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By G. Akdogan, S. M. Bradshaw, M. I. Isaacs, P. Van Wyk

In the mineral processing industry, Ni-Cu-Fe-S converter matte is leached in order to remove base metals from a concentrate containing platinum group metals (PGMs). This paper investigates the atmospheric leaching process, in order to develop a better understanding of the leaching behaviour of the base metals; in particular Cu, Fe, Ni, and the PGMs in particular Ru and Ir with key process variables, acid concentration, copper concentration under oxidative leaching conditions. Higher initial acid concentration resulted in a higher copper, iron and nickel extractions, as well as higher leaching rates together with faster Cu, Ru, Ir precipitation occurring. On the other hand, a higher initial copper concentration resulted in more nickel but less iron being extracted. Keywords: PGM, converter matte, leaching, precipitation

Jan 1, 2020

By L Dyer, G. J. Wilkie, P. Walters, B Tadesse, L. Keeney

Grade Engineering® is a term trademarked by the Cooperative Research Centre for Optimising Resource Extraction (CRC ORE) and includes five key levers for upgrading ores and rejecting waste prior to expensive downstream comminution and mineral processing. These five levers include natural deportment, induced deportment, bulk sorting, particle sorting and gravity separation. Over the past ten years, CRC ORE has progressed a range of technologies that exploit these levers from laboratory proof of concept through to large scale demonstration and validation. This paper details the work carried out by CRC ORE and Curtin University for assessing the amenability of an ore for its natural deportment and particle sorting attributes in an Integrated Screening and Particle Sorting (ISPS) Grade Engineering® process. ISPS is seen as a preferred method for Grade Engineering® as compared to individually operated unit operations as the benefits of each can be complementary. Furthermore, it is suggested that integrating the two levers has two important impacts: 1. Firstly, there is a risk that isolated particle sorting test results will be misinterpreted as being representative of the full sample without considering the mass balance impact of high-grade material that might have been lost in the fines fraction. This fine fraction will not be detected through the particle sorter. 2. Secondly, and potentially of more valuable impact, is that the opportunity may exist to upgrade the feed first through determining if there is a concentration of high grade to the fine (or coarse) fraction which can be separated through screening. Undertaking screening in the preparation stage of the particle sorting process will enable analysis and separation of the fine or coarse fractions of a rock mass. The result of this study provides the mining industry with an independent framework for undertaking an Order of Magnitude (ISPS) Grade Engineering® assessment on a range of constituent ore types. Keywords: Grade engineering, particle sorting, grade by size fractionation

Jan 1, 2020

By S. C. Maji, U. S. Chattopadyay, S. Chaudhuri, T. Gouri Charan

India is devoid of coking coal resources, which is a vital raw material for coke making. As a result it has to import about 80% coking coal for steel making. Indian National Steel Policy, 2017 has envisaged crude steel production around 300 million tonnes Mt) by the year 2030-31 and forecasts coking coal demand of 161 Mtpa (million tonnes per annum). One way of improving the indigenous resources is to study the performance of existing washeries and to improve the clean coal recovery by adopting suitable technology. A study was carried out, mainly to focus on the fine coal circuit of an existing coking coal washery, to generate the desired quality of clean coal. The operating coking coal washery being studied is presently feeding coal from nine different sources with varying feed ash contents. The coal fines varied in ash content ranging from 19.5% - 43.6%. For treating the coal fines, the washery has operated a spiral for the past few years. Performance studies were carried out, and it was found that the spiral is not efficient in recovering the cleans. Detailed investigations were carried out on the coal fines using flotation techniques, and it was found that to achieve a low ash clean coal, the froth flotation is a much better beneficiation option than a spiral, The studies showed that the recovery of clean coal through a spiral is 67.7% at ash content of 27.0%, while flotation tests showed a recovery of 68.1% at 16.5% ash content. Keywords: Coking coal washery, near gravity material, spiral washer, froth flotation

