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By M. Dworzanowski

The beneficiation of fine iron ore will increase in importance in the future because most new iron ore resources will be in the form of lower grade ore deposits that will require liberation of iron ore minerals at finer sizes. Generally this fine iron ore will be beneficiated to produce a pelletizing concentrate with very strict chemical and physical specifications. In addition, because of the increasing demand for iron ore there are now more opportunities to produce by-product iron ore from mining operations producing other commodities. In the past the associated iron ore minerals would report to final tailings but now there is potential value to be realised from by-product revenue. These by-product iron ore opportunities are almost all centred on producing pelletizing concentrate. Currently pelletizing concentrates are produced mainly by various combinations of flotation and magnetic separation. The selection of the beneficiation route will depend on ore mineralogy and considerations around plant capacity and final concentrate quality. The main economic iron minerals are magnetic, haematite being paramagnetic and magnetite being ferromagnetic. This, therefore, means that magnetic separation can be applied, in principle, to all fine iron-ore beneficiation plants. While flotation has a considerable capacity advantage over magnetic separation, the real advantage of magnetic separation over flotation in fine iron-ore beneficiation is that treatment of -10 µm iron ore is possible-in flotation, the feed is deslimed at 10 µm and the -10 µm stream is considered to be final tailings, even though there is often a significant amount of contained iron ore. This paper describes a study around the recovery of fine magnetite in the form of a pelletizing concentrate. The study is based on an evaluation of an iron ore by-product opportunity from an iron oxide copper-gold (IOCG) deposit. Experiments were conducted to quantify the differences in magnetic separation performance with decrease in particle size treated. A mineralogical evaluation of all the test work products was undertaken to facilitate the interpretation of the test work results. These results were then used to propose an economically viable flowsheet for maximizing fine magnetite recovery using magnetic separation.

Jan 1, 2012

Comminution is a vital part of minerals extraction, and therefore of the South African economy. The high cost and throughput-limiting nature of comminution forms a strong motivation for research directed at improving the efficiency of the process. Building on a ten year background of fundamental charge motion research, a new formal UCT flotation and communication group has been formed. The group is also moving strongly into the field of milling circuit modelling and simulation, based on close links formed with the Julius Kruttschnitt Mineral Research Centre (JKMRC) of Australia, and an international collaborative research programme.

Jan 1, 1998

By A. Nkolele

Paper written on project work carried out in partial fulfilment of B. Tech (Metallurgical Engineering) degree Fine coal of the Goedehoop Colliery is dewatered by centrifuging before being sold. Full-scale plant tests were carried out to reduce residual cake moisture by the addition of surfactants. It is believed that by modifying the interface between the coal surface and the adherent surface water, as well as the water occluded in the cake voids, drainage is improved. Two anionic surfactants at concentrations up to 150 g/t were tested on coal of <0.5 mm size. The results demonstrate that quite high additions of surfactant (80 g/t)were needed to reduce moisture from 20 to about 17?18%. It was observed that when increasing surfactant additions at low levels, within a very narrow concentration range, the retained moisture first increased sharply only to decrease sharply immediately thereafter; this effect points to a critical surfactant concentration. Based on the obtained results, the use of surfactants cannot be recommended at this stage; further investigations under more controlled conditions are required.

Jan 1, 2004

By A. S. Macfarlane

This paper describes how knowledge of the orebody morphology and ore morphology can be used to optimize the planning, mining, and metallurgical output from an open pit copper mining operation, such as to significantly increase the stability of the whole value chain process, and increase the reliability and value of the process outputs. In the case under consideration, the orebody contains both copper and cobalt. This in itself provides a challenge, in that the two metals do not occur in consistent ratios across the orebody as a whole. Furthermore, mineralogical differences within the orebody have a significant impact on plant performance in terms of throughput rates, acid consumption, and recoveries. In order to stabilize and optimize the plant performance, it is necessary to firstly have a complete understanding of the geometallurgical factors that affect performance, and then to have a sound knowledge of how these are distributed within the orebody. These models then inform the mine planning strategy that optimizes cash flow and NPV, and also allow the development of a stockpiling strategy that not only stabilizes the plant, but also allows variations in the plant feed according to ore type and grade in volatile price scenarios. Integral to the realization of these opportunities is the establishment of an appropriate measuring, control, and reconciliation system, customized to the optimization objectives. The paper describes how all of these factors and strategies can be integrated to produce optimal value from the orebody through to final dispatched product. It also shows the significant value that can be released through such an approach.

