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By G. J. McTeer, D. J. Rioux

Teck Metals Ltd operates an integrated zinc-lead complex at Trail, British Columbia, Canada. Since 1997, KIVCETTM flash smelting technology has been utilized for the treatment of zinc plant residues and lead concentrates. Trail Operations’ furnace uses four water-cooled jackets for bullion tapping. This paper provides an overview of KIVCET bullion tapping for the past 16 years, and discusses successes and challenges encountered with respect to operations, training, and monitoring.

Jan 1, 2014

By G. Akdogan, S. M. Bradshaw, A. P. Van Wyk

In the mineral processing industry, Ni-Cu-Fe-S converter matte is leached to remove base metals from a concentrate containing platinum group metals (PGMs). We investigated the atmospheric leaching process to develop a better understanding of the leaching behaviour of the base metals (Cu, Fe, and Ni) and the PGMs, in particular Ru, Ir, and Rh with respect to key process variables, acid concentration, and Cu concentration under oxidative and non-oxidative conditions. With oxidative leaching, a higher initial acid concentration resulted in higher Cu, Ni, and Fe extractions, as well as faster leaching reaction rates. A higher initial acid concentration also resulted in faster precipitation of Cu, Ru, and Ir under oxidizing conditions. Under non-oxidative conditions, Ni and Fe extraction was much slower, and the effect of initial acid concentration on Cu precipitation was less pronounced. The initial Cu concentration had a slightly smaller effect on the leaching behaviour of Fe and Ni, as well as precipitation of Ru, Ir and Rh. Moreover, a higher initial Cu concentration suppressed both Ni and Fe leaching and had a slight inhibiting effect on the precipitation behaviour of Cu, Ru, and Ir.

Nov 1, 2021

International Solvent Extraction Conference 1971 ISEC '71, which will be held in The Hague, The Netherlands, from 18th to 23rd April, 1971, is being sponsored by the Society of Chemical Industry in association with the Koninklijk Instituut van Ingenieurs, the Institution of Chemical Engineers and the Koninklijke Nederlandse Chemische Vereniging. The Working Party on Distillation, Absorption and Extraction of the European Federation of Chemical Engineering is participating in the Conference, which is the 101st event of the Federation. The scope of the Conference covers the entire science and technology of liquid-liquid extraction as applied in all branches of industry. Thus sessions will cover both chemical and chemical engineering aspects of the subject as applied to both inorganic and organic solutes. The conference aims to bring together academic and industrial workers in the field from all parts of the world. The programme includes over 100 papers by authors in 26 countries. Full details of the papers, together with registration forms, are contained in a detailed programme, copies of which are now available from: ISEC '71, 14 Belgrave Square, London, S.W.1, U.K. Department of Mining and Mineral Technology of the Royal School of Mines Postgraduate Courses Technical and economic challenges facing the minerals industry, together with progressive change in methods and equipment, increasingly necessitate re-training of experienced professional engineers who aim for top places. In order to meet this need, this Department has for some years run one year M.Sc. courses. Engineers, often sponsored by their employers, have a choice of three courses which are respectively devoted to mining, applied rock mechanics or mineral process design. The course in Mining is divided into five subjects, which are treated from the business management point of view. It is intended to provide middle management with a knowledge of those techniques that are required by the mining engineering function in the preparation of modern projects. The course in Mineral Process Design provides a systematic use of mineral sciences, engineering and economics for ore testing and process design, so as best to balance the technical and financial requirements for specific mineral resources. The course in Engineering Rock Mechanics is designed to provide a specialized training in the engineering applications of rock mechanics for engineers and geologists, so that they are equipped to treat a wide variety of problems in mining and civil engineering. Prerequisite qualifications are a good first degree in a related subject, plus industrial experience: The rewards include an M.Sc. of the University of London and the Diploma of the Imperial College (DIC). The limited number of places available (12 in each group) makes early application advisable. Full details are available from the Registrar, Imperial College, London, S.W.7.

