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Geologists in some underground gold mines collect grab samples from broken ore piles or trucks as a method of grade control. It is often known as muck sampling. Generally, the goal of grab sampling is to try and reconcile the mined grade at the ore source to the predicted grade and/or predict the mill feed grade. The mass of the sample collected is limited by health and safety issues, as well as the capacity of the laboratory to process the samples within a given timeframe. In general terms, grab sampling is known to be problematic because samplers tend to over sample the fines, and/or pick out high-grade fragments; surface sampling of piles does not test material within the pile; muck piles in development drives/faces are likely to be zoned due to the blasting sequence; high or low-grade material may preferentially segregate in the pile during mucking; the five percent mass reject size of the material in muck piles is very large from underground blasting; some correlation usually exists whereby the larger fragments are enriched or depleted in the critical component of value; and the average error made in estimating the true stockpile grade is likely to be high. The method is prone to chronic fundamental sampling, grouping and segregation, delimitation, and extraction errors. Substantial warnings must be given with respect to the use of grab sampling for grade control in gold mines. The method may appear to work sometimes, which can be attributed to a fine gold particle sizing and more disseminated distribution. As with all sampling methods, its appropriateness must be determined by ore characterization and heterogeneity testing to ensure the method suits the ore type.

Jan 1, 2009

By K. Andres

This paper presents the vibrating mill technology and summarizes the grinding principle of ultra fine grinding. In addition, a variety of operations is described and the benefits of these different operating modes? product size and efficiency are specified. A case study of an industrial application is presented to show the integration of vibrating mills into grinding circuits. The primary focus is the overall process scheme of this technology, the installation and operating costs, as well as the design parameters required for best performance. The vibrating mill can be used in a wide range of applications for process engineering duties. For a wide range of applications, from soft to extremely hard products, which require ultra fine grinding, surface activation or homogenization, the vibrating mill is well proven. Due to its easy operation, versatility and operation efficiency, the PALLA? vibrating mill gains in importance in the mineral processing industry. Keywords: Coal, comminution, grinding, mineral processing

Jan 1, 2010

By P. Saari

The Talvivaara deposits are located in Eastern Finland, within the Kainuu Schist Belt. These polymetallic sulphide deposits are of relatively low grade, but bioheapleaching enables economically profitable nickel extraction from the ore. Zinc, cobalt, and copper are also produced. Talvivaara?s production process begins with large-scale open-pit mining and four crushing stages, followed by stacking of the ore in bioleaching heaps. The ore is first leached for 13?14 months on the primary leach pad, after which the leached ore is reclaimed, conveyed, and re-stacked on the secondary heap pad. After secondary leaching, the barren ore will remain on the secondary heaps permanently. In the metals recovery process, the metals are precipitated from the pregnant leaching solution. Construction of the process was begun in spring of 2007 and first metal sulphides were produced at the plant in October 2008. The development of the bioheapleaching process was begun in a 17 000t on-site pilot heap operated during 2005?2008 and has continued in the industrial heap. At industrial scale, the development measures have focused on improving the permeability and aeration of the heap. Challenges with crushing and aerations systems at the beginning of industrial-scale leaching delayed the increase in metal recovery, but after the first two operational years the leaching results have improved significantly and the process is performing as targeted.

Jan 1, 2012

By J. L. Porter

This paper takes a personal look, through the author?s own experiences, at the implementation of innovations in the narrow-seam, hard-rock mining environment of South Africa?s mining industry over the past 40 years. A number of examples are used to illustrate some of the successes and failures over this period. More importantly, the examples are used to illustrate that the bulk of the investment for these projects should have been applied in a manner that could have achieved more sustainable results. The use of the word ?technology? in this context is also examined, as it is the author?s contention that only measuring the performance of machinery fails to encapsulate the potential of the entire system describing the scope of the innovation being implemented. These experiences and observations are projected onto the current backdrop of upheaval in the relationship between key industry stakeholders and the sustainability challenges facing areas of the mining sector in the South African economy. The paper concludes with some opinions on where attention can be focused in order to develop new thinking that can be applied for the safe and economic extraction of the nation?s mineral wealth.

