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By K. Naidoo, M. Pelser, J. Hagemann, K. C. Sole

The copper tankhouse at Rustenburg Base Metals Refinery is an essential component of the Anglo American Platinum value chain. The tankhouse uses starter-sheet technology that was adopted in the 1980s, so dependence on manually intensive labour and overall operational excellence has a significant impact on process performance. An efficient, stable, and sustainable electrowinning process contributes to minimising energy consumption and reducing operational costs, and enables improved product quality and increased throughput. Historic performance of this tankhouse has often been suboptimum over prolonged periods. An in-depth operational review of performance from 2018–2024 was carried out to understand challenges, risks, and high-impact factors that contribute to poor performance. Implementation of adherence to fundamental operational basics identified from global best practice, such as the frequency and quality of cell cleaning and maintenance, preventing backlogged harvesting or maintenance, preserving cell-top furniture conditions and integrity of electrodes, preventing short circuits and poor current distribution, and maintaining a high level of operational discipline, has since contributed to an era of exceptional performance. Root-cause analysis fault trees pertaining to poor current efficiency and high scrap rate are summarised. Current efficiency has significantly improved since 2021, now consistently exceeding 88%. The copper scrap rate, previously believed to be limited to a minimum of 4%, achieved a historic monthly low record of 2.06% in 2023. Chemical and physical quality has considerably improved, and cathodes exhibit minimal morphological defects.

Jun 27, 2025

By A. Singh, R. D. Govender

The current method employed to quantify the efficiency of separation of ferromagnetic ores by wet low intensity magnetic drum separators (WLIMS) incorporates the use of a conventional benchscale Davis Tube (DT) operating at a magnetic field intensity that is equivalent to that of the drum’s surface. However, empirical research has indicated that the magnetic force, or force index, rather than the magnetic field intensity, is the critical factor in the operation of the magnetic separator (Murariu and Svoboda, 2002). Furthermore, the current aforementioned practice would yield incorrect information as the magnetic field gradients produced by a typical WLIMS unit differs considerably from that of a bench-scale DT. In light of this, research on magnetite focusing primarily on the scale-up of DT results to pilotscale WLIMS were undertaken. The investigation entailed a comparative study between that of a typical WLIMS circuit and a bench-scale DT. The purpose was to practically evaluate the performance of a WLIMS, bench-marked against the traditional laboratory-scale DT unit. Moreover, the secondary objective was to produce a magnetite concentrate graded at 69% Fe, 95% -45μm, as a suitable source of separation media for use in the Dense Medium Separation (DMS) industry. Fundamental findings of previous works provided a framework for the study, however, a realworld approach was explored. Preliminary testwork conducted at Mintek investigated the performance of a DT and a typical multi-stage laboratory-scale WLIMS circuit (operating at 1000 Gauss at the surface). The results attained indicated that a DT operating at high intensities is comparable to a single rougher WLIMS stage. Additionally, it was observed that the three stage laboratory-scale WLIMS circuit performed similarly to the DT operating at 1000 Gauss. Moreover, piloting testwork was undertaken, carried out in larger 380mm drums, and the results attained showed a strong correlation with laboratory-scale findings. Keywords: Davis Tube, wet low intensity magnetic separation, magnetite

Jan 1, 2020

By F. Dong, F. Yang, J. Wang, Z. Wang, D. Mingxia

Antimony oxide ores are important antimony resources, but their recovery is still a problem. In this paper, the adsorption behaviour and mechanism of dodecamine and quaternary ammonium salt on the surface of cervantite and quartz were investigated. The flotation behaviour of cervantite and quartz using quaternary ammonium salts and dodecylamine as collectors was studied by single mineral flotation experiments. The adsorbed amount was measured and infrared spectroscopy was used to study the ability of several cationic collectors to float cervantite and quartz. The results show that quaternary ammonium salts can simultaneously float the cervantite and quartz. It is difficult to achieve separation of the two minerals using quaternary ammonium salts as collectors. At pH>10, dodecylamine can float quartz but not cervantite, which can achieve reverse flotation separation of the two minerals. The difference between the abilities of quaternary ammonium salts and dodecylamine to float cervantite and quartz lies in the different ionisation properties of the two reagents. Quaternary ammonium salt is a strong electrolyte that is completely ionised in the pulp and exists mainly in the form of quaternary ammonium ions. Dodecylamine is a weak electrolyte and predominantly forms molecules under alkaline conditions. Keywords: Cervantite, quartz, dodecylamine, quaternary ammonium salts, flotation