By A. Chuma, K. J. Nyembwe, H. Simonsen, J. H. Potgieter

Different concentration techniques were evaluated for preconcentration of a mineral ore at a coarser size to avoid energy and resource wastage. Specifically, the aim was to reduce milling costs and energy required in the beneficiation of tin. In this study, cassiterite (0.17% Sn) was the mineral of interest in a pegmatite ore body associated with quartz (SiO₂ > 60%) and alumina (Al₂O3 > 20%). Three concentration techniques, namely dense media, shaking table, and flotation, coupled with characterization analysis, were used to assess the concentration response. The results confirmed that particle size and mineral liberation impact the separation process. High recovery and grade were obtained with gravity concentration methods (dense media and shaking table) for coarser (+300 to +212 μm) and intermediate (+150 to +53 μm) particle sizes. Lower recovery and grade were identified for much finer sizes (−53 to −38 μm). Flotation produced a high-grade product at a relatively low recovery and appeared to be only applicable to finer grains. Separation efficiency based on Schulz’s equation measured a segregation performance of 74.8% for dense medium separation and 60.7% for the shaking table for the coarse and intermediate particle sizes. Flotation only achieved a separation of 30%–40%. The results suggest that use of dense media separation as a rough preconcentration method prior to further grinding, and the utilization of a more advanced concentration technique for mineral recovery and upgrade, constitute a successful approach to improve process economics.

Apr 14, 2024

By T. Oberthür

The Great Dyke of Zimbabwe constitutes the world?s second largest reserve of platinum group elements (PGE) after the Bushveld Complex in neighbouring South Africa. Within the Great Dyke, economic concentrations of PGE are restricted to sulphide disseminations of the Main Sulphide Zone (MSZ), which are currently mined at the Ngezi, Unki, and Mimosa mines. Near-surface oxidized MSZ ores have a large potential. Their total resources are in the range of ca. 160 ? 250 Mt; however, all previous attempts to extract the PGE from this ore type proved uneconomic due to low PGE recoveries (<< 50 per cent) achieved by conventional metallurgical methods. Within the ores of pristine, sulphide-bearing MSZ, the PGE are bimodally distributed. Platinum occurs mainly in the form of discrete platinum group mineral (PGM) grains (mainly bismuthotellurides, sulphides, and arsenides), whereas approximately 80 per cent of the Pd (and some Rh) is hosted in pentlandite. Within the oxidized MSZ ores, the PGE are polymodally distributed. Whereas arsenide- and sulphide-PGMs, making up ca. 25 per cent of the original Pt content of the ore, largely remain stable (relict PGMs), the remaining PGMs are disintegrated. The base metal sulphides are destroyed, partly releasing their base metal and PGE contents, and are replaced by iron oxides or hydroxides. Unspecified amounts of the PGE are redistributed and either form secondary PGMs, are found in chemically and mineralogically ill-defined (Pt/Pd)-oxides or hydroxides, or in iron-hydroxides, Mn?Co-hydroxides, and in secondary silicates. The problematic processing of oxidized MSZ ores is attributable to their complex nature and polymodal distribution of the PGE, prohibiting a significant upgrading of the ores by conventional metallurgical methods. Therefore, only bulk leaching methods are viable for ore treatment, and novel metallurgical methods have to be developed for the processing of these ores. Our ongoing work aims at locating the PGE in their mineralogical form in order to understand the mineralogical balance of the PGE in the ores and thereby facilitate the evaluation of metallurgical options for their recovery. A short overview on options and recent advances regarding the recovery of the PGE from oxidized ores is given.

Jan 1, 2012

By R. Castro, R. Gómez, F. Betancourt, M. Moncada

In block cave mining, rock fragmentation is a key parameter that influences the production level design and mine planning. Fragmentation occurs mainly by natural breakage during the caving process and in the draw column. The breakage that occurs within the column is known as secondary fragmentation. Secondary fragmentation has been successfully described using the block caving comminution model, which replicates the fragmentation mechanics between particles under drawn and vertical loads in a draw column. This model is based on a kinetic and population balance approach, in which non-normalized and normalized assumptions can be used depending on material and comminution system behaviour. In this paper, the non-normalized and normalized approaches are applied and compared to laboratory data to determine which assumption should be used for secondary breakage in block caving. Approaches are compared graphically, with the mean square error and the Fisher test with a false-rejection probability of 0.05. Based on a statistical analysis, the results show that the normalized model can be applied to all the rock types tested.