Jan 1, 2014

By J. R. de Wet

The Skorpion Zinc Project demonstrated the viability of the production of zinc from non-sulphide (commonly called ?zinc-oxide?) ores, using the leach/solvent extraction/electrowinning process route. The success of Skorpion raised the profile of a number of other zinc oxide deposits, considered to be similar. However, a study of three such deposits demonstrates that the application of whole-ore-leaching may be limited and that the concentration of zinc, or at least the separation from acid-consuming gangue minerals, prior to leaching is essential to the successful recovery of zinc from these deposits. The recovery of zinc is dependent on an understanding of the geology of the deposit, the mineralogical association of zinc minerals with gangue minerals (Boni, 2005) and limitations of mining practice. Flowsheet development and the associated metallurgical testwork to derive an economically viable treatment route from two of these deposits are discussed. Key parameters affecting zinc recovery by gravity separation and flotation are presented, demonstrating that even minor differences in mineralogy have a profound impact on zinc recovery and reagent consumption. The study also deals with the determination of appropriate design parameters through metallurgical mapping of the dense media separation process.

Jan 1, 2008

By E. L. Thyse, P. Bepswa

The Western Cape Mineral Processing Facility (WCMPF) is a collaborative educational initiative between the Department of Process Engineering at the University of Stellenbosch and the Chemical Engineering Departments at the University of Cape Town and the Cape Peninsula University of Technology. The primary objective of the WCMPF is to facilitate the education, development and graduation of suitably qualified engineering graduates and diplomats for the mining and mineral processing industries. In recent years the WCMPF has embarked on a number of initiatives aimed at improving the quality of mineral processing education which include, more importantly the introduction of novel ?end to end? or ?integrated? practicals. The practicals are developed around a specific mineral theme or route, which more than often includes the development of several new pilot plant practicals demonstrating key unit operations or processes in the selected mineral theme or route. The most recent mineral processing pilot plant practical programme is developed around the beneficiation of heavy mineral sands. The programme consist of the following developed pilotplant practicals: the online electrostatic separation of free flowing mineral sands using a Roche Mining Carrara high tension roll separator incorporating a Blue Cube Systems MQi in-line mineral quantifier; the production of titania-rich slag and pig iron from the smelting of ilmenite and anthracite in a 60 kW direct current (DC) plasma arc furnace as well as the mineralogical characterization of the feed and products; the continuous closed-circuit ball milling and screen classification of titania-rich slag. This paper illustrates the important role of a well-designed heavy mineral sands beneficiation pilot plant practical programme in facilitating the education and development of suitably qualified personnel for the mining and mineral process industries.

Jan 1, 2007

By S. A. Abdel Sabour

Strategic decisions in the mining industry are made under multiple technical and market uncertainties. Therefore, to reach the best possible decision, based on information available, it is necessary to integrate uncertainty about the input variables and model financial risk of the project?s merit measures. However, this provides few useful insights to decision-makers unless accompanied by modelling management responses to uncertainty resolutions. It is widely acknowledged that conventional decision-support methods based on static, no-change, discounted cash flow (DCF) techniques such as net present value (NPV) and internal rate of return (IRR) tend to provide inaccurate value estimates. This could mislead the strategic decision-making process and result in significant value losses. This paper aims to model financial risk related to uncertainty about market variables such as metal prices and foreign exchange rates. Other sources of risk that are related, for example, to geology and production costs are not considered in this work. The article outlines a flexible financial model that integrates uncertainty about market variables and management flexibility to react to uncertainty resolutions into mine project valuation using a real-options valuation technique based on Monte Carlo simulation. Significance of information generated from this simulation-based flexible valuation model to the strategic decision-making process is tested using an illustrative case study of a Canadian mining project. The project is a typical multi-metal, open pit mine that produces copper and gold. In this case, there are three uncertain market variables, which are: copper and gold prices and US$/CAN$ exchange rate. Financial valuations are carried out using both the conventional static DCF method and a flexible real-options model. In the flexible model, management flexibility to decide whether to go ahead with the next expansion or terminate production operations is integrated. Results show how the flexible financial model can enhance the decision-making process.

