METALLON GOLD ZIMBABWE (PRIVATE) LIMITED BULAWAYO MINING

COMPANY (HOW MINE)

Work Related Learning Final Report

A report submitted to Midlands State University, in partial fulfillment of the
requirements of a Bachelor of Science Honours Degree in Mining and Mineral
Processing Engineering to the Department of Mining and Mineral Processing
Engineering.

PRIDE TAFADZWA KUBVORUNO (R133485Z)

Senior Training Oficcer : Mr E. Damiso___________________

Supervisor: Mr T. Chokera __________________

Period: (January November 2017)

Bulawayo Mining Company:

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ACKNOWLEDGEMENTS

It gives me immense pleasure to present this report carried out at Metallon gold Zimbabwe (How
Mine) Limited in partial fulfillment of the requirements of a Bachelor of Science Honours
Degree in Mining and Mineral Processing Engineering to the Department of Mining and Mineral
Processing Engineering. No work can be carried out without the help and guidance of various
individuals. I am happy to take this opportunity to acknowledge and express my profound
gratitude to those who have been helping me complete this report.

Firstly I would like to thank the lord Almighty for granting me this opportunity to be part and
parcel of Global Insurance Company Limited.

Secondly I would like to pass my gratitude to the following people who were inspiring in the
completion of my attachment programme and from whom I got to appreciate mining as a whole,
Mr Manyenje (The mine captain), my mentor Mr T. Chokera (The mine training officer), all the
miners at how mine and lastly to the management staff of How Mine for giving me the
opportunity to proceed with my studies.

My gratitude also goes to the MSU (Manicaland College of Applied Sciences) academic staffs
who have imparted their vast knowledge which has so much assisted me during my industrial
attachment. It is through their unwavering support that I was able to appreciate the theoretical
aspects of insurance and reinsurance Industry. Many heartfelt thanks for their unwavering
support.

Lastly I would also like to thank my parents for their unconditional love and support and for their
financial support.

God bless you all.

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DEDICATIONS

Mostly, special dedication to my family (parents, brothers, sisters and my wife)

Finally but not least, to all the MSU (Manicaland College of Applied Sciences)Mining Students

who will have a blessing to be attached with Bulawayo Mining Company.

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ATTACHMENT SUMMARY

ACTIVITY TASKS PERIOD OFFICIALS

Familiarization Introduction to mining activities 1 week Skills Training

Officer

Lashing Development Lashing 4 weeks O/Miner

Stope Lashing
Shift Boss
Loader Lashing
Shaft bottom lashing
Drilling and Development 12 weeks O/Miner
Blasting
Lateral development Shift Boss
Raises
Face Marking
Drilling and Charging
Stoping

Long hole drilling

Ring charging and blasting
Production Loco Tramming 4 Weeks O/Miner
Grizzley Operations
Shift Boss
Ore handling and hoisting
Secondary Blasting
Explosives Distribution, storage and handling 1 week O/Miner
Handling
Mine Captain

P.T.V Installation of pipes and tracks 2 weeks O/Miner

Installation of barricades
Raise rigging
Pipe and track reclamation
Metallurgy Crushing 6 weeks Asst Met
Milling Manager
C.I.P
Elution
Tailings disposal
Smelting
Geology General geology of the mine 2 weeks Senior geologist
Exploration and sampling
Grade control
Use of computers in geology
Mine planning

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Survey Survey methods of production 2 weeks Senior Surveyor
plan
Basic surveying of and
installation of pegs
Computers and surveying
Preparation of mine plans
Maintaining and updating of
plans
Assay Laboratory preparations 2 weeks Chief Assayer
Information generation for
production grade control
Shafts Shaft Exam and Maintenance 3 weeks Timber man
Construction Transportation of heavy material
Shift Boss
Construction work waste disposal
Engineering Drainage and pumping 2 weeks U/G Services
Electrical reticulation Foreman
Compressed air reticulation
Equipment over hauls
Maintenance facilities and
schedules
Basic welding and cutting skills
MBL Training Revision and mock tests SHEQ Officer
MBL examinations
Training Officer

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Contents
1 EXECUTIVE SUMMARY................................................................................................................... 2
2 INTRODUCTION ................................................................................................................................ 2
2.1 Metallon Corporate Structure........................................................................................................ 4
2.2 Historical overview of the mine .................................................................................................... 4
2.3 Company profile ........................................................................................................................... 4
2.3.1 Vision .................................................................................................................................... 4
2.3.2 Mission statement ................................................................................................................. 5
2.3.3 Core Values ........................................................................................................................... 5
2.3.4 Operational statement ........................................................................................................... 6
2.4 ORGANISATIONAL STRUCTURE ........................................................................................... 6
3 DEFINITION OF TERMS.................................................................................................................... 7
4 GEOLOGY OF THE MINE ............................................................................................................... 13
4.1 GEOGRAPHICAL LOCATION ................................................................................................ 13
4.2 REGIONAL GEOLOGY SETTING .......................................................................................... 14
4.3 LOCAL GEOLOGY ................................................................................................................... 16
4.4 OREBODY MINERALISATION MODEL ............................................................................... 18
4.5 MINING METHOD.................................................................................................................... 19
5 INDUCTION ...................................................................................................................................... 20
5.1 Security Department ................................................................................................................... 20
5.2 SHEQ Department ...................................................................................................................... 20
5.3 Human Resources Department.................................................................................................... 20
5.4 Finance Department .................................................................................................................... 21
5.5 Technical Service Department ................................................................................................ 21
5.6 Metallurgical Department ........................................................................................................... 21
5.7 Mining department ...................................................................................................................... 22
5.8 Engineering department .............................................................................................................. 22
6 ATTACHMENT CONTENT ............................................................................................................. 23
6.1 Risks at the Company ................................................................................................................. 23
6.2 Lashing........................................................................................................................................ 24

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 6.3 Drilling, charging and blasting.................................................................................................... 27
6.4 Explosives ................................................................................................................................... 33
6.5 Ptv (pipe and track laying) .......................................................................................................... 40
6.6 Production ................................................................................................................................... 43
6.7 SHAFTS...................................................................................................................................... 44
6.8 PLANT OPERATIONS (REDUCTION) ................................................................................... 47
6.8.1 General Overview of the Reduction Process ...................................................................... 48
6.8.2 Crushing .............................................................................................................................. 48
6.8.3 Milling................................................................................................................................. 51
6.8.4 Knelson concentrator .......................................................................................................... 54
6.8.5 Acacia plant ........................................................................................................................ 54
6.8.6 Hydro-cyclone..................................................................................................................... 56
6.8.7 Screens ................................................................................................................................ 57
6.8.8 Carbon in pulp..................................................................................................................... 58
6.8.9 Elution ................................................................................................................................. 60
6.8.10 Tailings disposal ............................................................................................................... 62
6.9 TECHNICAL SERVICES .......................................................................................................... 65
6.9.1 Survey ................................................................................................................................. 65
6.9.2 Geology ............................................................................................................................... 74
6.9.3 Assay ................................................................................................................................... 75
6.10 Recommendations ....................................................................................................................... 78
6.10.1 To the company................................................................................................................... 78
6.10.2 To the school ....................................................................................................................... 79
7 PROJECT PROPOSAL ...................................................................................................................... 80

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 1 EXECUTIVE SUMMARY
This section gives a brief overview of aspects covered in this report. This report gives an account of the
activities covered by Pride Tafadzwa Kubvoruno, the Manicaland College of Applied Sciences student
(from here referred to as the Student) during the industrial attachment undertaken at Bulawayo Mining
Company- How mine (from here referred to as the Company). An industrial attachment is a pre-requisite
course for fourth year Mining and Mineral Processing students at the University in partial fulfillment of
the requirements of BSc Honours Degree in Mining and Mineral Processing. Bulawayo Mining Company-
How mine is located in Matebeleland-South province, about 30 kilometers southeast of Bulawayo town in
southern Zimbabwe which specializes in gold mining and processing. This report was compiled by the
Student and all materials used to compile this report were acquired legally from How mine officials and
approved by the training officer, Mr T. Chokera for academic use only. Any unauthorized use,
reproduction, distribution and publishing is prohibited or otherwise permission may be sought from the
author and/or directly from How mine.
This report provides a full account of the activities covered by the Student at the mine during the
attachment period highlighting the following key areas:
A summary of induction process which involve introduction to different departments, their roles,
regulations at the mine and how the departments work hand in hand.
A summary of different day to day activities, including the purpose, equipment, procedures,
observations and recommendations for each and every activity.
A brief account of the departmental visits done by the student to further understand linkages in the
mining industry.
The conclusion and lessons learnt during attachment period.
The challenges faced and recommendations brought forward by the student to both the University
and to BMC-How mine so as to continuously improve the Mining and Mineral Processing
industrial attachment program.

2 INTRODUCTION
Metallon Corporation limited is one of the leading gold producer, developer and explorer in Southern
Africa. The Portfolio of mineral assets in Zimbabwe comprises of five mining properties and two
exploration properties located within a significant land package (954.43km2).The mining properties
comprises of five separate underground gold mines: How, Shamva, Arcturus, Redwing and Mazowe

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which are serviced by their own dedicated processing facilities and accompanying infrastructures. The
mines are located in different Achaean greenstone belts on the Zimbabwean craton as shown;
Figure 1 :Metallon mineral assets in Zimbabwe (Source: Metallon website).

Bulawayo greenstone belt

Exploration activities at the mining assets are focused on extending existing orebodies and identifying
new orebodies both at existing and undeveloped sites. There is an exploration property at Motapa which is
the subject of active and ongoing exploration and some other exploration targets shown with yellow dots
on Figure 1 above. There is also significant exploration potential at all the mining operations, most of
which are the subject of active and ongoing exploration. Arcturus is currently under care and maintenance
due to poor performance and lack of funding for exploration, development and mining activities at the
mine; which is the main reason it was not included on the current corporate structure below:

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 2.1 Metallon Corporate Structure
Figure 2: Corporate Structure (Source: Metallon website).

The student was attached at Bulawayo Mining Company-How mine for the period of his industrial
attachment. Bulawayo Mining Company (BMC) owns How Mine which is Metallon's flagship low
cost, mining operation. It is one of the largest gold producers in Zimbabwe, producing at least
100kgs of gold per month

2.2 Historical overview of the mine

J. Howe pegged the How Mine claims as a virgin discovery in July 1941. In August 1941, the claims were
transferred to the Halo Syndicate, which changed the name to Halo Co. Ltd in October 1943. Two quarries
had been established by July 1944 with the southern quarry down to a depth of 30m and the mill had a 19-
stamp battery.
During the period 1950-51, the mine was put on option to Goldfields Development Co. Ltd. Frobisher Ltd.
had an option on the mine in the period 1952-53. In the same period, a diamond-drilling program totaling
2,020m was undertaken. This indicated potential for a large tonnage operation with an average grade of
4.9g/t Au. The option was abandoned in 1953 effectively ceasing all the milling operations. Ballarat
Mines (Pvt) Ltd took over the mine in June 1954 and sank the main shaft between the two open pits.
The property was taken over by LONRHO in 1973, first under the name of Rhodesian Gemstones (Pvt)
Ltd. then Attica Mines (Pvt) Ltd. and eventually Independence Mining (Pvt) Ltd. in 1986. Since 1970, the
mine has operated continuously and is one of the largest gold producers in Matabeleland region. In
October 2002, LONMIN (Lonrho) relinquished ownership of Independence Gold Mining (Pvt) Ltd. to
Metallon Corporation, then a South African based mining and finance company.

2.3 Company profile

2.3.1 Vision
To be a world class precious metals mining company with a footprint across Africa.

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The above statement is the inspirational position that the organization wishes to attain in the long run.
Metallon urges all its mines to adhere and align to this vision so as to globally recognized precious metals
mining company with traceable achievements in Africa in socially responsible manner.

2.3.2 Mission statement

To become a major precious metals producer in Africa and create real value for all our stake holders
through the expansion and optimization of current operations and an ambitious exploration and
acquisition strategy
In the bid to reach its vision, Metallon realizes that it needs to have a determination or purpose of the
organizations being. Thus it sets to produce more at the best quality and use up to full capacity the
available resources yet expanding its operations through exploration and acquisition. This is being done by
creating a real value for all the organizations stakeholders.

2.3.3 Core Values

Teamwork.
Leadership.
Excellence.
Empowerment.
Effective Communication.
Honesty and integrity.
Sustainable Development.
The above are principles that the company has set to live and uphold to govern its internal and external
conduct. All in the bid of creating a corporate culture that clearly spell what Metallon stands for as an
organization. The above discussed Vision, Mission and Values, is the backbone of Metallon and is
expected to be realized by all the five mines, therefore all mines have done likewise so as to identify with
the organization, thus Bulawayo Mining Company-How mines vision is to Create a golden Future
thus be:
The safest mine in the country.
Users of the best practice and available technology.
Providers of attractive working conditions and competitive benefits.
A global leader in low costs of production in an environmentally responsible way.

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 2.3.4 Operational statement
To conduct all the mining processing and service operations in a safe efficient, cost effective and
environmental acceptable manner
Training and technical services support and plays an important part in realizing stated goals.
The company shall develop and maintain high standards for all aspects of mining and processing
operations and aim to continuously improve on them.

2.4 ORGANISATIONAL STRUCTURE

To achieve the company objective of producing gold at a profitable, safe and environmentally friendly
atmosphere, How Mine is serviced by seven different but inter-dependent departments, each headed by a
Departmental Manager and a Security department headed by the Chief security officer. The departmental
managers reports to the General Manager at the mine who will report to the Chief Operation Manager at
the Head Office in Harare. The following Organogram summarizes the hierarchy of the all the
organization structures at How mine.

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Figure 3: How Mine Organogram

3 DEFINITION OF TERMS
TERM DEFINITION

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Abandoned or Disused An excavation where normal mining and related activities have not taken
End place for more than 6 months.

Air Column A column made of steel pipe for the conveyance of compressed air.

Anemometer An instrument for measuring the speed of the wind, or of any current of gas.

Barricade A device to limit, and or prevent, access to areas for the protection of all
personnel.

Battery Charging Bay A station that provides power to charge the batteries of a battery locomotive.

Battery Locomotive A battery powered self-propelled rail-bound machine used for pulling trains.

Blast The operation of rending (breaking) rock by means of explosives.

Blast Area The area near a blast within the influence of flying missiles, or damage-level
concussion

Blaster A qualified and competent person in charge of a blasting operation.

Blasthole A hole drilled into rock or other material for the placement of explosives.

Blowpipe A tool to which can be connected either a high pressure water supply or
compressed air and is used for revealing or cleaning the cavity of a blasthole
by forcing air or water into it.

Chain Ladder A ladder with stringers consisting of a mild steel link chains connected by
rungs of mild steel round bar.

Cocopan A small wagon running on narrow-gauge railway lines used in mines to ferry
ore.

Competent Assistant A person who assists a competent person; has had adequate training and
experience in a particular mine task; who is also able to assess the risks
related to the task and is able to perform the task without avoidable danger to
himself or any other person.

