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By N. Lock

"Despite the pre-eminence of the Jwaneng Diamond Mine as the world’s richest diamond mine, the discovery story has long been clouded in mystery. This is the 45-year old untold story of the Jwaneng discovery and contemporaneous Bechuanaland/Botswana political and socioeconomic history. Diamond exploration by De Beers in Bechuanaland began in 1955, with the first true kimberlite discovery near Letlhakane in 1967, before Clifford’s Rule was applied and before the use of indicator mineral chemistry. Surface deflation soil sampling and bioturbation by termites was the foundation for exploration into the Kalahari. The 1962 reconnaissance programme south of Jwaneng had failed to make any discoveries. Improved sampling methods were applied to the Kalaharicovered areas in 1969 and positive results were received by year-end. The Whateley’s Wish percussion drill-hole in December 1972 was confirmed as Jwaneng 2424D/K2 with drill core in early 1973. Jumper drills were required to penetrate the Kalahari sand cover. Diamond resources were demonstrated despite multiple technical problems. IntroductionThe Jwaneng Diamond Mine is, by value, the world’s richest diamond mine. Harry Oppenheimer is quoted as saying that Jwaneng is ‘the most important primary deposit found anywhere in the world since the discovery at Kimberley more than a century ago.’ (Taylor III, 1982) The mine opened in 1982 after some nine years of evaluation and construction since discovery in February 1973. Debswana (2017) states that 2015 production was 7.87 Mt of ore from which 10.408 million carats were recovered at a grade of 132 carats per 100 t (cpht). Although the value is not reported, it was noted that Jwaneng contributes 60–70% of Debswana’s total revenue from all mines, including Orapa, Damtshaa, and Letlhakane (Debswana, 2017)."

Feb 1, 2019

Bateman Engineering managed the establishment of a second diamond treatment plant at the Letseng Mine in the Mokhotlong District of northern Lesotho, about 100 km from the town of Buthe Buthe. Letseng Diamonds Proprietary Limited, is owned 70 % by Gem Diamonds and 30 % by the Government of the Kingdom of Lesotho. The second plant, which commenced construction in late 2006, doubled Letseng Mines' hard rock processing capacity from 2.6 million t/yr to 5.2 million t/yr, making it the worlds' seventh largest diamond mine by throughput. Bateman Engineering provided the engineering design, procurement and construction management of the new plant.

Jan 1, 2010

By N. C. J. Dempers, J. A. L. Parker, R. A. Wildenboer

More than half of global cobalt reserves are located in the Southern African Copperbelt, stretching over the northern tip of Zambia and southern area of the Democratic Republic of Congo. In these areas, cobalt is not typically produced as a primary product but as a byproduct of copper production. Ores from this region often contain uranium, which is readily leached under typical copper leach conditions and enters the process. Uranium does not pose a challenge to copper production, but it becomes a significant problem when it follows cobalt to the cobalt precipitation process and results in unacceptably high levels of U in the final Co product. This paper evaluates the existing process technologies that can be used to remove uranium from cobalt-bearing process streams, including phosphate precipitation and ion exchange. Advantages and disadvantages of the uranium removal processes are discussed, and important design considerations are highlighted.

Jan 1, 2023

By C. W. P. Finn

On 14th April, 1980, 76 delegates from industry, universities, and research laboratories gathered at the University of the Witwatersrand to attend the Pyrometallurgy Vacation School. Professor H. B. Bell, Chairman of the Department of Metallurgy at the University of Strathclyde, Scotland, was there to lead the School, along with 12 local lecturers, who had gathered at the Hotel Devonshire at 07h30 for an Authors' Breakfast. Analytical chemistry Euroanalysis IV will be held in the town of Espoo, approximately 9 km from the centre of Helsinki, from Sunday, August 23rd, to Friday, August 28th, 1981.