Jan 1, 2014

By A. D. Engelbrecht

An investigation was undertaken to ascertain the suitability of four selected low grade, South African coals for gasification in a bubbling fluidized bed for production of synthesis gas and for the development of integrated gasification combined cycles (IGCC). This study consisted of the characterization of the coals, laboratory evaluation of intrinsic reactivity, and experimentation with a pilot-plant fluidized bed gasifier. Results of the characterization experiments show that the selected coals are high in ash, rich in inertinites, very dense (low porosity), with low caking indices and high ash fusion temperatures. Reactivity measurements with a thermogravimetric analyser (TGA), under reaction rate controlling conditions with carbon dioxide, showed that the reactivity of the coal chars decreases with increase in rank of the coal, as expressed by the vitrinite random reflectance and carbon content of the parent coals. The fixed carbon conversion achieved in the fluidized bed gasifier also correlates well with the rank parameter of the coal, with higher conversions being obtained with the lower rank coals. Thermal shattering and attrition of the coal particles produce significant amounts of fines, which correlate with the grindability indices, and no agglomeration (non-caking) was observed. It is concluded that fluidized bed gasifiers are able to utilize typical low grade, high ash South African coals for synthesis gas production and for inclusion in integrated gasification combined cycles for power generation.

Jan 1, 2010

By M. L. Bakker

The ISASMELT? top submerged lance (TSL) bath smelting process was developed in Mount Isa, Australia by Mount Isa Mines Limited (now a subsidiary of Xstrata plc) during the 1980s. By the end of 2011, the total installed capacity of the ISASMELT? technology will exceed 8 000 000 metric tons per year of feed materials in copper and lead smelters around the world. Commercial plants, operating in Belgium and Germany, are also batch converting copper materials in ISASMELT? furnaces. This TSL technology is equally effective for continuous converting processes, in which role it is called ISACONVERT?. This paper presents the recently patented ISACONVERT? process for the continuous converting of nickel and platinum group metal (PGM) containing mattes using the calcium ferrite slag system. The paper focuses on the potential application of the ISACONVERT? technology to existing nickel and PGM smelting complexes.

Jan 1, 2011

Sishen Iron Ore Mine previously used only A-grade material (>60% Fe in situ value) from the pit for beneficiating in the DMS plant to a final product grade of 66% Fe in lump and 65% Fe fine ore. The B-grade (between 50% and 60% Fe) and C-grade material (between 35% and 50% Fe) were stockpiled separately, owing to the inability of the existing DMS plant to beneficiate material at densities higher than 3600 kg/m3. The ability to beneficiate the B-grade material at densities higher than 3600 kg/m3 was evaluated, and air-pulsed jigs were found to be techno-economically feasible and value maximizing. The beneficiation of B-grade material would add to the existing DMS production of 28 Mt/a, with no additional mining cost and only limited costs for the handling of waste and B-material. The objective of the Sishen Expansion Project (SEP), i.e. the jig plant, was to produce 10 Mt/a of saleable product with six modules to the set physical and chemical specifications by 2009. During the start of construction, it was decided to add another two jig modules to the plant to increase production to 13 Mt/a. During commissioning and ramp-up the shortcomings and advantages of the jigs were fully experienced and understood, resulting in many changes to optimize jigging performance..

Jan 1, 2014

By J. D. Stone

This paper briefly reviews the adequacy of existing management theories and practices and the managerial proficiency or competency in the South African mining industry. The investigation revealed that existing management practices are totally inadequate to enable all employees on all the levels of the mining industry to achieve the results required from them, in all aspects, at all times. As a result, the South African mining industry is gradually losing its long standing reputation as a relative cheap, competitive, and reliable supplier of minerals to the local and global markets. According to some prominent management authors and theorists, an all-inclusive unified management theory does not exist at present. In this paper the authors summarize the main aspects of a newly developed comprehensive, practical, and integrated management method. It is believed that the application of this method would significantly improve the future performance and competitiveness of the South African mining industry

