Search Documents

By L. Tartibu, S. Assuli, P. Nkul, A. Kabimba, W. Elongo, N. Makhotla, D. F. Verwey, F. G. Ndiitwani, J. Bilali, T. Mukongo

The presence of colloidal silica negatively impacts various hydrometallurgy processes. This paper details the nature of colloidal silica, operational issues caused by colloidal silica, as well as various mitigation measures. MMG Kinsevere observed severe phase-continuity instability, increased crud formation, and reagent consumption, and reduced current efficiency in electrowinning with a deterioration in copper quality. Historical mitigation measures were initially implemented but failed to solve the problem. MMG Kinsevere successfully achieved efficient silica removal without adverse effect on the solvent extraction with the use of DEHSCOFIX® SC12 coagulant. A week into the coagulant trial, silica concentration had dropped from > 1500 mg/L to within 500 mg/L. The solventextraction plant recovered its stability and again operated at maximum capacity. Additionally, improvement was observed on current efficiency and copper cathodes quality with use of the coagulant.

Jan 1, 2023

By N. Hadebe, A. Mampuru, F. Jantjies

Mintek conducted test work to study the effect of media wear when using Mintek’s Milling-in-raffinate technology. The grinding media consisted of high-chrome and ceramic balls. The tests were conducted using a laboratory 5L 316 stainless-steel rubber-lined mill. Magotteaux supplied the high-chrome and ceramic balls. The raffinate was synthetically prepared using a typical Cu/Co (2.2 g/L Cu, 3 g/L Co) composition. The milling rate, media wear, mill, leach extraction efficiencies, gangue acid consumption, and residence time were studied. The tests indicated that the high-chrome balls had a higher corrosion rate than the ceramic balls. The ceramic corrosion rate was lower than 0.1 mm/y. The highchrome balls performed better during the leach stages with faster milling time, higher leaching efficiencies for both Cu and Co, lower gangue-acid consumption, and lower residence time

Jan 1, 2023

By Y. Zhou, G. Chisakuta, P. Bwando, G. Mitshabu

A newly started copper hydrometallurgical plant was confronted with a manganese oxidation issue in electrowinning. This oxidation, in the absence of the amount of iron required to stabilise the electrolyte oxidation-reduction potential, is known to produce oxidants (MnO2, MnO4) that can cause accelerated degradation of the organic phase components in solvent extraction and corrosion of lead anodes in electrowinning. The overpotential required to build up the protection layer on new anodes causes an increased electrolyte potential that creates oxidized species in the electrowinning tankhouse, and these species come back to solventextraction plant with the recycled spent electrolyte. This paper discusses the impacts of manganese oxidants on the health of a plant organic phase. It also outlines the actions taken using iron scraps and sulfur dioxide to mitigate the problem that happened due to the lack of ferrous iron sulfate available on site, as recommended for better control.

Jan 1, 2023

By P. Kitobo, T. Nduba, D. Mbay, J. B. Vangu, R. Ciband

The flotation plant tailings at Kamoa Copper Mine concentrator were found to contain a high proportion of extremely fine particles. The potential issues with settling these fine solids were resolved by the use of a poly-di-allyl-di-methyl ammonium chloride (DADMAC) coagulant, Flobead DB 45 VHM, in conjunction with a standard anionic polyacrylamide flocculant. This paper outlines some of the issues encountered and how they were resolved at the Kamoa concentrator. The potential to use this process and technology at other sites is also considered

Jan 1, 2023

By Q. Fu, Q. Wang, L. G. Wen, M. X. Jia, J. J. Zhao, J. W. Zhou

The BGRIMM process mineralogy analyser (BPMA) is a new automated mineralogy software platform developed in China. This system consists of the BPMA software platform, controlling a combination of commercially available scanning electron microscopy (SEM) and energy dispersive Xray spectrometry (EDS). The BPMA software controls SEM and EDS through their application programming interfaces, to form an auto-SEM and EDS system that automatically acquires BSE images and X-ray spectra, respectively, and classifies minerals by spectrum-matching. After automated measurement and mineral identification, various quantitative process mineralogical data (e.g., mineral composition, mineral abundance, mineral liberation and intergrowth relationships, mineral associations, particle and grain sizes, particle density distributions, calculated assay, elemental deportments, mineral grade recovery and elemental grade recovery, etc.) would be calculated quickly, accurately and automatically. The BPMA could be used for ore characterisation as a new advanced automated mineralogy technology. Keywords: BSE image; X-ray spectrum; automated mineral identification; quantitative mineralogical investigation; automated mineralogy

