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JOURNAL OF THE SOUTH AFRICAN 'N$T'TI,IT~ OF MINING AND METAI-LURGY MAY 1971 201
Fig. I-Plan of No. 3 Shaft pillar, showing the location-of the settlers
202 MAY1977 JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
'. CQ\lICAL CLEAR OVERFLOW
2\1
FLOC
BLANKET
SLUDGE.
Fig. 2-lsometric view of the pump chamber, clear water Fig. 4-Flow pattern in a conical settler (the solids analyses
dams, and conical settlers are given in pop.m.)
OVERFLOW
LIP
~ 10
8 MEGALITRE
.,\~ ~
If)
w
ex:
RAW WATER ~
Ww
455 CHANNEL ~.J ---~~
jj ",'.' ~'~'~'~~""
~If) ""'" '",
CLEAR WATER ~
1(9
>-9
,1
RAW WATER
l \
\ " '.
\
\\
"
".
COLUMN
95 ,01
UJ
\
\
\ '.
> ,
,
I
~
:J
I
I
I
I
1=
m 001 10 100 1000 10000 100000
TIME - SECONDS ON LOG SCALE
JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY MAY 1977 203
10000
RM Wt>.TER
FEED
~
~
~1000
9
6 100
:::;
..J
~ ~17,5
Cl:
W
Cl.
10 -'I 1___-
PRESENT
~ O~TNG
~ PONT
~
cl
If)
I
0 2 3~ 4 6 8 10
FEED RATE -
tv1EGALlTRESPER Dt-y
Fig. 6-Feed rate to conical settler versus clarity of overflow water
ing 50464 p.p.m. of solids, with lime added but no Eleven different flow rates were forced onto a settler,
flocculent. The second sample had lime and half the and samples of the overflow were taken at various
regular dosage of flocculent, and the last sample had points round the periphery of the settler for each flow
lime and the regular flocculent dosage of 0,57 kgjM!. rate.
After the first 100 seconds, the sample of water fully Flow rates of up to 9,5 MIjd were achieved during this
loaded with flocculent had approximately 4,5 times the test, but the settling at this flow rate was unsatisfactory.
clarity Qf the unflocculated sample (i.e., 2000 p.p.m. The test indicated that flows in the region of 8 MIjd
as against 9000 p.p.m.). However, the final products per conical settler could be achieved with moderate
over a prolonged period of 2,7 hours were very similar. results, provided that the settled mud was drawn off
Flocculent greatly increased the speed of settling of regularly.
clear water to the mud interface - from 0,25 mmjs for To ensure that there would be no build-up of mud in
raw water with no flocculent to 1 mmjs, as shown in the settlers, a study was made of the drawing off of
Fig. 5. mud with the intention of making this a continuous
process. Various sizes of orifice were fixed to the bottom
Performance Tests of the settler in an attempt to find the right balance
As previously indicated!, the original layout was between a small orifice that would become choked and a
designed to treat a daily maximum of 4,59 MI of raw large orifice that would discharge so much that water
water per conical settler, with a norma.! daily rate instead of mud would be transferred to the mud dam.
of 1,636 MIld. However, the inlet-flow control plate has No satisfactory condition was attained, and it was
since been enlarged and the average throughput increased concluded that 150 mm valves opened at regular inter-
to 3,4 MIjd for a total of 27 MIjd (eight units). About 45 vals are still the best solution (Fig. 6).
per cent of the treated water is pumped to surface, while
the balance is recirculated for drilling and mining purposes. Daily Operating Costs
A series of tests was conducted to indicate the maxi- Labour (including benefits):
mum quantity of water that could be treated in an Part-time supervision R52,50
emergency, the maximum quantity being governed by Operators, 4 per shift 12,50
the quality of water acceptable for re-use as machine Lime R24,00jt at 10 tjmonth=0,33 tjd 8,00
water. Flocculent, 14 kgjd at R2,45fkg 34,30
For these tests, a variable-inlet (flow-control) gate Maintenance and repairs 5,00
was manufactured so that the flows could be in excess
of the 3,4 MIld being treated at present. Downstream Total daily operating cost R112,30
from this gate a rectangular weir was installed to measure
flow. The cost based on 27 MI settled per day is therefore
It was found that, owing to 'channelling' of the R4,15fMl.
