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By Sergio Burelli, Darren C. Megaw

"Operational challenges associated with solvent extraction (SX) plants include the effective on-line management of solids introduced from a variety of process streams. Solids are carried over from leaching circuits due to incomplete solid–liquid separation, may be formed as a result of chemical precipitation within the SX circuits, or introduced from downstream electrowinning operations. Solids in SX settlers result in operational challenges that impact plant availability and reduce optimized name-plate design capacity operation. Most available SX crud and bottom solids removal systems are limited in their effectiveness to handle high total suspended solids in SX circuits. Operations are often forced to take settlers off-line for complete removal of contained solids. These cleaning operations are hazardous, high risk, labour-intensive and costly in terms of production down-time and organic extractant and diluent reagent losses. Production pressure results in operations being reluctant to take SX settler units off-line for solids clean-out, resulting in continued operation of the SX, at reduced levels of mass transfer performance. Crud ForxTM is an SX solids removal system, for the on-line removal of interfacial and bottom solids associated with hydrometallurgical SX processes. A case study conducted at Glencore’s Mutanda Mining copper and cobalt operation in the Democratic Republic of Congo demonstrated the effectiveness of the Crud Forx. Benefits identified were an overall improvement in SX fire risk reduction, SX occupational health and safety and an improvement in copper mass transfer. INTRODUCTION Hydrometallurgical copper extraction and purification processes are often associated with ultra-fine solids distribution profiles throughout the process flowsheet (Virnig et al., 1999). The level and impact of the undesired deportment of solids to process streams varies from operation to operation, but the common denominator for all operations that employ solvent extraction (SX) as a copper upgrading and purification step is that, at some stage, they will have to manage solids (crud) within the SX circuit. Available crud removal systems in the industry have had limited success in continuous, effective interfacial crud and bottom solids removal from SX settlers. Most operations use basic removal methodologies which, at best, only result in delaying the requirement for taking the affected SX settler stages off-line for complete clean-out. This operational methodology results in production loss, increased SX organic extractant consumption and adds occupational health and safety risk to SX operations. The integrated Crud ForxTM/Crud FrogzTM SX solids management system assists operations in on-line SX solids management. The system has been proven to significantly reduce the requirement for off-line cleaning of settlers."

Jan 1, 2015

By A. Vien

Over the past several years, Svedala has developed a continuous charge monitor (CCM) for tumbling mills. It consists of a strain gauge embedded into a rubber lifter and associated electronics. This paper describes the results of a research program to evaluate the technical and economical merits of such a device on a SAG mill. The evaluation includes validation through discrete element modelling and comparison to measured static volumetric load. Inclusion of the measurement into a control strategy and its potential for condition monitoring is discussed.

Jan 1, 2001

By D R. Cohen

As one of the four basic sciences, the study of geology is intrinsically worthy as a means of increasing fundamental knowledge of the behaviour and evolution of the universe. Geological knowledge can also be translated into practical outcomes for society such as resource discovery and protection of the environment. Australia has a long tradition of providing very high quality geoscience programs to prepare graduates for a range of occupations. We are, however, reaching a nexus in the way universities should or can deliver engaging programs. This has been triggered by the rapid evolution of the digital world (the Internet of Things), new technologies, unprecedented access to information, better understanding of the processes by which we learn and adapt our thinking, growing complexity in the problems we must face or opportunities to grasp, and university funding models. Designing education programs for the next generation of geologists extends far beyond tinkering with syllabuses. We must develop skills sets that will allow graduates to work in rapidly changing landscapes, but in doing so may have to sacrifice content to build capability in our graduates. Whereas universities must respond to changing demands on graduates by ensuring degree programs contain an appropriate balance of material and high quality of delivery, industry and government must also fulfil their responsibilities to provide additional training programs for graduates to assist their rapid transition into independent professionals. This paper examines various educational issues being considered in developing the new Decadal Plan for the Earth Sciences, and reflects on directions that education is heading in many of our universities.CITATION:Cohen, D R, 2017. Educating the next generation of geologists, in Proceedings Tenth International Mining Geology Conference 2017, pp 3–10 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By Eugene Nel, Johan Theron, Chris Martin, Hans Raabe

