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By C. Chongo, F. X. Paquot, C. Ngulube

"Over the last six years, the Kansanshi copper-gold mine has continued to process significant quantities of complex transitional mixed ores. Initially, the ore treated came predominantly from accumulated stockpiles. Subsequently, the feed source shifted primarily to freshly mined ore that generally showed less tarnish with better flotation kinetics, but with the downside of lower concentrate grades. A number of changes were made to improve the efficiency of the rougher circuit and quality of concentrate produced. These changes were as a result of initial mineralogical studies and laboratory flotation test work that were discussed at length in a previous paper1. Salient among the recommendations adopted as a result of previous work were increased circuit capacity and a modified configuration to increase the residence time and the number of sulphidization stages. These modifications were completed and commissioned in 2011. This, however, resulted in significantly low rougher concentrate grades and a below-specification final concentrate product. This was due primarily to higher mass pulls from the extended rougher bank with multiple concentrate discharge streams, and which necessitated an enlarged cleaning capability. The extra cleaning capacity came on stream in 2014. Of note was the development of a recovery model, based on the strong correlation between the total copper and acid-soluble copper ratio, as a tool for monitoring plant performance. IntroductionThe Kansanshi mine, the largest copper mine in Africa, is 80% owned by Kansanshi Mining plc, a subsidiary of First Quantum Minerals. The remaining 20% is owned by the state through the parastatal Zambia Consolidated Copper Mines Ltd (ZCCM). The mine is located approximately 10 km north of the town of Solwezi and 180 km to the northwest of the Copperbelt town of Chingola. The mine has been in commercial operation since 2005."

Jan 1, 2016

By E. Spicer

X-Ray diffraction (XRD) provides useful information about the composition of an ore sample in terms of quantification of crystalline phases and amorphous content. The use of new, fast detection systems in XRD creates the opportunity to use this technique in modern process control. In the analysis of heavy mineral sands, XRD can identify the main mineral phases, such as ilmenite FeTiO3, rutile TiO2, Zircon ZrSiO4and quartz SiO2, and any other minor components present, such as anatase TiO2, magnetite Fe3O4, haematite Fe2O3or monazite (Ce, REE)PO4. Quantitative analysis is possible by various classical methods such as straight line or polynomial calibration with standards, but modern quantification analysis techniques such as Rietveld analysis (Bish and Howard, 1988) are attractive alternatives, as they do not require any standards or monitors. These methods offer impressive accuracy and speed of analysis. The Rietveld method compares calculated versus experimentally derived X-ray powder diffraction patterns for the sum of all crystalline phases. Another analysis technique offering great benefit to mining industries is cluster analysis. Enormous amounts of XRD measurement data are generated during the process control and material evaluation. New ways of handling such vast amounts of data are required to produce meaningful information for the end users. Cluster analysis greatly simplifies the analysis of a large amount of data from different processes or different raw materials, and automatically sorts closely related scans of an experiment into clusters and marks the most representative scan of each cluster as well as outlying patterns. The use of cluster analysis to evaluate the XRD data allows fast and reliable tracking of the process. It is the most economical procedure to have automatic data evaluation without involving any dedicated personnel in the process. Details of the techniques used, sample optimization methodologies, results, data precision and limitations will be discussed. The approach has potential as a relatively inexpensive, reliable tool, useful in the characterization of heavy minerals sand materials.

Jan 1, 2007

By Christopher J. Oates

Overview ? Mining Codes ? Best Practice ? Mining Standards Guidelines ? Get it right from the start ? External Auditors ? The 5% rule ? MMCRM's - The Key Components ? The MMCRM Report / Certificate ? MMCRM's & Round Robins ? Summary

Jan 1, 2005

By C. Kliem

Geological, tectonic, geochemical and geophysical data were utilized for the mineral resource assessment of the Biga Peninsula in NW Turkey. During the deductive phase of the project multivariate statistical methods were applied to accentuate characteristic parameters which sufficiently describe the different types of Pb - Zn mineralization. The parameters most likely to be indicative of mineral occurrences were determined. In the following prognostic phase these parameters were further statistically treated to determine favourability indexes for the occurrence of a deposit within each cell of the training area. Preliminary results of probabilistic, univariate and multivariate methods are presented.

