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By M. C. Holton

South Africa has the world?s largest in situ deposits of platinum group metals, but economically exploitable resources are shrinking due to escalating costs and technical challenges. The South African National Research and Development Strategy comments that an increase in the knowledge intensity of the resource-based sectors is required to turn these resources to account. Highly trained human resources, continuous improvement, technological innovation, and smart acquisition of know-how will become the major differentiators in the global mining market. Mechanization and, ultimately, automation in mining have the potential to reverse the negative mining trend and resolve safety and other challenges. However, the adoption rate of mechanized mining in platinum (and hard-rock gold) has been slow for various reasons. Changing systems from conventional drill?and-blast to continuous mechanized mining is a big step-change endeavour. The problem of transformation is discussed, and the discipline of systems engineering is examined because of its successful application in aerospace and defence.

Jan 1, 2012

By G. Akdogan, J. H. Zietsman, C. Dorfling, D. Attah-Kyei

The development of newer and improved electrical products has led to an increase in the rate at which older products are discarded as waste. The main focus of electronic waste is the printed circuit board (PCB) because of the inherently high value of contained metals such as gold and copper. Several options for treatment of the non-metallic fraction including material recycling, where the residue may be used as inclusions in concrete or asphalt materials with minimal processing or chemical recycling, where chemicals and fuels are produced from the residue using pyrolysis exist. In this paper, the utilisation of the non-metallic leached PCB waste fraction as reductant in secondary copper smelting was investigated. Analysis of the leached residue revealed that PCB is highly amorphous and has a carbon content of 28.5%, an oxygen content of 23.1%, with the ash and volatile matter contents 40.1% and 44.8% respectively. Thermodynamic simulations of secondary smelting of copper were conducted in terms of metal recovery, and the energy required when PCB was used as a reductant. The results were also compared with that of coal and PCB-coal blends. The simulations revealed that as PCB in the blend used as reductants increases, the amount of energy required for the smelting operation decreases. Metal recovery slightly decreased as the mass percent of PCB in the blend increased due to lower carbon content present in PCB relative to coal. The results also highlighted the energy saving with PCB-coal blends which was around 160 kWh per ton of feed relative to coal. The decrease in the amount of energy required for the operation is attributed to the higher volatile content of the PCB, which is also a part of the reduction process. Keywords: PCB leach residue, alternative reducing agent, secondary copper smelting

Jan 1, 2020

By J. Pelders, F. Magweregwede, S. M. Rupprecht

Increased depths of conventional gold and platinum mines, longer travelling times as working places move further from the shaft, and ancillary activities taking place in the mining cycle reduce the useable time spent at them workface. Current shift lengths of 8 hours 20 minutes may no longer be adequate ton complete required mining activities.The impact of mineworker commuting times on shift work is also not well understood. The aim of this research was to draft a framework to optimize shift cycles in order to maximize productivity, health, safety, and wellness in the South African mining sector. The framework was informed by a review of the literature, case studies at a local gold mine and platinum mine, and a workshop with industry experts. The findings indicate potential advantages of extended shift lengths and continuous operations, such as improved productivity, asset utilization, and employee morale. However, concerns included fatigue and the associated safety hazards, particularly when working longer shifts, night shifts, and numerous consecutive shifts. Job demands, personal factors, and commuting times are further considerations when scheduling shifts. The ideal shift system for the mining sector should holistically consider and balance operational requirements, health and safety, and employees’ and their families’ requirements, and suit the unique needs of each operation. Changes in shift cycles will require a structured change management process, which involves all stakeholders, and could help to enhance the viability of the South African mining sector.

Aug 1, 2021

By P Clive Hart

DRA - BACKGROUND [MULTI MINERAL DESIGN & BUILD COMPANY FOUNDED 1984 ENGINEERING FOCUSED CORE ENGINEERING DISCIPLINES INCLUDE: ?PROCESS ?MECHANICAL ?E&I CONTROL PRIVATE COMPANY, INDEPENDENT & INTERNATIONAL]

Jan 1, 2006

By K. Kotwica, P. Gospodarczyk, J. Sosnica, J. Pawlik, Z. Iwulski, K. Pawlik

The paper presents problems resulting from the mobile mining machines functioning and requirements concerning a machine control system, which controls successive operation stages of such machines. The problem is presenting on the example of a mobile hydraulic support to remove residual pillars in copper ore mines. The paper describes an algorithm and a flow chart to be followed when designing a supports control system. Design of control systems to ensure machine function under given circumstances is also presented.