Jan 1, 2010

By T. Wettainen

Malmberget town is located in northern Sweden, approximately 70 km north of the Arctic Circle. Parts of the town overlie more than 20 iron orebodies, consisting mainly of magnetite with smaller quantities of haematite. The mine is operated by the mining company LKAB. Mining started in the 17th century, but not until the railway to the coastal city of Luleå was completed in 1888 did large-scale production commence. Around 1920, mining proceeded underground and today sublevel caving is the only mining method used. Sublevel caving causes subsidence of the ground surface, and buildings and residential areas have been relocated due to the mining activities for more than 50 years. The number of seismic events accompanied by strong ground vibrations is now increasing. In 2008 the mine received a permit from the Environmental Court of Sweden to increase production to 20 Mt of crude ore per year. A prerequisite for the permit was that the mine conducts a number of investigations regarding the environmental impact on the residents of Malmberget. One of these investigations concerned how seismicity will change as production increases and what measures could be taken to reduce inconvenience to the town residents. Today the mine possesses an extensive seismic monitoring system with more than 180 underground and surface geophones. For this study, eleven seismically active volumes in Malmberget mine were identified, and for each of them, a yearly future maximum magnitude interval was estimated based on the current production plan. Relationships between historical seismic events and measured ground vibrations in the town of Malmberget were established, and future ground vibrations caused by expected seismic events were estimated using a probabilistic approach. The outcome was the number of intervals of expected ground vibration per year and per monitoring point. Possible measures to reduce inconvenience for the town residents include blast restrictions, sequencing, and possibly preconditioning. The ultimate long-term solution is an almost complete relocation of Malmberget town. This process has recently been formalized and LKAB is taking an active part in realizing this goal.

Jan 1, 2014

By D. Chetty

The characterization of platinum group minerals (PGMs) from concentrator flotation circuits provides valuable information towards understanding PGM recovery under given milling and flotation conditions. Additional mineralogical characterization also provides information on ore variability, which may affect recovery. Considering the low grades involved, automated scanning electron microscopy (SEM) characterization of PGMs has enabled relatively quick analyses, compared with older, time consuming and less accurate optical microscopy methods. Over the years, parameters, such as species, size distribution, liberation, gangue and base metal sulfide (BMS) associations, have been used to characterize the PGMs in a process mineralogical context, to aid metallurgical interpretation. This paper considers whether flotation indices determined for PGMs can be empirically validated, using initial results from analysis of PGMs in a concentrate bank from a South African concentrator treating UG2 ore from the western limb of the Bushveld Complex. The aim is to determine whether floatability is adequately described by these parameters, or whether other mineralogical factors must be considered when assessing PGM floatability, and hence accounting for recovery vs. losses to tails. The data obtained to date, show that flotation parameters (including liberation index, BMS/gangue relationships and size distribution) have merits where large changes in PGM concentration occur, as observed in the first four cells of the concentrate bank. Larger data sets, however, are required to assess floatability, particularly where concentrate cell grades are similar, as observed in the last six cells of the concentrate bank. Furthermore, the floatability indices could be enhanced by the incorporation of selected associated gangue mineral information, chief amongst these being the content and mode of occurrence of naturally floatable talc and associated orthopyroxene.

