This research aims to optimize ground support systems for underground tunnels in geologically challenging environments, specifically addressing the reduction of Fall of Ground (FOG) incidents in a gold mine in Mashava, Zimbabwe. The study integrates advanced detection and classification methodologies to enhance tunnel stability and safety. Tunnel Reflection Tomography (TRT) was employed to identify unfavorable geological structures ahead of excavation, while core logging at 20 locations on level 7 provided rock mass quality assessments using three classification systems: Bieniawski’s Rock Mass Rating (RMR), Laubscher’s Mining Rock Mass Rating (MRMR), and Barton’s Q-system. The results consistently indicated poor rock mass quality, informing the design and refinement of a robust ground support system. Fallout height data from past FOG incidents and probabilistic key block analysis using J-Block software further validated the support system's effectiveness. The findings significantly reduce collapse risks and downtime, enhancing operational safety and efficiency. This research contributes to developing practical strategies and tools for improving tunnel stability in complex geological settings, offering valuable insights for future advancements in mining support technologies. The study's necessity stems from the industry's growing demand for innovative solutions to enhance tunnel stability in adverse geological settings, particularly in regions with limited access to advanced technologies or methodologies.

Sustainable energy consumption in cement production involves practises and strategies aimed at reducing energy use and minimising environmental impact. The efficiency of a cement kiln is dependent on the kiln design, fuel type, and operating temperature. In this study, a dynamic simulation analysis is used to investigate heat losses and distribution within kilns with the aim of improving energy efficiency in cement production. This study used Computational Fluid Dynamics (CFD) with Conjugate Heat Transfer, Turbulent Flow, and the Realisable k−ϵ turbulence model to simulate heat transfer within the refractory and wall systems of the kiln, evaluate the effectiveness of these systems in managing heat losses, and establish the relationship between the heat transfer coefficient (HTC) and the velocities of solid and gas phases. The simulation results indicate that a temperature gradient from the kiln’s interior to its exterior is highly dependent on the effectiveness of refractory lining in absorbing and reducing heat transfer to the outer walls. The results also confirm that different thermal profiles exist for clinker and fuel gases, with clinker temperatures consistently peaking at approximately 1450 °C, an essential condition for optimal cement-phase formation. The results also indicate that phase velocities significantly influence heat absorption and transfer. Lower velocities, such as 0.2 m/s, lead to increased heat absorption, but also elevate heat losses due to prolonged exposure. The relationship between the heat transfer coefficient (HTC) and the velocities of solid and gas phases also indicates that higher velocities improve HTC and enhance overall heat transfer efficiency, reducing energy demand.

Optimising stope support design is crucial in mining engineering to ensure underground safety and stability. Traditionally, rock mass classification methods have guided support strategies, but they come with inherent limitations. This study takes a novel approach by adopting support resistance design criteria, providing a more effective alternative. Using advanced numerical modelling techniques, the research evaluates stope support systems by considering key factors such as geomechanical properties, stope geometry, and support configurations. The study specifically examines three primary failure modes wedge failure, block failure, and spalling through simulations that replicate real-world mining conditions. By integrating empirical data with sophisticated analytical tools, the research accurately determines support resistance requirements, ensuring structural reliability and minimising failure risks. The optimised design, tailored to local geological conditions, significantly enhances worker safety and operational resilience by reducing the likelihood of support failures. A comprehensive economic analysis indicates that while the initial implementation costs are slightly higher, the long-term advantages such as reduced downtime, fewer ground falls, and improved safety protocols far outweigh the investment. This approach strikes a balance between economic feasibility and operational sustainability by prioritising durable and effective support systems. By moving away from traditional methodologies, this study highlights the need for innovative strategies in stope support design, ultimately contributing to safer, more efficient, and sustainable mining practices. The findings also promote resource optimisation, reducing unnecessary support material usage and mitigating the need for ground fall reclamation.