"Impala Platinum Limited is the world’s second largest platinum producer, producing more than 1.7 million ounces of the precious metal last year, much of this from the UG-2 reef located in the Bushveld Complex, South Africa. As part of Impala’s ongoing expansion programme, tonnage through their principal UG-2 processing facility, near Rustenburg, was increased 40% in 2001.To accommodate the increased throughput, the role of the existing primary mills was converted from conventional semi-autogenous grinding units, to attrition and selective grinding units, operating in fully autogenous mode. The finer chromite and coarser silicate components in the mill discharge are then separated by screening and processed in dedicated circuits downstream. This way, the need to spend considerable capital to increase primary grinding capacity was averted.In the last year, considerable work has been conducted to evaluate and optimise the two downstream circuits. This has involved an optimisation programme of sampling and diagnostic flotation testing, supported with QemSCAN analysis. This paper will describe the operation of the new circuit. It will also describe some of the more novel aspects and interesting findings from the optimisation programme.INTRODUCTIONThe South African platinum industry is the world’s largest producer of platinum and the world’s second largest producer of palladium. Located in a wide area north of Johannesburg, the industry mines ores from the Bushveld Complex, one of the world’s great mineral treasure chests, containing over 70 percent of the world’s platinum, as well as extensive reserves of the other PGE (platinum group elements), chrome, manganese and vanadium. The industry employs about 180,000 people in, predominantly, underground mines, which together form an almost unbroken circle of mining operations 200 km in diameter."

Jan 1, 2004

By Robert B. Bittner

"AbstractLarge diameter tubular piles offer significant advantages in terms of design performance and economy for major marine structures. This is particularly true for foundations of major overwater bridges in regions of high seismicity such as the west coast of North America. The use of large diameter piles in the range of 2 to 3 m diameter means that fewer piles are required, and the size and mass of the pile caps can be significantly reduced, thereby greatly reducing lateral load demand during seismic events. Another advantage of using larger diameter piles is increased pile stiffness that allows the pile caps to be located at or near the waterline rather than being positioned at or below the mud line. This elevating of the pile cap offers significant cost savings by eliminating the need for deep cofferdams. However, relocation of the pile cap creates new problems and opportunities in regard to the means and methods used to construct the pile cap. With the pile cap at depth, conventional steel sheet pile cofferdams with thick tremie seals are typically used to isolated the cap location and allow dewatering for construction of the cap. However with pile caps positioned up off the bottom, conventional bottom founded cofferdams are no longer cost efficient. Float-in or lift-in cofferdams have been developed to address the need for a more cost efficient method for cap construction. This paper describes the key features of the concept and provides three case history examples of its successful implementation.Pier Construction Using Conventional Sheet-Pile CofferdamsCofferdams are temporary structures used in the construction of bridge piers and other marine structures. Their primary purpose is to hold out water and unstable soil from the construction area, and thereby, allow in-the-dry construction of the permanent structure below the water line and quite often below the mud line. Typically, cofferdams consist of long interlocking steel sheet piles driven through water into the bottom of the waterway. The sheet piles form temporary exterior walls which are typically braced internally with wales and struts. The bottom of the cofferdam is typically sealed with tremie concrete or an impervious clay layer if one exists. The depth at which this type of cofferdam can be used is typically limited by the length of steel sheet pile that can be transported and handled by conventional marine equipment."

Jan 1, 2014

By Heikki Laurila, Sirkka-Liisa Jämsä-Jounela, Jarkko Karesvuori

"Artificial Intelligence includes excellent tools for the control and supervision of industrial processes. Several thousand industrial applications have been reported worldwide. Recently, the designers of the A1 systems have begun to hybridize the intelligent techniques, expert systems, fuzzy logic and neural networks, to enhance the capability of the A1 systems. Expert systems have proved to be ideal candidates especially for the control of mineral processes.As successful case projects, an expert system based on on-line classification of the feed type using neural data analysis is described in this paper. The essential feature of this expert system is the classification of different feed types and their distinct control strategies at the plant. In addition to the classification, the expert system has a database containing information about how to handle the determined feed type. This self-leaming database scans historical process data to suggest the best treatment for the ore type under processing. The system has been tested in the Outokumpu Finnmines Oy, Hitura mine. Other projects have been reported to be in progress.INTRODUCTIONIn the past ten years considerable researches have been done in the application of artificial intelligent methods in process industry. The technologies of fuzzy logic, neural networks and expert systems have received several thousand applications worldwide: monitoring and analysis of process operations, fault diagnosis, supervisory control, feedback control and scheduling and planning of operations. Recently, the designers of these systems have begun to hybridize these intelligent techniques to enhance the current capability of expert system. Complex signal processing, neural networks, fuzzy logic and rule-based systems are also implemented to develop new so-called smart or intelligent sensors, actuators or components. Field buses are playing a more and more important role in automation systems and in imbedded systems. The development of field buses has allowed the distribution of smart components over networks."

