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By D. Minson, G. Lindner, S. Miskovic

Thickening is an essential process in the mining industry and currently one of the most costeffective technologies for recovering water from tailings streams. Improved performance of thickeners can lead to significant energy savings, and increased recovery of water close to the mill. Its performance is directly affected by the rheological properties of slurry at the raking zone. To further understand the dynamics of slurry inside thickeners, a multiphase particle-in-cell method (MP-PIC), is used to investigate its behaviour on a sliding channel. Parameters like particle-size distribution (PSD), rheological properties, and domain discretisation were benchmarked to study its influence on highly dense flows. The slurry concentration by weight of the samples ranged between 60 to 70% of solids by mass, under which conditions it is known to behave like a non-newtonian fluid. An experimental flume, 0.2 m wide and 2 m long, was used for validation under different angles and slurry composition. Visual analysis of the slurry height and shape, as well as velocity measurements, were compared with numerical data. The preliminary results show the ability of MP-PIC method to represent different types of highly dense flows, while still being computationally affordable and practical for industrial use. Keywords: High density thickener, CFD, MP-PIC, multiphase-flow

Jan 1, 2020

By G. M. Evans, S. Mitra, A. V. Nguyen

As an alternative to the conventional flotation method, there has been continual research in an effort to enhance base metal ores and combustibles recovery using ultrasonics. These studies however were largely limited to the pre-treatment of ores for the removal of surface contaminants while the effect of ultrasonics on the bubble and pulp-phase interactions remained somewhat unexplored. Noting this deficiency, this study aimed to investigate the mechanistic effect of an ultrasonic field in an impeller less flotation cell specifically focusing on the bubble-particle interaction dynamics. A lab-scale flotation cell (capacity 1 litre) was designed, involving a vertically oriented ultrasonic probe (20 kHz, rated at 1.2 kW) and operated in the output power range from 1 to 20% with continuous liquid recirculation. Particle suspension was achieved by the combined action of recirculation and ultrasonic pulses. Interactions of coarse size glass ballotini particles (D32 = 314 μm) with bubbles (< 1 mm diameter) in the presence of a surfactant were studied, using high-speed imaging. Application of an ultrasonic pulse in the aqueous medium resulted in the generation of numerous microbubbles which increased with increasing input power and duration of the ultrasonic pulse time. Such periodic pulses introduced at a high level of turbulence in the pulp phase facilitated adequate bubble-particle contacts. Microbubbles played a key role in forming particle clusters which were observed to be floatable even in the absence of any carrier bubbles. When carrier bubbles were introduced, some of these particle clusters attached to the bubble surface and conveniently floated. It was noted that a favourable state of bubble-particle interaction was achievable to produce stable bubble-particles aggregates by suitably controlling the input power and period of the applied ultrasonic pulse. Keywords: Flotation, bubble-particle interactions, collision, attachment, detachment, ultrasonic pulse

Jan 1, 2020

By M. Kumral, S. Li, M. Balci, Z. Shao

Main haulage roads play an important role in the performance of underground mines because of the cost of transportation of the extracted ore, equipment, and workers. During mine development, these roads are designed through manual tools or CAD-based software. However, the optimisation of these roads is still a complex problem due to some constraints such as minimum turning radius and maximum gradient. By utilising Dubins path theory, three elevation cases; namely low, medium and high are defined, considering gradient constraint as well as the minimum turning radius in a three-dimensional space. The shortest path between two points can then be found by the three-dimensional Dubins path algorithm with elevation constraint. As a further step, a three-dimensional Dubins path algorithm with elevation constraint for multiple points is also developed for multi-point cases. The effectiveness of these algorithms is tested through case studies in order to determine the optimal path between different points.

Sep 1, 2021

By T. C. Huber

The southern African region has a high concentration of mineral resources and supplies much of the world?s platinum demand. As a result, the international community watches South Africa to understand the impact of supply on global markets. An analysis of supply certainty and risk plays a key role in the future of growing demand in various sectors. The southern African platinum industry experienced substantial growth in the early part of the 21st century, resulting in bullish forecasts for growth during the period of 2000?2006. However, southern African platinum producers saw a significant drop in production over the following three years as a result of many dynamic factors in operations and the global economy. Between 2006 and 2009 there was a million-ounce shortfall between forecast and actual production. This was raised as a concern at the Fourth International Platinum Conference in 2010 by Stephen Forrest during his keynote address, specifically regarding the lack of understanding in the market of the causes of this shortfall and any action that was being taken to address them. This paper reviews publicly available information in the media and corporate reports and communications for the period January 2006 to December 2009. In addition, several interviews were held with key stakeholders in the industry to provide further perspective. The paper then highlights the main reasons that are reported to have affected the loss in production over the period and discusses the possible implications of the information that the mining industry does and does not disclose regarding platinum supply.

