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By A. v. E. Conradie, I. Nieuwoudt

Comminution and flotation circuits are frequently perturbed by disturbances, such as feed particle size variations, ore hardness and varying mineral liberation, which can have a significant impact on the recoveries and grades. Although advanced control strategies can neutralize many of these disturbances, few such systems have been implemented at present. One reason is that it is only recently that the requisite sensor systems have been developed and used to control froth flotation systems. Another is owed to the complexity of these non-linear interactive systems. In this paper, a plant-wide control strategy is considered, wherein both unit operations have a single overall control objective. The automated design of the controller is based on an advanced evolutionary algorithm viz., Symbiotic, Memetic Neuro-Evolution (SMNE), for developing neural network controllers in a reinforcement learning framework. A rigorous phenomenological comminution and flotation model was used to develop suitable neurocontrollers, which used all possible sensor inputs and available manipulated variables. The neurocontroller managed to identify optimal or near-optimal operating conditions consistently and showed robust performance in the presence of significant disturbances. The results suggest that evolutionary reinforcement learning offers a very competitive approach towards the development of integrated non-linear controllers for mineral processing plants. Keywords: neural networks, control, flotation, comminution, evolutionary reinforcement learning

Jan 1, 2003

By M. -B. Kime

This study applies attainable region analysis to optimise cobalt recovery from oxidised ores via reductive leaching with sulphur dioxide and sulphuric acid. The attainable region framework enables systematic visualisation of trade-offs between cobalt yield and sulphur dioxide loss, guiding reactor network design beyond conventional mass balance modelling. Experimental column leaching trials, supported by validation runs, were conducted under controlled flow and reagent conditions. Kinetic parameters for cobalt dissolution and sulphur dioxide consumption were used to simulate reactor trajectories and construct attainable region envelopes. To ensure hydrodynamic realism, residence time distribution tests confirmed partial plug flow behaviour with dispersion effects, justifying the use of hybrid reactor models in the attainable region simulations. The results revealed that increasing recirculation ratios improves cobalt yield while reducing sulphur dioxide losses, with attainable efficiencies exceeding 90% cobalt recovery and < 20% sulphur dioxide loss. Importantly, the study proposes practical reactor network configurations for future implementation, including staged percolation columns with intermediate mixing zones, oscillatory flow reactors, and modular fluidised bed systems. These designs offer scalable pathways to translate attainable region-based optimisations into industrial practice. Compared to traditional modelling, attainable region analysis provides a geometric decision support tool that captures multi-objective trade-offs and reactor interactions, offering novel insights for continuous leaching system design. This work advances the application of attainable region methodology in minerals engineering by bridging theoretical optimisation with practical reactor design, supporting sustainable cobalt recovery from both primary ores and recycled feedstocks.

Mar 30, 2026

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

By H. M. Stewart, N. F. Dawson, J. P. Beukes, P. G. van Zyl, Q. P. Campbell, A. Jordaan, R. I. Glastonbury, L. N. Sadiki