Jan 1, 2000

By D. R. Shoemaker, H. W. Judges

A 16.5-kt/d underground molybdenum mine is being developed at Questa in northern New Mexico by Molycorp Inc., a wholly-owned subsidiary of Union Oil Company of California. The new $200-million underground project will revitalize mining and milling activity at Questa, where small scale underground mining first began in 1920. Large scale open-pit mining was initiated in 1965 but now, because of the high stripping ratio, surface mining is being phased out. Construction of the underground mine began in 1979, and first produc¬tion is scheduled for early 1983. The company expects full capacity-9 Gg of molybdenum per year-to be reached in 1984.

Jan 6, 1980

By R. W. Lawrence, J. B. Austin, P. B. Marchant, J. T. Chapman

"Biohydrometallurgy is the use of microbiological reactions to assist in the extraction of metals. Bioleaching offers an innovative alternative for the treatment of refractory gold-bearing sulphides (1). One particular cost advantage of bioleaching is the potential to enhance gold extraction after only partial sulphide oxidation. The apparent selective sulphide oxidation is more prevalent where the refractory gold is associated with arsenic and antimony (2). Oxidation of the pyrite minerals and arsenopyrite at different oxidation rates can result in high gold extractions at relatively low levels of sulphide oxidation due to preferential, or selective, oxidation of the arsenic mineral. Arsenic extraction rates in a bioleach process typically exceed the iron extraction rate. Therefore, in concentrates in which the precious metals are principally associated with arsenic minerals, liberation of the precious metals may be possible with high recoveries and less than complete sulphide oxidation. The capital and operating cost advantages of partial sulphide oxidation are inherently obvious and are briefly illustrated herein.Ultra fine milling (UFM) is another alternative for enhancing gold extraction from refractory sulphides. Some refractory gold is simply particle size sensitive and UFM can improve gold extraction without the need for costly sulphide oxidation (3). Fine grinding technology for enhanced gold recovery developed by Metprotech, South Africa, is currently producing 2 - 4 micron ground product using a single pass, stirred ball mill. Proper application engineering has ensured that plug flow occurs through the mill. Plug flow from the feed inlet at the bottom of the reactor ensures that short circuiting of feed does not occur and as a result, the mill product does not require classification.A combination of UFM as a pretreatment for bioleaching could provide a mechanism for enhanced selective sulphide biooxidation and/or increased overall gold extraction following biooxidation due to improved particle liberation ( 4). The effect of UFM on biooxidation costs will be discussed. Only sulphide concentrates are considered herein for application of UFM in combination with biooxidation."

Jan 1, 1990

By D. Schreuder

Conditions in the South African market relating to atmospheric emission control has changed dramatically over the last 10 years. Companies have become more responsible, environmentally aware, and have to comply to more stringent environmental limits set by legislation. This paper describes briefly the current best available atmospheric pollution abatement technologies relating to particulates, acid gases, NOx, acid mists, aerosols, mercury, dioxins and furans. Mention is also made as to the best practices for product work-up and waste product disposal.

Jan 1, 2006

By Pfeifer H. C, Nicacio P. A D

Sinter has been used as part of the metallic charge in large-scale blast furnaces for many years with the well-known benefits in terms of productivity and fuel consumption. However, because of the high investment in a conventional sinter plant, small blast furnaces and the associated integrated mini steel plants have not taken the advantages of using sinter. Recently KTS Korf Tecnologia Siderurgica, a division of Mannesmann Demag Ltda in Brazil, has developed a mini sinter plant for which the investment is compatible with small blast furnaces. Consequently, it is of great interest to evaluate the economical impact of using sinter in such small-scale integrated steel plants. In order to compare two alternatives, ie 100 per cent ore and 70 per cent sinter in the blast furnace burden, mass and heat balances for the entire operation from sinter plant through the blast furnace and EOF-based melting shop, were performed to evaluate the final production cost of the liquid steel. It was found that, depending on the sinter feed price, substantial savings can be obtained with the use of sinter.