Jan 1, 2020

By I. O. Flores, A. Anani, H. Li

Current technological advancement has increased the exploitation of deeper ore bodies using underground methods. In certain cases, the mineral deposit starts near the surface and continues deep within the earth's crust. Such deposits are best mined with both underground and surface methods. Two main techniques are used to determine the optimal transition depth from surface to underground - a disintegrated approach and an integrated approach. Both methods have limitations in their use to determine the optimal transition depth. The objective of this research is to investigate the conditions in which an integrated approach to the transition depth problem is superior to a disintegrated approach. Three binary integer linear programming models are developed for this purpose: a surface and underground model for the disintegrated instance and an integrated model. A case study is performed to validate the models, with a comparative sensitivity analysis to obtain operational insights.

Sep 1, 2021

By C. B. Carelse, M. Manuel, D. Chetty

Automated mineralogical analysis of platinum group minerals (PGM), using the mineral liberation analyser, provides information used to understand flotation efficiency, primarily from a PGM liberation and association standpoint. To date, however, there is no consistent understanding regarding PGM speciation and its impact on floatability. Previous studies of PGM from UG2 ores concluded that a larger dataset is needed from which the various parameters can be modelled. Parameters on telluride, arsenide, sulfurarsenide and alloy species need to be integrated to fully understand the impact of PGM speciation on flotation, and for this, ores other than PGE-sulfide-rich UG2 must be assessed. Flotation rougher rate tests were performed on feed samples from two Platreef ores to determine the flotation response of individual liberated PGM species. This was achieved through automated mineralogical analysis of feed, rougher concentrates and tails. Based on 1529 liberated PGM grains assessed over the circuit for two Platreef ores, preliminary results show that PGM speciation, species grain size and competition from gangue appear to influence floatability in an ‘optimised’ laboratory environment. Keywords: PGM, PGM species, flotation, liberation

Jan 1, 2020

By M J. Daniel

The diamond industry is no newcomer to High Pressure Grinding Rolls (HPGR) as it has used the technology for more than 20 years, predominantly in secondary crushing and recrushing roles. In fact it could be argued that the diamond industry has led the way for the wider minerals industry to consider its application. In existing conventional secondary cone crushing applications, large valuable diamonds are" won" through meticulously managing the recovery process within defined particle size ranges. Conventional crushers operate with relatively large closed side settings, but have the potential to damage diamonds by making direct contact with the sides of the crusher. Cone crushers also result in steep product size distributions that run a high risk of losing many of the smaller, unliberated but more abundant diamonds from the rock. This current comminution paradigm of particle size reduction management results in recrushing processing applications or plants where HPGRs are often used.

Jan 1, 2010

By B. P. Watson, A. Carpede, W. O. Kekana, N. Fernandes, W. Theron, M. P. Mahlangu, G. Betz

The research described in this paper was done to confirm the Upper Group 2 (UG2) PlatMine peak pillar strength formula (Watson et al., 2007), which was determined from a back-analysis of failed and unfailed pillars. Underground measurements were made on a stable pillar that was loaded by firstly reducing it’s length and then by mining the surrounding pillars until pillar failure took place. The pillar was instrumented with suitably positioned strain cells and closure meters, which allowed both the average pillar stress and strain to be determined. The paper describes the methodology applied to identify a suitable position for the instrumentation, as well as the results. A stress/strain curve is presented for a UG2 pillar with a w/h ratio of 2.0, at Booysendal Platinum Mine. The measured pillar strength was similar to the predicted strength using the PlatMine pillar strength formula for UG2 pillars. The PlatMine formula has been successfully implemented on Booysendal Platinum Mine, and about 3 670 pillars have been cut without a single failure. An additional revenue of US$1.3 billion was calculated for the 25-year life of the mine as a direct result of the improved pillar design, given the January 2020 platinum group metals basket price. An extended life of mine and better mining efficiencies will also be realized.