Jan 1, 2012

By N. Gibson

The application of oxygen in a copper smelter by N. GIBSON* (Visitor) This paper describes how the problem of increasing the capacity of the Rokana copper smelter was handled, and how oxygen was found to be technically and economically the best solution. The first phase of its implementation is outlined.

Jan 3, 1974

By S. Northey, N. Haque, S. Stoddart, W. Bruckard

Development of new technologies and procedures for managing mineral residues and wastes may benefit from a clear understanding of existing tailing management practices. There is a considerable variability in tailing management techniques used in the Australian copper and gold operations, with associated differences and flow-on effects for the mine site water balance. A database was created, capturing a total of 41 copper and gold processing operations in Australia. The database provides information on tailing generation rates, tailing properties (solids contents and particle size distributions) and tailing storage facility (TSF) types and configurations (e.g. total TSF surface area and wetted surface area). Significant variability was found for the above-mentioned parameters. The solid tailing generation rates ranged from 0.5-37 Mt per annum in 2015. Furthermore, both the solids contents and particle size ranges of the tailing were highly site-specific, and largely dependent on the processing flowsheets. Solids contents of tailings ranged from 45-74% by weight whilst P80 sizes of the concentrator (flotation) feed varied from 75-185 μm. The estimated pumping distance was up to 15 km. The presented data can potentially be used to better tailing management strategies by estimating the potential recoverable water and recycling it, thereby thus reducing tailing footprints. Keywords: Tailing management, tailing storage facility, water balance, mine site, flowsheeting

Jan 1, 2020

By F. K. Crundwell

The rate of dissolution of sulphide minerals is frequently interpreted in terms of the passivating behaviour of a layer of material on the surface. This interpretation has driven research to identify and possibly remove this layer from the surface, and thus yield higher rates of dissolution. The identification of such layers has proved difficult, with different researchers claiming different compositions for possible layers. An alternative framework has been pursued by the author and co-workers, who have argued that the rate of dissolution is governed by the electronic structure of the minerals which give rise to their semiconducting properties. Researchers sceptical of this approach have argued that semiconducting properties are only important in highly pure substances. In this paper, we review the electronic and semiconducting properties and discuss how they impact dissolution behaviour. These properties affect their colour and dissolution properties even though the minerals are not high purity substances. Keywords: Dissolution, leaching, passivation, semiconductor, chalcopyrite

Jan 1, 2020

By S. T. L. Harrison, M. Smart, C. J. Edward

Biooxidation, a biohydrometallurgical process, utilizes a mixed microbial consortium to mediate the dissolution of refractory gold-bearing ores to enhance gold recovery during cyanidation. Recognition of water as a critical resource has prompted improved water management strategies within mining and minerals processing. Bioremediated wastewater from the cyanidation tailings provides a potential water source to supplement the water required for the biooxidation circuit, reducing freshwater extraction. Gold biomining operations have typically been reluctant to recycle this wastewater due to the potential inhibitory effects of cyanide and thiocyanate (SCN-) on the microbial population. Historical process upsets suggest that the microorganisms are sensitive to SCN- concentrations as low as 1 mg/L. However, effective bioremediation processes resulting in effluents with low or negligible SCN- concentrations may allow gold biomining plants the opportunity to recycle available water. Microbial activity as well as alteration in community structure were monitored as a function of increasing SCN- concentration over the range of 0 mg/L to 5 mg/L to investigate the response of the biooxidation community to potential SCN- spikes resulting from upsets in the remediation process. Appropriate microbial growth and ferrous iron oxidation activity with a nominal shift in community structure were observed at SCN- concentrations up to 1 mg/L. Thiocyanate concentrations above 1 mg/L resulted in the complete inhibition of ferrous iron oxidation activity. This was attributed to Leptospirillum ferriphilum’s sensitivity to SCN-. Exposure to a SCN- concentration of 5 mg/L resulted in a lower cell concentration and a significant increase in growth lag time, and the absence of L. ferriphilum from the microbial population. At. caldus and Ap. cupricumulans were still present at 5 mg/L SCN-, although Ap. cupricumulans was unable to oxidise ferrous iron at this SCN- concentration. It was concluded that recycling bioremediated cyanidation tailings wastewater within the biooxidation circuit is feasible; however, to retain process performance, SCN- concentrations should not exceed 1 mg/L. Keywords: Biooxidation, thiocyanate, water recycling, community structure