Jan 1, 1999

The Stability Graph Method is widely used in Canadian underground hard rock mines for open stope support design and is frequently used in the mine planning phase to assess the viability of stope geometries and to determine maximum permissible spans. The Method is well accepted due to its simplicity and suitability to a wide range of mining methods requiring the use of sublevels to access and extract the mining blocks. While this Method is reliable in situations where the maximum induced tangential stress creates adequate compressive stress keeping the face in a state of confinement, the Method fails to reflect the effect of low confinement caused by lower compressive stresses and instances where tensile stresses are developed. In this paper, a new Rock Stress Factor, A?, an update to the original Rock Stress Factor, A, is proposed, which will reflect the impact of low confinement or overstress regime on critical face stability. Two case studies, based on two Canadian operating gold mine shows that using the new Rock Stress Factor A? to predict the stability of stope hanging-wall and footwall gives better agreement with the CMS survey results, compared with the prediction using the original rock stress factor.

May 1, 2011

By J. Bongardt

Ecologically acceptable techniques are described for the handling of waste materials from the fabrication industry. New production methods and the recycling of sludges from grinding and other waste materials are suggested.

Jan 1, 1997

By M. A. W. Bryson

Platinum group metals are extracted almost exclusively in South Africa from three very different zones in the Bushveld Igneous Complex, called the Plat, Merensky, and the UG-2 reefs. The Plat reef is currently being exploited only by Anglo American Platinum, whereas the Merensky reef is exploited by them, Impala Platinum, Northam, and Lonplats. The UG-2 reef, on the other hand, is also processed by these producers, but Kroondal and Barplats have operations that exclusively treat ore from this reef. At present the extraction of pgms from ores in South Africa follows the traditional route of upgrading to a concentrate in a minerals processing circuit, further upgrading to a matte in a smelter, and final upgrading and separation of the individual metals in a refinery. Thus all operations that extract pgms require a minerals processing circuit, the design and performance of which is a topic of much interest, as it is a poorly understood and not a very efficient process in relative terms, compared to the other processes. Recoveries across the minerals processing circuit of between 75 and 90% are the norm.

Jan 1, 2004

By K. Mondal

A macroscopic approach integrated with microscopic analyses for wettability characterization is presented. Wetting depends on 1) Contact between the dust and the fluid droplets, 2) Wettability of the particles by the wetting fluid, and 3) Wettability rate (due to low contact times). The goal of this paper is to show that the wetting rate is a significant factor in dust control. Samples from the roof, three different horizons of the coal seam and the floor were pulverized to less than 25 µm. Experiments were conducted with known wetting fluids to correlate surface tension and equilibrium wettability. Further analyses were performed in terms of surface charge (zeta potential), particle size, mineral composition, elemental composition, and quartz content. The surface tension reduction was also achieved by the use of chemicals and/or altering the temperature of the water. Two methods were used to evaluate wettability rates: a) near real-time comparison of wettability rates, and b) comprehensive evaluation of the intrinsic wettability rates. The data obtained provides meaningful insights towards the design of engineering controls for an economical solution to dust control in coal mines.

Jan 1, 2012

Mine ore, reduced to minus 71/2 in. by primary crushers, is stockpiled. Size reduction of the reclaimed material by secondary and tertiary crushers is achieved in a closed circuit crushing and screening plant. Screen products of minus 30 mm plus 6 mm lump, and minus 6 mm fines are stockpiled by conveyor and stacker systems prior to rail despatch 10 port facilities at Dampier. Crusher settings, determined from experience, are closely maintained to obtain the desired lump/fines ratio. Chemical and sizing analyses from automatically taken samples are used to maintain product specifications. The beneficiation plant upgrades the fines product when this is necessary. The recorded wear life of individual plant components is the basis of a planned maintenance programme.

Jan 1, 1970

By B. Law, M. Menabde, B. Baird

Blasor is a new mine planning tool which is being used in the long and medium-term optimization of multi-open-pit operations throughout BHP Billiton’s Base Metals and bulk commodities portfolio. It is not just a scheduler, nor even only a schedule optimizer—although this function lies at the heart of the tool’s functionality—but a pit development plan optimizer, used from ultimate pit design and process plant capacity sizing right through to mining phase design and optimal panel scheduling. The tool uses a mixed-integer-linear-programming optimization engine to determine when material should be excavated and where it should be sent to optimize discounted operating cash flow over the life of operation. The core software design concept of Blasor is to provide a tool which is intuitive and flexible enough so that a competent mine planner can perform a pit development plan optimization without assistance from optimization specialists. To this end, a generalized graphical user interface has been implemented which allows full configuration of the optimization problem, including the definition of all inputs and constraints, specification of the material flow topology, bin and destination class definitions and full specification of the economic model encompassing prices and costs. This paper describes the capability of Blasor and outlines the design concepts underlying its design philosophy.