Aug 1, 2021

By L. C. Woollacott, A. K. Tripathy, J. H. Potgieter

This paper presents the second of a two part study on density stratification in a laboratory batch jig. The first study, reported elsewhere, investigated the effect of operating conditions on the stratification profile achieved at equilibrium. The study reported in this paper investigated their effect on the kinetics of density stratification under 18 different sets of operating conditions - five for binary systems with different particle densities; and 13 for a ternary system with different configurations of the jig cycle. Although the study was academic in nature (it involved simple systems of 8 mm glass beads) it has a number of practical implications. It found that the most influential operating variables affecting stratification kinetics are the amplitude of water displacement, the pulsion hold time, and, to a lesser extent, the pulsion time. It also found that reasonable rates of stratification can be expected in systems with density differences as low as 237 kg/m3 but below this the kinetics deteriorate significantly. The two studies together suggest that, within a broad range of operating conditions, the equilibrium stratification profile is independent of control variables and it is the control of stratification kinetics that has the primary influence on the quality of density separations in a jig. Keywords: Jigging kinetics, stratification, equilibrium stratification, batch jig

Jan 1, 2020

By van der Merwem J. N.

"Coal pillars are prone to scaling over time, and are progressively reduced in size and consequently subjected to increased load and reduced strength. The effective factor of safety therefore reduces. Databases of failed and stable pillars cannot, therefore, be regarded as definitive.More than a decade has passed since the first attempt to predict the lifespan of pillars. This paper presents a review based on the new database and pillar strength equations. The methodology for the analysis is based on the fact that pillars scale. The ultimate safety factor (defined as the ratio between strength and load at the time of failure) is derived, followed by an estimate of the rate of pillar scaling, which results in an estimate of the expected time of failure.It is suggested that the predicted lifespan should not be used as an absolute indicator of expected pillar life, but rather as an index – the pillar life index (PLI) – to complement the safety factor and related probability of failure when evaluating pillar stability. A pillar with a predicted lifespan of less than 500 years would be regarded as being in danger of imminent collapse, while a lifespan of at least 1 000 years should be required for long-term purposes.The differences between this analysis and that published in 2003 constitute a strong case for regular reviews of all the empirically based stability indicators, namely the safety factor, probability of failure, and the PLI. Reviews at 10 year intervals appear to be required.The constants in the proposed method are valid only for the Witbank No. 1, 2 and 4 seams and the Highveld No. 2 and 4 seams.IntroductionIt is well known that over time, coal pillars are prone to scaling, and thus are progressively reduced in size and consequently subjected to increased load and reduced strength. The effective factor of safety therefore reduces and it is quite possible for failure to occur after a long time interval. In fact, scrutiny of the database of failed pillars indicates that failure occurred after periods ranging from 2 to 49 years, and not immediately after mining.The factor of safety for pillars at the time of failure is not the same as that immediately after mining. The concept of the safety factor is based on the pillar strength obtained by statistical analysis of pillar dimensions immediately, or within a month after mining, when the surveys are conducted. Strictly speaking, the safety factor as commonly used is valid only immediately after mining, and it continues to reduce thereafter. The ideal situation would be to base analyses of pillar strength on pillar dimensions at the time of failure, but that is simply not possible because the real dimensions cannot be measured at that time."

