Search Documents

By P. W. Lotz

Traditionally, bottle roll tests have been used to optimize the extraction process for best gold extraction and recovery. Such tests typically involve exposing the ore to defined reagent concentrations (lime, cyanide and sufficient oxygen) and balance the gold input with recoveries and losses. With mounting pressures to accommodate sustainability issues during development work, it became apparent that much more information would be required on the interactions and kinetic behaviour of solid and solution species during the entire leach process. This information is vital to enable proactive management of critical issues such as cyanide, arsenic, water and tailings management. Inadequate management of these aspects has led to temporary closures and, in cases of non-compliance, to the dynamically changing regulations. MINTEK?s advanced leach facility (ALF) is being developed with the aim of bridging the knowledge gap between the gold leach process and the predictable environmental impacts upon discharge. The facility aims to monitor all parameters of relevance such as pH, Eh, dissolved oxygen, metals, cyanide species, and viscosity during the entire process to enable more informed decisions on practical interventions. The presented set of data reflects first experiences gained from processing a refractory gold ore concentrate. Attempts at optimizing the process were limited due to the developmental nature of the work. Data relating to leaches with differing preoxidation conditions and cyanide staging is presented.

Jan 1, 2009

By H. Möhle

Premier Mine is a large underground diamond mine, situated at Cullinan in the Gauteng Province of South Africa. The mine hoists over 3 millions tons of diamond bearing kimberlite per year, from a modern, mechanized panel retreat block cave mining operation. Troughs sited at the base of the cave are developed into the overlying caved ore, allowing loading access to the ore through draw points. Trough opening is therefore a vital aspect of the mining operation. Most of the production is dependent on fast, reliable and safe trough opening. Successful trough openings are achieved under difficult mining conditions due to restricted void, long up-holes and the inherent properties of kimberlite?soft, elastic rock with a high swell factor. Early in 1998, Premier Mine undertook a joint development project (with an electronic initiation system supplier) to determine whether the use of a fully programmable electronic detonator system would enhance the mining cycle in the trough opening process. Blasting commenced in February 1998, initially with blasts of a similar size and duration to those that had been previously blasted with shock-tube systems, to confirm the operational capabilities of the blasting system. The accuracy, reliability and flexibility of the electronic delay detonators (EDDs) minimized associated risks for re-engineering of the trough opening process. Further, as blast timing was optimized, larger blasts were successfully initiated. To date over 20 troughs have been opened successfully with the use of EDDs. Not only did it take less time to open troughs, but also drilling and blasting operations have been optimized, as well as an overall improvement in safety. This paper details the benefits that EDDs have delivered to Premier Mine in this area. The logic followed is: ?Review of the original trough opening practices ?Re-engineering of the trough opening process ?Implementation of EDDs ?Evaluation of improvements and conclusions.

Jan 1, 2000

The use of a time series variogram as an aid in controlling the quality of a product was pioneered by Pierre M. Gy and is described. The ability to analyse and interpret covariance relationships time series data is possible using the variogram. The concept of stream heterogeneity allows sources of variability in process streams to be identified and isolated. Principally this is distributional heterogeneity that is due to a short range effect of segregation in the process stream related to size or composition distribution of the material on a local scale and due to a long-range change in the size and grade of the material stream. The variogram is simply a tool for representing these sources of variability in a way that is explicit, allowing identification of the source and providing important insights to temporal continuity between samples. This paper describes the chronologically related large-scale variability in an iron ore process stream (%Fe), and illustrates the control and mitigation of variability at various stages within the process using a variogram. Three main sources of variability are identified including the random variability V[0], the process variability V[1], and the variability due to cyclical phenomena V[cyclic], arising from human routine or mechanical defects. These sources of variability can be represented on the control chart that provides the plant superintendent with insights as to the sampling capability of the systems in place. Maintaining levels of variability within customer specification limits requires that production systems be controlled without overcorrecting for the trends in changing quality. This can be done only by representing the limits of control relative to the limits of specification on a control chart. Where the specification limits encroach on the control limits, one or the other, or both, may need to be changed; specification limits that constrain the control limits lead to reactive decision making that is expensive and stressful for plant operators.

