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By X. W. Pan

It has been found that the MnO content of a slag decreases sharply when direct current is applied to a 1T1£tal-Slagsystem consisting of liquid Mn-Si-Ccsat metals and MnO-SiO2-CaO-AI203 slag in graphite crucibles. This paper reports a preliminary investigation into the electrochemical effects of direct current on the metal-slag system, the silicon content of the metals, and the MnO content of the slag. The results show that, when a direct current of 7 A is maintained, the MnO content of a metal containing 10 to 11 per cent silicon by weight is reduced rapidly from 26,5 to 17,2 per cent by weight. This reduction seems to proceed further when the process is continued. When the direct current and the voltage are kept constant at TA and 4 V respectively, the MnO content of a metal containing 1 to 2 per cent silicon by weight is reduced to 1 from 25 per cent by weight, which results in a manganese yield of 96 per cent.

Jan 1, 1995

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 S. Erçayhan, B. Derin, O. Yücel

In the present study, the production of low carbon ferrochromium (LC-FeCr) from chromite concentrates containing 55.09% Cr2O3 and 13.06% Fe via metallothermic process was investigated. For this aim, in the experiments, the aluminothermic reduction method was applied in an open crucible. 10% CrO3 + 10% NaClO3, 15% CrO3 + 5% NaClO3 and 20% CrO3 by weight of concentrate were added to the charge, respectively and the charge was reduced with aluminium. The experiments were done with the additions of 90, 100, 110, 120 and 130% of stoichiometric requirement of aluminium. The highest Cr content in alloys was found as 71.7% at 120% of stoichiometric Al whereas the highest Cr recovery in alloys was found as 71.8% at 130% of stoichiometric Al when the both charge contained 15% CrO3 + 5% NaClO3 by weight of chromite concentrate.

Jan 1, 2004

By I. R. Firth, D. L. Taylor

Metal mining operations, in particular gold mining operations, use intensive ore control procedures in order to manage the extraction of ore zones from benches containing both ore and waste material. Typical grade control procedures rely on blast hole samples to indicate ore grade. Statistical techniques and geological controls are then used to create two-dimensional polygons, which indicate zones of material designated as ore. These ore-polygons are calculated using pre-blast material locations and are generally not corrected for rock movement caused by blasting. This lack of correction appears to exacerbate the material mischaracterization problem of sending ore to the waste dump and/or waste to the mill. One Nevada gold mining company has estimated that this could be a $10 million per year problem for their operations. Using a simplified vector field algorithm, a method of taking point movement data and interpolating post-blast positions for all nodes in a polygon has been developed. Currently working in 2-dimentions (X-Y), this algorithm utilizes the movement vectors calculated from pre-and post-blast positions of targets placed in a blast, to generate a spatial transformation function for any point on the bench. This transformation is then applied to the nodes of the ore-polygons to produce modified dig lines ore polygons reflecting distortion and movement resulting from the blast. The method as implemented uses common mine planning routines and is performed using the Surpac software suite. The method may be adapted to use any pre-and post-blast point movement data available, and most mine planning suites include the simple interpolation algorithms used. Keywords: Blast movement; Ore control; Open pit blasting; Grade control

Jan 1, 2003

By J. M. Descour, K. Aoki, S. Shirasagi

This paper describes the tunnel seismic reflective survey, which has been developed by the authors in order to detect the geological condition ahead of the tunnel face three-dimensionally using reflected seismic waves. In addition, the applicability and the accuracy of the result of this system has been validated by comparing with the geological observation results at the tunnel face and the result of the drill logging system, which was conducted simultaneously with this survey in order to predict the rock properties using the data acquired during drilling from the tunnel face by rotary percussion drilling. In dieser Arbeit werden Reflektionsseismische Tunneluntersuchtungen beschrieben, die von den Autoren entwickelt wurde, um die geologischen Eigenschaften am Tunnelstirnende dreidimensional an Hand reflektierter seismischer Wellen bei minimaler Unterbrechung der Arbeit zu untersuchen. Darüber hinaus wurde die Anwendbarkeit und Genauigkeit der mit diesem System erhaltenen Ergebnisse durch Vergleiche mit den Ergebnissen geologischer Beobachtungen am Tunnelstirnende sowie den Ergebnissen des Bohrlogsystems bewiesen. Das letztgenannte System wurde gleichzeitig mit dem hier genannten System eingesetzt, um die Gesteinseigenschaften mit Hilfe der Daten vorherzusagen, die beim Bohren von Probelöchern im Tunnelstirnende mit einer Drehschlagbohrmaschine erhalten wurden. Cet article décrit une méthode de prospection sismique de tunnel, développée par les auteurs, pour déterminer en 3 dimensions les conditions géologiques existant derrière le front de taille, au moyen d’étude et de mesure des ondes sismiques réfléchies dans le sous sol, et ce, avec un minimum d’arrêt des travaux d’excavation. En outre, l'applicabilité et l'exactitude des résultats de ce système ont été vérifiées, en comparant les résultats des observations géologiques effectuées au front de taille, avec ceux du log de forage qui a été effectué parallèlement à ce système, en vue de prévoir les propriétés de la roche, grâce aux données collectées au cours du forage d’un trou de sonde depuis le front de taille à l’aide d’une foreuse rotative à percussion.