This study comprehensively evaluates the integration and effectiveness of green mining technologies within the mining sector, specifically focusing on mitigating the environmental impact of traditional mining practices. The primary goal is to establish a sustainable mining model that significantly reduces energy consumption and minimizes ecological disturbances. To achieve this, the study employs a mixed-method approach, integrating quantitative data analysis from monitored mining sites and qualitative insights from industry experts. Key parameters include energy consumption, greenhouse gas emissions, and reductions in chemical use. The findings reveal that effective integration of green mining technologies leads to significant reductions in greenhouse gas emissions, lower energy consumption, and improved waste management compared to traditional methods. Specifically, the use of electric vehicles and renewable energy sources in mining operations has resulted in decreased carbon emissions and energy usage across studied sites. The research concludes that green mining practices, when supported by robust technological integration and regulatory frameworks, not only enhance environmental sustainability but also boost economic efficiency within the mining industry. This study recommends increased investment in the research and development of green technologies and calls for tighter regulatory oversight to ensure the widespread adoption and optimization of these practices.

Open pit coal mining near electrical power lines presents distinct geotechnical challenges and regulatory demands, particularly under Section 17.6 of South Africa's Mine Health and Safety Act. This section requires a minimum 100 m buffer between mines and structures such as power lines unless deemed safe at closer distances. To balance safety with economic considerations, a detailed geotechnical risk assessment was performed to reduce this distance without compromising safety. This practical study is pivotal in optimising coal extraction while ensuring the integrity and safety of nearby power lines through well-considered geotechnical design. Employing empirical methods based on geological and geotechnical data, the study proposes a suitable geotechnical design, incorporating slope stability, ground control, and real-time monitoring to evaluate risks. This approach not only ensures compliance with regulatory standards but also enhances economic feasibility by increasing the minable coal resources. The findings highlight the critical role of comprehensive geotechnical design in allowing mining operations to coexist safely with essential power infrastructure. This research provides valuable insights for engineers, regulators, and industry stakeholders, establishing a framework for responsible mining in complex geotechnical environments. The recommendations from this study also guide future mining projects facing similar challenges, promoting sustainable and compliant mining practices.

The demand for cement has significantly increased, growing by 8% in the year 2022 and by a further 12% in 2023. It is highly anticipated that this trend will continue, and it will result in significant growth by 2030. However, cement production is highly energy-intensive, with 70 to 80% of the total energy consumed during the clinker formation, which is the main cement production process. Minimising energy losses requires a radical approach that includes optimising the performance of the kilns and significantly improving their energy efficiency. One of the most efficient approaches to optimise the performance of the kilns and reduce energy losses is by integrating process re-engineering models, which leverage process data analytics, machine learning, and computational methods. This study employed a model-based integration approach to improve energy efficiency during clinker formation. Energy consumption data were collected from two semi-automated cement production plants. The data were analysed using a regression model in Minitab (Minitab 21.1.0) statistical software. The analysis resulted in a linear energy consumption equation that links energy consumption to both production and energy loss. Dynamic simulations and modelling using Simulink in MATLAB were performed based on a proportional–integral–derivative (PID)-controlled system. The dynamic behaviour of the model was evaluated using data from Plant A and validated with data from Plant B. The energy efficiency equation was established as a mathematical model that explains energy improvements based on incorporating parameters for the cement kiln system and disturbances from the environment.

Historically, secondary pillar extraction has been successful in the soft rock mining environment. Several hard rock platinum mines have conducted selective remnant extraction with backfill as a regional support measure. A hard rock tabular platinum mine instigated the extraction within a non-yield pillar layout without backfill support. The mine is situated within the Great Dyke of Zimbabwe in a shallow depth environment of approximately 100m. Pillar extraction without backfill in a hard rock mine is a novel mining method. A study was carried out to make a quantitative comparison between the various design parameters and the rock mass response measurements. The primary mining utilised the mechanised room and pillar mining method to extract ore from the wide tabular reef. Similar, low profile mechanised equipment with additional automated systems were adopted for ore extraction and transportation to the surface crusher. The risks associated with the extraction of pillars include large localised falls of ground due to wide spans, pillar run, high severity injuries due to windblasts and large regional collapses through to the surface. The pre-feasibility study for the mine layout design used MAP3D to assess the expected displacement and stress limits post-extraction. MAP3D uses the boundary element method of analysis and has an in-built CAD system for stress analysis and 3-dimensional visualisation of models. A monitoring strategy consisting of displacement, deformation, stress change, ground motion and groundwater level measurements was put in place to record the variations resulting from the pillar extraction. The rock mass response analysis aimed at trending the monitoring results, conducting a comparison to the design parameters and previous pillar collapse trends. Minor stress, strain, and displacement changes have been recorded within a period of one year since the project began with no visible deformation noted on accessible pillars. The current system was identified as including the hazard identification and first-pass monitoring stages. Real-time monitoring systems with a higher sensitivity are required to ensure long-term data retrieval and timeous emergency response.