Jan 1, 2008

By T. Celik, B. Genc, C. Musingwini

"Mine planning software continues to be an important factor when it comes to the development of the South African mining industry. To contribute to this development, a new methodology to define and measure mine planning software utilization in the South African coal mining sector within an evolving data-set framework was developed. An initial data-set showing the mine planning software providers, their corresponding software solutions, as well as the software capabilities and information on the number of licences was collected and compiled in 2012 in an online database for software utilized in the South African mining industry. Details of the database development and implementation were published in the Journal of the Southern African Institute of Mining and Metallurgy in 2013. In 2014 the data-set was updated with additional and new information.In this paper, using the 2012 and 2014 time-stamps, a methodology for estimating the software utilization is developed. In this methodology, three variables: commodity, functionality, and time factor are used to define and measure the software utilization in order to ultimately inform decision making strategies for software utilization. Utilization in the coal sector was measured according to six different functionalities, namely Geological Data Management, Geological Modelling and Resource Estimation, Design and Layout, Scheduling, Financial Valuation and Optimization. The methodology is useful for stakeholders reviewing existing software combinations or intending to purchase new software in the near future and wanting to estimate the comparative attractiveness of a certain software package. These stakeholders include mining companies, consulting companies, educational institutions, and software providers. The work presented in this paper is part of a PhD research study in the School of Mining Engineering at the University of the Witwatersrand."

Jan 1, 2016

By Mauri Kauppi, Pekka Niemelä

World HCFeCr production is 6.0 million tonnes. Correspondingly 1.1-1.6 t slag / t FeCr is produced depending on the raw material basis. Essentially all FeCr is produced in submerged arc furnaces, while the role of competitive technologies like DC is limited. In all furnaces fluxes are used to optimize the slag composition. Vital characteristics are smelting point, electric conductivity and viscosity. The main components of FeCr slag are SiO2, Al2O3 and MgO. Additionally it consists of Cr-, Fe-oxides and CaO. Granulated slag and/or classified slag products are produced depending on the production process. The slag products are mainly marketed in road and civil construction purposes but also in producing refractories. Normally crushed and screened slags are produced simultaneously when recovering alloy. The leachate of slag products is low and performance results are excellent. Slag products successfully replace natural sand and macadam. Generation of waste is essentially reduced. Producing and using slag products are described as BAT-technology and it is an essential environmental aspect. Outokumpu Tornio Works produces 320 000 t FeCr-slag/a. This paper deals with formation of slag in smelting process, its chemical composition, physical and structural characteristics, utilization and product specifications as well as environmental aspects. The slag products are standardized and CE marked. Additionally the role of slag in smelting and alloy recovery is reviewed in this paper.

Jan 1, 2007

?Longhole blast hole drilling? techniques are not new to the mining industry. Appropriate mechanization and improvement of the techniques and application has evolved from the industry requirements. Today safety and economics play a larger role in the excavation of ore passes, ventilation passes, and relatively small inclined excavations in the conventional gold and platinum industry. The application of dropraise drilling from the top or from the bottom is discussed investigating the current techniques available, DTH application, advantages and disadvantages, limiting factors, typical layouts and proposals, the drop raising technique and future applications. Similarly, the application of longhole blast hole drilling in tabular and massive orebodies is discussed with emphasis on the DTH application, advantages and disadvantages, limiting factors, typical layouts, the long hole stoping techniques and future applications.

Jan 1, 2003

By E. Pizarro, A. Videla, G. Compan

One of the main problems related to mining investment decisions is the use of accurate prediction models. Metallurgical recovery is a major source of variability, and in this regard, the Chuquicamata processing plant recovery was modelled as a function of geomining-metallurgical data and ore characteristics obtained from a historical database. In particular, the dataset gathered contains information related to feed grades, ore hardness, particle size, mineralogy, pH, and flotation reagents. A systemic approach was applied to fit a multivariate regression model representing the copper recovery in the plant. The systemic approach consists of an initial projection of the characteristic grinding product size (P80), based upon energy consumption at the particle size reduction step, followed by a flotation recovery model. The model allows for an improvement in the investment decision process by predicting performance and risk. The final geometallurgical model uses eight operational variables and is a significant improvement over conventional prediction models. A validation was performed using a recent data-set, and this showed a high correlation coefficient with a low mean absolute error, which reveals that the geometallurgical model is able to predict, with acceptable accuracy, the actual copper recovery in the plant.

