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By Gerhard Nel, Huziel Masiiwa, Marthie Kotze, René du Preez, Simon Donegan

Tati Nickel is currently operating a hydrometallurgical demonstration plant in Botswana, using the Activox® process developed by LionOre Technology, to produce nickel cathode and a cobalt salt from a sulphide concentrate. Cobalt is extracted using Cyanex 272. This reagent also extracts all the iron, aluminium, copper, zinc, and manganese from the nickel stream. Versatic 10 carboxylic acid is then used as extractant to recover nickel from the stream, separating it from calcium and magnesium, and upgrading it to provide a suitable advance electrolyte for nickel electrowinning. However, the selectivity of Versatic 10 for nickel over calcium is limited, and gypsum formation in the extraction circuit is a problem when it is attempted to maximise the recovery of nickel. Mintek has developed a synergistic system with Versatic 10 for improved separation of nickel from calcium and magnesium. Laboratory test work was conducted on the raffinate of the cobalt solvent extraction circuit to optimise the Versatic 10/Nicksyn? (Mintek synergist) system to be employed. Extraction and stripping parameters suitable for this stream were optimised in the laboratory and then applied on the demonstration plant. A commercial batch (0.5 tons) of Nicksyn? reagent was produced for the demonstration plant. The laboratory test work results and the demonstration plant performance are discussed in detail in this paper.

Jan 1, 2007

By M. Okada

Consumption of refined copper in Asia, especially in China and India, has soared, and the copper price is at its historic height. New smelters and refineries have been built in the region with state-of-the-art technology to meet the unprecedented demands. Supply of copper concentrate, on the other hand, has fallen short of the growing demand for concentrate by the smelters and refineries with expanded production capacities. The shortage of copper concentrate is attributable to the delay in the mining development, caused by the prolonged price slump of before 2005. The mismatch between supply of concentrate and smelting and refining capacities may cause disorderly movement of copper price, and hamper the sound development of the industry. The recent high copper price may prompt substitution with alternate materials. With electrical and thermal conductivity and workability, copper is one of the most customer-friendly materials. It is regrettable for both customers and suppliers if the high copper price would become an impediment to promoting copper use. Some outdated and environmentally unfriendly facilities still operate. In view of recent lower-grade copper concentrate with higher sulfur content, these facilities must reform their equipment to environmental-responsive one. The current level of per capita consumption of refined copper in Asia shows that the demand of copper will further grow. It is necessary to realize stable supply of refined copper and stable copper price, to help developing countries including China and India to economically take off. Hence, it is essential that the development of the copper industry be accompanied by environmentally friendly facilities, and harmoniously increased capacities between mining and smelting and refining.

Jan 1, 2007

By D Henderson, K Howie

In 2005, Glass Earth Limited (GEL) commissioned two large area detailed airborne geophysical programmes in the Taupo Volcanic Zone (TVZ). In the first survey Bell Geospace Ltd of Scotland conducted an Air-FTG« (airborne Full Tensor Gravity Gradiometry) survey covering 2338km2 at 300m line spacing. The second survey by UTS Geophysics, Australia included detailed airborne magnetic, radiometric and digital terrain data capture covering 5341km2 at 150m line spacing.   From the detailed geophysical data collected it is possible to identify major deeply penetrative crustal structures within the TVZ, as well as define subsurface geological features, such as intrusive bodies and alteration zones. These major deep crustal structures are thought to have a controlling influence on the distribution of epithermal gold mineralising systems, and along the corridors defined by these deep crustal zones, the chances of discovery of an economic epithermal gold discovery are greatly increased.   In this paper GEL gives some examples of the application of its integrated data driven approach to exploration in the TVZ at both regional and project scale. The paper focuses on how GEL identifies regional scale highly prospective deep crustal structures. Then, using the Horohoro epithermal gold system as an example, we show how GEL applies innovative geological and geophysical data processing to model and understand detailed subsurface geology, focusing subsequent exploration to ensure the best opportunity for a new economic epithermal gold discovery.

