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This paper presents the development of a regrind facility design at BHP Billiton's Leinster Nickel Operations (LNO) in Western Australia. The recovery opportunity was identified from an analysis of plant operating data together with scanning electron microscope (SEM) measurements on relevant tailings streams from LNO. A laboratory procedure was developed to determine the potential recovery improvement of installing a regrind facility at LNO. The last step in formulating the process flow sheet and defining the process design criteria was to construct and operate a pilot plant, which incorporated four banks of flotation cells and an Xstrata M20 Isa Mill. Pilot plant on/off trials were used to define the expected metallurgical benefit. A prefeasibility engineering design and cost estimate was completed. Following a successful internal business evaluation, a feasibility study is currently underway.

Jan 1, 2007

By G. Poropat, A. R. Guest, H. P. Grobler

At the De Beers Consolidates Mines operations it is common practices to perform Geotechnical mapping of the newly exposed faces in the waste and ore rock. The purpose of Geotechnical mapping is to quantify the in-situ fracturing of a rockmass that in turn is required during the planning and application of a mining method. Whether it is to determine slope angles, caveability, impact of blasting or support requirements. This mapping involved a cumbersome and time consuming procedure that requires individual examination and description of the natural inherent fractures exposed by mining. During highwall mapping in an open pit this can be a safety concern due to the duration of time spent below a highwall. The advantages gained through the recent introduction and application of SiroVision® allows safer mapping, an increase in statistical fracture population, archiving of rock faces and the more accurate reflection of the true mapping. This paper aims to describe in detail the application of the recently developed SiroVision®, photogrammetry software, to replace conventional face mapping. A De Beers Consolidated Mines, il est pratique courante de faire une cartographie géotechnique des tailles récemment exposées dans le rocher stérile ou minerai. Le but de la cartographie géotechnique est de quantifier la fracturation in-situ d’une masse rocheuse, qui sera nécessaire lors de la planification et application d’une méthode minière, que ce soit pour déterminer les angles des galeries inclinées, les possibilités de foudroyage, l’impact du dynamitage, ou les besoins en supports. Cette cartographie nécessitait une procédure longue et compliquée qui demande l’examen individuel et la description des fractures naturelles propres exposées par l’opération de mine. Pendant la cartographie de parois dans une exploitation à ciel ouvert, cette opération peut être dangereuse à cause du temps passé sous la paroi. Récemment, le lancement et application de Siro Vision apportent l’avantage d’une cartographie plus sûre, une augmentation des statistiques de population de fracture, l’archivage des tailles de roches, et le reflet plus précis de la cartographie. Le but de l’étude présente est de décrire en détail l’application du développement récent de Siro Vision, logiciel de photogrammétrie, pour remplacer la cartographie de taille conventionnelle. Bei den De Beers Consolidates Mines Operationen ist es gängige Praxis geotechnische Aufzeichungen des Taub- und Erzgesteins neu geöffneter Abbaustellen zu erstellen. Zweck dieser geotechnischen Aufzeichnungen ist die vor-Ort-Quantifizierung des Bruches der Gesteinsmasse, welche im Gegenzug während der Planung und der Anwendung einer Abbaumethode erforderlich ist, sei es um einen Neigungswinkel festzustellen, Abbaubarkeit, Auswirkung von Sprengungen oder Anforderungen an Unterstützungen. Die Aufzeichnungen waren mit umständlichen und zeitaufwendigen Prozeduren verbunden, die eine individuelle Prüfung und Beschreibung der durch den Abbau freigelegten natürlichen inhärenten Brüche, verlangten. Dies kann auf Grund des Zeitraumes der unterhalb einer Flözoberschicht verbringt wird zu einer Frage der Sicherheit werden wenn die Aufzeichnung einer Flözoberschicht im Tagbau erfolgt. Die Vorteile auf Grund der jüngst erfolgten Einführung und Anwendung der SiroVision® gestatten sichereres Aufzeichen, eine Zunahme in der statistischen Menge an Gesteinsbrüchen und eine akkuratere Reflektion der tatsächlichen Aufzeichnungen. Diese Arbeit hat zum Ziel im Detail die Anwendung der kürzlich entwickelten SiroVision®, eine photogrammetrische Software, die die konventionelle Abbauortaufzeichnung ersetzen soll zu beschreiben.