Jan 1, 2016

By L. Robles-Stefoni

"Multiple-point simulation (MPS) methods have been developed over the last decade as a means of reproducing complex geological patterns while generating stochastic simulations. Some geological spatial configurations are complex, such as the spatial geometries and patterns of diamondbearing kimberlite pipes and their internal facies controlling diamond quality and distribution.Two MPS methods were tested for modelling the geology of a diamond pipe located at the Ekati mine, NT, Canada. These are the single normal equation simulation algorithm SNESIM, which captures different patterns from a training image (TI), and the filter simulation algorithm FILTERSIM, which classifies the patterns founded on the TI. Both methods were tested in the stochastic simulation of a four-category geology model: crater, diatreme, xenoliths, and host rock. Soft information about the location of host rock was also used. The validation of the simulation results shows a reasonable reproduction of the geometry and data proportions for all geological units considered; the validation of spatial statistics, however, shows that although simulated realizations from both methods reasonably reproduce the fourth-order spatial statistics of the TI, they do not reproduce well the same spatial statistics of the available data (when this differs from the TI). An interesting observation is that SNESIM better imitated the shape of the pipe, while FILTERSIM yielded a better reproduction of the xenolith bodies. IntroductionThe simulation of geological units poses several technical problems that challenge the capabilities of available geostatistical simulation approaches and their ability to deal with spatial complexity of categorical variables. The spatial geometry of diamondbearing pipes and their internal facies controlling diamond distributions are a specific and well-known difficult modelling problem. The geometry of a kimberlite pipe is typically like an inverted cone (Figure 1); the wider part is known as the crater and is located near the surface, and the narrower, deeper part is known as the diatreme. Xenolith bodies can also be found inside the pipe. A very important contribution to the geological modelling of the contours of the pipe is the measure of uncertainty about the location of the contact between the kimberlite pipe and the host rock."

Jan 1, 2016

By Paul B. Crawford, Gerald N. Pitts

"A new method is introduced for the simulation by computer of the flow of liquid underground. The method has application in simulating, for example, liquid withdrawal systems, injection systems or injection-well systems. The computer simulation of liquid flow permits the utilization of the known properties of the rock in developing a model of the permeable rock mass.The flow properties of the rock at a specific site arc generated statistically using a random number generator. After defining in this manner the rock properties of each element in the computer grid, the streamlines or flow paths of the liquid are traced using the new method. The simulation is designed especially for computers. The meandering character of the liquids paths is displayed clearly as the fluid moves underground, thus providing the technical information required for the control of the movement of liquid."

Jan 1, 2014

By A. Yañez, J. Yianatos, P. Vallejos, R. Grau

This paper presents an evaluation of the effect that the mineral feed characteristics have on the metallurgical performance in an industrial flotation circuit. Variables such as mineralogy, particle size, solid content and mineral grade were evaluated using a flotation simulator, which was previously developed and validated using industrial data from different concentrators. The metallurgical performance was evaluated not only from the point of view of recovery and concentrate grade, but also by analysing less common variables such as froth carrying rate, froth and collection recovery, water recovery and others. Then, new data from the industrial flotation circuit was used to complement this analysis and evaluate the simulator predictability by comparing simulated and measured data. The results allowed for the quantification of the significant effect that mineralogy and particle size have on recovery and/or concentrate grade. Therefore, the grinding stage and flotation cells design become important factors to avoid a significant loss in metallurgical performance when feed mineral characteristics change in an industrial operation. In this context, an evaluation of cells design and arrangement should be performed to compensate the loss in recovery and concentrate grade in order to find an optimal operating condition. Keywords: Flotation circuits, mineral feed, modelling, particle size, liberation, mineralogy

Jan 1, 2020

By and Z. S. Abisheva, Z. B. Karshigina, Ye. G. Bochevskay, A. S. Sharipova

The production of precipitated silica in the United States is about 145,000 tons of SiO2 and its prices vary significantly (from $ 1 to $ 4.5 per kg) depending on the area of its application. One of the most important parameters is its specific surface characterising dispersion (particle size and shape, presence or absence of pores), at a certain value of which the material acquires new properties and quality. At present, a technology has been developed for processing slag from phosphorus production to produce precipitated silica (‘white soot’) with a high specific surface and the possibility of extracting valuable components such as rare-earth metals (REMs) into a product enriched with them has been shown. However, the content of impurities in the deposited silicon dioxide, such as aluminum and iron, is above acceptable limits and may affect the quality of the final products. Therefore, along with the structure and specific surface, a very important characteristic of ‘white soot’ is the chemical purity of the material. In turn, calcium oxide occupies a significant share in the concentrate of rare-earth metals, which affects the content of ΣREMs oxides, which does not exceed 17.3 %. The low content of a valuable component may affect the feasibility of further processing. For the most complete utilisation of phosphorus slag, the authors propose a method for their acid processing, which allows for minimising the conversion of impurities to finely divided silica and collective concentrate, which will improve the quality of these products. Keywords: Phosphorus slag, precipitated silicon dioxide, rare earth metals, leaching, white soot, specific surface, technology

