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By G. T. van Rooyen

In this overview of materials engineering, the author, drawing on his long experience from his student days until the present (emeritus professorship), briefly recounts the main developments in this field: dislocation theory, fracture problems, and the development of alternative materials such as ceramics and polymers. He then takes a look at the future, in which he foresees a greater demand for materials engineers, and leading roles for universities and technikons in collaboration with industry.

Jan 1, 1996

By A. Marek

The safe and optimal installation of roof support remains one of the biggest challenges in underground mining today. Traditional hand-held, roofbolt installation in conventional mining has been replaced, in a lot of mining operations, by mechanized equipment. This was a first step to moving the operators out of the unsafe working environment and a start on the trend toward a changed support regime in mechanized mining. However, the challenge of handling of the drill steel itself, as well as inserting resin cartridges and bolts, remains a major hazard and the cause of many lost-time injuries. The paper describes and discusses developments in this area, of mechanized bolting and on-board automation, presenting solutions to known problems, achievements to date, and future developments. The solutions presented will identify with addressing customer needs while touching on possibilities for further technology changes, keeping focus on the safety aspect for operators and the need to bring the operators even further away from the unsafe working environment. The-state-of-the-art technology in mechanized bolting equipment is presented and a brief outlook on the past, current, and future developments is given.

Jan 1, 2012

By C. van der Merwe, R. Lumbule, J. Kgomo

"The mining industry in the Democratic Republic of Congo has seen a significant expansion in copper and cobalt production in recent years. The greater proportion of this expansion has arisen through processing of oxide ores. The design of metallurgical processes for these oxide ores is based on the conventional equipment and layout for processing of sulphide ores, and comprises milling followed by leaching, solvent extraction, and electrowinning. The physical characteristics of the oxide ores, however, provide the process design engineer with an opportunity to examine critically the principles on which equipment selection is based and to design processes better suited to these ores. In 2015, ERG Africa began a project to expand the leaching capacity of the Luita hydrometallurgical facility. A number of innovative changes to the conventional process design were included in the modified flow sheet, which were validated when the project reached design throughput in November 2017. Of these changes, the most novel presented an alternative approach to mitigate the impact of colloidal silica on the operation of the solvent extraction plant. Introduction ERG Africa operates the Luita hydrometallurgical facility located at Kakanda in the Democratic Republic of Congo (DRC), treating malachite and heterogenite minerals to recover copper as electrowon cathode and cobalt as a hydroxide precipitate. The process was originally conceived as a heap leach operation followed by direct electrowinning of copper, with solvent extraction (SX) and electrowinning (EW) of cobalt. In preparing the sized ore for the heap leach operations, the undersized ore fraction at a P80 of 625 µm was discharged to a fines storage facility for later processing. This fraction carried with it approximately 30% of the copper contained in the run-of-mine (ROM) ore feed, and an equivalent proportion of cobalt.In a subsequent development, the cobalt SX section was converted to a copper SX facility, the leached cobalt being recovered from a bleed stream from the copper heap leach circuit. The operating cost for the process as then installed placed this facility well in the fourth quartile of the industry cost curve. The initial Luita operation was established in 2010 at a time when metal prices were above long-term averages (copper above US$3.00 per pound; cobalt above US$20.00 per pound), and the drop in prices in 2015/2016 presented a major challenge. The London Metal Exchange (LME) copper price dropped below US$2.00 per pound, with cobalt dropping below US$10.00 per pound in Q1 2016. This set in motion a range of improvement initiatives for the Luita operation. Central to this was the installation of a tank leach circuit to process the discarded fines and a modified SX circuit to manage colloidal silica. The revised Luita circuit reached design capacity in November 2017 and has proven to be well suited to processing of the oxide ore feed. This process design challenges the boundaries of conventional thinking in the areas of leaching, solid/liquid separation, solution management, impurity management, and metal recovery, and is the subject of this paper."