Jan 1, 2003

By G. F. Balderson

In response to the written contribution made by G. J. C. Young to the above paper, I would like to make the following points. Paragraph 1 The build-up of oxidized coatings on cone surfaces has not been a problem in other applications similar to that at President Steyn. The following companies have commented.

Jan 1, 1982

By S. Z. Shkundin

An evaluation of the accuracy of tachometric and hot-wire anemometers in mine workings and gas-media ducts is given. The acoustic means of gas flow rates measurement is considered with particular reference to the equations of acoustic waves propagation in aerodynamic fields. The paper defines how it is possible to minimize the error of integrating acoustic anemometers.

Sep 1, 2001

By T. A. Claasen

Exceptionally low yields in the coking-coal fields of the Soutpansberg area in the northern Transvaal, are taxing the skill and ingenuity of preparation engineers. The coals are highly intergrown, and a series of crushing and washing steps may be required to extract the maximum usable tonnage. In addition, novel preparation techniques may have to be employed. This paper, which is a case study of work recently undertaken, gives a general account of raw coal properties, emphasizing those related to maximum recoveries, and outlines the steps involved in the design of appropriate flow sheets based on laboratory studies.

Jan 1, 1980

By Kevin Peacocke

The future of Gravity ? Primary mineral recovery ? Enhancement of existing process efficiency ? Pre-Concentration ? Alternative? or ?New? production

Jan 1, 2006

By N. Moemise, M. B. Shongwe, P. A. Olubambi, M. M. Ramakokovhu

"Near-infrared (NIR) spectroscopy sorting technology is incorporated in an automated optical mineral sorter that can discriminate between materials using the differences in characteristics when exposed to near-infrared radiation. During September 2014 to April 2015, a pilot plant that utilized NIR technology to discriminate between kimberlite and waste materials was commissioned to determine the viability of including this technology in the diamond winning process flow sheet at Cullinan Diamond Mine. The plant was used to minimize the waste content in the size fraction -70+35 mm that reports to the crushing section and then to the dense media separation process. This paper describes the initial test work, conducted at Mintek, that led to the decision to conduct a pilot-scale study. The mineralogical characterization of the feed and product streams to establish the sorting criteria and the operational data obtained during the pilot plant campaign are described. The results indicated a good possibility of discriminating between the kimberlite and waste material using NIR technology. However, the consistency of discrimination was not good enough to avoid the risk of potential diamond loss. Furthermore, a lower than expected availability of the machine reduced the throughput capabilities. IntroductionUsing near-infrared spectroscopy (NIRS) technology for ore sorting is a new concept for the mineral processing and mining industry. NIRS has been used for decades in the laboratory for the identification of pure minerals, and has its roots in the recycling, food, and pharmaceutical industries (Salter and Wyatt, 1991; Robben et al., 2009). Ore sorting in itself is not a new concept; it was introduced during the Stone Age with handsorting being the first method to separate valuable materials from gangue (Wills and Napier-Munn, 2006; Sassos, 1985). However, over the years the scale of mining has increased and hand-sorting has become challenging to implement (Joensson, 2014).Sensor-based sorting is an advanced technology that can help overcome problems such as ore dilution experienced in mineral processing operations. The benefits are lower energy and water costs, reduced ore dilution, lower environmental impact, and improved profit margin (Mathew, 1974; Jonsson, 2014; Salter and Wyatt, 2009; Death et al., 2009). In sensor-based sorting, materials are mechanically sorted based on certain physical properties that are detected by a sensor (Dalm, 2013). Research has found that with NIR scanners it is possible to obtain a ‘fingerprint’ of a sample that is directly related to its mineralogical composition. According to Woutruba et al. (2009), molecules absorb NIR radiation by means of electronic and vibrational transitions. Nowadays, there are many sensors available in the market that utilize different material properties; the choice of a sensor is dependent on the mineralogy of the ore."