Jan 1, 2020

By K. Moxham, A. Smit, R. Pickering

Since the early 1970s research has been ongoing to develop a cost-effective way of continuously mining the narrow reef, hard rock, typical of South African gold and platinum mines. In the late1980s it was shown that impact ripping was a practical solution for the deep gold mines. In March2001 Lonmin and Sandvik agreed to co-operate in an endeavour to design and manufacture a prototype narrow reef mining machine with the ultimate aim of producing such a machine on a commercial basis that would enable Lonmin to create a safer and more productive environment within its mines and for Sandvik to enhance its leading position as a supplier of a new generation hard rock cutting machine. This paper describes the developed technology, the current progress of the delivery of the required objectives and the optimum mining layout for the roll-out of the mining method.

Jan 1, 2006

By J. C. D. Gush

Paper written on project work carried out in partial fulfilment of Laboratory-scale testwork was undertaken to recover oxidic copper-cobalt minerals by froth flotation, which requires maintaining a certain sulphide level in the pulp. To improve control of the sulphide concentration, an electronic closed-loop system was designed that responds to the potential output of an ion-selective electrode. The PID control was improved by adding a pre-emptive control and a self-calibration feature; a data logging facility is also included. An inexpensive valve design was incorporated using locally available parts. The operating results of this control design are presented.

Jan 1, 2005

The nature of metallurgical engineering?applying and optimising chemical and physical processing of ores into useful materials?is reviewed. Important trends that shape the context in which metallurgical engineers practise are identified ? increased global production of primary metals, declining prices, environmental constraints, and increased property requirements of materials. A successful department of metallurgical engineering is one which employs a team of academic leaders to develop graduate engineers who are productive across the full range of metallurgical processing. Keywords: metallurgical engineering, primary metals, commodity prices, processing

Jan 1, 2003

By K. L. Morton, R. .. J. Connelly, P. C. Bouw

Uncertainties in the forecasting of the volume of groundwater likely to enter underground workings present difficulties for mine management in planning and costing the water-related activities of mining. This paper describes a technique that was developed to assess future inflows into a gold mine in the Orange Free State. The approach employed was based on the interactive operation of two separate computer models: a regional-flow model and an inflow model. As a first stage, a regional finite-element model of groundwater flow was set up and calibrated. Predictive runs were made to establish the influence of mining on the water levels from base-line conditions. This step was necessary since observations of the regional water levels were sparse. The predicted water levels were transferred to the inflow model, and the future flowrates were calculated. Both models were calibrated by trial and error until a satisfactory match was obtained between historical records and the values predicted by modeling. In this way, an improved monitoring system to record regional water levels and pressure heads within a mine was established. By the use of information, the initial model predictions can be refined as mining progresses. The models used are based on a non-linear relationship between the area mined and the inflows. A phased behaviour in the rates of inflow increase was noted. In conclusion, the modeling approach can provide mine management with guidelines for dewatering requirements. The confidence levels depend upon the records that have been collected during the mine's history.