Nov 1, 2018

By W. Gabryk

A large new underground platinum mining project required that all different mining options were investigated during an option study before proceeding to the prefeasibility stage of the project. The capital project team identified 21 different options requiring investigation. These options considered 10 different access methods and 4 different mining methods. Each of the 21 options required a mine design, a valid production schedule, and the associated economics in order to facilitate a comparison on project Net Present Value (NPV) and other metrics. The project sponsors required this work to be completed in 3 months and therefore the project team decided to adopt an object-oriented modelling approach as implemented by Cyest Corporation. This would allow all 21 options to be valuated within the tight time frame due to the generation and re-use of templates. Standard objects were configured into templates containing the mine layout, design, and scheduling logic. These templates could then be assembled into a model to represent the option being investigated. The adoption of rules-based design and production scheduling then allowed for the rapid generation of a valid production schedule for each option with different iterations of varying production ramp-up and mining efficiency assumptions. The activity-based operating costs, labour, and capital were also linked to the standard templates such as a half level or barrel, which were then replicated to represent the overall mine structure for each option under consideration. Using this approach for each option, a full production schedule was produced per mining activity, the operating costs were calculated using activity-based costing, an infrastructure capital expenditure estimate was determined, the development capital requirements costed, and an overall NPV determined. This options study was completed in an unprecedented 10 weeks and a recommendation was put through to the Business to take three of the options to the next study phase.

Jan 1, 2012

By F. Smit

Mining and plant disciplines can benefit from pre-concentration of UG2 platinum ores in a dense medium separation (DMS) plant. The main benefit of DMS is the selective discard of waste from the feed stream, thus improving project economics while reducing the power and water requirements for processing. On the mining side, with the correct combination of variables, implementing DMS as a pre-concentration step can reduce cut-off grades and, as a result, increase ore reserves. In addition, the use of DMS technology gives the mine team the opportunity to consider alternative mining methods for an operation. The challenges of balancing the mining tonnage, methods, and resulting grades with the process plant size, recoveries, and DMS discard volumes have resulted in the development of a model to optimize value on new projects or existing operations. This paper will focus on these benefits from a mining and plant perspective, quantifying the water and power savings, and look at the economic benefits of pre-concentration and the effect of metal prices, plant feed grade, and DMS efficiency in different mining environments.

Jan 1, 2012

By K. M. Seiler

Automation in mining requires accurate maps of road networks on site. Because roads on open-cut mines are dynamic in nature and continuously changing, manually updating road maps is tedious and error-prone. This paper investigates the possibility of automatically deriving an accurate representation of the road network using GPS data available from haul trucks operating on site. We present an overview of approaches proposed in literature and test the performance of publicly available methods on GPS data collected from trucks operating on site. Based on shortcomings seen in all tested algorithms, a post-processing step is developed which geometrically analyses the created road map for artefacts typical of free-drive areas on mine sites and significantly improves the quality of the final road network graph.

Sep 1, 2021

By C. C. E. Pretorius, V. M. Mathoho, A. van Zyl, R. J. Mostert

The in-service degradation of the mechanical properties of steel components through the damage mechanism of high temperature hydrogen attack (HTHA), is a topic of concern in the refining and green hydrogen industry. This damage mechanism occurs in susceptible steels operating in environments at high temperatures and hydrogen pressures. The current investigation deals with the indirect monitoring of mechanical degradation via tracking of the swelling strain in affected structures. An autoclave with an AISI 316 shell was utilized to simulate accelerated HTHA damage at 550 °C and 46 bar for exposure times ranging from zero to 700 hours. The progress of the HTHA damage was tracked using encapsulated high-temperature strain gauges. The correlation between the swelling strain and mechanical property degradation was studied to develop a methodology for the continuous monitoring of embrittlement. The tensile sample orientation of the carbon steel plate was included as a variable, i.e., samples parallel, transverse, or perpendicular to the plate rolling direction were included, since it has been shown that the sample orientation influences the HTHA damage features. For the through-thickness orientation, and upon exceeding a threshold value of exposure time, all tensile properties were severely degraded, with values in the order of a 90 per cent reduction being observed. It was found that the degradation of carbon steel mechanical properties can be correlated to the swelling strain measured during exposure. The critical point for mechanical property degradation in the plate through-thickness orientation, whereafter a severe decrease in the ductility of the material occurs, was found to be in the order of 1% of the total swelling strain measured during exposure, equivalent to 65 microstrain. This threshold was found to be significantly lower than that expected from the literature, where limits of 400 to 1000 microstrain were postulated.