"SynopsisThe physical properties of oxidative sintered pellets produced from typical South African UG2 ore are compared with the physical properties of pellets produced with conventional South African metallurgical-grade chromite ore (from the Lower Group 6 or the Middle Group 1 and 2 seams). A statistical evaluation of the cured (sintered) compressive strengths proved that pellets prepared from UG2 ore are likely to have the same, or better, compressive strength than pellets prepared from metallurgical-grade chromite ore. The cured abrasion strength of the UG2 pellets was also superior to that of the metallurgical-grade pellets. Scanning electron microscopy (SEM) backscatter, secondary electron, and elemental X-ray mapping were used to determine the reasons for the general superior strength of the UG2 pellets. The case study UG2 ore also required 13 kWh/t less energy for milling to attain the required particle size distribution prior to pelletization, which can lead to substantial cost savings. Results presented in this paper can be utilized by ferrochromium (FeCr) producers to better quantify the advantages and disadvantages associated with the use of UG2 ore for FeCr production.IntroductionChromite, a mineral of the spinel group, is the only commercially viable source of virgin chromium units. Geologically, commercial chromite deposits in the world are found in three forms, i.e. alluvial-, podiform-, and stratiform-type deposits (Murthy et al., 2011; Cramer et al., 2004). Alluvial deposits were formed by weathering of chromite-bearing rock with the subsequent release of chromite and gravity concentration by flowing water. However, these deposits are relatively small and of comparatively minor commercial interest. Podiform-type chromite deposits usually occur as irregularly shaped pods or lenses, and their distribution within a mineralized zone is usually relatively erratic and unpredictable, making the exploration of these deposits difficult and costly (Cramer et al., 2004). Stratiform-type chromite deposits occur as parallel seams in large, layered igneous rock complexes with more regular layering and lateral continuity (Cramer et al., 2004). The largest example of a stratiformtype chromite deposit is the Bushveld Complex (BC) in South Africa, which holds an estimated three-quarters of the world’s viable chromite ore resources (Cramer et al., 2004).Several chromite seams exist in the BC. The seams of economic interest are the Lower Group 6 (LG6), the Middle Group 1 and 2 (MG1 and 2), and the Upper Group 2 (UG2) seams (Cramer et al., 2004). The LG and MG seams are specifically exploited for their chromium content, while the UG2 seam is mined primarily as a source of platinum group minerals (PGMs) (Xiao and Laplante 2004). Extraction of the PGMs from the UG2 ore usually involves the liberation of the sulphide by milling and subsequent recovery of the PGM concentrate through flotation (Xiao and Laplante, 2004). Chromite in the PGM concentrate is undesirable; therefore, PGM recovery circuits are specifically designed to ensure maximum rejection of the chromite to the tailings stream. However, the chromite in the PGM tailings can potentially serve as feedstock for ferrochrome (FeCr) production, after beneficiation to increase the chromium content."

Jan 1, 2015

By L. A. Jordan, D. van Vuuren

A two-dimensional finite difference model has been developed to describe the reduction of kilogram quantities of dehydrated phosphogypsum. The model’s scope has been limited to focus on the heat transfer and reactions that occur within a mass of material contained in a vessel inside a furnace rather than also including the effects of heat transfer to the vessel. Changes in the heat transfer properties (k, ρ, and Cp) are incorporated as the composition of the mass changes as the chemical reactions progress. The model is validated against experimental data, with samples heated to 1000°C at 3°C min−1 while purging with nitrogen gas. A sensitivity analysis of model predictions to the pre-exponential factor of the reaction rate constant of the main chemical reaction and the thermal conductivity of the powder bed indicated that, at the envisaged process conditions, the behaviour of the system depends much more on the rate of heat transfer than on the rate of the chemical reaction. The model demonstrated a significant increase in accuracy when the thermal conductivity was modelled to increase linearly with temperature compared to assuming a constant value.

Oct 1, 2022

By J. A. Batista-Rodríguez, F. J. López-Saucedo

A new methodology is proposed for the preliminary assessment of coal blend quality, which combines gamma-ray spectrometry and magnetic susceptibility measurements. This methodology does not replacethe conventional methods of assessing coal quality, but can help to control the quality of the coal blending process, as well as reduce the amount of proximate analysis required and the determinations of calorific value and total sulphur. The methodology includes five steps. First, both geophysical measurements aremade with handheld equipment. The samples with magnetic susceptibility ≤ 1 × 10-3 SI are then separated. From these samples, those with total gamma intensity ≤ 20 nGy/h are separated. These samples have a higher calorific value and lower ash and moisture content. To separate the samples of better quality and with lower total sulphur content, in step four the samples with total gamma intensity > 20 nGy/h are separated from those with magnetic susceptibility ≤ 1 × 10-3 SI. This last group includes samplesthat will cause less total sulphur-related environmental pollution. In the final step, the quality of both radioactive sample groups is corroborated from the calorific value measurement and ash, moisture, andtotal sulphur contents in at least 10% of all coal blend samples from both groups. In this study, more than1000 samples were analysed with this new methodology, and the results are remarkably similar to the ASTM classification of the Sabinas Basin coals.

