Search Documents

By X. Goso

Laboratory-scale tests were conducted at Mintek for the production of titanium powder from particulate Kroll sponge by the hydrogenation-dehydrogenation (HDH) process. The aim of this work was to produce titanium powder for powder metallurgical consolidations. The work involved the production of titanium powder at optimized conditions, which included hydrogenation in a horizontal tube furnace at 600°C for 2 hours, milling using planetary and roller mills, and dehydrogenation in a vacuumed retort fitted in a muffle furnace running at 700°C for 36 hours. The titanium powder produced in this project matched the elemental specifications of commercially available titanium powder, except for high carbon content. Nevertheless, the powder has been tested further in mechanical alloying and has been found suitable for the production of powder metallurgical compacts. Keywords Powder metallurgy, titanium components, HDH process, ball milling.

Jan 1, 2011

By M. Pineda

Sublevel stoping (SLS) is one of the oldest and most used methods for underground mining. It relies heavily on the use of drilling and blasting techniques to remove the rock, and gravity to transport the broken rock to drawpoints located at the base of the stope, with LHDs to transport material from the drawpoints. Current SLS operations are based on the assumption of stable geometry of the stope. Thus, the stope design includes the definition of the geometry according to the orebody shape and geomechanical constraints to avoid instability, which may cause excessive dilution. Under some circumstances, dilution could enter the stope due to geotechnical instability, especially when large stope geometries are used. A review of current design and planning practices for large SLS operations indicates that no consideration is given to the material flow and the mixing that occurs after blasting. Material flow could have a large impacton the mixing of ore when grades are heterogeneous in the stope. In this paper, we discuss the influence of gravity flow on the design and planning of large sublevel stopes with and without vertical dilution, based on laboratory experiments. The outcomes of this investigation are used todevelop guidelines towards the design and planning of large SLS mines, which would complement the currently used geotechnical considerations.

Jan 1, 2015

By D. S. Richards

Computers have revolutionized the collection of data on modern mines. Never before has it been possible to collect data from all aspects of the mining value chain at rates now common. With this has come a new challenge. Deriving information from these copious amounts of data and disseminating it. This problem is being exacerbated by technical software systems, which use proprietary and binary data formats that severely inhibit the flow of data and information both across departments and the larger organization. Generally this had led to data duplication and data redundancy. The Gemcom Enterprise Mining System (GEMS) makes use of industry standard, secure and open databases for all its data objects. It manages multiple users accessing the same bits and bytes in the database, preventing data duplication and redundancy. Developed in the Microsoft BackOffice ® environment, GEMS is also able to leverage the enormous amount of tools available in this environment, whether it’s for e-mail notification, reporting or data capture. Microsoft’s® Active Server Pages are one of these tools. These are standards used to create dynamic and interactive web pages with links into databases and many other objects. The real example outlined in the text, demonstrates how a user anywhere in the world is able to login to a web page and run a query that returns a report with vector plots of performance for the user-selected time frame. As integration is tightened between the various components of the mining value chain, the importance and reliance on ASP pages will grow as the need for management information tools develops. Keywords: mines, computers, ASP, GEMS, integration, Microsoft, Management Information.