Nov 27, 2024

By I. V. Filippova, Y. Foucaud, M. Badawi, O. Barrès, L. O. Filippov, S. Lebègue

Sodium silicate (Na2SiO3) is one of the most common reagents used in the froth flotation process, in which it is an efficient dispersant as well as a powerful gangue minerals depressant. Due to its high affinity with a lot of minerals, mostly silicates, it adsorbs on their surfaces and prevents the adsorption of the collectors, maintaining them hydrophilic. Hence, Na2SiO3 is widely used in the flotation separation of rare earth minerals, zinc minerals, iron minerals, scheelite, fluorite, apatite, and many other minerals. For decades, authors have demonstrated higher efficiency of Na2SiO3 when it is used in combination with sodium carbonate (Na2CO3), a common pH regulator. Among many well-known depressants, this system presented the best efficiency for many ores, including the Tabuaço scheelitebearing skarn studied herein. However, the mechanisms resulting in these strong positive synergistic effects are not well understood at the moment. Hence, the response surface methodology (RSM) was applied to this ore, considered as a case study, to optimize the depressing conditions and to study deeply the flotation behavior of this system. Strong synergistic effects between the two reagents were exhibited by the RSM, mostly affecting the scheelite, fluorite, and calcium-bearing silicates recoveries. This was attributed to surface carbonation of the minerals by Na2CO3, subsequently leading to a better depression by Na2SiO3. Overall, a 1:1 ratio between the two reagents displayed the best results in terms of WO3 grade and recovery. To gain understanding in the molecular mechanisms responsible for the aforementioned synergistic effects, FTIR studies were combined with state-of-the-art molecular modelling (Ab Initio Molecular Dynamics at 300 K) on fluorite, an archetype of calcium minerals. Keywords: Synergistic effects, scheelite, depressants, FTIR, DFT calculations

Jan 1, 2020

By N. B. Strydom

I have read with interest all the papers dealing with heat transfer and the setting of heat stress limits that have appeared during the past two decades. Scientifically speaking, most of them can be rated as being of a high standard, and some of them have been acclaimed internationally as masterpieces of logical and calculated reasoning. Weathering of ore minerals A short course on 'The Weathering of Ore Minerals and the Textural Evaluation of Base Metal Gossans' is to be given by Dr I.M. Reynolds in Grahamstown from 4th to 6th October, 1982.