Jan 1, 2020

By S. Khan, M. Auret

Due to the modernisation of mines, traditional training methods may be supplemented to support the upskilling of supervisors in mines. A project was initiated by the SAMERDI SATCAP programme to demonstrate the “art of possibility” through a modern training methodology. Two exemplar digital supervisory leadership development modules for underground gold and platinum-group metal conventional and modernising mines, were developed for potential uptake by the mining industry. These exemplar modules were exhibited on a digital platform, towards leading and driving mining modernisation. The research adopted a mixed method approach that included a literature review, a review of an existing supervisory leadership development programme, data gathering, a pilot study, and stakeholder validation workshops. The research supported the development of exemplar digitised modules. The two digitised modules were showcased to the industry for potential adoption. Training slides, a facilitator guide, and a training video were developed for ease of use by industry. The training modules are generic and not specific to a particular mine. They may be used by multi-commodity mines, including gold and platinum-group metals, as ‘stand-alone’ modules. They are customisable, through consultation with relevant service providers for specific working environments. The findings indicated that both the traditional classroom training and the new digitised online learning solution offer advantages for supervisory leadership development. Digital learning is not a new concept for supervisors at mines and modern training methods are well-supported by supervisors in the industry. A ‘modernised’ training solution may consider a ‘blended’ learning approach that combines traditional training with digital methods.

Jun 27, 2025

By C. Hsu

Underground coal gasification (UCG) is becoming more popular as the reserves of good quality, mineable coal are starting to diminish, and yet the global energy demand from coal is still increasing. The purpose of this research project was to investigate cavity formation within a coal block due to the combustion reactions in the context of UCG. The cavity plays a pivotal role in the UCG process, as it is essentially the gasification reactor. Cavity formation in an in situ gasification process using the forward combustion linking method (FCL) had been investigated, and a laboratory model was created to simulate the process. The experiment was performed by drilling a U-shaped tunnel into a coal block, which was then combusted internally with air that was fed through an injection hole. A heating element (at approximately 500°C) was used to supply the required heat for combustion at the base of the injection well. The coal blocks were analysed using micro-focus X-ray tomography. The tomography results showed that the coal tended to crack along the bedding plane after a short duration of combustion, due to either the formation of clinker or the expansion of swelling vitrinite along the horizontal tunnel. The deposit was thicker at the base of the injection well compared to the base of the production well; this may have been caused by the turbulence of the air flow and the relatively high oxygen concentration at the base of the injection well. A comparison of the results with work by Daggupati et al. (2010) showed the same trend, despite the slightly different methodology applied.