Competent Person A person who has had adequate training and experience in a particular mine
task who is also able to assess the risks related to the task and is able to
perform the task without avoidable danger to himself or any other person.

Coupling The degree to which an explosive fills the borehole. Bulk loaded explosives
are completely coupled. Untamped cartridges are uncoupled. (Also intimate
contact between explosives and rock.).

Cut The group of holes fired first in a round to provide additional free faces for
the succeeding shots.

Decoupling The use of cartridge products significantly smaller in diameter than the
borehole.

Delay Blasting The use of delay detonators or connectors that cause separate charges to

8
 detonate at different times, rather than simultaneously.

Delay Connector A nonelectric, short interval delay device for use in delaying blasts that are
initiated by detonating cord.

Detonating Cord A flexible cord containing a centre core of high explosives which may be
used to initiate other explosives.

Detonator Any device containing a detonating charge used to initiate an explosive.

Development Call The total expected excavation advance from a development end over a
prescribed period of time.

Development Junction The connection between a main tunnel and sub-tunnel or crosscut.

Development Profile An outline of the development tunnels and workings

Drain A channel or pipe or conduit carrying off water from one area to another.

Drilling A cutting process that uses a drill bit to cut or enlarge a hole of circular
cross-section in solid materials.

Drill Bit A rotary cutting tool, often multipoint which when cutting is pressed against
the rock face and rotated at rates from tens to hundreds of revolutions per
minute.

Drilling Machine A machine driven by either impact or simple rotation and used to drive
cutting tools into rock to bore holes or recover core.

Drilling Pattern An arrangement showing location, direction and depth of the holes drilled
into the face of a tunnel.

Drill Round The set of holes including their depth and direction drilled, to be charged and
blasted to excavate an opening.

Easer One of a ring of holes drilled around cut holes and fired after cut holes.

Egress A path or opening for going out or an exit which shall be an alternate shaft,
decline, ramp, portal or adit not normally used for day-to-day operations.

Emergency Evacuation The immediate and urgent movement of people away from the threat or
actual occurrence of a hazard.

Explosion The thermochemical process whereby mixtures of gases, solids, or liquids

react with the almost instantaneous formation of high gaseous pressures and
a heat release.

Explosive Any chemical compound, mixture, or device, the primary or common

purpose of which is to function by explosion or to initiate explosives; the
term includes dynamite and other high explosives, black powder, pellet
powder, initiating explosives, detonators, safety fuses, squibs, detonating
cord, igniter cord, and igniters.

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Fan A machine for producing airflow, often for cooling.

Flat Development A horizontal tunnel mined to connect the workings to each other and to the
main mine access.

Flyrock Rock that is propelled through the air from a blast. Excessive flyrock may be
caused by poor blast design or unexpected zones of weakness in the rock.

Fragmentation The extent to which rock is broken into small pieces by primary blasting.

Fresh Air Natural air free of contaminants including explosive fumes (containing
nitrous oxide and carbon monoxide), airborne dust, and naturally occurring
gases such as methane, carbon dioxide, hydrogen sulphide and radon

Gangleader A mine employee possessing a mine blasting licence who is a competent

person and who has been trained to manage and is given the responsibility of
supervising mining tasks.

Gas Detector A device that detects the presence of gases in an area.

Geological Mapping The depiction of geological features and their transposition onto paper in the
form of drawings or symbols

Grade Control Process to quality check and control the grade and variability of an ore.

Grizzly A grating placed over the top of a chute or ore pass for the purpose of
stopping the larger pieces of rock or ore that may hang up in the pass.

Hand Tramming The movement of rolling stock on rails, manually by a person or persons.

Ignitor Cord A fuse that burns progressively along its length with an external flame at the
zone of burning, used for lighting a series of safety fuses in a desired
sequence.

Initiation The act of detonating a high explosives by way of a mechanical device or

other means.

Jackhammer A tool designed for drilling blast, anchor and rock-splitting holes. It drills
diameters to 40 mm and depths up to approx. 3 m using pneumatic power for
impact and rotation.

Ladder A vertical or inclined set of rungs or steps. Rigid ladders consist of vertical
members called stringers or rails or stiles connected at specified spacing by
rungs or steps.

Lamproom The designated room or building where cap-lamps for issue to personnel
proceeding underground are stored, charged and maintained

Life of Mine The time in which, through the employment of the available capital, the ore
reserves (or such reasonable extension of the ore reserves as conservative
geological analysis may justify), will be extracted. The mining plan dictates
a schedule of ore delivery to the process plant.

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Locomotive A self-propelled rail-bound machine which requires either a driver for
manual operation or an operator for automatic operation.

Magazine Any building or portable structure used to store explosives and blasting caps.

Mineral Resource A concentration or occurrence of natural, solid, inorganic or fossilized

organic material in or on the earths crust in such form and quantity and of
such a grade or quality that it has reasonable prospects for economic
extraction

Mine Survey A branch of mining science and technology which includes all
measurements, calculations and mapping which serve the purpose of
ascertaining and documenting information at all stages from prospecting to
exploitation and utilizing mineral deposits both by surface and underground
working.

Mining Layout The design of the working area represented in plan-view

Misfire The complete or partial failure of explosive material to detonate as planned.

The term also is used to describe the explosive material itself that has failed
to detonate.

Ore Reserve The economically mineable part of a measured or indicted mineral resource
demonstrated by at least a preliminary feasibility study.

Overseer Miner A competent person possessing a full blasting licence who has had adequate
training and experience in supervising all mine tasks including lashing,
drilling, construction and production; and is given the responsibility over a
mine section or certain tasks in the mine.

Powder Factor The tons of rock affected per kilogram of explosives used.

Primed Cartridge A cartridge of explosives to which a detonator has been attached as a means
of firing, and intended to be placed in the bore hole or other explosive
chamber for the purpose of exploding the remainder of the charge.

Primer A unit, package, or cartridge of explosives which contains a detonator and is

used to initiate other explosives or blasting agents.

Primary Blast The blasting operation covering all sections of the mine which takes place at
the end of the main operational shift.

Rail Track Rail track is the structure consisting of the rails, fasteners, railroad ties
(sleepers) and ballast (or slab track), plus the underlying subgrade. It enables
trains to move by providing a dependable surface for their wheels to roll.

Rail Sleeper A rectangular support for the rails in railroad tracks. Generally laid
perpendicular to the rails, sleepers transfer loads to the track ballast and
subgrade, hold the rails upright and keep them spaced to the correct gauge.

Raise An underground mine tunnel excavation at an inclination greater than 35o to

the horizontal.

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Re-entry The procedure of accessing an area or mine working in which blasting
operations have been conducted, where work is abandoned or temporarily
suspended to ascertain conditions and make safe.

Re-entry Period Time that is allowed to elapse before personnel are allowed to return to the
mine workings.

Relief Hole The uncharged hole in a cut.

Round A set of holes drilled and charged with explosives in any phase of explosives
work, which are fired instantaneously or with delay detonators.

Sampling The process of taking small representative portions of ore in order to

determine the nature of the whole

Safety Fuse A slow burning commercially used blasting fuse having a controlled burn
rate, usually consisting of a core of powder overspun with yarns and tapes,
and which ma y be treated with a waterproofing compound, and intended to
convey fire to the blasting caps or explosive mass while minimizing the
danger to the person lighting it.

Secondary Blasting Using explosives to break up larger rock masses resulting from the primary
blasts.

Spacing The distance between blast holes or charges in a row.

Socket Any shot hole or part of any shot hole, known not to be a misfired hole,
which remains after having been charged with explosives and blasted or
which, for any other reason, may be suspected of having contained
explosives at any time and includes any shot hole, or part of any shot hole,
from which all explosives have been extracted

Socket Plug A device or tool to plug blasthole sockets

Standard Raise An underground mine tunnel excavation at an inclination greater than 35o to
the horizontal and whose travelling height does not extend beyond 30m

Stope An underground mine excavation where mineral ore is excavated for

processing.

Sublevel A horizontal mine tunnel developed between two main levels connecting the
mine workings which is accessed through raises and ramps.

Sump An excavation in which drain water collects.

Survey Grade A survey marker showing the desired elevation an excavation should
proceed at.

Survey Layout The drawing to scale of development to be carried out

Survey Line A survey marker showing the desired direction an excavation proceed to.

Travelling Way Safe access and egress to and from the workplace and all work-related areas.

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 Travelling Way A structure for persons to land on which enables them to safely rest as they
Platform climb up or down the travelling way.

Ventilation The replacement of stale or noxious air with fresh air or the system used to
circulate air replacing stale air with fresh air.

Waiting Place A special bay in an underground mine provided for use by mineworkers
before they are deployed to their workplaces.

Waterblast A device which is designed to produce a jet of water vapour when connected
to high pressure water and compressed air.

Winze An underground mine tunnel excavation at a downslope inclination to the

horizontal.

4 GEOLOGY OF THE MINE

4.1 GEOGRAPHICAL LOCATION

How Mine is situated about 35km southeast of the city of Bulawayo in Matabeleland South Province, in
the Bulawayo Mining District of Zimbabwe (grid reference 853540). The location is at an altitude of
about 1,250m above sea level. The mine is linked with the city of Bulawayo by a narrow tarred road that
branches from Old Esigodini road and serviced by the Joshua Mqabuko International Airport (Bulawayo
International Airport). Disused gravel roads and foot path connect the mine with the local communities
and commercial farming areas. The area covered by the lease was surveyed and declared to be 2 587
hectares shown below:

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 Figure 4 How mine lease area along How shear zone (Source: How mine in-house document)

4.2 REGIONAL GEOLOGY SETTING

How mine is situated in the Umzingwane Formation of the Bulawayo Greenstone belt. This formation
occupies the area in the broad centre of an almost triangular greenstone belt that tapers to the southeast
and links with the Filabusi greenstone belt to the east.
The lithological units characteristic of the Umzingwane Formation include clastic metasediments, fine-
grained tuffaceous rocks, banded shale and siltstones, ferruginous cherts (BIF), rhyodacites and andesitic
lavas. This assemblage has been subjected to metamorphism of lower greenschist facies and high grade
deformation up to amphibolite facies and in places up to granulite facies. High grade deformation is
found associated with the lower greenstones and also localized at contacts with intrusions and within shear
zones.
The setting of the volcaniclastic sediments is thought to be a rift-type basin, possibly fault bounded. Part
of the deformation in the Upper Greenstones affecting the Umzingwane Formation was due to the
intrusion of diapiric granites like the Esigodini granite to the east and the Matopo granite to the west. The
effect of this deformation phase was significant shortening, thrusting and shearing.
Rocks within the Umzingwane Formation are strongly deformed with shortening in the northeast-
southwest direction, parallel to direction of compression force of higher magnitude and extension along a
northwest-southeast axis perpendicular to compression. The How and Umzingwane shears are oriented in
this direction. The regional geology map of the Bulawayo Greenstone belt is shown in Figure 5 below.

14
 Figure 5 Regional geology (Source: How mine in-house document).

ESGODINI GRANITES

MATOPO GRANITES

All of the formations in the map above are constitutes in the Bulawayan Supergroup and are subdivided
into Upper Greenstones and Lower Greenstones. This forms the following stratigraphic column:
Table 1 Stratigraphy of the Bulawayo greenstone belt (Garson, 1991)

GROUP FORMATION ROCK TYPES

UPPER GREENSTONES TORNBRIDGE Mafic- ultramafic volcanic

(Shamvaian-sediments UMZINGWANE Clastic metasediments, BIFs, shale,

felsites
dominated)

Unconformity

UPPER GREENSTONES ALVON (West) Metavolcanics

(calci-alkaline dominated) KESINGTON (East) meta-andesitic lavas and flow-breccias

Unconformity

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 UPPER GREENSTONES SAUERDALE Ultramafic suite

(Basaltic and komatitic UMGANIN Mafic metavolcanic rocks

dorminated) WESTARCE Clastic & calcareous metasediments
with minor BIFs

Unconformity

LOWER GREENSTONES LONSDALE Calc-alkaline metavolcanics

VREIGEVEIGHT Mafic- ultramafic metavolcanics,

BIF and calc-silicate rocks

UPPER GREENSTONES:
Tornbridge formation: consists of extrusive metabasalts, basal metakomatiites and associated with sills
and dykes of metadolerite and metagabbro, some of which are intrusive into the underlying Umzingwane
formation. The contacts between the two formations are not well exposed and those recognizable are
strongly tectonized making it difficult to establish the stratigraphical relationships.
Umzingwane formation: consists of the ferruginous cherts (BIF), rhyodacites clastic metasediments,
fine-coarse grained tuffaceous rocks, banded shale , siltstones, andesitic lavas and some dolerite dykes in
places noted underground but are barren (not mineralised). .
Avalon formation: comprises of a 3-km wide largely rhyodacitic dome and is also with associated
andesitic and rhyodacitic breccias. This formation is made up of Calc-alkaline metavolcanics.
Kensington formation: mainly comprises of meta-andesitic lavas and flow-breccias.
Sauerdale formation: consists of a suite of metamorphosed ultramfiic and mafic rocks ranging in
composition from peridotitic or pyroxenite or komatite to magnesia-rich basalt and theoleitic basalt.
Umganin formation: mainly comprises of metabasalts and intercalated high-magnesia metabasalts with
both rock types commonly pillowed.
Westarce formation: Clastic and calcareous metasediments with minor BIFs.
LOWER GREENSTONES:
Lonsdale: consist of calc-alkaline metavolcanics.
Vreigeviht Formation- mainly comprises of stripped amphibolitic gneisses consisting of highly deformed
volcanic pyroclastic and subordinate mixed pyroclastic-epiclastic rocks with altered mafic volcanic rocks.

4.3 LOCAL GEOLOGY

16
How mine is located in the Umzingwane formation of the Bulawayo greenstone belt. The mapping of the

Figure 6 Local geology (Source: How mine in-house document)

local area established the following sequence from southwest to northeast: Talc chlorite schist, laminated
black shale, silicate facies BIF, tuffaceous units and siltstone (see Fig 6).
Several ore zones occur as an en echelon array of parallel and steeply plunging linear shoots and these
shoots are confined within an extensional right-stepping, northerly trending strike-slip duplex.
Faulting has followed preferred lithological contacts. Mineralization is dominated by a pyrite-gold
association and occurs as disseminations. Alteration is widespread and dominated by carbonation,
silicification, and propylitic alteration. In the north area of the mine, ore zones are developed within the
fault-bounded tuff unit (e.g., the north 180 ore zone) and in the south the ore zones are parallel to the
Hanging-wall fault-shear zone and transgress major lithologic contacts. The occurrence of felsic porphyry
intrusions and mafic dykes in the quarries is also expressed in exposures underground. The disposition of
the quarries show that the ore channel locally transgresses lithological boundaries and is therefore not
strictly strata-bound. There are no big mines in the immediate environs of How Mine though several

17
small, narrow reef old workings do exist especially within the mining lease area. All the old workings are
currently inactive but are targets for off-mine exploration.