Jan 1, 2016

By M. Wrobel, J. Hammerschmidt, M. Runkel

Fluid-bed technology is a key pyrometallurgical step for processing a vast number of ores and concentrates. Over the past 50 years, considerable research and development efforts have been made by Metso Outotec to expand the application window of this technology. This paper illustrates different processing routes where fluid-bed technology plays an important role in the production of the copper. The fluid-bed processes utilized are partial, sulfate-producing, and dead roasting. The focus of this paper considers the advantages of the dead-roasting process. This “zero waste” process can provide copper oxides, steam, electrical power, and sulfuric acid for new and existing solvent extraction–electrowinning plants. In a case where an operation is running out of oxidic ores and concentrates, fluid-bed roasting can be applied to close this gap and provide the required copper oxides in a sustainable way.

Jan 1, 2023

By Q. G. Reynolds

The presence of dust and fume suspended in the freeboard region is a common feature of the operation of direct current (DC) plasma smelting furnaces. This occurs primarily as a result of the use of fine feed materials together with the open-arc, open-bath operation of such smelters, and is exacerbated by the high velocities and turbulent mixing of the gas in the vicinity of the arc jet. Dust and fume losses into the furnace off-gas system can be significant in some cases and may have economic, operational, and environmental impacts on the process. A computational modelling study is presented in which the concentration of dust material was considered as a continuous field subject to a governing partial differential equation. Settling behaviour was calculated as a function of particle size, local gas/plasma temperature, and other physical properties. Development of the coupling between the concentration field and a magneto-hydrodynamic description of the arc is shown, and the resulting models were used to compute various aspects of the behaviour of the concentration field in the arc region for a variety of furnace conditions. Time-averaged as well as transient models of the arc were used to generate the results presented. Qualitative case studies produced several practical suggestions for furnace operation, including increased dust capture by the bath when feed ports are located closer to the electrode, and the possible effects of feed segregation in the furnace freeboard based on dust particle size and density.

Jan 1, 2014

By Ike Madingoana, Stephan van Zyl, Antoine F. Mulaba-Bafubiandi

"The study presents a control strategy implemented at the Nkomati nickel mine flotation plant for process stabilization and improvement. The control strategy involves flotation concentrate volumetric flow rate stabilization and the flotation cell mass pull control. The flotation concentrate volumetric flow rate is operated at a fixed set point. The initial control strategy involved varying the flow rate to maintain the concentrate tank level thereby reducing pump cavitation. The flotation cells mass pull control comprises air rate manipulation into the cells with the exception of the recleaners. The air rate into cells is automated to adjust based on the concentrate tank level variation. The control strategy was implemented on the roughers, cleaners and the recleaner circuit. The recleaner cells air flow rate is adjusted based on the MgO content in the concentrate. The stabilization of the flotation concentrate volumetric flow rate and the mass pull by aerate automation will increase the scope of optimization for further process improvement. The immediate benefit of the control strategy implementation was plant stability. Disturbance to the flotation cells downstream was minimized due to stable flow rate, and the air addition manipulation ensured that the concentrate tank levels are maintained, minimizing pump cavitation. INTRODUCTION Froth flotation is a challenging process because it is influenced by a large number of factors, including the flotation feed characteristics. One of the ore types mined at Nkomati nickel mine is the main mineralized zone (MMZ). The MMZ ore is hosted in the Uikomst complex, a Ni-Cu-PGE-Cr- mineralized, layered basic to ultra-basic intrusion which hosts commercially viable magmatic base-metal sulphides (De Waal et al., 2001). The MMZ ore is a heterogeneous sulphide mineral resource with a varying sulphide mode of occurrence and texture. The beneficiation of the complex sulphide ore is challenging due to the presence of impurities in the ore. The impurities report to the flotation final concentrate and penalties are levied if the impurities are beyond the contractual limits."

