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By B. Kweto, W. Legodi, C. van Buuren, R. F. Sandenbergh

Biooxidation, and especially the BIOX® process, is a viable, economical and environmentally attractive process to liberate gold hosted in refractory sulfides by oxidatively leaching the sulfides as soluble sulfates. The moderate to high cyanide consumption during the subsequent cyanidiation of the washed biooxidation residue is probably caused by the retention on the solids of labile sulfur species formed during the multi-electron oxidation process of sulfide to sulfate. In this work the nature and mode of transport of the cyanicides in the products from the mesophile BIOX® process, as well as that of the combined mesophile and thermophile bioxidation process, were considered and strategies to reduce cyanide consumption evaluated. It was found that labile sulfur species were the major cyanide consumers in the mesophile biooxidation product, forming predominantly thiocyanate during cyanidation. The transfer of labile sulfur species was only marginally decreased by more intensive and thorough washing of the biooxidation products with warm and hot water, intense stirring and warm caustic leaching. A major reduction in cyanide consumption was however achieved by using a combined mesophile and thermophile biooxidation process. Keywords: Biooxidation, refractory sulfide gold ores, cyanide consumption

Jan 1, 2020

By Neal Harries

The monitoring of rock slopes is a common procedure in the management of hazards associated with slope instability. Slope stability radar has become widely accepted as the state-of-the-art method for management of hazards associated with unstable slopes in open pit mines. This is confirmed by the rapid adoption of the technology since inception in mid 2003, with over 70 GroundProbe slope stability radars now in use at open pit operations throughout the World. The use of a monitoring system such as slope radar to identify slope hazards is only part of the solution to minimise the consequences associated with slope instability. The presence of the hazard must also be effectively communicated to the mine personnel, so that the correct response to the hazard can be enacted, and the risk mitigated to an acceptable level. In some surface mines, due to the geotechnical characteristics of the rock mass, hazards can develop rapidly; with slopes progressing from stability to ultimate collapse in just hours. In these situations, it is vital that efficient systems are developed to evacuate the area of the pit affected. Such a system has been developed by GroundProbe in South Africa, with the vital driving force for the project being provided by the Anglo Platinum Mogalakwena mine operation based at Mokopane. The mine based development of the system was perceived as an essential aspect in the development of the successful system. From an early stage, the mine provided essential input on both hardware and software developments to allow the system to be rapidly integrated into the mining operation. This paper describes the pit evacuation alarm system that was developed and discussed the benefits obtained from a mine based development program.

Jan 1, 2008

By Peter N. Calder, Alan Bauer

The complexity of modem open pit load-haul-dump systems is described, and the need for realistic working models is pointed out. Both standard and probabilistic simulation procedures are discussed, probabilistic simulation being indicated as the more powerful and practical technique. Acquisition of the necessary pit operating data required for simulator construction and general modelling procedures are described. Finally, results from a typical open pit simulator are used to indicate the scope of the technique.

Jan 1, 2014

By L. Lorig

"Two types of extreme event, earthquakes and rainfall, potentially affect open pit slope stability. In the case of earthquakes, there are rather well-developed analysis procedures and acceptability criteria. The analysis procedures relate mainly to selection of the dynamic loading either through design earthquakes and/or pseudo-static seismic coefficients. The acceptance criteria are typically expressed in terms of a minimum safety factor in pseudo-static analyses. The acceptance criteria are often promulgated by governments despite the fact that no open pit slope has ever been adversely affected by an earthquake. This paper explains why open pit slopes are seemingly more resistant to dynamic loads than natural landforms, which can experience catastrophic landslides.Extreme rainfall events are much more likely to cause open pit slope problems than earthquakes. Two types of problem are common – slope erosion and slope instability. Slope erosion is often mitigated by appropriate surface water controls. Slope instability due to elevated transient water pressures is more difficult to mitigate. Analysis procedures and acceptability criteria are rare. This paper will discuss the mechanisms for rainfall-induced slope instability, as well as analysis methods. Examples will be discussed and analysis methods are proposed. IntroductionTwo types of extreme event, earthquakes and rainfall, potentially affect open pit slope stability. In the case of earthquakes, there are rather well-developed analysis procedures and acceptability criteria. The analysis procedures relate mainly to selection of the dynamic loading either through design earthquakes and/or pseudo-static seismic coefficients. The acceptance criteria are typically expressed in terms of a minimum safety factor in pseudostatic analyses. The acceptance criteria are often promulgated by governments (e.g., Peru, Chile) despite the fact that no open pit slope has ever been adversely affected by an earthquake. This paper explains why open pit slopes are seemingly more resistant to dynamic loads than natural landforms, which can experience catastrophic landslides.Extreme rainfall events are much more likely to cause open pit slope problems when compared to earthquakes. Two types of problems are common – slope erosion and slope instability. Slope erosion is often mitigated by appropriate surface water controls. Slope instability due to elevated transient water pressures is more difficult to mitigate. Analysis procedures and acceptability criteria are rare, but do exist. In Peru, for example, slopes are required by law to be designed for a 100-year storm."