Apr 2, 2022

By M. Seeger

The demographics and the growing numbers of people provide a strong signal that the demand for electrical power in Southern Africa will grow considerably over the foreseeable future. Without a steady and increasing supply of electricity development of the continent is likely to be constrained. The inventory of solar, wind, hydrothermal, geothermal and biomass resources will probably provide sources of energy for the future The parallels between extraction of natural resources in the minerals industry and the green energy industry is striking, and the well-established project development process in the minerals industry provides an ideal and useful template for comparing the establishment and development of green energy projects. The potential levels of power generation and carbon savings are described.

Jan 1, 2010

By G. Akdogan, I. J. Geldenhuys, Q. G. Reynolds

Efficient recovery of titanium from titaniferous magnetite ores continues to be a promising, yet unrealised opportunity, despite significant occurrences of titaniferous magnetite deposits worldwide and the existence of established industrial-scale practices. Current smelting processes only recover iron and vanadium, while the titanium is discarded in the waste slag. These slags are stockpiled and present massive environmental challenges, while still containing value as residual iron, vanadium and titanium. The complex mineralisation of these deposits does not allow for a significant opportunity to separate the titanium and magnetite minerals through normal physical upgrading processes. An upgrading process is therefore required to derive economic value. An efficient process technology could create an opportunity to unlock all three valuable commodities. South Africa’s Bushveld Complex, the largest known deposit of its kind in the world, is known for the high vanadium content but is also associated with relatively high concentrations of titaniferous magnetite. The quality of the Bushveld Complex was one of the drivers for the establishment of the Highveld Steel and Vanadium Company in the mid-1960s. The unfortunate demise of Highveld Steel and Vanadium created an opportunity to review current practices and evaluate the best available process for this complex ore in the context of the three elements of interest. Past and current processes, the nature of these deposits and the potential to recover titanium are assessed to highlight the potential of fluxless smelting of titaniferous magnetite to produce a titania-rich slag as feedstock to the pigment, titanium metal industry in conjunction with recovery of iron and vanadium. Ilmenite smelting practices are proposed as a suitable alternative to achieve the goal, namely sustainable processing. Keywords: Titaniferous magnetite, titanomagnetite, smelting, titania slags, comprehensive processing

Jan 1, 2020

By K. Lomberg

In this paper the process of sampling and assaying as it relates in particular to the platinum group elements (PGEs) is presented. A discussion of the geology of PGE deposits is included to provide an understanding of the mineralization that is considered necessary prior to sampling, as this has a direct bearing on the mineral resource estimate and also the selection of an appropriate mining cut. The discussion includes the selection of the sampling technique (drilling or face sampling), the size of the sample relating to the requirements of the laboratory, the potential mining cut, as well as a reference to sampling theory. The selection of an assay technique that is appropriate and will yield the optimal result based on sample turnaround, precision, accuracy, and cost is then considered. Examples are drawn from work undertaken on the Bushveld Complex (Merensky Reef, UG2 Chromitite Layer, Platreef) and Great Dyke (Main Sulphide Zone). A discussion of the appropriate QA/QC programme includes the chain of custody, CRM selection and the QA/QC process. Keywords sampling, assaying, QA/QC, platinum group elements.

Jan 1, 2014

By Onuralp Yücel, Süheyla Aydin, Erçin Ersundu

Turkish iron and steel sector, the base of which was established in the 1930?s, plays an important role in the industrialization and development of the country?s economy. In Türkiye this sector is the major consumer of ferroalloys. There had been a great improvement in Turkish Iron and Steel industry, especially after the 1980?sand as a result, 20.9 million tons of yearly crude steel production placed Türkiye 11th in the global steel output and 3rd in Europe. 15 % of steel produced in Türkiye is flat products, while the long products make the rest. The product composition and the general characteristics of steel production process led to an increase in ferroalloy consumption. Domestically consumed ferroalloys are especially ferromanganese, silicomanganese, and ferrosilicon. As of today, ferroalloy production capacity of Türkiye is 173,800 tons/year; 161,500 tons of which is ferrochrome with high and low carbon grades, 7,300 tons of ferrosilicochrome and the rest is ferrosilicon (5,000 tons/year). Türkiye is one of leading ferrochrome producers in the world considering the above mentioned production figures. However, this production is mainly exported since Türkiye?s stainless steel production level is modest requiring low amounts of ferrochrome. The products of iron and steel industry in Türkiye require large quantities of other ferroalloys, which make Türkiye a major importer and exporter of ferroalloys. The aim of this work is to present production, consumption, import and export quantities of: ferrochrome, ferromanganese, ferrosilicon, ferromolybdenum, ferrotungsten, ferrotitanium and ferrovanadium of Türkiye, between 1990 and 2006.