Jan 1, 2007

By R. Matusewicz

The key drivers for the copper smelting industry are a complex mix of economic and "human" factors which combine to drive technology in new directions and can provide a strong indication of future industry trends. Recent examples have been the drive to achieve increased scale of production and resultant cost efficiencies by using a single furnace high intensity smelting vessel, and the broad acceptance of Top Submerged Lancing (TSL) technology for this duty. The development and adoption of continuous converting processes to counter the increased pressures faced by the Peirce Smith converting process is another example of the need for innovation. This paper discusses the merits of the continuous converting process, describes how the Ausmelt TSL batch converting process has been adapted to the new Ausmelt Continuous Copper Converting (C3) process in response to these industry trends and examines the Ausmelt continuous converting flowsheet options available to the end user.

Jan 1, 2007

By M. Behrouz

Thermal power plants convert thermal energy due to nuclear reactions or the combustion of coal, gas, heavy oil, or some other hydrocarbon to electrical energy. They consist of a variety of equipment, such as boilers, turbines, generators, cooling towers, and auxiliary equipment. Any factor that affects the equipment efficiency affects the overall efficiency. Analysis of the cooling tower and raw water using the Langlier Saturation and Ryznar Stability Indices showed that the cooling water at Sarchesmeh was slightly scaling with respect to silica. Cold lime softening was found to be a cost-effective method to produce cooling water with adequate properties to reduce the cooling water make up from 85 to 70 m3/h and blow down rate from 35 to 20 m3/h.

Jan 1, 2007

By G. Kordosky

The experience of one plant regarding degradation of copper solvent extraction reagents in the presence of 20 to 30 g/1 nitrate in the leach solution was described at Cobre 2003. However, little information is available about the degradation of copper solvent extraction reagents where the nitrate concentration of leach solution is much lower. Analysis of plant organic samples taken from an operating copper SX plant over a long period of time shows that small amounts of nitrate in the leach liquor can be a significant contributor to reagent degradation provided certain other conditions are present. These conditions are discussed and cautionary suggestions on copper SX plant operations in the presence of even low levels of nitrate in the pregnant leach are made based on industry experience with copper solvent extraction plants and copper solvent extraction reagents.

Jan 1, 2007

By Geoffrey Berry

Exposure?response relationships between the relative risk of lung cancer and quantitative measures of exposure to asbestos are available from a number of epidemiological studies. Meta-analyses of these relationships have been published by Lash et al. (1997) [Lash, T.L., Crouch, E.A.C., Green, L.C., 1997. A meta-analysis of the relation between cumulative exposure to asbestos and relative risk of lung cancer. Occup. Environ. Med. 54, 254?263] and Hodgson and Darnton (2000) [Hodgson, J.T., Darnton, A., 2000. The quantitative risks of mesothelioma and lung cancer in relation to asbestos exposure. Ann. Occup. Hyg. 44, 565?601]. In this paper, the risks derived in these meta-analyses have been compared. Lash et al., concentrated on process and found that the risk of lung cancer increased as the asbestos is refined by processing. Hodgson and Darnton concentrated on fibre type and found that the risk was highest for exposure to amphibole asbestos (crocidolite and amosite), lowest for chrysotile and intermediate for mixed exposure. Some of the differences between the conclusions from the two meta-analyses are a consequence of the choice of studies included. The range of asbestos types included in the studies in the analysis of Hodgson and Darnton was wider than that in Lash et al., enabling differences between fibre types to be analyzed more readily. There are situations where occupational exposure to chrysotile asbestos has shown no detectable increase in risk of lung cancer. Taconite miners have shown no increased risk of mortality due to lung cancer. © 2007 Elsevier Inc. All rights reserved. Keywords: Mesothelioma; Amosite; Grunerite; Taconite; Crocidolite; Tremolite; Anthophyllite; Winchite; Risk assessment; Etiology

