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By S Sondashi, F. J. Chidley, W. A. Grobler

Some of the challenges facing the flotation of base metal sulphides are the opening of new and varying ore bodies as well as maintaining essential skills in plants. Flotation reagent research focuses not only on improving flotation grade and recovery, but also on producing reagents robust enough to cope with changes. A group of recently developed co-collectors, activators, depressants and frothers are described together with a summary of results measured on base metal sulphide ores.

Jan 1, 2005

By L. M. Tavares, H. A. Petit, P. P. Cavalcanti

Iron ore pellets experience degradation during handling due low energy impacts and stresses. These impacts lead to volume or surface breakage of the pellets, creating fine particles that accumulate along the process. Some of the particles are in contact with the air and are dragged as dust into the workplace or into the atmosphere. The aerodynamic size of the particles allows them to be potentially inhaled by the workers or to be carried to nearby communities. Dust emission becomes critical at specific locations, such as transfer chutes and stockpiles. This work models the dust generation that occurs in an iron ore pellet stockyard using a methodology that combines experiments to quantify the degradation of the pellets to mathematical modelling of the dust emission mechanisms in the stockyard. First, laboratory tests were used to characterise the amount of mass and the particle size distribution of the dust generated by degradation under controlled conditions. Second, the flow over a stockpile of an iron ore pellet company was simulated with the aid of computational fluid dynamics (CFD) simulations. Third, semiempirical equations linked the data generated by simulations and laboratory tests to estimate the dust emission in the stockyard. Finally, results were validated with measured field data, obtained with a novel online measurement tool. Results suggest that the approach is able to predict dust emission with sufficient accuracy and can be used for further implementation in the management of operations and decision making in order to reduce the environmental impact of the process. Keywords: Iron ore pellets, abrasion, dust emission, mathematical modelling

Jan 1, 2020

By Krogerus. H., P. Jokinen, T. Lintumaa

Keywords: Pyrometallurgy, furnace, coke, smelting charge, optimization, ferrochrome The main consumer of ferrochrome is stainless steel production. Stainless steel must maintain a reasonable price against other competitive materials. Therefore, the ferrochrome price must be low enough and profitable for the producers of stainless steel. The investment and operational costs of ferrochrome production are greatly dependent on the availability of the process and the production rate. Thus the furnace size and production rate in submerged electric arc furnaces will be greatly increased in the near future. The ferrochrome production per furnace, e.g. at Outokumpu?s Tornio Works, increased from 30 000 t/a to 165 000 t/a in about 35 years. The same trend will continue globally but now much more quickly. The Outokumpu ferrochrome process at Tornio Works uses sintered chromite pellets and upgraded lumpy ore as a chromite source. Metallurgical coke is used as a reductant. Reliable smelting in a large furnace demands the correct charge composition and well-known characteristics of the charge components. The quality and electrical conductivity of cokes (normally used) has the most important role for the electrical conductivity of the smelting charge. The results of the measured electrical conductivity of different cokes and the smelting charge with many controlling factors are presented here. These measurements were performed over the years for our own purposes at the laboratory of Outokumpu Research Oy (ORC), in Pori, Finland.

Jan 1, 2006

By O. Naiker

Xstrata has modified and improved on the solid state reduction of chromite (SRC) process that was pioneered by Showa Denko in Japan and previously used at Xstrata?s Lydenburg plant. The history of pre-reduction is a long one, with the SRC process being the first and only commercially successful one prior to Premus. Krupp developed the chromite direct reduction and the rotary hearth for the pre-reduction of chromite. However, these processes have not been successfully commercialised. The are a number of significant differences between Xstrata?s patented Premus and the original Consolidated Metallurgical Industries (CMI) process. These include, the use of lower cost anthracite fines as the reductant source together with the use of unactivated bentonite as the binding agent. In addition the use of oxygen as an energy source is used in Premus but not in the original CMI process. There was a fundamental change in the operational philosophy of the process in that while the original CMI process aimed to maximize metallization of the pellets, the Premus process seeks to maximize the energy output from the kiln while still achieving the required efficiencies and hence increasing furnace output. Premus is designed to reduce electrical energy consumption, provide high recoveries of metallic oxides, and utilizes low cost reductant and energy sources such as anthracite and oxygen respectively. Due to the fact that Premus is one of the most technologically advanced and competitive processes used today in the production of ferrochrome it was the process selected for Xstrata?s new ferrochrome facility, Project Lion, that is due to be commissioned in the third quarter of 2006 in the Steelpoort Valley in Mpumulanga, South Africa.