Jan 1, 2007

By G. Kang

The ferroalloys industry has generated historically substantial solid waste. The accumulated waste causes serious problems to the environment. However, it is possible to transform the solid waste into an environment-friendly resource to serve the human being. Consequently, the construction of plants that are ?environment-friendly? and that accommodate ?recycling? has become a target of most ferroalloy producers in the world to ensure sustainable development. This paper introduces the practice of Shanxi Jiaocheng Yiwang Ferroalloys Works, the biggest manganese metal producer in China, in the development of an ?environment-friendly and recycling? process. The process includes power generation using coal gangue, waste from local coal mines; hollow bricks manufacture using slag and fly ash from the power station; cement production using slag from ferroalloy smelting; recovery of ferrous and non-ferrous elements in the dust from the furnace gas cleaning system; application of silica dust in construction and so on. The final objective of the plant is to realize zero discharge of solid waste. The profit of the ?environment-friendly and recycling? process compensates in part for the operational expense of the environment facilities.

Jan 1, 2004

By F. Yang, S. S. Long

Mixed fatty acids, such as oxidised paraffin soap, are frequently used as a substitute for oleic acid in flotation of scheelite in China. Not only because it is cheaper than oleic acid, but also because it is superior in flotation performance to oleic acid. This superiority is generally attributed to the mixed fatty acids' synergistic effect. In this paper, the synergistic effect of oxidised paraffin soap was investigated. We found it mainly consists of a series of saturated fatty acid salts, with six to nineteen carbon atoms. All the contained fatty acids were classified into four groups based on their chain length to make the research work practical. Also, the groups were labelled as 1, 2, 3, and 4 in order. The research was simplified into studying the synergistic effect of four equivalent collectors, instead of fourteen fatty acids. It is justified by the fact that neighbouring fatty acids are expected to have a similar flotation performance. The synergistic effect of the four groups of fatty acids was studied by single-mineral flotation with single groups, binary mixtures, ternary mixtures, and the full component, as collector respectively. The flotation performance index and synergy value were introduced to evaluate flotation performance and synergistic effect of groups, respectively. The results show that the mixture 1+2+3 has the strongest synergy of all followed by the mixtures 1+3 and 2+3. The mixture 3+4 and 1+2, on the other hand, have negative synergy. The synergistic effect of mixtures of groups indicate that being consecutive in length and a broad range of lengths are vital for fatty acids to enhance synergy. Group 3 is fundamental for the collecting action of 733 oxidised paraffin soap in the flotation of scheelite. The fatty acid soap in group 4 is not suitable for flotation due to its low solubility. Keywords: Mixed collectors, synergistic effect, scheelite

Jan 1, 2020

By J. Ojeda, R. Kuyvenhoven, M. Ziemski M

This paper focusses on the identification of operational opportunities in a 1100 tph pellet plant to reduce the specific energy consumption in its comminution circuit, which is designed to process magnetite ore and produce pellets to be used as raw material in the iron and steel industry. The assessment is carried out through a frequency analysis for three of the four processing lines of the plant, consisting of one ball mill each with an installed power of 4.5 MW and 280 tph of mill throughput design capacity. The methodology, as described in this paper, facilitates the visualisation and quantification of plant performance and provides a good first approach to prioritise alternatives for optimisation. In a pellet plant, grinding is a critical stage due to its high energy consumption and its major impact on the physical properties of the iron pellets, which quality depends to a large extent on grind size and Blaine index. From the evaluation that was performed it can be concluded that production line 2 has the lowest specific energy consumption of 15.1 kWh/t, while line 1 has the highest with an average of 16.6 kWh/t for the same type of ore. On the basis of the results and current operational practices, it is recommended to increase the average mill throughput from 240 tph to 265 tph, translating into specific energy reduction of 10%, without affecting the chemical and physical properties of the final product. The implementation of an HPGR for regrinding the magnetic concentrate is proposed to assure adequate specific surface area in case grinding coarser becomes an alternative, which would also be beneficial for the subsequent water recovery stages. Keywords: Iron ore pelletisation, grinding circuit, energy efficiency, particle size, frequency analysis