Jan 1, 2007

By J Col, D La Rosa, W Valery, A Jankovic

Metso Minerals Process Technology Asia-Pacific and South America (MMPT) has been working with operations around the world to increase their efficiency through æMine-to-MillÆ or Process Integration and Optimisation (PIO) projects. These projects have delivered significant improvements in mine efficiency, mill throughput and reduced operating costs at mines around the world. The MMPT methodology involves rock characterisation, site auditing, data collection, modelling/simulation and implementation of integrated operating and control strategies on site. This results in significant benefits to the operations û for example, 5 to 20 per cent increases in concentrator throughput have been measured. MMPTÆs rock characterisation utilises simple and inexpensive measurements that can be performed by trained site personnel. The advantage of these measurements is that a large amount of data can be collected in a very short timeframe, as the samples do not require shipping to an outside laboratory. Typically, a PIO project starts with a site visit to perform blasting and process audits, collect high quality data including measurements of run-of-mine fragmentation and survey data around all crushing and grinding circuits. These measurements are combined with rock characterisation and the definition of strength and structure domains to model the complete production chain. Site-specific models of the blast fragmentation, crushing, grinding and flotation processes can then be developed. This proven methodology has applications ranging from greenfield projects to long-standing operations with AG/SAG or conventional grinding circuits. Process improvements can be higher mining productivity, higher mill throughput, decreased overall operating costs and higher flotation or leach recovery. This paper discusses a recent application of PIO conducted at a large open pit operation in South America and emphasises the potential that every operation has to ædo more with what they haveÆ.

Jan 1, 2007

By J. Scalise

The paper covers a wide range of topics relative to filtration for continuous cast copper and aluminum. Subjects include system concepts, filtration concepts, system components, filter types, filter media selection, caster water filtration, coolant disposal, and recommended materials of construction.

Jan 1, 2007

By S. Ngidi

Palabora Mining Company operates a low grade underground copper mine situated in the Limpopo Province, South Africa. Full production was first reached in May 2005 after a successful transition from an open pit operation to an underground block cave operation. The operation faces a number of technical and operational challenges, not the least being fragmentation of a competent rock mass and external dilution. The cave is subdivided into three main sectors being the east, the west and the central sectors. Caving was initiated from the weaker central sector, which has the majority of its drawpoints located directly under the open pit bottom currently filled with about 130 million tons of waste material from the pit wall failure incurred in 2004. About 48% of the ore reserve has to be extracted from the western sector, which has a much courser fragmentation compared to the other two sectors and only 25% from the central sector with the finest fragmentation. The main constraint during the ramp-up stage has been secondary breaking of drawpoint blockages. Ground-breaking secondary breaking and cave management initiatives and practices have made it possible for Palabora to realize and sustain high production rates.

Jan 1, 2007

By A. Warczok

Smelting slags contain payable metals in a dissolved form and as mechanically entrained matte or metallic inclusions in the size range from 2 to 1000 µm. Slag cleaning requires reduction of magnetite and metal oxides and sedimentation of inclusions. Slag cleaning in an electric furnace is carried out in batch or semi-continuous mode. The strong trend for continuous slag cleaning generates the basic question about the optimal geometry of the electric furnace. Results of combined CFD, potential distribution and heat transfer modeling allowed for the determination of the fluid flow pattern and the temperature distribution in a classical, circular electric furnace as well as in a rectangular furnace. For the rectangular furnace, various length/width ratios and position of electrodes have been simulated. Analysis of key phenomena pointed out the advantages of the rectangular electric furnace over the circular furnace, particularly for continuous slag cleaning. Phenomena that have been analyzed were mass transfer, the rate of slag reduction, coalescence and settling of inclusions, all on the basis of the calculated slag flow pattern and the temperature distribution.

Jan 1, 2007

By F. Habashi

In the period 1970-1995, a number of hydro metallurgical processes to treat copper concentrates to overcome the pollution problem due to S02 emission in smelters were developed. Pilot and commercial scale plants were built and operated for some time, but eventually all were abandoned a few years later. It is constructive to examine why these processes were abandoned after so much expenditure of funds and effort, so that errors should not be repeated in the future and lessons from the past are learned.