Jan 1, 2020

By E. Marè, D. R. Groot, R. Engelbrecht, T. Coetsee

Hydrogen peroxide is often used as an oxidising agent in experimental waste electronic equipment (WEE) leaching work. However, the high cost of peroxide is a negative factor in its consideration in further process development. A few studies have reported on the efficient application of peroxide addition schedules to ensure optimum reagent consumption. Large quantities of unleached substrate material contained in WEE feed material result in a large dead volume of material in the leaching reactor. This factor necessitates fast reaction rates to enable the use of a high feed material throughput reactor to enhance overall project viability via hydrometallurgical processing. In this study the effects of hydrogen peroxide addition schedules on base metal leaching efficiency and solution temperatures were tested at laboratory scale. The results showed that overall peroxide consumption can be optimised to lower levels by matching peroxide additions to the particular feed material’s leaching behaviour. A simplified integrated model for peroxide decomposition is used to explain its effect on solution temperatures and leaching rates. Keywords: Peroxide consumption, waste electronic equipment, copper leaching, integrated model

Jan 1, 2020

By A. Chryss

Tailings management aims to dispose of tailings at the minimum cost consistent with meeting or exceeding imposed standards, including legislative obligations. This simple business objective requires managing the tailings storage facility (TSF) risks associated with surface water, groundwater, dust, sustainable closure, and potential catastrophic failure. The individual nature of every orebody and specific site topography ensures that no one size fits all. It has been suggested that paste and thickened tailings (P&TT) provides the ability to tailor the production and transportation of tailings to suit the deposition site, rather than the traditional approach of accepting that the deposition site has to accommodate tailings of high variability. While the traditional approach can be made to work, it is directly linked to the catastrophic failures of tailings impoundments, where large volumes of decant water have triggered failures due to overtopping, piping or slope instability, or saturated tailings have simply liquefied. P&TT offers an ability to mitigate these risks, and when implemented into new projects with variable tailings streams there are significant benefits to be realized. This paper identifies the interdependencies between the various tailings disposal processes, such as thickening, pumping, and deposition. It demonstrates that there are benefits in taking a more integrated approach to the design and operation of tailings disposal facilities. A collaborative industry project to tackle this challenge is described.

Jan 1, 2012

By F. Nakhaei, A. Noury, S. Ghodrati

To achieve maximum efficiency in any purification stage, the flotation should be continued until the concentrate grade reaches the feed grade. During sampling from rougher cells of the Iranian Sarcheshmeh copper concentrator plant 1, it was revealed that the concentrate grade of the last five cells of rougher circuit was close to feed grade. Therefore, it was suggested that the concentrate of the aforementioned cells be mixed with rougher feed. In this study, one of eight rougher circuit rows was selected and evaluated. The floatability tests were performed to compare the flotation behaviour of rougher feed and mixture of concentrate of the last five cells with rougher feed in the laboratory scale by a tree analysis process. The results showed that mixing of rougher last five cell concentrate with feed has a detrimental effect on flotation efficiency that leads to a 3% decrease in recovery. It was also observed that with grinding of this concentrate, recovery can be improved. Keywords: Efficiency, flotation, rougher, tree analysis, floatability, concentrate, mixing