Jan 1, 2015

By K. P. Kavun, M. N. Denisov

Discussed in the paper is the redesigned reserve/resource classification for solid minerals being put forth by the authors to replace the acting Russian classification of 19961. The new version is based on the traditional foundations of former Russian classifications and the principles of the ‘McKelvey box’, both categorizing mineral resources according to the degree of geological assurance and economic viability. Based on these approaches the classification deliberately deals with both reserve and resource categories very similar to those established by the Geneva Accords in terms of definitions implied. The authors proceed from the UN-ECE proposed concept of ‘reserves’ being a part of ‘total resources’ explored in great detail by geological and feasibility studies and economically mineable at the time of reporting. The draft classification distinguishes ‘proved’, ‘probable’ and ‘possible’ categories of reserves depending on the stage of feasibility assessment carried out, i.e. the degree of detail and accuracy with which modifying factors affecting mineability of an orebody are taken into account. The reserves are regarded as a product of feasibility assessment of ‘measured’, ‘indicated’ and ‘inferred’ resources. The portions of them not having been classified as ‘reserves’ are regarded as composed of two classes: ‘subeconomic’ and ‘potentially economic’ resources (or ‘resource base’). All the cells of the classification matrix are provided with traditional for Russia alphanumeric designations and appropriate UNFC codes. The classification scheme recommended is viewed as a step forward in improvement of the State inventory and reporting mineral resources in market conditions, conducive to cross-border professional collaboration in the field of providing reliable information on the mineral rawmaterials base of the world’s economy. Besides, it recommends an easy way to get rid of amethodological error in the UNFC classification scheme where consecutive stages of geologicalexploration are identified with a single inherent degree of geological assurance. Keywords: mineral resources, mineral reserves, classification, geological assurance, feasibility studies, subeconomic resources, undiscovered resources, competent person.

Jan 1, 2003

By V Kveldsvik, N Ragvin, T Eiken, G Grøneng, G V. Ganerød

Catastrophic rock slope failures have caused destructive tsunamis in Norwegian fjords. At the Åknes rock slope the tsunami generating potential is large due to the potential large volume involved in a possible catastrophic failure. Widening of the upper crack has been recorded since 1986, and in recent years, a quite extensive investigation and monitorin campaign has been conducted. Data from some of these investigations are presented and analysed with respect to a preliminary evaluation of the stability of the slope.

Jan 1, 2006

By Gift Chisakuta, Bravo Mbao, Nils Schwarz, Angus Feather, Anthony Mukutuma

Bwana Mkubwa is a 50 000 tons per annum copper cathode producer, owned by First Quantum Minerals and located in Ndola, on the Zambian Copperbelt. The Bwana Mkubwa solvent-extraction circuit was started up in 1997. In 2002, the plant began treating ore from First Quantum?s Lonshi mine located in the Democratic Republic of Congo. The Lonshi ore is exceptionally fine and the amount of solids in the feed solution reporting to the solvent-extraction feed solution increased dramatically. Initially, crud was filtered in a filter press, but this rapidly blinded and seldom produced anything better than a wet sludge containing large quantities of organic. In December 2003 the decision was made to install a Flottweg Z4E-3/441 Tricanter® centrifuge to recover organic from the crud. The installation was completed in June 2004 and has since led to significant improvements in plant operability and savings in organic consumption.

Jan 1, 2007

The additive property of dispersion variances was found experimentally by D.G. Krige using data from the gold deposits of the Witwatersrand. In this property, called ?Krige?s relationship?, the dispersion of a small unit, v, within the deposit is equal to the sum of the dispersion of v within a bigger unit, V, and the dispersion of these units, V, within the deposit, D. It is known that the variance of the grades decreases as the support increases, the so-called volume-variance relationship. To analyse volume-variance and Krige?s relationship, the methodology herein proposed combines blending piles and geostatistical simulation to simulate the in situ and the pile grade variability. Variability reduction in large piles is based on the volume-variance relationship, i.e. the larger the support, the smaller the variability (assuming perfect mix). Based on a pre-defined mining sequence to select the blocks that will form each pile for each simulated block model, the statistical fluctuation of the grades derived from real piles can be simulated. Using this methodology, one can evaluate within a certain time period the expected grade variability for various pile sizes, and also calculate the Krige?s relationship between the small blocks and the piles of different sizes. A real case study using a large Brazilian iron ore deposit illustrates the methodology and demonstrates the validity of the results.