Jan 1, 1980

By A. Tello

Variography was introduced by Dr. Pierre Gy to monitor a process, in the sixties. Later on, Francis Pitard extended this concept, building a complete system of variographic controls for different applications. Nevertheless, the existence of information about its use as a way to effectively control plants has been limited. There are infinite areas where variography and chronostatistics can be used. In this paper, two different cases related to gold and silver recovery, through well known but complex metallurgical routes are studied. The use of effective management of process variability software (EMPV) has shown to be a suitable solution to clarify problems at the plant and, consequently, a solution to the encountered problems has been proposed. Chronostatistics is like opening a new world to the metallurgist, making the process variability speak in a more comprehensive and in depth way. Once the ore has been extracted from the mine, sampling is necessary at each sequence of the metallurgical process involved. As a first example, leaching of the ore with cyanide in agitated tanks is another case of a complex metallurgy. The aim of the process is to know about residual values in the tailings in order to optimize process. As a second example, leaching of gold and silver in ore heaps, has to be optimized in terms of time, reagents consumption and, of course, in predicting a reasonable recovery. This last issue appears to be crucial. After cyanide leaching at the heaps, a carbon in columns process is involved, where there are a series of carbon loaded columns that are submitted to a dynamic process of load and unload, to finally deliver an enriched solution to the precious metal electrowinning plant. In both cases, variography has been a good approach to show metallurgists ways to improve the operation.

Jan 1, 2009

By D. O’Connor, A. Pytlik, D. J. Corbett

The resistance of yielding rockbolts to multiple impact loads was tested by means of a drop hammer. The methodology was based on the ASTM D7401-08 standard as well as the requirements specified for rockbolts by Luossavaara-Kiirunavaara Aktiebolag (LKAB – a Swedish mining company) and the Safety In Mines Research Advisory Committee of South Africa (project number GAP 423). During the tests, the loading force and bolt elongation were measured with a sampling frequency of fs = 19.2 kHz. In order to analyse the phenomena involved, the tests were recorded using two independent high-speed video cameras (600 and 1000 frames per second) and one thermal camera (128 frames per second). The tests demonstrated that all the samples transferred double the gravitational potential energy of Ep = 50.85 kJ from the impact load of mass m = 2825 kg and impact velocity of v = 6.0 m/s without failure. Damage to the bolt-resin contact in the upper anchoring zone of the bolt in the steel tube occurred after subsequent impacts. As a result, the macro-deformed bolt exhibits additional yield, and its operation following the shearing of the resin bond is similar to that of a ‘cone bolt’. Only one test resulted in damage to the threaded bolt rod-nut coupling, during the fourth impact; however, no damage to the bolt-resin contact zone was observed.

Nov 6, 2023

By E. R. Leeman

INTRODUCTION The first references in the literature to the so-called C.S.I.R. 'doorstopper' strain cell were made in 1964 1,2,3,4. These were the climax of nearly two years of experimental and developmental work with the instruments and the operating techniques involved. Since that time numerous field measurements have been made with 'doorstoppers' and they have been developed to a stage where they are in commercial production and are being supplied to users throughout the world. No detailed description of the latest 'doorstopper' equipment has, however, appeared in print and this paper is written to bring the literature up to date in this respect. The triaxial strain cell was developed three years ago 5, 6, 7 and was first described at the First Congress of the International Society for Rock Mechanics in Lisbon in 1966 8. Since that date laboratory tests and-particularly important-field tests 7' 9 have demonstrated the validity and practicality of the instruments and techniques. These instruments have also been developed to a stage where they have been released for commercial production. In this form they are very different from those described two years ago and a full description of them at this stage seems to be justified. THE INFORMATION SUPPLIED BY 'DOORSTOPPER' AND TRIAXIAL STRAIN CELLS Both the 'doorstopper' and triaxial strain cells were designed specifically to determine the absolute stress in rock using an overcoring stress relieving technique. They were not designed to measure changes in stress. They may, however, be used for the latter purpose provided the glue which is used to stick the strain gauges to the rock is known to possess sufficiently stable strain-time characteristics as not to affect the accuracy of the results during the time the measurements are made. The 'doorstopper' was designed primarily to measure the major principal stress in situations where its direction and those of the two other principal stresses were either known or could be assumed. For example, at great depth in undisturbed virgin ground, it is reasonable to assume that the maximum principal stress is vertical and that the other two lie in a horizontal plane. The borehole in which the 'doorstopper' is installed would thus be drilled in the horizontal plane parallel to one of the minor principal stresses, the direction of which would either have to be assumed or determined as described later. The stresses measured would be the vertical major principal stress and the principal stress acting in a horizontal plane normal to the borehole axis. It is possible, as will be shown later, to obtained the complete state of stress using 'doorstoppers'. In this event, it is necessary to make measurements in three boreholes drilled in any three known directions to each other and relative to a system of three orthogonal axes. The triaxial strain cell was designed to determine the complete state of stress in a single borehole drilled in any direction in any stress field. At first glance it would appear to supersede the 'doorstopper'. This is not necessarily true since there are