Jan 1, 2003

By M. Thurston

This case study shows that for a set of lognormal data with a low coefficient of variation the semi-variogram of the logs has almost the same shape as the semi-variogram of the raw data. This means that the variogram of the logs, which is numerically more stable, can be used to krige the raw data. This technique is tested on samples from a sedimentary gold deposit and the results compared to those obtained from ordinary and simple lognormal kriging.

Jan 1, 1987

By C. M. Suhr

n order to validate the borehole analysis valuation procedure commonly used in the South African gold mining industry, a simulated orebody was used to create borehole values which would serve as data for the procedure. After confirming the distribution, calculating the variance size of area relationship, estimating the block variance, and calculating a profit measurement for each set, comparisons were made to the known population parameters. Results show only one overall bias (in the estimation of the lognormal third parameter), which is carried throughout the analysis. The remainder of the analysis is unbiased, validating the procedure.

Jan 1, 1987

By I. J. Barker

This paper argues that the scale up of furnaces and the supply of electricity are going to be two major issues that will affect the ferro-alloy industry in the near future, and that economic factors will drive this development. The most common type of furnace for producing ferroalloys at present is the submerged-arc furnace with three electrodes, fed from a three-phase AC electrical supply. The scale up of this technology has now reached a fundamental constraint, which is caused by the electrical reactance of the secondary circuit. If the economy of any further scale up is to be achieved in the future then a different technology will have to be used. The supply of electrical power in future is likely to become amore complex issue than it is at present. Existing submerged-arc furnaces tend to run at fairly steady loads, but the ability to swing the load under demand-side management may offer advantages, and may allow a furnace to obtain cheaper power from the organizations that supply this power. This will have to be counterbalanced against the nuisance factors incurred by having a varying load in the operation of the furnace. Various options are therefore discussed in this paper. The possibility of scale up of Søderberg electrodes is discussed, as well as the use of DC power and multiple electrodes. Some of the issues with load swinging are also examined. A particular scenario is also briefly presented to show that considerable further scale up of ferro-alloy furnaces is still possible.

Jan 1, 2011

By Ralph H. Nafziger

This paper reviews the major deposits of lower-grade chromite in the world, and a wide variety of methods used for the recovery of chromium from them. Gangue materials in more coarsely sized ores can be separated by gravity means, whereas flotation techniques are required for finer-grained materials. However, unless there is considerable Iron In the ores, physical means cannot increase the Cr/Fe ratios. Chemical techniques such as hydrometallurgical methods, chlorination, roasting and leaching, and smelting are required for this purpose. A greater understanding of the physical properties of chromites and the chemical reactions that take place in the recovery operations is required before. the recoveries from lower-grade chromites can be maximized. More efficient recovery operations can be realized If It can be shown definitively that the reduction of chromites occurs via either a gas-solld or solid-solid mechanism, for example. The effects of specific impurities on the chromite reduction reactions need to be better understood, as do reagent and pH control in the flotation of chromite.

Jan 1, 1982

By Z. Nzimande

The Constitution of the Republic of South Africa advocates the importance of sustainable economic development and justifiable environmental consciousness by business. The government needs to ensure that every citizen of the Republic has access to an environment that is protected, pollution free, and sustainable by enacting certain regulations. However, there are more than 5 700 derelict and unrehabilitated mines of all types in South Africa. Former asbestos operations were among the first to be targeted for clean-up under the programme instituted by the Department of Mineral Resources (DMR), owing to the proven direct impact of asbestos pollution on health. This paper seeks to investigate the challenges faced by the coal sector as far as mine rehabilitation and closure is concerned. For the purpose of this paper rehabilitation is defined as per the Chamber of Mines Rehabilitation Guidelines publication, which defines rehabilitation as putting the land impacted by mining activities back to a sustainable and usable condition. Some of the current rehabilitation challenges are technical skills (know-how), leadership focus, poor planning, cost saving initiatives, and the government's lack of capacity to enforcement rehabilitation requirements. It is imperative that mining companies identify rehabilitation as a critical strategic pillar that directly influences license to operate. The case study evidence indicates that relevant policies, appointment of accountable people, sufficient leadership support, and the correct choice of rehabilitation equipment can assist to improve the rehabilitation and land management challenge.