4.4 OREBODY MINERALISATION MODEL

The outline expressed by the quarries provides a hint of structural controls that are believed to be
responsible for the localisation of the mineralisation at How Mine. The main control is believed to be an
extensional duplex whose long axis is along the direction of extension. Previous models suggesting that
the ore was stratabound within felsites and syngenetic are now disregarded because of the transgressive
nature of mineralisation. The felsites are in fact, propylitised tuffs. Prominent shears are evident on
hangingwall and footwall contacts of the ore channel and these represent the principal shears of the duplex
system. Orebodies are elliptical in plan, strike north-south and dip steeply around 800 to the west, with a
steep northerly plunge. The major orebodies are the 300N, 180N, 400N and 10S, which have a combined
strike length of about 500m.
A waste or low-grade parting separates the 300N and 180N zones and this becomes narrower at depth and
from below 20 Level is 5 to 10m wide (see Appendix for How mine long section). Where this occurs the
two orebodies were combined into a single entity for resource evaluation purposes between 20 level and
24 level with a maximum width of 55m. Between 24 level and 26 level, the waste parting between the
300N and 180N was left intact. This is as a result of the recommendations by the Rock Mechanics
consultant in mid 2012 and resource evaluation was done accordingly. However, between 26 level and 28
level the 300N and 180N orebodies merged and currently are being mined as one orebody. In general the
orebody width is not always constant. Current information generated from deep drilling indicates the
orebodies gradually taper in width with depth and becomes shallower deep around 60.
The deposit shows significant hydrothermal alteration that is frequently associated with sulphide
mineralisation. Strong carbonation, silicification and in extreme cases propylitisation occur together with
sulphides. Pyrite is the dominant sulphide (90%), with much less chalcopyrite and occasional pyrrhotite
present. Chalcocite and arsenopyrite have also been reported. Ore microscopy has shown that gold is
associated with a late generation of pyrite and chalcocite. The site of the gold mineralisation is either in
fractures within the sulphides or on sulphide grain surfaces. The ore was formed by hydrothermal
solutions migrating along structurally controlled channels predominantly caused by an extensional thrust
duplex with its long axis parallel to the direction of extension.
The current underground exploration drilling between 26 and 28 level has identified another orebody
namely 400N situated to the north of 300N. Another orebody, 350N was discovered between the 300N

18
and the 400N on strike. During evaluation drilling other two small orebodies were discovered namely the
320N and 330N located also between the 300N and 400N but found on the far western side.
Information at hand shows that 400N and 350N have the same geological characteristics as the other
known orebodies. However, current evaluation work focuses on establishing the orebodies down dip
extension below 26 level. This discovery was thought to serve as a strong confirmation of the extensional
duplex theory. The mineralised zones at How Mine have sharp grade boundaries that in most cases can be
defined with confidence.
However current mapping at 28 level 10m carried out by R. Muzulu (Senior Geologist), Mr G. Sibanda
(Section Geologist) and two students on attachment, established presence of some positive flower
structures (faults) which are evidence of transpression which occur at strike slip fault zones making it
more complicated to establish a proper orebody model.

4.5 MINING METHOD

The method employed is sub-level open stoping because of the structurally competent steeply dipping
orebody (about 80). It involves parallel long-hole drilling and draw point loading. Ore from stoping
operations breaks into a common slot, which develops into a stope on retreat. Main levels are about 35m
vertically apart whilst sub-levels are developed at 10m vertical intervals and intersect with the slot raises.
Figure 7 Underground long section showing mining method following orebodies

19
 5 INDUCTION
This was covered prior to arrival at the mine; it involves general introductions to all departments so as to
get a brief know how of what How mine is mining, processes involved in each and every department, the
main roles of these departments and the standards that guides all activities being done. The following
departments were covered during induction:

5.1 Security Department

The security department has the ultimate responsibility of safe guarding the mines assets and property.
The Chief Security Officer heads the department. Security personnel are deployed to critical and strategic
points within the mine premises. The roles of this department includes: development, maintenance,
implementation of the mines security policies, vetting of new employees, issuance of staff ID cards and
investigation of acts of misconduct which have criminal elements.

5.2 SHEQ Department

It deals with Safety, Health, Environment and Quality control, guided by three international systems:
1. OHSAS 18001: deals with Occupational Health Safety Assessment Specification. It covers
identification of hazards, risks to human life and controls. Activity procedures must always be followed
(no short cuts) to ensure no injury at work and no health compromise to all the workers.
2. ISO 14001: is an international standard for environmental management. Three significant parameters of
the environment were identified at how mine which include land degradation, air and water pollution
management. It also includes waste disposal management, spillages and re-use for waste reduction as a
solution to pollution.
3. ISO 9001: deals with quality management which is the fitness for use with satisfaction of the end user
in this case the product managed its quality being gold and the end user being the buyer on the market. It
also ensures a systematic and reliable approach so as to prevent stakeholders dissatisfaction, occupational
injuries, ill health and pollution as this result in increase in loses.

5.3 Human Resources Department

The Human Resources Manager is the head of this department. The department is responsible for ensuring
that the mine has an adequate (qualitatively and quantitatively), motivated and disciplined workforce at
any given time. Functions of the department include recruitment and selection, training and development,
industrial relations, performance management and compensation. The department is also responsible for
employees health and welfare. The other sections in the department are:
Clinic provision of primary health services to employees and their dependents

20
 Community Services responsible for housing and welfare services
LDV Country Club a social and recreational facility for senior staff.

5.4 Finance Department

The administration department is headed by the Finance Manager and is responsible for all financial
accounting and cost management functions of the Mine. The department has six sections of which the
student was inducted which include: Main Accounts (which consolidates all financial transactions); Stores
(stock control of all inputs and raw materials the mine acquires from external sources); Buying (sources
the raw materials from suppliers); Creditors (liaises with suppliers and monitors account status); Time
Office (process junior employee salaries, time sheets and overtime claims for payroll purposes) and I.T
departments (which does procurement; installation and maintenance of information and communication
technology).

5.5 Technical Service Department

The department is headed by the Technical Services Manager and the sections are under this department
include Geology, Survey and Assay headed by the Resident Geologist, Chief Surveyor and Chief Assayer
respectively.
Geology- It oversees the direction of mining activities by exploring, analyzing samples and then advising
the mining department on which areas to direct their efforts in the extraction of ore.
It also determines and assesses ore extracted daily, ore sent to the plant, grade control and estimating the
life the mine.
Survey- Generates accurate information of surface and underground workings through surveying;
develops and updates working plans and is also responsible for draughting.
Assay- Samples are received from geology for assessment and grade determination. Samples are initially
dried of all moisture in a drying room before being crushed and pulverized into finer particles. Samples
undergo a rigorous process until the amount of gold in each sample can be measured and recorded. These
statistics are sent back to geology then mining to advise on mining direction.

5.6 Metallurgical Department

The metallurgy department is headed by the Metallurgical Manager and oversees the reduction of ore to
gold through the following processes.
a. Crushing- Ore is trammed from the North Shaft to the plant where it undergoes through primary
crushing (jaw crusher), secondary crushing and tertiary crushing (barmac crusher).

21
b. Grinding- Ore is fed into the mill together with steel balls and water, the mill is run at 80% the critical
speed.
c. Thickening- Cyclone overflow is de-watered in the thickeners and the underflow from the thickener is
pumped to the CIP plant. In the first CIP tank, cyanide and oxygen are added into the leach pulp whilst
in the last tank activated carbon is added and allowed to flow with the pulp.
d. Elution- The loaded carbon is then transferred to the elution column where the carbon is stripped of
gold. The gold is brought to solution and elctrowinned.
e. Smelting- Gold from the cathodes from electro winning is collected and smelting is done in a furnace.
Stages of ore processing flow diagram
Figure 8 Processing of ore to gold bullion (Sourced from How mine in-house document

5.7 Mining department

The department is headed by the Underground Manager and is responsible for the extraction of ore from
underground. Mining Method is sub-level open stoping(shown above). The roles include mine planning
and designing, development, production drilling at stopes done by enlarging slot raises.

5.8 Engineering department

Headed by the Engineering Manager, this is a service department which consists of four main sections i.e.
mechanical engineering (underground and surface), electrical engineering, planned maintenance and the
transport section. The major objective of the department being to ensure that user department has
functional machinery and equipment through repairs and servicing.

22
 6 ATTACHMENT CONTENT

6.1 Risks at the Company

EMS OHS QMS

Noise pollution Injury from fly dirt Wrong grinded angles

Water pollution Injury from rotating machine Uncallibrated Gas detectors

sharpening components

Air pollution Noise Compressed air and water hose leaks

Oil Spillage Death from electrocution Poor advances

Disposal of explosives packaging Gassing Poor drilling direction

Weather conditions when Fall of ground Incorrect marking

transporting explosives
Mine flooding Incorrect drilling pattern

Dust Poor powder factor

Accidental detonation Wrong drilling angle

Drill-steel breakages Poor burden and spacing

Rock fall Compliance of the vehicle

(explosives transportation)
Drill-rod breakage Use of canvas bags (explosives
trasportation)
Machine collapse Use of red flags

Fall from height Accountability

Cracks on bench Time management

Improper handling (equipment and Misfired rounds

explosives)

Bad hangings Over/undercharging

Heat Dilution

Falling into tipping area Non-completion of ends

Undercutting of muck pile Over/underfilling of ore

Cocopan derailment Poor track laying

Slippery tracks Ore overthrows when loading

Mud rush Improper alignment of the shaft

23
 Cage overloading Malfunction of machinery

Cage run-away Failure to meet mining target

Pipe leakages

Poor track alignment

Poor sleepers spacing

6.2 Lashing
It is the transfer of ore\waste from a blasted end to a tipping point.

Working areas

a. Level 28 10 Drive South

b. Level 28 20 Drive North
c. Level 27 North North South

Lashing procedure

Firstly safety talks are carried out before work progresses

Pre-task risk assessment is carried at workplace before lashing commences.
The muck pile is then watered down to suppress dust and dilute mine gases, enough water
is indicated by clear water flowing from the muck pile
When watering down, you bar down bad hangings using a pinch bar to a distance of 8m
from the muck pile
After the working place has been made safe, lashing can then commence
In manual lashing ,ore\waste is lashed using a shovel into a wheelbarrow which then tips
into an ore\waste pass
For purposes of safety, at a stope or within 2m of an ore\waste pass, a safety chain
anchored to a lifeline must be used
A tipping barricade should also be placed
Not undercutting the muck pile to avoid collapse of the muck pile which might cause
accidents
11 shovels = 1 wheel barrow on average
22 wheelbarrows=2t coco pan

24
Purpose of lashing

To measure tonnage from previous blast

To check for over breakage which might be caused by undercharging or drilling shorter holes
than required
To expose lifters and misfires
Hauling of ore to create safe working place.
Create space for another drilling and blasting shift.
Equipment used
EQUIPMENT DESCRIPTION
- 60 litres liquid capacity
- These are used in drives of smaller dimensions (in sublevels) where tracks have not
Wheelbarrows been laid and the space is too confined to allow movement of larger equipment.
Wheel barrows are loaded using shovels and hand pushed to the tipping points for
dumping of ore or waste
- 1.1 m (length), 0.4m (blade), 0.07m (handle)
- Capable of supporting aggressive motions such as cutting, lifting and
Hand shovels
tossing the muck.
- Are used to load wheel barrows, cocopans or granby cars.
- These come in different lengths of 1m, 1.5m, and 2m.
Pinch bars - They are used for barring down bad hangings from the hang, face and side walls of a
drive to make safe the working area.
- Type used is the MSA 10107602 Altair 4X Multigas Detector.
- Utilizing a rough and tough exterior casing and capable of recording the
Gas monitor
amount of different gases present at any environment at the same time.

Observations

development lashing
- Drive had dimensions of; 1.8m height, and a width of 1.5m

25
- Hole depth was 1.5m trying to achieve an advance in meterage of 1.3m
- Volume in cubic metres of ore per round was approximately1.8 1.5 1.5 = 4.053
- The specific gravity of the rock at How Mine is 2.8 tonnes/m3
- Volume in tonnage is then 1.8 1.5 1.5 2.8 = 11.34
- Wheelbarrows used have a capacity of (60litres) 0.06m3 , in tonnage, it then become
0.06 2.8 = 0.168
11.34
- Expected number of wheelbarrow loads per blasted round = 67.5,
0.168
approximately 68.
- No round produced exactly this amount of wheelbarrows, more than 68 were produced.
- This was because the wheelbarrows where not filled up to the 0.168 ton capacity and also
muck will be more than 11.34tonnes mostly.
- Therefore per round approximately a range of 80-100 wheelbarrows were produced.
- Student worked at 2 work places (2820 drive south and 2810 drive north)
- Distance from muck to tipping point at 2820 drive south was about 50-60m
2 manpower pushed wheelbarrows relaying to the tipping point.
A range of 1minute 30 seconds to 2 minutes was the cycle time to and from
tipping point with reference to loading point
A range of 30 to 90 seconds was taken to load one wheelbarrow depending on
availability of delays and also the effort by lashers.
Wheelbarrow trackers always found a wheelbarrow already full and ready to be
hauled hence the total cycle time only includes the cycle time of hauling and not
that of loading.
Manpower comprised of 4 people; gangleader, student and other 2 people
Distribution of manpower, 1 lasher and 2 on hauling and dumping
Equipment; 3 or 4 wheelbarrows and 1 or 2 shovels.
- Distance from muck to tipping point at 2810 drive north was about 70-80m
Manpower comprised of 5 people including gang leader and student. (2 lashers
and 2 wheelbarrow trackers)
Equipment; 2 shovels and 3 wheelbarrows
A range of 120 to 180 seconds cycle time was taken to and fro tipping point with
reference to loading point.
A maximum of 40 seconds was taken to load one wheelbarrow.

stope lashing

- This is the removal of broken rock from blasted ends (slipped ends) in stoping operations.
- The lashing crew from Stoping Section 2 are responsible for these duties and since their
work is not intensive they are very few compared to lashers from other sections.

26
 - The reason there is less mucking in stoping operations is because after blasting most of
the broken rock falls directly into an ore pass or previously mined open stopes thus less
ore remains to be removed.
- This is done to clean a bench preparing for longhole drilling.
- Technical information about stope lashing is hard to get because some of muck blasted
fall directly into stope.
- Stope lashing is the most dangerous of all lashing operations due to the presence of open
stopes.
- Safe procedures to be followed.
- These include installation of a lifeline and a barricade.
- Therefore every time upon arrival at the working place after blasting a barricade and a
lifeline must be constructed or extended to make the area safe to work.

