Search Documents

By Y. Tanaka, H. Miki, Y. Aoki, H. Okamoto, G. P. W. Suyantar, T. Hirajima

Due to environmental limitations and the scarcity of freshwater, flotation using seawater or desalinated seawater as process water becomes more common for mining operations. On the other hand, seawater has been reported to affect the flotation behavior of sulfide minerals. Few reports are available on influence of pyrite depression, recycled seawater and lime consumption on flotation by using seawater. In this study, the flotation tests were performed using ore sample to investigate the effect of pH with seawater and process water used in plant on the flotation behavior in a laboratory-scale flotation cell and a pilot plant-scale. The results of laboratory scale flotation indicated that copper and molybdenum flotation kinetics decreased with increasing pH. Furthermore, the iron (mainly pyrite) recovery decreased with increasing pH. The pilot plant-scale flotation test showed that water with a higher concentration of magnesium and calcium (plant processes water) consumed a higher amount of lime. Because of low lime consumption and high copper and molybdenum recovery and grade, pH 8 is suitable compared with pH 8.5 for flotation. Keywords: seawater, process water, copper-molybdenum rougher flotation, pH, pilot test

Jan 1, 2020

By A. Mainza, I. Govender, Elbasher M. E. Ahmed

A mechanistic description of axial segregation in rotating drum flows remains an open question. Consequently, optimal mixing of grinding balls and rocks for efficient breakage, maximum production of fines, and slurry transport is seldom achieved. Experimental and numerical studies of granular mixtures in rotating drums identify alternating axial bands that eventually coarsen in the long-term limit. Most models of axial segregation are limited to binary mixtures and cannot always predict the logarithmic coarsening effects observed experimentally. A key missing factor is a robust description of the axial free surface profile that is valid across a wide range of flow regimes. We present a practical model of the axial free surface profile by linking it to readily-derived geometric features of the cross-sectional S-shaped free surface profile. A parametric study shows good agreement with experimental measurements reported in the literature and heuristically valid trends.

May 1, 2021

By J. Moema, L. Mampuru, M. Phasha, D. Mkhonto

The global liquified natural gas (LNG) storage market size is projected to reach USD17.5 billion by 2025. Currently, owed to its high toughness, tensile strength, and excellent weldability, the 9% nickel steel is the most used in building infrastructure for cryogenic applications such as the construction of tanks and pipes for storage and transportation of LNG. However, this alloy is not readily available because of its complex production process and high cost. This provides an opportunity for suitable alternative materials to build infrastructure for cryogenic applications. Among strong contenders is the Fe-Mn based alloys, which have sparked global interest due to their desirable properties such as relatively lower density, low cost, high toughness and strength, due to a high manganese (Mn) content. These attractive properties render Fe-Mn based alloys preferred candidates to replace traditional steels in engineering applications in which strengthweight ratio is critical. In response, as a build-up to designing and developing austenitic Fe- Mn alloys, the present study employed density functional theory (DFT) based first-principles computational materials modelling technique to investigate the structural, thermodynamic, and magnetic properties of binary Fe-Mn alloy composition in competing FCC, HCP, and BCC crystal structures. Using this approach, it was possible to unravel the key underlying elastic properties that are directly correlated to experimental tensile strength and high toughness in binary Fe-Mn alloys. Besides successfully validating the existing experimental data, the current predicted properties and the deployed approach will serve as a benchmark from which further alloying required to improve other properties will be conducted.

Mar 4, 2025

By M. P. Brandt, T. P. Knoetze, I. I. M. Kessler

It has generally been accepted that the volatile mater in a coal is the factor that determines whether or not a specific coal dust is an explosion risk. This paper presents the results of an attempt to relate the explosibility index (Kex) of South African coals, as determined in a AD-litre explosion vessel, to the volatile mater content of the coal and the calorific value of the volatiles. A good relationship between the calorific value of the volatiles and the explosibility index was established, which makes it possible to calculate the violence of an explosion, as expressed by Kex, for South African coals. The Kex value is but one of a number of parameters that influence the explosion hazard in a specific colliery and cannot be used as the sole predictor of the propagation of an explosion underground. Other parameters include the ignitability of the coal, temperature, humidity, dispersibility of the dust, methane concentration, amount of incombustibles present, and ventilation.