Jan 1, 1988

By R. L. Machunda, A. M. Rugaika, D. D. Mdachi

Sedimentary and igneous rocks are the two primary sources of phosphate that are mined and beneficiated to fertilizer. During the beneficiation process, phosphate is lost into the tailings. We investigated phosphate concentrations in tailings dumps at Minjingu mine, Tanzania using energy-dispersive X-ray fluorescence spectrometry to quantify the chemical compositions. The phosphate content in the tailings varied from 12.91% phosphorus pentoxide (P2O5) in Tailings 2 to 19.61% in Tailings Dump 1. The naturally occurring phosphate concentration in rocks ranges from 3% to 35%, and phosphate tailings from various locations with P2O5 concentrations as low as 6.46-12.65% have been beneficiated to commercial fertilizer. Our investigation revealed that phosphate concentrations in Minjingu tailings may be sufficient to be recovered for commercial applications. Suitable recovery methods are discussed, and we recommend that beneficiation should be performed to minimize the loss of phosphate into tailings. Further research is needed to identify the optimal beneficiation methodology.

Aug 8, 2024

By A. Drumond, J. F. C. L. Costa, M. G. Lemos, A. L. Rodrigues, F. G. Niquini

The past decade has seen a renewed possibility of using machine learning algorithms to solve a large collection of problems in several fields. Data acquisition for mining operations has increased with the growth in sensor-based technologies, and therefore the amount of information available for mining applications has dramatically increased. Ore sorting equipment is available for separating ore from waste based on differences in physical properties detected by a real-time analyser. The separation efficiency depends on the contrast in these properties. In this study we investigate the application of machine learning models trained using data from the output of a dual-energy X-ray ore sorting apparatus at a gold mine. The particles were first hand-sorted into ore and gangue classes based on their mineralogical composition. Classification models were then used to help decide the balance between the number of true and false positives for ore in the concentrate, with a view to economic parameters, using their receiver operator characteristic (ROC) curves. The results showed AUC (area under the ROC curve) scores of up to 0.85 for the classification models and a maximum reward condition Fpr/Tpr around 0.5/0.9 for a simplified economic model.

Aug 8, 2024

By T. Marin, J. E. Seccatore, M. Cardu

The most energy-intensive process in the mining industry is particle size reduction – comminution. The first phase of this process is blasting to fragment the rock from the initial Boussinesq’s halfspace size. Scientific literature demonstrates that the output of a blast in terms of fragment size distribution can be manipulated by varying the specific charge (powder factor) and charge distribution. This study focuses on the influence of blasting on the internal resistance of the blasted fragments; in particular the influence of the spatial distribution of charges. Small-scale blasts were performed on 14 marble blocks using different powder factors and charge distributions. Three control blocks were fragmented by mechanical means for comparison. The results show the correlations between charge distributions and the specific energy of mechanical comminution. Opportunities for adjusting charge diameter and distribution in opencast blasts to improve the performancet of comminution circuits are discussed.

Aug 8, 2024

By K. Dagdelen , S. K. A. Owusu

Uncertainty with regard to estimated grades and tonnages of a mineral deposit demands risk assessment in order to build investor confidence and attract the interest of other stakeholders in the success of a project. Uncertainties associated with Mineral Resource estimates can lead to unreliable production schedules and unpredictable cash flows. However, the techniques used in the mining industry to determine these uncertainties are inconsistent, because the important decisions taken in the process are solely dependent on the responsible Competent Person (CP), without limitations. This leads to disparities between different CPs’ results, using data-sets from the same drill-holes. The various standard codes for public disclosure provide guidelines and recommendations for the classification of Mineral Resources and Reserves but do not provide details on, for example, the amount of geological and geostatistical information needed to qualify for each category of Resources and Reserves. The parameters used to generate the classification categories are subjectively assumed by the responsible CP. In this paper we investigate the impacts of different CPs’ judgements on resource classification, using the same data-sets. The results underpin the need for the mining industry to develop a uniform Mineral Resources and Reserves classification framework that can minimize or avoid significant discrepancies that lead to potential misleading public disclosures.

Aug 8, 2024

By G. Song, X. Liu

The global coal industry has changed significantly in recent years. In this paper we analyse the coal production and consumption, imports and exports, and coal prices in China and other major coal-producing countries during the past four decades. The analysis shows that global coal production and consumption have declined over the last three years, in striking contrast to the continuous growth for most of the past 35 years. Australia, Indonesia, and Russia have become the world’s major coal providers, while China, India, and the USA, and Germany are the major coal consumers. The world’s, and China‘s, coal industry can be classified into four stages of development: the stable growth phase, stable phase, rapid growth phase, and high-quality phase. Coal prices rose in the world’s four major coal markets in 2016 after four consecutive years of falling prices. The elimination of overcapacity and production-optimizing operations in China could assist in achieving a demand and supply balance.