Jan 1, 2014

By Petrus Christiaan Pistorius, Makunga Daudet Seke

The flotation response of a Pb-Zn sulphide ore from the Rosh Pinah Mine (Namibia) was studied in the presence of inorganic depressants such as sodium cyanide and zinc sulphate. Poor flotation selective was observed in the rougher concentrate of the galena circuit despite the use of excessive amount of sodium cyanide. Batch flotation tests have shown that the use of cyanide alone is not efficient for the depression of sphalerite from the Rosh Pinah ore when milling is carried out according to the current plant particle size distribution. The use of both cyanide and zinc sulphate improved the selectivity between galena and sphalerite much better than cyanide alone. Flotation selectivity is limited by the mineralogical texture of the Rosh Pinah ore sample. Microscopic analysis has shown that the presence of sphalerite in the galena concentrate is also due to poor liberation between galena and sphalerite, especially in the middlings. Hence selectivity could be improved by regrinding the rougher concentrate prior to the cleaning stage. Keywords- Sulphide ores, Flotation, Flotation depressant, Mineralogy.

Jan 1, 2005

The Annual General Meeting of the South African Institute of Mining and Metallurgy was held in Kelvin House on Wednesday, 24th August, 1977. Dr M. D. G. Salamon (President) was in the chair and declared the meeting open at 16h00. Obituaries The President: It is my sad duty to announce the death of the following members of the Institute : C. G. Evans, J. P. Rees, Life Fellows ; S. R. Bryant, H. MacConachie, M. Mrost, and A. W. van Zyl, Fellows; L. T. Campbell-Pitt, F. W. Collins, A. J. Duncan, I. G. Evans, F. W. Kleinschmidt, P. L. Vaughan, R. W. Wallace, and H. Wason, Members. As a mark of respect to the memory of the deceased and in sympathy with the bereaved, I would ask you to rise and observe a few moments' silence. Minutes The President: May we confirm the minutes of the General Meeting held on 23rd March, 1977, as published in the June issue of the Journal? Agreed.

Jan 1, 1978

By K. Liddell

Current practice for the recovery of platinum group metals (PGM) from flotation concentrates is by energy-intensive smelting processes followed by separation and refining of the base and precious metals. Energy costs are rapidly increasing in South Africa and this trend is forecast to continue in future years. Moreover, the smelting operations are highly susceptible to deleterious constituents, particularly chromite; and the increasing tonnages of UG2 chromititic ore being mined results in an increasing chromite content of smelter feeds. Hence there is a substantial incentive to assess and implement alternative processes to smelting for the treatment of PGM concentrates. The Kell process is a patented hydrometallurgical alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations (pressure oxidation leaching of base metals and sulfur, roasting and chlorination of precious metals). The Kell process provides the opportunity for existing and new PGM producers to significantly reduce their energy consumption, and in particular their consumption of electricity, by removing the need to smelt PGM concentrates. Energy costs, greenhouse gas emissions and installed power requirements are also much reduced. Compared with smelting and refining these reductions are calculated as: ? Total energy consumption-50% reduction ? Electrical energy consumption-84% reduction ? Energy consumption costs-76% reduction ? C02 emissions-70% reduction ? Installed power requirement 92% reduction. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection and process optimization. The applicability of Kell to treating low-grade 'dirty' concentrates with high UG2 content as well as to polymetallic concentrates containing base metals as the major payable metals with subordinate PGM means that these savings can also be expected when the process is used for treating a range of concentrate types and grades. Keywords PGM,UG2, Merensky, smelting, chromite, electricity, hydrometallurgy, Kell Process, Eskom.