Jan 1, 1993

By D. V. J. W. Groenewald, T. M. Louw, L. Auret, S. M. Bradshaw, A. V. Cherkaev

Unexpected equipment failures lead to financial losses due to production disruption. Time-based maintenance, based on checks over regular time periods, has been employed to minimise disruption. However, the improvements it can offer are limited as it may lead to unnecessary service of healthy equipment or missed failures occurring between service intervals. Condition-based maintenance (CBM) provides a further improvement to equipment reliability by detecting faults and predicting remaining useful life (RUL) based on equipment health monitoring. Its application in the mineral processing industry is hindered due to the high cost of health monitoring equipment. In this study, two stochastic process models, the adaptive auto-regressive model and the gamma process, are compared in their ability to forecast the degradation state and to provide RUL prediction. The gamma process model was found to be effective in both tasks. Due to its simplicity and minimum hyperparameters requirements, it is proposed to use the gamma process as a baseline for comparison with other models. Keywords: Condition-based maintenance, remaining useful life, slurry pump, adaptive autoregressive mode, gamma process

Jan 1, 2020

By A. J. H. Newell, K. Doherty

A copper-gold project has required a number of trade-off studies underpinned by test work to settle on pragmatic flowsheets and throughputs to support a pre-feasibility study that provides a compelling financial case. The primary trade-off studies were based on the mine schedule, ore type feed-grade recovery relationships, likely concentrate grades and typical marketing terms as well as the estimated capital and operating costs for a range of throughputs and mining strategies. Secondary trade-off studies were conducted for specific circuits and additional processing options. Although the details of these studies are not presented, the technical options and subsequent flowsheets are discussed. While the flowsheets will be optimised during the feasibility study stage, the basis is now fixed for the four ore types that would be mined from the copper-gold orebody. The ore types, resulting from a strong weathering profile, exhibit a wide range of copper mineralisation and gold associations, as well as gangue types. They display a range of characteristics that necessitated a nuanced approach to flowsheet development. The primary separation techniques that have been employed include gravity, classification, flotation and leaching while a range of comminution methods have been selected to suit the properties of the ore types. While technical issues are important factors in terms of maximising the quality of separations, recoveries and revenues, attention to material handling, equipment characteristics, the mine schedule, and capital and operating costs are equally important considerations for settling upon a suitable and robust flowsheet. Keywords: Flowsheet, testwork, studies, saprolite gold, native copper, chalcocite, chalcopyrite