Aug 8, 2024

By E. Öğretici, S. Kahraman

The indirect estimation of intact rock properties is particularly useful for preliminary investigations in engineering projects. In this paper we examine the usability of electrical resistivity, a nondestructive measurement, for the prediction of physical and mechanical rock characteristics. Physico-mechanical tests (uniaxial compression, Brazilian tensile, density, and porosity tests) and electrical resistivity measurements were performed on specimens of 36 rock types. Before the resistivity tests, the specimens were completely saturated with saline solution. Evaluation of the test results showed that there are medium or strong correlations between resistivity and rock properties. There are also strong or stronger correlations between the two parameters for the rock classes. The regression equations developed were statistically tested, and their validity was confirmed. The results were also compared with previous studies. The conclusion is that electrical resistivity measurement can be used for reliably estimating physical and mechanical rock characteristics.

Aug 8, 2024

By F. T. Cawood, C. C. Birc

The South African mineral resource royalty system, initiated in 2010, employs a hybrid ad valorem approach tied to profitability ratios. This rate is then applied to the total revenue from mineral sales. In this article we explore how the profitability ratio in the mineral resource royalty formulae interacts with the gold tax formula as applied to South African gold mines, devising a strategy for cut-off grade optimization. The study focuses on nine narrow, tabular-reef (Witwatersrand) gold mines. The approach involves a mixed-integer cut-off grade optimizer utilizing Excel Solver, incorporating relevant royalty and income tax formulae. Different mineral resource royalty cost scenarios were examined. Ignoring these costs in the break-even analysis lowers the cut-off grade but slightly boosts profits compared to considering expected costs. The developed optimizer model, recognizing the profitability aspect of the mineral resource royalty and income tax formulae, yielded a 6% lower cut-off grade than the base case. This is significant for increasing mine life. While the profit differences are marginal (0.2% compared to the break-even base case), substantial improvements were noted: a 6% increase in stope tons above cut-off grade, and a 4% rise in total revenue. Enhanced resource utilization (3% extra gold kilograms) reduces necessary development and overall costs, allowing for a reduction in the cut-off grade and ultimately, more profit.

Aug 8, 2024

By L. Roux

The initial evaluation of a coal deposit often raises uncertainty with regard to the accuracy of the reported Resources and Reserves. Reconciliation of results from mining and beneficiation with the original raw field data highlights deficiencies in original estimations. Credible Resource and Reserve estimation forms the basis on which an entire mining enterprise is motivated, initiated, funded, and established as a commercially viable proposition. This is required for sustainable extraction purposes and to support vital downstream industries such as power generation. Accurate determination of the density of the matrix of the material being evaluated is the key to credible values being obtained for Resources and Reserves. Losses between 15% and 20% of the Resource/Reserve can be realized if incorrect densities are applied to the tonnage derivation. Coal plies and particles have different relative densities, determined by the maceral composition, rank, and mineral and moisture content. These factors in turn contribute to the moisture, volatile matter, ash and carbon contents of a coal, which affect the overall density of the raw coal. More specifically, the relationship of ash to density and the effective matrix porosity were found to be critical in solving the greater majority of the problems in predictive calculations. A major deficiency identified is the inability to determine effective porosity, allowing absorption of adventitious moisture and altering the mass of the core sample. Although the volume of the raw material is altered through crushing, the change in mass after controlled air-drying, used with the original geometrical volume of the raw material, provides a credible air-dry density and allows the determination of the volumetric change related to effective porosity. This parameter can be validated through the evaluation of proximate ash using the ash-adjusted algorithm and a correction for the inherent moisture applied to also give a credible relative density value for an air-dried sample. A combination of theoretical, empirical, and reconciliatory evaluations of the available data, taken from the exploration phase through the mining process to final production, has shown that an integrated approach using the ash-adjusted density (AAD) methodology, in conjunction with other evaluative techniques, provides credible results with a considerably higher degree of accuracy than is currently possible.