By M. Z. Emad, N. Abbas, Y. Majeed

Room-and-pillar mining is commonly employed for the extraction of rock salt in undergroundmines. Pillar stress is a major concern in these mines as it is directly related to stability and mineralrecovery. In this study a flat jack method was used to measure pillar stresses in three undergroundrock salt mines in Pakistan. The field work included determination of in-situ stress, in-situ elastic modulus, recording of field variables (pillar length and width, height and width of opening, opening width to height ratio, extraction ratio, and overburden height) and collection of salt block samples. The geomechanical properties of rock salt (uniaxial compressive strength, Young’s modulus, Brazilian tensile strength, and density) were also determined to estimate overburden stress, pillar strength, and factor of safety (both estimated and actual). It was found that the measured pillar stresses are proportional to the overburden stress values, with their magnitude ranging from 6.05 MPa to 11.97 Mpa, and the pillars were found to be stable. Regression analysis was performed to develop statistical models for in-situ stress and in-situ elastic modulus. Finally a quick guideline chart was developed to determine the suitable length of pillar for a given span and required level of safety.

Jun 5, 2023

By G. Bezuidenhout, N. C. Steenkamp

Buying centres are the first point of contact that determines whether ore will be considered as having sufficient provenance to be considered ethically sourced. The information that needs to be captured on the blockchain platform ranges from reports on in-loco inspections and audits of mining and purchase sites. This will guide passive and active monitoring of mining activities, trade-offs for identification systems, including biometrics for the registration of artisanal sellers, scrutiny on the selection of security measures and companies for buyer centres and stockpiling warehouses, evaluation of active and passive infrastructure security, and remote monitoring applications. Assistance with selection and training in geochemical testing instruments to determine the grade of ore material or concentrates and sorting, on-the-ground investigations, guidance on monitoring methods from stockpile and packing area along the transport route to the final destination are required.

Jan 1, 2023

On 23rd October, 1969, 54 members of the Institute set out at an early hour from Rand Airport in two chartered Dakota aircraft for a visit to the Hendrik Verwoerd Dam site. The weather was at the start rather unpromising but after passing Bloemfontein the overcast cleared and it turned into a glorious day for a most memorable visit. The Institute is indebted to U.C-Dumez-Borie Dams Limited, the main civil engineering contractors, and Mr J. D. McNamara their executive manager, for the very excellent arrangements made for this excursion. From the time the aircraft landed till a slightly belated departure the organisation of the extensive tours arranged for the parties was quite outstanding and a matter for congratulation to all concerned. At each of the many places visited there was a senior official to give an authoritative and comprehensive description of the work under his control. In addition the guides on the buses, loaned by the Department of Water Affairs, kept up an interesting running commentary throughout the day. A further much appreciated facet was the introduction of many of the experts on the site and a brief talk by each after an excellent lunch served at the recreation club. Each visitor also received a brochure with a progress report and a detailed site plan, with various sections highlighted in colour, and obviously prepared at the cost of much time and effort. The visit included tours of the large dolerite quarry, where some 150 000 tons of rock are removed each month, the 42 in. gyratory primary crusher, the secondary crushing and screening plant, the rod mill plant for sand production, and the automated blending and concrete batching plant. The transport of mixed concrete by 'silobuses' to the 6 cu. yd buckets of four Blondin cableways, two of which are radially movable and two with buffing towers, and the placing of the concrete in the huge blocks of the wall was watched from a vantage point. The most interesting part of the visit was without a doubt the inspection of the wall itself and the explanations of the many intricasies of its design and care in construction, covering aspects such as positioning of galleys, interlocking of blocks, reinforcement, refrigeration, actual concrete placing, subsequent grouting, etc. Other points of interest were the very complicated design of the wall itself, the river diversion plans, with three stages of coffer dams, the spillways, and the very well cut penstock tunnels.