Jan 1, 2009

By B.E. Hall

Maximizing shareholder value has become a common aim for mining companies. This paper discusses the results of a number of studies developing strategic mine plans, covering a wide range of commodities, styles of mineralization, mining methods, and processing facilities, for single and multiple deposits. It has become evident that traditional methods and conventional wisdom often do not in fact achieve these goals. Operating policies at many mines ensure that shareholder value is not maximized. Changing the overall strategy can provide significant value gains. Typically, the new optimal plan involves a significant increase in the cutoff grade, at least in the earlier years. An increase in the underground development rate or open cut stripping rate is often associated with this, at least in the short term, to establish the new strategy. Cost minimization is found to be counter-productive. Counter-intuitive plans are often found to be optimal. For example, optimal cutoffs for different parts of an underground mine may be significantly different, even if mineralisation and cost structures are similar. Sub-optimal strategies are also frequently found to have a significantly greater financial risk than optimal plans, which have been found in many cases to be relatively insensitive to changes in major value drivers, such as metal prices. This paper shows how identifying and then operating within the framework of an optimal strategic plan can have substantial benefits over being continually driven by short-term tactical issues.

Jan 1, 2009

By T. Feroze, B. Genc

"Blind headings in room and pillar coal mines are a major source of methane and coal dust. Most methane and coal dust explosions therefore occur in the blind headings. The primary cause of these explosions is the disruption of the local ventilation system. Line brattice (LB) ventilation systems are used to ventilate blind headings by directing air from the last through road (LTR) into the heading. The amount of air available to ventilate the face of the empty heading depends on the heading dimension, settings of the LB, and velocity of air in the LTR. LBs are commonly installed by underground supervisory staff based on work experience, which may result in ineffective ventilation. The correct installationof LBs remains a challenge. In this study, a validated computational fluid dynamics (CFD) model has been used to analyse the effect of the LB ventilation system variables on the air flow rates close to the face of the empty heading. Full-scale three-dimensional models with various heading heights, heading depths, LB settings, and LTR velocities were simulated. The air flow rates and patterns at various locations inside the heading were analysed. A comparative study was carried out to quantify the effect of each of these system variables on the flow rates close to the face of the heading. Based on the findings, a user-friendly numerical model was formulated that can be used to estimate the flow rate close to the face of an empty heading for different practical settings of the system variables. This model can help the supervisory staff to swiftly implement the ventilation plan according to the regulations and the mine standards. The model can also serve as part of the curriculum for educating future mining engineers."

Jan 1, 2017

By T. Feroze, B. Genc

"Blind headings in room and pillar coal mines are a major source of methane and coal dust. Most methane and coal dust explosions therefore occur in the blind headings. The primary cause of these explosions is the disruption of the local ventilation system. Line brattice (LB) ventilation systems are used to ventilate blind headings by directing air from the last through road (LTR) into the heading. The amount of air available to ventilate the face of the empty heading depends on the heading dimension, settings of the LB, and velocity of air in the LTR. LBs are commonly installed by underground supervisory staff based on work experience, which may result in ineffective ventilation. The correct installation of LBs remains a challenge.In this study, a validated computational fluid dynamics (CFD) model has been used to analyse the effect of the LB ventilation system variables on the air flow rates close to the face of the empty heading. Full-scale three-dimensional models with various heading heights, heading depths, LB settings, and LTR velocities were simulated. The air flow rates and patterns at various locations inside the heading were analysed. A comparative study was carried out to quantify the effect of each of these system variables on the flow rates close to the face of the heading. Based on the findings, a user-friendly numerical model was formulated that can be used to estimate the flow rate close to the face of an empty heading for different practical settings of the system variables. This model can help the supervisory staff to swiftly implement the ventilation plan according to the regulations and the mine standards. The model can also serve as part of the curriculum for educating future mining engineers."