Jan 1, 1982

Dr Hanekom I would like to thank Dr Hanekom for a very valuable -contribution; it summarizes careful statistical test work which was an omission from the original paper. Minor manipulative details, the application of a finer measuring graticule and the reproducibility of the procedure are described and the author accepts with gratitude this ready-made answer to the first and second points of Dr Finkelstein's comments. Mr Williamson The author is indebted to Mr Williamson for historical background to early experiments with captive bubbles and it is conceded that the original paper described another avenue to an old flotation goal. The field of application is restricted and we would not work with all the material illustrated by Klassen and Mokrousov.1 The particles in Figure 74(a) are far too large and irregular; material in Figures (b) through (d) could be employed for semi-quantitative work in spite of obvious disadvantages; Figure 74(f) represents ideal conditions. We have studied this mineral-collector association in the size range given and results were satisfactory. For larger pick-up values than that illustrated an induction period of more than 0.01 second was required (actually 90 seconds for a maximum bubble load at pH 7.2 with 25 g/t oleic acid!). REFERENCE 1. KLASSEN,V. I. ANDMOKROUSOV,V. A., 'An Introduction to the Theory of Flotation,' Butterworths, London, 128, Figure 74, (1963). Mr Slander and Mr Kooij Researchworkers in a practical mineral development laboratory may well ask what contribution yet another micro-technique can make to the problems of large scale ore flotation. The obvious answer is that there can be little or no direct translation of results obtained with a static system comprising air bubble and pure mineral concentrate to a dynamic multicomponent operation. However, for the rapid study of one mineral or variable some small scale apparatus must be employed. In the Anglo American Research Laboratory, the described semi-quantitative pick-up technique has filled a niche and requirement. For ourselves, the system represents a definite advance over the contact angle approach in that samples of minerals conventionally prepared in laboratory or plant may be used, which is a desired step nearer flotation. We bracket this pick-up apparatus with the Hallimond tube1,2 and evidence is now to hand that pick-up curves may often be related to flotation recoveries obtained from this tube with pure mineral samples and from the Fuerstenau glass cell3 with the total ore at low pulp densities. We would not wish to push the comparison of pick-up results past this stage for there is much published development work relating the Hallimond and Fuerstenau equipment to flotation on a larger scale. At the Anglo American Research Laboratory for example, a test in a Fuerstenau cell is often the final integrated step in laboratory investigations into the TORCO process. As these contributors rightly point out, pick-up tests can offer nothing towards the determination of optimum reagent dosage for large scale flotation. This is the function of bench-type flotation cells with up to 2 kg batches of ore. At this level, collector performance and consumption and physical properties of the froth are more comparable with large scale operation. The pick-up cell, Hallimond tube and Fuerstenau cell are essentially equipment from which the effect of control parameters can be derived. For the assessment of collector behaviour, the pick-up approach is rapid and economic and we offer here a pick-up contribution towards the flotation of Witwatersrand uraninite with anionic sulphonate collectors (Fig. 1). A large crystal of the local mineral was not available for contact angle measurements and owing to its low concentration in Witwatersrand gold-bearing reef, a small sample was laboriously obtained by tabling, superpanning and heavy medium separation. The pick-up values of a sized portion were determined by the described procedure in the presence of nine petroleum sulphonate collectors. Responses fell into two categories; "normal" curves (dotted lines) and a group of collectors which were very active at low concentration but showed depression of pick-up at the higher levels. The similarity in form of curves for collectors 1 and 3 was apparent and reagent 3 was found to be simply a diluent of 1. Otherwise, collector performance could not be related to either sulphonate content or molecular weight of the active constituent. However, reagent 2 gave the best performance in a bench flotation cell with regard to overall uranium distribution but, as predicted, reagent 1 yielded the best grades. Later pick-up tests with a similar class of collector have suggested that depression at high reagent concentrations may be due to "bubble armouring" whereby an hydrophilic air-liquid interface is produced which rejects mineral attachment. Prolonged investigations with the same mineral sample have not been required except for the study of uraninite which lasted for more than a year. Variation in pick-up response could not be detected over this period during which the mineral was stored under distilled water. The only visible change was a small efflorescence of lead sulphate, readily removed and decanted off after stirring with a glass rod in the sample tube. In its main role as a "trouble-shooter", the pick-up method is applied to fresh mineral samples taken from a flotation plant and soon discarded or from a current run in the ore-dressing laboratory. After production of a concentrate, a solvent cycle, as described in the original paper, may be required to remove heavy organics or other contaminants as when a sample has been taken from circuits containing detergents, grease or return flotation solutions. This solvent cycle will not remove chemisorbed collectors and we prefer not to work with minerals from flotation tailings or with pick-up cell discards. It has been thought preferable to answer the contributors' other apprehensions with regard to sample preparation, activators, depressants and the physical properties of reagents in another paper on offer to this Journal. It covers pick-up investigations relating to the flotation of nickeliferous pyrrhotite at two Anglo American Corporation Mines, which approach seemed the correct orientation for a reply to another contributor to this paper.