Jan 1, 2020

Slope stability is a fundamental part of a successful mining operation. It impacts directly on the safety of personnel and the economics of the mine. The Jwaneng Mine in Botswana is planning a push back of 644m depth in the south east wall. Mining will commence in 2010 and be completed in 2024. This will put the mine in the deep pit category. The mine has invested in extensive geotechnical data gathering and design programs that started as far back as 2003 for the south east wall. The south east wail of Jwaneng Mine is characterized by foliation that dips adversely into the mining faces. The orienta1ion of the foliation is variable due to intense tectonic movements that have also caused the occurrence of faults that are sub-vertical. A considerable amount of information on the characteristics of structural patterns and the rock mass has been collected. This paper presents an overview of the feasibility level geotechnical design that is about to be concluded.

Jan 1, 2010

By I. Y. Motovilov, S. A. Telkov, M. B. Barmenshinova, Z. S. Abisheva

As a rule, removing waste rock at the beginning of the process improves the conditions for the flotation of minerals, and also reduces the operating costs of crushing, grinding and flotation. Lead-zinc ores in the Shalkiya deposit of the Republic of Kazakhstan are classified as difficult for enrichment, but taking into account their significant reserves, they are one of the main potential ores for the production of lead and zinc. Under industrial conditions, for processing ores of the Shalkiya deposit, a selective flotation concentration scheme with the production of lead and zinc concentrates is recommended. However, according to the recommended scheme, it is not possible to obtain high-quality concentrates of lead and zinc, with high metal recovery. The paper presents the results of studies of preliminary gravitational enrichment of lead-zinc ore in the Shalkiya deposit. Based on the fractional analysis for the particle size range of -40+8 mm, Henri- Reingard enrichment curves were constructed, separation density (2730 kg /m3) was established to isolate the light fraction with the lowest possible lead and zinc content, and gravity enrichment indices (0.7-0.71) were determined. It was found out that when using gravitational enrichment of the original large-sized ore in the Shalkiya deposit, tails are released at the beginning of the technological process with a yield of up to 20% with the extraction of silica up to 30%, calcite up to 11% and carbonaceous matter up to 12%. As a result of the studies, it was found that the beneficiation of crushed lump ore could be conducted in heavy suspensions. One of the positive aspects of the use of gravitational enrichment is the reduction of energy costs for grinding the heavy fraction, which was experimentally proved in this article. Keywords: Lead-zinc ores, Shalkiya deposit, fractional analysis, gravitational enrichment, floating fraction, sunken fraction, separation density

Jan 1, 2020

By Z. Botha

Sheryl Sandberg, the COO of Facebook, published a book titled 'Lean In', where she invites women to sit at the table. In summary, to 'sit at the table' entails not only embracing opportunity, but to actively seek out opportunities in leadership positions. Sandberg points out that, unfortunately, apart from institutional obstacles, a woman's own perceived limitations have a negative impact on her leadership ambitions. To create an environment where diversity will flourish, where everyone has a seat at the table and everyone has a voice, safety must be established first. To establish safety within a diverse team, there is power in relationships and connections. This study will first and foremost review theories in literature as to why diversity and inclusion are so important and the value that diversity brings to our industry. The study also recommends a few focus areas for improving diversity and inclusion in the industry.