Jan 1, 2007

By F. Díaz-Fierros, D. Rubinos, M. T. Barral

The present work explores the reutilization of red mud, an industrial waste arising from the production of alumina, as a component of isolation technologies for hazardous substances. The work involved the study and optimisation of the geotechnical properties of red mud in conjunction with adsorption experiments of As(V) and Hg(II). The results from both types of experiments were integrated in a dispersion-diffusion model to calculate migration curves and minimum thickness of the red mud compacted layer. The geotechnical studies showed that compaction increased the stability and decreased the hydraulic conductivity of red mud barrier. Red mud sorbed high amounts of As (up to 44 mmmol kg-1) and Hg (up to 9.2 mmmol kg-1). The calculated minimum thickness of the red mud barrier was 1-10 cm for As and 2-19 cm for Hg, for an operation period of 35 years. The results obtained let to conclude that the reuse of red mud as a component of isolation systems of hazardous substances represents a viable alternative use of this residue.

Jan 1, 2011

By Ivan C. Machado

Jaguar Mining Inc. is implementing a 1.1 Mtpy, 7-year LOM gold project in the Iron Quadrangle (?Quadrilátero Ferrífero?), Brazil. Construction is on schedule and startup is programmed for Q2 2010. Mill feed grade averages 4.43 g/t and LOM gold production is estimated at 800,000 oz. The project entails two sulfide underground mines and three oxide/transition open pit mines. A state-of-the-art flotation/gravity concentration/CIP Plant has been designed based on testwork carried out by internationally recognized Canadian, U.S., and Brazilian laboratories. The mass recovery of the flotation section is only ca 10%, while its gold recovery is about 90%. Therefore, the CIP-ADR Plant will treat only 10% of the solids mass contained in the mill feed, while 90% will be fully cyanide-free material that will be partially used to feed a Backfill Plant. The leached tailings will be conveyed to a rather small tailings dam, whose 20- m3/h supernatant solution will be treated by a new electrolytic technology. The plant design contemplates a High Density Thickener for the cyanide-free rejects exceeding the backfill demand and a Regrinding Section before the Leaching Circuit. The estimated overall metallurgical recovery sits around 92%. This paper focus on the use of modern technologies to reduce costs, risks, and liabilities.

May 1, 2010

By M. Mead, J. Dumouchel, W. Yule, J. Giroux

The QMM mineral sands of South East Madagascar contain approximately 1,900 million tonnes of mineable sand with a total heavy mineral (THM) content of roughly 4.5wt%. The QMM deposits are the world’s largest known reserves of 60% TiO2 ilmenite and also contain a small volume of zircon. The deposits are semi-continuous and homogenous and the mineralized sands are free flowing with minimal overburden, induration & slimes. These characteristics are favourable to dredge mining and allow the application of conventional wet gravity, electrostatic & magnetic separation to final products. A mature THM mineral suite of high valuable heavy minerals (VHM) content has enabled the development of a relatively simple separation process.

Jan 1, 2005

By Denis Labrie

Le minage en profondeur sous contrainte modérée à élevée présente de nombreux défis aux opérateurs et aux ingénieurs de mine notamment au niveau du contrôle de terrain et de l?environnement minier souterrain, pour assurer la sécurité des travailleurs sous terre et la continuité du cycle d?opération. Des conditions de contrainte élevée signifient une pression accrue au front de taille et sur les structures minières tels les piliers de mine et les fins de zone, un risque de rupture violente ou de coup de toit plus élevé, des zones de rupture plus grandes au pourtour des excavations, des charges accrues sur le support de terrain, etc. Le présent article fournit un aperçu du travail fait à l?intérieur du Programme de Contrôle de terrain de CANMET au cours des sept (7) dernières années, entre 1995 et 2001, pour comprendre et suivre l?évolution des niveaux de contrainte à l?intérieur des structures minières. Les propriétés déterminées en laboratoire sur des échantillons rocheux et les prévisions effectuées au moment de la conception sont comparées avec les observations effectuées en chantier à la paroi des excavations et à l?intérieur de la masse rocheuse. La plupart des cas discutés ici montrent une corrélation satisfaisante entre les observations effectuées en chantier d?une part, et les résultats d?essai obtenus en laboratoire et les calculs réalisés lors de la conception d?autre part. Ces observations peuvent donc être considérées comme des moyens relativement sûrs pour vérifier et suivre l?évolution des niveaux de contrainte présents à l?intérieur des structures minières.

May 1, 2002