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By J. E. McGill

The junior and small-scale mining sectors in South Africa play an important role in the livelihoods of numerous communities. Mining presents an opportunity, in the post-1994 democratic era, for many individuals to obtain access to much required empowerment and socio-economic development. These sectors are, however, not without numerous characteristics that pose problems for operators, legislators, and other role-players. Mining is inherently risky, with operators experiencing frequent difficulties and challenges throughout the life of mine. Opportunity exists, and needs to be enhanced, for junior and small-scale prospects and operations to include technical risk assessment techniques in documentation presented in search for funding, and in optimizing monthly planning and longer-term functioning. The focus here is to explore how the risk management cycle may currently be applied to a mineral resource suitable for exploitation by the junior and small-scale mining sectors. No management process can create additional value in the ground, but various available mechanisms can go a long way to quantifying the inherent risk that exists, highlighting the need to manage the risks and hopefully allowing the entrepreneur access to the intrinsic opportunities of the emerging mining sector in South Africa.

Jan 1, 2006

By Grant Loveday, Vincent Dieudonné, Andrew Jonkers

Bateman Minerals & Metals supplies the APIC Technologies which include the under-bed air-pulsed APIC jig and related technologies such as the JigScan controller and advanced mathematical models of the jig process. Bateman have developed a methodology for predicting process performance for jigs from simplified testing and modelling, based on batch equipment matched to industrial designs. Batch tests conducted on laboratory scale air-pulsed jigs can process small batches of material, such as those obtained from drill core samples. The novelty comes from using an advanced jig process model, ASTRAD, to link the results of batch and continuous jigs. The batch jig presented as a novelty in this paper has been designed to be hydraulically equivalent to the full-scale APIC Jig, allowing the generation of equivalent pulse shapes and using JigScan controller. Lump and fine ferrous ore material have been separated in this unit and any feed >1mm can be tested and extracted. The global test procedure and further modelling focus on the stratification of material, with emphasis on key aspects such as pulse shape, feed characteristics and residence time. The splitting of rejects from concentrates is itself more difficult to reproduce in batch jigging, however the ASTRAD model includes a separation imperfection module, and the APIC Technologies have extraction systems adapted to each type of material. Air pulsed batch jigs are available in several locations and are relocatable. They have been used to treat samples from Australia, South Africa and India as part of studies into ore processing using jigs. Each test layer is available for various physical testing procedures (density and chemical analyses). Test-work is performed on a case by case basis, and analysed using an advanced model ?now available over the internet. Some fundamentals of air-pulsed jigging are recapped along with some of the features of APIC jigs. The process of designing a ?hydraulically equivalent? batch jig test is then described. Some results from jigging tests are presented plus the results of the ASTRAD advanced jig model, which was first developed at the JKMRC with ferrous ores and coal and is now being supported and further developed and utilised by Bateman.

Jan 1, 2006

By Georg Breitsprecher

The technique of Stabilising Columns (product names are for example "Stabilisierungssaulen" (STS) or "Coplan Stabilisierungs-verfahren" (CSV)) is gradually becoming well accepted for ground improvement. The installation, dimensioning and quality control are standardized by DGGT (German Association for Geotechnique), working committee 2.8, of which until now only part one exists for dry columns. This paper describes the installation and testing of stabilising columns for a ground improvement project. To achieve comparable results in testing both ready mixed concrete and dry binder had been used for production.

Jan 1, 2006

By A. P. Paiva

The solvent extraction properties exhibited by some /V,N'-tetrasubstituted malonamides to efficiently and selectively recover iron(III) from concentrated chloride leaching solutions can be found in the recent literature. The iron(III) extractive chemistry exhibited by some of these derivatives is revisited, in order to compare their chemistry with that shown by a few of the new malonamide compounds. The generally good extraction efficiency towards Fe(III), from >4 M hydrochloric acid solutions, and the relative ease of Fe(III) stripping by distilled water are remarkable findings that are confirmed for the malonamide derivatives described in this work. Furthermore, additional data regarding their selectivity towards Fe(III) extraction over several base metal ions and their behavior when subjected to successive Fe(III) extraction-stripping tests are also presented and discussed.

Jan 1, 2006

By M. J. Latva-Kokko

This paper describes the behaviour of iron and the methods used for iron control in the nickel matte leaching process. OMG Harjavalta Nickel Oy processes approximately 10 000 t/y of iron, which enters the process with the nickel matte raw material. Iron dissolves and precipitates in several different stages of the leaching process. Compounds like ferric hydroxide, parabutlerite, goethite, hematite and jarosite are found. Iron removal is done within the leaching process, and this means that the dissolution of nickel sets the limiting conditions for iron precipitation. A leach residue consisting mainly of the iron precipitates is neutralized and stacked in the waste pond. When iron is precipitated from concentrated nickel sulphate solution, some nickel is lost by co-precipitation. Recent studies have shown that Ni-Fe ratios less than 1%, attributed to co-precipitation, can be obtained with jarosite precipitates, compared to 2-3% ratios typically found with hematite precipitates. Iron can be precipitated as jarosite under the optimal nickel leaching conditions by adding ammonium sulphate to the feed slurry of the autoclave.