Jan 1, 2003

By K. Lombard

"‘Roof support awaiting time’ (RSAT) is a term used at Goedehoop Colliery’s Simunye Shaft to describe the potential production time lost due to the continuous miner (CM) standing idle waiting for roof support to catch up. Investigations revealed that in 2013, Simunye Shaft had approximately1400 hours of RSAT, which suggests that the mine could have potentially produced an additional 280 000 t of coal. This project consisted of two parts. Firstly, the causes of the high RSAT and means to improve the situation were investigated. Secondly, as insisted by mine management, the CM cutting sequence was investigated as a possible cause of high RSAT. Machine-related challenges due to the roofbolter installing support too slowly, geological conditions (mostly hard roof conditions and slips),logistical challenges pertaining to the CM cutting sequence, man-related challenges related to operator fatigue, re-support, operator inexperience, and the absence of support targets were identified as main contributors to RSAT. Furthermore, results showed that the roofbolters in the sections at Simunye Shaft are slower than the CMs. A target of 28% reduction in RSAT was set. Experts from Kennametal and Fletcher were consulted to find solutions for the identified causes. In total, eight solutions for RSAT were identified, but the solution that contributed most significantly to reducing RSAT was to use hard roof drill bits as a standard product at Simunye Shaft. Calculations showed that by using hard roof drill bits, RSAT can be reduced by 43%, which is more than the specified 28% target. The cutting sequences at Kriel, Greenside, and Simunye Shaft, togetherwith three newly developed cutting sequences, were simulated using the UCMS (Underground Coal Mining Simulation) program. A re-aligningprinciple was incorporated into the newly developed cutting sequences toalign the cutting sequences to general support work and to reduce RSAT. A decision matrix revealed that a cutting sequence in which boxing takesplace in R3 (third road to the right of the belt road) and in which the re-aligning principle has been incorporated will be the best option for Simunye Shaft. The recommended cutting sequence will lead to a 5% increase in production.The work presented in this paper was carried out as partial fullfilment for the degree BEng (Mining Engineering)"

Jan 1, 2015

By Gift Chisakuta, Bravo Mbao, Nils Schwarz, Angus Feather, Anthony Mukutuma

Bwana Mkubwa is a 50 000 tons per annum copper cathode producer, owned by First Quantum Minerals and located in Ndola, on the Zambian Copperbelt. The Bwana Mkubwa solvent-extraction circuit was started up in 1997. In 2002, the plant began treating ore from First Quantum?s Lonshi mine located in the Democratic Republic of Congo. The Lonshi ore is exceptionally fine and the amount of solids in the feed solution reporting to the solvent-extraction feed solution increased dramatically. Initially, crud was filtered in a filter press, but this rapidly blinded and seldom produced anything better than a wet sludge containing large quantities of organic. In December 2003 the decision was made to install a Flottweg Z4E-3/441 Tricanter® centrifuge to recover organic from the crud. The installation was completed in June 2004 and has since led to significant improvements in plant operability and savings in organic consumption.

Jan 1, 2007

By J. N. Van der Merwe

The current state of the South African mining industry is briefly reviewed from the point of view of an engineer not schooled in the finer details of predictive economics. Based on the assumption that current world exploration targets are indicative of which commodities the world will want in the future, it is concluded that the South African mining industry will continue to be viable and growing well into the future. South Africa holds the minerals the world wants and needs, and as long as the world has people, the demand for those, including gold, will continue to grow. There still is a growing demand for vanity commodities' and even the demand for platinum as a jewellery material displays significant growth. Mine safety still needs to improve, but significant improvement has already been made although the industry is not always acknowledged for the effort in this field. The safety target set for 2013 is within reach but will require sustained effort. The physical mining conditions for the main revenue earners, coal, platinum, and gold, will change substantially in the near future. Research in mining has declined alarmingly and it is urgently necessary for that to be revitalized to generate the knowledge that will be required. In order to streamline the transfer of knowledge to the mining engineers of the future, research needs to be conducted with the full involvement of the universities. It will also be necessary for the universities to continually review curricula to incorporate the latest knowledge and to embark on a campaign of knowledge transfer to the older generation of mining engineers. The mining industry is well supported by the universities, who have done their duty with regard to societal transformation, and the universities are in turn supported by the industry through vehicles like the METE Industry is also strongly supported by a number of professional and vocational societies. The SAIMM will continue to play its vital role as the meeting point of the mining technical sciences, and will continue to disseminate knowledge via the journal, schools, and conferences. In the future, it will review its modus operandi to support the needs of growing membership in the remote branches. It will enter the research arena in an appropriate manner and give effect to the developing integration of mining and society. The most important threat to the future of the mining industry is the recurrent mention of nationalization. While interaction between the mining industry and political and economic development of South Africa has always been characteristic, the current debate is emotional more than rational, and engineers are not well equipped to participate. This matter needs to be finalized before it becomes a popular force that politicians cannot control.