Jan 1, 2012

By John Freer

On 25th November, 1983, nearly forty members of The South African Institute of Mining and Metallurgy, together with Doris Gardner and Judith Money from Kelvin House, travelled by luxury motor coach to Secunda, there to visit the coal-mining and conversion operations of Sasol Limited.

Jan 1, 1984

By R. M. Kear

The Mine Planning Department of Rio Tinto Management Services South Africa has installed an interactive graphic work station to assist with the long- term mine planning of Palabora. Previously, the planning was drafted manually after which digitised areas were fed to the computerised ore reserve system. This method was slow, tedious, prone to error and was becoming incapable of meeting new planning parameters. To assist the planning engineer an interactive graphic system was developed, and subsequently a rewrite of the ore reserve reporting system was incorporated. The work station has reasonable computing power and, when not utilised for graphics, has been found suitable for the evaluation of various non- graphical applications, a recent example of which was the in-pit crusher investigation. This project, in contrast to similar studies, was not based on a fixed system throughput but rather on a well designed system which would be operated at its own optimum capacity. In order to determine the probable throughput a simple simulator was designed to model the crushing and conveying system. This paper describes the investigation into the specifications for the work station, the selection of hardware, operating system and languages. An over- view is then given of the graphic planning system. The in-pit crushing simulation has been included as an example of how the work station has been applied to other, non graphical, applications.

Jan 1, 1987

By H. Rosenberg

Haldor Topsoe A/S has developed its WSA technology to meet the demand in the market for a simple and reliable process that converts sulphurous emissions from off-gasses into high-grade sulphuric acid. With more than 50 references in 25 countries, the WSA technology has proven its ability to generate acid at 98% concentration, efficiently and economically. The wet gas sulphuric acid (WSA) technology treats the furnace off-gas directly from upstream gas cleaning plants. No further drying is required, since the humidity present in the off-gas is used to hydrate the SO3generated in the converter and produce sulphuric acid. The heat generated during the oxidation, hydration and condensation processes is principally reused in the process to preheat the off-gas to the required temperature level, and also to generate high pressure superheated steam for process use. This advantage of steam production, coupled with lower water and power consumption requirements, is particularly important in the African production environment. Having fewer process components than conventional acid plants, the WSA technology is a simple and compact operation, which makes it easier to retrofit into an existing smelter plant. Further, the WSA technology simultaneously offers the possibility to treat multiple gas streams arising within the production facility due to superior flexibility in terms of SO2concentration and turndown ratio.

Jan 1, 2006

By M. Dobbins

Magnetic separation has long been used to upgrade and beneficiate a wide variety of industrial minerals. Advances in both wet and dry magnetic separators over the years has broadened their use, and questions are often raised about which separation technique or equipment type is most appropriate for a particular operation. This paper will provide a brief look at existing magnetic separation technologies, and discuss their potential advantages and disadvantages when applied to heavy mineral applications. Relevant case studies for the separation of ilmenite and chromite are then presented. The process development efforts undertaken for each case are described, and the rationale for selecting appropriate magnetic separation technology is explained. The nature of the material being treated must clearly be understood, knowledge and access to testing the best separation technologies is required, and careful process development and economic evaluations are a must. As is shown in the case study discussions, it is imperative that these principles drive the separation technology selection and placement, rather than looking at typical or existing similar flowsheets as rules. As examples, the ilmenite tailings case study presented in this paper shows how advances in technology have allowed for increased recovery of -45 µm ilmenite by utilizing a multi-stage SLon® wet magnetic separator circuit equating to an additional 30 000 tons of ilmenite produced per year. The virgin chromite case study presented shows that through careful testing and circuit design efforts using RED technology, a 20% increase in overall chromite recovery was achieved over previous demonstration work.