Jan 1, 2006

By S. Sundararajan, J. Brousseau, P. Bocher, M. Galopin, N. Barka

This research is committed to the prediction of the hardness profile produced by induction heating, using a computer-modeling software. The paper presents the simulation of the induction hardening process to analyse the sensitivity of the induction parameters on the hardness profile of a low alloy steel specimen. The developed numerical model includes the coupling effect between electromagnetic and thermal fields, and takes into account the non linear behaviour of the material properties. The study applies an enlightened experimentation method to build the feasible domain of the process and to achieve predictive empirical modeling. The ultimate goal is to replace the trial and error method that is usually used for the development of new parts, by costless experiments with the numerical model. Further development of this approach will lead to the computation of the residual stresses and finally to the assessment of the mechanical properties of the part. The end result will be the ability to shorten the development time and to improve the quality of the hardened part.

Jan 1, 2006

By M. Cross

Heap leaching presents a complex physico-chemical process to model and a significant challenge to develop a comprehensive model enabling reliable predictions of heap behavior over the long term. A computational modeling framework is described for the analysis of multi-phase flows in reactive porous media suitable for tracking metals recovery, for example, in heap leaching and environmental recovery processes. This modeling framework employs appropriately formulated, parameterized, and solution procedures to capture: 1) liquid and gas flow through heterogeneous porous media subject to variably saturated flow conditions, 2) the complex and dynamically changing nature of the porous media structure, 3) the transport of reactants and products of reaction, 4) the simultaneous mass and heat transfer, and 5) the role of bacteria as a catalyst for reactions. A second class of challenges to accurately model heap processes is to identify and then capture all the process data to characterize the reactivity of particular ores, the mine planning for the construction of the heap, leach schedules, meteorological data, etc. The objective of this paper is to outline these challenges and to describe a modeling framework that can cope with arbitrarily complex geometries and provide tools for rapid and accurate process assessment.

Jan 1, 2006

By John O. Marsden

The past fifteen years have seen a number of important developments in copper hydrometallurgy, including the commercial application of biological heap leaching of secondary (chalcocite-dominant) copper ores, the commercial demonstration of chalcopyrite concentrate leaching technology using pressure leaching and biological processes, and the application of novel configurations of solution extraction circuits. Significant emphasis is now being placed on the development of effective stockpile leaching practices for primary ores (chalcopyrite and bornite-dominant mineralization). Some of these developments have been highly successful, and will pave the way for further development and commercialization. Others have been less successful. These developments are reviewed in the context of the metal price cycle and trends for the future are identified.

Jan 1, 2006

By Rachel De Lucas

Current methods of hydrogen storage are an impediment to the transition of our energy infrastructure from a hydrocarbon to a hydrogen base. The transportation, handling, and storage costs of hydrogen gas account for a majority of its selling price. Magnesium hydride slurry is a safe, environmentally friendly alternative for hydrogen storage. If this form of storage is to be adopted on a large scale, a cost-effective method for recycling the enormous amounts of magnesium hydroxide byproduct must be identified. The solid oxide membrane (SOM) process can be used to recycle the magnesium hydroxide byproduct into magnesium metal, which can be reformed into magnesium hydride and reused for fuel storage. Conventional magnesium extraction/recycling technologies require a great deal of energy and create byproducts that are harmful to the environment and human health. The SOM process poses none of these detrimental effects and requires less energy and feed preparation. The economic viability of a facility that utilizes the solid oxide membrane process for the direct reduction of magnesium must be examined in more detail if industry is to consider it. Cost analysis data related to the commercial viability of a scale-up will be compared to two standard industrial processes: current magnesium production techniques including electrolytic and metallo-thermic processes. We have shown in our cost comparison that the SOM process is cheaper than these traditional techniques and that it is also comparable to aluminum's Hall-Héroult process in cost but with none of the environmentally harmful byproducts.

Jan 1, 2006

By Yang Tian-zu

The separation of precious metals from base metals containing in gold-antimony alloys by selective chlorination leaching under controlling potential was studied in this work. The effects of the consumption of hydrogen peroxide, the concentration of hydrochloric acid, the concentration of sulfuric acid, leaching temperature, leaching time and the liquid-solid ratio in hydrochloric acid system on the leaching efficiencies of the base metals have been investigated. The optimal leaching conditions of the gold-antimony alloys are as follows: hydrochloric acid concentration 4.0mol?L-1, sulfuric acid concentration 1.2mol?L-1, liquid-solid ratio L:S=7.5:1, the leaching temperature 80 0C, leaching time 2h, and the oxidation potential of the leaching system 400±20mV( vs SCE).The leaching efficiencies of copper, nickel and antimony are more than 99% and the gold leaching efficiency is about 0.042% under the above leaching conditions. The base metals containing in the gold-antimony alloy are separated from the precious metals thoroughly.