Jan 1, 2009

By A. Hotta

Reduction of CO2 emissions is the key driving force behind the development and implementation of new solutions for energy production. One solution is circulating fluidized bed (CFB) combustion technology combined with a high-efficiency once-through water-steam cycle. Foster Wheeler&apos;s CFB technology is today commercially available in capacities up to 800 MWe with ultra-supercritical steam parameters. Simultaneously, the Flexi-Burn® CFB technology is being developed to provide capability of flexible operation in air firing and oxy-combustion for carbon capture. CFB technology can offer an attractive solution for the reduction of CO2 emissions, owing to advantages such as fuel flexibility and low emissions that the air-fired CFB technology offers today. Pilot test facilities provide information about the performance of CFB oxy-combustion technology, and the acquired knowledge is being incorporated in boiler modelling and design tools. One of the European R&D initiatives on carbon capture and storage (CCS) is the Technological Centre for CO2 Capture and Transport, which is supported by the Spanish Government through the Fundación Ciudad de la Energía (CIUDEN). CIUDEN is a research and development institution created by the Spanish administration in 2006 and fully conceived for collaborative research in CO2 capture, transportation, and storage. The Technology Development Centre for CO2 Capture and Transport comprises two technologies on oxy-combustion: pulverized coal (PC) and circulating fluidized bed (CFB). This paper will focus on the design and main characteristics of the 30 megawatt-hour thermal capacity (MWth) oxy-CFB boiler. Foster Wheeler is the technology provider of the Flexi-Burn CFB unit, for which commissioning has been completed in the first quarter of 2011. The CFB unit design allows operation either under conven¬tional combustion with air or under oxy-fuel conditions. The size of this experimental boiler is sufficient to allow the scaling of the results to commercial units. In this way, multiple fuels and operating conditions can be tested economically. The results will validate the design of a future 330 MWe supercritical Oxy-Combustion Power Station (OXY-CFB-300 Compostilla Project) intended to demonstrate the CCS technology at commercial scale. The Compostilla OXY-CFB-300 Project is one of the six CCS demonstration projects funded under the European Energy Programme for Recovery (EEPR) of the EU. The project is based on a future 330 MWe CFB supercritical oxy-combustion plant, with CO2 storage in a deep geological formation. The first phase of the project, granted by the EEPR programme and led by the Spanish utility ENDESA, includes all studies and characterization work needed on CO2 capture, transport, and storage, as well the costs, financing, and regulatory and permitting required, prior to the final investment decision for the construction phase of the plant by the end of 2012.

Jan 1, 2012

By M. Hopf

The use of water-cooled copper components as sidewall elements of submerged arc furnaces and other pyrometallurgical applications has become increasingly common. The high cooling efficiency of copper has made it possible to increase the service life of furnace refractories when compared to conventional refractory linings. However, even the self-healing effect of ?freezing? worn areas of the lining does not necessarily protect the copper coolers against wear or corrosion completely. In order to avoid furnace explosions, various methods have been used to monitor the wear of coolers. Unfortunately, these have not been able consistently to identify localized wear. Thos Begbie (South African) and SAVEWAY (German) jointly developed technology to embed a line sensor into the copper cooler during the casting process. This system allows an exhaustive monitoring of the copper cooler. A SAVELINE sensor is placed inside the copper-cooling panel between the water-cooling passage and the hot face of the panel. The sensor follows the meandering shape of the cooling water channels. In the first instance, the sensor provides analogue information as the thickness of the copper reduces. Secondly, this wear signal will be confirmed by a signal of interruption if the sensor is washed away. Because of the structure of the sensor, a self-diagnosis is possible and indications can be confirmed (double proofed).Subsequent to the manufacture of some test pieces, coolers for a large submerged arc furnace were manufactured. The sensorized coolers have been installed at the intermittent surface (slag line) where the largest amount of corrosion has been encountered. The system has been operating since December 2005 in what is considered one of the largest submerged arc furnaces in South Africa. Keywords: Pyrometallurgy, furnace, copper coolers, freeze lining, monitoring, Saveway

Jan 1, 2006

By G. O. Rading, B. O. Odera, M. J. Papo, R. Couperthwaite

"Platinum-based alloys are being developed with microstructures similar to nickel-based superalloys for potential high-temperature applications in aggressive environments. Since the chemistries of nickel and platinum are similar, Pt-based alloys can be made with gamma prime ~Pt3Al precipitates in a gamma (Pt) matrix. Currently, the Pt-Al-Cr-Ru system is one of the bases for developing Pt-based alloys, where Al allows the formation of thePt3Al precipitate and also gives protection from the alumina scale formed, Cr provides oxidation resistance and stabilization for the L12~Pt3Al phase, and Ru provides solid solution strengthening in the (Pt) matrix. Four Pt-Al-Cr-Ru-V and two Pt-Al-Cr-Ru-V-Nb alloys were made, with compositions based on a quaternary alloy, ~Pt82:Al12:Cr4:Ru2, which hadpreviously been identified as having optimum properties. Four of the as-cast alloys had the targeted two-phase structure of ~Pt3Al and (Pt), and two were single-phase ~Pt3Al. Vanadium partitioned more to (Pt) than to~Pt3Al. There was an improvement in hardness compared to the quaternary alloys. The best addition of V was ~15 at.%; higher additions resulted in brittle intermetallic phases of the Pt-V system. The effect of Nbcould not be ascertained because of its high losses."