Jan 1, 2020

By L. Makua, K. Langa, Ndlovu. S., C. Saguru

"Global demand for the three platinum group metals (PGMs) Pt, Pd, and Rh has been steadily growing due to their widespread use in emission control, industrial catalysis, and numerous other applications. The primary supply of PGMs is currently the mining industry. However, legislative, operational, and environmental challenges faced by many mining operations result in erratic supply patterns and deficits for these three metals. Naturally, recycling scrap material to recover Pt, Pd, and Rh has therefore aroused research interest in the scientific and engineering communities. Given that the majority of the global demand for these three metals is driven by emission control devices, autocatalytic converters are therefore a significant source of already processed and beneficiated PGMs for recycling.Although pyrometallurgical processes dominate the recycling industry, hydrometallurgical processes may offer certain advantages, chief among these being lower emissions and reduced energy consumption. In this investigation, scrap converter material was leached in acidic chloride media and the leach liquor subjected to solvent extraction and cloud point extraction (CPE) to recover the PGMs. The recoveries for Pt and Pd using Alamine 308® dissolved in kerosene with decanol as a modifier were 95% and 81%, respectively. The maximum recoveries using CPE after complexation with 2-mercaptobenzothiazole (2-MBT) in the presence of Triton X-100 and tin (II) chloride dihydrate as a reductant were 97% for Pd, 96% for Pt, and 91% for Rh. This demonstrates that CPE, although relatively new, may have some potential as a breakthrough PGM recovery technology. IntroductionPlatinum group metals (PGMs) have found a wide variety of applications in different industries due to their chemical, catalytic, and physical properties. PGMs are essential in automobile emission abatement, petroleum refining, and the pharmaceutical and electrical industries (Carabias-Martinez et al., 2000). However, the abundance of PGMs in the Earth’s crust is low and their primary sources are fast depleting (Crundwell et al., 2011).The high demand for PGMs, together with social, economic, environmental, and political aspects related to their production, has led to concerns about their future supply. This has resulted in renewed interest in recycling end-of-life material. PGM supply from recycling has doubled over the last decade, and currently contributes 22% to global supply (Johnson Matthey, 2016). This is in part due to the environmental, social, and operational challenges associated with mining of PGMs. For example, labour unrest, energy cuts, declining commodity prices, and declining ore grades have collectively made the mining landscape economically challenging (KPMG, 2015). On the other hand, the high content of PGMs in secondary sources makes their recovery from the increasing quantities of waste products important from a resource conservation viewpoint. Moreover, PGMs obtained through recycling have been demonstrated to have a 1% environmental cost from a life-cycle perspective, whereas PGMs obtained from mining contribute the remaining 99% of environmental cost (Bossi and Gediga, 2017). Sustainable resource recovery and the economic incentive of recycling have therefore been major drivers to justify investment in PGM recycling. The autocatalytic converter industry accounts for about 70% of the global consumption of these metals (Johnson Matthey, 2016) and therefore recycling spent converters has become a major source of Pt, Pd, and Rh (Figure 1)."

May 1, 2019

By A. Adeli, A. V. Metcalfe, E. Addo, E. Sepulveda

"The accurate modelling of geometallurgical data can significantly improve decision-making and help optimize mining operations. This case study compares models for predicting copper recovery from three indirect test measurements that are typically available, to avoid the cost of direct measurement of recovery. Geometallurgical data from 930 drill core samples, with an average length of 19 m, from an orebody in South America have been analysed. The data includes copper recovery and the results of three other tests: Bond mill index test; resistance to abrasion and breakage index; and semi-autogenous grinding power index test. A genetic algorithm is used to impute missing data at some locations so as to make use of all 930 samples. The distribution of the variables is modelled with D-vine copula and predictions of copper recovery are compared with those from regressions fitted by ordinary least squares and generalized least squares. The D-vine copula model had the least mean absolute error. IntroductionIn this paper we compare the use of D-vine copula, generalized least squares (GLS), and ordinary least squares (OLS) for modelling geometallurgical data from an orebody in South America. The first objective is to construct models for predicting copper recovery (Rec) from the Bond mill index test (BWi); resistance to abrasion and breakage index (A*b); and semi-autogenous grinding (SAG) power index test (Spi). This involves fitting a D-vine copula and regression models fitted by OLS and GLS. The second objective is to investigate the performance of the fitted models for predicting Rec (Willmott and Matsuura 2005).Traditional resource model approaches either ignore the mineral processing characteristics of extracted tonnages or treat processing as an independent component of a mining operation. The net present value (or any other objective) can be truly optimized only by considering the mining operation as an integrated system in which net value is defined as the end-product that the company sells. This approach requires the resource model to be extended to include all relevant rock properties and processing responses."