Jan 1, 2003

By K. I. Afewu

A modified approach to the implementation of Gy?s sampling theory is discussed and used to design a procedure for sampling crushed gold ore feed to metallurgical process plants. The approach involves calibration of certain ore-specific parameters. These parameters were calibrated for two different crushed gold ores en route to grinding mills in process plants. The model predictions were compared with the predictions from Gy?s original model. Far smaller masses of samples are required by the modified model than by Gy?s model at the same relative variance. The representativeness of the sampling procedure if normally distributed errors are assumed was also calculated. These procedures and evaluations lead to significant savings on cost of handling and preparation of the samples and to a quantifiable degree of confidence in the analytical results for the process plant.

Jan 1, 1998

By P. Lundman, L. Rosengren, T. Brandshaug

Tunnel 99’, the Swedish National Road Administration´s (SNRA) general technical specification for road tunnels requires that the load bearing system must be designed to withstand specified design explosion loads. This paper presents the results of an SNRA study to provide a perspective of design analyses tailored to comply with the new requirement. The paper provides an example of a design analysis for assumed tunnel conditions using a numerical model. Dynamic predictions of potential damage to the rock mass and ground support system (rock bolts and shotcrete) from the specified explosion loads are presented including the nonlinear response of the shotcrete. “Tunnel 99”, qui fixe les règles de l’Administration nationale suédoise des Routes (Vägverket) concernant la conception et la construction des tunnels routiers, requiert entre autres que la structure porteuse soit capable de résister à certaines contraintes spécifiques résultant d’explosions. Cette étude présente les résultats d’une étude effectuée par Vägverket en vue d’obtenir une perspective d’analyses de conception spécialement élaborées pour se conformer aux nouvelles règles. Il contient un exemple d’analyse en fonction de conditions déterminées, basée sur un modèle numérique. Des prévisions de’études dynamiques de dommages potentiels subis par la masse rocheuse et les systèmes de soutènement (boulons d’ancrage et béton projeté) du fait des contraintes libérées par la force d’explosion spécifiée sont également présentées, y compris dans le cas d’une réaction non linéaire du revêtement en béton. “Tunnel 99” - die Vorschriften für Strassentunnel der Nationalen Schwedischen Behörde für Straßenwesen - (Vägverket) - fordern vom Tragsystem eine Auslegung in der Form, dass es spezifischen Explosionsbelastungen standhält. Dieser Artikel präsentiert die Ergebnisse einer Studie der Behörde, um einen Ausblick über konstruktive Auslegungen zu geben, die geeignet sind, die neuen Vorschriften zu erfüllen. Der Artikel zeigt ein Beispiel einer konstruktive Auslegung für eine angenommene Tunnelsituation mit Hilfe eines numerischen Modells. Voraussagen unter Beachtung der vollständigen dynamischen Berechnung zu potentiellen Schädigungen des Gebirges und des Ausbaus (Anker und Spritzbetonauskleidung) durch die spezifizierten Explosionsbelastungen, einschließlich des nichtlinearen Verhaltens der Spritzbetonauskleidung, werden gezeigt.

