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By J. H. Schubert

Mintek has developed a level-control system, FloatStar, for use in flotation circuits. Instead of controlling levels separately in each unit, the controller monitors levels throughout the circuit. It can thus take account of the global effects of any control actions. A collaborative project between Mintek and Karee Platinum Mine has begun, looking at aspects of flotation control. Karee plant was chosen as the site for this work because of its good existing control infrastructure. As a first stage of the joint project FloatStar was installed. Analysis during installation and running of the FloatStar has illustrated how circuit design and measurement technology can affect process control. Severe interactions have been observed in the levels of adjacent banks. The effect of FloatStar on flotation performance was tested and an improvement in level control was observed. Similarly, a faster settling of the plant after start-ups was observed. Both the improved level control and faster start-ups lead to higher platinum recovery.

Jan 1, 1999

In ilmenite smelting, the FeO content of the feed material (nominally FeO.TiO2) is decreased by reduction with carbon. In a parallel reaction, a significant amount of the TiO2 is reduced toTi2O3. One of the striking features of these reactions is a consistent relationship between the extents of FeO and TiO2 reduction; this relationship is independent of furnace size. It was recently proposed that this relationship follows from the solidification behaviour of the slag, where the final slag composition corresponds to the minimum melting point (?eutectic groove?) in the FeO-TiO2-Ti2O3 phase system; the hypothesis is that solidification equilibrium with the freeze lining stabilizes the slag composition. If this is the case, the system of slag and freeze lining must be capable of correcting two types of disturbances: thermal and compositional. Thermal disturbances result from incorrect power input, for the feed rates of ilmenite and reductant. For example, excessive power input will tend to overheat the slag, causing the freeze lining to melt partially, establishing a new steady-state heat loss from the furnace. Compositional disturbances result from an incorrect reductant input for the given power and ilmenite input. In this work, the dynamic response of the slag and freeze lining to different inputs (flow rates of ilmenite and reductant, and power input) is modelled. The model is based on solidification equilibria, and quantified heat loss through the freeze lining. The conclusion is that the solidification equilibrium cannot constrain the composition to the eutectic groove for typical operating conditions. Keywords: ilmenite smelting, freeze lining, solidification, high-titanium slag

Jan 1, 2004

By R. L. Lawson

I?ve been asked to appraise the global role of coal and mining, and the best place I can think of to begin is with the World watch Institute, which purports to monitor all things global. Last fall the institute?s magazine, entitled World Watch, in a cover story called for a worldwide campaign to outlaw the use of coal before this century?s end. To my mind the article began the campaign. However, the institute had to admit that no such ban will be possible unless there is special help and heavy intervention?that is, novel policies and punitive taxes. I?ll quote directly from the magazine to underscore the point: ?without them the market will continue to deceive us into thinking coal is cheap, abundant and irreplaceable?.

Jan 1, 2001

By G. Laing

On scheduled commissioning and effective operation of a solvent extraction circuit relies on getting the design of both the core contact equipment and the peripheral plant right. Experience has shown that poor performance of new plants is frequently a result of ?utility? systems that do not match the requirements of the circuit, rather than the mass transfer equipment itself. Both the operator/owner and designer need to understand the ?complete requirements? for the circuit to get the balance of the design right. This paper reviews generic issues, frequently overlooked or altered during cost-cutting exercises, which have a significant impact on plant performance.

Jan 1, 2002

By W. Kotze

The gold mining industry has mainly relied upon the use of highly polluting chemicals, such as mercury and cyanide to recover gold from its ores. The Coal Gold Agglomeration (CGA) process was developed some years ago and has the advantage in that gold is recovered by a procedure which has little or no negative impact on the environment. A gold ore containing liberated gold particles is contacted with coal-oil agglomerates, where by the gold is recovered into the coal/oil phase. Laboratory scale batch tests were performed on an artificial mixture gold slurry and gold recoveries of up to 85% were found under optimized conditions. By recycling the coal/oil phase, it was found that the gold loading onto the agglomerates was increased. Tests performed on an industrial ore yielded slightly lower gold recoveries, and X-ray Diffraction (XRD) analysis on the coal/oil phase showed that minerals other than gold was recovered into this phase. A comparative study was conducted whereby the CGA process was compared to mercury amalgamation. Gold recoveries obtained through amalgamation were 15% lower than by the agglomeration process, which indicates that this process can be considered favourably as an alternative to amalgamation.

Jan 1, 2000

By E. Yalçin

The data set often contains one or more secondary variables. These secondary variables are usually spatially cross correlated with the primary variable. The addition of the cross-correlated information reduces the variance of the estimation error by using the cokriging method. The grade estimation results of ordinary kriging and cokriging methods are evaluated and it was found that the estimation variance of cokriging method is slightly lower than ordinary kriging. The effect of variation of block dimension on the estimation results is also investigated and it was seen that the cokriging estimation variance values also decrease as the block dimension increases.