Jan 1, 2011

By R. Hummel

When the slope angles of the southern side of the Venetia open pit were required to be flattened by some 20 degrees after an analysis completed by De Beers geotechnical engineering in conjunction with SRK, the additional waste stripping tonnage generated was in the order of some 70 million tons. The potential cost of having to move this tonnage had a significantly negative effect on the Net Present Value of Venetia Mine, challenging the viability of the third pushback and rendering a potential fourth pushback completely uneconomic. This paper details some of the innovation that went into the design and planning process undertaken to virtually negate the instantaneous effect of the flattened slope angles and the associated waste tonnage as well as further improve the NPV of Venetia Mine and bring the fourth pushback back into economic viability. This process has become known as NPV+ and is anon going exercise in waste reduction/deferment and revenue advancement.

Jan 1, 2001

By J. Daavittila, P. Jokinen, M. Honkaniemi

In the latter part of the 1980?s Outokumpu Chrome in Tornio, Finland, was in a situation when its twenty-year-old ferrochrome plant was becoming inefficient to sustain economically sound production. The company made extensive studies on the then available processing methods to find out the best possible processing route. As a result the whole plant was practically rebuilt and expanded. When equipment was proven in practical operation an application for FeMn production was developed. Now when Tornio FeCr-plant is considering the expansion the same type of exercise is to be performed with today?s challenges, which will be discussed in the paper. These challenges include increasing costs or decreasing quality of raw materials, increasing energy costs, stricter environmental regulations and demand of better working conditions. The possibilities to respond to these challenges will be discussed in the paper. The future and continuing development with FeCr includes the better utilization of process dusts and a lower consumption of energy. By adapting the latest automation tools to better control of the process even higher efficiencies can be achieved with present technology. New processes are considered for development in the future and some possible technologies will be described.

Jan 1, 2004

By F. Lanaro, K. Röshoff, R. Christiansson, L. Jing

This paper presents the results of a project for developing a methodology for empirically determining some of the mechanical properties of the rock mass at the Äspö Hard Rock Laboratory, Southern Sweden. Using the equations available in the literature, the deformation modulus, friction angle, cohesion and unconfined compressive strength of the rock mass were estimated. A comparison of the results using different classification methods (Q, RMR, GSI, RMi, Ramamurthy’s) was made to estimate the range of variations in the mechanical properties with the considerations of: i) the quality/quantity of the geological data; ii) the technique for partitioning of the rock mass into homogeneous domains; iii) the sensitivity and subjectivity of the empirical methods; and iv) the need for validating the empirical methods against a test case. Cet article présente les résultats d’un projet visant à établir une méthodologie, pour déterminer, de façon empirique, les propriétés mécaniques de la masse rocheuse. En utilisant les corrélations disponibles dans la littérature, quelques-unes des propriétés de la masse rocheuse ont pu être déterminées (module de déformation, angle de friction, cohésion, force de compression illimitée). Une comparaison des résultats obtenus par différentes méthodes (Q, RMR, GSI, RMi, de Ramamurthy) a permis d’établir une échelle de variations des propriétés mécaniques et de formuler une série de recommandations concernant : i) la qualité/quantité des données géologiques ; ii) la technique de partition de la masse rocheuse dans des domaines homogènes ; iii) la sensibilité et la subjectivité des méthodes empiriques ; iv) la nécessité de valider les méthodes empiriques à l’aide de nouvelles études de cas. Dieses Paper präsentiert die Ergebnisse eines Projekts mit dem Ziel, eine Methodik für die empirische Festhellung von mechanischen Eigenschaften im Gesteinmassiv zu etablieren. Durch Verwendung der in der Literatur zugänglichen Korrelationen, wurden einige Eigenschaften des Gesteinmassivs festgestellt (Entstellungsmodul, Reibungswinkel, Kohäsion, unbeschränkte Kompressionsstärke). Ein Vergleich der Ergebnisse unterschiedlicher Methoden (Q, RMR, GSI, RMi, Ramamurthy’s) wurde durchgeführt und dies erlaubte die Feststellung der Variationsskala von den mechanischen Eigenschaften, sowie eine Reihe Empfehlungen für: i) Qualität/Quantität der geologischen Dateien; ii) die Technik für Teilung des Gesteinmassivs in homogene Domäne; iii)die Empfindlichkeit und Subjektivität der empirischen Methoden; iv) das Bedarf die empirische Methoden gegen neue Fallgeschichten zu validieren.