Jan 1, 2020

By A. N. Clay, N. N. Moeketsi, S. Joubert

For many years, mine-impacted water has been regarded as a problem and linked to long-term environmental liabilities. However, this water can be a renewable and a sustainable resource, provided that it is managed in a responsible and sensible manner. South Africa’s National Water Resource Strategy (NWRS, 2013) considers water that can be used to contribute to economic activity to be a water resource. Although all water resources are considered as belonging to the State, government does not appear to have meaningfully explored the use of mineimpacted water to contribute to the country’s economic activity. Africa is blessed with more sunshine than anywhere else, apart from Australia, yet we see no rollout of vast quantities of solar panels to ensure every African family has access to affordable power. This suggests that governments are incapable of managing such a free resource. At the same time, apart from the equatorial areas, water is a seriously constrained resource and yet we expect the same entities to manage a commodity none of us can live without. This paper explores the conversion of mine-impacted water from waste to a resource and how the inclusion of other stakeholders (such as water users, landowners, and ordinary South Africans) could benefit the process.

Jan 2, 2022

By M. Kerr

Background- History The most significant change in mining since the late 1970?s has been the emergence of very large scale mining operations , which have been developed to ensure profitability with relatively low grade ores. These large tonnage operations have resulted in the development of larger unit sized machines in all operations of beneficiation, solid-liquid separation and dewatering. Often only a few flotation lines are installed and tonnages up to 25 ktpd and beyond are not uncommon. The increased throughputs have led to the development of circular, reactor type tank designs. The reactor cell system is the most up to date flotation cell design to utilise the principles of circular cell design. The Svedala DV mechanism was specially developed to suit the RCS machine giving good solids handling characteristics and excellent metallurgical performance. Development of UG2 ore type flotation equipment The equipment was developed and optimised by Svedala process from 1995. A higher energy specification was requested by industry. This amounted to 3kW/m3 for installed volume. Existing designs were at 1.5kW/m3. Hence various modifications were required to achieve the required power input. The first 50m3 machines were installed and developed at Impala Platinum?s UG2 circuit over a one year period. Once reliability and performance was achieved, over 300 large volume flotation cells were installed at Anglo Platinum and Lonmin operations as well. Pilot Plant Development The Impala Platinum High Energy pilot plant was commissioned in 2002 and had an installed power exceeding 5kW/m3. It was operated for over a year at the tailings dam booster station and was fundamental to the large scale scavenging plant design. All experience in overcoming mechanical and operational problems was applied in scale up design principles. A very robust mechanism was designed to accommodate the additional power input from installed motors, as well as the high SG (>1.5) of the feed source. The pilot plant flowsheet is shown in the figure below.

Jan 1, 2007

Standards And Laboratory Monitoring In Gold Assay Key Components Of Best Practice