Jan 1, 2005

By O. Gunaydin

Performance measurements of large-diameter circular saws were conducted on eight different carbonate rocks in marble factories located in some areas of Turkey. Rock samples were collected from these factories for laboratory tests. Uniaxial compressive strength, tensile strength and impact strength were determined in the laboratory. The brittleness of B3 (the ratio of compressive strength minus tensile strength to compressive strength plus tensile strength), the brittleness of B5 (the product of percentage fines in the impact strength test and compressive strength) and the brittleness of B8 (half of the product of compressive strength and tensile strength) were calculated from the test results. Hourly slab productions were correlated with brittleness indexes. It was concluded that sawability of carbonate rocks can best be predicted from the brittleness of B8.

Jan 1, 2004

By R L. Langak, R A. Heins

The use of differences in specific gravity between minerals to separate them has long been utilized in the extractive industries. The environmental and cost benefits of the commercialized forms of these processes are well understood and widely used. Gravity concentration is used inter alia in the primary beneficiation of gold, diamonds, coal, tin, ferrous metal ores and andalusite. The potential for economic loss due to poor performance of these gravity processes is significant, but diverse in manifestation and regular process monitoring can prevent or at least reduce these losses. The measurement of performance of gravity processes has always presented a challenge, due primarily to the masses of material involved and the physical nature of the processes, generally typified by long reporting time, and hazardous materials (such as Tetrabromoethane) for float and sink type tests. The development of density tracers has improved this situation, however recovery of these tracers from the process streams created the next set of challenges, requiring significant manpower to physically remove tracers from product dewatering screens. Additions to these tracers (magnetic or x-ray fluorescent) eased the recovery mechanism issues but made them much more expensive to produce, hence operators became concerned about losses during process testing. In addition, magnetic recovery of smaller size tracers by a magnet suspended above a loaded screen panel is still problematic. The development of new low cost magnetic tracers has improved statistical significance of tracer tests, as the tracers themselves can be bought and used in much larger quantities, whilst still remaining economically viable. Coupled with the development of effective magnetic recovery technology, such as the Gekko MagScreen, for even fine sized tracers, on-line, continuous tracer testing is now becoming a reality. Whilst the development of high technology radio frequency detection tracer systems continues, enabling the real time measurement of the process and interpretation of results, miniaturization and recovery of these tracers, which is critical given their costs at present, remains an issue. Keywords: Gravity, process measurement, tracers, magnetic recovery

Jan 1, 2006

By P. van Dorssen

In South African metalliferous mines, stoping operations are largely confined to narrow, tabular orebodies making mechanization extremely difficult. Limited flexibility in terms of stope width has necessitated drilling by means of handheld, pneumatic rock drills at most of our operations. As the largest producer of platinum in the world, we drill in excess of forty million stope blast holes per annum. Cleaning of the broken ore is also done by conventional means?utilizing scrapers and scraper winches. Conventional methods such as these carry high costs in terms of risk exposure as well as labour intensity. The purpose of this paper is to describe the development of a long hole stoping system suitable for the narrow platinum reefs. The new system had to be substantially safer and more cost effective than conventional mining. We selected a site that was conducive to mechanized mining and set out the parameters that we considered would meet our requirements. We then conducted a feasibility study to evaluate the conceptualized long hole stoping system in terms of specific goals. An analysis of the proposed system identified the Key Performance Indicators (KPIs). One of the most critical goals was to be able to create a man-free stope. This would mitigate the safety risk associated with normal stoping operations, as well as the inefficiency cost previously referred to.

Jan 1, 2002

By I. K. Craig, F. R. Camisani-Calzolari

Defects which occur at the surface of a continuously cast slab impede the throughput of final product, because an extra stage in the process is required to grind the defects away before further processing can take place. Defect prediction and the minimization of the occurrence of defects is required. The use of two models to define the defect propagation is explained. Both models are derived using system identification techniques such as auto-regression with exogenous input(ARX). One model is used to determine the effect of manipulated variables such as casting speed and measured disturbances such as mould level on temperatures within the mould. The other isused to determine or indicate the effect of the mould temperatures on the occurrence of defects such as transversal cracks. The latter model can be used to predict when the defects will occur and the former can be used to control the occurrence of the defects. Keywords: continuous casting, surface defect, control system, predictor, system identification, ARX

Jan 1, 2003

By R. P. H. Willis

For technology transfer to be successful a process, from research to full scale application, has to be followed. This paper describes such a process and how it is applied in practice. Some of the ?do?s? and ?don?ts? are highlighted. Recommendations are made on how to communicate existing knowledge and to ensure that a framework exists to effectively plan future projects with final technology transfer objectives firmly in place. The Impact Ripper System is used as a case study to illustrate lessons learned. Key words: Technology transfer, implementation

Jan 1, 2002

By D. François-Bongarçon

When it comes to sampling theory, a bad sampler is a bad sampler, no matter what, and a sampler is either bad or good. It also is of critical economic importance to tell and understand the difference, especially in a metallurgical plant. In this paper, the grand principles of Sampling Theory are first recalled, then the most popular types of sample cutters for plants are critically reviewed. It is concluded that the industry has a lot of progresses to make in that direction, although improvements usually pay for themselves very quickly.