Jan 1, 1987

By J. M. Eriksen, T. Rosenqvist, H. Elstad, S. Seim, A. Hildal

The titanium industry demands high titanium feedstock for their processes. As rutile resources are limited, ilmenite has become the most important titanium source. Ilmenite smelting is an important part of upgrading ilmenite to high titanium feedstock. In the year 2005, upgrading of ilmenite by smelting, producing a slag with 80-90% Ti02, accounted for approximately 40% of the feedstock to the Ti02 pigment industry. In ilmenite smelting molten iron is produced together with a slag, which in addition to titanium oxide contains iron oxide as well as various impurity oxides of manganese, magnesium, silicon, aluminium, etc. Titanium is present mainly as Ti02 but partly also as Ti203. It is known that the concentration of Ti203 increases with decreasing concentration of FeO, but this dependency is affected by the nature of the impurity oxides. Sigurdson and Moore1 showed that slags high in CaO and MgO had a lower concentration of Ti203 than slags high in Si02 for the same amount of FeO. Pistorius2 showed in 2002 that if the impurity oxides MnO and MgO are counted, on a molar basis, as FeO, and Cr203, V203 and part of the A1203*), as Ti203, industrial slags will have a composition close to that of the M305 phase, where M denotes the elements Ti, Fe, Mn, etc, and which has the pseudobrookite structure. However, for equilibrium with liquid metallic iron he computed, by means of a computer program FACT, that the slag equilibrium composition is represented by a curved line in the ternary phase diagram FeTi03-TiO2-Ti2O3, but with a significantly higher concentration of trivalent titanium than actually observed in the industrial slags, and he discussed various mechanisms by which the slag during solidification could change its composition to a lower Ti203 content, but the possibility that the computed compositions might be wrong was not mentioned. Trane113 found in her research on titaniferous silicate slags a lower Ti3+/ Ti4+ ratio than that which is computed by the FACT program. The purpose of the present investigation was to study the equilibrium composition of Fe-Ti-O slag in equilibrium with liquid metallic iron, as well as the effects of impurities such as Si02, CaO and MgO on the slag composition. Industrial slags from TINFOS Titan and Iron KS (TTI) will also be discussed and their compositions will be plotted in the ternary phase diagram. These are slags produced from Tellnes ilmenite, quite high in magnesium and iron. Experimental In the past, equilibrium studies of the Fe-Ti-O slag system were difficult when it came to producing the slag. It was difficult to find a suitable crucible for the meltings. The highly corrosive slag would attack all known refractories, and the metal would attack metallic crucibles such as those made of platinum and molybdenum. In the present investigations the slag-metal combination was prepared in a high-frequency induction furnace with a vertically segmented water-cooled copper crucible. The crucible is shown in Figures 1 a and 1b. It was designed by the Australian Nuclear Science and Technology Organisation (ANSTO) with power from a 75 kVA high-frequency generator (750 kHz) supplied by Farfield Electronics Pty, Ltd, Australia. This enabled the slag-metal combination to be melted with turbulent stirring and is expected to be isothermal. The entire temperature gradient

Jan 1, 2007

By E. A. Brinkmann

A kinetic model framework for single particle kinetics in combined diffusion and adsorption processes is presented. The framework applies to the general case in which both diffusion and the adsorption reaction play important roles in determining the overall rate in processes where the migrating species can both adsorb and accumulate. The technique, which should be applicable to a wide range of reaction mechanisms, consists of an iterative integration procedure for the coupled diffusion and reaction equations. The case of a reversible linear adsorption reaction rate is developed. In order to verify the technique as a legitimate method of model development, an analytical solution for the identical case is derived and compared to the numerical solution. Excellent agreement exists between the two solutions.

Jan 1, 1987

By C. M. Suhr

n order to validate the borehole analysis valuation procedure commonly used in the South African gold mining industry, a simulated orebody was used to create borehole values which would serve as data for the procedure. After confirming the distribution, calculating the variance size of area relationship, estimating the block variance, and calculating a profit measurement for each set, comparisons were made to the known population parameters. Results show only one overall bias (in the estimation of the lognormal third parameter), which is carried throughout the analysis. The remainder of the analysis is unbiased, validating the procedure.

Jan 1, 1987

By R. Haldenwang, R. Erasmus, P. T. Slatter, R. P. Chhabra

Notches are used routinely for measuring the flow rate of water with free surface flows. As far as can be ascertained, no work has been done to investigate the performance of these flow rate measurement devices for non-Newtonian suspensions. The Flow Process Research Centre at the Cape Peninsula University of Technology has investigated the flow rate of kaolin and bentonite suspensions from a tank for two notch shapes, namely rectangular and triangular, and for 3 different concentrations of each suspension. The notches were calibrated using water and then the kaolin and bentonite suspensions were tested in them. The rheological characterisation of the fluids was done with a Paar Physica MC-1 rotary viscometer fitted with a cup and roughened bob. Analysis of the results shows a significant increase in discharge coefficient with increase in concentration, and the discharge coefficient has been correlated to the yield stress. This is the first such study, and further investigation is needed to confirm and extend these findings.