6.3 Drilling, charging and blasting

A report on jackhammer drilling, charging and blasting. Jackhammer drilling is a process
that involves the use of pneumatic jackhammers to make a hole or create a free face for
the purpose of blasting using explosives. The student did this activity for a period of 5
weeks.
Objectives
To obtain knowledge on how to carry out a proper re-entry for the purpose of drilling.
To obtain practical knowledge on drilling.
To have knowledge on charging, timing and blasting an end.
To have knowledge on how to improve advance and to point out factors which lead to
poor advance.
Principle of operation of a jackhammer(s215)
The jackhammer operates by driving an internal hammer in a percussive motion through
the use of compressed air.
It works with a centrifugal piston driven by compressed air with strokes ranging between
1800 to 3500/min in reciprocating motion and is controlled by a flutter valve.
Water is used as the flashing agent in jackhammers and its absence causes drill steels to
be jammed due to sludge accumulation. It is also a statutory requirement to use water in
all underground drilling mainly to allay dust and to cool the drill steels (SI 109 section
60)

27
 Jackhammers use a lubricant called RD compound oil which is constantly supplied to the
machine throughout its operation. The oil is supplied by means of a line lubricator which
is filled with the lubricant at the commencement of the drilling shift.
Tapper steel sizes used are 0.8m, 1m, 1.3m, 1.8m and 2.3m together with 38mm bits
(starters/collaring) and 36mm (finishers/deepening)
Spares, tools and equipment
ITEM SIZE QUANTITY

2way blow pipe 2.5m 1

Hammer 2kg 1

Wrench spanner 300ml 1

Drill steel spanner Standard 1

Pinch bar 1.2/1.5/2.0 m 3

jackhammer Standard 1

Long telescopic airleg Standard 1

Inline lubricator 1 litre 1

Oil can 500ml 1

Air hose 25mm 30m

Water hose 12.5mm 30m

Tapered steel set 0.8/1.0/1.3/1.8/2.3 As required

Button bit 36/38/41 mm As required

Collaring gasket 45mm 1

Flat end drilling (haulages & sub drives)

At the surface the supervisor checks the lashing returns to see ends lashed and cleaned.
At the underground waiting place, safety talk is carried out and checking of PPE
Tasks are allocated to the drilling crews i.e. 2 people per machine.
Assistants collect RD compound oil at the rock drill workshop on their way to their
respective workplaces.
Making safe

28
 Upon arrival at the end, a pre task risk assessment is done whereby hazards associated
with work to be done are identified and controls are provided.
Water down from 8m away from the face, barring down advancing towards the face.
Expose lifters for a distance of 2m to make sure that there are no misfires from lifters of
the previous round.
Water down the face, searching and pumping out all misfired holes using an aluminum 2
way blow pipe.
All misfires are placed in a stout canvas bag and taken to 26L production for destruction
(secondary blasting)
Plug all sockets using wooden plugs.
Marking the round
Suspend 2 bobs on 2 survey pegs (Front Line and Back Line pegs) and project the centre
line on the roof and on the face.
Mark all the holes using a red paint or chalk and 15cm away from sockets. Holes are
marked according to the standard drilling patterns and dimensions as given on the
layouts, with sub-drives normally being 2m wide X 2m high and haulages 3m wide X 3m
high.
Mark direction lines on either sides of the centre line parallel to the centre line.

29
Figure 9 marking of a haulage face

3m

3m
30
cm
m

50cm

Preparation for drilling

Blow out hoses until they are free of dirt and connect the lubricator.
Connect hoses to the jackhammer and the airleg. Secure the air hose to the rockdrill with
a sling to prevent backlash of the hose should it become accidentally detached from the
rockdrill connection. Open air valve and check for air leaks and remedy all leaks.
Open the water valve and check the pressure of the water by holding the machine
vertically upwards. The water should fountain upwards for at least 0.7m and the water
will be at approximately 200Kpa.
Check drill steels for slipped collars and return faulty steels to the rock drill workshop.

During drilling

30
 Do not dry collar a hole. This leads to overheating and premature failure of the drill steel
and is also a health hazard since a lot of dust is produced.
Do not hammer jammed drill steels, but rather extracted using a key spanner.
Drill on marked positions and maintaining a distance of 15cm from sockets.
Avoid deviation as this lead to poor fragmentation of the blasted muck.
Use a rubber gasket when collaring to prevent grit from damaging ones eyes.
In a haulage, use a platform when drilling backholes to maintain a height of 3m.
Drilling sequence; Collaring(38mm bit, 0.8m tapered steel) deepening (finalized with a
36mm button bit and longer tapered steel)
Raise drilling
Before drilling can commence in raises, they are rigged. This is done by the PTV crew.
Raise rigging
- 16 L pins are used for both the safety and drilling platforms
- Chain ladders are secured with 4 pins
- Round poles and flat timber is used for raise rigging.
Making safe
Upon reaching the end to be drilled together with a competent person, connect the hoses
to the water valve outlet.
Water down the whole area around the brow of the raise and bar down thoroughly all bad
hangings.
With a grizzley hook standing clear off the raise, shake the ladders to dislodge any rock
which may have been caught up and to make sure that the ladders are still secure.
With a 12.5mm water hose and short pinch bar, climb up the raise and thoroughly water
down the face and bar down all bad hangings.
After extracting misfires, circle the sockets with a red paint. Socket plugs are not used in
raises since they can be hazards.
Face marking
Suspend bobs on 2 survey pegs and project a centre line of the raise on the face and roof.
The direction lines are marked on the side walls of the raise using a clinometer rule as
given in the survey layout.

31
 5 hole burn cut is used in raise drilling
Drilling procedure is the same as the one in flat end drilling except that precaution is
taken when removing drill steels as these can accidentally fall, injuring workers.
Charging
Explosives used
29 X 270mm Megamite
- Nominal density - 1.14 g/cm3
- VOD 3500 to 5000 m/s depending on rock characteristics
- Gap sensitivity contact required for propagation
- Shelf life 12 month from date of manufacture
- Packaging 25 kg box, 125 cartridges per box
- Cartridge weight 200g
Shocktubes
Electric detonators
Igniter cord
Procedure
Test the water blast if its functioning and that it is properly positioned i.e. not more than
15m from the face.
Remove all equipment and place it in respective racks where it is safe from flyrock.
Dismiss all men not partaking in charging.
Post a no entry sign at a suitable distance.
Priming
This is a process of inserting a detonator inside a blasting cartridge.
Megamite and shocktubes are used.
Prepare one primer and insert in the blast hole at a time. Piling up of primers must not be
done because it can be a disaster in case of a premature detonation.
Charging and timing
Only a non-ferrous charging stick should be used to press the charges home and at How
mine, wooden charging sticks are used.

32
 Insert a primer first followed by 3 cartridges covering 1.08m of the hole, leaving 0.42m
for stemming. (subdrives)
For haulage put 4 cartridges after primer thereby covering 1,5m leaving 0.5m for
stemming
Gently press home and compact the cartridges for a favorable coupling ratio.
Old explosives cardboard boxes are used for stemming.
Timing is done using shocktubes
Below is a time motion study showing time taken to drill a 1.5m hole, compressed air at
700Kpa
HOLE NUMBER 1M 0.5M
1 3min 12s 1min 55s

2 2min 54s 2min 02s

3 2min 58s 1min 49s

4 3min 09s 1min 46s

5 3min 16s 1min 50s

AVERAGE 3min 05s 1min 52s

Therefore it takes about 4min 57s to drill a 1.5m hole.

Using the average time taken to drill one 1.5m hole it shows that about (4mins 57sec x 23 holes)
114minutes whuch approximately 2 hrs for a subdrive face with 23 holes, if no delays occur

6.4 Explosives
Types of explosives

They are found in accessories and fractures.

33
Fractures Accessories

Safety fuse (0.9)m Shock tubes (2.4/3.0/3.6)m

Emex 70 IED (Instantaneous Electrical Detonators)

Explogel v10

1. Emex
This is a catridged emulsion explosive.

function
Emex is a packaged emulsion explosive. The emulsion is robust and sensitisation with
microspheres ensures excellent shelf-life and reliability of detonation. It is a firm, water resistant
cartridge which has a formable consistency for tamping. The high velocity of detonation (VOD)
and relatively lower gas volumes (compared to ANFO and watergel) ensure fi ner fragmentation
in tough ground whilst limiting over-break.
Description
The Emex range consists of four product grades with a RBS (Relative Bulk Strength) relative to
standard ANFO (Ammonium Nitrate Fuel Oil) of 129% to 179%. Cartridges are available in
specific diameters from 25mm to 50mm and specific lengths from 200mm to 550mm. The
cartridges are packed into a 25kg plastic inner bag inside a boldly printed carton, identifying the
product as Emex explosives.
Advantages

34
safety All products are brightly coloured for easy identification in storage and in the field.
All explosivesare classified as dangerous goods and can cause personal injury if not
handled correctly

reliability Emex is manufactured to order with excellent water resistance, flexibility and
performance reliability with every initiation

quality Manufacturing of this product conforms to the ISO9002 quality standard. All
materials are tested and approved before use. Tests are conducted to confirm that
the density, fuel content, moisture content and aluminium content conform to
specifications.

custom - Each carton is marked with a sticker that identifies the product according to grade,
packaging cartridge dimension, date of manufacture, production team, batch number and
carton number
-The information enables Sasol Nitro to refer to quality records in order to
investigate customer complaints.
The information allows full traceability of manufacturing details under the
ISO9002quality system

flexibility Wide range of applications.

Excellent in wet or dry conditions

Product information
At The Company the product of emex used is E70 though there are other products; E30, E50 and
E90
Emex E70 is a high energy product designed for typical hard rock development, tunneling or
very tough stopping conditions
Emex E70

Velocity of Detonation (m/s) >4900

Colour identifier Green

Nominal density (kg/l) 1.16

Relative weigh strength 112

Relative bulk strength 162

Gas volume (l/kg) 864

35
Water resistance Excellent

Operating temperature (C) -10 to+55

Net packaging weight (kg) 25

Carton dimensions (mm) 595 x 210 x 260

Cartridge dimensions (Diameter x length (mm) 29 x 270

38 x 550

Cartridge count /packing density (29 x 270) =120 123

(38 x 550) = 35

Recommended storage 6 months in magazines

(dry, well ventilated and under cover)

Shelf life 2 years

2. Explogel
This is a catridgedwatergel explosive
function
Explogel V is a revolutionary cartridgedwatergel explosive range that combines proven
explosive technology with the proprietary Expan Ammonium Nitrate technology. The inclusion
of Expan ensures a product with enhanced sensitivity and energy partitioning for improved
advance and generally coarser fragmentation.
Description
The Explogel range consists of six product grades; covering energies from 82% to 239% the
energy of standard ANFO (Ammonium Nitrate Fuel Oil). The products are sold in individual
cartridges , wrapped in a plastic sleeve which is crimped at both ends with an aluminium clip.
The cartridges are then packed into a plastic bag which, in turn, is packed into a boldly printed
carton, identifying the product as a watergel explosive
Advantages
Safety All products are brightly coloured for easy identification in storage and in the field.
All explosives are classified as dangerous goods and can cause personal injury if
not handled correctly.
Explogel cartridges are not impact and friction sensitive

36
Reliability Explogel is manufactured to order with very good water resistance, flexibility and
reliability withevery initiation.

Quality Manufacturing of this product conforms to the ISO9002 quality standard. Tests are
conducted on each batch to confirm that the density and PH levels conform to
specifications.

flexibility Wide range of applications.

Excellent in wet or dry conditions

Product information
At How mine we make use of explogel v10 though there are other explogel products that is;
explosmooth, explogel v4,explogel v6, explogel v8, and explogel v12. They come in increasing
energy. V12 has an exceptional high energy compared to all others.
Explogel v10 is a high energy product particularly suited to deeper hole applications, such as
shaft sinking, surface and quarry mining, but we use it at longhole. The product is ideal when
used in cold conditions where other packaged products may become problematic.v6 or 8 is the
suitable for our stoping operations.
Explogel V10

Velocity of Detonation (m/s) 3500

Colour identifier Writing grey

Film - orange

Nominal density (kg/l) 1.18

Relative weight strength 105

Relative bulk strength 155

Gas volume (l/kg) 955

Water resistance Very good

Operating temperature (C) 25+

Net packaging weight (kg) 25

Carton dimensions (mm) 600 x 270 x 220

Cartridge dimensions (Diameter x length (mm) 38 x 550

Cartridge count /packing density (38 x 550) = 34

37
Recommended storage months in magazines
(dry, well ventilated)

Shelf life 6 months

Magazine controller

How mine magazine controller is appointed as the person in charge of the How mine Explosive
Magazine as per requirement of clauses 4.4.1 of OHSAS 18001 standard, 4.4.1 of ISO
14001:2004 standard, 6.2.1 of ISO 9001:2008 and the statutory instrument 72 of 1989.

The duties of the magazine controller among other things include;

1. Receipt of explosives into the magazine

2. Ensuring proper storage of explosives within the magazine
3. Issuing of explosives from the magazine
4. Record of an receipt, storage or issue of any explosives
5. Keeping the magazine locked at all times
6. Safe custody of the keys to the magazine
7. Reporting any anomalies to the miner in charge or mine captain
8. Internal and external transportation of explosives

Legal books and licenses

1. Magazine register book

2. Temperature record book

Temperatures in magazine

- According to the explosive regs, SI 72 of 1989 section 91. the temperature is supposed to
be regulated and maintained within range of 2 35oC
- (a) Provided with a reliable thermometer showing maximum and minimum temperatures;
and
- (b) Shielded from the suns rays or provided with other means so as to ensure that the
temperature inside the magazine does not at any time exceed 35C

EXPLOSIVE ISSUING

38
 - Below shows a table showing date, type of explosives and workplace where they were
issued to.
- DV stands for development
- ST stands for stopping
- Prd stands for production
- IED instantaneous electric detonator
- Per box/case/pack/rim below are the amount of units/sticks/metres found;
1. 38x550 = 34sticks
2. 29x270 = 123
3. SB cord = 2rims x 250m
4. 15m Ezdets = 100units
5. 0.9m fuse = 600units
6. 2.4m shock tubes = 400units
7. 3m shock tubes = 275units
8. 3.6m shock tubes = 275units
9. IED = 1000

Date Workplace cartridges SB cord Shock tubes Fuse 0.9 IED

2017 38x550 29x270 2.4m 3.0m

10/07 Prd 26 8cases 500m 25 units

ST 28207N 60 15 1

ST 27/7N 84 24 1

ST 2820350 60 12 1

ST 2810350 90 18 1

DV 27/400N 105 21 1
Cub

DV 27/400 105 21 1

DV 28 180 35 1
haulage

DV 27107N 84 21 1

39
 Drive south

DV2710400 84 21 1

DV2820400 105 21 1

DV2810400 105 21 1

DV2820320 84 21 1

DV2810320 72 18 1

- At 16 level magazine, a record of quantity of explosives received from surface magazine

and those issued to 26 and 28 levels is kept.
- Below is an example of a table showing type and quantity of explosives in and out and
the balances left in 16 level magazine.
- All explosives were accountant for in the same way as fuses below.
0.9m fuse

Date received Issued Location balance

10/07/17 50units 1 case

11/07/17 50units 26L 550 units

11/07/17 100units 28L 450 units

12/07/17 50units 26L 400 units

13/07/17 75units 325 units

17/07/17 75units 125 units

18/07/17 25units 28L 100 units

18/07/17 100units 26L Nil

18/07/17 1 case 1 case

6.5 Ptv (pipe and track laying)

The duties of the P.T.V crew are;

track laying
pipe fitting and repairing
installation of water blasts at development ends
installation of force and exhaust fans
construction of ventilation doors
40
 placing of barricades and lifelines

Tools and equipment used

Spanners(sizes 24 and 48), size 48 ranch spanner, hacksaw, chisels, 4 pound hammer, bends, T-
pieces, clamps, blockers, nipples, spots, couplings, valves, reducers, gaskets, bolts and nuts,
Frenchs

Insallation of a waterblast,

A water blast was installed at every development end being blasted

A water blast unit is a device that uses compressed air to produce a fine spray of water
that is used to suppress dust and fumes at all development ends
A water blast should discharge at a distance of between 8m and 15m and should be
opened for a period of not less than 15 minutes
It has 2 inlets , one for water and the other for compressed air and outlet for the discharge
pipe

Track laying at 28 level main haulage drive

The top of both tracks shall be 1m below the grade line and shall be horizontal. The spirit
level should be used to check this. At bends the outer rail should be 12mm above the
elevation of the inner rail

The top of the drain shall be at the same height as the bottom of the slippers in order to
allow the tracks to drain freely.