Jan 1, 2002

By C. Ware, R. Uken, G. Whitmore

The coastal dune cordon of northern KwaZulu-Natal is among the highest in the world reaching heights in excess of 180 m and up to 2 km in width. It comprises a complex system of Quaternary stacked dunes of various geomorphologies, types and ages (Sudan, 1999; Maud and Botha, 2002;Ware et al., 2001; Ware, 2003). The dunes contain economic heavy minerals that have been exploited for the last two and a half decades. Dune units have recently been defined based on sand composition and texture(Sudan, 1999; Ware, 2003). Despite this, little work has been undertaken on the clay-fraction (< 2 um). This work documents the weathering of dunes to form clays. From the documented clay assemblages and relative abundances, a simplified weathering sequence with increasing maturity can be summarized as follows: primary minerals ? illite + vermiculite ?illite +interstratifications ?illite + montmorillonite ?halloysite + interstratifications + kaolinite ?kaolinite. The dominant controlling factors in determining clay assemblages is pH and leaching conditions. The presence of carbonates results in an alkaline pH and high concentrations of Ca2+and Mg2+which favours the formation of montmorillonite and vermiculite. However, vermiculite tends to form under slightly acidic conditions and is indicative of palaeosols where organic acids produce localized acidic pH’s. In contrast to this, kaolinite will only form and concentrate when carbonates have been leached. Kaolinite dominated samples are considered very mature under current climatic conditions(Chamley, 1989). Halloysite represents a transitional phase between montmorillonite and kaolinite (Herbillon et al., 1981). Ion mobility and evacuation is also critical in determining clay assemblages. Past work and field studies indicate that the dune cordon acts as an open system, resulting in carbonates and mobile ions being readily leached and lost from the system. However, when prolonged weathering has caused an accumulation of fine-grained material, the permeability decreases substantially whereby mobile cations and silica cannot be readily evacuated. This results in the formation of montmorillonite rather than kaolinite, even when carbonates have been leached. Illite (sericite) is considered to alter directly from feldspars. However, dune stacking and geometries, vegetation, water fluxes, reworking and erosion complicates this sequence.

Jan 1, 2003

By J. L. Human, N. Fernandes

The rockfall hazard is the major contributing agency to fatal accidents in South African platinum mining operations. The majority of these accidents occur in close proximity to the working stope face. The collapse of fractured or blocky ground between individual temporary support units or the closest permanent support line to the stope face has not yet been adequately addressed. A large-scale stope support system testing facility funded by the Safety in Mines Research Advisory Committee (SIMRAC), has been designed and constructed to test support systems and stimulate innovative thinking by mining personnel, support manufacturers and suppliers by providing a facility where the interaction of stope support systems, a rigid stope face and a discontinuous hangingwall beam can be observed during quasi-static and dynamic conditions. Tests have been carried out on various types of stope support systems, focusing on the temporary support systems used in the immediate stope face area. The interlinking of the temporary support units with mesh or safety netting has been explored in the prevention of falls of ground between support units during gravity driven falls of ground. These tests illustrate the facility?s ability to be used to stimulate innovative thinking and provide a testing ground for the development of temporary support systems in order to reduce the risk off all of ground injury to mining personnel at the stope face.

Jan 1, 2004

By D. Pohl

The past decade has seen rapid expansion in the West African mineral exploration environment. This expansion has been largely driven by changes in ?Political climate ?Fiscal and legal regimes ?Exploration approaches ?West African geology. Major regional mapping and geochemical surveys by the UNDP, and the BRGM in the late 1970s and early 1980s laid the foundation for the rapid development of mineral exploration and resources during the past decade. An additional driving impetus was the discovery by native artisanal miners of many significant new gold occurrences at Libiri, Essakan, Bouda and Tirahori, during the great droughts of the late seventies and early eighties.