Jan 1, 2014

By L. Bam, R. Machaka, S. Chikosha, N. S. Muchavi

"Parts manufactured through power metallurgy (PM) typically contain pores that can be detrimental to the final mechanical properties. This paper explores the merits of 3D X-ray computed tomography over traditional microscopy for the characterization of the evolution of porosity in metal injection moulding (MIM) and direct powder rolling (DPR) products. 17-4 PH stainless steel (as-moulded, as-debound and sintered) dog-bone samples produced via MIM and Ti-HDH strips (as-rolled and sintered) produced via DPR and were analysed for porosity. 3D microfocus X-ray tomography (XCT) analysis on specimens from both processes revealed spatial variations in densities and the existence of characteristic moulding and roll compaction defects in agreement with traditional microscopic microstructural analysis. It was concluded that micro-focus XCT scanning can be used to study MIM and DPR parts for the characterization of the amount, position and distribution of porosity and other defects. However, the majority of the sub-micron sized pores could not be clearly resolved even at the highest possible instrument resolution. Higher-resolution scans such as nano-focus XCT could be utilized in order to fully study the porosity in MIM and DPR parts. IntroductionMetal injection moulding (MIM) is a novel process, which combines the advantages of powder metallurgy (PM) and plastic injection moulding. MIM has found widespread applications in the cost-effective production of high-sintered density small parts with complicated shapes and mechanical properties equivalent to those of wrought materials (German and Bose, 1977; Machaka and Chikwanda, 2015; German, 2013). There are four basic processing steps involved in MIM, namely; feedstock preparation, injection moulding, debinding and sintering. These steps are discussed in greater detail elsewhere (Machaka, Seerane and Chikwanda, 2014; German and Bose, 1977; Machaka and Chikwanda, 2015; German, 2013).Feedstock preparation involves mixing metal powder with a carefully selected composition of polymeric binder materials at a specific temperature. The feedstock is then granulated and injected into a predefined mould die with the desired shape. The part produced during the moulding step is referred to as a ‘green’ component. The green component typically contains no porosity since the spaces between adjacent powder particles are readily filled with the binder materials (German and Bose, 1977; Li, Li and Khalil, 2007). Debinding is the systemic removal of the binder components by chemical, catalytic, or/and thermal means while maintaining the shape of the component. The part produced after the debinding step is referred to as a ‘brown’ component. Debinding is known to be the source of porosity in brown components (Ji et al., 2001; Tsai and Cen, 1995). Finally, the brown debound part is sintered to full or nearfull density (Sotomayor, Varez and Levenfeld, 2010). The sintering step and associated densification closes up the majority of the pores. Sintered MIM parts are typically sintered to high density (95–99%) and retain an irreducible amount of residual porosity (Barriere, Liu and Gelin, 2003; German, 1990)."

Jan 1, 2016

By J. C. Vreugdenburg, B. A. Dippenaar, J. Muller, T. L. de Vries

Iron ore fines are agglomerated in the sintering process to produce sinter: an important feed material for blast furnaces worldwide. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed mixtures is evaluated. The model aims to predict sinter quality, including chemical quality and physical strength, as well as key sinter process performance parameters such as production rate and fuel consumption rate. The model uses the finite difference method (FDM) to solve heat and mass distributions within the sinter pot over the sinter bed height and time dimensions. This method can further be used for establishing empirical relationships with measured sinter properties. Inputs into the model include the feed material physical properties, chemical compositions, and boundary conditions that vary over time. Sub-models describe relationships between applied pressure differential and gas flow rate through the bed of granulated fine ore particles, combustion of carbonaceous material, calcination of fluxes, evaporation and condensation of water, and melting and solidification. Four sinter pot tests were performed and the model predictions validated against temperatures measured at depths of 100, 230, and 420 mm. Differences between predicted and measured temperatures indicated the need for optimization of some model parameters that are uncertain. Optimization resulted in an improvement in the correlation between the predicted and measured temperatures for all tests, although an acceptable level of agreement was not achieved in all cases. Using these parameter values, reasonable agreement was found in terms of typical performance parameters for three out of the four tests.

Jan 1, 2014

By P. Ramsaywok, S Ndanduleni, G. Legodi

The objective of this paper is to share the optimisation journey of a pilot Reflux classifier (RC) circuit in the Exxaro GG1 plant, at Grootegeluk beneficiation complex in Lephalale, South Africa. The RC circuit was commissioned in 2016 to produce semi-soft coking coal at its fines circuit; however the stability of operation as well as the quality control of the coal product was not fully achieved. Various test campaigns and optimisation studies were conducted to understand and optimise the RC circuit at GG1. The studies revealed circuit design inefficiencies; provided an improved technical understanding of the current pilot circuit and the parameters required for the circuit to reach a stable operation. The operation was stabilised with its current inefficiencies to produce an average 12.5% ash semi-soft coking coal product for sustained periods, above the initial target of 10.3% ash. Keywords: Reflux classifier, coal