overflow, i.e., overflow concentrated in certain sections
of the overflow lip, the maximum quantity that could New Settlers and Pump Chamber
be treated efficiently occurred when the water level in
the conical settler rose to a point just below the top of Excavation work is in progress for a new pump
the V-notches round the periphery of the settler. chamber, conical settlers, and clear water sumps that
204 MAY 1977 JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY
CLEAR WATER
DAMS
CONICAL
SETTLERS
FI,. 7-Layout of new pump chamber, clear water dams, and conical
settlers
are to be situated in overstoped ground. The layout is zontal settlers, both because they cut across planes in
shown in Fig. 7. the geological succession and also because stress distribu-
The capital cost ofthis project, without any mechanic- tion round circular openings is more uniform. Further,
al or electrical equipment, is estimated to be R219 000. with suitably designed and installed support, any rock
The following are the rea.sons for the establishment of failure and eventual slabbing can be effectively
this new pumping complex. restrained. The conical settlers have a shape closely
(I) Because of the extensive ground movement in approaching that of a vertical cylinder.
No. 2 Shaft pillar, the settling and pumping arrange- The application of smooth-wall blasting techniques
ments at this shaft were abandoned in 1971. The is very much more effective in circular excavations,
present settling and pumping facilities are confuied particularly when they cut sharply across the geological
to No. 3 Shaft and will have to be abandoned when strata and when the excavation has a vertical orientation.
the mining of No. 3 Shaft pillar takes place at some
future date. Practical considerations
(2) The existing layout of No. 3 Shaft is being subjected
Analytical,- a.s well as analogue- and digital-computer,
to high rock pressures, which are affecting the pump
techniques clearly demonstrate that induced compress-
alignment and pipe connections in the pump
ive-stress concentrations and deformation magnitude
chamber, together with caving of the tunnels
increase rapidly towards the~ perimeter of a shaft pillar.
connecting the settlers and the water dams. Ex-
Factors determining the stress field within the pillars
penditure on rock support became necessary in
include depth below surface, excavated stoping width,
1972 and has risen rapidly as conditions deteriorate.
and extent of stoping radially away from the pillar.
As a result of (I) and (2), it was decided to excavate
and install new pumping and settling arrangements in Theoretical and practical analysis of complex hori-
overstoped ground. The pumping capacity of this ]Jump zontal layouts shows that circular excavations should
station will be increased from the present capacity of not be sited closer together than three times the maxi-
34,5 MIld to cope with any emergency flooding condition. mum dimension of the excavation, while rectangular or
square excavations should never be sited closer than
Rock Mechanics Aspects six times the maximum dimension.
Ideally, vital excavations such as dams, settlers, and
Theoretical Considerations pump chambers should be sited outside the shaft
Vertical excavations with circular profiles are structur- protection pillar and overstoped as expeditiously as
ally stronger than the profiles typically used for hori- possible. However, extra expense during the initial
JOURNAL OF THE SOU'fH'AFRICAN INSTITUTE OF MINtNG AND METALLURGY MAY 1977 205
establishment of operatIons at shafts has generaUy been mony have proved to be very successful both from a.
against the adoption of such a policy. Because of their rock mechanics point of view and from the point of view
superior strength, conical settlers can be placed closer of efficient operation.
together and therefore occupy less space. Space is at a
premium because of the gold values contained in shaft AcknowledgeDlent
pillars.
The theoretical strength of conical settlers has been The authors thank the Management of Rand Mines
borne out in practice. Actual observation shows less Limited for permission to publish this paper.
side-wall and genera.! deterioration, and therefore less
initial support cost and less subsequent support involve- Reference
ment.