Jan 1, 2017

By T. Moyo

"The oxidative leaching of chalcopyrite in ammoniacal solutions has been evaluated using electro-analytical techniques and controlled bulk leaching studies. The anodic dissolution process has been established to be a sevenelectron transfer process under nitrogen in ammonia–ammonium sulphate solutions and ammonia–ammonium carbonate solutions, which suggests that the sulphur is oxidized to thiosulphate and the copper and iron released as Cu+ and Fe2+ in these systems. The deportment of Fe2+ and S2O3 2- is affected by choice of the ammonium salt used in the leaching process. In the perchlorate salt, only five electrons are transferred, supporting formation of different sulphur species as proposed for the sulphate and carbonate salts. Scanning electron microscopy and energydispersive spectroscopic analysis of the mineral surface after leaching indicate presence of an iron–sulphur surface layer completely free of copper in the sulphate system, an iron-rich surface layer in the perchlorate solutions, and absence of surface layer build-up in carbonate solutions. XRD analysis of a bulk leach residue from leaching in ammoniaammonium sulphate solutions showed the surface layer to be mostly amorphous (90%). The crystalline content (10%) is composed of 95% polymorphs of anhydrous iron oxide hydroxide FeO(OH). Choice of ammonium salt and the hydrodynamic environment of leaching have been shown to influence the presence or absence of the surface product, as well as its nature. IntroductionHydrometallurgical processes for copper extraction provide a viable route to recover the metal from mixed and low-grade ores, as well as overcome the environmental challenges faced by the traditional pyrometallurgical processes. Chalcopyrite is not only the most abundant of the copper sulphides, but also the most stable, making it recalcitrant to hydrometallurgical processes. Hence, hydrometallurgical processing of chalcopyrite continues to be an attractive area of research due to the vaguely understood surface chemistry of the mineral in different aqueous media. Different routes for hydrometallurgical treatment of chalcopyrite can be followed. These include thermal treatment prior to leaching, direct leaching and direct electrochemical leaching (Venkatachalam, 1991). Direct leaching of chalcopyrite can be carried out in various solution systems, as reviewed by Roman and Benner (1973) and Venkatachalam (1991). Ammoniacal solutions are attractive and effective lixiviants that form stable amine complexes with some base metal cations while rejecting iron. Leaching of chalcopyrite in ammoniacal solutions in the presence of an oxidant is possible due to the stabilization of copper (I) and copper(II) by ammonia at elevated pH levels. In oxygenated ammonia solutions, it has been suggested that chalcopyrite dissolves according to Equation [1] (Beckstead and Miller., 1977a):"

Jan 1, 2016

The influence of Harold Hotelling?s work in the field of mineral economics is both unusual and outstanding. In the 66 years since its development, theory surrounding the economics of exhaustible resources has only been significantly researched since the early 1970s. At that time a wave of research into the economics of exhaustible resources arose from the threat of global resource scarcity and continued into the late 1990s. Current East Asian and global demand for natural resources as well as mineral and metal commodities, has stimulated interest in the optimal and sustainable exploitation of exhaustible resources to the point that the subject is worthy of review. Hotelling?s theory and the assumptions that he made in establishing a model for the optimal exploitation of mineral resources at the industry level and at the level of the individual mine owner, are examined. He showed that the rate of increase inexhaustible resource prices should be equivalent to the market rate of interest and that in a market with rising prices the rate of extraction should be constant. In markets where demand is stable optimal exploitation requires that the rate of extraction should decline over time, while in a monopoly market he showed that the rate of extraction is retarded. In addition, the effects of cumulative production on costs and prices, the uncertainty associated with estimates of the resource stock, the impact of exploration and issues of intergenerational equity are examined. An analysis of the optimal price path, extraction costs and mineral rents at an industry level is presented as a model. An analysis of the rates of production and optimal benefits at the individual mine level including total, average and marginal costs on the optimal rate of production, is considered. Optimal extraction rates for a mine with a clearly defined concave positive cost equation vary according to the position on the marginal cost curve. The influence of discount rates and the size of the ore reserves on the rates of mineral extraction are also examined and could define the frontier of usefulness for the ?economics of exhaustible resources?.

Jan 1, 2007

By J. A. L. Napier

Computer programs which rely on the assumption of linear, elastic rockmass behaviour have been used routinely for many years in the South African mining industry to determine the stresses arising in the vicinity of mining excavations. A description is given of the theoretical background and novel solution techniques used in the recently developed MINSIM-D boundary element program. Features of the program include the ability to analyse multiple interacting reef planes at arbitrary orientation to one another, slippage on fault planes and the effects of backfill placement in mined areas. Incremental mining sequences can be modelled, and digitizer and front-end routines have been written to assist in the capture of mining outlines and general problem specifications. A brief indication is given of design problems for which MINSIM-D is appropriate, as well as some future extensions of the system.