Jan 1, 2007

By S. M. Spottiswoode, A. J. Jager, N. C. Gay, J. A. Ryder

The South African mining industry is at present planning to extract orebodies at depths of up to 4 km. To do this cost effectively and, at the same time, ensure safe working conditions for mining, the personnel will require both the development of new strategies and the implementation of current rock-engineering technological developments on a wide scale. This paper covers most of the technological developments likely to be required for mining at very high stresses, but it is clear that improved regional support systems will need to be developed to ensure defective stability of the rockmass during mining operations. Similarly, it is clear that improved strategies for mining in large-scale geologically disturbed areas, where slip on faults or dykes can result in wide-spread rockburst damage, will have to be addressed

Jan 1, 1995

By S. Shamaila

The design and efficient operation of density-based mineral processing units requires regular densimetric analysis to be carried out on the various associated process streams. The results obtained from such analyses can have wide application, including the generation of washability and partition curves, which are critical for process design, control, and simulation. This paper describes some of the collaborative efforts that Kumba Iron Ore, in partnership with Springer New Technology and Anglo Technical Solutions Research, is pursuing in developing a novel density determination technique exploiting X-ray transmission (XRT) and optical imaging. This technique is being developed with the aim to determine sample density distributions that apply to washability characterisation of ores. This technique is aimed to be an alternative to the traditional sink and float method. For certain applications sink and float has required the use of tetrabromoethane (TBE) solution?a chemical that has been classified as harmful and environmentally unfriendly. This paper therefore presents some achievements in developing this novel technique which seems to be very promising.

Jan 1, 2012

By Anthony K. Anyimadu, Chris M. Rule

Froth flotation is the primary mineral processing separation step employed in the beneficiation of PGM ore bodies. Anglo Platinum operates a significant portion of the total installed flotation capacity in the PGM industry, which is installed at 20 operating plants across the Bushveld. PGM flotation has undergone a considerable evolution in both the capacity of flotation cells employed as well as in the circuit design configuration over the past thirty years. Certain of Anglo Platinum?s flotation circuits have been in operation for a relatively long period of time, (in some operations installed equipment dates from the 1960?s) and this allows comparative operating performance between various equipment types and circuits to be evaluated. This paper summarizes some aspects of this experience. Research trends in flotation are continuously monitored to incorporate appropriate findings into existing and future circuit designs. Continuous evaluation and monitoring of flotation performance is undertaken to identify opportunities for increasing flotation efficiencies. Mineralogical and fractional analyses of plant composites and survey samples are analysed to interrogate speciation and association data. This analysis has enabled a better understanding of priorities and opportunities for improved metallurgical performance. These opportunities are divided into three improvement areas: stability, liberation, and fines flotation. The paper discusses these, as well as the circuit design improvements required to take full advantage of the opportunities identified.

Jan 1, 2007

By G. E. Blight

Many mines engaged in deeplevel gold mining in South Africa are experimenting with the use of tailings fills, or are implementing tailings backfilling programmes on a limited scale. The approach varies from mine to mine, depending on circumstances and available fill materials. Several mines are backfilling with a cyclone underflow product; the cyclone overflow is then combined with the balance of the tailings stream and directed to surface disposal. As the extent of backfilling increases, the proportion of the surface tailings stream composed of overflow material will rise, and the properties of the tailings requiring surface disposal will approach those of the cyclone overflow. As the latter will be finer, less permeable and possibly weaker than the total tailings currently being disposed, the design and operation of surface tailings dams will have to be modified. Dams may have to be designed with flatter outer slopes of a reduced maximum height. Lower rates of rise may be required and, as a consequence, larger disposal areas may be demanded. To offset the negative aspects is the fact that the quantity of tailings requiring surface disposal will be reduced. The paper explores the dam-building properties of two cyclone overflow products. It shows that although these materials are inferior in dam-building characteristics to the corresponding total tailings, their geotechnical proper- ties still fall within, or close to, the range of properties typical of gold tailings. Although the design and operation of tailings dams may have to be modified, existing technology is adequate to handle these changes.

Jan 1, 1988

By C. Van Rhee

In dredging practice sand is eroded at very high flow velocities using water jets. The existing pick-up functions overestimate erosion. By taking the permeability into account conventional pick-up functions can be made suitable for high velocity erosion. This can be achieved by modifying the critical Shields parameter. The procedure is demonstrated using the pick-up function of Van Rijn. The theory is compared with experiments and agreement is good.