Jan 1, 2007

By Swapan Ghosh, Amitava Sengupta, Proloy Das

Ferro-alloys are very important ingredients used for making of quality steel with desired composition. In view of high demand in various types of ferro-alloys, it has become necessary to produce the same efficiently, safely and cost-effectively with consistent quality maintaining the anti-pollution norms. To achieve this goal, it is necessary to adopt latest process/equipment with the state-of-the-art instrumentation and automation system. A Programmable Logic Controller (PLC) based automation system with suitable Human Machine Interface(HMI) terminals along with intelligent field mounted sensing/control devices allows to monitor and control the complete plant effectively with optimum deployment of man-power. In association with this, use of process optimization controllers enables to achieve specialised functionalities of the submerged arc furnaces like material management, lining management, electrode management, power management, overall production management etc.

Jan 1, 2007

By F. Navarro, F. Soto, G. Díaz, E. Jélvez, G. Morales, N. Morales

The increasing availability of tools on the web provides a great opportunity for the research community to boost investigation by accessing computational resources from all over the world. For example, data analytics libraries implemented in languages like Python can be accessed through many open and commercial platforms, therefore providing researchers with a common set of tools or shared datasets. Unfortunately, that is not the case with research in resource assessment and mine planning, where the most standardised tools are commercial applications designed to work on the desktop, but there are not many standard platforms for research. As a result, researchers from different groups often need to start from scratch in order to develop their work, and rarely share implementations details. Similarly, apart from a few publicly available examples, there is a lack of common datasets that are validated and can be used to compare results between different approaches. In this paper, we introduce a platform that provides tools for resource assessment and mine planning, which can be accessed remotely utilising Jupyter Notebooks. In its current version, the platform provides (i) definition and implementation of basic structures for managing samples and models (loading, saving, adding or removing columns, etc.), (ii) definition of experimental and modelled variograms for spatial continuity analysis, (iii) definition of standard interpolation methods in resource evaluation (inverse distance and kriging), (iv) definition of standard problems in mine planning (ultimate pit and precedence constrained production scheduling), (v) generation of 2D standard graphs like grade distribution, conditional means, tonnage-grade, and production plans (vi) a set of datasets, which can be used for case studies, and (vii) a set of notebooks with examples and documentation. In this paper, we introduce the platform and show some examples that illustrate some of the possibilities that it has for research and education in the area of resource assessment and mine planning.

Sep 1, 2021

By M. S. Shishvan, J. R. van Duijvenbode, L. M. Cloete, M. W. N. Buxton

Geochemical and mineralogical datasets from Tropicana Gold Mine, Australia, have been used to define ore fingerprints. VNIR/SWIR spectral data were represented by four normalised wavelength regions and were clustered to form spectral classes. Sequentially, these spectral class proportions within a block and collocated XRF data were clustered to form material types (fingerprints). The material types were related to an Equotip-BWi correlation. These correlations can be used to extrapolate a hardness signature and generate a BWi proxy for different blocks. The combined fingerprints and BWi proxy can assist as a tool for enhancing the prediction of comminution behaviour. They can explain specific domain-related hardness variations. For example, one material type could be separated into a softer (~15-18 kWh/t), and harder (>20 kWh/t) material blend. This was accomplished using the commonly overlooked VNIR region at 605 nm. This outcome has significance for blending strategies.

Sep 1, 2021

By P. S. G. Leon

One of the most difficult areas in concession contracts in resource-rich developing countries is achieving an equitable balance between the interests of investors, host states and, increasingly, mine and near mine communities. While some countries in the Andean region have resorted to outright or creeping expropriation of natural resource contracts under the guise of resource nationalism, others such as the Democratic Republic of the Congo (DRC), have claimed international best practice in the review (and setting aside) of important concession contracts.