Jan 1, 2003

By B. J. Vorster

AngloGold South Africa region currently consists of twelve gold plants. These plants use a combined total of $20 million of cyanide per annum. Of this, the major portion (60%) is consumed at two Ergo dump retreatment plants. Historically the primary motivation for cyanide control at Ergo has been one of leach/cost optimization. However, more recently, with the increased public awareness of cyanide in the environment, a secondary but increasingly important motivation for control has been to ensure that only the minimum amount of cyanide is added to the process whilst not compromising leach performance. Following a brief overview of the Ergo process, the methodology in determining the amount of cyanide to be added is described. The paper then traces the developments in cyanide control from very basic manual systems to the current automated control system. In line with the increasingly sophisticated control systems, developments also took place in regards to the method of cyanide analysis. The development of these analysers is also discussed. Whilst cyanide is one of the major drivers, if not the major driver of gold dissolution, it cannot be viewed in isolation particularly with respect to the relationship between cyanide and oxygen as ascertained from the Elsner?s well-known equation. Consequently, in order to control cyanide addition, knowledge of the relative cyanide/oxygen profiles is necessary. Various means investigated at Ergo for pulp oxygenation have therefore been included for the sake of completeness. Finally a comparison is made of the control achieved from the current system compared to the original manual system. The knowledge and experience gained at Ergo is now being used to draw up guidelines for the installation and optimization work at the other AngloGold plants. The net effect of this will be reduced cyanide consumption for the region, which also, apart from the obvious economic benefit, translates into a reduced environ-mental risk.

Jan 1, 2001

Existing processes for the recovery of platinum group metals (PGM) from UG-2 ores place stringent requirements with regard to chromite content upon feed material to the plant. An alternative hydrometallurgical process for which this is not an issue is proposed that involves reductive roasting of the ore followed by leaching with HCl/chlorine, ion exchange, and recovery of PGM from the ion exchange eluate by reduction. Problems associated with leaching of PGM are discussed and results of laboratory testwork for each of the process steps are given.

Jan 1, 2004

By J. Rajala

The Kupol mill facility processed a high grade free milling gold/silver ore containing 28.2 g/t Au, 324.8 g/t Ag and approximately 0.5% pyrite during 2008 operation. Gold predominantly occurs a selectrum in the ore and silver is predominantly present in the forms of acanthite, stephanite, pyrargyrite and proustite. Mill start-up was in mid-May 2008 and the mill reached the design throughput of 3 000 tpd in October. The ore was ground to approximately 70%?53 microns. A Knelson Concentrator recovered 9.8% gold and 0.5% silver. The gravity tails reported to a cyanidation circuit that has 14 hours pretreatment and 116 hours leaching. The slurry from cyanidation was then processed by counter current decantation (CCD) thickening to wash and separate the leach residue from the pregnant leach solution. Precious metals are recovered fromthe pregnant solution using the Merrill-Crowe process. The washed CCD leach residue slurry is treated with calcium hypochlorite to destroy cyanide and then sent to the tailings impoundment. Leaching is performed with a new technology called ?CELP? (CANMET Enhanced Leach Process). The Kupol mill overall gold and silver recoveries for 2008 were 95.4% and 85.6% respectively, which were 2.8% and 7.5% higher than targets. Gold and silver extractions in the leach circuit were 94.2% and 84.5% respectively. Leach profiles indicated that gold extraction reached a plateau in the 4th tank while minor silver dissolution occurred in the 5th tank. With the CCD circuit included, total gold and silver extractions increased to 95.4% and 86.6%, respectively. Optimization of the leaching strategy made it possible to reduce sodium cyanide concentration to as low as 410 ppm without compromising precious metals extractions. Silver was effectively leached from the refractory silver minerals because CELP produced more oxidized mineral surface relative to the conventional cyanidation leached mineral surfaces. The average cyanide consumption for 2008 was 1.3 kg/t. The new leaching technology proved to be very robust and performed efficiently even with changes in feed grade and ore mineralogy. Laboratory experiments produced results that were indicative of plant performance. The robustness of the technology and the laboratory test work contributed to the success of the Kupol mill start-up.

Jan 1, 2009

The Modified Zincex® Process, developed by Técnicas Reunidas, is highly flexible dealing with a wide range of pregnant leach solutions. No matter if those solutions are produced from primary or secondary raw materials, and/or are based on conventional leaching, pressure leaching, heap leaching or bio leaching the result is always high-purity zinc product. The zinc solvent extraction unit within the process is a very effective barrier for impurities and a buffer for the composition of the pregnant liquor. This unit achieves an extremely pure aqueous extract that can be converted into different final products. All of them are characterized by fulfilling the highest purity standards. Also, there is the possibility to adapt the global process to a wide range of pregnant liquor compositions and various production capacities up to a zinc production limit over 150 000 t/a with a single solvent extraction plant.