Jan 1, 2006

By A. A. Sizikov, V. A. Sizikova

Key parameters to consider for any producer: bring down production cost and lead time; Lean production as a tool to achieve maximum efficiency; How to implement lean principles: discontinuous vs. continuous production (aluminum industry); About RUSAL: global top-three aluminum producer; Lean tools at use at RUSAL's production facilities; Pull system, Standardization of work, Just in time, Continuous improvement, Customer-Supplier relations, etc.

Jan 1, 2006

By A G. L Pratt, J R. Grant

Mining companies face the ongoing challenge of sustaining and growing production. This paper outlines business investment concepts to grow reliable returns on investment from a portfolio of choices by:improved visualisation, diagnosis and tune up of the investment pipeline (pipeline management); good corporate decision making (governance) to select the right project mix, risks and sequence; and delivery strategies to enhance and reliably execute projects.

Jan 1, 2006

By Bernard Bonnetot

The potentialities of hydrogen storage using borohydrides are presented and discussed especially in regard to the recoverable hydrogen amount and to the recovery conditions. A rapid analysis of storage possibilities is proposed taking in account the two main ways for hydrogen evolution: the dehydrogenation obtained using thermal decomposition of borohydrides or the hydrolysis of solid or dissolved borohydrides. The recoverable hydrogen is related to the dehydrogenation conditions and the real hydrogen useful percentage is determined for each case of use. The high temperatures required for dehydrogenation, even using catalyzed borohydrides, lead to poor outlooks for this storage technique. The hydrolysis conditions fix the yield of the recovered hydrogen and rule the storage capacity of the dissolved borohydride, the "fuel".

Jan 1, 2006

By S. Kashani-Nejad

The formation of oxides during the dehydration of MgC12,6H20, Bischofite, was studied by heating the bischofite over a range of time and temperatures in ambient atmosphere. Using a methanol-leaching technique developed by authors, the oxides that formed were isolated, identified and assayed. Three distinct regions of oxide stability were identified. The oxide produced at dehydration temperatures less than 300 °C was Mg2(OH)3C1,2H2O; at 300 °C, mixtures of MgOHC1 and Mg2(OH)3C1.2H2O were formed and at 400 °C, MgOHC1 was the only oxide produced. The presence of MgO observed in the products of the dehydration of bischofite at temperatures above 400 °C was due to the thermal decomposition of the MgOHC1 that was formed while the sample was heating to over 400 °C.

Jan 1, 2006

By Clarence Zink

Aside from the mechanical properties and process of actual rock breakage, rotary drill bit performance is affected by several “post breakage” items: cuttings size, flushing air pressure, flushing air volume, cuttings load, drill hole geometry, etc. We all recognize that more efficient drilling creates bigger cuttings, more air pressure cleans the hole bottom better, more air clears the cuttings from the hole, and a better hole geometry allows cuttings to escape with a minimum of “regrind”.

Jan 1, 2006

By Francis Vanbellen

Umicore Precious Metals Refining operates an integrated precious metals smelting and refining plant in Hoboken, Belgium. Once a smelter and refiner of complex concentrates, the plant today?s feed consists exclusively of industrial and consumer recycled products, making it the world?s largest recycling facility for precious metals. Unlike the fairy tale of the Frog Prince, it took much more than a princess? kiss to successfully realize this makeover. A completely renewed plant has been built over the past decade. The most visible technological innovation was the commissioning of the Pb-Cu smelter. Its flexibility towards very different types of feed makes it perfectly suited as main entry to the Hoboken flow sheet. A new Cu-leaching & electro winning plant and precious metals refinery make up the Precious Metals Operations (PMO) whose targets are fast throughput and maximized yields for gold, silver and the platinum group metals. The Base Metals Operations (BMO), flexibly process the by-products from the PMO, valorizing ?impurities? like indium, tellurium, selenium and others. Off gas and waste water treatments ensure compliance with strict environmental standards. Precious metals recycling is an art that goes beyond mastering a unique flow sheet. Umicore Precious Metals Refining offers a complete recycling service, taking care of sampling and assaying, metals management and logistics. The quality of this integral service is recognized through the attribution of ISO certifications for our operational activities, sampling and the environmental care. And it?s an art that follows Michelangelo?s experience: ?Art is 5% of inspiration and 95% of transpiration.?