Jan 1, 2011

By M. Z. Naghadehi, F. F. Nasategay, J. Sattarvand, R. Battulwar, E. E. Gohari

After the recent increase in catastrophic failures of tailings dams such as the Burmadinho, Brazil failure in 2019, the mining industry has actively engaged in the stabilisation of tailings dams. Most of the tailings storage facility (TSF) guidelines suggest a laborious action that can be facilitated through imaging by unmanned aerial vehicles (UAVs). Although UAVs are not unknown to most mining operations, automated rill detection through aerial image processing is a new concept. This study utilises images from sites in the U.S. and employs semantic segmentation with a UNet architecture to detect location and size of these rills. The developed model can be used as a tool for monitoring surface erosion of TSFs.

Sep 1, 2021

By Z. Gxowa, L. H. Chown, U. Curle, G. Govender

This work evaluates the deformation behaviour, at warm working temperatures, of green particle-reinforced aluminium composites produced by powder blending in a high-energy ball mill. The work focuses on metal matrix composites (MMCs) based on the 2124-Al alloy, reinforced with 10 or 15 vol.% SiC and metal matrix nanocomposites (MMNCs) based on the 2124-Al alloy, reinforced with 5 or 10 vol.% Al2O3. Three batches for each powder were blended and powder properties such as particle size distribution (PSD) and shape were consistent after blending. It was observed that a more uniform distribution of the reinforcement phase in the aluminium alloy matrix was achieved in 2124-Al/Al2O3 than in 2124- Al/SiC composites. The powders (unreinforced 2124-Al and blended) were initially over-aged at 350°C for 2 hours to reverse any natural ageing that may have occurred prior to use. The over-ageing was incorporated to improve compressibility of the powders with the aim of achieving green compacts with higher integrity. Uniaxial compression tests performed at ambient temperature on a Gleeble® 3500 thermomechanical simulator were unsuccessful as the green compacts fragmented. Engineering stress-strain curves showed that green compacts of unreinforced 2124-Al, 10%SiC MMC and 5%Al2O3 MMNC deformed in a similar manner at ambient temperature and had the same compressive fracture stress of approximately 170 MPa. When the deformation temperature was increased from ambient to warm working temperatures (170–280°C) it was observed that electrical resistance heating (the heating mode of the Gleeble®) of unreinforced Al alloy, MMC and MMNC green compacts did not occur. This was attributed to the high electrical conductivity of aluminium, which resulted in poor heat generation due to the low electrical resistance in the samples. It was presumed that the small sample size (d=8 mm, h=12 mm) also caused rapid heat loss. After further experimentation, the green compacts were heated successfully by insulating the samples to retain heat. It was found that at 280°C, increasing the soaking time from 6 to 20 minutes decreased flow stress and improved plastic flow in the 2124-Al/10%SiC green compact.

Jan 1, 2016

By N Morales, G Nelis

Short-term plans must meet the long-term goals while accounting for shovel selectivity, operational space, and scheduling restrictions. There are several approaches that deal with these issues to deliver a feasible short-term schedule. This paper compares two approaches based on mathematical programming to address the short-term mining cut definition and scheduling in an integrated way. They work by scheduling extraction to comply with long-term production goals, but they differ in how mining cuts are modelled. The first approach schedules Selective Mining Units (SMUs) but aggregates them around predefined locations. The second approach does not work on SMUs; it decides directly what mining cuts are to be used from a pre-defined set of shapes. It assigns a destination and schedules the extraction for the selected mining cuts. We applied both approaches in a real case study to compare their results in terms of profit, mining cut design, expertise needed, profit, and optimisation performance.

Sep 1, 2021

By B. P. von der Heyden, T. Blenkinsop, A. Mamuse

Zimbabwe hosts a varied array of coloured gemstones. With the exception of emerald deposits and several world-class pegmatites, few of the gemstone occurrences have received detailed attention from the scientific or mineral exploration communities. In the present contribution we summarize the status of knowledge of the gemstone deposits and occurrences in Zimbabwe, paying particular attention to the geological settings in which they were formed. Synthesis of this regional geological approach reveals that there may be significant exploration potential for further gemstone occurrences, particularly in the extensive pegmatite fields and in Al-enriched orogenic belts that have undergone greenschist to granulite facies metamorphism. Further socio-economic and developmental initiatives will aid in optimizing the value generation from this important sub-sector.