Nov 1, 2021

By W. K. Brinsden

In August 1965, the late Mr Alan Smith, then Mill Superintendent at Gold Mines of Kalgoorlie (GMK), Australia, asked me to investigate the planting of vegetation on the GMK slimes dams in order to ease the dust problem in urban and industrial areas-a problem that is caused largely by dust from these barren slimes dams. My early sources of information were the comprehensive papers in various issues of the Journal of The South African Institute of Mining and Metallurgy. However, the climate of Johannesburg differs from that of Kalgoorlie. The average Johannesburg rainfall, which falls mostly in summer, is 730 mm, and the average maximum summer temperature is 26°C (top 34°C). The winters are cool, the average maximum being 18°C (low -7°C). Kalgoorlie, on the other hand, receives, on average, 257 mm of sporadic rainfall, has hot dry summers with an average maximum of 35°C (top 45°C), and cool winters with an average maximum of 18°C (low -2°C). My obvious choice was to look at established trees growing on the GMK lease. A number of Athel pines were growing vigorously adjacent to the Oroya mining and geology offices and also on a nearby sand dump. The Athel pine (Tamarix aphylla), which is native to North Africa, Asia, and India, was originally introduced into Australia in 1936 by Mr Essington Lewis, then manager of BHP. His cuttings were planted in Whyalla, where some difficulty had been experienced in finding trees and shrubs that would flourish despite the district&apos;s low rainfall. In August 1965, cuttings of approximately 20 cm length and 1 cm diameter were taken from the GMK trees, stripped of leaves, and placed in jars of water in the sun. When the cuttings had sprouted both leaves and roots, they were planted in local soil in tins (about 20 cm high and 10 cm in diameter), and watered daily. In October 1965, when the new shoots were about 8 cm long, the trees were transplanted onto a lower flat section¬approximately 30 m wide, 30 m long, and 2 m high-of the Trafalgar slimes dam. No additional soil or fertilizer was used, and the trees were planted in their tins, the bases of which had been removed (the tin would eventually rust away). A few common varieties of non-prickly cactus and two native salt bush (spp Atriplex) were also planted, but did not survive, probably because of the acidity of the slime. During the summer of 1965/1966, Kalgoorlie&apos;s rainfall was 88 per cent above the average, and this probably helped the trees to survive. The moisture content was usually about 2,5 per cent from about 10 cm below the surface, and the pH value of the slime (d80 approximately 75 µm) was about 6. The trees were watered twice a week for the first four months and then left untended. By 1974 they had grown to only about 0,7 m, which indicated that their growth in slime was very slow. Other Athel pines were planted on the wall of the dam, but did not survive beyond 1974, probably because of the steep (about 500) slope and the hardness of the walls, which were initially formed by hand-shovelling of the slime as the height of the dam was raised. Five of the six Athel pines planted in 1965, which probably reached maturity (approximately 5 m in height) in 1981-16 years after being planted-have survived. In the early 1980s, waste rock had to be dumped on the dam, but the management of KMA (now KCGM) took care to ensure that the trees were not buried. Trials are being conducted on other tailings dams so that the performance of cuttings taken from the trees on Trafalgar dam can be compared with that of cuttings taken at various sites in Western Australia. It might also be worth while for an attempt to be made to strike cuttings from Trafalgar dam in pots containing different mixtures of soil and slime.