Mar 1, 2019

By L. Naude, J. Cloete, S. Engelbrecht

The results of an investigation evaluating whether an industrial plant, currently operating using sodium isobutyl xanthate (SIBX) as primary collector for sulphide minerals (mainly chalocopyrite), could adapt to operate using an alternate primary thiol collector without compromising plant and metallurgical performance. Initial laboratory scale flotation tests identified commercial dithiophosphate (DTP)-based and thionocarbamate (TC)-based collectors, that when blended, showed potential to replace the incumbent SIBX primary PGM collector. Industrial plant trail results show that there was no deterioration in recovery of 4E PGMs, even at a lower concentrate grade when operating the plant on the identified (DTP + TC)-based collector blend compared to SIBX. The effect on Cr2O3 content in the final concentrate was also found to be negligible. The (DTP + DTC)-based collector blend also showed promise in terms of plant adaptability in accommodating a new primary specialty collector blend. These observations highlighted the potential of replacing xanthate primary collectors with alternate thiol collector blends for PGM flotation. Keywords: PGM, xanthate replacement, specialty collector, sodium iso-butyl xanthate (SIBX), dithiophosphates (DTP), dithiocarbamates (DTC)

Jan 1, 2020

By H. P. Kritzinger, T. C. Kingsley

Rotary kilns are used for a variety of mineral processing operations. Hatch makes use of a kiln model developed from first principles to evaluate designs for its clients. This tool has been applied to a variety of pyrometallurgical applications. This paper illustrates the application of numerical optimization techniques in combination with the kiln model in the interrogation of a generic iron-ore reduction process. The fundamental modelling concepts are explained, followed by a description of the optimization approach. The results show how the combination of the two methods, with modern computing power, can generate a large number of viable design and operating candidates.

Jan 1, 2014

By A. C. Johnstone

The aim of the study is to determine if pit lakes are a sustainable coal mine closure option in South African. The water balance, chemistry, limnology, and bacterial population of three selected pit lakes were investigated. The lakes are in the three major coal basins of South Africa and are associated with different lithologies and mining methods. The major factors driving the water balance of the pit lakes are direct rainfall, runoff, inflow from old mine workings, and groundwater infiltration, with the major losses being evaporation or discharge onto surface. The study indicated that pit lakes can be designed as ’terminal sinks’ to provide a sustainable mine closure option. The pit lakes sampled have an alkaline pH, and mostly a sodium/calcium sulphate water with total dissolved solids content of less than 3000 mg/l. The phytoplankton and microbiological data indicates that the pit lakes support aquatic life. The study shows that correctly designed pit lakes can be an environmentally sustainable closure option for South Africa’s coal mines. A suggested design manual has been developed to assist mine owners and regulators in developing sustainable coal mine pit lakes as a closure option.

Oct 1, 2021

By D. Weijie, S. Kai, Y. Hu, X. Ning, M. Shiyi, W. Junpeng, Z. Guihong, L. Xianjie

Flotation is one of the most important processes in the copper production industry. The copper grade in the concentrate is a pivotal indicator of the flotation process performance. However, it is difficult to achieve real-time measurement through hardware sensors. Based on the production data provided by an industrial operation, a novel soft sensor based on multi-layer perceptron (MLP) is proposed for effective monitoring of this pivotal indicator. The proposed soft sensor uses the nonnegative garrote (NNG) to perform global variable selection for MLP, while a local search (LS) approach is incorporated to improve the model presented by NNG. Simulation results show that the proposed algorithm has higher prediction accuracy and better model simplicity than other algorithms. Furthermore, the variables selected are consistent with the field experience, and the developed model can provide reference of feedback control for the optimisation of the process. Keywords: Flotation process of copper ore, nonnegative garrote, local search, soft sensor, multi-layer perceptron

Jan 1, 2020

By A. Della Rocca, P. Jonker, B. Henning

Successful prediction of the collection efficiency of cyclone separators is a necessary step in cyclone design and verification. Aside from standard empirical relations, CFD modelling is widely adopted to supplement the design of cyclone units in relation to the desired separation performance. Nevertheless, effective adoption of numerical modelling is sometimes prevented by large modelling errors, especially for small size particles which are more subject to turbulence effects than larger particle classes. In the past, this motivated the adoption of more refined turbulence modelling approaches, such as large-eddy simulations. These approaches provide greater insight into time dependent behaviour, while leading to larger computational cost with respect to more standard approaches. In this paper, an effective Eulerian-Lagrangian Reynolds-averaged Navier-Stokes (RANS) approach is investigated, which is able to predict the complete separation efficiency curve with satisfactory accuracy, without requiring prohibitively long computational times. An assessment of the proposed approach is carried out against experimental data from large laboratory scale cyclones, in the form of mean and fluctuating velocity profiles from LDA measurements (Hoekstra, 2000), as well as with respect to the experimental separation curve (Zhao, 2005). The final application to a full-scale industrial cyclone unit is then carried out with the aim of tuning the cyclone design to the separation efficiency curve as required by downstream processes. Keywords: Cyclones, separation, CFD, RANS, RSM, Lagrangian

