measuring the level of compliance for every activity performed by the commissioning entity during the adoption. The reliability of the new blueprint was verified by assessing the performance of the Wits Mining Institute (WMI) in its installation project of the Schauenburg system. The outcome of the new blueprint verification reveals poor planning and inadequate preparation during the installation of this project. The outcome also indicates that application of the new blueprint will reduce the problems associated with the adoption and speed up new digital technology adoption and its installation for better functionality.
  • No Thumbnail Available
    Item
    Yielding pillar design in South African collieries
    (1997) Oldroyd, Oldroyd
    Three cases of pillar failure on Southern African Collieries have been studied to analyse the behaviour of both the pillars and the overlying strata. Each of the cases shows a different type ofpillar and strata behaviour during failure and thus provides an opportunity for back analysis. In the first case, pillars failed in a controlled fashion while the overlying strata behaved in an elastic fashion. In the second pillars failed in a controlled fashion while the surrounding strata behaved inelastically. In the third failure was initially controlled but became uncontrolled. Computer models have been run to determine the theoretical critical post peak pillar slopes and the results of these models have been compared with the actual pillar behaviour as derived from in-situ measurements during failure and that which might be predicted from the theory of controlled and uncontrolled pillar failure. Comparisons are also made with the expected behaviour implied from the results of in-situ strength tests carried out on small coal pillars to ascertain their load deformation characteristics. The results indicate that the behaviour of the pillars more closely resemble that predicted from in-situ tests carried out by Van Heerden4• The results also indicate inadequacies in using elastic methodologies to determine whether pillar failure will be controlled or uncontrolled.
  • No Thumbnail Available
    Item
    The application of ash adjustable density in the evaluation of coal deposits
    (2017) Roux, Leon
    The initial evaluation of a coal deposit often raises uncertainty with regard to the accuracy of the reported resources and reserves. Difficulty is experienced in reconciling tonnages produced during mining and beneficiation with the original raw field data. The credibility of resource and reserve estimations, which form the basis on which an entire mining enterprise is motivated, funded and established as a commercially viable proposition, is of paramount importance. In essence, this research has sought to establish and validate a more realistic and accurate method for (i) coal resource and reserve estimation and (ii) the reconciliation of saleable tonnages produced following beneficiation. Previous research undertaken by this author resulted in the formulation of a methodology to provide a more accurate assessment of a coal body by using the dry density of the coaly material derived from proximate analytical data for the ash content for float fractions obtained from float sink analysis. The determination of the dry density was obtained through the application of the ash adjusted density algorithm derived from the regression of the median proximate ash values at fixed float densities in the range 1.35 g/cc to 2.20 g/cc. The derived density results were validated against laboratory pycnometer determined densities and found to be applicable to both of the two major geological stratigraphic units in the Waterberg Coalfield. This resulted in significantly more accurate predictions of coal product tonnages from the Waterberg Coalfield. In the current research, this methodology has been applied to cover the entire coal value chain, from exploration through to final products. The primary purpose was to ascertain the correct resource and reserve values relative to that originally reported using conventional methods and to match those values to actual saleable tonnages produced down the line. Density is the key factor underpinning such calculations and this varies not only due to geology, and specifically coal rank, type and grade, but also to the method used for its measurement. It plays a major role in the estimation of reserves and in the beneficiation process because density is the primary separation medium utilized in coal beneficiation. Coal plies and particles have different relative densities and physical properties, as determined by their maceral composition, rank, mineral (ash) and moisture contents. The relationship between such parameters, as measured by ash, moisture content, matrix porosity and density, was found to play an even greater critical role in establishing the correct tonnage of coal at any single point in the value chain. A combination of theoretical, empirical and reconciliatory evaluations of the available data from the exploration phase through the mining process to final production has shown that an integrated approach using the ash adjusted density methodology provides more accurate and credible results with a higher degree of confidence at all stages across the coal value chain than is currently possible using conventional practices.