Jan 1, 2011

By T. Maejima, K. Aoki, T. Mori, K. Iwano

Concerning the excavation of rock cavern, it is one of the most important issues to evaluate the behavior of rock joints. But few detailed measurements for joint behavior had been conducted. Therefore, in order to evaluate the stability of rock cavern, effective approach for monitoring and analyzing the joint behavior needs to be developed. In this paper, authors described the results of analysis for joint behavior during the excavation by comparing with both results of the in-situ measurement by BTV and the numerical analysis by MBC model. Bei Ausschachten von Gesteinshöhlen ist es von besonderer Bedeutung, das stark von den Verbindungsteilen beeinflusste Gesteinsverhalten zu bewerten. Jedoch wurden bisher nur wenige Beobachtungen über das Öffnungsverhalten von Verbindungen durchgeführt. Daher muss ein effizientes Verfahren zur Überwachung der Stabilität unterirdischer Höhlen und der Analyse des Verhaltens von Verbindungsstellen entwickelt werden. In der vorliegenden Studie beschreiben die Autoren das Verhalten von Verbindungsstellen während der Ausschachtung durch Vergleiche sowohl mit den Ergebnissen von in situ Messungen mittels BTV als auch numerische Simulation mit dem MBC Modell, welches auch Diskontinuitäten berücksichtigen kann. Quand il s’agit d’excaver une caverne dans une roche ayant des joints très développés, il importe fort d’évaluer le comportement de la roche. Cependant, le nombre d’observations du comportement des roches effectuées au niveau de joints est loin d’être suffisant. Par conséquent, pour s’assurer de la stabilité des parois des cavernes souterraines, il a fallu mettre au point une méthode fiable de détection et d’analyse du mouvement des joints. Dans cet article, les auteurs décrivent leurs études de comportement des joints pendant l'excavation, en comparant les résultats des mesures effectuées in-situ, dans un chantier d’excavation par BTV , avec ceux d’analyse de la simulation numérique par MBC permettant de tenir compte des discontinuités.

Jan 1, 2003

By Antonio Karzulovic, Sergio Olavarría, Patricio Adriasola

The economical analyses of different Chuquicamata open pit mine planning scenarios, indicate that the pit closure should occur at latest in the year of 2017. However, about 60,000 m of drill holes have demonstrated that below the pit bottom there is a potential of 2.3 billion tons of ore. Hence, Division Codelco Norte developed the scoping engineering for a large underground panel caving operation, similar to El Teniente mine. This project considers the exploitation of a 2500 m 300 m footprint, with three 250 m lifts. The plan considers to initiate the construction in the year 2009, to begin the production in the year 2015 and achieve a production rate of 45 million tons per year in the year 2021. A large-scale transition from open pit to underground mining like this one presents three main challenges: (1) to include the geotechnical aspects relevant for mine design and mine planning, (2) to define the proper surface and underground infrastructure, and (3) to fulfil the project deadlines and to achieve the production targets. This paper summarizes this transition project and discusses these three main challenges.

Jan 1, 2006

By D. F. Malan

This paper presents an overview of work conducted over several years to investigate the continuous stope closure profiles recorded in tabular excavations and the use of this data as a hazard indicator. In spite of the brittle nature of the rock, measurements in gold mines and intermediate depth platinum mines revealed a significant time-dependent closure component. Various approaches to simulate the time-dependent closure have been investigated. Viscoelastic theory is able to simulate the time-dependent closure behaviour, but there are subtle problems with the use of this theory as it cannot simulate the failure processes in the rock. To overcome these problems, continuum and discontinuum elasto-viscoplastic models were developed by the authors. Discontinuum models have the advantage of being able to simulate the creep behaviour of prominent discontinuities. Development of these models has led to useful insights into rock mass deformation and has made the numerical simulation of parameters, such as rate of mining, possible for the first time. A number of practical applications for the mining industry have been developed from this study. Among these are the delineation of geotechnical areas using closure data, use of the data as a hazard indicator and to give warning of large collapses in the platinum mines, identification of areas to be preconditioned in the gold mines, measurement of the effectiveness of preconditioning and improved da