Jan 1, 1991

By E. Govender-Opitz, L. Lelia

The South African mining industry plays a significant role in the economy of the country. Nonetheless, the negative impacts on the environment continue to prevail. In regions where mining exists in proximity to communities, mining activities have led to the disruption of modality. Rural communities are mostly affected as they depend on land use for agriculture to sustain their livelihoods. The conversion of land for mining activities often leaves the communities vulnerable when mines close because of the limited life span of mines. An ongoing discourse focuses on how the mining industry can contribute to sustainable development of the communities in which they operate. Post-mining transformation offers an approach for the mining companies to contribute to sustainable livelihoods post-mine closure by strengthening rural-urban linkages, which ensures inclusive development of both rural and urban areas. The paper employs a case study approach to Richards Bay Minerals and the adjacent rural communities of Sokhulu and Mbonambi. It sets out to understand the post-mining transformation employed by RBM and explore the rural-urban linkages that manifest as a result. Findings show that sand dune rehabilitation employed by RBM is successful in restoring soil fertility and establishing the natural ecosystem. The casuarina planted to rehabilitate the dunes is used to spur an alternative charcoal industry post-closure. The main rural-urban linkages that manifest are flows of people due to job opportunities and flows of goods from the sale of charcoal produced. However, there is a lack of communication and lack of authority to ensure responsible management of the casuarina plantation and equitable sharing of benefits. The paper recommends that other post-mining transformation strategies such as eco-tourism should be explored and that the government, at both national and local level, the community and the mine should be involved to ensure overall success and sustainability of the strategy. Keywords Post-mining transformation, rural-urban linkages, alternative land use

Jan 1, 2020

By N. Sacks, N. B. S. Magagula, I. Botef

"Low-pressure cold gas dynamic spraying was used to deposit WC-4wt%Ni and WC-4wt%Ni-1wt%Mo coatings onto mild steel. Dense coatings with very low porosities were produced. No decarburization occurred during deposition and no deleterious phases were formed. The coatings were subjected to standardized material characterization tests, as well as slurry abrasion testing to assess their wear behaviour. The wear tests were conducted in synthetic minewater-silica slurries, while distilled watersilica slurries were used as a control. The hardness of the coatings, 512HV0.3 and 458HV0.3 for WC-4wt%Ni and WC-4wt%Ni-1wt%Mo respectively, are comparable to those achieved using high-temperature coating processes. The abrasion wear rates for both coatings were less than 5 mg/min and 10 mg/min in the distilled water-silica and synthetic mine water-silica slurries respectively. The approximately 50% increase in wear rate in the synthetic minewater slurry is attributed to a synergistic corrosive wear mechanism. The predominant wear mechanisms were identified as binder smearing and delamination, with carbide grain fracture and pull-out. IntroductionSlurry abrasion is a common phenomenon in mining operations, particularly in pipelines transporting, for example, sand-water slurries. This type of wear can cause pipeline fracture, shortened operational lifetimes, and impede pipeline efficiency. To reduce or limit abrasion, thermally sprayed tungsten-carbide-based coatings are often used as pipe linings (Kanchan et al., 2010). This is due to their attractive mechanical properties, which include high wear resistance, stiffness, hardness, compressive strength, and tensile strength. These properties are provided by the coating microstructure and composition, which is a blend of hard, wear-resistant tungsten carbide (WC) particles embedded in a fracture-tough metallic binder phase (Brookes, 1997). Cobalt (Co) is the most commonly used binder due to its excellent wetting of the WC phase and moderate mechanical properties; however, its application is limited to non-corrosive environments as it has a low corrosion and oxidation resistance (Andren, 2001). Nickel (Ni) may also be used as a binder, and has been shown to have superior oxidation and corrosion resistance, but in some applications may not have the required mechanical properties (Kim et al., 2006)."

Jan 1, 2016

By L. Chanderman, C. E. Dohm

"Mineral Resource estimation (MRE) and classification are highly dependent on the confidence in the model of the orebody geometry, known as the geological model, within which the estimates are constrained. An understanding of the geology of a deposit is thus fundamental to the Mineral Resource evaluation process. The geological model is a function of the structural and depositional complexity of the geology captured by drilling information, which is limited in the early stages of a project. The information effect has a significant impact in terms of the interpretation of the geology as well as the estimation of grade continuity and the resultant risk associated with the Mineral Resource estimate and classification.Therefore, as new drilling information becomes available, it is necessary to update and refine the geological model to appropriately constrain the resource estimates. The grade information is also updated, including statistics and the spatial correlation characteristics. This refinement is based on geological interpretations derived from the drillhole information that becomes available throughout the life of the mine; orebody knowledge that comes from working experience of the deposit, as well as familiarity with the software package used for modelling, is also important.In updating, the potential to identify new resources in previously unknown areas may be realized. The opposite may also occur where previous interpretations of ore continuity are refuted. Both scenarios could result from a better understanding of the geology of the deposit and thus a more realistic MRE, which reduces geological risk. This paper describes how newly drilled advanced grade-control holes for a gold deposit in Mali were used to refine the 3D geological model for the deposit in an attempt to identify the potential for additional oxide ore using conventional geostatistical evaluation techniques."