Jan 1, 2016

By Kym L. Morton

Ground water and associated pore pressure represent elements which can have a negative impact on surface mining and slope stability. Ground water flow and deformation within a slope influence each other. An increase in pore pressure will result in a decrease of effective stress; and conversely if the pore pressure decreases, the effective stress increases. Slope analysis and slope design calculations require good information on pore pressure distribution around an open pit excavation. Until recently very little pore pressure data was available and assumptions had to be used. Location and design of measuring points depend on geological and structural setting, geotechnical domains and practicality. Good planning and the use of sensitive point piezometers to measure in situ pore pressures means that real-time data can be collected and used for the construction of flow nets, the determination of pore pressure distribution around an open pit mine, the validation of the dewatering/depressurization requirements, the calculation of the efficiency of the dewatering system and finally the use of pore pressure data in slope stability analysis. The recommended layout for a monitoring system, types and design of piezometers, data collection and use of the pore pressure data are presented.

Jan 1, 2008

By M. Arnesen

Mining professionals recognize the need to continuously evaluate and refine mine planning standards and scheduling. We must examine our current reality, and evaluate the following: •How well do our planning standards represent the actual mining process? •To what extent do they support the requirements of the downstream mining activities? •How we apply them to operational management and control? In most operations, mine-planning standards are global averages. Little differentiation is madein quantifying key planning variables. Often standards used in the long-term, are applied to the short-term, and the standards and scheduling precedents are only reviewed occasionally. Mine-planning standards applied to production schedules are often only focused on the management of functional mining performance, and play no role in managing the requirements of down stream processing. Many mining operations are characterized by high levels of fluctuation, and typically incorporate a wide range of factors and adjustments to compensate for deviations from performance targets, in mining operations as well as for the other business areas. The reason for using global averages is because of a lack of understanding of the causes of deviations that occur through the process, and the impact that they may have on the performance of the business as a whole. Average standards and factors are often used to quantify the variability in a system. From these average values, measurement standards and performance targets are derived for the planning and execution environments. During the execution of a plan/schedule there will be deviation in actual performance and the planned ‘average’ standards. In reality the ‘average’ conditions seldom occur and the impact of variability and interdependency are seldom constant or predictable. The predictability of variability and interdependency is further complicated by the fact that mining conditions have a role to play in the actual production performance, and they too are variable. By developing the throughput knowledge of our production systems, we can better understand the nature of variability and the interdependency within the systems as well as the impact of interdependency between the links in our production chains. With this knowledge, planning standards and scheduling precedents can be better defined and sensibly differentiated. This will improve planning and management of ore utilization, mining production and the effectiveness of processing. As a result the business will be more stable and predictable and business performance will be improved. The purpose of this paper is to describe: •At a high level, the scope for refining and differentiation in mine planning standards, and incorporating geological and plant parameters into mine scheduling. This will improve planning and scheduling and the overall performance of the mine. Given our current level of scientific knowledge and the technological tools at our disposal we should be able to plan and schedule production so that we can manage pro-actively and improve business performance. In doing so we can also improve reconciliation and value tracking through mining and processing •The flexibility and functionality of the XPAC planning and scheduling tool that will enable a throughput management approach.

Jan 1, 2003

The Barrick North Mara Mine and the Advanced Systems Group at SGS Minerals collaborated on the implementation of a grinding expert system for the control and optimisation of a single semi autogenous (SAG) mill. Over the last 5 years, grinding expert control has gained wide acceptance by mineral processors. In this paper, two key factors for success are highlighted: the adaptability of the software tools and the interaction with site personnel. Created with SGS?s MET expert console (MEC) toolkit, and running on Gensym?s G2 real time inference software, the North Mara expert logic has been set up to keep a steady and on spec leaching feed slurry while striving to maximize throughput. Leach feed stability was achieved by standardizing operating practices across shifts; a result of successful collaboration with site personnel in developing a consistent control strategy. The strategy maintains the SAG load and power draw in an optimised range by manipulating SAG feed rates and inlet water flow. The project life-cycle was slightly longer than average due to site specific constraints. One of these was the high turnover rate of site?s workforce during the project, coupled with the availability of key staff on site due to the fly in fly out work roster. These constraints called for different, and innovative ways of project commissioning and hand-over. This paper describes details of the control solution, its implementation as well as results and conclusions.