Jan 1, 2007

By R. F. Taberer

Within the technology field generally known as biological heap leaching or percolation leaching, lies a wealth of technological knowhow that is potentially patentable and therefore can form the subject matter of patent applications. An organization often overlooks the potential for generating intellectual capital during its research by dismissing the possibility that what it is working on may be novel and inventive and therefore patentable. The organization labours under the misconception that there is nothing patentable in its work mainly because the novel aspect is overlooked against the general background state of the art or, if identified, is not recognized as having sufficient inventive merit. In the field of biological heap leaching, patents have issued on inventions that extend across a large range of technology, including microbiological inventions-for example a particular strain of microbe used in a heap leach application, electro-mechanical inventions, for example a column simulator that simulates the heap leach environment, and thermodynamic inventions such as methods of generating and maintaining heat in a heap.

Jan 1, 2012

By S. L. Miller

The development of a pilot gold geostatistical ore reserve system proved that geostatistical methods worked well for the routine production of annual ore reserves on gold mines of the Gold Fields of South Africa (GFSA) group, and that the techniques could also be practically implemented, understood and accepted by Survey Department personnel. Many side benefits of the pilot system became apparent, and a variety of useful management information was provided by manipulating the data values that were already captured. It was decided that it was a priority computing project to develop a standard production system (GORS) for routine use by all the GFSA gold mines. Experience with the pilot system enabled detailed functional specifications for GORS to be laid down. These, together with group computing policy determined the terms of reference and constraints for the GORS development. System design could not be finalized until new and appropriate mainframe database software and graphics workstation equipment and software had been found. With these in place the basic system was structured to take best ad- vantage of the interactive features of the workstation, the number-crunching power of the mainframe and the flexibility offered by a relational database and associated 4GL tools. Application sub-systems were developed for data capture, statistical applications, geostatistical calculations, contour plotting and graphical queries. GORS is being introduced to the mines in a phased manner with suitable documentation, training and support structures to enable it to be routinely and effectively used on a day-to-day basis by all group gold mines.

Jan 1, 1987

By P. R. Mothemela

The objective of the investigation is to optimize the truck and shovel operations for pre-stripping at New Vaal Colliery by introducing campaign mining. The aim of campaign mining is to improve the efficiency of the loading, hauling, dumping, and maintenance operations which are critical to the success of truck and shovel operations. The current loading (single-sided loading method), hauling, and dumping operations at New Vaal Colliery were found to be inefficient. Time studies were used as a major indicator to highlight the inefficiency of the truck and shovel operations, and it is recommended that an improved loading configuration, hauling, and dumping operations be implemented by using campaign mining. It is also recommended that a service truck be used to maintain the pre-stripping fleet in order to reduce travelling times to the main workshop. As expected, the improved operating conditions will lead to an increase in pre-stripping production.

Jan 1, 2013

By J. Githiria, C. Musingwini, J. Muriuki

"The maximization of net present value (NPV) is a primary objective in open pit mine planning processes. In an attempt to meet this objective, cut-off grades are considered in all the stages of mining. There are three stages involved in resource extraction, namely mining, processing, and refining/marketing, which are all defined in Lane’s approach. Using Lane’s approach, the economics involved in each stage are identified independently and interact to provide an optimum cut-off grade.A hypothetical block model is used to illustrate how a computer application (Cut-off Grade Optimiser) that was developed in this study is used in the optimization of cut-off grades using Lane’s algorithm. This paper analyses the application of Lane’s approach for a single element in cut-off grade optimization as applied in the calculation of the optimum cut-off grade through a computer-aided application.Although Lane’s approach is not complex it is not widely applied to maximize the NPV of mining operations as the iterative calculations can be lengthy. The computer application developed in this study shows how Lane’s algorithm combined with a linear programming function can optimize cut-off grade with regard to the complex situations faced by mining operations. The application saves users from performing otherwise lengthy, iterative calculations.Background and previous researchAn open pit mining complex constitutes multiple pits, ore processing streams, and metal refining options. An open pit mine produces ore (valuable) and waste material. Ore is transported to an appropriate processing stream for producing concentrate. A refinery processes the concentrate to produce marketable metal product (Lane, 1964, 1988).Cut-off grade optimization is based on Lane’s theory, where a mining system consists of three major stages such as mining, milling, and refining. In this approach the cut-off grade selection is done between six cut-off grades that involve all stages of a mining operation. Selection of the optimum cut-off grade influences the net present value (NPV) by maximizing the net cash flows from the operation."

Jan 1, 2016