Jan 1, 2020

By C. Musingwini

The South African mining industry continues to be a major source of employment at a time when at least 25 per cent of the working age population is unemployed. At the same time the industry faces a skills shortage in many of the disciplines necessary for its future health. The University of the Witwatersrand, University of Pretoria, University of Johannesburg, and University of South Africa have historically produced mining graduates for the South African industry, with any shortfall being met by the recruitment of overseas graduates. More recently the global shortage of engineers and other mining industry professionals has seen a reversal of this trend and a very significant emigration of well-educated and highly skilled personnel. The traditional career path for mining graduates is in production and mine management. However, there is the parallel and possibly more pressing need for specialized skills in such fields as ventilation, rock engineering, mine planning, mineral resource evaluation, and mineral asset valuation. It is in these essential areas that chronic shortages continue to hamper the development of the industry and may well frustrate its ambitions to be safe, healthy, and profitable into the future. The permeability of skills across sectorial boundaries within the mining industry requires that skills shortages in the platinum sector are not looked at in isolation, but within the context of the entire industry. This paper reviews the efforts being made by the universities at both undergraduate and postgraduate levels to meet the needs of the South African mining industry, in terms of the required numbers and the range of specialized skills.

Jan 1, 2012

By J. Petersen, H. Naderi, M. H. Nikzad, M. Karimi

In this research, the thermodynamic study of sodium persulfate (Na2S2O8) solution in the presence and absence of H2SO4 and Fe3(SO4)3 was done. Eh-pH and equilibrium distribution diagrams were constructed using Outotec HSC Chemistry Software and the main stable ionic species were determined. Also, the mean activity coefficient and Pitzer model coefficients were evaluated. Effects of system composition, sodium persulfate concentration and temperature were investigated. According to the results, HS2O7 -, HS2O8 -, S5O3 2-, S4O3 2-, S3O3 2-, HS- and NaSO4 - are the main stable species in these three systems. Increasing of sodium persulfate concentration resulted in disappearing of SO4 2- and the appearance of NaSO4 -. The main effect of increasing the temperature from 25 to 75oC, is changing the stability regions of HS2O7 -, NaSO4 -, SO4 2- and S2-. From equilibrium studies, it was concluded that at 25 and 50oC, increasing the persulfate concentration results in a 55-60% decrease for HS2O7 - and an 20- 30% increase for HS2O8 -. At 75oC, HS2O8 - becomes the main species and its percentage decreases with increasing the persulfate concentration. Keywords: Thermodynamic, sodium persulfate, activity coefficient

Jan 1, 2020

By I. James, R. J. Durrheim, M. S. D. Manzi, O. Valeshin, J. Lepine, L. V. Socco, C. Colombero, A. Malehmir, M. K. Rapetsoa, M. Sihoyiya

The FUTURE project aims to enhance seismic surveying in South African mining by integrating advanced acquisition technologies. In this paper, we detail surface and underground seismic surveys at the South Deep gold mine as part of the project. Surface seismic acquisition used co-located broadband micro-electromechanical sensors, one and three component recorders connected to geophones, distributed acoustic sensing using a straight fibre optic cable, along with a 6 ton broadband seismic vibrator operating with 4–180 Hz linear sweeps. In addition, underground surveys employed a combination of straight, and helically wound fibre optic cables, cabled-based and nodal sensors, along with a 500 kg drophammer mounted on a skid steer bobcat. The surface and underground seismic arrays were time synchronised using a GPS-time transmitter to allow for accurate seismic data recording in a GPS-denied environment. Results show the efficacy of these techniques in acquiring high-resolution seismic data, revealing detailed subsurface geological structures and mineralisation down to 3500 m below ground surface. Surface data revealed clear seismic reflections corresponding to the Black Reef and Ventersdorp Contact Reef. An underground P-wave velocity model exhibits low velocity anomalies that are associated with fracturing, while a P-wave reflection stack section shows significant reflections and a degree of faulting below the tunnel floor that was not observed on the surface reflection seismic data. We highlight the potential of these technologies to enhance safety, efficiency, and sustainability in mining. This study sets a benchmark for future reflection seismic surveys, paving the way for safer, more efficient, deep mineral exploration and extraction practices.