Jan 1, 2007

By J. O. Claassen

A study was initiated and solutions implemented to address the root causes of a 30%?40% lower than predicted product yield achieved at a Mpumalanga coal mine. A holistic MRTM approach, which focused on improving exploration, geological sampling and analysis, geological modelling, planning, mining, and beneficiation practices, was used. The study indicated that deviations in the planned versus actual yields at the DMS plant were caused mainly by incorrect geological yield predictions, high and variable levels of dilution, and near-dense material, as well as the textural properties of the ore. Keywords MRTM, mining value chain improvement, Witbank coalfields, complex geology.

Oct 1, 2013

By P. Beukes, D. Bessinger, R. Glenewinkel

High titania slag is produced by the smelting of ilmenite and a suitable carbonaceous reductant in electric furnaces. Currently liquid slag is cast into large blocks, which take about 10 days to cool down before they can be crushed, milled and classified into two final products. The two products, chloride and sulphate grade slag, are differentiated according to their size. Granulation of titania slag has been identified as a possible alternative to the conventional block route. This paper discusses some of the work carried out at Exxaro Research and Development to investigate both wet and dry granulation of titania slag.

Jan 1, 2007

By E. Bakhtavar

There are many near-surface deposits with considerable vertical extent that have the potential to be mined by a combined method of open-pit and underground methods. In this regard, there is often a point called ?transition depth? where a decision has to be made whether to continue deepening the pit or change to underground methods. Recently, optimization of the transition from open-pit to underground operation has become an important challenge in mining engineering. Optimally, to model the transition problem on the basis of maximization of the profit from open-pit and underground mining, (0-1) integer programming has been used. In this method, block economic values of open-pit and underground methods should be imported to the transition model. A hypothetical example is presented in order to assess the model in detail.

Jan 1, 2012

By A. P. I. Popoola

Aluminium AA1200 was laser alloyed with a combination of nickel and titanium diboride using different weight ratios. Chemical reactions took place with the formation of different phases. The characterization of the alloyed surfaces was carried out by x-ray diffraction (XRD), optical and scanning electron microscopes. The alloyed surfaces are composed of the initial phase of Al-Ni dendrites and eutectics of TiB2/Al and TiB2/Ni distributed on the initial phase. Experimental results obtained showed that Al-Ni intermetallics brought about a significant increase in the hardness property of Al; however, these intermetallics are highly brittle and prone to fail by brittle fracture or stress corrosion cracking when put in service. The addition of TiB2 brought about a reduction in the formation of the seintermetallic phases. A microhardness increase of over 10 times the hardness of the substrate was achieved. Keywords Dendrites, intermetallics, metal composite, Nd: YAG laser.

Jan 1, 2011

By D. Bessinger, N. Rughubir

Exxaro Sands KZN produces?among other heavy mineral products?high titania slag, which is used as feedstock to the pigment industry. The titania slag is produced from the smelting of ilmenite in two 36 MW DC furnaces. In this smelting process carbon monoxide gas is produced. This gas is cooled, scrubbed and washed to remove entrained dust. This paper provides details on the gas cleaning plant system and the chemistry, mineralogy and size distribution of the particulate material contained in the off-gas stream. Characterization of the dust shows that is consists mainly of ilmenite, but with relatively high levels of SiO2and MnO. Smelting of the dust in a 500 kW DC furnace was carried out to investigate the potential for recovering valuable elements from the dust.

Jan 1, 2007

By H. Rosenberg

Haldor Topsoe A/S has developed its WSA technology to meet the demand in the market for a simple and reliable process that converts sulphurous emissions from off-gasses into high-grade sulphuric acid. With more than 50 references in 25 countries, the WSA technology has proven its ability to generate acid at 98% concentration, efficiently and economically. The wet gas sulphuric acid (WSA) technology treats the furnace off-gas directly from upstream gas cleaning plants. No further drying is required, since the humidity present in the off-gas is used to hydrate the SO3generated in the converter and produce sulphuric acid. The heat generated during the oxidation, hydration and condensation processes is principally reused in the process to preheat the off-gas to the required temperature level, and also to generate high pressure superheated steam for process use. This advantage of steam production, coupled with lower water and power consumption requirements, is particularly important in the African production environment. Having fewer process components than conventional acid plants, the WSA technology is a simple and compact operation, which makes it easier to retrofit into an existing smelter plant. Further, the WSA technology simultaneously offers the possibility to treat multiple gas streams arising within the production facility due to superior flexibility in terms of SO2concentration and turndown ratio.