The application of the Internet of Things (IoT) in industrial systems and other new technological advancements led to the development of the Industrial Internet of Things (IIoT). IIoT can help overcome the shortcomings of the conventional monitoring and control system while enabling enterprises to create a unified monitoring system to automate operations, provide a safe working environment, enforce compliance effectively, and regulate environmental issues. Given the advantages that IoT brings to the forefront, it makes sense that so many mining companies have raised their investment following the implementation of IoT-enabled solutions in their organisations. To increase safety, productivity, and environmental sustainability in mining operations, this article examines the current state of information technology in the mineral industry with an emphasis on the implications and challenges brought on by the technological diversity of various systems and devices used in those activities. The study contributes valuable insights into the integration of IoT technologies in the mining industry, highlighting its potential to improve safety, efficiency, and sustainability. The paper paves the way for future research and development efforts aimed at overcoming the challenges of adopting IIoT in mining operations by identifying gaps and proposing a comprehensive IoT architecture. The innovations of the study are encapsulated in its approach to detailing the application of IoT technologies in enhancing mining operations and the establishment of an overall IIoT architecture suitable for the general operations in the mining industry.

Ensuring the stability of pitwalls in open pit mining is a critical aspect of the safety of personnel, equipment, and the surrounding environment. Complex geological and geotechnical conditions encountered in practical open pit mining often present challenges in accurately assessing slope stability. This study employs both DIPS and Swedge software to enhance pitwall stability analysis. DIPS examines discontinuity orientations and distributions, providing essential geological insights,while Swedge simulates potential wedge failure modes, determines their sizes, and calculates factors of safety crucial for pitwall stability assessments. While both DIPS and Swedge have found individual or combined applications in numerous studies, a comprehensive and systematic evaluation of their performance across a spectrum of pitwall conditions, particularly in extreme weather environments, remains a major research subject. By combining the strengths of DIPS and Swedge, the study - not only refine our understanding of pitwall stability mechanisms but also developed a robust methodology applicable across diverse geological and climatic conditions. The results of this research contribute significantly to the body of knowledge in rock mechanics and open pit mining practices, offering practical guidance for enhancing pitwall stability in various operational contexts.

One of the most important sectors of the world economy is the mining and metals sector. Although, many operational and commercial procedures continue to be ineffective and out-of-date, which results in crucial data omissions, security flaws, and sometimes corruption. Given that the mining industry wants to increase the emphasis on ethical and open mining practices, the industry has been looking for ways to incorporate these practices. It is envisioned that such practices will contribute to the modernisation of supply chains in addition to helping to reduce risks related to sustainability and reputation. The application of blockchain technology in the minerals industry capable of tracking natural resources has been discussed in this study, giving a much-needed layer of transparency of this technology. However, there are a lot of difficulties and problems that come up when thinking about blockchain technology; if it is to advance as an industry standard, stakeholders will need to evaluate the usefulness and scalability of the technology. While blockchain technology can be applied to a wide range of areas in the minerals industry, this study shines more light on the application of this technology to conflict minerals tracking, mineral resources reporting cheating scandals, rock mechanics designs and monitoring strategy, blasting designs and operation, mine ventilation designs and applications, mining machinery maintenance and management, and mining surveying. The study reveals that blockchain technology is starting to be seriously evaluated and used by a variety of stakeholders, even though broad acceptance has not yet been attained.