Jan 1, 2009

By J. E. Quintanilha de Menezes, L. Ribeiro e Sousa, I. Ferreira

The Paradela dam has a spillway that makes it possible to discharge a maximum flow of 400 m3/s, the water discharges being on the river Sela, about 2km upstream the river Cávado. After the first use of the spillway, some landslides have occurred on the right bank of the river Sela as a result of the erosion generated on its base about one hundred meters near some houses of a small village. This paper presents a study performed for the slope stability where finite element results are taken into account. A monitoring program was established that essentially consisted of measuring sub-horizontal displacements in points located in boreholes at different depths and also phreatic levels. Some monitoring results are presented. Le barrage de Paradela a une décharge d’eau avec un débit maximal de 400 m3/s sur le fleuve Sela dans un endroit situé environ 2km sur l'amont du fleuve Cávado. Après la première utilisation de cette décharge, quelques glissements se sont vérifiés sur le versant droit du fleuve Sela résultant de l’érosion générée sur sa base dans une zone à 100 mètres de quelques maisons d’un petit village. Ce travail présente une étude réalisée concernant la stabilité du versant avec la considération des résultats des éléments finis. Un programme d’auscultation a été mis en place pour mesurer les déplacements sub-horizontales sur des points situés en forages à des différentes profondeurs. Quelques résultats de cette monitorization sont présentés. Der Ueberlauf des Padela Dammes ermoeglicht das Ablassen einer max. Wassermenge on 400 m3/s in den Sela Fluss, ca. 2 km flussaufwaerts des Cávado Flusses. Nach Inbetriebnahme des Ueberlaufes traten in ca. hundert Meter Entfernung zur Wohnbebauung eine Dorfes Erdrutschungen am rechten Ufer des Sela Flusses auf, die auf Erosionen am Flussbett zurückzuführen waren. In der vorliegenden Studie wurde die Boeschungsstabilitaet unter Beruecksichtigung von Berechnungsergebnissen der Finiten Element Methode untersucht. Es wurde ein essprogramm ausgearbeiten, das im Wesentlichen auf Messungen der Untergrundverformungen in verschiedenen Bohrlochteufen sowie auf Grundwassermessungen beruht. Im Folgenden sind einige Messergebnisse dargestellt.

Jan 1, 2003

By K. Premlall, R. M. Dire, H. Bissett, D. Delport

Tungsten carbide is a fine grey powder. It can be formed into shapes by compacting with the addition of a binder. Spherical particles are generally preferred in additive manufacturing as they pack together more efficiently than non-spherical particles, promoting a uniform powder bed density, better flowability, and elimination of internal cavities and fractures, resulting in a better quality of final product. The particle shape of powders can be transformed into spherical through the process of spheroidization. However, due to its high melting point, tungsten carbide could be difficult to spheroidize. Tungsten carbide was spheroidized using an inductively coupled radio frequency plasma at various plate powers between 9 and 15 kW. The influence of additional H2 in the sheath gas on the chemical composition of the tungsten carbide product was also investigated by means of XRD, which indicated that WC is converted to W2C at higher H2 concentrations. Optical analysis of SEM micrographs indicated that the spheroidization ratio increased with increased plasma energy.

Apr 1, 2021

By D Olivier

De Beers' Finsch Mine is situated in the Northern Cape province, 170 km northwest of Kimberley. The concentrator facility, designed and constructed by Bateman Engineering, was commissioned in 1967 and upgraded in 1979 using diamond liberation and extraction technology available at the time of design. Since then significant advances in diamond processing and technology have been made and these -have been incorporated into the new main treatment plant and recovery plant flowsheets, making diamond liberation and recovery from the Pre-1979 dumps a viable economic option at Finsch."