Jan 12, 2025

By K. C. Corin, M. S. Manono

The mining and mineral concentration of Cu-Ni-PGM sulfide ores in South Africa occurs in semiarid regions. The scarcity and availability of water resources in these regions has become one of the biggest challenges facing mineral concentrators.S Owing to this challenge, concentrators have to find ways through which they can manage and control their water usage. Recycling and re-use of process water in mineral concentrators has therefore become common practice. This practice is beneficial in that it reduces reliance on municipal water, harnesses compliance to stringent environmental regulations on water usage, and it also offers a better response to the Sustainable Development Goals. This could however be somewhat concerning to the operator as recirculated water often has higher concentrations of ions compared to fresh or potable water. The unintended change in the process water quality may potentially affect critical aspects of flotation such as the stability of the froth. This has led to the need to find those process water ions that have the greatest impact on froth stability. Thus, this paper investigates the effect of various ions common in process water of a typical Cu-Ni-PGM concentrator on froth stability. Bubble size, water recoveries, foam height, and dynamic froth stability in both twophase and three-phase flotation systems are used as proxies for froth stability. Findings of this study are deemed crucial towards the development of a process water management protocol in sulfidic Cu-Ni- PGM ore concentrators. Keywords: Bubble diameter, electrolytes, flotation, froth stability, water quality

Jan 1, 2020

By H. von Blottnitz, B. E. Isheloke

Mining is a significant economic activity in most Southern African Development Community (SADC) countries, and mineral beneficiation has been identified, and controversially discussed as one of the possibilities for industrialisation. With many member countries being economically too small to muster the human and financial resources which beneficiation requires, the recently adopted Regional Mining Vision (RMV) envisages interventions at a regional level. An opportunity arose to ask industry role players to what extent the SADC appears to support regional beneficiation policy interventions undertaken by member countries, and what the challenges are in undertaking beneficiation regionally, as a complement to, or substitute for country-specific beneficiation policies. Twenty-five semistructured interviews were conducted with experts from SADC member countries during the 2019 Mining Indaba. Participants were divided on whether beneficiation should be carried out nationally or in the SADC region. While beneficiation could support value-keeping, key challenges were found to be infrastructure development (i.e. energy, water), scarce skills, access to technology and related costs, but also lack of free trade and movement. We submit that a more integrated beneficiation strategy for the SADC region, as is being developed through the RMV, would indeed be relevant in the future. Keywords: Mineral beneficiation, regional integration, beneficiation policy interventions, African mining vision, mining, SADC

Jan 1, 2020

By W. C. Joughin

The science of soil mechanics is 100 years old, and rock mechanics is about 80 years old. While methods of analysis and design have been developed and have evolved over time, these are relatively young sciences. The rapid increases in computing power and new technologies have enabled more sophisticated modelling and monitoring. However, there are still many aspects of soil and rock mechanics that are not well understood. Geotechnical failures, which have major consequences, still occur. These consequences may include environmental damage, major production holdups and associated loss of revenue, damage to infrastructure, and loss of life. High-consequence events, which are rare, are more difficult to anticipate and to design for, because by their nature they involve extraordinary circumstances or conditions, often geological in nature. The risks are usually mitigated by conservative designs and monitoring. Detailed geotechnical investigations help us to understand the natural variability of soil and rock masses and identify unusual or unexpected conditions. Investigating and researching major geotechnical failures is essential to enable these unusual circumstances to be anticipated. In the past, severe unanticipated events may have been treated as natural events or ‘acts of God’. However, society now has much greater expectations and it is essential to have policies and procedures in place that enable appropriate management of these rare, high-consequence risks. A good example is the Global Industry Standard on Tailings Management (GISTM), which was introduced after the catastrophic dam collapse at Vale’s Corrego de Feijao mine in Brumadinho, Brazil. The address will explain the concepts of uncertainty and variability, and how they should be taken into account in geotechnical design. The challenges facing geotechnical engineers, mine owners, and managers will be discussed. referencing a number of real case studies.