By W. H. Holtzhausen

The purpose of this project was to compare two underground, batch coal haulers ? battery haulers and shuttle cars ? in order to determine the more viable machine to implement. The specific standards for battery haulers were investigated and compared to the requirements of shuttle cars in order to identify the unnecessary expenses related to the legal requirements that are attached to the machines. Costs such as running costs, capital costs, and maintenance costs were researched and compared over a typical life of machine. Average production rates and breakdown times were obtained and used to determine which machine would be more reliable in achieving the required annual production.

Jan 1, 2014

By O. A. Bascur

Ores are becoming extremely variable with mineralogy and hardness disturbing the grinding and flotation circuits. The current grinding and flotation sensors provide large amounts of data for process optimisation. Adding the right context and operational events augments operational knowledge for proactive actions to improve the performance of the grinding and flotation circuits. A data-driven strategy is needed to enable operations, maintenance, and business personnel to quickly and easily take corrective action when abnormal conditions occur. A digital plant template transforms data into operational insights in real-time. It uncovers the hidden, idle and downtime losses. By measuring and managing these unproductive times, people find new ways of avoiding them, improving the profitability of the plant. The information created by the real time analytics enables the calculation of recovery in real time and develops predictive analytics models to find the best operating condition based on the type of ore currently mined. The creation of new workflows and collaboration between mining and concentrator plant and the enterprise, including services providers, are enabled. A grade recovery model is used to identify the best operating conditions in real-time. An optimal Gaudin size distribution shape is used to find the grinding operating conditions that optimise the metal recovery in the rougher sections of the mineral processing plant. Sensors in the flotation circuits enable estimation of metal recovery and determine the optimal froth depth and aeration profiles, using an industrial air holdup flotation model. The implementation of a recovery/grind strategy with industrial examples in non-ferrous metal concentrator is presented in the paper. Keywords: Digital transformation, soft sensors, predictive analytics, grinding flotation optimisation, flotation bubbles, particle size, particle size distribution shape, froth aeration profiles, flotation air hold up model, recovery predictive analytics

Jan 1, 2020

By F. J. N. Bruwer, T. R. Stacey

The research described considers whether the variability in coal material strength, as derived through a series of uniaxial compressive strength (UCS) tests, could be used to indicate the variability in coal pillar strength. The aim is to be able to use a distribution of UCS tests as input into the coal pillar strength calculation. This will allow the pillar design to be expressed in terms of a probability of failure rather than as the commonly used safety factor. To achieve this, the bulk strength factor associated with commonly used pillar strength formulae was replaced with a distribution of UCS results divided by an adjustment factor. The factor was determined so as to ensure that the resulting bulk strength does not deviate from the statistically determined bulk strength published in the original formulae. This approach enabled pillar strength distributions to be obtained using industry-accepted strength formulae, subsequently allowing for a probability of failure to be calculated for a specific pillar design. Using a regional coal material strength curve as a baseline, coalfields in which the coal is stronger than the regional mean can be identified and the pillar designs optimized. This is based on the stronger coals achieving lower probabilities of failure at similar safety factors. The research has considered actual UCS data from multiple mines in the Mpumalanga coalfields of South Africa, and has proved that the variability in material strength between coalfields could allow for some optimization using the proposed approach. Based on the data used in the study, a 2.78% increase in extraction could be achieved. However, further research will be required to validate the results of the study in an underground environment.

May 3, 2023

By S. Kauvosaari, M. Olofsson, O. Haavisto, M. Kosonen, J. Martikainen

The target in grinding circuit operation is usually to maximise the throughput and energy efficiency while keeping the product particle size on an optimal level for downstream operations. Furthermore, feed ore variations in size and hardness need to be compensated in order to stabilise the process. This is a challenging task for any circuit and requires good instrumentation, combined with careful control design. This study investigates the control of a two-stage iron ore grinding circuit with an AG and pebble mill at LKAB Kiruna KA3 concentrator in northern Sweden. A new control approach based on multivariable model predictive control (MPC) is designed, implemented and evaluated for the circuit. Additionally, advanced instrumentation including a volumetric charge measurement for grinding mills is utilised. The MPC control approach starts with step tests that are used to model the effect of manipulated variables (MVs) like feed rate, water addition and primary mill speed on controlled variables (CVs) such as final product particle size, power consumption and volumetric charge of the mills. In the control implementation phase, the models are then utilissed together with current process measurements and known operating limits to predict optimal future changes for the manipulated variables in order to reach the desired process output values. It is shown that the new control approach improves the stability of the circuit and reduces energy consumption. Keywords: Model predictive control, grinding, optimisation