Jan 1, 2007

By C. Hutton

"SynopsisThe last commodities supercycle (2003 to 2011) was characterized by a belief in volume at any cost, where absolute output was deliberately prioritized over productivity considerations. This practice fuelled overoptimistic forecasting and planning, which in turn contributed to the economic crisis that followed. The sudden collapse of commodity prices has resulted in mining companies scrambling to find the right balance between optimizing current operations and preserving sufficient flexibility to grasp future opportunities. The runaway costs of building and operating mines have almost squeezed out profit margins, while lower ore grades are inflating production costs. Mining companies therefore need to look at the business with fresh eyes, and develop strategies to attract equity capital as traditional approaches are simply not working anymore. This is especially so in the context of a dwindling investor base that continues to demand greater returns, despite a significantly lower appetite for risk. This paper revisits the micro-economic concepts and demonstrates how pressure from shareholders to prioritize output contributed to spiralling costs and value destruction. Practical techniques are described to model cost curves to optimize a Mineral Resource endowment and address the need to rightbalance a business and preserve agility.IntroductionHenry Lazenby (2014) for the Mining Weekly writes, ‘Bruised and battered, the global mining industry today is undergoing a sea change. Practices and policies that might have worked wonders in the past are not as relevant today, and new approaches to running profitable mining operations need to be found.’ One significant practice the mining industry had during the last commodities supercycle (2003 to 2011) was chasing volume at any cost; absolute output was deliberately prioritized over productivity considerations (Goldsmith, 2013). Lazenby contends that in the face of falling and volatile commodity prices, many mining majors ‘across all commodity groups are currently grappling with sagging profits and low company valuations. This is often regarded as the result of the were in pursuit of growing their output at all costs in a high commodity price environment.’ Lee Hodgkinson, KPMG’s Canadian mining industry leader and quoted by Lazenby, says that ‘mining companies are now trying to find the right balance between optimizing current operations and preserving their agility to grasp future opportunities. The runaway costs of building and operating mines have almost squeezed out profit margins [whilst] lower grades of ore are inflating production costs. Mining companies need to look at the business with fresh eyes, and develop strategies to attract equity capital as it seems clear that some of the traditional approaches to the mining business are simply not working anymore."

Jan 1, 2015

By J. A. Kromhout, J. Trouw, A. A. Kamperman, M. Kick

Mould powders play an important role in the stability of the continuous casting process. The main functions of mould powders are to provide sufficient lubrication and to control the horizontal heat transfer. Because process control of thin slab casting is more stringent, it is generally assumed that mould powder properties become more critical as well. In 2000, the Direct Sheet Plant at Corus IJmuiden (DSP) was commissioned, incorporating a thin slab caster designed for casting speeds up to 6 m/min. During commissioning, several operational problems with mould powders were encountered i.e. insufficient liquid pool depth and the formation of rims/lumps. To investigate the operational mould powder problems, some of the mould powders were characterized using physical and mineralogical methods. The results were linked to operational experiences. It was concluded that for thin slab casting, a stable slag formation is obtained with a proper choice of free carbon and an even distribution of the carbon particles within the granules. The physical properties of mould powders are not as critical as expected when the additional mineralogical requirements are taken into account. Keywords: mould powder, characterization methods, thin slab casting.

Jan 1, 2004

By Du Sichen, K. Mukai, S. Seetharaman

Viscosities of slags constitute an important physical property needed for an understanding of the mass transfer phenomena in metallurgical processes. Viscosity is also the key that leads to a better understanding of the structure of slags. It is well known that the viscosities of silicate slags decrease with the addition of basic oxides due to the breaking of the silicate network. The measurements of slag viscosities often pose experimental challenges, especially to the choice of materials. The keynote lecture takes up the experimental problems and the various techniques adopted. Dynamic viscosity measurement, as a powerful tool towards an understanding of the kinetics of some high temperature reactions, is brought out. A number of semi-empirical models have been developed to estimate the slag viscosities in the case of multi component slags. A critical survey of these models is presented in the lecture. Earlier models by Riboud et al., Urbain et al. and Mills et al. have been developed further into a new generation of models. Some of the current important models are (1) Model by Iida et al. (2)CSIRO model (3) Pyro research Model (4) Model by Tanaka et al. (5) Model approach by Reddy et al. and (6) KTH-model. The predictions and capabilities of the various models are compared. Estimations of viscosities from thermodynamic data and prediction of liquidus temperatures from viscosities are presented. The concept of surface viscosities with reference to slags and viscosities of two-phase mixtures are also taken up in the presentation.

Jan 1, 2004