Jan 1, 2015

By N. F. Dawson

Recovery of a chromite concentrate from UG2 flotation tailings streams, of a grade suitable for further pyrometallurgical treatment for the production of ferrochrome, has certain specific challenges not only by virtue of the decoupled nature of the primary PGM recovery process and secondary gravity based chromite recovery circuits, but also because of intrinsic variations in the nature of the ore and its mineral composition. Variability in the ore, together with upstream process dynamics, creates a challenging environment in which to achieve optimal recovery of a gravity concentrate with accurate grade control. This paper examines certain inter-relational aspects between the ore gangue and chromite mineral types, the influence of the primary PGM extraction circuit and secondary chromite extraction activity as applied specifically to UG2 ore against a background of actual plant experiences and circuit configurations applied in order achieve a suitable quality of chromite concentrate.

Jan 1, 2010

By J. Levin

The Bond standard grindability test provides a Work Index that is widely used to estimate the energy required for grinding, but the test cannot be applied to fine materials such as plant tailings and middlings. For such materials, a comparative grinding test must be used in which a reference material from an operating plant is ground in a laboratory mill to determine the 'equivalent' energy consumption per revolution of the laboratory mill. As the Bond grindability test mill and its operating conditions are specified, its equivalent energy consumption per revolution should be a constant, here designated as B. Once B has been determined, the mill can be used to estimate the grindability of fine materials without the need for reference materials. A value of B can be calculated from any Bond grindability test, and 245 tests that were conducted at Mintek were examined to determine its value. A wide range of values was found, but most of them were grouped around 198 x 10- 7 kWh/rev, which is taken as the best estimate of B that is available at present. Values of B that are not close to this figure are obtained from materials for which the Bond grindability test gives misleading or 'spurious' Work Indexes. These spurious Work Indexes lead to the apparent departure of B from its true value. Some limitations of the Bond grindability test arise from its use of a mill without litters and of screening, instead of classification, to close the circuit.

Jan 1, 1989

By Y. Fu, C. Aldrich

This study investigates the use of dense convolutional neural networks to estimate bubble size distributions in flotation froths. 20 videographically captured images of froths from an industrial platinum flotation plant in South Africa were labelled semantically with an image annotation tool, LabelMe (https://github.com/wkentaro/labelme). As a result, pixels in the images could be categorized into three classes, namely ‘bubbles’ (class 0), ‘bubble boundaries’ (class 1) and ‘background’ (class 2). A U-net architecture with a ResNet34 backbone was trained to segment the images via classification of the pixels in the images. 5 of the 20 images were used to validate the performance of the neural network. Explicit inclusion of the bubble boundaries as a class proved to be significantly more effective than training the network with two classes only (i.e. bubbles and background). However, the thickness of the boundary layer regions were critical. If too thin, it was difficult to distinguish between some contiguous bubbles and if too thick, some fine bubbles may not be identified. The results were promising, although there is still significant scope for improvement, among other by making use of more images for training and validation. Keywords: Flotation Froths, Convolutional Neural Networks, Deep Learning, Bubble size Analysis

Jan 1, 2020

By H. E. Bartlett

In the operation of some flotation plants treating platinum ores it was found that there were imbalances between the inputs and outputs. The inputs and outputs were sampled as slurries and it was determined that the imbalances arose from biases in the sampling, despite the samplers having been designed according to well-established rules. The launders feeding the sample cutters, and the sample cutters themselves were redesigned using finite element analysis to model the flows. A new set of design rules were formulated. The application of a Components of Variance Analysis, to determine the variance of primary and secondary sampling and of analysis in the lab for a concentrate is presented to illustrate the need for frequent sampling of process streams.