1. THIEL, E. W. Use of cylindro conical settlers for under-
SuDlDlary ground water clarification on Harmony Gold Mining Corn.
pany Limited. Association of Mine Managers of South
From experience, conical settlers as installed at Har- Africa, 1959.
Company Affiliates
The following members have been fraser & Chalmers S.A. (Pty) limited. R. J. Spargo Limited
admitted to the Institute as Com- Gardner-Denver Co. Africa (Pty) Ltd. Rooiberg Minerals Development Co.
pany Affiliates. Goldfields of S.A. Limited. LImited.
The Grootvlel (Pty) Mines limited. Rustenburg Platinum Mines limited
Harmony Gold Mining Co. limited. (Union Section).
AE & Cl limited. Hartebeesfontein G.M. Co. limited. Rustenburg Platinum Mines LImited
AfroxjDowson and Dobson limited. (Rustenburg Section).
Hlghveld Steel and Vanadium Corpo-
Amalgamated Collieries ofS.A. LImit- ration Limited. St. Helena Gold Mines LImited.
ed. Hubert Davles Heavy Equipment Shaft Sinkers (Pty) Limited.
Apex Mines limited. (Pty) Ltd S.A. Land Exploration Co. limited.
Associated Manganese Mines of S.A. Impala Platinum limited. Stllfontein G.M. Co. LImited.
limited. Ingersoll Rand Co. S.A. (Pty) Ltd. The Griqualand Exploration and Fi-
Bllllton Exploration S.A. (Pty) Johannesburg Consolidated Invest- nance Co. LImited.
limited. ment Corp. Ltd. The Messina (Transvaal) Develop-
Blackwood Hodge (S.A.) limited. Klnross Mines Limited. ment Co. limited.
Blyvoorultzlcht G.M. Co. Ltd. Kloof Gold Mining Co. limited. The Randfonteln Estates Gold Mining
Boart International LImited Lennlngs Holdings Limited. Co.Witwatersrand Ltd.
Bracken Mines LImited. Leslie G.M. LImited. The Robbins Co. (Africa) (Pty) Ltd.
Buffelsfonteln G.M. Co. limited. The Steel Engineering Co. Ltd.
Llbanon G.M. Co. LImited.
Trans-Natal Coal Corporation LimIt-
Cape Asbestos South Africa (Pty) Ltd. Lonrho S.A. limited.
ed.
Compair S.A. (Pty) limited. Loraine Gold Mines limited.
Tvl Cons. Land & Exploration Co.
Consolidated Murchlson (Tvl) Gold- Marlevale Consolidated Mines LImited Tsumeb Corporation Limited.
fields & Development Co. limited. Matte Smelters (Pty) Limited. Union Corporation Limited.
Deelkraal Gold Mining Co. Ltd. Natal Cambrian Collieries limited. Vaal Reefs Exploration & Mining Co.
Delfos & Atlas Copco (Pty) Limited. Northern LIme Co. LImited. Limited.
O'oklep Copper Company LImited. Venters post G.M. Co. Limited.
Doornfonteln G.M. Co. limited.
Otjlhase Mining Co. (Pty) LImited. Vergenoeg Mining Co. (Pty) Limited.
Durban Roodepoort Deep ~imited. Palabara Mining Co. limited. Vlakfonteln G.M. Co. Limited.
East Drlefontein G.M. Co. limited. Photometric Sorters. Welkom Gold Mining Co. Limited.
East Rand Prop. Mines LImited. President Stern G.M. Co. limited. West Drlefonteln G.M. Co. LImited.
Engineering Management Services Pretoria Portland Cement Co. limit- Western Areas Gold Mining Co. Ltd.
(Pty) Ltd. ed. Western Deep Levels Limited.
Envlrotech (Pty) Ltd. Prleska Copper Mines (Pty) limited. Western Holdings limited.
Free State Saalplaas G.M. Co. limited. Rand Mines limited. Wlnkelhaak Mines Limited.
208 MAY 1977 JOURNAL OF THE SOUTH AFRICAN INSTITUTE OF MINING AND METALLURGY