Jan 1, 2003

By Valérie Léveillé

As new legislation drives to lower SO2 emissions from metallurgical plants, plant managers face the challenge of keeping their costs under control. The Cansolv® SO2 Scrubbing System has been broadly adopted in the non-ferrous industry as a cost effective solution for smelter operators to meet the new SO2 emissions targets. The Cansolv® SO2 Scrubbing System is an amine-based regenerable process that selectively absorbs SO2 from a variety of gases, including dilute smelter gases, such as furnace and converter gases. The system produces a pure, water-saturated SO2 byproduct stream, which can then be directed to the front end of a sulfuric acid plant for conversion to sulfuric acid. When deployed in a smelter complex, the Cansolv® SO2 Scrubbing System may also be used to process acid plant tail gas, allowing single absorption sulfuric acid plants to achieve emissions an order of magnitude lower than that of a double absorption acid plant with a lower capital investment. Depending on inlet gas temperature SO2 emissions in the treated gas can be controlled to as low as 55 mg/Nm3. This paper will describe some of the applications where customers have or are planning to use the Cansolv® SO2 Scrubbing System and what as well as which features and cost advantages for the treatment of smelter gases were key to the technology choice.

Jan 1, 2009

By E. Ringdalen

Keywords: Pyrometallurgy, research, Norway, SINTEF, NTNU The Norwegian Ferro-alloy Industry and the model for research cooperation between SINTEF, NTNU, and the Norwegian ferro-alloy industry is presented as an introduction. The research within pyrometallurgy is illustrated by examples from characterisation of Mn-ores and characterisation of carbon materials. Examples from studies of reaction mechanisms in laboratory- and pilot-scale experiments are presented, in addition to an example of industrial off-gas measurements. Education possibilities at NTNU are also described.

Jan 1, 2011

By C. Lemmer

The resolution with which the different categories of resources are forecast for Witwatersrand gold reefs should ideally tie in with block sizes that are optimal in terms of the variability structures of the reefs. A tool, called the ?variancegram?, is proposed as a basis for block size choice. A variancegram is intrinsic to the particular reef and mine concerned. A further requirement is the ability to attach global confidence limits to weighted average estimates built up from combinations of local kriged estimates. Approximations to derive global kriging variances based on variables derived from local kriging deliver hugely inflated results if ordinary kriging is used, and markedly better, but not accurate, values if simple kriging is used. These approximations improve as the number of samples used in kriging each block is increased. It is shown that the behaviour of the different components of the global kriging variance with increasing number of samples, all differs, but they all link to the variancegram for the particular reef. The variancegram can thus be used to correct the different components to the values they would have had if all samples were used in kriging each block, and so deliver the ?correct? global kriging variance, even though only a limited number of samples were used in kriging each block. The desirability of having very stable solutions implemented in production systems is taken into account in the proposals. It is anticipated that the same variancegram findings will also hold for other densely sampled deposits, but this remains to be investigated.