Jan 1, 2002

By S. Marsland

Reference materials have always been important for validating and controlling analytical methods. They have recently become even more important as quality requirements have become more stringent and customer demands for properly verified and controlled results increase. Clients, especially from the resource exploration industry, demand critical validation of all results reported. Mintek has been producing geological and semi-processed ore references since the early 1970s and recently, due to increase in demand, other manufactures have entered the South African market. This paper describes analytical challenges from the customers? perspective, the customers being metallurgists, mine geologists, environmental scientists and geologists from resource companies. Reference materials with their appropriate use and a good understanding, can aid greatly in building confidence in the results, choosing the right laboratory for a project, deciding which set of results is correct and providing evidence to the customers? clients that the best possible results have been obtained

Jan 1, 2007

By S. A. Scott

Mintek developed the MinataurTM leach-solvent extraction-precipitation technology as a cost effective, easily operated alternative to conventional gold refining processes. The technology was first commercialized at the Harmony Gold Refinery in 1997 to produce 99.99 per cent gold product and has subsequently led to development of various value-addition steps including the casting of various investment bars, gold wire drawing and gold potassium cyanide powder production. In addition to refining gold to high purity, if an appreciable amount of silver is present in the feed material it is also refined to 99.99 per cent purity. The major advantage that the Minataur? technology has over other gold refining processes is the relatively low gold lock-up and reduced operating costs. The operating cost1as at April 2001 for the expanded Harmony refinery (24-ton per annum gold production) was approximately half that of conventional smelting and toll refining. The extractant employed for solvent extraction is relatively cheap and highly selective for gold, making the technology attractive in situations where significant quantities of platinum group metals or base metals are present.

Jan 1, 2004

By E. Wolmarans

Dowding, Reynard and Associates Mineral Projects (DRAMP) was approached by the ARM/Lion Ore JV during July 2006 to conduct a feasibility study and control budget estimate for a new greenfield project for their NKOMATI Nickel mine 45 km east of Machadadorp. The scope included the evaluation and review of previous studies as well as a techno-economic trade-off on four possible comminution circuits ranging from conventional crushing and ball milling to fully autogenous milling. The following document encapsulates the thought process, decisions and the references used in selecting the final comminution route for the new 375 ktpm MMZ concentrator. Apart from the pilot test work performed, design simulations from a number of sources, performance results from a recently commissioned 100 ktpm MMZ concentrator, together with an understanding of the geology and mineralogy of the orebody and possible variations in the characteristics of the orebody over the life of mine were assessed. The results from all the above-mentioned work indicated that it would be possible to treat the MMZ ore at the desired throughputs to the desired grind sizes in a fully autogenous grinding (ABC-type) circuit. Autogenous milling is generally considered to be one of the higher risk milling circuits. This is mainly due to the fact that the ore, which is utilized as the grinding media, could be variable in terms of hardness and mineralogy/geology. Nevertheless, it is a very popular route as the cost benefits, more specifically the operating cost, are normally very attractive. This is especially the case when large low grade orebodies are evaluated. In North/South America, autogenous and semi-autogenous grinding circuits have been successfully employed during the past 20 years on large scale low grade operations. Taking all the above factors into account, the DRA/Nkomati project team recommended an autogenous circuit with the option to add steel to both the primary and secondary mills (if required) for the new operation in order to create the opportunity for significant operating cost savings. One has to bear in mind that all the new design simulations and decisions are based on previous work and potential unknown variations within the orebody will never be fully understood until the pit is operational for some time.

Jan 1, 2009

By Kurt R. P Petersen

This paper discusses the current approaches to modelling the DMS cyclone within the De Beers group. Current efforts are split into short term value-adding process understanding and longer term semi-fundamental analysis of separation mechanisms. To date, the basic applied approach has yielded significant value to the group, enabling operators to focus on simple diagnostic measures to control their process. The more involved modelling approach has given rise to a new understanding of the separation field, in particular that the high density gradients within a cyclone are highly localised, indicating that separation of medium to heavy density material takes place low in the cone. The model has proven to be conceptually robust, but still requires further development and validation to become a complete modelling and simulation tool for De Beers.