Jan 1, 1998

This paper presents an initial investigation into the viability of co-kriging the grades of multiple mining cuts in a two dimensional, thin reef scenario. Deposits with gradational mineralized zones, in the perpendicular sense, are not as well served by the use of reef accumulation and thickness as deposits characterized by a sharp distinction between ore and waste rock. South African Bushveld Complex platinum deposits and Witwatersrand gold deposits are examples of this distinction. The calculation of an optimal mining cut is of paramount importance in the mining of Bushveld platinum. Two-dimensional kriging of a constant stoping width mining cut is an effective method for resource calculations once a cut is decided, but this begs the question of how to decide on the cut. Comparison of multiple cuts is used as a way of achieving this decision on many of Anglo Platinum’s operations. Although the kriging of each cut is valid in isolation, occasional negative values occur when incremental grades between overlapping cuts are calculated. Negative incremental grades cannot reflect reality. They are thought to be related to the inability of the method to include the strong continuity in the perpendicular direction demonstrated by the relevant variograms. Co-kriging of related variables has been investigated as a potential means tore impose this inherent order relationship. Various co-kriging options have been investigated. The method has been tested on a real data set from an established platinum operation. One of three types of anomaly has been investigated so far. The results show that co-kriging the mining cut grade as the primary variable, with just one secondary variable, the reef thickness, eliminates most occurrences. Severe anomalies remaining are arguably indicative of population mixing and might be more effectively treated by rezoning the data. Aim—To investigate the viability of co-kriging the grades of multiple mining cuts as a method for resolving anomalies in the estimation of such cuts on Bushveld platinum deposits, with applicability to other thin reef type deposits with a gradational not sharp cut-off between ore and waste in the direction perpendicular to the reef. Keywords: co-kriging, cross variograms, ordinary kriging, platinum, two-dimensional, grade profile

Jan 1, 2003

By J. R. G. Williamson

The Mining Division of Iscor, an integrated minerals and metals company, has recently completed a feasibility study for the establishment of a new heavy minerals mine and smelter in the Richards Bay area of KwaZulu-Natal, South Africa. The mine will produce a heavy mineral concentrate containing ilmenite, zircon, rutile and leucoxene which will be beneficiated at a central processing complex close to Empangeni. The ilmenite will be smelted to produce high-grade titania slag and pig iron for export. The ancient dune containing the mineral deposit is located some distance inland of the coastal dunes, and the sands contain a high proportion of extremely fine material which must be extracted ahead of the gravity separation process. Of the 56 million tonnes to be mined annually over the ten-year life of the mine approximately 23,4%?a total of 13,1 million tonnes of minus 45 micron residue fines?will have to be disposed of in a containment facility. The origin of the fine material is from the weathering of amphibole minerals. The remaining coarse sands will be returned to the mined area to re-create the original dune configuration. A number of options for the disposal of the residue fines have been examined and specialised laboratory tests undertaken to determine the deposition behaviour of the fines. The final solution involved the use of a ?sub-aerial? technique for deposition of fine material in a disposal facility. The resulting arrangement will adequately meet technical and environmental criteria. Upon closure after 10 years of operation, the surface of the disposal facility will be returned to sugar cane cultivation The paper refers to the various options considered and describes the problems associated with competent disposal of the residue fines and the development details of the final disposal facility.

Jan 1, 1997

By G. Broadbent

It is an honour to be invited as a speaker to this ICCR conference and a pleasure to be with you here in South Africa. I have been asked to talk about the competitiveness of coal versus other energy alternatives. Coal supplies nearly one-quarter of the global primary energy. Its most direct competitors are gas, nuclear and renewables. Oil is predominantly for transport fuels. Fuel oil is competitive with coal when crude is below its long-run average price and has some niche opportunities. But I will confine my comments to nuclear, renewables and particularly natural gas as the most potent current competitive threat to coal. Competitiveness is more than just cost and price; there is environmental acceptability, security or reliability and increasingly image. These factors are more of a spectrum than discrete issues. Dollars and cents remain the key issue for competitiveness but one must recognize the impact of politics in sustainable development and energy security.

Jan 1, 2001

The validity of a steady state assumption made by Adams and Nicol (1986) in the modelling of the elution of gold from activated carbon was investigated. It is shown that the accuracy of the steady state approximation is dependent, not only on the magnitudes of the solution flow rate and reactor volume, but also on the lumped elution rate constant. Under the experimental conditions used by Adams and Nicol (1986) the steady state assumption was inaccurate. This could be circumvented in this instance by applying a rigorous general model which accounts for unsteady state behaviour in the solution and in the activated carbon to the experimental data.

Jan 1, 1997

Recent studies on the physico-chemical properties of molten slags and oxide solid solutions of interest are reviewed. The review covers redox and phase equilibria in slags, viscosity, diffusivity, electrical conductivity, kinetics of interfacial reactions between slags and CO-CO2, interfacial properties and phenomena. Some highlights from ongoing work on modelling phase diagrams, component activity, viscosity and electrical conductivity of multi component slags will be presented and results compared with published experimental data on slags with or without suspended solid phases.

Jan 1, 2004