Track layout

0,61
Rail
Cotch screw mmm
45lb

Wooden
slipper

Drain apex

41
Salvaging of old slippers and cotch screws in old working areas which were to be used at 070
cross cut. Safety should be considered when working in old working areas since gases like
hydrogen sulphide are likely to be present.

Bending of rails using Jim crow

Procedure

Lay the rail in a convenient position, and secure one end.

Lay out the curve on the footwall of the haulage or drive using chalk or paint.
Alternatively, use a curved rail as a guide, or use the line of holes in the sleeper.

Mark the crown of the rail every 0,3m. These will be the positions where the shoe of the
Jim Crow will bear. Do not bend up to the fish plate holes, except for particularly sharp
curves that will not be used for normal tramming.

Place the Jim Crow, with the claws gripping over the crown of the rail. Screw the shoe
hand down tightly.

Raise the arch of the Jim Crow to a horizontal position, and hold it in place by sliding a
pinch bar over the rail and under the arch.

Place a raise pin or piece of round bar into the hole in the screw head, and turn until light
strain is produced in the rail. The same amount of strain should be used for each bending
operation. Actual bending is measured by counting the number of turns of the screw
beyond this point.

Give the screw one complete turn. Release the screw and repeat at every chalk mark.

After completing a length of bend, check the track. Repeat the above steps if further
bending is required.

Supply of compressed air should be in such a manner that it is pure air without water hence water
traps should be incorporated in the main compressed air line. According to SI 72 of 1989 section
62 the air valves in case of raises should be placed at the foot of the raise.

Mending of leaks

Clamps are used for sealing all leakages on pipes,

Barricading

Safety barricades are put at all open stopes, ore passes, pits or anywhere else where there is a risk
of someone falling in

42
Barricades are removed prior to blasting operations and then re-constructed after are-entry
procedure

6.6 Production
This includes activities such as; Air loader lashing, Loco Tramming, Grizzly Operations, Ore
handling and hoisting and Secondary Blasting.
Tramming is the transportation of ore through a track work system to the designated tipping
point or using a LHD or conveyor in a trackless system. The main production levels are 26 and
28. Ore is trammed in haulages from the draw points where an air loader-locomotive
combination is used and then tipped at grizzley by the locomotives. Ore is mined from above
levels; it can be either from open Stope sublevels or from coning levels. Ore that is drilled and
blasted goes through ore-passes and is collected in the cones and goes through the ore passes to
the draw points.

Type of machinery used for tramming from draw points to the grizzleys

Air loader with a 1 tonne capacity bucket.

Battery powered locomotive which pulls Granbys with a 5 tonne capacity each

In the case of large boulders choking the cones or at the draw points, secondary blasting is
carried out to further fragment these large boulders

Loco tramming signals

The following whistle signals should be used:

1 blast - stop when loco is in motion

1 blast - move forward when loco is stationary
2 blasts - reverse
2-2- reverse slowly
1 long blast- move to grizzly

Secondary blasting

Secondary blasting is a result of poor fragmentation of primary blasting

Poor fragmentation is caused by poor stemming, poor timing, hole deviation and poor
burden and spacing
During secondary blasting of several large boulders, detonating fuse is used in
conjunction with 0.9m capped fuses, mega mite cartridges and ignitor cord
Detonating fuse is used as it results in all the boulders breaking up at the same time hence
reducing the chance of misfires occurring like when only capped fuses and ignitor cords
are used on separate rocks

43
 During secondary blasting, first an alarm is rang thrice then after initiating the ignitor
cords, verbal warnings should be given by guards who also barricade and prevent persons
from coming to the area to be blasted
The re-entry period is 15minutes, so after 15 minutes the compressed air pipe is closed as
it would have been opened soon after blasting

ore handling and hoisting

ore skips are 5tonne each

28 L there is a crusher

Conveyor belts at 29, 2410and 25 levels

6.7 SHAFTS
Uses of shafts

To access the orebody

To transport men and material to and from underground quiet

For hoisting ore and waste from underground

To serve as intake and return airways for the mine (ventilation)

To provide secondary egress as required by mining law

- In use they had 3 shafts that were the north, main and 16N7

NORTH SHAFT

44
 - The skip is for hoisting ore and waste from level 25 and transportation of heavy materials
MAIN SHAFT

- Is used to transport people and waste material, heavy material and explosives from

surface to 16L

16N7 SHAFT

- Is the one which takes from 16L all which proceeds to 28L which comes via main shaft

Below show a diagram which gives a picture of dimensions of the shafts

Figure 10 aerial view of how mine shafts

Duties of the shaft crew

45
Shaft examination and maintenance

Shaft equipping

General shaft house keeping

Shaft construction, includes barricading and pipe fitting

Shaft examination procedure

Log in the hoist drivers log book indicating time of commencement of exam and official
in charge before the exam starts
After logging in the book, communicate verbally with the hoist driver in regards to
carrying out the exam
Shaft examination of the main shaft was carried out on Tuesdays and Thursdays and that
of the north shaft was carried out everyday
6-6 bells are rang to indicate to the driver that shaft exam was to begin making use of the
key bell
Driver replies 6-6 bells acknowledging that the exam may begin
The cage was lowered using 2-2 bells so that a safety hood can be fastened on top of the
cage
1 short bell signals the driver to stop the conveyance
A platform was put once the cage was low enough such that the shaft crew can disembark
on top to fasten the hood , then the platform was removed
Safety chains must be used throughout this procedure
After the hood was fastened , the cage was raised slowly using 3-3 bells and stopped
using one short bell
The safety chains of the men are tied on the humble hook of the conveyance along with
the rest of the equipment they need which will be placed on top of the conveyance such
as cutting torch, hoses and the two gas cylinders, tool box containing spanners, hammers,
chisels, bolts and nuts, washers, tape measures, pinch bars, T-pieces and gaskets
After the men are satisfactory secured they then proceed with the examination
Movement of the conveyance was through the 2-2 and 3-3 bells

46
 As the conveyance was descending slowly men will be knocking the runners with a
hammer to check for their rigidity and alignment as well as checking all the buntons to
make sure they are secure , all nuts that are loose should be tied and all bad hangings
should be brought down
All pipe leakages are sealed
The shaft was searched throughout its length and upon reaching the shaft bottom, it
returns to the surface where the hood was removed
Upon removal of the hood ,6-6-6 bells are rang to release the conveyance and to mark the
completion of the shaft examination
The official in charge then signs out in the hoist drivers log book

6.8 PLANT OPERATIONS (REDUCTION)

"As-mined" or "run-of-mine" ore consists of valuable minerals and gangue. Mineral processing,
sometimes called ore dressing, mineral dressing follows mining and prepares the ore for
extraction of the valuable metal from metallic ores to produces a commercial end product
GOLD. Apart from regulating the size of the ore, it is a process of physically separating the
grains of valuable minerals from the gangue minerals, to produce an enriched portion, or
concentrate, containing most of the valuable minerals, and a discard, or tailing, containing
predominantly the gangue minerals. The gold ore reduction process involves

Crushing
Milling
Carbon In Pulp
Elution and Electro winning
Smelting
Tailings Disposal

47
6.8.1 General Overview of the Reduction Process

Jaw crusher
Crushing Gyratory crusher
Barmac crusher
Ball mills
Milling Hydrocyclones
Knelson Concentrators

Carbon
Carbon In Cyanide
Pulp Hydrogen Peroxide
Oxygen

Hydrochloric Acid Wash

Elution Caustic-Cyanide Soak
Electro winning
Super Flow Tank
Tailings Pumps and Delivery
Disposal Lines
Dam wall Cycloning and
Paddock systems

6.8.2 Crushing
Crushing is the first mechanical stage in the process of comminution in which the main objective
is the liberation of the valuable minerals from the gangue.It is generally a dry operation and is
performed in three stages which are

i. Primary crushing ( Jaw crusher)

ii. Secondary crushing (Gyratory crusher)
iii. Tertiary crushing (Barmac crusher)

Vibrating screens are placed in line with the crushers to remove undersize material, or scalp the
feed, and thereby increase the capacity of the crushing plant. Undersize material tends to pack
the voids between the large particles in the crushing chamber, and can choke the crusher, causing
damage, because the packed mass of rock is unable to swell in volume as it is broken.

Crushing may be in open or closed circuit depending on product size. In open-circuit crushing,
undersize material from the screen is combined with the crusher product and is then routed to the
next operation.Open circuit crushing is used in intermediate crushing stages. Since the tertiary
crusher produces ball-mill feed, closed-circuit crushing is employed in which the undersize from

48
the screen is the finished product. The crusher product is returned to the screen so that any over-
size material will be re-circulated.

Process flow of ore in the Crushing Plant

Rough Ore Bin
Capacity - 578 tonnes
Ore size +150mm
Grizzly bars above 3 ore passes

Vibratory Feeders / Vibro chutes 1,2&3

Fitted with adjustable gate iron bars supported on
chains, to control feedrate onto conyeyor belt Ore size -150mm

Conveyor Belt 1
Fitted with a Tramp metal detector for detection of Ore size -150mm
metal objects on the conveyor

Vibrator 1
Screen size : 2.5m * 1.25m Undersize : - 50 mm
Aperture Size : 50 mm Oversize : + 50mm

Jaw Crusher 1&2

Size : 14 * 24 Inch Ore Size reduction : 150mm to -50mm

Conveyor Belt 2
Fitted with magnet to trap metal objects that could
Ore size : -50mm
have escaped the tramp metal detector

Vibrating screen 2
Size : 2m * 1m Undersize : -25mm
Aperture size : 25mm Oversize : + 25mm

49
 Gyratory Crusher
Size : 36 Inch Diameter
Ore Size Reduction : 50mm to - 25mm
Gap : 25mm

Conveyor Belt 3
Ore Size : -25mm

Conveyor Belt 4
Ore Size : -25mm

Conveyor Belt 6
Ore size : -25mm

Main Vibrator 3
Barmac Crusher Conveyor Belt 5
Size : 5.2 * 2.15 m
Ore Size : - 15mm Ore Size : +20mm
Poly Screens
Oversize : + 20mm
Undersize : -20mm

Fine Ore Bin 2

Conveyor Belt 8 Conyeyor Belt 7
Capacity : 800 tonnes
2 Discharge Chutes Ore Size : - 20mm Ore size : -20mm
Ore Size : -20mm

Fine Ore Bin 1

400 tonnes

50
6.8.3 Milling

6.8.3.1 Milling Circuits

There are two milling circuits in the milling circuit, the primary circuit being the first stage of
grinding and the secondary circuit which is mainly the re-grind circuit

Primary Milling Circuit

Process Flow

Description

Ore from the fine ore bin is fed onto Conveyor belt 1 through volumetric chutes and is
discharged onto conveyor 2 (incline conveyor). Conveyor 2 feeds Conveyor 3 (jump conveyor)
which in turn feeds conveyor 4. Ore on Conveyor 4 goes into the banana chute together with mill
feed water and oversize from the vibratory screen. 100mm steel balls are manually fed onto
conveyor 2 and are conveyed together with the ore until they go into the mill.steel ball addition is
done on morning shift and 2 tonnes are added daily.

Primary mill discharge is diluted and pumped to the vibratory screen. Oversize from the screen
goes back into the mill while underflow becomes Knelson Concentrator feed. Knelson

51
concentrator concentrates are deposited into a concentrates box and are later further processed in
the Acacia Plant. Knelson Concentrator tailings form Primary Mill Cyclone Feed. The Primary
mill cyclone overflow is discharged in the Regrind 1 and 2 mill discharge sumps while the
underflow becomes regrind 1, 2 and 3 feed.

Secondary Milling Circuit

Process Flow

Description

Primary mill cyclone underflow is split into three forming feed for the three regrind mills. A
tonne of 60mm steel balls are added to each regrind mill a day. Regrind mill 1 and 2 have similar
circuits where the mill discharge goes to the Knelson concentrator and tailings from there
become the cyclone feed. Underflow from each respective cyclone is fed back into the mill and
the overflow goes to the Delko Screen for trash removal. The underflow becomes the final
product that goes to downstream processes.

Major Equipment

The major equipment used in the milling section are:

- ball mills

52
- knelson concentrators
- acacia plant
- vibrating screens
- linear screen
- cyclones
- centrifugal pumps

Ball Mills

mill diagram

Operating principle of a ball mill

The ball mill is lined to protect the shell from the grinding media, At How Mine, the feed size of
the ball mills is generally fines, therefore interaction of the feed itself does not result in
comminution. Steel balls are fed into the ball mill as grinding media and comminution occurs
due to the interaction between the charge and the steel balls.

Comminution in a ball mill

53
Comminution is mainly by abrasion, as grinding media is dragged against the shell and impact as
grinding media falls to the toe of the mill.

6.8.4 Knelson concentrator

There are three Knelson concentrators in the plant, KC 48, KC 20 and KC 30. The numbers
denote the size of the diameter in inches

6.8.4.1 Operating principle

The Knelson concentrator is a high-speed centrifuge that sets a centrifugal force to the particles
in the slurry against a fluidization water flow. The conical shape of the concentrating cone
incorporates a series of rings, increasing in diameter from bottom to top. Around the
circumference of each ring, holes allow the injection of fluidization water into the concentrating
cone. Positioning the concentrating cone inside the rotor housing creates a water cavity.
Fluidization water flows into the cavity through the rotor shaft. Once the cavity fills to capacity,
pressure forces water through the fluidization holes and into the concentrating ring. During
operation, the entire rotor assembly spins at a pre-determined speed according to the size and
model of the unit. This rotational speed creates a centrifugal acceleration.

Feed slurry enters the unit through a stationary feed tube. It flows down into the concentrating
cone, where centrifugal force drives it outward to the cone wall. As the solids reach the wall,
they fill each ring starting from the bottom. Once every ring reaches capacity, a concentrating
bed is established. Water injected from the water cavity fluidizes this bed. Optimum fluidization
occurs when inward flow of water through the bed balances with outward forces of solids. This
enables fine grained target heavy mineral particles to sink into the bed through interstitial
trickling. Provided that the flow of fluidization water is maintained, the selection and
concentration of high specific gravity particles and rejection of low specific gravity particles will
continue.