Jan 1, 2020

By F. Bornman

Ore quality is declining, and the current spirals in mineral sands extraction is deemed inadequate to efficiently extract the valuable minerals. A new spiral was developed, the 117HM with the aim to extract the total heavy minerals in the order of 4.0% - 6.0% and the economic heavy minerals in the range 1.0% - 2.2% from the feed. An important measurable in the gravity concentration of mineral sands is recovery. Recovery measures how effectively the separator has extracted the valuable mineral contained in the input stream. The number of turns on the spiral trough influences the residence time of the feed slurry. A further optimisation followed with the development of the twelve-turn 117HM spiral. Four more turns were added for better recovery. The paper quantifies the effect of residence time on recovery.

Mar 30, 2026

By R. Altındag, D. Akbay

The point load index is a simple, fast, and inexpensive method for determining rock strength and can be applied both in the field and in the laboratory. There are, however, some disadvantages and limitations to the method, and the test results can be affected by the person carrying out the test, the rock characteristics, or the test device. In this study we describe an investigation into how the point load index value is affected by the shape of the conical platens used in the test. Point load index tests were carried out using different devices fitted with conical platens of different spherical radii, and on a modified device which circumvented the limitations/disadvantages. It was seen that the point load index value increased as the platen radius increased, as expected. In the case of testing using non-standard conical platens, an equation is proposed to normalize the point load index value with respect to the standard spherical radius value.

Nov 1, 2021

By B. Hayen

The principal advantages of fibre optics as compared to copper wire are well known and include almost perfect electromagnetic isolation, light weight, small size, excellent transmission security and substantially better bandwidth/distance performance. The decreasing cost of the optical fibre technology (both fibre cable and equipment) has led to another generation of private networks, which provide much larger bandwidths, very high reliability and an increase of the maximum geographical coverage. The larger bandwidth allows to transport all types of information on a single network. Typical communication requirements are speech (audio), computer data, LAN info, control information, video, etc. OTN or ‘Open Transport Network’ is a transmission system based on the latest available technology in fibre optics. It is characterized by the dual ring approach, resulting in high network availability, and the integration of different types of services in one network. As such, it can fulfil almost all transmission requirements for voice, data, LAN, video and any special service required.

Sep 1, 2001

By D. Pienaar, C. O’Connor, B. McFadzean

Dithiophosphate (DTP) is classically used as a co-collector in sulphide mineral flotation, where xanthate-DTP mixtures have been shown to synergistically improve mineral flotation performance. Notwithstanding the improved recoveries observed, ethyl DTP does not appear to behave as a conventional collector, since it has been shown that it does not adsorb onto certain sulphide mineral surfaces. Recent investigations have nevertheless indicated that when ethyl DTP does not adsorb onto the sulphide mineral surface, the presence of a non-ionic frother can activate a synergistic increase in pulp phase mineral recovery, and bubble-particle attachment probability. A regular solution approach was used to determine the interactions between thiol collectors and non-ionic frothers at the air-water interface. Attractive interactions were observed between longer alkyl chain DTPs and frothers, whereas the activity of xanthates at the air-water interface were too weak to determine if an interaction was occurring. This is the first time that such interactions have been shown for the DTP-frother system and represents an important contribution to our understanding of the role of DTP reagents in the flotation process. Keywords: Collector-frother interaction, dithiophosphate, surfactant synergism