Feb 12, 2024

By Gordon Chunnett, Ron Sheets, David Grant

[Power-Point Presentation]

Jan 1, 2005

By M. B. C. Brandt

Richter magnitudes for seismic events were calibrated for use as a Local magnitude scale in the West Rand (WR), Far West Rand (FWR), and Klerksdorp–Orkney–Stilfontein–Hartebeesfontein (KOSH) gold mining areas. Richter magnitudes are currently calculated from seismograms recorded by local surface cluster networks using tabulated calibration values for Southern California, published in 1958. The Richter (1958) model is incorrect for distances of less than 30 km and should be applied only to crustal earthquakes in regions with similar attenuation properties to those of Southern California. When compared to the South African National Seismograph Network (SANSN), the cluster networks, on average, overestimate seismic event magnitudes by approximately 0.1 of a magnitude unit. A calibrated Local magnitude scale was derived by means of a multiple regression analysis between the Local magnitudes reported by the SANSN and the largest zero-to-peak trace amplitudes measured on the cluster network horizontal seismograms, after modelling the attenuation of the seismic waves as these progress from the epicentre to the station position. Magnitudes reported by individual stations for the same event show a significant scatter around the average magnitude owing to the near-surface amplifications of the seismic waves at the recordings sites. Average magnitude should be estimated using as many magnitudes of individual stations as possible to ensure an accurate estimate. Larger event magnitudes should be compared with those recorded by the SANSN.

Nov 1, 2021

By D. He, A. Yaacoubi, A. Baçaoui, K. Boujounoui, A. Abidi, K. El Amari

The effects of utilizing recycled tailings pond water from the flotation plant at the Mining Company of Guemassa (MCG) on galena recovery and selectivity towards chalcopyrite (RPb-Cu) , sphalerite (RPb- Zn), and pyrrhotite (RPb-Fe) were studied at bench scale. The results showed that recycling the tailings pond water in the lead circuit without addition of fresh water gave a good flotation performance in terms of lead recovery (Rpb) (75%) and selectivity towards the other metals: RPb-Cu (54%), RPb-Zn (60%) and RPb-Fe(65%). This allows the water to be recycled at least four times. However, increasing the d80 from 100 μm to 160 μm currently used at the MCG plant had a negative effect on the lead flotation performance.

Nov 30, 2022

By M. Rudolph, J. Sygusch

Froth flotation is well-established and efficient in the selective separation of valuable particles from unwanted material with sizes ranging from 10 μm to 200 μm. However, when it comes to the separation of ultrafine particles (< 10 μm) there are still some challenges, or rather opportunities. This research aims at developing a method for the separation of ultrafine particles based on multiple particle properties. Amongst such properties are wettability, morphology (shape or roughness) and size with applications not only in mineral processing but in general chemical engineering. In this study, three differently shaped fractions are used as valuables for testing: spherical particles, elongated particles and irregularly shaped particle fragments; together with ultrafine magnetite as the gangue material, in order to investigate the effect of particle morphology on ultrafine particle flotation, as well as wettability, which is varied by esterification using alcohols. Flotation tests are carried out using a novel flotation device that was designed especially for the flotation of ultrafine particles, combining advantages from machine-type froth flotation and column flotation. The results showed that, in contrast to previous studies, recoveries for ultrafine spheres were higher than for ultrafine fragments for all wettability conditions, and hydrophobisation generally increased particle recoveries for said morphologies. Tests using fibres showed different behaviour as hydrophobisation had negative effects on their recovery, despite increased selectivities and kinetics. These findings suggest that apart from influences of particle properties within the suspension zone, their effects on the froth characteristics should be studied in more depth. Keywords: Ultrafine particles, Flotation, Particle shape, Wettability, Esterification of glass, Hydrophobisation