  • No Thumbnail Available
    Item
    Coal mine ventilation: a study of the use of ventilation in the production zone
    (2016) Feroze, Tariq
    The blind headings created in room and pillar mining are known to be the high risk areas of the coal mine, since this is where the coal production is actually taking place and hence the liberation of maximum quantity of methane. The ventilation of this region called the localized ventilation is carried out using auxiliary ventilation devices. This ventilation may be planned and be the subject of mine standards, but it is not very well understood and implementation on a day to day basis is usually left to the first level of supervisory staff. Majority of the methane explosions have been found to occur in these working areas and blind headings. The correct use of auxiliary ventilation devices can only be carried out once the effect of the system variables associated with each device is very well understood and can be calculated mathematically. Presently, no mathematical models or empirical formulas exist to estimate the effect of the associated system variables on the flow rates close to the face of the heading. The extent of ventilation of a heading ventilated without the use of any auxiliary device is not clear. Furthermore, to design additional engineering solutions, the flow patterns inside these heading ventilated with the auxiliary ventilation devices needs to be understood. The study of the face ventilation systems and the effect of the system variables associated system with each auxiliary ventilation device can be carried out experimentally, but doing a large number of experiments underground is very difficult as it disturbs the mine production cycles. Furthermore, studying the flow patterns experimentally is even more cumbersome, and can only be done to some extent using smoke or tracer gas. Therefore, Computational Fluid Dynamic‟s (CFD) advanced numerical code ANSYS Fluent was used to study the effect of a number of system variables associated with the face ventilation systems used in blind headings. As part of the procedure, the CFD model used was validated using four validation studies, in which the numerical results were compared with the actual experimental results. The numerical results differed to a maximum of 10% for all the experimental results. The system variables associated with ventilation of a heading, without the use of any auxiliary device, with the use of Line Brattice (LB) and fan with duct were selected. A range of values was chosen for each variable, and scenarios were created using every possible combination of these variables. All the scenarios were simulated in Ansys Fluent, the air flow rates, air velocities, velocity vectors, and velocity contours were calculated and drawn at different locations inside the heading. The effect of each system variable was found using a comparative analysis. The results were represented in simple user-friendly form and can be used to estimate the air flows at the exit of the LB and face of the heading for various settings of the LB and fan and duct face ventilation systems. The analysis of the ventilation of a heading without the use of LB shows that a maximum penetration depth is found with the Last Through Road (LTR) velocity of 1.35m/s. The flow rates and the maximum axial velocities increase with the increase in the LTR velocity up to a depth of 10m (maximum air flowing into a heading of 1.26m3/s and 1.58m3/s is found for the 3m and 4m high heading using 2m/s LTR velocity). For the LB ventilation system the LTR velocities, heading height, length of the LB in the LTR and heading, angle of the LB in LTR, and distance of the LB to the wall of the heading (side wall) were varied to identify clearly the effect of these control variables, on the flow rate at the exit of the LB, and close to the face of the heading. The flow rate at the exit of the LB is found to be proportional to the product of the distance of the LB to the wall in the LTR and heading. The flow rate at the exit of the LB, face of the heading, and inside the heading is found proportional to the LTR velocity and height of the heading. It is found that a minimum length of LB is associated with each distance of the LB to the wall in the heading, to maximize the delivery of air close to the face of the heading. This length is found to be equal to 15m for 1m LB to wall distance, and 10m for 0.5m LB to wall distance. Mathematical models were developed to estimate the effect of each studied system variables on the flow rates at the exit of the LB and close to face of the heading. For the fan and duct systems the length, diameter, and the fan design flow rates were varied. It is found that for a force fan duct system only a maximum of 50% of the total air that reaches the face is fresh and the remaining 50% is recirculated air. The flow rate with the exhaust fan system is found to be much lower than the force fan duct system. It increases with the reduction in duct mouth to heading face distance, and increase in duct diameter. Mathematical models are developed to calculate the flow rates at the face of the heading using the effect of each studied system variable. The research reveals that the ANSYS numerical code is an appropriate tool to evaluate the face ventilation of a heading in a three dimensional environment using full scale models. The South African coal mining industry can benefit from the outcomes of this study, specially the mathematical models, in a number of ways. Ventilation engineers can now estimate the flow rates close to the face of the heading for different practical mining scenarios and ensure sufficient ventilation by using the appropriate auxiliary ventilation settings. The results can easily be developed into training aids using easy to use excel spread sheets to ensure that mineworkers at the coal face have a better understanding of the working of the auxiliary ventilation devices. It can also serve Academia as part of the curriculum to teach the future mining engineers how the different variables associated with the auxiliary ventilation system affect the ventilation in a heading. The research therefore, has the potential to provide a significant step toward, understanding airflow rates delivered by the auxiliary devices close to the face of the heading and the air flow patterns inside the heading as a basis for improving the working environment for underground mineworkers.
  • No Thumbnail Available
    Item
    Prediction of spontaneous combustion in coal by use of thermogravimetry
    (2016) Mthabela, Zamashinga Amanda
    The self-heating of coals is a complex problem which has been occurring for centuries. This problem has been fatal to coal miners, an economical challenge to coal mines and a health risk in a release of greenhouse gases to the public in general. Therefore, everyone is affected by the self-heating of coal, which leads to spontaneous combustion when the ignition temperature is reached. There are many test methods that have been used to test spontaneous combustion in coal, but all have one common factor or disadvantage of requiring long periods of time before a conclusion can be deduced. This then creates a need for a rapid and reliable method to test the liability of coal to self-heat in the coal industry and thus the motivation for this project. The thermogravimetry analysis (TGA) method was selected to test the liability of coal to self-heat due to its short analytical duration. The Smith-Glasser oxidation test was selected to validate the TGA results obtained. The main aim of this project is to investigate the reliability of the TGA method to predict the propensity of coal to self-heat. 29 samples from different regions of South Africa were used, prepared to 250 μm for all the analyses and self-heating tests. All samples were analysed for proximate, calorific value, sulphur and petrographic properties before the spontaneous combustion liability tests began. The TGA method followed two tests: 1) the O2 adsorption and 2) the ignition test. Five different heating rates (3, 5, 7, 10, and 20) °C/min were run in order to obtain five derivative slopes which would be used to obtain the TGspc index. The oxygen adsorption test studies the mass increase at low temperature under exposure of air between the temperature ranges of 100 – 300°C. The Smith-Glasser oxidation test method studies the reaction of coal with O2 and calculates the O2 absorbed per amount of coal tested. The Smith-Glasser test results collaborated with most of the other analytical results, and with the TGA results to a certain extent. The TGA spontaneous combustion liability test requires additional analytical work to back up its results because the results do not appear as accurate as the Smith-Glasser oxidation test. It also requires repeatability tests to ensure the integrity of the results.