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 J. N. Baloyi

"In atomic emission and atomic absorption spectrophotometry, the sample is heated to a high temperature and thereby decomposed into atoms and ions that absorb or emit visible or ultraviolet electromagnetic radiation at energies characteristic of the elements involved. The flame test is a very simple form of this technique. The yellowing of a flame by the addition of salt, for example, occurs because the sodium in salt emits strongly in the yellow portion of the visible spectrum. These methods are especially useful for low concentrations of metallic elements in both qualitative and quantitative analysis.Interference on Iep-OES has not always been considered a serious problem, especially in the beginning, when compared with Atomic Absorption Spectroscopy. This was due to the euphoria created by the new technique. It meant that criticism was subdued. The Iep was vastly superior to the Atomic Absorption technique, that the interferences suffered by the Atomic Absorption technique dwarfed the little interferences suffered by the rep-OES technique. This is how rep-OES has had a reputation as an interference free technique."

Jan 1, 2014

"Chairman: Dr N. G. W. Cook Rapporteur: Mr M. P. RobertsPapers:Planning open pit mining operations using simulation by A. Bauer and P. N. Calder Simulation for control of underground liquid flow by G. N. Pitts and P. B. CrawfordEvaluation of production strategies in a group of copper mines by linear programming by P. H. Williams, J. N. Brooke and D. M. PoulterAn equipment maintenance system by D. W. Dean and J. A. RyderTaken as a whole, the difference between the four papers in this session were perhaps more illuminating than their similarities. The titles of the first and second papers contained the word 'simulation', and in both papers random number generation was relied upon in the selection of inputs from empirical distributions, but the nature of the models to which these values were inputs were quite different. The third paper displayed another method of uniting the empirical and the theoretical in a linear programming formulation whose matrix coefficients were measured empirically, and here some apt remarks on computer implementation were included. This paved the way for the last paper which abandoned all theoretical pretensions in favour of a detailed description of computer implementation and perhaps as a result gave rise to the most feeling audience participation.The systems mentioned were developed for the iron, petrol, copper and gold producing industries in the US, Canada, Zambia and South Africa..As with all the parallel sessions, contributions from the floor may have been limited by the shorter time available to delegates to acquaint themselves with the papers before the session. In spite of this, and due largely to the active chairman¬ship of Dr Cook, the discussion during the session which is summarized here contributed much to the information contained in the papers themselves.In his presentation, Dr Calder summarized his paper. He expected that simulation would be used in future on an almost universal basis in open pit mining. It could contribute new knowledge more cheaply than experimentation in the flea For example, this study had shown what was previously thought to be a matter of more shovels and trucks was really a blasting problem, and improving blasting had increased production to the desired level. The simulation had shown that uniformity of truck performance was a desirable factor. It had also been used to study the advisability of a dispatching system.Dr Ramani contended that where equipment characteristics were available, deterministic standard simulation could adequately simulate systems in which interference occurred. Operator performance could be measured against perfor¬mance curves predicted by standard simulation and poor operators spotted and retrained. The present system did not take into account variability in truck loading, for instance. Dr Calder replied that if the number of variables was large, the standard approach became too complicated for operating personnel to follow. He admitted he had not tried it. The variability of truck loading could be coped with easily using the Monte Carlo approach. Operator variability was already incorporated because the time studies are actual."

Jan 1, 2014

By Z-B. Cheng, X-J. Liu

"Intensive mining of shallow coal seams tends to result in severe subsidence of the ground surface. Surface subsidence is a complex dynamic spatiotemporal process that constantly changes as mining advances. With Liangshuijing coal mine as a case study, 3DEC numerical software was used to simulate the development of the moving subsidence field from open-off cut to full subsidence on the working face. The results demonstrate that the formation of a subsidence field is directly related to the coal seam depth H and the extent of the mine workings. Taking the advance distance of the working face as the unit of scale, the process of surface subsidence can be divided into four stages: micro-change (H/ p), the development of surface subsidence (2H/ p), the formation of a movement subsidence field (3H/ p), and dynamic balance (4H/ p). The changing movement of a subsidence field can be fully described by the characteristics of surface subsidence value, curve slope, and the inflection position. The results provide important technical support for predicting surface subsidence and the temporal–spatial evolution features of mining subsidence. IntroductionChina’s coal output was about 3.52 Gt in 2017 (China National Coal Association, 2018), making it the largest coal producer in the world, accounting for almost half of total world coal production. Coal production and distribution play a vital role in the energy industry of China. However, entire overlying strata, from coal seam to surface, are disturbed as a result of long-term, high-intensity and large-scale mining, causing surface subsidence. This results in groundwater loss, surface desertification, vegetation loss, and mud-rock flows. These issues have become topics of common concern throughout society. According to related research results (Liu 2008), the area of surface subsidence caused by coal mining in China has reached about 600 000 ha, some 0.2 ha (and up to 0.42 ha) of surface subsidence for every 10 000 t of coal produced. Surface subsidence disasters not only damage buildings, water conservancy, transportation infrastructure, and farmland, but also cause adverse effects on individual and community lifestyles, environmental hygiene, and economic development. Deterioration of the ecological environment in mining areas has a long history and is very harmful (Lu, 2015)."