May 1, 2021

By F. Roelofse, D. Grobler, and M. Purchase, C. Gauert, E. Kotze

Scandium is an important industrial metal for which demand is projected to increase in the future. Although many Sc deposits are secondary, Sc is scavenged by clinopyroxene during fractional crystallization of primary, mafic-ultramafic magmas. Sc may thus occur in sub-economic concentrations in mafic-ultramafic intrusions. In this work, we present new data on the concentration of Sc in the Bushveld Complex (BC) of South Africa. The eastern and western limbs of the BC are considered to be largely pristine, primary magmatic deposits, whereas the northern limb shows evidence of largescale, localized crustal contamination. Samples from the primary magmatic cumulates of the eastern limb, from the mineralized Flatreef of the northern limb, and from the crustal-contaminated Footwall Assimilation Zone (FAZ) of the Flatreef were analysed for Sc. Despite the FAZ containing abundant clinopyroxene, interpreted to have recrystallized from the original cumulates in the presence of melted sedimentary rocks, no significant differences are seen in the concentration of Sc compared to other cumulate rocks of the BC containing less-abundant clinopyroxene. The concentration of Sc in the analysed samples is mainly controlled by mineralogy, with anorthosites, chromitites, and harzburgites containing under 20 ppm, and norites and pyroxenites containing 20–40 ppm. The parapyroxenites of the FAZ are less enriched in Sc than expected, suggesting that Sc may have been lost during alteration and recrystallization.

Sep 1, 2022

By M. Z. Emad, Y. Majeed, G. Rehman

Massive deposits of rock salt are mined in the Salt Range area of Pakistan. The main export products of rock salt include salt lamps, blocks, and tiles, while local consumption includes the chemical industry and domestic use. The profitable production of salt for value addition depends on the quality, size, and shape of the block. Salt processing for value addition is easier when very few cracks are present in the blocks. The current salt mining practice involves drilling and blasting, which introduces undesired fractures in the material. This paper focuses on the extraction of rock salt blocks by applying conventional cuboidshaped block mining methods used in quarries. The techniques include wedges and feathers, expansion chemicals, and blasting with low-yield explosives. Experimental work involved both laboratory-scale and in-situ field testing. Laboratory experiments assisted with the determination of splitting force, loaddeformation curves, and other rock mechanics parameters. Regression analysis proposes a relationship for the estimation of radial strain from the load in the case of the wedges and feathers method. The splitting force obtained from the laboratory tests was used to confirm the accuracy of the already published empirical relationship. The results of the laboratory as well as in-situ tests showed that the wedges and feathers technique is the most suitable method for mining rock salt blocks of the desired size, shape, while minimizing cracking.

Mar 2, 2022

By S. Gan, E. van Niekerk, L. Birrell, D. Robbertze, L. Ncubi, B. Zhao

Quality assurance and quality control (or QAQC) plays a key role in safeguarding the level of confidence of the data generated during mineral exploration and mine development, and is also part of the reporting code requirements for resource estimation and reporting, as well as mining investment. Implementation of good policies and working protocols in quality management will result in the generation of reliable information, which is critical for decision-making on the future of the mining project. The use of certified reference materials, i.e., standard, blank, and duplicate samples, proves effective and efficient for ensuring the level of data confidence in terms of precision, accuracy, and sample contamination. This is well demonstrated by the practice of QC in the exploration programme for the chrysotile tailings storage facilities of Havelock Mine, using 1254 samples from 53 drill-holes. Different statistical tools were applied to analyse the assay results from these samples. The outcome substantiates that the QC practice established during the Havelock exploration project is aligned to best practice guidelines in the industry. The resource delineated indicates that the tailings material at Havelock could potentially become a significant source of supply to the global magnesium market.

Jul 2, 2022