When the concentrating cycle ends, the flush cycle is initiated and the rotor power is shut off.
When the rotor comes to a complete stop, the fluidization water flow valve is opened for several
seconds. Opening the valve while the rotor is stationary allows water flow into each ring to wash
out the concentrates. Concentrates flush out through the bottom of the concentrating cone and
into the concentrate launder. R

6.8.5 Acacia plant

All the concentrates collected from the concentrate boxes of the three Knelson concentrators are
processed in the acacia plant.

6.8.5.1 Working Principle

54
ACACIA Plant layout

1. Transfer of Concentrate to the reactor.

Knelson Concentrator gravity concentrate generated over a 24-hour period held in the
concentrate boxes is transferred to the ConSep ACACIA Reactor in bags which are
emptied into the Reaction vessel.
2. Pre-washing of the gold concentrate to remove ultra-fine solids (slimes)
To ensure the leach overflow solution does not carry suspended solids that interfere with
the subsequent gold electrowinning, and that water and subsequently pregnant solution
can be recovered by drainage, the concentrate solids are fluidized until overflow runs
clear.
Reaction vessel overflow solution containing fine solids is discharge back to the milling
section into the primary mill discharge sump
3. Mixing of the Leach Reagents
The leach solution is made up in the mixing tank
Reagents Added:
Potable water (2.8 m3)
3.5 buckets of Cyanide 53kg
13kg caustic soda
2kg leach aid
4. Leaching of the Concentrate
The leach solution is pumped from the mixing tank to the reaction vessel at a rate
sufficient only to fluidize the concentrate. This ensures that no fine are carried over to in
the pregnant overflow.
The leach solution is circulated through the reaction vessel for about 24 hours.
5. Recovery of Pregnant Solution
At termination of leaching, the reaction vessel overflow is sampled for assay, the flow is
stopped and drainage of the solution through the distributor to the reaction vessel feed
tank is commenced.
6. Transfer of Solution to Electrowinning

55
 The gold bearing solution, which is now all located in the solution tank, is transferred to
direct electrowinning feed tank
7. Discharge of the Leach Residue
The leached residue is fluidized and then discharged to the milling section.
8. Electrowinning
The pregnant solution is pumped to the electrowinning cell feed tank where it is sampled.
The solution in the electrowinning cell feed tank is pumped to the EW cell at controlled
flow rate. Solution is circulated on the cell for a specific period of time determined by the
cell tail assay.
9. Disposal of Electrowinning Tail
The EW tail is transferred in total to the CIL circuit

6.8.6 Hydro-cyclone
Hydro-cyclones are used for different purposes which include de-chipping, de-watering and
classification, at How Mine however, they are mainly used for classification.

hydro-cyclone

Feed is introduced under pressure through the tangential inlet generating a vortex with a low
pressure zone along the vertical axis. The particles in the feed are subjected to two opposing
forces, an outward centrifugal force and inward dragging force. The centrifugal force accelerates
the settling rate of the particles thereby separating them according to size and density. Heavier
and fast settling particles move to the wall where velocity is lowest and migrate to the apex or
spigot as underflow. The drag force pushes slower settling particles to the zone of low pressure
along the vertical axis where they are forced upwards through the vortex finder and report to the
overflow.

56
The internal of the hydro-cyclone is lined in order to protect the shell and to increase its life
span. Spigots wear out due to the abrasion forces as the coarse material exits. As a result they
should be measured regularly and replaced when worn out.

The How mine milling section has 4 cyclones, one for each mill and their main function is
classification.

6.8.7 Screens
Screening is the mechanical separation of particles on the basis of size by passing the particles of
various shape and sizes through holes or slots on the screen surface.

The milling section has two types of screens, the vibrating screen and the linear screen. The
Delko Linear screen is a non-vibrating linear screen.

6.8.7.1 Vibrating Screens

The screens are mounted with two vibrating motors running in parallel resulting in the whole
screen vibrating linearly at the support of absorbers. The vibrating screen is composed of the
screening box, vibrating motors and an absorber system. Also on the screen are spray water
nozzles to aid in de-sliming the oversize material as it moves along the screen.

6.8.7.2 Linear Screen

The linear screen is used to remove trash from the regring cyclones overflow. The screen has a
perforated feed box positioned above the wear resistant polyester cloth with an aperture size of
1000m. The screen cloth is driven by a pulley system powered by a motor .The oversize
material (trash) is retained on the screen and is washed off the screen by water sprays into the
discharge chute.

linear screen

57
6.8.8 Carbon in pulp
After the final communition stage (milling) the pulp is normally dilute and thickening is
performed to increase pulp density to about 50% solids by mass. This reduces the size of the
leaching plant that would be required as-well as reduces the amount of leaching reagents
required. The leaching of gold can be conveniently be represented by the Elsener equation,

4Au + 8NaCN + 2 H2O 4 Na Au (CN)2 + 4 NaOH

With optimum Cyanide concentration , clean gold particles dissolve forming a gold aurocyanide
complex in the aqueous phase which is readily adsorbed onto the activated carbon.In addition,
oxygen is a crucial reagent for leaching. Pulp may contain organic and inorganic components
that consume oxygen, reducing the overall level of dissolved oxygen in the pulp and thus
reducing the leach kinetics.

Advantages of lime addition include

i. decomposition of Bicarbonates in mill water,

ii. improvement in settling rate in thickeners and
iii. improvement in extraction rates

Pulp densities which are too high, as-well as those which are to low can affect gold leaching
performance. Densities should be maintained at 48 50% solids.

Other parameters which affect adsorption include

i. the concentration of free ions such as calcium, sodium and potassium, oxygen
concentration and pH
ii. mineralogy of the material,
iii. particle size of the feed and finely divided material is preferred.

6.8.8.1 Carbon adsorption

The technique involves contacting the leached pulp with granular carbon in series of gently
agitating tanks 1 - 18 with a sufficient retention time.The loaded charcoal is then separated from
the pulp on a vibrating trommel screen, coarse enough to retain the carbon but fine enough to
allow the pulp to pass through. The carbon is next sent to the stripping column for deposition and
regeneration. In the final tank 18, 2 tonnes of fresh or barren carbon is put in contact with low
grade or tailing solution.As it moves up the train, the carbon loads to higher and higher
concentration of gold, as it comes in contact with high grade solution.

Tank volume Leach tanks Carbon tanks

1 6 : 140 cubic metres 1;3;4;5;6 2 and 7

7 17 : 80 cubic metres 8;9;11;12;13 10 and 14

58
18 : 180 cubic metres - 18

6.8.8.2 Process flow of ore at the CIP section

Water Storage
concrete tank
Clear water from
CIP

High Rate Thickener Tank 1 High Rate Thickener Tank 2

Flocculent : 1.5kg/hr Overflow from Tank 1
Liquid cyanide : 0.042 litres/sec Clear water
Hydrogen Peroxide : 5litres/hr

Leach Tank 1 Carbon Tank 2 Leach Tank 3 Leach Tank 4 Leach Tank 5
Addition of Production Tank Positioned Compressed Compressed
oxygen Pump agitation Sieve Bend air agitation air agitation
Compressed Round blowers Compressed
air agitation around carbon air agitation
retention screen

Carbon Tank 10 Leach Tank 9 Leach Tank 8 Carbon Tank 7

Leach Tank 6
Pump agitation Compressed Compressed Pump agitation
air agitation Compressed
Round blowers air agitation Round blowers air agitation
around carbon around carbon
retention screens retention screen
Positioned carbon Positioned carbon
transfer pump transfer pump

59
 Tank 11

Leach Tank 11 Leach Tank 12 Leach Tank 13

Carbon Tank 14
Compressed air Compressed air Compressed air
agitation agitation Pump agitation
agitation
Round blowers around
carbon retention screens
Positioned carbon
transfer pump

Leach Tank 17 Leach Tank 16 Leach Tank 15

Carbon Tank 18
Compressed air Compressed air Compressed air
Pump agitation agitation
agitation agitation
Round blowers around
carbon retention screens
Positioned carbon
transfer pump
Positioned sieve bend

6.8.8.3 Carbon movement

Tank 18
Tank 2
2 tonnes
barren carbon Production
Tank 14 Tank 10 Tank 7 tank
from elution
Loaded carbon
2 hours
receiving time

6.8.9 Elution
The final loaded carbon is removed by pumping out of the production tank 2, via a sieve bend
on tank 3 and trommel screen on tank 11, and transferred to the elution section where it pours
into the receiving hopper up to a marked 2 tonne level for 2 hours. It is soaked in
Hydrochloric Acid before undergoing elution or deposition of gold cyanide at high
temperatures and pH. The elution of loaded carbon is obtained by using a pressure elution of

60
2 bars at 1200C in 6-8 hours. The rich eluate solution that emerges from the elution process is
passed through electro winning cells where gold and other metals are precipitated onto the
cathodes.

6.8.9.1 Process flow of carbon and elute solution at the Elution section

Carbon Receiving Acid wash column Elution Column

Hopper 2.8m3 of the 3 % acid solution Carbon transfer into column : 25
Acid pump into column : 10 mins
2 tonne level marked mins
in red Cold cycle at 2 bars: 15 min
Acid soak : 1hr Hot cycle to 120 : 1hr 30mins
2 hours receiving
time Acid drain : 5min Caustic - Cyanide pump : 30
Caustic soda pump : 10min mins
Caustic - Cyanide soak : 1 hr

High Grade Tank 2B High Grade Tank 1A

High Grade Tank 3C
Low grade solution Solution samples of eluant
Filled with barren are obtained from discharge
Takes 3 hrs to fill
solution after every 30 mins untill tank is
electrowinning tank 2B Continuation of obtaining elution solution
samples every 30 mins full.
Barren solution is later Takes 3 hrs to fill
on used to wash the 4 Repeat solution samples are obtained
during the cold cycle after elution Solution samples of
next elution
Continuation of obtaining electrowinning electrowinning are
solution samples every 2 hrs obtained every 2 hrs after
tank is full
HGC 2B solution sample is taken when
closing electrowinning

6.8.9.2 Elution Plant Operations

Reagents prepared are 3% hydro chloric acid, caustic soda solution and high cyanide
strength solution.
Two tonnes of Carbon is transferred from the carbon receiving hopper to the acid wash
tank by pumping using water.

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 2.8m3 of the 3 % acid solution is pumped from the bottom of the acid wash tank through
the carbon bed and over flows into a recovery sump. Carbon is soaked in acid for 1 hour
to remove in-organic flocculants.
Spent acid is drained from the bottom of the acid wash tank and caustic soda solution is
pumped from the bottom of the acid wash tank to neutralize residual acid remaining after
the acid wash cycle.
Treated 2 tonnes of carbon is transferred to the elution column by pumping using water.
The elution column loaded with carbon is pressured using cold water 2 bars and pre
heating using boiler steam is done to elevate temperatures to 120C.
2.8 m3 of Caustic cyanide solution is pumped from the bottom of the Elution column
through the bed of carbon. The overflow from the elution column as a result of pumping
the caustic cyanide solution is transferred to high grade tank 1A.
After transferring all the caustic cyanide solution into the elution column, carbon is
soaked for one and half hours at a temperature of 120C and a pressure of 2 bars.
Low grade strength recycled water (from HGC 3B) is pumped from the bottom of the
elution column to strip high grade mineral value from carbon. Carbon is fluidized and
suspended in solution by maintaining a solution flow rate of 2 bed volumes and the
resultant overflow is transferred into high grade tanks HGC1A and HGC2B.
High grade solution is immediately pumped to the electro-winning circuit when the
stripping process commences. After filling the two high grade tanks, a third tank is also
filled in preparation for the next elution (low grade strength solution). 30 minutes before
end of the elution cycle, the steam is switched off and a cold cycle strip is done (that is,
striping using cold water for 30 minutes).
The elution and electro wining process is carried out ensuring critical operating
parameters are within range, that is, a working pressure of 2 bars, working temperatures
of 1200 C and flow rates of 2 bed volumes for the elution process and flow rates of
20m3/h, a working voltage in the range of 4-6 V and current in the range of 350-500 A for
electro winning process.

Hazards associated with elution and electro winning include

i. Chemical spills
ii. Pressure vessels-explosions
iii. Ground flooding
iv. Air pollution
v. Suffocation, Respiratory effects and Fatalities due to (caustic-cyanide fumes)
vi. Steam &Heat stress (boiler steam)
vii. Electrocution

6.8.10 Tailings disposal

Pulp from the last tank 18 gravitates to the tailings thickener were it is dosed with ferrous
sulphate at a rate of 0.4kg/t to neutralise residual cyanide in the pulp.
The tailings attendant checks the high pressure pump and tailings bank pumps whether
they are in good operational condition. There are 2 banks B and C running consisting of 4

62
 pumps per bank and 1 spare bank A used in case of emergencies, however currently bank
A is not functional as some pumps are not available.
The tailings attendant also checks the quality of water used for running the high pressure
pump in terms of clarity and open the water supply valves to the high pressure pump.
The tailings attendant starts the high pressure pump and the operating pressure for the
Curo pump should be in the range of 1500-1700 kpa before starting the banks.
After the required pressure for the high pump is achieved, the tailings attendant starts up
the banks. On starting the bank, the tailings attendant start by starting the first pump
(pump number 1) which is connected to the thickener discharge pipe followed by the
preceding pump up-to the last which is the fourth pump. The fourth pump is connected to
the tailings dam delivery line.
A plug is then inserted on the suction of the pumps which is before pump number 1 (drain
plug) and feed valve (thickener discharge valve) is opened to allow flow of pulp into the
pumps.
The tailings attendants hourly checks and records the amperage for the running banks and
Curo pump pressure. The operating amperages for the running bank(s) pumps should be
in the range of 30-35 Amps. If one the pumps operating amperage falls below the
standard operating amperage then the bank is immediately stopped and the pump is
inspected. If all the pumps operating amperage falls below the standard operating
amperage then the bank is immediately stopped and the delivery line to tailings dam is
inspected. A stand bybank is left running and if the running bank is not coping up with
the pulp inflow resulting in the thickener filling up ,the plant is immediately stopped to
prevent spilling of pulp from the thickener. Corrective action is taken to correct the
anomaly.
When shutting down the tailings plant, the tailings attendant stops the first pump and all
the pumps would stop immediately as they are interlocked. Pulp would back flow back
into the thickener and the pumps would be stationery after all the pulp in the delivery line
has been cleared through back flow. The attendant would then close the feed valve and
removes the drain plug.
Finally the high pressure pump is stopped and all water valves supplying water to the
high pressure pump are closed.
In case of emergence the tailings attendant allows the pulp to back flow into the thickener
before closing the feed valve and removing the drain plug. The CIP supervisor ensures
that the emergency pump near the emergence ponds is operating well and the drainages
feeding the emergence pond are clear or not blocked.