Jan 1, 2017

By M. Karsten

Platinum mines in the Bushveld Complex are located in areas with a high geothermal gradient. This means that, compared to, for example, gold mines of the Witwatersrand region, high rock temperatures are encountered at relatively shallower depths. Thus air cooling and refrigeration need to be considered at early stages in mine development. Another factor that influences air cooling and ventilation requirements is the use of trackless diesel equipment for loading and hauling broken rock. At shallower depths it will be more cost-effective to locate the cooling and ventilation equipment on surface, whereas for deeper mines the more cost-effective option is to locate cooling equipment underground. For intermediate depths, trade-off studies need to be undertaken to determine the optimum mix between more cooling and less air or more air and less cooling, as well as the optimum location for this cooling equipment. Factors that are taken into account include power requirements, positional efficiency, and additional infrastructure requirements. Traditionally the approach has been to ventilate ?all of the mine all of the time?. However, with increasing power costs and growing pressure to ensure sustainability, this strategy must be modified to apply ventilation and cooling on demand. In other words, both cooling and ventilation equipment should be operated only when needed and should be adjusted to the demand at the time. Obviously there will be areas that will need to be ventilated (and cooled) continuously (for example, for dilution of flammable gases), but this can be built in to the overall strategy. In addition, in devising ventilation on demand (VoD) strategies, occupational criteria relating to exposure to gases, noise, and heat need to be taken into account. This paper discusses options available for implementing energy-efficient ventilation and cooling systems and suggests ways of changing traditional thinking in the overall ventilation and cooling of mines. Efficient ventilation and cooling designs can play a major role in improving sustainability and reducing energy costs and carbon footprint.

Jan 1, 2012

By D. van der Westhuizen, H. Krieg, M. Kruger

In the field of Fischer-Tropsch synthesis catalysts, cobalt, platinum, and aluminium are the primary metal constituents of the conventionally used cobalt catalyst. While platinum recovery remains a focal point in this field, a recent endeavour by a South African company emerged, which aimed to recover cobalt and aluminium from spent Fischer-Tropsch synthesis catalysts for potential use in the agricultural sector. This study aimed to optimally separate cobalt and aluminium from spent Fischer-Tropsch synthesis catalyst for this purpose. It further leverages the OLI database to predict metal speciation during solvent extraction to aid with experimental planning. Shake-out tests were conducted to determine optimal separation. conditions, which were validated using three distinct methods: (i) evaluating the experimental error, (ii) comparing results with similar research, and (iii) validating results against the OLI database. The investigation revealed the pivotal role of the aqueous pH yielding effective separation at pH 3.13 ([H2SO4] = 2.5 × 10−4 M) when using 20 vol.% CYANEX 272 and 50 mol.% pre-neutralisation. Effective cobalt scrubbing was achieved with 50 g/L Al at pH 2.8, while successful stripping required 1 M H2SO4. Competitive interactions between complexing aluminium and cobalt species were observed when contacting with CYANEX 272 at a pH < 4. Equipment design analysis for a targeted separation efficiency of 87% dictated the necessity of two mixer stages and a settler measuring 1.5 m × 1.5 m × 6.0 m (height × width × length). This settler would ensure sufficient residence time for gravity separation at a flow rate of 10 m3/h.