Jan 1, 2015

The 108th Annual General Meeting of The South African Institute of Mining and Metallurgy was held at The Country Club, Johannesburg, Napier Road, Auckland Park on Thursday, 11 August, 2005. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations, also to recipients of awards, senior members of industry, Honorary Life Fellows, past-presidents, our members and other guests, among them the following: Dr Con Fauconnier, President, Chamber of Mines of South Africa Prof. Jay Barton, President, The Geological Society of South Africa V. Townshend, President, Institute of Certificated Mechanical and Electric Engineering, South Africa M. Livingstone-Blevins, President, Institute of Certificated Mechanical and Electrical Engineers, South Africa Prof. B. Lacquet, President, South African Institute of Electrical Engineers Dr F. Malan, President, South African National Institute of Rock Engineering

Jan 1, 2005

By M. McWha

Laboratory bias is a universal problem in all branches of analytical science. It results from differences in methods, techniques, equipment, and calibrations between laboratories. Notwithstanding that it is a property that can be measured by the use of standards or by inter-laboratory testing, laboratory bias remains a material issue for the mining industry. There is extensive literature and clear guidelines on measurement from the International Organization for Standardization (ISO) and its worldwide federation of national standards bodies (ISO member bodies) and from the science of metrology. ISO guides cover the manufacture and use of standards. An accessible source of literature covering laboratory quality control comes from the public health sector, particularly pathology. There is little doubt in financial reporting rules about the meaning of materiality. Public reporting guidelines are clear that material matters need to be disclosed for investors. Unfortunately there is currently no clear guidance what to do about biased assay results in mineral industry public reporting guidelines. This paper reviews the requirements for the manufacture and use of reference materials, public reporting requirements in the mining industry, and presents proposals to improve management and reporting of laboratory biases. Keywords laboratory bias, reference materials, ISO Guides, financial reporting, materiality.

Jan 1, 2014

By M. Pineda

Sublevel stoping (SLS) is one of the oldest and most used methods for underground mining. It relies heavily on the use of drilling and blasting techniques to remove the rock, and gravity to transport the broken rock to drawpoints located at the base of the stope, with LHDs to transport material from the drawpoints. Current SLS operations are based on the assumption of stable geometry of the stope. Thus, the stope design includes the definition of the geometry according to the orebody shape and geomechanical constraints to avoid instability, which may cause excessive dilution. Under some circumstances, dilution could enter the stope due to geotechnical instability, especially when large stope geometries are used. A review of current design and planning practices for large SLS operations indicates that no consideration is given to the material flow and the mixing that occurs after blasting. Material flow could have a large impacton the mixing of ore when grades are heterogeneous in the stope. In this paper, we discuss the influence of gravity flow on the design and planning of large sublevel stopes with and without vertical dilution, based on laboratory experiments. The outcomes of this investigation are used todevelop guidelines towards the design and planning of large SLS mines, which would complement the currently used geotechnical considerations.

Jan 1, 2015

By X. Q. Cao, D. S. Zhang, L. Q. Ma

To solve the support stability control problem for a coal face with large angles along both strike and dip (CLSD), the ’support-surrounding rock’ mechanical model has been developed, which takes into account the impact of the dip angle of the seam on the stability of the support in the strike direction. The mechanical relationships of the critical topple angle and critical slip angle of the support along the strike of the coal face with large dip angle and the support height, support resistance, friction coefficient, and other factors have been derived through the mechanical analysis of support stability in the strike direction of CLSDs in the free state, the operating state, and the special state. The research findings were applied to a fully mechanized CLSD in Xinji Coal Mine. The maximum underhand angle and overhand angle in strike are 42° and 25° respectively, and the maximum dip is 39°. It is calculated that during underhand mining and overhand mining, the critical support resistances for avoiding support toppling are 3723 kN and 1714 kN respectively, and the critical support resistances for avoiding slipping of the support are 7405 kN and 6606 kN respectively. Thus, the selection of type ZZ7600/18/38 hydraulic roof support for the coal face is justified. Measures to prevent sliding of the support and the installation of a limiting stop maintain the support runs in good condition and ensure safe and efficient mining of CLSD.