  • No Thumbnail Available
    Item
    Sinkhole risk management process within thermal collieries : A practical approach thereof
    (2016) Joel, Felix
    Previously undermined areas pose a significant challenge to mining by opencast due to the risk of sinkhole occurrence. In order to optimise reserve utilisation as well as safeguard personnel and equipment there was need to develop a “Sinkhole Prediction Model” to assist in the prediction of areas prone to sinkhole formation. The aim of this research therefore was to develop a “Sinkhole prediction tool” with a view to pre-identifying areas of potential sinkhole hazard to inform better controls to assist in mining these areas safely. This was done utilising the current Hill (1996) caving height method culminating in the development of a hazard index model dividing the mining zones into high and low hazard. These areas were colour coded Red (High hazard) and Green (Low Hazard). The “Sinkhole Prediction Model” evolved to include over hundred sinkhole incidences that were statistically analysed to firm up on the robustness of the Prediction Model capabilities. The Hill (1996) caving height formula was discounted after the statistical analysis indicated that a good prediction model lies in the interrogation of site specific data. The outcome of the work conducted in this research report indicated a 97% correlation between the refined “Sinkhole Prediction Model” and the actual sinkhole occurrence at the Anglo American case study area (Mine X). Various refinements inclusive of lithological assessments, blast and drilling reconciliations as well as the implementation of the roughening up quality audits led to the implementation of a robust sinkhole management process that has managed to consistently assist in safeguarding equipment and personnel thus allowing for coal extraction optimisation in areas that could have been written off due to the sinkhole hazard. This risk can only be eliminated by mining the areas with the sinkhole risk. Currently the method is being impacted by significant roughening up cost incurred in a drive to make the areas safe to allow for coal extraction. The roughening up process on average costs R3.5 million per sinkhole and is a function of the number of sinkholes found, which translates to an equivalent cost of R7 / sales tonne. The current sinkhole prediction model being employed in deficient in that it cannot pinpoint the actual location of the void in the area previously undermined by bord and pillar and this is a great limitation of this report. Various geophysical techniques were pursued to assist in the precise identification of the actual sinkhole spatially. This process was aimed to reduce the roughening up cost (entire block stabilisation) as opposed to targeted sinkhole excavation and stabilisation. This process proved futile as the void identification systems are highly incapable of identifying the voids / iv sinkholes spatially (x, y and z coordinates) to assist targeted sinkhole treatment as a result of the following:  System inability to penetrate areas comprised of highly conductive strata such as clays.  Inability to distinguish between the underground voids and geological anomalies such as dykes.  Not suitable for penetrating wet strata.  Impacted by noise interference from mining machinery. The major result of this research is the establishment of a site specific “Sinkhole Prediction Model” that can generate hazard plans in real time thus informing the management on areas associated with a potential sinkhole hazard. The hazard plans can be generated timely and decisions made to facilitate safe coal extraction in areas of high sinkhole hazard. This has culminated in a robust sinkhole management process within the group that has managed to eliminate the risk of personnel and equipment exposure at Mine X. The roughening up process is accepted as the primary sinkhole mitigation or rehabilitation process with the need to work towards reducing the roughening up costs through development of the tool capable of precisely identifying the voids routinely to facilitate targeted rehabilitation. Significant research is required in this area as the mining environment is comprised of strata that currently cannot support the use of real time void identification to facilitate targeted void identification and rehabilitation. There is also merit in the future to formulate the database capable of assisting in the prediction of sinkholes in the Witbank coalfield as well as assist in robust management of mining boundaries across the different mining houses. The system implemented at Mine X is currently being deployed to other operations in the group where modification will be made to match the site specific conditions. Future research into understanding the sinkhole occurrence dynamics is quite crucial if targeted rehabilitation is to be achieved for cost reduction and mining sustainability. A combination of the understanding of the sinkhole occurrence driving mechanisms in conjunction with use of modelling packages such as ELFEN (a hybrid Modelling) tool will go a long way in enhancing the development of precise sinkhole prediction point in space.