Jan 1, 2006

By M. A. W. Bryson

It is well documented that a significant amount of the new PGM (Platinum Group Minerals) production that is coming on stream now, and over the next few years, is to come from the UG-2 reef. Clearly the reservations, or perhaps the perceived reservations, attached to the processing of this ore are no longer there. What were the metallurgical issues that delayed the exploitation of the PGM values from this reef? Traditional furnaces treating Merensky concentrates were not able to accept the concentrate produced from a UG-2 plant due to the relatively high chromite content of this product. The chromite reports to an insoluble spinel phase that accretes in the furnace, resulting in the necessity to shutdown and dig the furnace out periodically. This was clearly not an attractive economic option, so producers stayed away from it in the early days. The Merensky ore had all higher base metal credits anyway, and you needed them to get a matte fall, so there was no driving force to look seriously at the UG-2 reef. Platinum demand at this time could be easily met from the Merensky ore, so the motivation to tackle more complex ores was not there. The low price of PGMs meant that these operations were not particularly profitable and there was little effort directed at improving the operations. Concentrators were generally not run very efficiently and the emphasis was on cost reduction through increasing milling rates.

Jan 1, 2004

By H. Ozturk

In this paper, the computer program ‘SHAFT’ developed for estimation of support requirements for circular mine shafts is introduced. Theory of support design is based on the analytical solutions of circular excavations under non-hydrostatic loading (Detourney and St. John1), and Lame’s thick-wall cylinder theory (Timoshenko6). For rock mass strength property determination Hoek-Brown failure criterion (Hoek et al.2) is used. Mainly two types of support, concrete and steel are taken into consideration as a support member. Program is written in Quick Basic language. Input parameters of the program are shaft radius, number of zones having the same properties along the shaft depth, and depth, unit weight, horizontal to vertical stress ratio, GSI, and uniaxial compressive strength of intact rock of each zone, and compressive strength and safety factor of support member. Output of the program is the graphical representation of shaft with the required support member and thickness throughout the depth of the shaft.

Jan 1, 2003

By M. S. M. Aljuhani

In this paper, one of the human factors that affect productivity in an underground gold mine in Saudi Arabia was investigated and analysed for the purpose of improving productivity. The human factor that was investigated is labour utilization and labour productivity. In the selected mine, labourer?s performances were measured carefully. It was found that in this mine, workers spend only 65% of the shift time in a productive work, and they spend 35% of the shift time in non-productive activities. As a result, recommendations were presented to enhance productivity in the selected underground gold mine by enhancing labour utilization.

Jan 1, 2002

By M. Tangstad, H. Brun, P. Calvert, A. G. Lindseth

In 1999, Eramet bought the ferromanganese plants in Porsgrunn and Sauda (Norway) and Marietta (USA). With an ownership in the Comilog mine, the plants will operate with a high amount of Comilog ore. The properties of Comilog ore are reviewed and compared to a number of industrial operations. Important ore properties are chemical and mineralogical analyses, CO reactivity and mechanical strength. The advantage of Comilog ore is its contribution to lower energy and coke consumption. However, special precautions must be taken regarding the amount of fines and water introduced in the furnace, as Comilog ore is more porous compared to other Mn ores.

Jan 1, 2004

By Deon van Tonder, Bert Van Hege

Comparison of various technologies for uranium recovery from sulphuric acid leach solutions shows that Resin-in-Pulp (RIP) and/or Solvent extraction (SX) based processing routes are usually cost effective (11). A combined RIP-SX recovery-purification route and a CCD-SX recovery-purification route were investigated and optimised. The design basis used for the investigation was a production rate of 200 kg/h U3O8 over a solution concentration range of 40 to 1500 mg/L U3O8. The OPEX for the RIP-SX processing route was found to be sensitive to the variation in uranium concentration in the leach liquor. One of the main drivers for this trend is the leach acid concentration. Conversely, the CAPEX of the CCD-SX processing route was sensitive to the uranium concentration in the leach liquor. The leach acid concentration only affected the OPEX of the CCD-SX processing route modestly, as the bulk of the acid is recovered in a pre-leach circuit. Contrary to expectation, the effect of extractant loss assumptions on the overall processing route economics was found to be modest to insignificant. It should be noted that the CCD-SX processing route OPEX was more sensitive to extractant loss assumptions than the RIP-SX processing route OPEX. Economic optimum wash ratios were determined for the CCD-SX processing route and increased with leach concentration ? the increase in wash ratio was less than proportional. A 5-stage CCD configuration was found optimal over the concentration range investigated.

Jan 1, 2007