Jan 1, 2015

By K. Liddell

Current practice for the recovery of platinum group metals (PGM) from flotation concentrates is by energy-intensive smelting processes followed by separation and refining of the base and precious metals. Energy costs are rapidly increasing in South Africa and this trend is forecast to continue in future years. Moreover, the smelting operations are highly susceptible to deleterious constituents, particularly chromite; and the increasing tonnages of UG2 chromititic ore being mined results in an increasing chromite content of smelter feeds. Hence there is a substantial incentive to assess and implement alternative processes to smelting for the treatment of PGM concentrates. The Kell process is a patented hydrometallurgical alternative to smelting that is totally insensitive to the chromite content of the feed concentrate and comprises three commercially proven unit operations (pressure oxidation leaching of base metals and sulfur, roasting and chlorination of precious metals). The Kell process provides the opportunity for existing and new PGM producers to significantly reduce their energy consumption, and in particular their consumption of electricity, by removing the need to smelt PGM concentrates. Energy costs, greenhouse gas emissions and installed power requirements are also much reduced. Compared with smelting and refining these reductions are calculated as: ? Total energy consumption-50% reduction ? Electrical energy consumption-84% reduction ? Energy consumption costs-76% reduction ? C02 emissions-70% reduction ? Installed power requirement 92% reduction. The data obtained from simple laboratory batch amenability testing can be readily applied to the Simulus mass and energy balance simulation procedure to determine energy and reagent consumptions, equipment selection and process optimization. The applicability of Kell to treating low-grade &apos;dirty&apos; concentrates with high UG2 content as well as to polymetallic concentrates containing base metals as the major payable metals with subordinate PGM means that these savings can also be expected when the process is used for treating a range of concentrate types and grades. Keywords PGM,UG2, Merensky, smelting, chromite, electricity, hydrometallurgy, Kell Process, Eskom.

Jan 1, 2011

The influence of varying amounts of magnesia, silica, and alumina in iron ore sinter on its mineralogy, reducibility index (RI), reduction disintegration index (RDI), physical breakdown (AI and TI), and production properties (coke breeze rate) were examined. It was found that the mineralogy of iron sinter can more easily be predicted from its chemical composition than from the RI, RDI, AI or TI. Anticipating the consequence that varying amounts of MgO and SiO2would have on sinter properties is complex, and not necessarily predictable. High concentrations of Al2O3in the sinter result in high concentrations of the SFCA phase, but with drastically deteriorated properties. This study also confirmed that the form in which fluxes are added to the raw material sinter mixture affects the mineralogy and properties of the produced sinter.

Jan 1, 2010

By T. Celik, B. Genc, C. Musingwini

"Mine planning software continues to be an important factor when it comes to the development of the South African mining industry. To contribute to this development, a new methodology to define and measure mine planning software utilization in the South African coal mining sector within an evolving data-set framework was developed. An initial data-set showing the mine planning software providers, their corresponding software solutions, as well as the software capabilities and information on the number of licences was collected and compiled in 2012 in an online database for software utilized in the South African mining industry. Details of the database development and implementation were published in the Journal of the Southern African Institute of Mining and Metallurgy in 2013. In 2014 the data-set was updated with additional and new information.In this paper, using the 2012 and 2014 time-stamps, a methodology for estimating the software utilization is developed. In this methodology, three variables: commodity, functionality, and time factor are used to define and measure the software utilization in order to ultimately inform decision making strategies for software utilization. Utilization in the coal sector was measured according to six different functionalities, namely Geological Data Management, Geological Modelling and Resource Estimation, Design and Layout, Scheduling, Financial Valuation and Optimization. The methodology is useful for stakeholders reviewing existing software combinations or intending to purchase new software in the near future and wanting to estimate the comparative attractiveness of a certain software package. These stakeholders include mining companies, consulting companies, educational institutions, and software providers. The work presented in this paper is part of a PhD research study in the School of Mining Engineering at the University of the Witwatersrand."

Jan 1, 2016