Jan 1, 2007

By T. Phiri, Antoine Floribert Mulaba-Bafubiandi

Microwave energy has been recently used in minerals processing to speed up the leaching process or to improve the liberation of targeted minerals (Al-Harahshed and Kingman, (2003); Bradshaw et al., (2001)). Applied to the roasting of sulphide minerals, microwaves allow the ?tunning? of calcine types and products quality in addition to the energy savings as opposed to the conventional roasting (Mulaba, 2006). As more than 85% of world zinc is produced through the ?roast-leach-electrowin? route, an attempt was made to optimize cost, energy and product quality for metal extraction process route. The use of microwaves was the alternative process route selected for the optimisation. Pyrite concentrate (0.17% Zn, 0.09% Cu, 35.71% Fe, 43.76% S) and sphalerite concentrate containing 43.81% Zn, 0.37% Cu, 3.86% Fe and 44.39% S were microwave roasted in a multimode cavity of 2.45 GHz with varying power levels and for different durations. The produced calcines were characterized using AAS, XRF, XRD and Mossbauer spectroscopy while the determination of residual Sulphur was used as products quality control tool to ascertain the degree of roasting achieved on the feed. The leachability of the produced calcines in HCl, HNO3, H2SO4 and HNO3 + HCl has been studied in terms of the best leaching yield, process kinetics economics and environmental aspect. With 800 W power for 30 minutes, ZnO and Fe2O3 were formed corresponding to a 70% sulfur removed from sphalerite and 80% from pyrite concentrates respectively. While the roasting of the above concentrates appeared to be a first degree processes, it was noticed that the microwave assisted roasting of sphalerite and pyrite concentrates yielded lower sample surface temperature for a shorter time (i.e.less than 30 minutes) microwave exposition. Longer time (more than 30 minutes) microwave exposure showed a linear increase in temperature in function of power level used. While optimum roasting conditions were found at 800W, 30 minutes, a 10% increase of sulfur removal was noticed while pyrite concentrate was microwave roasted. Sulfuric acid was seen to give higher leaching yield than nitric acid. Zinc dissolution was hindered by the presence of franklinite.

Jan 1, 2007

By I. Mazalov, G. Ospanova

Introduction Today, uranium is of great interest because of its application to nuclear power and nuclear weapons. Kazakhstan has been an important source of uranium for more than fifty years. All uranium products are exported. Results In Kazakhstan uranium exploration started in 1948 and developed in several parts of the country thru mining of hard rock deposits. There are known around 50 uranium deposits in six provinces: Shu-Sarysuyskaya (57%), North Kazakhstan (18%), Syrdaryinskaya (15%), Ilyiskaya (7%), Caspian (2%), Balkhash (1%). In the Northern Kazakhstan province, KazSabton took over Tselinny Mining & Chemical Co in 1999. In this province the stockwork is of Paleozoic and Paleozoic folded complexes origin. In the Balkash province some mining of volcanogenic deposits occurred during the Soviet era. This province’s stockwork is of Endogenous origin.In the Ili province uraniumis mainly found in uranium-coal deposits formed by oxidation of the lignite beds roofs. In the Caspian province the Prikaspisky Combine operated since the 1960s a major mining and processing complex on the Mangyshalk Peninsula. This led to the founding of Aktau. It was privatised as Kaskor in 1992 and operations ceased in 1994. The uranium occurrence is associated with the phosphorous from fossil fish bone detritus conglomeration. In the Chu-Sarysu province, which has more than half the country's known resources, both Stepnoye and Tsentralnoye have been operating since 1978 and 1982 respectively. Uranium mineralization occurred in the regional stratum oxidation zones. In the Syrdarya province slightly to the west of the province’s center the No.6 Mining group has been operating since 1985. Uranium mineralization occurred in the regional stratum oxidation zones.

Jan 1, 2007

The aspect ratio (mill diameter/mill length) of autogenous and semi autogenous mills varies widely and can be as high as three or as low as 0.5. The literature on the subject of what effect aspect ratio has on grinding mill performance or energy efficiency is almost non-existent. However, at the design stage of many grinding circuits the subject is often vigorously debated amongst metallurgists. In this paper the performance characteristics of mills with different aspect ratios are examined to determine whether process performance characteristics are a function of aspect ratio and whether high aspect ratio mills are any more or less energy efficient than low aspect ratio units. Data from both pilot and full-scale mills are used for this purpose in open and closed circuit configurations.