Jan 1, 2006

By K. Tada

A surface of a magnesium slab (hereinafter, referred to as Mg slab) or magnesium alloy slab (hereinafter, referred to as Mg alloy slab) becomes black with the use of conventional manufacturing methods. The methods also involve a danger that an explosion of the molten magnesium occurs through contact with cooling water. Thus, it has been impossible to produce a slab having a smooth surface. In the present method, a molten magnesium alloy is supplied into a mold, which is sheltered from the surroundings, from a pool in tundish, which is shielded from the surroundings. AZ31B slab formed in the mold is drawn horizontally out to the outside from an outlet of the mold by revolving of the pinch rolls. A cooling water is jetted at an acute angle onto the slab on the outer side of the mold outlet. Further, an inert gas is sprayed at the inner side of the mold outlet in order to seal in a gap between a free surface of the molten magnesium alloy and a sheltered board surrounding an upper surface of the mold. As a result, oxygen and droplets of the cooling water are prevented from running back to the mold side through the gap. AZ31B slab has a smooth surface condition and high quality without a gas porosity, a segregation or the like. Further, the slab has a size of a width of 100 to 120 mm, a thickness of 5 to 20 mm and a span of 10 m or more.

Jan 1, 2006

By G Muller, P Larrondo, M C. Godoy

The categories of Mineral Resources and Ore Reserves that may be used for public reporting in Australasia are defined in the current JORC Code (2004). Most internationally accepted codes emphasise the principles of transparency, materiality and competence in classifying resources. They also provide some guidance in considering the impact of data quality. There is no method recommended in the JORC Code to classify a Mineral Resource into the allowed categories of Measured, Indicated and Inferred for public reporting. A clearly defined procedure is desirable for many reasons, including consistency, repeatability and auditability. The demonstrated use of geological knowledge in the classification method is desirable. In deposits with abundant historical data there can be large variations in data type and quality. Quantification of the error of the estimates may also be considered. Ways to formally incorporate such information into the resource classification process are presented as a first step towards establishing an objective, repeatable methodology that allocates resources into appropriate categories based on defined criteria of accuracy and precision.

Jan 1, 2006

By Y Gu

The Mineral Liberation Analyser (MLA) employs the technologies of scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX). The use of backscattered electron images to define phase boundaries produces very high resolution image analysis and subsequently detailed and accurate particle images and data output. The mineralogy, elemental deportment, grain size, liberation characteristics and mineral associations of a large number of samples can be described. The MLA uses a comprehensive set of analysis methods to meet a wide range of applications. The data from ore characteristion projects completed during feasibility studies are important aids for effective plant design. The MLA can be used to establish variation in the mineralogy of an orebody, identify and quantify the deportment of deleterious elements, and provide valuable information to support comminution and flotation test work. In established plants the MLA data is an important component of plant survey work and monthly composite samples. Changes in feed characteristics and/or operating conditions can be monitored and solutions to any deterioration in recovery and grade performance found. The MLA has extensive applications in the minerals industry. Rare and precious metal samples can be accurately measured using high-resolution grey-scale images. Several new measurement techniques have been developed to perform rapid searches of a large number of samples to provide efficient and accurate analyses of fine-grain, low concentrate material. Quantifying the mineral variability in mineral sands operations is essential to maximising grades and recovery. The MLA produces particle-based data on density, mineralogy, size and shape and has developed measurement techniques to provide the elemental quantification required for the characterisation of these deposits. Nickel sulfide ores can be analysed to provide modal mineralogy, elemental deportment and liberation and locking data. The low-grade and variable nickel mineralogy of these deposits makes the use of quantitative mineralogy an essential component of maximising returns. Coarse particle measurements preserve the in situ textures of ores and support flotation and breakage test work for feasibility studies. The deportment of penalty and bonus elements can be quantified and the association and grain-size data can be used to identify potential separation issues.

Jan 1, 2006

By P. A. Olubambi

The effect of ore mineralogy on the bioleaching of metals from complex sulphides was studied by investigating the bioleaching of zinc and copper from a bulk complex sulphide ore from Ishiagu, Nigeria, using mixed cultures of Thiobacillus ferrooxidans, Thiobacillus thiooxidans and Leptospirillum in mechanically stirred reactors at varying particle sizes. Mineral phases within the varied particle sizes of -53, 53, 75 and 106µm were identified using X-Ray Diffraction (XRD), while the elemental distribution within the varied particles sizes was determined by X-Ray Fluorescence (XRF) and Optical Emission Spectrometry using Inductively Coupled Plasma- Optical Emission Spectrometer (ICP-OES). Bulk ore and the leached residues were examined by X-Ray Diffraction. The highest bioleaching recoveries were obtained at particle size of 75µm, while particle size of 106µm gave the least recoveries. Lower recoveries at particle sizes of 53 and -53µm were as a result of their higher silica and siderite content which affects pH, iron mobility and oxidation.

Jan 1, 2006