Jan 1, 2005

By J. Saunders, N. Pretorius, G. Krafft, T. P. Katakwa

Imagine being able to see all the future planned mining activities in real time. This is exactly what SIMS (Short Interval Management System) will enable you to do. SIMS is a real time short interval control system that continuously measures and sets optimised plans for mining production processes. The system utilises algorithm-based software that takes resources (people, equipment, tasks, and workplaces) and gives you the best achievable plan. The algorithm was developed using methods found in the field of metaheuristics. A metaheuristic is a strategy to designed to efficiently search for optimal or near optimal solutions to problems that are very complex computationally. (Glover, 1986) There are several algorithms that have been developed to solve optimisation problems which are difficult to solve using traditional techniques. This has given rise to a field called evolutionary computing. (Simon, 2013) Examples of these techniques are genetic algorithms, particle swarm optimisation, and ant colony optimisation. These methods are used to solve problems in a variety of fields. As an example, Kok and Lane (2012) used particle swarm optimisation for equipment allocation in a mechanised underground mining environment. The first SIMS deployment took place in a platinum underground tabular mechanised mine near Burgersfort (province?) from 2017-2019. This included the development from a paper-based system to a fully operational online system. SIMS then moved to a second site and is currently being tested in a second platinum underground tabular mechanised mine in South Africa. Full deployment of the system is currently being phased in. SIMS was built in response to issues that have been plaguing the mining industry for years. These issues are all aligned into one major problem statement: how can we optimise mining production processes without compromising safety? This product was developed by combining years of mining experience with software development. SIMS is based on a four-pillar concept. Safety, productivity, accountability, and business improvement. SIMS uses a set of pre-configured mining and production rules, and with the resources that are available, to determine valid short term production plans. A background algorithm then determines the optimum plan to be executed. The system continuously produces a set of job cards that are pushed to respective operators on their allocated tablets. The management portal component allows you to view and manage all current and planned work on any connected device available. This allows real time visibility of completed, current, and planned work to operators, service departments and management, i.e., seeing into the future.

Sep 1, 2021

By I. O. Flores, A. Anani, H. Li

Current technological advancement has increased the exploitation of deeper ore bodies using underground methods. In certain cases, the mineral deposit starts near the surface and continues deep within the earth's crust. Such deposits are best mined with both underground and surface methods. Two main techniques are used to determine the optimal transition depth from surface to underground - a disintegrated approach and an integrated approach. Both methods have limitations in their use to determine the optimal transition depth. The objective of this research is to investigate the conditions in which an integrated approach to the transition depth problem is superior to a disintegrated approach. Three binary integer linear programming models are developed for this purpose: a surface and underground model for the disintegrated instance and an integrated model. A case study is performed to validate the models, with a comparative sensitivity analysis to obtain operational insights.

Sep 1, 2021

By S. Schutte, J. Pelders

Worker participation in equipment development can result in improved user acceptance and product quality. This paper focuses on worker engagement in equipment development processes in the South African minerals sector. Qualitative data was gathered during interviews with original equipment manufacturers (OEMs) and industry experts. A lack of inclusion in equipment design from workers from all organizational levels in mines was reported. Meanwhile, the historical context and workplace culture of the mining industry (including leadership, trust, training, performance, and remuneration factors) were evident barriers to the implementation of new technology. Worker engagement processes should include securing management commitment, creating multidisciplinary teams, effective facilitation, shared understanding of needs, training and development, and iterative design. Human-centred design approaches and independent platforms for engagement on equipment design requirements are recommended.

Feb 2, 2021

By M. I. Mabala, B. P. Watson, M. J. Kanda

A failed and stable Upper Group 2 chromitite pillar database was collected in 2007 as part of the PlatMine 1.2 pillar strength project. The database consisted of 177 pillars, of which 33 had failed. Most of the data were collected from various intermediate-depth mines near the town of Thabazimbi. Spans between rows of chain pillars were about 30 m. Pillar loads were estimated using pseudo-3D, elastic, boundary element modelling software. The pillar-load data were evaluated using a maximum likelihood regression analysis to determine strength parameters, following a similar approach to historically acceptable practice. The original formula was named the PlatMine Formula. This paper describes re-evaluations of the database, using a linear formula and several variations of the power formula. The formula providing the lowest standard deviation to the data in the database was considered the best representation of the pillars in the database. Through this rigorous process, a new formula for peak pillar strength was developed for Upper Group 2 chromitite pillars, which is unaffected by volume. The small standard deviation provided by this formula suggests a reliable relationship between strength and w/h ratio, in the w/h ratio range between 1.5 and 4.7. Accuracy, precision, and recall analysis confirmed the efficacy of this equation to the data in the database. Importantly, the new formula provided in the paper does not predict a significantly different strength to the current PlatMine formula, within the confines of the database.

Nov 27, 2024