May 27, 2025

By T. M. Chagwedera, A. E. Lewis, J. Chivavava

Eutectic freeze crystallisation is a novel separation technique that can be applied to treat brine solutions such as reverse osmosis retentates, which are often a mixture of different inorganic salts. The treatment of calcium sulphate-rich brine solutions through eutectic freeze crystallisation has resulted in gypsum scale formation on the walls of the crystallisers and ancillary equipment. In order to prevent gypsum scaling on equipment surfaces, it is essential to understand the mechanism of gypsum scaling on cold surfaces. This paper focused on the interaction between gypsum crystallisation in the bulk solution and scaling on the crystalliser walls in the presence of gypsum seeds. A cooled, U-shaped stainless-steel tube suspended in the saturated solution was employed as the scaling surface. Preliminary results showed that the scale layer was predominantly composed of needle-type and hexagonal prismatic crystals. The rate of scale deposition was highest during the first 24 hours, thereafter it decreased. A thin scale layer was observed to have coated the tube within the first hour of the experiment. Seeding, using reagent grade gypsum crystals, was effective in reducing scale layer formation through providing a surface for growth. The highest scale reduction, 81%, was realised at a seed loading of 0.50 g/L. At a high seed loading of 4.01 g/L, the seed material adhered to the tube. Keywords: Gypsum, eutectic freeze crystallization, seeding, scaling, cooling crystallisation

Jan 1, 2020

By J. Mulenshi, J. Rosenkranz, P. Khavari, S. C. Chelgani

The geometallurgical concept has mainly been applied to primary ore deposits, starting from ore characterisation to the economic optimisation of the mining operation. However, as primary ore resources are becoming depleted and lower in grade, alternative sources need to be explored and a question of adaptability of the geometallurgical approach to the secondary resource repositories arises. The particle size distribution, chemical and mineralogical compositions of the Smaltjärnen historical tungsten tailings from physical separation in Yxsjöberg, Sweden were studied using drill core samples collected from different locations within the tailings repository in order to assess the amenability of the tailings to reprocessing. The tailings are dominated by the –600 to +149 μm particle size fraction. This fraction contains most of the elements of interest (W, Cu, S, Sn, Zn, Be, Bi and F) hosted by scheelite, chalcopyrite, pyrrhotite, cassiterite, danalite (both Zn and Be), bismuthinite and fluorite, respectively. The particle size distribution and mineralogical composition vary across the repository, suggesting a possible existence of geometallurgical domains, which require further assessment to evaluate metallurgical performance. Keywords: Historical tailings, tungsten, scheelite, geometallurgy, characterisation, mineralogy, reprocessing

Jan 1, 2020

By F. H. Deist, M. P. Roberts

"The Collieries Research Laboratory of the Chamber of Mines of South Africa is developing a coherent system of programs to aid in the full spectrum of activities arising in the planning of new as well as operating mining enterprises. It is the purpose of this paper to describe the design and application of two subsystems in the complex.One of these subsystems is an initial version of a production simulator. This program draws upon a model of a mining enterprise and simulates the operational and financial aspects of a set of alternative mine production plans.These plans are specified in terms of proposed sequences of operations. Details such as reserves, production rates, resource requirements and so on, are taken from the model.Physically, the model takes the form of a cross-referenced data base, maintained by means of a general file maintenance system which is another subsystem described.The paper concludes with a description and analysis of the first practical application of the two programs."

Jan 1, 2014

By C. T. O’Connor

Since the first IMPC took place in London in 1952 there have been many developments in our understanding of flotation, both in terms of chemical and physical factors influencing the process. Many of these developments have been captured in the proceedings of thirty congresses that have taken place since that first event, as well as in numerous journal papers and special volumes dedicated to flotation. This paper attempts to highlight the individual contributions which many eminent researchers and engineers have made over the past 70 years towards extending our understanding of, especially, the effects of chemical factors on flotation. Although the focus is mainly on more fundamental aspects, it seems that the ‘pull’ of practice has often preceded the ‘push’ from laboratory-based research. As the fundamental understanding of the role of chemical factors on flotation continues to be developed, the major challenge remains to transfer this knowledge effectively into the domain of operations of this profoundly complex process.