Jan 1, 1987

A set of six design principles for rock engineering was developed by Bieniawski: design objectives; minimum uncertainty; simplicity of design components; state-of-the-art practice; optimization; and constructability. These principles translate into a ten-step design process. Although this methodology was developed for rock engineering, it is applicable to any design process, feasibility study, etc. Diligent use of such a process will ensure that a defensible design or evaluation has been carried out. Recently a ?strategic conversation? process has been identified by Ilbury and Sunter that includes the following ten steps: scope; players; rules of the game; key uncertainties; scenarios; SWOT analysis; options; decisions; measurable outcomes; and meaning of winning. A comparison of these steps with those of the design process shows a remarkable correlation. This is perhaps not surprising since engineering design is a strategic up-front issue, and front end loading in a project is critical to achieve the expected project performance. Based on the close correlation between the strategic conversation and engineering design processes, a circular design process, rather than a linear process, is proposed. The ?circle of design? better reflects the importance of review and monitoring in the two phases of successful design and implementation?defining the design, and executing the design.

Jan 1, 2009

When designing coal mine roof support, it is necessary to account for the uncertainties and variability that inherently exist within the rock mass and support elements. The performance of a support system is affected by these uncertainties, which are not taken into account in the current deterministic design methodologies used in South Africa. The key to the design of a roof support system is a better understanding of roof behaviour and uncertainties that can been countered during extraction. This paper sets out to develop a method that takes all uncertainties that exist within the rock mass and the mining process into account and provides a quantitative risk-based design methodology.

Jan 1, 2009

By A. S. Nhleko, P. R. Lobe, H. Mtegha

"Government’s equity role in the minerals sector is one of the nationalist measures implemented in order to ensure greater control and management of a country’s mineral resources. This paper evaluates the Tanzanian government’s equity participation in the minerals sector from 1996 to 2015. The research methodology included determination of the number of mineral rights, minimum allowable exploration expenditures in prospecting licences (PLs), and forms of equity role of the government. Data was collected and analysed for PLs, mining licences (MLs), and special mining licences (SMLs).The study revealed a number of challenges faced by the Tanzanian government as regards its equity strategy in the mineral sector. One of the major challenges was the secrecy surrounding agreements and contracts entered into between the government and private sector investors, which were concluded via various business ownership and mineral development projects. This secrecy resulted in non-transparency and lack ofaccountability in the mining industry.The financial benefits accruing to the government were inadequately realized, evident through inconsistent payments of corporate income tax and mining royalties by the mining companies. Furthermore, the government does not have solid mechanisms and frameworks for assessing non-financial benefits, thus it is difficult to measure the impact of these factors.It is recommended that the Tanzanian government review the Mining Act and Regulations of 2010 to include the provision of solid mechanisms and frameworks for all forms of government equity role.This paper is based on an MSc research study undertaken at the University of the Witwatersrand.IntroductionGovernments can grant private companies mining rights to extract mineral resources, or take a stake in the companies as well as establish state companies to oversee their interests in the minerals sector. The establishment of a state company to oversee government interests in the mining sector implies the direct participation of government by way of equity participation. Equity participation or role is defined as the holding of shares in an enterprise, company, or asset by individuals or a body corporate (Otto, n.d.; Brown, 2013; Natural Resource Governance Institute, 2015)."