Jan 1, 2002

By Z. Zhang, J. Niu, H. Wang, Y. Xu, J. Shi

Tribo-electrostatic separation is a promising method for effectively utiliing low-grade magnesite resources by removing quartz and improving the grade of magnesite. To determine the chargeto- mass ratios of pure magnesite and quartz, a triboelectric measurement system was employed, and a laboratory tribo-electrostatic separation system was used to separate low-grade magnesite. The results showed that the maximum difference in charge-to-mass ratio between pure magnesite and quartz particles was observed after friction with polyvinyl chloride. The grade and recovery of magnesite increased with temperature and initially increased with increasing voltage, feed rate, and air flowrate before gradually decreasing. The optimal conditions resulted in a concentrate with 46.91% MgO content and 77.36% recovery, while the quartz content decreased from 7.02% to 1.95%. These experimental results demonstrate the effectiveness and potential of tribo-electrostatic separation in removing quartz and upgrading magnesite.

Apr 14, 2024

Book review Proceedings of the Symposium on Mining Methods. London, Institution of Mining and Metallurgy, 1974. 160 pp. The Symposium was held from 30th October to 1st November, 1974, and the papers include an interesting range of subjects in coal-mining operations, covering the improvements achieved to date, current practice, and required development for the future. Salamon, M.D.G., and Oravecz, K. 1. Rock Mechanics in Coal Mining. 119 pp. NIM reports Report no. 1822 Stability constants and linear free-energy relations for the platimtm-group metals. (22nd Oct., 1976). Report no. 1852 A revised method for the dissolution of platiniferous materials by the sealed-tube technique. (18th Oct., 1976). Report no. 1828 y-picoline adducts of the nickel, copper, and zinc chelates of 2-thenoyltrifluoroacetone. (26th Nov., 1976) Report no. 1847 A pilot-plant investigation of a kinetic model for flotation.(19th Nov., 1976)

Jan 2, 1977

"Chairman: Professor E. P. PFLEIDER Rapporteur: Mr P. R. JANISCHPapers:Optimum design of an open pit by D. A. PhillipsAn open pit design system for stratiform ore bodies by L. A. J. Pronk van Hoogeveen, J. R. Cutland and M. WeirAn open pit design model by R. H. Robinson and N. B. PrennThe Chairman in opening the session highlighted the current situation in the United States of America where some 85 to 90 per cent of all mining (except for coal) is done by open pit methods, and where some 40 per cent of the coal is mined by open pit. The South African industry is, of course, dominated by the deeper level underground gold mines; however, with the aid of an extensive open-pit technology developed in other countries, South African companies arc continuing to explore possibilities of open-pit exploitation of base mineral, coal and diamond deposits. Several successful ventures are already in operation at Phalabora, Optimum Colliery, Kimberley and elsewhere, and South Africa is undoubtedly benefitting in this regard by drawing on the experience of others.The papers of this session were therefore particularly pertinent, particularly when viewed in conjunction with those presented at an earlier South African conference devoted specifically to open pit mining.Two themes dominated the discussion which followed presentation of the three papers at this session. The first related to the practicability of using the reported techniques as a tool for management, and their acceptability as such to mine management. This was, of course, not peculiar to this particular session, but rather the major point of debate over the entire conference.The second theme concerned the reliability of the initial drill hole data on which any open-pit design must necessarily be based. This gave added emphasis to the problem of practicability, for no management is likely to accept an elaborate pit design unless confidence can be placed in the ore reserve assessment.In noting these two features of the discussion, it should be remembered that all the three papers dealt largely with design and pre-planning; there was an unfortunate lack of papers or discussion on the subject of controlling the day-to-day mining of open pits, and this is an area where the potential impact which can be made by the computer is even greater.In introducing his paper, Mr D. A. Phillips pointed out that it was concerned only with optimization, and that it therefore assumed, firstly, an adequate subdivision of the orebody into ore blocks characterized by grade, rock type, structure, etc., and, secondly, an acceptable forecast of costs and mineral prices in order to generate a suitable profit matrix. However, programs dealing with these problems for both massive, disseminated and stratiform ore bodies are available to Roan Consolidated Mines. The method of optimization which he had described had been used on a region split into 28 000 blocks, for which the program used three hours of C.P.U. time on an IBM 360/40 computer. The computer design had provided a three per cent improve¬ment on a normal design of the same area."

Jan 1, 2014