Jan 1, 2020

By R. Simon, P. Pagé, L. Li, P. Yang

The Mathews-Potvin stability method is widely used in the Canadian mining industry as a starting point to determine the maximum dimensions of mine stopes. However, it cannot be applied to inclined (more frequently encountered) mine stopes without conducting numerical modelling to obtain the stress factor A, defined as a function of the ratio of unconfined compressive strength of intact rock to the induced principal stress on the exposed stope walls. The need to conduct numerical modelling significantly limits the application of the Mathews-Potvin method. In addition, given its empirical nature and main application for preliminary design, it is deemed undesirable to conduct numerical modelling, especially elaborate modelling. Alternatively, theoretical methods can provide a much simpler and quicker way to estimate stresses around stopes and the corresponding stress factors. Over the years, a large number of studies have been conducted to estimate stresses around openings excavated with various crosssections. However, theoretical or graphical solutions remain unavailable for mine stopes that typically consist of horizontal floor and roof, and two parallel inclined walls (hangingwall and footwall). To remedy this situation, a series of numerical simulations is first performed for openings with vertical and inclined walls, including typical stopes commonly encountered in underground mines. A group of empirical solutions is then formulated to estimate the induced principal stresses at the roof centre and mid-height of the stope walls. The validity and predictability of the proposed solution have been verified using additional numerical simulations. The proposed solution can thus be used to calculate stresses and the resultant stress factors A around typical mine stopes with any inclination angle and height to width ratio, under any in-situ stress state, without conducting numerical modelling.

Aug 1, 2021

By P. Valicek

Anglo American Platinum Limited is constantly striving to improve safety and productivity. There are many different initiatives taking place within the organization in order to ensure continued safe operation and profitable ounces for the future. One of the opportunities and potential growth areas that has been identified and is being explored is that of mechanization. In order to do this, the approach that has been adopted by Anglo American Platinum is to fully understand and analyse the current mechanized mining methods. Once each configuration is fully understood, the method can then be optimized and new mining technologies and systems can be developed to overcome the current shortfalls. This paper will discuss a methodology that was developed by Anglo American Platinum (in conjunction with Cyest Corporation) and adopted to optimize the mechanized mining layout and fleet configuration, and will also present the final findings of the study. Due to the impracticability of piloting every possible option in the workplace, extensive modelling and simulation exercises were conducted to determine realistic parameters for productivity and value. The study resulted in a full understanding of mechanized mining systems and their associated layout. From the results of the study a mining / logistic layout was developed which highlighted the following opportunities: 1. Create safe operations through the reduction of personnel in the ?high-risk zone? of stopes 2. Separate machines and personnel by use of remotely operated machines 3. Create focused mining on primary development from the production stoping, thus having dedicated teams on development and stoping. 4. Develop primary development ahead of the stoping activity. This enables: a) Understanding of the geology and subsequent implementation of the correct b) technology (?fit-for-purpose?) required to mine that area based upon this geological knowledge c) Ability to install tipping points ahead of stoping, creating ?immediate stoping reserves?, thus increasing flexibility and reducing production risk d) Improved productivity by having adequate faces available and reduction in re-development to establish faces. 5. Quicker return on Investment due to recovering revenue from ?on-reef development? 6. The layout allows flexibility between stope sections enabling better ?resource sharing? 7. Optimize the long-term ratio of machine makeup of the fleet in relation to the production outputs 8. Creates an agile mining layout allowing rapid response to market pressures. The findings and work presented in this paper is currently being implemented at different test sites within Anglo American Platinum and will demonstrate that improved safety and productivity can be achieved through the adoption of mechanization.