Mar 1, 2019

By N. Mulaudzi

The use of SO2/air gas mixtures as an oxidant to precipitate Mn from Co(II) leach liquors was investigated. The effects of SO2/air ratio, pH and temperature on Mn precipitation were evaluated. It was found that the use of SO2/air gas mixtures resulted in significantly higher Mn precipitation kinetics compared to using air or pure O2 alone. The SO2/air ratio was varied from 0% to 6% SO2(v/v) in air and similar Mn removals were achieved at 0.75% to 3% SO2 at pH 3. The solution pH was varied from pH 2 to pH 4; Mn precipitation did not increase considerably from pH 2 to pH 3, but increased significantly at pH values higher than pH 3. Cobalt co-precipitation also increased as pH increased, with 1% Co co-precipitation at pH 3. An increase in temperature from 30°C to 60°C also increased Mn precipitation and 100% Mn precipitated at 50°C. Cobalt co-precipitation also increased significantly with an increase in temperature. An activation energy of 25 kJ/mol was calculated from the Arrhenius plot, which is an indication that the precipitation reactions were both chemically and diffusion controlled. XRD analysis showed that Mn precipitated in the form of Mn2O3 instead of MnO2 that was predicted from thermodynamic data. SEM and XRD analysis also revealed that the precipitate consisted mainly of gypsum or bassanite (99%), with the Mn containing phase (< 1%) distributed within the gypsum phase. The co-precipitated Co reported to the Mn phase. Keywords: manganese precipitation; SO2/O2 gas mixtures; cobalt solutions.

Jan 1, 2009

By P. J. Kinver

This paper deals with the development of backfilling methods and systems at the Broken Hill orebody of Black Mountain Mineral Development Company (Pty) Limited, at Aggeneys in the north-western Cape Province. Production started in 1979, being confined to large diameter blasthole stoping methods in the upper, steeply dipping areas of the orebody. This blasthole reserve is now depleted and the production tonnage, 100000 tons per month, is produced from eight cut and fill stopes in the flatter dipping areas of the orebody. The fill methods of the blasthole stoping area evolved prior to the pillar extraction are briefly discussed together with the resulting experiences gained that enabled virtually 100% extraction to be achieved. The original cut and fill mining used costly hydraulic cemented fill; this was replaced partly by unconsolidated river sand and later by dune sand which occurs in abundance. The paper describes the planning, research work and commissioning of a cycloning plant that now enables dune sand to be used successfully as an unconsolidated hydraulic fill. The development of drainage, placement and control methods are also reviewed.

Jan 1, 1988

By A. Dabbagh

The aim of this research was to investigate the effect of coke particle size on the thermal profile of the charge bed in the sintering process of iron ore. Six different ranges of coke particle size that could be used in practice in the sintering line of Esfahan Steel Company (ESCO) were used while parameters such as ratios and particle sizes of other ingredients, ignition temperature, and suction power were kept constant. Thermal profiles were obtained by measuring the temperature changes at three points in the sintering bed. The influence of coke particle size on rate of temperature rise, maximum temperature of the sintering bed, and the flame front velocity of the sintering bed was determined by analysing the thermal profiles. Moreover, the cold strengths of the sinters were measured using the Tumbler method. The results indicated that the coke particle size has a significant impact on the thermal properties of the sintering bed. Based on the results, a coke particle size between 0.212 mm and 3.350 mm was determined as the optimal range for the specific conditions in the sintering line of ESCO. Keywords iron ore sintering, coke particle size, thermal profile, flame front velocity, Tumbler index.

Dec 1, 2013

By P. S. Piper

In the 1960s it was suggested that the volume of stope convergence, and hence the rockburst hazard, could be reduced by the emplacement of backfill. Recent advances have facilitated the placement of large quantities of backfill underground, and a reassessment of its potential benefits as part of a regional support strategy is now timely. In this paper the principal criteria of effectiveness of backfill are taken to be its impact on face energy release rate (ERR) and average pillar stress (APS) levels, and maximization of acceptable ore extraction ratios. The possible effects of backfill on excess shear stresses (thought to modulate large seismic events) are also briefly reviewed. Analytic solutions describing backfill properties and their impact on ERR and APS in certain idealized geometries are also presented, and compared with the results of an extensive suite of computer simulations, in which parameter sensitivities are explored. Results indicate that a regional support strategy is required at depths exceeding 2 km in order to maintain acceptable levels of ERR, and backfill ribs can on their own fulfil this role at depths less than 3,3 km. At greater depths use of stabilizing pillars becomes imperative, but here too supplementary backfill ribs can reduce ERR and APS levels and permit significant increases in ore extraction ratios.

Jan 1, 1988