Sep 6, 2023

1. Book reviews Phosphate rock, a bibliography of world resources. London, Mining Journal Books Limited, 1984. £10 (surface mail), £12.25 (airmail). Reviewer: P.Le. Grubb Ok Tedi, by William S. Pintz. London, Mining Journal Books Limited, 1984. 206 pp. £19 (surface mail), £22.25 (airmail). Reviewer: R.P. Plewman 2. Publications of the Canadian Mineral Policy Sector Lime by D.H. Stonehouse. 5 pp. Phosphates by G.S. Barry. 9 pp. Statistical summary of the mineral industry in Canada. 77 tables. Talc by M. Prud'homme. 6 pp. Zirconium by M.A. Boucher. 6 pp. Cement by D.H. Stonehouse. 13 pp. Gypsum and anhydrite by D.H. Stonehouse. 7 pp. Regional review by T.M. Buch. 12pp. SaltbyG.S. Barry. 7pp. Silicon, ferrosilicon and silicon carbide by D.G. Law-West. 6pp. SulphurbyB.W. Boyd. 9pp. Mineral Report 31. Canadian Minerals Yearbook 1981. Available from the above address at $40.75 per copy. 3. Mintek reports Report M18D The recovery of pyrite and gold from acid-leach residues from the Merriespruit Gold Mine. (First issued Feb. 1982; reissued Mar. 1984). Report M2OD The separation of ore from Cooke into high- and lowgrade fractions. (First issued Feb. 1982; reissued Mar. 1984). Report M33D Explanatory tests on the reduction of the sulphur content of sponge iron. (First issued Apr. 1982; reissued Mar. 1984). Report M43D Beneficiation tests on andalusite-bearing shales from a farm near Thabazimbi. (First issued Aug. 1982; reissuedMar. 1984). Report M129 The determination of tin, niobium, and tantalum in pegmatite by X-ray-fluorescence spectrometry. ReportM131 The determination of copper and nickel in iron- and chromium-bearing materials by a pressed-powder technique and X-ray-fluorescence spectrometry. Report M135 The installation of a 100 kV A plasma furnace at Mintek. The selection and installation of a 100 kV A a.c. plasma Report M136 The determination of gold in activated charcoal by use of a loose-powder technique and X-ray-fluorescence spectrometry. Report M140 The effect of physical and chemical factors on the corrosivity of a synthetic mine water.

Jan 1, 1984

By J. O. Claassen

"SynopsisMining value chains are dynamic systems and should be managed according to systemic flow-based principles. This includes a detailed focus on the impact of variable geological conditions on material flow, product quality, and production cost, visibility of the total mining system to operators and managers, as well as the synchronization of resources and activities in downstream processes. Thirty mining operations across the African continent were studied to establish to what extent systemic flowbased principles are applied in day-to-day operations. The study indicated that although most mining operations have identified the relevant geoprocessing variables, only a small number apply this information in a flow-based management approach. Most mining operators do not focus on developing a clear flow view of the mining value chain and on making it visible to operators and managers to enable them to optimally set and reset operations. Daily synchronization of geoprocessing variables is limited to a small number of variables, e.g. synchronizing ore hardness with drilling or milling requirements, in less than 30% of the operations evaluated. Operations where these principles have been adopted reported a noteworthy improvement in performance. The study indicates that notable potential exists in most of the operations evaluated to implement flowbased management principles, including geometallurgical principles. This can significantly improve value chain performance without exorbitant capital layouts and enhance ROCE. IntroductionObjective of the studyThe study seeks to establish to what extent systemic flow-based principles have been adopted in the southern African mining industry and the implications thereof. Specific attention is given to the importance of defining and managing geoprocessing dependencies (geological variables directly impacting mining and plant performance – the geometallurgical approach), establishing a flow view of the mining system, which typically includes a dashboard of the flow of ore/product quality and cost from the mining face to the customer, and limiting the impact of dependencies through synchronization of activities and resources, e.g. ensuring that a continuous miner does not wait for a roofbolter, or that reagent addition rates are matched with a specific ore/concentrate composition."