Jan 1, 2020

By M. A. Reuter, N. J. Bartie

Metals make modern societies function, and increasingly, various high purity precious and special metals endow sustainability-driving technologies with specific functionalities. These metals become heavily intertwined within products, complicating end-of-life treatment. To counteract the resulting downcycling and potential depletion of scarce resources, maximising both the quantities and qualities of materials recovered during primary extraction and recycling, processes should be a priority in the pursuit of sustainable circular economy. Adopting a process simulation approach; a digital twin for the life cycle of cadmium-telluride solar photovoltaic (CdTe PV) modules was created. The system comprises an integrated metallurgical production system that produces, among others, cadmium, tellurium, selenium, zinc, copper, and lead, all of which are required to manufacture PV modules. System-wide resource efficiency and environmental impacts are assessed using exergy analysis and life cycle assessment, respectively. Simulation of this large and complex product life cycle at a high level of detail allows for the evaluation of potential system-wide effects of various production, recycling and residue exchange scenarios aimed at maximising the sustainability of the entire system. It diminishes the need to make arbitrary choices about allocation methods for the distribution of environmental impacts in multipleoutput production systems. Furthermore, it demonstrates the key importance of metallurgy in achieving circular economy. Keywords: Circular economy, sustainability, simulation, metallurgy, CdTe photovoltaics, life cycle assessment

Jan 1, 2020

By I. du Plessis

The metallurgical response of a difficult to treat coal and an easy to treat coal orebody were investigated in terms of the coal yield and the coal quality in a basic coal recovery flowsheet. The purpose of this paper is to show trends and derive principles for the treatment of different coal types. This investigation entailed using the LIMN simulator to simulate the metallurgical response by varying the plant operational parameters. The controllable plant variables investigated were: ?Cyclone size ?Screen and hydro-cyclone cut points ?Medium cut density ?Feed particle size distribution.

Jan 1, 2010

By I. Kaabachi, F. Meunier, N. Morales

In open pit mining, ore and waste are hauled outside of the excavation area by trucks that move along a system of ramps. The design of these ramps must be carefully addressed because they have to comply with geomechanical constraints to ensure the stability of the pit walls, provide access to the different levels and phases, but also maximise the value of the extracted ore and reduce the extraction of waste. Because an optimisation approach able to deal with the design of the full ramp system seems to be out of reach at the moment, this paper addresses the problem of designing one ramp providing access to a single pushback, which has been determined beforehand. The optimisation objective is therefore to find a ramp that gives access to one given potential volume, while minimising its impact on the economic value of the volume. Two versions of the problem are formalised. One version allows the extraction of ore and waste only if this extraction is necessary for the ramp system. This version somehow minimises the intrinsic value of the ramp system. In the second version, it is possible to extract more than is needed by the ramp system. For instance, this takes into account the possibility of attaining ore on the wall opposite to the ramp as soon as the ramp reaches its level. In the setting mentioned above, the contribution of this work is three-fold. First, the computational complexity of the two different versions of the problem is presented and discussed; in particular, they are shown to be NP-hard. Second, compact integer programs modelling these two versions are proposed. Third, an efficient GRASP algorithm able to cope with the large instances of the problem is proposed. To assess the proposed approaches, the models and algorithms are applied to real instances with an off-the-shelf solver, illustrating and discussing their potential and relevance for the two versions of the problem. They are also compared with other approaches from the literature in terms of value and resulting designs.

Sep 1, 2021

By V. W. Lumadi, S. Nyasha

The mining industry has yet to fully accept and embrace the strategic role of technology and innovation in successful business planning and execution. In this study, we empirically determine the factors that influence acceptance of technology solutions in the mining industry in South Africa, assess critical success factors influencing adoption of advanced technology in the South African mining industry, and explore challenges faced by the mining industry in South Africa in adopting advanced technology in its operations. Thematic content analysis is employed in the data analysis. Results show that critical success factors to the adoption of mining technology include learning culture, knowledge sharing, high labour costs, and behaviour of other firms in the industry; commonly identified challenges include inadequate engagement with external stakeholders, uncertainties, the cyclical nature of the sector, and high risk related to the adoption of unproven technology and performance systems focused on volumetric production. The study encourages mining companies to implement usage of technology. This can be properly done through regular engagement with the Minerals Council South Africa.

Apr 14, 2024