Jan 1, 2010

By R. C. Nkhoma, K. A. Annan, S. Ngomane

The effects of welding current, electrode force, and welding time in a resistance spot weld were studied to investigate the effectiveness of welded joints between a thin EN10130: DC04 material and a thicker 817M40 part, through analysis of the microstructural and mechanical properties. All welded specimens were subjected to tensile testing at room temperature (25°C) and sub-zero temperature (–46°C) to test the strength of the welded joints. No full button failure was observed at either room temperature or sub-zero temperature after optimization of the weldng parameters. The fusion zone was observed to consist mainly of martensitic phase, due to rapid quenching, while the HAZ was composed of clusters of martensite in a ferrite and bainite matrix. The base 817M40 metal remained fully ferritic after welding. The hardness was found to increase with increasing welding current. An increase in nugget size, indicating good fusion of the weld, was observed with an increase in the welding current.

Oct 1, 2021

By O. S. L. Bruinsma, M. J. Matsela, D. J. van der Westhuizen

The free ligand (FL) model is an intuitive model to calculate the equilibrium concentrations in solvent extraction (SX) based on the distribution coefficient (Kd) at infinite dilution and the fraction of free ligand available for extraction. In this work, the FL model is validated to account for co-extraction of Ni and for designing the extraction and scrubbing sections of Co/Ni separation in a base metal refinery. Cyanex 272 is employed as a selective Co extractant in the process to yield high purity Ni. To enhance the loading capacity of the extractant, 50 mol% of NaOH is pre-loaded into it. Experimental and FL modelling results show that four equilibrium stages are required to purify the 99% Ni feed to a 99.97% Ni raffinate. The 53.59% co-extract with 26.76% free ligand is purified with a reflux scrub of 30 g Co/L in one equilibrium stage to 99.01%, Co in the scrubbed extract. The FL model as well as the Co/Ni/Na-analysis of the aqueous phase confirm that in the scrubbing section, Ni in the extract is mainly replaced by Co. Finally, in the one stage stripper the Co concentration in the scrubbed extract is increased from 5.6 g Co/L in the extract to 30.5 g Co/L that is partially used as reflux scrub liquor.

Dec 11, 2024

By H. Zhong, S. Wang, Q. Lin

To improve the flotation performance of chalcopyrite collector, 2-(tert-butoxy)ethyl xanthate (TBEX) and its derivative O-(2-(tert-butoxy)ethyl)-N-ethyl-thionocarbamate (TBEETC) were designed and prepared by the introduction of a 2-(tert-butoxy) ethyl group into xanthate and thionocarbamate. TBEX and TBEETC were both prepared via the one-pot method with superior efficiency, which has significant commercial implications. The micro-flotation tests demonstrated that compared with sodium isobutyl xanthate (SIBX) and O-isopropyl-N-ethyl-thionocarbamate (Z-200), TBEX and TBEETC both possessed better collecting ability and selectivity for chalcopyrite. DFT calculations and XPS were utilised to investigate the flotation mechanism involving TBEX or TBEETC and chalcopyrite. The results demonstrate that although 2-(tert-butoxy) ethyl group does not interact with minerals directly, its introduction reduces the energy of HOMO, so that they can better accept electrons instead of donating electrons which leads to better interaction with copper atoms rather than iron atoms. Keywords: Chalcopyrite, flotation, thionocarbamate, xanthate, synthesis

Jan 1, 2020

By L. Thomas, A. Argyn, B. Mbao, G. Longo Banza

Since the first application of solvent extraction as part of the hydrometallurgical processing of copper, several studies have been carried out to optimize extractant formulations. In 2006, Solvay developed the ACORGA® OPT series of solvent-extraction reagents to optimize copper transfer by use of a blended formulation containing both aldoxime and ketoxime as well as selected modifiers. The incorporation of selected modifiers in these blended reagents resulted in increased copper transfer, due to the interaction between the modifier and oximes within the blend. By changing the ketoxime concentration and ratio of modifier to aldoxime, the strength of the formulation was optimized to enhance copper transfer and improve Cu:Fe selectivity. This formulation is well known in the African region under the ACORGA® OPT5540 name and provides the best performance at the conditions of agitated leach plants with pregnant leach solutions that fluctuate in Cu grade and pH. This paper discusses advantages of using ACORGA® OPT5540 in the Copperbelt