Feb 1, 2019

By A. M. Venter

"SynopsisThe availability of advanced characterization techniques is integral to the development of advanced materials, not only during development phases, but in the manufactured components as well. At Necsa, two modern neutron diffractometers equipped with in-situ sample environments, as well as complementary X-ray diffraction instruments, are now available as User Facilities within the National System of Innovation in support of the South African research and industrial communities. Neutrons and X-rays, owing to their different interaction mechanisms with matter, offer complementary techniques for probing crystalline materials. Both techniques enable nondestructive investigation of phenomena such as chemical phase composition, residual stress, and texture (preferred crystallite orientation). More specifically, the superior penetration capabilities of thermal neutrons into most materials allows for the analysis of bulk or localized depth-resolved properties in a wide variety of materials and components. Materials that can be investigated include metals, alloys, composites, ceramics, and coated systems. In particular, depth-resolved analyses using neutron diffraction complements surface investigations using laboratory X-rays in many scientific and engineering topics. The diffraction techniques can add significant downstream value to the anticipated nuclear industry development activities.IntroductionMaterials characterization is central in understanding the relationship between the structure, properties, and performance in order to engineer materials that fit the performance criteria for specific applications. This is conveniently represented in the form of a tetrahedron, generally known as the material science paradigm (Figure 1).The availability of advanced characterization techniques is integral to the development of advanced metals, not only during development phases, but in the form of manufactured components. At Necsa (South African Nuclear Energy Corporation), modern X-ray and neutron diffraction instruments are now accessible to the South African research and industrial communities. These facilities enable nondestructive investigations of materials and components that could add significant downstream value to the anticipated nuclear industry development activities."

Jan 1, 2015

By I. du Plessis

The metallurgical response of a difficult to treat coal and an easy to treat coal orebody were investigated in terms of the coal yield and the coal quality in a basic coal recovery flowsheet. The purpose of this paper is to show trends and derive principles for the treatment of different coal types. This investigation entailed using the LIMN simulator to simulate the metallurgical response by varying the plant operational parameters. The controllable plant variables investigated were: ?Cyclone size ?Screen and hydro-cyclone cut points ?Medium cut density ?Feed particle size distribution.

Jan 1, 2010

By J. van der Merwe, C. Phetolo, V. Matjeke

The mechanical properties and microstructure of AlSi10Mg alloy samples that were printed by selective laser melting (SLM) were studied to determine the effect of processing parameters and building orientation. After printing, the alloy was stress relieved at 250°C for 2 hours. The microstructures were analysed by optical microscopy and scanning electron microscopy (SEM) to determine the alloy phases and distribution. Phase transformation characteristics of the material were evaluated using differential scanning calorimetry (DSC). Mechanical properties were determined by subjecting the XY- and Z-built samples to tensile and nano-indentation testing. The samples from the tensile tests were then used to perform fractographic analysis by SEM. The microstructural properties in each orientation revealed a non-homogeneous microstructure which was characterized by a semi-elliptical tract and fine silicon precipitates, which were found to be softer along the fusion zone. The DSC thermograms revealed that the material underwent two phase transformations during the first heating cycle. The mechanical properties revealed a higher UTS, higher yield strength, and a lower percentage elongation in the Z orientation than in the XY orientation. Fractographic analysis showed that crack initiation in both orientations started from the surface in a brittle manner due to surface flows, and then propagated via microvoid coalescence.