Jan 1, 2020

Zincor operates four Lurgi fluidized-bed roasters at its roast-leach-electrowin refinery in Springs, South Africa. In 2006, Zincor?s four roasters had reached ages ranging between 26 and 38 years, while the expected life of this type of roaster is generally 20 to 25 years. Roaster 3 was the first to be rebuilt in 2006 because its condition had deteriorated the most. Roaster 4 is being rebuilt in 2007 and the last two roasters will be rebuilt over the next few years as necessary. The main damage to Roaster 3 was caused by buckling of the roaster steel shell. This caused the freeboard and dome areas to shift, resulting in cracks in the dome brick lining and crumbling of the bricks lining the freeboard. The steel shell buckled owing to the combined effects of excessively high operating temperatures and corrosion. These were caused by the following two main factors: ?Thicker external insulation was installed during a previous maintenance shut, which resulted in an increased steel shell temperature and exacerbated the normal metal fatigue ?SO2/SO3 containing gas that had permeated the brick lining passed through its dew point during frequent planned and unplanned shuts over the life of the roaster. This caused acid formation between the refractory brick lining and steel shell, resulting in corrosion of the shell. The initial plan was to replace only the damaged areas of Roaster 3, but when it was dismantled more damage was found, and the roaster was rebuilding from the tuyeres upwards. During there building the opportunity was taken to modify the design of some of the brickwork to extend its life and make future repairs easier. This paper discusses the mode of failure of Roaster 3 and the lessons learnt during its dismantling and rebuilding.

Jan 1, 2007

By N. Hamlef

In this study, the effects of heat treatment on phase formation and surface morphology of the Cr-Pt coated system are investigated using X-ray diffraction and electron microscopy techniques. The CrPt andCr4Pt (Cr3Pt - A15 type) phases were formed after heat treatment of the coated samples. Heat treating at 1000°C renders a distinct island coating morphology that is non-continuous in nature. A diffusional model is proposed for this coated system with regards to the surface morphology formation after heat treatment.

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

By S. T. Johansen, B. T. Løvfall, T. Rodriguez Duran

In this paper we develop a physics-based model for lining erosion in steel ladles. The model predicts the temperature evolution in the liquid slag, steel, refractory bricks, and outer steel shell of the ladle. The flow of slag and steel is due to forced convection induced by inert gas injection, vacuum treatment (extreme bubble expansion), natural convection, and waves caused by the gas stirring. The lining erosion takes place by dissolution of refractory elements into the steel or slag. The mass and heat transfer coefficients inside the ladle during gas stirring are modelled based on wall functions which take the distribution of wall shear velocities as a critical input. The wall shear velocities are obtained from computational fluid dynamics (CFD) simulations for a sample of scenarios, spanning out the operational space, and a model is developed using curve fitting. The model is capable of reproducing both thermal and erosion evolution well. Deviations between model predictions and industrial data are discussed. The model is fast and has been tested successfully in a ‘semi-online’ application. The model source code is available to the public at [https://github.com/SINTEF/refractorywear].

Apr 16, 2024

By B. Genc

Improving student success rates without compromising the quality of graduates is one of the biggest challenges expanding university programmes are facing in South Africa. By establishing a new Mine Design Laboratory (MDL) for higher learning in Mining Engineering, the School of Mining Engineering at the University of the Witwatersrand (Wits Mining) has achieved one of the important goals in its five-year strategic plan, i.e. to improve throughput in all years of study. Although the establishment of the laboratory has been a costly exercise, results so far have shown an improved success rate in most subjects taught in the facility. This paper outlines the design and equipment of the laboratory, the facilities incorporated, a comparison with the old laboratory, and the performance of students?all of which indicate how important it is to have proper facilities to improve the teaching of, and learning by, large classes. Through this initiative, Wits Mining has taken an important step that will contribute to addressing the skills shortages in the mining industry.

Jan 1, 2012

By R. Pipeleers

Recent experience has shown that all underground workplaces in the Campine Coalfield in Belgium will require controlled cooling within three years. Considering the socio-economic and legal importance of the climatic problems underground, IREA has undertaken studies in forecasting the climate of future workplaces, planning the necessary cooling equipment and optimizing efficiency in the existing cooling equipment. These studies are being carried out using the climate forecasting program of Bergbau-Forschung. So far, the German model has been obliged to utilize manually measured data from a few workplaces in the Campine. As the model does not fit very well with these measurements, it has been thought necessary to&apos; develop a system of continuous data acquisition and transmission. This system is being tested in the Beringen mine of the N.V. Kempense Steenkollenmijnen. In the first part of this paper the digital tranmission system is described; in the second the sensors used to collect the necessary climatic data are presented, and in the third some results are given.