Jan 1, 2023

By N. Naude, W. P. Roux

Fine particle beneficiation plays an ever-increasing role in mineral processing plants and it seems that technology can’t keep up with the challenges involved in the treating of these fines. The REFLUX™ classifier has proven itself able to treat high tonnages of fine material, especially in the coal industry. There are various fine ore applications that can benefit from such a process, yet laboratory and pilot-scale tests on many of these ores show poor efficiencies and recoveries. A better understanding of the design, operation and mechanisms of the REFLUX™ classifier is required to determine if and how it fits into these applications. The mechanisms in gravity separators are very complex due to the complex hydrodynamics, and the REFLUX™ classifier is no exception. The mechanisms of these systems are usually described through theoretical single particle-models that are hard to verify through analysing the feeds and products of these processes. To verify these models the movement of individual particles must be measured, which is not an easy task. In this paper the separation mechanisms in the incline channels of the REFLUX™ classifier were investigated with high-speed videography. A small lab scale model of the incline channel was constructed for this purpose. It was possible to capture and track the trajectories of particles under certain conditions and match these trajectories with theoretical models. The resuspension of particles, clustering and streaking was also observed and captured. Keywords: REFLUX™ classifier, particle trajectory, beneficiation, high-speed videography

Jan 1, 2020

By F. M. L. Mulaudzi

Metal dusting is a corrosion phenomenon that occurs in strongly carburizing gas atmospheres at elevated temperatures. Reaction kinetics and product characterizations of Alloys 602CA and 800 were examined by scanning electron microscopy with energy dispersive X-ray analysis (SEM-EDX) and X-ray diffraction (XRD).The results showed that Alloy 602CA is more resistant to metal dusting than Alloy 800. Visual examination and SEM surface analysis showed that Alloy 800 suffered metal dusting attack after a relatively short exposure period. The amount of coke deposits increased on Alloy 800 with increased exposure from 96 to 336 hours. X-ray diffraction on the reacted surfaces identified graphite and austenite in both alloys and some iron oxides/spinel for Alloy 800.

Jan 1, 2012

EMMES Sampling Conference BACKGROUND & INTRODUCTION ?Impala acquires toll material to supplement production from ROM ?Toll material consists of filter cake, slurry and catalysts ?Samples are collected to determine the commercial values of the lots ?Slurry deliveries projected to remain relatively constant at 120tons dry solids per month, whereas filter cake deliveries set to increase five-fold to 800 tons dry solids per month ?Due to projected increase in toll material, new sampling and offloading facility presently under construction at Impala ?Presentation will cover two projects aimed at reducing the uncertainty associated with sampling of toll deliveries ?i.e. slurries and filter cake.

Jan 1, 2005

By Mike Stanley

This is a case study of an opencast coal mining operation where the physical and financial performance was improved via applying a process of transformational leadership development. [ ]

Jan 1, 2008

By N. Steven

Published parameters from the Mufulira copper in situ leach (ISL) in Zambia are used for order-of-magnitude flow-rate calculations for an envisaged gold ISL in back-filled Witwatersrand stopes. A successful leach operation requires that the porous medium, usually a sand, has a hydraulic conductivity in excess of 5 x10-7m/second (i.e. a permeability >50 millidarcies).Empirical evidence suggests that average linear velocities would be of the order of 60 m/day if the backfill has the grain size of a fine sand. The proposed gold lixiviant would probably be an alkaline or ammonium thiosulphate, not cyanide. The resultant sulphate-rich ground and drainage waters could probably be processed using existing purification techniques to produce gypsum and magnesium/calcium carbonate. Within the next 100 years it is inevitable that solution mining will find widespread application on the Witwatersrand, if not for gold extraction, then certainly for water remediation purposes.

Jan 1, 2009

The development of short- and medium-term mine production schedules in isolation from each other has meant that only a local optimum can be achieved when each scheduling phase is carried out. The globally optimal solution, however, can be achieved when integrating scheduling phases and accounting for the interaction between short-term and medium-term activities simultaneously. This paper addresses the task of integrating short- and medium-term production plans by combining the short-term objective of minimizing deviation from targeted mill feed grade with the medium-term objective of maximizing net present value (NPV) into a single mathematical optimization model. A conceptual sublevel stoping operation comprising 30 stopes is used for trialling segregated and integrated scheduling approaches. Segregated medium- and short-term scheduling using separate models achieved an NPV of $42 654 456. The final scheduling approach involved integrating the two scheduling horizons using the newly-developed globally optimal integrated production scheduling model to achieve an NPV of $42 823 657 with smoother mill feed grade. The larger the stope data set, the larger the difference between the two scheduling approaches is likely to be. At the very least, an integrated approach ensures feasibility across the two scheduling horizons, which cannot always be assumed when using a segregated approach.

Jan 1, 2012