Jan 1, 2015

By J. Petersen, M. Reuter, E. Asselin, M. Becker, N. Uys

In order to meet society’s ever-increasing demand for metals and address the numerous technical, economic and environmental challenges within the current mining context, a holistic approach to process design, which is grounded in mineralogy, is needed. This would ensure that the impact of varying process mineralogy (and associated chemistry) on technical considerations and the associated economic implications and environmental consequences are taken into account upfront. This investigation focuses on the commodity zinc due to its strategic value coupled with limited resource availability and the wide variety of substantially different process technologies in existence. As the most commonly processed zinc ores contain zinc sulphides, the mineralogy/chemistry of these ores and their associated process routes will be discussed. The findings have been generated through the analysis of two case studies, Teck’s Trail Operations (British Columbia, Canada) and Hudbay Minerals’ Flin Flon Operations (Manitoba, Canada). The flotation of zinc sulphide ores to produce concentrates with varying mineralogy, represents the starting point for both case studies. The hydrometallurgical process routes for the further refining of zinc and other valuable metals include roast-leach-electrowinning (RLE), and zinc pressure leaching (ZPL). The effect of process route choices on primary metal recovery (Zn), coproduction of other base metals (Cu, Pb), potential for other valuable metal production (Ag, Au) including less well known, but increasingly important trace elements (In, Ge), and the production of other by-products (H2SO4, S0) are discussed. The economic and environmental implications of these aspects will also be considered. It is concluded that a quantitative modelling approach must be taken where waste management is integrated into process system design and simulation as a key unit operation. Keywords: Zinc Sulphide Processing; Design Decisions; Mineralogy

Jan 1, 2020

By G. Akdogan, I. Mwandawande, S. M. Bradshaw, M. Karimi

The mixing characteristics of industrial flotation columns were investigated using computational fluid dynamics (CFD). Particular emphasis was placed on the clarification of the relationship between the liquid and solids mixing parameters such as the mean residence time and axial dispersion coefficients. The effects of particle size and bubble size on liquid dispersion in the column were also studied. An Eulerian-Eulerian method was applied to simulate the multiphase flow, while additional scalar transport equations were introduced to predict the liquid residence time distribution (RTD) and particle age distribution inside the column. The results obtained show that particle residence time decreases with increasing particle size. The residence time of the coarser particles (112.5 μm) was found to be at least 60% of the liquid residence time, while the finer particles (19 μm) had a residence time similar to the liquid. The results also show that an increase in the particle size of the solids results in a decrease in the liquid vessel dispersion number, while a decrease in the bubble size increases liquid axial mixing. Finally, the simulated axial velocity profiles confirm the similarity between the liquid and solids axial dispersion coefficients in column flotation.

May 2, 2022

By W. Jilowa, C. Nguni, M. Simukoko, C. Nampungwe

The upsurge in cobalt price and demand is propelled by high demand from the electronics and electric vehicle industry. Konkola Copper Mines has cobalt occurring with copper in the ratio 1:10 in ore. The ore is treated in the concentrator and recovered at the smelter as an alloy (Cu 70%, Co 4%–7%, 15% Fe). Subsequent processing of the cobalt alloy is challenging, with very few plants able to treat it, leading to marketing challenges. Konkola Copper Mines sought to improve the cobalt alloy by producing a slag that is easier to handle and process in subsequent processes. Cobalt alloy (3.60% Co, 85.4% Cu) was re-melted in a copper bath four times the mass of the alloy. Silica and lime were added for phase separation and fire refining commenced. Following completion of fire refining and after holding the temperature at 1200°C, cobalt-rich slag was skimmed and blister copper was cast into anodes for electrorefining

Jan 1, 2023

By O. Dahl, B. Musuku, N. Schreithofer

Recovery of fine pentlandite is proving to be a challenging task in the Kevitsa sequential flotation operations, with over 60% of the nickel losses reporting into the -25μm size fraction. Since commissioning, the Kevitsa process has undergone major changes to address throughput and flotation performance. Major changes were implemented in the configuration of the milling and flotation circuits as well as in the operating conditions and reagent regime. Some of these changes improved nickel flotation while others deteriorated flotation performance. Most of the changes have had a direct impact on nickel flotation. This paper reviews the systematic analysis, laboratory testing and salient changes done to the process with special focus on the impact on the fine pentlandite flotation. Keywords: Blending, Flotation, Chalcopyrite, Pentlandite, Fines

Jan 1, 2020