Jan 1, 2012

By G. A. Bezuidenhout, S. Bradshaw, W. Malan

"Currently, the matted-based collection process is most widely used for platinum group metal (PGM) recovery. However, because PGM-containing concentrates are becoming more enriched with UG2 (Upper Group 2) low-grade concentrates, this is expected to be integrated or replaced with an alloy collection process.The reduction LG (low-grade) concentrates with silicon carbide (SiC) was investigated. The purpose of the study was to ascertain the feasibility of using SiC as reductant with regard to metal fall, PGM grade in the alloy, slag composition, and overall PGM recovery, and if possible, the integration of such a process in the current matte-based collection process. Rowland and Easterns LG concentrate samples from Lonmin were analysed by Xray diffraction (XRD), X-ray fluorescence (XRF), and inductively coupled plasma mass spectrometry (ICP-MS). It was found that SiO2 and MgO are the most abundant oxides and Pd is the most abundant of the PGMs. Sulphide-bearing minerals such as chalcopyrite were detected in low concentrations (below 1%), and Cr2O3 concentrations are between 2-4%. SiC reduction of Rowland and Easterns concentrate were conducted at 1600°C with reductant to concentrate ratios ranging from 2.5 to 3.5 kg SiC per 100 kg concentrate.The reduction experiments revealed that PGM recoveries from Rowland concentrate were poor. SEM images showed entrained metal prills in the slag phase. The slag viscosity at the end of the melt was calculated by using FactSage, and the results indicated that the viscosity was higher than 4 poise, which is above that of Easterns slag. PGM recoveries for Easterns concentrate were significantly better. More than 85% of the Ir and Pd and almost 60% of the Pt were recovered in a test with a reductant to concentrate ratio of 3.5 kg SiC per 100 kg Easterns concentrate. At this reductant to concentrate ratio, Fe recovery was also the highest, at 66%. SEM imaging of a slag sample revealed few or no metal prills entrained. The FeO content in the initial concentrate charge was then increased by adding Peirce-Smith converter slag in order to decrease the slag viscosity and further increase PGM recovery. A test was conducted with the addition of 10 kg converter slag per 100 kg Easterns concentrate. The reductant to concentrate ratio was kept at 3.5 kg SiC per 100 kg Easterns concentrate. The Ir and Pd recoveries were more than 95%, while Pt recovery was almost 70%. Fe recovery increased to 76%. On the basis of these results an optimum feed ratio between Easterns and Rowland concentrates and Peirce-Smith converter slag were calculated. FactSage predicted that the concentrate charge should consist of 70-80% Easterns concentrate with 20-30 kg converter slag per 100 kg LG concentrate. SiC reduction of this optimum LG concentrate charge is expected to recover more than 90% of all PGMs. Cr and Si concentrations in the alloy will be below 1% in total.The effectiveness of SiC as reductant was also compared to carbon reduction. Carbon reduction of an optimum concentrate charge at the same reductant to concentrate ratio resulted in a marginally higher metal fall than SiC reduction. However, gas emissions and energy requirements are higher for carbon reduction.The study has shown that base metals and PGMs can be recovered in an iron alloy by SiC reduction of LG concentrate with converter slag additions. Integration of such a process into the matte-based collection process could be considered as a future alternative for smelting UG2 LG concentrates."

Jan 1, 2014

By Y. Rajpal

The Hedley and Grant pillar strength formula is widely used within the South African mining industry to calculate pillar strengths in bord and pillar mining layouts, and is currently being used at Bathopele Mine. Bathopele is an operation of Anglo American Platinum near Rustenburg, mining the UG2 reef at depths ranging from 40 m to 300 m below surface. The formula includes a parameter K, which is a downrated uniaxial compressive strength value of the rock, used to calculate the strength of a pillar. At Bathopele Mine, for the shallower areas Less than 150 m the value was 33 MPa, but this was increased to 44 MPa due to the fact that rock mass conditions improved and there were no incidence of failure in the shallower areas. Underground observations showed pillars to be stable with no signs of failure, and it was questioned whether the design was not still too conservative, resulting in sub-optimal extraction ratios and consequently a loss of revenue to the mine. A trial mining section was started at the mine where the pillars were reduced from 6 m x 6 m to 5 m x 5 m and the pillar behaviour was monitored for the onset of failure. Numerical modelling was conducted using the TEXAN code to back-analyse pillar stresses in order to find a more realistic value for K. Results from the trial section indicated that the pillar design was in fact too conservative, and the value for K was adjusted to 54 MPa for future designs. This paper details the findings from underground monitoring and numerical modelling results, and includes details for further calibration of the K value in order to further optimize the extraction of the orebody.

Jan 1, 2012