Jan 1, 2006

By Jonty Tshipa

The Mine Site Technologies, MST BlastPED ST is a wireless/remote blasting system used in more than sixty (60) mines (including two mines in Zambia and one in Tanzania) since its release in 2002. The system consists of a controller and signal tube initiator which communicate wirelessly using spread spectrum frequency. This technique ensures a robust and secure wireless link between the controller and the signal tube initiator. The configuration of the system ensures ease of use with all the instructions for initiating the blast printed on the equipment. This means little or no formal training is required to use the system. The technology enables you to have your blasting point at a distance of up to 4 km, line of sight (LOS), as opposed to the traditional distance of 500m from the blast. This ensures the blast takes place from a safer and secure location. The paper and presentation will provide the audience with the benefit of many years of international mining know-how in this technology as well as more recent local African experiences. There will be references to demonstration blasts done in South Africa, current users in Africa and elsewhere. Practical Return on Investment (ROI) calculations and references to safe blasting practice will also be included.

Jan 1, 2008

By Sh. Arshadnejad

Stress analysis in a rock medium is essential to determine the stress concentration between two consecutive circular holes and prediction of fracture behaviour. When two consecutive circular holes in a hard rock medium such as granite are loaded internally by the pressure of non-explosive expansion material (NEEM), stress concentration occurs between the holes which then causes the rock to fracture. In this work, finite element (FE) analysis using Phase2 code was employed to study the stress concentration between two consecutive circular holes under internal pressure induced by NEEM. Effects of different hole diameters and spacings, rock properties and NEEM pressures have been analysed. The data gained from the numerical analysis and analytical solutions were then used to develop two models. These models were then modified by using the FE data and polynomial regression analysis. The developed analytical models showed to be in a very good agreement with the FE analysis. Hence, the developed models can be used with confidence to determine stress distribution and concentration factors around two consecutive circular holes in a hard and brittle rock which are loaded internally by the pressure induced from the NEEM. Keywords Finite element method, non-explosive, quarry mining, stress concentration..

Jan 1, 2011

By O. S. Tinkler, K. C. Sole

"Although the first large-scale application of copper recovery by solvent extraction took place in Zambia in the early 1970s, it is only in the last decade that this technology has become widely employed in this part of the world and is now a mainstay unit operation in copper hydrometallurgical flow sheets. The mineralogy of the ores of the African Copperbelt, and hence the characteristics of African leach liquors, differs significantly from those in Chile and the southwestern USA, where copper solvent extraction has had a long and successful history. These differences provide operators, metallurgists, reagent vendors, and engineers with many challenges: new approaches are needed to adapt solvent-extraction technology for successful implementation in this region. This paper examines typical operating practice in the African Copperbelt, discusses differences compared with other parts of the world, and looks at some of the challenges and opportunities presented by these flow sheets. IntroductionFollowing the success of the Rancher’s Bluebird and Bagdad solvent extraction and electrowinning (SX–EW) operations in Arizona in the late 1960s, the Tailings Leach Plant at Chingola, Zambia, became the first large-scale copper SX plant in the world, commissioned in 1974. Despite the equipment design now being outdated, this plant still continues to operate successfully, indicating the versatility and adaptability of this technology. Today, there are some 75 copper SX operations worldwide with cathode production above 10 kt/a. The top ten producers currently account for about 40% of the global 4.3 Mt/a SX–EW copper production. South America (predominantly Chile and Peru) is the largest copper cathodeproducing region, with annual production of some 2 Mt. The Central African Copperbelt (Zambia and the Democratic Republic of Congo (DRC)) is second, with cathode production of 1.2 Mt/a, and North America (USA and Mexico) third, producing close to 0.8 Mt/a Cu (Solvay Cytec data, 2014). The remaining 0.35 Mt/a comes from all other regions combined (referred to as ‘Rest-of-World’)."