6.8.10.1 Tailings dam 5

Pulp with densities between 20-25 % solids are pumped from the tailings plant by a series
of pumps on banks A and B ,via a conveyance of HDPE pipes.
Cyclones are mounted at the discharge ends of the pipes from B- Bank. Cyclone
performance is influenced by the feed slurry density. The underflow solids are used to
construct the outer embankment (dam wall) and the cyclone overflow gravitates along the
beach towards the return water pool. The cyclone underflow is mainly coarse material

63
 with an average percentage solid of 80% and overflow contains average percentage solids
of 20%.
Water from the cyclone overflow is temporarily contained in the pool which is centralised
in the dam and is pumped back to the plant for recycle/re-use. A free board of 9m is
maintained and a slope of 33 on the dam wall is maintained.
Pulp from C-Bank is discharged during paddock construction or bypassed to discharge in
the beach.
Under-drains were installed during initial bench constructions and they contains clear
water which is collected at the seepage pond. Water from the seepage pond is recycled
back to the dam for irrigation and suppression of dust on the dam wall. An automated
pump is used to pump seepage water.
The under-drains flow-rate are measured on a daily basis and the results logged.
The tailings facility has storm water drains around so as to contain and prevent all the
storm water from entering the dam.
Duties of the TSF supervisor include
1. Ensuring that all wall building, repairs of rat holes, erosion and gullies is done.
2. Measuring and logging the progress length on the dam wall
3. Ensuring that the catwalks are stable and are not damaged. Catwalks are constructed by
filling in empty lime bags with sand.
4. Inspection to ensure that the berm is maintained at 7m and the wall slope is maintained at
33. The dam wall is constructed until the vertical height is 9m and next wall has to be
constructed with the same parameters.
5. To inspect and check for any leaks along the delivery line and comments on the status of
the lines at the end of the shift and any deviations are corrected immediately.

Crest marker poles/ Datum poles are installed at the dam wall berms to measure
elevation, total free board and vertical free board. Currently there are 17 crest marker
poles around the dam wall approximately 40m apart, 10 basin marker poles in the beach
and a center marker pole in the pool/pond.
Dam 5 is 39Ha big and managed by the Fraser Alexander company based in South Africa
which has got great expertise in tailings management.
The cycloned dam wall is currently on bench 5. Cyclones A and B are used and
connected to the B-Bank delivery line.
5 under drain pipes were installed and discharge into the seepage pond

64
 Phreatic levels are measured by a piezometer/ dip meter from the installed piezo pipes on
a monthly basis and weekly or daily in the rainy season.
Rehabilitation is in progress and it involves planting trees to avoid soil erosion.

6.8.10.2 Paddock system

Paddocking is another way of dam wall construction which is currently in progress at the
western side of the dam opposite the cyclone dam wall. It involves mostly manual work
compared to cycloning and raises the dam wall at a much slower rate than the cycloning
systems. Two rectangle paddocks A and B are under construction, with A being 55m by 13m
and B is 50m*13m .

1. The 1st stage is packing. This involves construction of boundary mounds of 30cm height,
33 slopes and a crest width of 50cm to form a rectangle of length 50m and width 13.
Butter boards are used to maintain angle of slope.
2. The 2nd stage is tipping. Pulp is discharged into the packed paddock pool from C-Bank
delivery lines. The off take valve with a connected armored hose is opened and the main
line valve is closed. Close monitoring of tipping pulp is observed to avoid packing failure
and pulp spillage.
3. The 3rd stage is decanting. Decant pipes are installed at the beach side crest of the packed
mound strongly secured by burying one end into the packing and leaving the other end to
discharge into the beach. As slime level rises in the packed pool, water is removed/
decanted into the beach and flows to the pond.
4. The last stage involves leaving the slime now level with the packing to dry off whilst
repeating the above stages in construction of the adjoining paddock. High consolidation
pulp is preferred as it dries faster. When the paddock ground has stabilized, the paddock
is raised by packing, tipping, decanting and drying to the next level.

6.9 TECHNICAL SERVICES

6.9.1 Survey
The survey section is under Technical service department. It is responsible for

Plan preparation.
Layouts.
Directing mining by use of survey pegs, lines and measurements.
Ensure that the plans and layouts produced are being adhered to.
Ensures that accurate underground and surface plans are produced for mining
operations, guidance and control timorously.
Provides technical information in the form of mining layouts and surface plans on a
day to day basis.

65
 Ensures that all development and stoping activities of the mine are measured
accurately in order to determine weekly/monthly achievements.
For the purposes of pre-planning and long term planning, the Survey department also
ensures that all development ends and stopes are up to date so that management can
be able to make feasible decisions during planning.
Month end measurements done to monitor and control mining operations so as to give
informed decisions to senior management by physically taking measurements.
The survey section also checks and signs all survey data plans for control and
compliance to mining regulations.
Ventilation team also ensures that there is a continuous supply of fresh air to all the
underground working areas.

Survey department visit

Machine familiarization

The student started with the instruments used for basic traversing and taking survey
measurements for directing developments during peg installation.
The equipment includes
Theodolite
Tripod
Plumb bobs
Clinometers
Tape measures
Hammer and chisel
Spads
The following are some of the major equipments used and their functions:
Theodolite T16

This is the most important instrument used for accurate measurements of horizontal and
vertical angles. The instrument is setup on a tripod at approximately 1m above the ground.
After use and when moving from one peg to another the instrument must be put back in its
case correctly positioned and secured safely. The instrument should never be left unattended
and should never be transported on a tripod because that can damage the equipment.

The following adjustments may be required

66
 To set the vertical axis of the instrument truly vertical and to adjust the plate bubble
To set the telescope sighting line at right angles to the horizontal or trunnion axis of
the instrument
To set the horizontal axis at right angles to the vertical axis
To adjust the altitude bubble and vertical circle zero

Tripod
This is used to support the theodolite when traversing. The tripod is set at 1m above the
ground and its clamps are securely tightened when setting up so that there will b e no
movement during taking of readings as this can affect the results.
Plumb bobs
A plumb bob is a brass weight, usually with a pointed tip on the bottom that is suspended
from a string and used as a vertical reference line.
Measuring tapes
These are used to measure distances between two or more points. The 50m tape is used for
measuring long traverse distances from one peg to another and the 5m tape is used to measure
machine heights and development off-sets such as width of the drive from the centre line to
the wall.
Basic Traversing

Traversing is a form of a control survey that is used in a wide variety of surveys. Traverses
are a series of established stations that are linked together by the angle and distance between
adjacent points. The angles are measured by theodolites, and the distances are measured by
an EDM

Traverse networks involved placing the survey stations along a line or path of travel, and then
using the previously surveyed points as a base for observing the next point.It is mandatory to
start by carrying out a pre-task risk assessment for each and every area to be surveyed where
you identify hazards, list the risks and ensure that they are controlled properly before
progressing to work.

Description of activities covered by the Student

i. Underground surveying site set up procedure

Conduct a pre- task risk assessment.

67
 Liaise with other employees working in the vicinity of your workplace to avoid
conflicts of interest.
Check that the pegs on the ground correspond with those on the plan.
Check that the pegs to be used have not been tampered with or disturbed by
blasting.
When establishing a new peg, make sure it is on competent ground and its safe
from future blasts or accidental disturbances.

ii. Surveying procedure:

Set up the total station or theodolite under a survey peg.
Check the plumbing and level of the machine again before starting to take
observations.
Write neatly and clearly in the field book using a pencil.
Carry out the back check to ensure that there has been no movement of the
existing pegs before advancing the survey. Limits to be within +/-0.008mm for
distances and elevations.
Different base settings to be used for each new peg established.
The sum of each set of reduced horizontal angles shall not differ from 360 by
more than 30 seconds of arc.
The differences between the two faces left and the two face right reduced angles
shall not exceed 30 seconds of arc.
The difference between the reduced vertical angles on face left and face right to
each button shall not exceed 30 seconds of arc.

iii. Preparing to leave the working place

Check that the instrument is still in plumb and level if not repeat all
observations and measurements.
Check that all reduced angles and distances are within the limits laid down. If
not, repeat all the observations and measurements.
Check that all equipment brought into the working place is accounted for.
Check that all equipment is packed into its correct carrying bags.
The gang leader is responsible for carrying the total station/theodolite.

Month End Measurement

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 Development and stoping month-end measurement is done so as to quantify the tonnage of
ore from the underground and to calculate the advance of development ends. A list of ends is
received from the mining department, and these are then allocated to surveyors. Contact with
mining is made before proceeding underground for the miners to escort the survey crew and
make sure that the ends are accessible and safe.

Month end measurement is a survey process used:

To quantify the amount of work done which has been done during the month.
This is when the potential development and production areas are identified.
For reconciliation of mining statistics i.e. how much was extracted from the mine.
Each section development and production figures can easily be estimated by using
these results compiled as a draft.
Preparatory Activities
Listing of development and stopping mined out areas for the month.
Updated development and stopping ends in terms of line peg extension.
Measuring equipment (5m, 30m and 50m tapes), distometer , field books.

The instruments used are:

Field book, Pencil, 30m & 50m tape measure, Clinorule, Bobs & bob tapes

Development ends Measuring

Each working place will be measured from a fixed reference point. All necessary dimensions
will be noted so that an accurate calculation of tonnages will be made. Record the measured
distances in the field book under the distance column.Check that all the working places in the
list supplied have been measured.

Stoping ends Measuring

A 30m tape is aligned through two pegs to the stope face. Offsets are then taken on either
side of the tape at 90 to the main tape at 2m intervals and the readings are booked. Two or
more different heights are then taken in order to come up with average height. The offsets are
plotted on plans and the tonnage mined is calculated. Put on the safety belt when taking
measurements at the stop face. Wear the earplugs, gloves and dust respirator where necessary
to manage the OHS risks.

Development ends Reduction

69
Calculate the meters advanced for the month using the development reduction format.Plot the
measured distances on the plan. Measure the distance between the previous months date and
the current months date. Check the result with calculated advance. If it checks then the
measuring and plotting was correct.
Stoping ends Reduction
Plot the measured stope faces on the plan (CAD plans). Join the strings to the previous month
face. Create another string for the level below taking the orebody orientation into
consideration. Assign elevations to the created strings e.g. footwall elevation for the level
above, hanging wall elevation for the level below. Save the string in a DXF format. In Vulcan
import the strings. Create a solid model using the two strings. Calculate the tonnage using
Vulcan software applying as SG insitu of 2, 8.Send the stope models to geology for grade
estimation.
2. Installation of pegs
Equipment used: Theodolite T1, Tripod, 5m and 100m Steel tape, Field book and bobs.
This generally involves 2 types of pegs to be installed:
a) Installation of Line Pegs
Line pegs are used to control and direct mining. Activity took place at 27L10m; 28 Level
Haulage South and at 28L10-320N Dr North. The line pegs are at least 15m away from each
other. The instrument used to install these pegs is known as a Theodolite. The first step is to
install a Front-Line Peg (FLP) which is just used to align pegs. The Theodolite machine is
set on a tripod support bar accurately vertical. The peg position is determined and it is
installed using hammer and chisel. Checking is then done to ensure there are no errors of
distance and angles. The errors must not exceed 30 seconds for angles and must not exceed
0,008mm for distance.
b) Installation of Side Grades
Grade pegs are pegs installed on side walls to central either the inclination or declination of
any excavation such as that of drives, crosscuts, haulages, etc. These demarcate the orebody
boundaries and are also used in directing mining. Side wall grade pegs are installed in pairs,
each pair having the same elevation and set opposite one another so that the line joining them
is at right angles with the direction of the tunnel. Therefore, the angle measured is the angle
of deviation from the centre line. Sidewall grade pegs are installed at an interval distance of
3m. The Theodolite machine is set under the line peg.

Draughting And Interpretation of Plans

70
This enabled the student to know how the measurements taken underground for
developments are then plotted on plan and layouts and how they are interpreted for geological
and mining purposes. This also included how Assay data is plotted on plan and how it is used
to delineate orebodies. This was done on a draughting film and use of rotrin pen. Set squares,
scale ruler, straight edges should be available.
Description of Draughting process or activity

Draw the grid lines in pencil at the front of the draughting film. Draw the border lines using a
0.5mm size rotrin.The grids are to be drawn at 25m apart for a 1:200 scale. Check the
dimensions of the grids. If there is variation, adjust to the required dimensions. If satisfied
with the pencil drawn grids, draw the same grid lines at the back of the film using a 0.25mm
rotrin pen and a straight edge. The rotrin pen should be upright when draughting. Make sure
the drawn grid lines are of the same width. All the survey draughting should be in black ink.
Erase the pencil marks at the front of the film. Write the grid coordinates on the grid line at
the edge of the plan. Draw the north sign at the right edge corner of the film. Draw the box at
the bottom right corner of the film. Fill the appropriate information e.g. level of the plan,
scale and sheet number. Write the survey system constants on the plan. Then plot any
required information e.g. peg and development offsets.
Description of Plotting process or activity

Use a sharp pencil for plotting pegs. Plot your work on the relevant plans and sections as
soon as the calculations are completed. All survey information to be neatly stencilled on
plans and sections using standard stencils. Assay results may be hand written. The symbols
used on South African mines to depict various features will be standard on all plans. All main
pegs to have their number and elevation. All offsets to be plotted and inked on standard mine
plans. All stoped areas to be indicated by bold broken lines with dates of updating. Where
there is some doubt of the accuracy of a survey, the draughting should be done in pencil until
such a time it is confirmed then it is inked.
Ventilation

The student managed also to spent time with the Ventilation Officers of How mine. The main
objective was to conduct ventilation measurements and investigate if the mine was complying
with the company standards and legal requirements. Ventilation is the continuous supply of
fresh air to the underground system and working sites. How mine uses mechanical ventilation
system to supply fresh air to all parts of the mine, since natural ventilation is normally

71
inadequate and unreliable. There is use of large out-casting/exhaust fans (45Kw) which
exhaust polluted air from the mine system. Down casting of air is through the shafts
supported by Auxiliary fans which pulls the air and directs it to the mining environments. The
pulling of air by auxiliary fans is what creates the negative pressure system, thus enabling
more down casting of air. The polluted air out-casted contains pollutants such as gases, dust
and heat. The objective of ventilation inspections done by the student were taking
measurements and investigating if the mine is complying with the company standards and
legal requirements. This is done through determination of the following parameters:

Air utilization
Leakages within the system
Temperature and humidity levels

There are three surface fans 1220(48)* 45Kw located at the Plant, Main shaft and Hill top
fan at How South. These acts as upcasting fans and there are also three downcasting shafts
which includes the North shaft, Main shaft and South raise bored shaft. Kestrel 4000
instrument is used to measure ventilation readings at How mine such as the temperatures,
humidity, volume and velocity of air both being down casted and being up-casted to ensure
that there is a balance and low leakages within the system. The Kestrel 4000 used is shown
below:

Kestrel 4000 used for recording ventilation measurements

The air underground is further directed to different sublevel, haulages and drives by us of
pipes referred to as ventilation columns. The air circulation is also aided by raises that are
72
excavated from one main level to another. The ventilation parameters measured using the
Kestrel 4000 are compared with the ventilation standards shown below and
recommendations are then made basing on the results whether the ventilation conditions are
good or need to be improved.