Sep 1, 2022

By P. J. Le Roux

"Mining companies are under constant pressure to reduce their cost structures to sustain profitability. In mines using an open stoping mining method, dilution often has a significant effect on profitability. At Target mine in South Africa, dilution in some open stopes was found to exceed 10%, falls of ground being a major contributor to the problem. This dilution can reduce the recovered grade from 5.5 to 4.5 g/t, resulting in a potential loss of about R21 million per month based on a gold price of R240 000 per kilogram. In addition to the cost of dilution, the cost of damage to, or loss of, trackless equipment as a direct result of falls of ground in open stopes is significant. Other associated costs include transport, hoisting, secondary blasting, milling, and plant treatment of waste material. Stable open stopes are essential in order to reduce falls of ground. Back-analyses of stope instability at Target mine have indicated that conventional rock mass failure criteria are unsuitable for stope design. An alternative strain-based criterion has been developed, and has proved to be very successful, allowing the stability of open stopes to be calculated reliably. Since its implementation in 2010, dilution and equipment damage have decreased markedly, creating value for the mine. IntroductionMines that make use of an open stoping mining method aim to extract only the ore, leaving the waste behind. Many orebodies have well-defined boundaries between the ore and the waste rock. In such orebodies, the introduction of waste into the ore due to overbreak dilutes the grade. In massive disseminated orebodies, dilution is less problematic. Overblasting, falls of ground, or other causes may result in dilution. A study undertaken in Canada (Pakalnis et al., 1995) found that approximately 51% of all underground metal mines utilized open stoping mining methods and, from surveys conducted at these mines, open stoping operations experienced dilutions of up to 20%, and occasionally more. Dilution of this magnitude has a significant economic impact on any mining venture. Research carried out in Australia by Capes (2009) came to the same conclusion."

Jan 1, 2017

By A. Buncombe

In March 1984, two years' work by senior metallurgical personnel from the six major mining groups culminated in the formation of the Mine Metallurgical Managers' Association of South Africa. This Association has joined a group of specialist Associations operating within the South African mining industry whose aims are to uphold the standards and promote the interests of their various professions.

Jan 1, 1987

By K. J. Craig, M. A. Swart, Q. G. Reynolds, L. Hockaday

A solar reflector soiling study was carried out at a ferromanganese smelter in South Africa to assess the soiling rates at different locations around the plant. Several meteorological parameters were monitored to give insight into the conditions that lead to increased soiling. Mineralogical characterization of dust samples collected from the reflectors and the atmosphere revealed that only a certain size fraction is of importance with regard to soiling, and that the dust can be attributed to both raw materials and smelter products. Proximity to the dust source was the primary driver for increased soiling. The site that experienced the most soiling was very close to raw material heaps; this was deemed an outlier and was excluded from the summary statistics. The secondary driver for increased soiling was location relative to the smelter dust sources and the wind’s direction and speed. The reflector set at the best location experienced 13.1% less soiling than the set at the ‘worst’ (but still feasible) location, represented by an averaged mean daily reflectance loss of 0.0186. The study revealed that while there are periods of intense soiling at this particular site, proper planning of reflector location in relation to the smelter dust sources can significantly mitigate the soiling rate.

Jun 5, 2023

By M. S. Moholwa, J. D. Steenkamp, H. L. Rutto

Manganese ores are the major source of manganese for the production of manganese ferroalloys. There is a gap in the knowledge of the decrepitation behaviour of manganese ores, which presents a problem in the operation of smelters. Decrepitation, which is the breakage of the ore particles upon heating, is an important quality parameter for these ores. The purpose of this investigation was to determine the extent to which South African manganese ores decrepitate during preheating in a rotary kiln. The effects of temperature, rotational speed, and particle size decrepitation were investigated. Manganese ores were heated in a laboratory-scale rotary kiln at temperatures of 600, 800, and 1000°C, and rotational speeds of 3, 6, and 12 r/min. The size ranges were +6-20, +20-40, and +40-75 mm and the residence time was constant at 30 minutes. The decrepitation index (DI) is quantified as the ratio of the mass of <6 mm particles after pre-heating to the total mass of the sample. It was found that the DIs for all ores used were proportional to the temperature and the rotational speed and inversely proportional to the particle size range with temperature being the most important parameter. Ore A was the most susceptible to decrepitation followed by ore C and ore B; this was mainly to the decomposition of kutnohorite, the content of which was the highest in ore A and the lowest in ore B.

Nov 30, 2022