Jan 1, 2016

By M. R. Khalesi, S. Arfania

"Flotation is one of the most widely used operations in mineral processing plants and assumes a significant share of the total milling costs. The purpose of this paper is to introduce a new set of capital and operating cost models for major flotation machines based on the application of single (SRA) and multiple regression analysis (MRA). Thirty-seven major flotation machines were analysed for this purpose. Depending on the machinery type, different technical variables such as diameter, required air flow rate, required floor space, cell volume, required air pressure, and power were considered as predictor variables, individually (in SRA) or simultaneously (in MRA). Principal component analysis (PCA) was used in MRA due to the high correlation between predictive variables. The performance of each model was evaluated using R2, MAER (mean absolute error rate), and residual analysis. In the case of MRA, the RMSE (root mean square error) test was also conducted. Maximum obtained MAER of 13.5% and minimum R2 of 0.86 indicated that these models could be applied as credible tools in estimation of capital and operating costs of flotation machines for design and feasibility studies.IntroductionMineral processing is a vital part of mining projects and mainly involves comminution, sizing, concentration, extractive metallurgical processes, and dewatering. Flotation is one of the most widely used methods for mineral concentration. Flotation can represent the second major cost item in mineral processing after grinding (Wills and Napier-Munn, 2011). Accordingly, it is a main concern of mining project managers to select and optimize flotation circuits in order to decrease costs and increase productivity. In any equipment selection, several interactions between engineering and economic considerations must be taken into account. Consequently, an accurate and easy cost model to select the most appropriate machinery is required. Moreover, cost models could be used in flow sheet simulations applied in design and optimization. Models of unit operations built into the simulators could be improved by linking the equipment cost models (Khalesi et al., 2015)."

Jan 1, 2017

By J. Tikka, E. Bäcklund, N. -O. Lindfors

Tornados are the most violent weather events in the world, and we have all seen the forces and phenomena created by tornados in nature. Airgrinder AB has been working with a material treatment technology, which most easily could be described as an artificial tornado. The process consists principally of one air fan providing a high-velocity airstream that enters a mechanical cyclone. When the gas enters the cyclone, an outer vortex is created. This outer vortex rotates next to the cyclone wall, and at the bottom of the cyclone funnel the gas stream is turned and an inner vortex is created. The control of the air flow is tuned by a special device on top of the cyclone. The gas outlet is at the top of the cyclone and the material outlet at the bottom. The material is fed through a feeding device into the air stream channel prior to the inlet into the cyclone. The process is basically an improved grinding and dehydrating system, which is very efficient and environmentally friendly and can even be employed with very sticky materials. Also due to its rotating comminution, the material particles become rounded during grinding, hence more free flowing and easier to handle. MEFOS has already tested more than 30 different applications in the pilot equipment. The materials tested range from metallurgical slags containing 2?3% moisture to sludges with up to70% moisture. This technology has a potentially strong impact on mineral beneficiation, including the drying of sticky fine-grained materials, improved and selective gas scrubbing and the manufacture of free flowing powders.

Jan 1, 2007

By Oaitse Medupe

The feed to the BCL concentrator is made of the ore from Phikwe No3 shaft, Selebi shaft and Selebi North shaft. The receiving bin of the concentrator has daily throughput of 7869mt live capacity of ore with feed grade from underground operation of 0.70%Ni, 0.75% Cu and 0.05% Co. The valuable minerals in the ore are Pentlandite, Chalcopyrite. Cobalt is present mainly in the solid solution in pentlandite. The common non-sulphides minerals are Amphibolites, quartz, micas, and Feldspar while pyrite and pyrrhotite are the major gangue sulphides. Pyrrhotite contains between 0.1% and 1% Ni in solid solution. From the mineralogical investigation, it was found that approximately 65% of the pentlandite in the ore occurs as exsolutions in the pyrrhotite and the grain sizes ranges from 8 to 38µm. about 25% of the nickel bearing pentlandite is medium grained and subhedral. This kind of pentlandite occurs along the cracks of pyrrhotite or as inclusions in pyrrhotite. The rest of pentlandite present is disseminated in the gangue matrix. Because of the fine occurrence of pentlandite, fine grinding was conducted in order to improve the recovery as well as the concentrate quality. A series of subsequent flotation test were performed in order to evaluate grinds of 35, 40, 45, 50, 60 and 80% passing 75µm. It was observed that ? The mass pull increased together with increasing fineness of grind ? Similar nickel recoveries were obtained at 35 and 40% passing 75µm but from 50% and 60% the grind was seen to adversely affect the nickel recovery. At 80% passing 75µm the recovery increased by small amount. ? Flotation kinetics showed higher initial nickel recoveries but these did not translate into higher final recoveries. ? Grinding finer than 80% passing 75µm yield very high grades of the concentrate in the first minute of the flotation test, and the grade is dramatically reduced in the fifth minute of the test. It was concluded that the current grind of approximately 48% passing 75µm is close to the optimum and no significant benefit were found to be associated with finer primary grinds. The inconsistence of the grade and recovery as well as the pentlandite losses will be discussed. Keywords: Pentlandite, Nickel losses, Grain size, Flotation

Jan 1, 2007