Ventilation standards

PARAMETER RECOMMENED MINE STANDARD

Wet bulb temperature <27.5 0C

Dry bulb temperature <32.5 0C

Velocity in workings 0.3-0.5m/s

Quantity in development ends 0.15m3/s per square meter of development

end

Downcast shaft velocity(man and materials) 5-8m/s

Upcast shaft velocity 18.0m/s-22m/s(unsupported)

Ventilation of diesel equipment 0.06-0.12m3/s/Kw

Intake airways(declines on reef) 5m/s

Water blast distance to face (development) 15m

Exhaust intake to advancing face 20-25m

Overlap distance 6-10m

Force delivery to advancing face 10-15m

Force quantity at face 0.25m3/s/m2

Exhaust quantity at face 0.30m3/s/m2

Leakage 20%

Water pressure 150Kpa

Humidity 75%

Respirable dust 5.0mg/m3

Total dust 10mg/m3

Heat stress 170w/m2

Noise 85dbA'

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6.9.2 Geology
This section oversees the direction of mining activities by drawing and analysing samples
and then advising the mining department on which areas to direct their efforts in the
extraction of ore. This section therefore has the task of determining and assessing ore
extracted daily, ore sent to the plant, grade control as well estimating the life the mine.
There are plans to begin exploration of new areas to complement existing operations. This
section is headed by the Senior Geologist

Desktop study Surface and

Geophysics Underground
Trenching mapping
Diamond drilling Shaft designs

Mine
Exploration Planning
and Design

Monitoring
Reports
and Control

Mineral Resource Stope and

and Reserve development
Estimations ends inspection
Daily production Grade control
tracks Sampling

6.9.2.1 Diamond drilling

Diamond Drilling is the use of a drilling machine with a hollow diamond set bit for boring
rock and yielding continuous columnar core. It provides most of the information used for
resource evaluation which ultimately determines whether a target is minable or not.

Purpose of Diamond Drilling

Mineral exploration and Development.
Ore-body delineation,
Control/Directing of mining grade
To obtain geological data such as rock formations at depth, faults and geological structures
at depth.
Ore reserve estimation and evaluation.
Geotechnical engineering to determine areas that need support.

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6.9.2.2 Sampling
Sampling is a means whereby small amounts of materials (samples) are used to evaluate a
much larger amount of material (the ore-body).Sampling methods used are channel
sampling, hand chip sampling, grab ( draw point )sampling and stock pile sampling

Equipment used for sampling:

Grab sampling: Sampling pan, Sampling bucket, Gloves, Pencil, Notebook, Sample bags,
clean canvas and a Sample ticket book.
Channel sampling: Chisel, Tape measure, Sampling pan, Diamond Saw Cutter, Sample
ticket book, Sample bags, Chalk, Goggles, Gloves, Pencil and Notebook.
Chip sampling: Chisel, Sampling pan, Wire brush, Gloves, Goggles, Tape measure, Chalk,
Sample bags and a Sample ticket book.

Stockpile Sampling

Samples are collected and ticketed from the entire face of the stock pile and samples are
sent to assay. A sketch of the stockpile is made and the location and ticket number of
every sample is included in the sketch, so that when the grades come back from assay
they are plotted on the sketch giving each sampling point its grade. Stockpile sampling is
used as a way of tracking the grade of gold that is expected to be processed at the plant.

6.9.2.3 Blending and dilution

Blending mostly takes place at draw points; here ore with low grade values is blended
with ore which has high grade values to increase the tonnage being put into the system at
an acceptable overall grade which is above the cut-off grade.
In mining dilution is all external material with grades lower than the cut-off grade that
should not mix with the ore. Dilution tends to lower the grade of ore and if not monitored
closely this can drop the grade below the cut-off limit however an over break of 0,5m is
allowed. Control of dilution is done by following up on miners to check if they are
adhering to layouts and that long hole machines are rigged at the correct position and
angle.

6.9.3 Assay
Samples are received from geology and reduction plant for assessment and grade
determination. Samples are initially dried of all moisture in a drying room before being
crushed and pulverised into finer particles. Samples undergo a rigorous process of Fire
Assaying until the amount of gold in each sample can be measured and recorded. These
statistics are sent back to geology then mining to advise on mining direction.
A fire assay is a chemical fusion method for separating, concentrating, and measuring the
content of gold and silver in exploration samples, ores, and concentrates. The pulverized
sample is weighed, mixed with a lead oxide-alkali carbonate flux and a small amount of
reducing agent such as flour, and fused in a fire-clay crucible. The reduced lead collects
the precious metals as it settles down through the melt. The molten chargeis then poured

75
 into a mold to cool. The lead sinks to the bottom of the mold and is broken from the
glassy slag when cool. The precious metals are separated from the lead by cupellation.
The lead button containing the precious metals is placed in a cupel of bone ash or
magnesia which is heated in the furnace under oxidizing conditions. The cupel acts as a
semi-permeable membrane allowing the lead oxide formed from the button to be
absorbed into the cupel, leaving the precious metals in a tiny bead on the surface of the
cupel. The gold and silver are separated chemically and quantified gravimetrically or by
instrumental analytical techniques.
The basic assay operations are
i. Sample receiving and drying
ii. Crushing and pulverizing

iii. Flux making and fluxing of samples

iv. Sample fusion and cupellation

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 v. Sample parting

Principle of parting

To dissolve the gold silver alloy in parting acid and remove all silver to leave gold.
The bead obtained from cupellation must be flattened to facilitate ease of parting, it must
contain ratio of gold and silver of about 1:3.
Other conditions to observe are the kind of acid, purity of acid and wash water, acid
temperature, acid quantity, time of contact to achieve optimum separation.

vi. AA Finish

Principle of operation of the Atomic Absorption Spectrometer

The AAS consist of a light source, an atom cell, a monochromat and a read out system. It
requires an energy source, a hollow cathode lamp (HCL) containing the same element as
that being investigated.
The solution is aspirated into a flame and the sample elements are atomized. The flame
then contains atoms of gold most of which are at ground state.
When a beam of light passes through a gaseous cloud of atoms, they absorb photons and
make a transition from ground state to an excited state. The net energy of this state is
equal to the energy of the absorbed photon.
The analysis of the sample is determined by measuring the absorption of the constant
intensity of the EMR that passes through the flame.

vii. Gravimetric Finish

Final weighing
Zero the micro balance before weighing.
Calibrate the balance using standard weights.
Weigh the samples (prills) and enter the results in the Gold record book.
Calculate the sample(s) results as follows

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- Concentration of gold in grams per tonne is 1000 divided by mass of sample taken multiply
by mass of final prill in miligrams (mg).

Gold grade = (weighed mass*1000mg )

( catch weight )
Actual grade recovered = Mill feed grade ( ROM CIL Solids + ROM CIL Solution )

Statistical and Mathematical Manipulation

Sample Description Catch weight (g) Weighed mass Grade Au (g/t)

(mg)

HSMI (Mill feeds) 25 0.127 5.08

HSMI 25 0.120 4.78

HSMI 25 0.123 4.92

For further calculations and recording on the metallurgical sheet, only readings within 10%
deviation are used. Checks are conducted as follows:
Obtain the average of two grades: 5.08 + 4.78 = 4.93 g/t
2
Find difference between grade and average and divide by average: 5.08 4.93 = 3.04%
4.93
The two grades (5.08 and 4.78) can be recorded on the metallurgical sheet.

The major occupational hazards in the department are tabulated below, together with their
mitigation strategies.

6.10 Recommendations

6.10.1 To the company

- For the benefit of some unfortunate students, company to offer full Protective
equipments.
- Improve on implementation of operational procedures by the SHEQ department
through follow ups and running refresher training programs
- The drainage hole should be drilled every round to avoid stagnant water during
drilling.
- Buy explosives in bulk that last long.
- Need for another shaft which will be used as another access to and from access with
people rather than depending with one. This will be used also in case of emergency
and during those times when the other shaft is under examination and maintenance.

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 - People who go underground within a space of 24 hours are too many compared to
caplamps available, there is need to buy more caplamps to avoid overusing the few
available which at most occasions do not last for the whole shift.

- Improvement of fragmentation in stope drilling and blasting. Possibly a revision of

blast designs and drilling standards. Possibly increase grizzley attendance labour to
speed up the handling of boulders at the grizzlies.

- Provision of spares will reduce the mean time between breakdowns; spare equipment
could also be used to avoid any production stoppages.

- Dust suppression mechanism required at 28L grizzly point. A dust scrubber is a better
option.

- All machines and their associated drilling equipment should be frequently monitored,
repaired and maintained to avoid breakdowns during drilling operations which affects
production expectations

- Increase training of students on various managerial skills and involvement in decision

making.
- Procurement of functional agitators is vital to avoid slimes from settling below the
tanks. At one point each tank at a time should be emptied and checked for settled
slime and cleaned so as to maintain the tank volume and improve leaching and carbon
adsorption

6.10.2 To the school

- The School Mining Department to continue building strong relations with the mine to
ensure that the company will put MSU students on priority for attachment at the Mine.
- The Faculty to increase industrial attachment assessment/ visits for Mining department to
at least three visits (initial- mid- final) as this will increase interaction and guidance to the
student by their Academic Supervisors.
- School to assist students to get attached to industries in time so that they have enough
time to learn.

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7 PROJECT PROPOSAL

TOPIC:

VENTILATION: DUST ELIMINATION MECHANISM (WET SCRUBBER)

A dissertation proposal submitted in partial fulfilment of the requirement for the Honours
degree in Mining and Mineral processing Engineering

By

KUBVORUNO PRIDE TAFADZWA

OF

MIDLANDS STATE UNIVERSITY

MANICALAND COLLEGE OF APPLIED SCIENCES
(Department of Mining and Mineral Processing Engineering)

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EXECUTIVE SUMMARY

Noticing the need for a creation of best working condition at 28 level, the thought of doing a

project which will help create a best possible working condition hit the proposer. The

proposer together with his team mates will design a system which will suppress dust by

sucking it from the ore pass and capture it by the use of fine water sprays in a cyclone. The

design of the system is drawn to scale, mathematical calculations done on how it will operate.

The teams members will each have a role to play doing tasks as per assigned until the

systems is done and running as per expected

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Problem Statement

Bulawayo mining company (BMC) is a mining company which is in a business of mining

gold. It is an underground mine using sub-level open stope as a mining methods. It is

comprised of sublevels and main haulage levels which are used as production levels

(tramming of ore). Currently 26 and 28 levels are being used as production levels. There is an

ore pass from 26 to 28 level passing through 28 level. At 28 level there is a grizzly also

used to tip ore into that same ore pass from 26 level. This ore pass is also used to downcast

some fresh air from 26 level to 28 . When tipping of ore is done at 26 level, the ore face

some attrition with the side walls of the ore pass as it go to 28 level, thereby dust results

from the attrition. An exhaust fan was installed facing the grizzly at 28 level to suck the dust

where by its efficiency is not seen as it exhaust the dust after it had already attacked those

working at grizzly and still the dust levels are more than the maximum required standards.

Unfortunately the dust created then becomes part of the down-casted air and is distributed

into 28 level through the grizzly openings and affects those working at the grizzly at 28 level.

Dust levels are more than the maximum required by How mine standards in conjunction with

OHSAS 18001.

Justification

- Bulawayo Mining Company has its own standards which they set extracting from the

OHSAS 18001 and they should abide to that all the times.

- Project also needs to reduce workplace hazards and boost employee morale.

- To achieve the best possible working conditions at 28 level grizzly.

- The project will strive to eliminate dust from the source with the use the wet scrubber

mechanism.

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Objectives

- AIM to eliminate dust from foul air at 28L grizzly with the use of wet scrubber and

use the cleaned air to ventilate 26L.

- At the end of the project there is hope of dust being completely exhausted direct from

the source into the wet scrubber mechanism and dealt with to an extent that we have

new fresh air to again ventilate the working place of 26 level.

- The dust suppression mechanism will comprise of;

name size Work description

1 fan 22kw Exhaust foul air (dust)

2 ducts 22 inch Direct exhausted air to wanted

destinations

3 Cyclonic spray Shown on diagram Create votex where separation

chamber below of dust and air occurs

4 Mist eliminator Remove mist from air

5 Water pipe 2 inch To carry water

6 pump 18.5Kw Pump water into cyclone

8 6 fine spray Produce fine water sprays to

nozzles capture dust

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 - The design will have an exhaust fan which will suck foul air from the ore pass and

create a negative pressure system to give room for the 28 level grizzly to down cast

some air. The foul air exhausted is entered into a cyclone where fine sprays of water

are introduced to it to capture al dust particles and to dissolve some gasses present.

The captured dust particles will come as underflow as the air will continue as

overflow but now with mist in it. A mist eliminator will then do the magic to produce

a clear air which will be tested for gasses and dust before used for ventilating working

areas.

Methodology

Steps in the design process

1. Recognizing the need; listening to the workers needs and say about the dust at 28

level. Noting down of the dissatisfaction with the existing situation. Planning for

needs to accomplish new functionality at workplace. The projects purpose is to give

workers a non-complaining attitude towards working at 28 level grizzly and to create

the best possible working condition for the workers and maintain their wellness at

workplace.

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2. Defining the problem; with the needs of the workers and the standards and

regulations say, I define a problem statement as explained above, the goal for the

response to the problem, its objectives and also laying out the constraints of the

design as also explained in previous pages.

3. Gathering Information; this will include underground mapping, taking vent

measurements (volume of air, temperatures, humidity, ), dust sampling. This will

include the survey department, ventilation department and the geology department of

Bulawayo Mining company. Solutions to the similar problems are researched and also

some background research to the design.

4. Modelling (project design); here there will be development of functional

specifications (details of engineering design), system architecture, preliminary design

specifications, detailed design specifications and developing acceptance test plan.

5. Planning the project; with the Bulawayo Mining Company ventilation department

putting a helping hand, activities will be broke down to certain individuals which are

part of the project and the company management will be asked to help financially and

in any way they can to make the project a success.

Project management; departments to add value to the system include the survey,

ventilation, mine planning and the projects of the Bulawayo Mining company.

i) Work plan template

ii) Evaluation

iii) Plan template

iv) Budget

- Tasks broken down to team members involved in the project design.

Time factor;with the situation underground the project is way much behind hence the

system is supposed to be installed anytime now as soon as it is ready.

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 Assumptions and constraints;

i. assumptions

o the design will be able to deliver an output of fresh air perfect to ventilate

again

ii. constraints

o Air from the design might be misty.

o There might be gasses still present in the output air.

o Lack of funds by the company

6. Project delivery; installation of the system, training of staff to operate the system,

performing of acceptance test, post project review and providing warranty support

then archive materials

Expected results;

a smoothly running dust scrubber mechanism

Safe production

New fresh air to ventilate 26L haulage

Zero gas particles at 28L grizzly

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Project Team;

name qualification position department

Kubvoruno Mining Engineering Student Mining Attachee Mining

Pride

Fabiyano E Degree in Mechanical Lab assistant Assay

Engineering (HIT)

Muvhavhauri T Diploma in Ventilation Ventilation Ventilation

technician

Chokera T Diploma in Mining (ZSM) Mining Training Mining

Officer

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