Jan 1, 1987

By G. van Aswegen

The geometry and morphology of a set of low-angle fractures around a stope in a deep Witwatersrand gold mine are explained in terms of extension fractures forming under variable conditions of stress. Primary extension fractures (E1) form some distance ahead of an advancing stope along the s1, s2 plane. With stope advance, a couple of these fractures end up in a stress regime conducive to transpressional shear and a secondary set of extension fractures(E2) is formed at a high angle to the primary fractures. i.e. at a low angle to the stope. As the E2 fractures are undermined, they migrate into a stress regime of transtensional shear and a third set of extension fractures (E3) may develop between E2 fractures. These have sigmoidal shapes, being parallel to the E2 fractures at the E2 discontinuity where s3 is negative, and curved through the unfractured rock between E2 fractures where s3 is positive at the instant of fracturing. The fractures all display fractographic features characteristic of dynamic extension failure with striae indicative of the direction of rupture propagation and the local, instantaneous orientation of s1.

Jan 1, 2012

By N. Duda, P. Śliwiński, P. Stefaniak, B. Jachnik

Ventilation and air-conditioning are some of the most energy-consuming processes in deep underground mining. Additionally, the energy consumption of these processes systematically increases along with the expansion of the mine. Therefore, proper energy efficiency assessment and consumption forecasts of these systems are particularly important in modern mines for ongoing tracking and planning of the likely costs. In the article, a short-term prediction model for surface air–conditioning stations is described. This model takes into account dependencies that were identified, based on the data from the supervisory control and data acquisition (SCADA) systems. These dependencies between the response value and the external conditions are then incorporated into the model. This way, for example, the ambient temperature or the total number of specific days of the week (with sometimes significantly lower or higher than the weekly average energy consumption levels) are included. Taking into account these dependencies, and e.g. forecasted average monthly temperatures allow us to include the seasonality of energy consumption in the presented model. In the article, a sample energy efficiency analysis of the A/C system based on an example of the KGHM Polish Copper Polkowice-Sieroszowice mine is performed. The results of the solution proposed in the article are then evaluated, and compared to the currently functioning, more basic forecasting methods. However, given the general nature of the dependencies used in the model, similar solutions could be used in other case studies.

Sep 1, 2021

By Z. Gxowa, L. H. Chown, U. Curle, G. Govender

This work evaluates the deformation behaviour, at warm working temperatures, of green particle-reinforced aluminium composites produced by powder blending in a high-energy ball mill. The work focuses on metal matrix composites (MMCs) based on the 2124-Al alloy, reinforced with 10 or 15 vol.% SiC and metal matrix nanocomposites (MMNCs) based on the 2124-Al alloy, reinforced with 5 or 10 vol.% Al2O3. Three batches for each powder were blended and powder properties such as particle size distribution (PSD) and shape were consistent after blending. It was observed that a more uniform distribution of the reinforcement phase in the aluminium alloy matrix was achieved in 2124-Al/Al2O3 than in 2124- Al/SiC composites. The powders (unreinforced 2124-Al and blended) were initially over-aged at 350°C for 2 hours to reverse any natural ageing that may have occurred prior to use. The over-ageing was incorporated to improve compressibility of the powders with the aim of achieving green compacts with higher integrity. Uniaxial compression tests performed at ambient temperature on a Gleeble® 3500 thermomechanical simulator were unsuccessful as the green compacts fragmented. Engineering stress-strain curves showed that green compacts of unreinforced 2124-Al, 10%SiC MMC and 5%Al2O3 MMNC deformed in a similar manner at ambient temperature and had the same compressive fracture stress of approximately 170 MPa. When the deformation temperature was increased from ambient to warm working temperatures (170–280°C) it was observed that electrical resistance heating (the heating mode of the Gleeble®) of unreinforced Al alloy, MMC and MMNC green compacts did not occur. This was attributed to the high electrical conductivity of aluminium, which resulted in poor heat generation due to the low electrical resistance in the samples. It was presumed that the small sample size (d=8 mm, h=12 mm) also caused rapid heat loss. After further experimentation, the green compacts were heated successfully by insulating the samples to retain heat. It was found that at 280°C, increasing the soaking time from 6 to 20 minutes decreased flow stress and improved plastic flow in the 2124-Al/10%SiC green compact.

Jan 1, 2016