Jul 1, 2021

By M. Rudolph, R. Tolosana-Delgado, G. van den Boogaart, M. Reuter, U. Peuker

This paper addresses the challenge to define a concept of entropy (state of order) for a textured particle system. Both the particle texture, the intergrowth respectively, and the particle size influence the order of a particle system. The smaller the particles become, the more particles form the solid system and the more permutations of the structure of the particle bed are possible. The texture within a particle is fixed, as long as it is not subjected to changes due to comminution, flocculation or agglomeration. The paper will present a definition of entropy, which is able to reflect qualitatively and quantitatively the intergrowth and the size (distribution) of the particles. Theoretical examples will show how different breakage mechanisms can be identified using the entropy definition. Furthermore, we will define the specifications for data sets to calculate the entropy of a particle system. Keywords: Milling, mineral liberation, intergrowth, statistical entropy, modelling

Jan 1, 2020

By S. T. L. Harrison, M. A. Fagan-Endres, M. D. Odidi

This paper investigated the ability of eight common hydrodynamic models – tanks in series (TIS); three compartmental model configurations (Comp-1, Comp-2 and Comp-3); advection dispersion (AD); piston exchange (PE); piston exchange-diffusion variant (PE-D) and piston dispersion exchange (PDE) – to simulate residence time distribution (RTD) data generated from tracer tests conducted on a packed bed composed of different size fractions of malachite ore. The chosen materials were packed into 0.1 m internal diameter columns to a depth of 0.155 m and drip irrigated at 5.11 L/ m2.h. The four size fractions tested were: 1 – 2 mm, 2 – 2.8 mm, 4.75 – 5.6 mm and 13.6 – 16 mm. Step-up tracer tests were conducted using potassium chloride. The results showed that an increase in the particle size of the malachite ore had little effect on overall bed porosity but resulted in significantly lower values of liquid holdup. Two of the monoporosity models tested, TIS and Comp-2, were the most affected by the changes in bed size fraction due to their inherent inability to cope with high degrees of non-ideal flow present in the larger particle systems. The dual porosity models performed relatively better with the dominant trend being a reduction in dynamic to total liquid holdup as particle size increased. Of all the models tested, the PDE and TIS models were the best and worst performers respectively, with R2 values averaging at 0.997 and 0.679 across all experiments respectively. Though the Comp-1, Comp-3 and PE-D models also performed well, the addition of the dispersion coefficient to take the axial spread of fluid molecules into account added a layer of complexity that allowed the PDE model to perform relatively better than the other dual porosity models. Keywords: Heap leaching, packing material, hydrodynamics, malachite, PSD, modelling

Jan 1, 2020

By W. Soetaert, P. Dhar, H. R. Kota, M. Thornhill, S. Roelants, I. V. Chernyshova

Yeast-derived bola-amphiphiles have attracted considerable attention for their applications in various industrial sectors in recent years. However, only a few studies on this class of surfactant were reported to be relevant to mineral processing applications. In this paper, one of the novel surfactants, acidic glucolipid obtained from Candida bombicola sophorolipids and modified by using Penicillium decumbens naringinase substrate has been evaluated for its interaction with chalcocite and calcite minerals because of a new Cu-ore Nussir deposit in Norway containing calcite impurity. The interaction of glucolipid biosurfactant with copper sulphide and carbonate minerals was investigated with zeta potential, adsorption and FTIR studies, and also by Hallimond tube and bench scale flotation tests using pure minerals and Nussir copper ore, respectively. The results illustrate collector adsorption and flotation of copper sulfides at neutral pH. The bench-scale flotation results demonstrate that copper sulphides can be selectively floated from carbonate and silicate gangue minerals. This study underlines the glycolipid’s high potential for its use as collector for flotation of valuable copper sulphide minerals. Keywords: Flotation, biosurfactants, adsorption

Jan 1, 2020