Jan 1, 2020

By X. Xiang, W. Xia, J. Yin

"TiCl4 slurry containing valuable metals is an unavoidable by-product of the titanium ore chlorination process. The recovery of these valuable metals, which include titanium, niobium, tantalum, and aluminum, is an urgent issue to tackle in the titanium industry. The results of this investigation show that the valuable metallic elements can be recovered from the slurry by evaporation in a sealed container and leaching with dilute hydrochloric acid. After evaporation at 200°C for 60 minutes, nearly 99% of the titanium was recovered in the form of TiCl4, which was formed by the reaction of the TiO2 in the slurry with AlCl3. After evaporation, metals like niobium, aluminum, and tantalum remained in the residue. By leaching with 2.1 mol/L HCl at a L/S ratio of 6:1 mL/g at 80°C for 60 minutes, the soluble metals, such as aluminum, iron, and copper were all removed from the residue, and the niobium and tantalum were further enriched in the leach residue. A concentrate containing 53.40 wt% Nb and 5.57 wt% Ta was obtained by washing the leach residue with dilute aqueous ammonia under stirring. A potential waste water purifying agent containing 263.75 g/L AlCl3 was produced by purifying the leaching solution with Al(OH)3 and modified polyacrylamide. IntrodutionTitanium tetrachloride (TiCl4) is an important intermediate in titanium metallurgy that is widely used in the production of titania and titanium sponge (Akhtar, Xiong, and Pratsinis, 1991). In conventional titanium metallurgical processes, high-titanium materials such as synthetic rutile and high-titanium slag are reacted with chlorine to produce TiCl4 in a fluidized-bed furnace. Accompanying elements, such as Al, Nb, and Fe also react with chlorine to form chlorides, which are mixed with gaseous TiCl4 (Anderson, 1917). In the condensation process, gaseous TiCl4 is refrigerated and high-boiling-point chlorides are precipitated in the liquid TiCl4 to form a slurry containing 50~60 wt% TiCl4 (Wang, Xiang, and Wang, 2012).Various methods have been proposed to recover TiCl4 from the slurry, including microwave heating and spray drying (Wang, Xiang, and Wang, 2012, Wang et al., 2010a). To date, the only way to recover the TiCl4 is to return the slurry to the fluidized-bed furnace. However, this causes fluctuations in the temperature in the furnace, resulting in incomplete reaction between titanium-rich materials and chlorine. Therefore, the slurry is often rinsed with water and neutralized by adding lime, which caused serious environmental pollution and wastes a valuable resource (Roy, Bhatt, and Rajagopal, 2003)."

May 1, 2019

By M. Kerr

Background- History The most significant change in mining since the late 1970?s has been the emergence of very large scale mining operations , which have been developed to ensure profitability with relatively low grade ores. These large tonnage operations have resulted in the development of larger unit sized machines in all operations of beneficiation, solid-liquid separation and dewatering. Often only a few flotation lines are installed and tonnages up to 25 ktpd and beyond are not uncommon. The increased throughputs have led to the development of circular, reactor type tank designs. The reactor cell system is the most up to date flotation cell design to utilise the principles of circular cell design. The Svedala DV mechanism was specially developed to suit the RCS machine giving good solids handling characteristics and excellent metallurgical performance. Development of UG2 ore type flotation equipment The equipment was developed and optimised by Svedala process from 1995. A higher energy specification was requested by industry. This amounted to 3kW/m3 for installed volume. Existing designs were at 1.5kW/m3. Hence various modifications were required to achieve the required power input. The first 50m3 machines were installed and developed at Impala Platinum?s UG2 circuit over a one year period. Once reliability and performance was achieved, over 300 large volume flotation cells were installed at Anglo Platinum and Lonmin operations as well. Pilot Plant Development The Impala Platinum High Energy pilot plant was commissioned in 2002 and had an installed power exceeding 5kW/m3. It was operated for over a year at the tailings dam booster station and was fundamental to the large scale scavenging plant design. All experience in overcoming mechanical and operational problems was applied in scale up design principles. A very robust mechanism was designed to accommodate the additional power input from installed motors, as well as the high SG (>1.5) of the feed source. The pilot plant flowsheet is shown in the figure below.