Jan 1, 2020

By W. T. Ruhmer

Slimes-dam construction in the gold mines of the Anglo American Group by w. T. RUHMER. Pr.Eng.. B.Sc. Eng. (Met.) (Fellow) Current practices generally in accordance with the principles of design and operation of slimes dams within the Gold Mining Division of the Anglo American Corporation are described. Although many of the details given are either obvious or have been amply dealt with elsewhere, these have been included for the sake of completeness. The selection of suitable ground for the deposition of slimes, the initial design and construction of a slimes dam, and its consequent operation are presented in logical sequence. Emphasis is placed on the code of practice for the construction of slimes dams issued by the Chamber of Mines of South Africa, and draft regulations (Water Act of 1956) dealing with pollution. Operating costs are included, and possible future trends are discussed.

Jan 2, 1974

By T. Nghipulile, M. Moys, M. Bwalya, H. Simonsen

The quest for efficiency in comminution is an ongoing concern as comminution usually constitutes a major cost component in the metal production industry. Such improvements can be made by circuit optimization or development of more efficient equipment. A novel crusher, known as the rotary offset crusher (ROC), promises to deliver in this space. The ROC was invented in 2002 by Michael Hunt, Henry Simonsen, and Ian Sinclair, but failed to garner enough support to progress to production. The original design concept was recently rekindled, and a laboratory version of the crusher has been built and commissioned at the University of the Witwatersrand. The crusher is simple in design, with two cylindrical discs that are parallel to each other, and, as the name implies, there is an offset between the vertical axes of the discs. The top disc has a conical section on its lower face, and this creates a crushing zone between the opposite faces of the two spinning discs. Centrifugal motion transports particles through the crushing zone. Batch experiments have been conducted with quartz at various crusher settings (discs offset, rotational speed, and vertical exit gap) for various feed size distributions. The indications so far suggest that the disc speed is a key factor affecting the performance. Size reduction ratios as high as 11 were recorded from experiments with quartz at a speed of 830 r/min.

Jan 1, 2021

By D. N. Golenkov, N. I. Lomaka, A. V. Kozub, T. V. Ignatova, E. V. Shelepov, D. O. Sharkovskiy, A. V. Chanturiya, R. I. Ismagilov

The modern Russian iron ore mining industry is faced with multiple challenges from everincreasing requirements of steel-making, the value of iron ore concentrates, depletion of high-grade ore reserves and complications of the mining and geologic environment’s necessity to process low-grade ores with complex material composition and low valuable mineral content; with finely disseminated aggregates of metal and non-metal minerals responding similarly to processing. The upgrade of the existing operations’ fine wet screening was implemented by Metalloinvest; as well as the design of a process flowsheet for concentration oxide ferruginous quartzites with low concentrating ability. The scientific basis for improvement of low grade ore concentrating efficiency and the upgrade of market product quality is supported by an in-depth study of ore characteristics, application of high performance equipment for separation of fine-grained mineral aggregates and use of depressor selective to ferruginous minerals in the flotation process. The benefits of wet fine screening have been proven by industrial scale tests; as well as the feasibility of significant upgrades in product quality which have been confirmed as a result of the tests. A road-map for the upgrade of an existing process for the concentration of unoxidised ferruginous quartzites deposited in the Mikhailovskoye ore field was developed, based on the industrial scale test of a fine screening process. With reference to the ability for concentration, three major ore types oxidised ferruginous quartzites were defined as a result of comprehensive geological mapping and process sampling: oxidised ferruginous quartzites with good concentrating ability: over Fe67% grade of concentrate with ca. 80% iron recovery; oxidised ferruginous quartzites with moderate concentrating ability: Fe65-67% grade of concentrate with 70-72% iron recovery oxidised ferruginous quartzites with low concentrating ability: below Fe60% grade of concentrate (cannot be processed into desired grade market product). A process flow diagram combining magnetic separation and flotation has been designed and recommended for implementation based on the in-depth research of defined Mikhailovskoye deposit iron oxide types, including grain size, chemistry, petrographic, mineralogy, hematite and magnetite grain size distribution and liberation analysis.

Jan 1, 2020