Jan 1, 2007

By P K. Banerjee, S Kumar

Indian iron ores with less than 62 per cent Fe are currently unexploited, except for a few sectors which export them to foreign countries. It is anticipated that by 2012 the countryÆs domestic steel production is likely to rise to the tune of 60 million tonnes per annum. To meet this requirement, it is necessary to utilise not only the existing high-grade deposits but it is also necessary to look into exploiting the leftover iron ores of lower grades. Hence, reserves with Fe content 62 per cent and below (particularly the ores with In the present paper, an attempt has been made to beneficiate three different types of low-grade iron ores selected from three different parts (states) of the country. In the paper, alternative routes for beneficiation and effective utilisation have been tested using different techniques in the laboratory in an attempt to match their (Al2O3/SiO2) ratio after thorough characterisation and liberation studies. The paper also encompasses the geological formations, occurrences and distribution of Indian iron ores as well as highlighting the problems associated with the fines, possible metallurgical routes, and their market segregation from the perspective of end users.

Jan 1, 2007

By W. M. Jansen

In many mineral processing operations, the reported production figures for an accounting period may not make the best use of available data. While most of the mathematical approaches, such as check-in/check-out, mass balancing, used in effective metallurgical accounting strategies are well understood, the sources and magnitude of measurement errors generally are not. As part of the 'AMIRA P754-Metal Accounting and Reconciliation' project, a study was undertaken at the Northparkes copper/gold concentrator near Parkes, New South Wales to examine the data used in their concentrator metallurgical accounting system. This paper summarises the results of a detailed examination of the mass measurement systems around the concentrator as well as the primary sampling system used for grade estimation. The goal of this work was to develop practical techniques to quantify the error (ie both accuracy and precision) of the measured metal accounting information. With this information, statistical confidence levels for this data can then be calculated. If the errors are small, the effect of error in each piece of measured data can then be propagated to other calculated production figures such as recovery and feed grade using a statistical technique called `the propagation of error'.

Jan 1, 2007

By P. Anciaux

The EUs? manufacturing and construction industries are vital to Europe?s economy. They rely heavily on a steady supply of materials which meet appropriate quality criteria and are available at a competitive price. The steadily rising global demand for (non-energy) raw materials due to increasing consumption in upcoming economies such as China, India and Brazil, is in some cases leading to rapid price increases, but also supply disruptions which affect the European industry chain. These considerations are at the basis of new policy initiatives that are being prepared by Enterprise and Industry Directorate-General in relation to the competitiveness of the European metals industry. Over the last year the raw materials supply issue has increasingly become the topic of de-bate among various stakeholders. In July 2006 the European Economic and Social Committee adopted an opinion on risks and problems associated with the supply of raw materials to European industry. It is therefore important to identify and analyse the future needs for European industry, the possible constraints and impacts on its competitiveness. The raw materials supply issue should also be looked at from the view-point of the EU extractive industry, which plays an important role in supplying raw materials to the downstream industries and which faces very specific challenges. Within the Enterprise and Industry Directorate-General the different factors that influence the competitiveness of the non-energy extractive industry are being assessed, in order to help identify policies and actions which could contribute to and enhance the competitiveness of the industry.

Jan 1, 2007

By Dan Martz, Bill Moler, David Young, Wally Chen, Matthew Crow, Steve Norris, Tolga Togan

Two 610 m (2000 ft) long tunnels were driven through water bearing silts, sands and clays beneath the Sacramento River using a 4.59 m (15.1 ft) diameter Earth Pressure Balance Tunnel Boring Machine (EPBM). Four sheet pile shored shafts were sunk with and without dewatering. The pre-cast concrete segmentally lined and grouted tunnels were driven down at 6% grades beneath the river flood protection levees, buildings, roads, a railroad and adjacent to a Freeway Viaduct. Details of the schedule, cost, shaft construction, TBM, tunnel construction, and installation methodology for the twin1.676 m (66 in) steel force main pipes and environmental constraints are provided.

Jan 1, 2007

By Sverre Olsen, Kai Tang

The composition of ferromanganese slag is very important as it determines the slag/metal equilibrium relations including MnO content of final slag, melting relations and slag viscosity. The slag composition is further expected to influence the process temperature. The properties of ferromanganese slags are suitably described by its basicity and A/S mass ratios. The influence of slag basicity has been discussed in the previous papers. The present paper will discuss the effect of Al2O3 on melting relations, viscosity and MnO-content of final slag. This discussion will be based on assessed thermochemical databases and a recently developed viscosity model.

Jan 1, 2007