Jan 1, 2007

By K McLeod

{Figure 1} The Placer Dome-Western Areas Joint Venture?s South Deep Twin Shaft Complex, has been planned and dreamt of for nearly 20 years. [ ] The gold reserve at the bottom of these shafts is one of the largest single intact gold deposits remaining in the world today, containing an estimated 57 million ounces. This is about the size of the fictitious reserve created by inventive prospectors for the infamous BREEX scam in Kalimantan about ten years ago and about the size of the reserve Harmony claims as its own in it?s current hostile takeover bid for Gold Fields. So it is certainly of the magnitude that dreams are made of. [ ] {Figure 2} The unique orebody lies in a continuous, highly concentrated, thick deposit, an estimated twelve kilometres along dip and a two kilometre wide strike. Due to the thickness of some sections of the reef, up to 60 metres in places, bulk mining methods will be required for it?s extraction. [ ] {Figure 3} The twin shaft system comprises a main shaft which had an initial design depth of 2765m and a ventilation shaft of 2760m, making them the world?s deepest to be sunk in a single lift. The shafts were

Jan 1, 2005

By A. Chagnes

This paper presents a modelling tool that can be used to predict the behaviour of solvent extraction processes. In particular, this model allows calculating metal extraction efficiency as a function of pH, solvent flowrate, stripping flowrate and aqueous feed flowrate in the mixers-settlers. This model is applied to the recovery of cobalt from acidic chloride media by using CYANEX® 272 as extractant diluted in kerosene. Keywords: Cobalt, mixer-settler, modelling, solvent extraction

Jan 1, 2020

By M. Wrobel, J. Hammerschmidt, M. Runkel

Fluid-bed technology is a key pyrometallurgical step for processing a vast number of ores and concentrates. Over the past 50 years, considerable research and development efforts have been made by Metso Outotec to expand the application window of this technology. This paper illustrates different processing routes where fluid-bed technology plays an important role in the production of the copper. The fluid-bed processes utilized are partial, sulfate-producing, and dead roasting. The focus of this paper considers the advantages of the dead-roasting process. This “zero waste” process can provide copper oxides, steam, electrical power, and sulfuric acid for new and existing solvent extraction–electrowinning plants. In a case where an operation is running out of oxidic ores and concentrates, fluid-bed roasting can be applied to close this gap and provide the required copper oxides in a sustainable way.

Jan 1, 2023

By P. Lenegan, R. Masethe, R. I. L. Ferreira

Underground mining in high rock-stress environments can induce unanticipated dynamic rockmass deformation, posing a serious risk to the workforce. Data collected by seismic networks are imperative for the design-as-you-mine process. Often an inappropriate assessment of the seismic hazard is done when unnecessary data are included in analytical techniques, particularly short-term time frames. Depending on the methodology or application of data analysis and interpretation, some of the information may not be relevant and even detract from the objective. By using the spatial event clusters associated with active workplaces to define the shape and size of the polygons for data selection for subsequent analysis, a problematic subjective component can be eliminated. The mining of tabular reefs in South Africa, be they gold- or platinum group metals, is very extensive, and underground workplaces are often widespread. Production stoppages are very costly, especially for marginal mines, so there is just cause not to evacuate an entire operation’s workforce following the occurrence of a large mining-induced seismic event. A rationale based on the damaging peak particle velocities (PPV) of the past seismicity can exclude the unaffected underground personnel and allow a quick orderly withdrawal where required. Micro-deformation may precede rockbursting, which can occur on-shift close to the workface. A mine-wide array of geophones suitable for the accurate location and analysis of seismicity may not be able to detect these higher-frequency emissions. Inexpensive but fit-for-purpose accelerometers, providing real-time, continuous measurement of acoustic rockmass deformation near the workplace, integrated through underground and surface communications networks, are shown to record ‘rock-talk’, clearly distinguishable from the instrument background noise, which can be in the order of hours leading up to an imminent damaging seismic event.

Jan 12, 2025