Jan 1, 2014

By M. Rafie, M. Rinne, F. Samimi Namin

"SynopsisRock mass classification systems constitute an integral part of empirical underground excavation design. One system that is commonly used to classify rock mass is the Rock Mass Rating, or RMR, system. The RMR system has evolved over time to better reflect the perceived influence of various rock mass factors on excavation stability. While the introduced modifications have enhanced the applicability of this classification system, there are still areas that cause potential ambiguity. The RMR system cannot deal with input data ambiguities, uncertainties, and vagueness. To deal with the uncertainty, a Fuzzy Rock Mass Rating (FRMR) has been developed. This study aims to describe the main concept of the fuzzy approach, which is implemented in the FRMR to classify rock mass. The FRMR considers the uncertainty associated with the input data (uncertain variables) used in rock mass classification. The Gol-e-Gohar (GEG) area 3 iron ore deposits in the south of Iran were chosen as the case study for investigating the applicability of FRMR. The results of this study show that the FRMR software tool can easily be used for rock mass classification, even if uncertain input parameters have been used. FRMR consists of three parts, each of which is suitable for certain conditions.IntroductionNowadays, rock engineering classification systems, which constitute the backbone of the empirical design approach, are widely employed in both civil engineering and mining engineering. Rock mass classifications have recently been quite popular and are being used mostly for the preliminary design and planning purposes of projects. According to Bieniawski (1989), a rock mass classification scheme is intended to classify the rock masses, provide a basis for estimating deformation and strength properties, supply quantitative data for support estimation, and present a platform for communication between the exploration, design, and construction groups."

Jan 1, 2015

By N. L. Ayres

Tendon support systems have been successfully used to stabilize excavations. Tendon support systems are routinely designed using the axial load-bearing capacity of tendons, namely the tensile strength. To attain tensile strength the tendon must be loaded along its length, which often does not occur in practice. Tendons should optimally be installed at 90° to the surface of the excavation to achieve maximum penetration depth, yet this is often not physically or practically possible, and installations at angles less than 90° occur. Furthermore, the intersection of geological features within the rock mass frequently results in complex loading situations on tendons. The position and angle at which loading occurs results in different combinations of tensile and shear forces acting on the tendon, which can impact on the support performance of each unit and ultimately the whole system. All factors that influence the support system should be understood and taken into account to ensure a sound support design. Combination loading situations are further investigated and tested to obtain a better understanding of the mechanisms involved and the effects on tendon load-bearing capacity. Tendon support units were tested at different installation angles to establish the tendon performance, mechanical behaviour, and load capacity during these loading situations. The results and outcomes are aimed at providing rock engineers with additional data and improved understanding of how tendons could perform under certain conditions.

Jan 1, 2014

By M. Soleymani Shishvan

"Continuous mining systems containing multiple excavators producing multiple products of raw materials are highly complex, exhibiting strong interdependency between constituents. Furthermore, random variables govern the system, which causes uncertainty in the supply of raw materials: uncertainty in knowledge about the reserve, the quantity demanded by the customers, and the breakdown of equipment. This paper presents a stochastic-based mine process simulator capturing different sources of uncertainties. It aims to quantify the effect of geological uncertainty and its impacts on the ability to deliver contractually defined quantities and qualities of coal, and on the system efficiency in terms of utilization of major equipment. Two different areas of research are combined: geostatistical simulation for capturing geological uncertainty, and stochastic process simulation to predict the performance and reliability of a large continuous mining system.The process of modelling and simulation in this specific production environment is discussed in detail. Problem specification and a new integrated simulation approach are presented. A case study in a large coal mine is used to demonstrate the impacts and evaluate the results in terms of reaching optimal production control decisions to increase average equipment utilization and control coal quality and quantity. The new approach is expected to lead to more robust decisions, improved efficiencies, and better coal quality management.IntroductionContinuous coal mining systems containing multiple excavators producing multiple products of raw materials are highly complex and exhibit strong interdependencies between constituents. A network of conveyor belts is used for transportation of the extracted materials to different waste dumps or the coal stockpile.Optimal decision-making in short-term planning and production control are impacted mainly by geological uncertainty associated with incomplete knowledge of the coal deposit represented in the reserve block model. These uncertainties cause deviations from expected process performance. For more robust decision-making, understanding the impacts of these stochastic elements plays a key role."

Jan 1, 2016

By H. Dong

This paper presents a heat conduction model to determine the erosion profile of freeze linings in a ferronickel submerged arc furnace. Kirchhoff transformation was adopted to simplify the nonlinear equation governing heat conduction. The boundary element method (BEM) and Nelder-Mead simplex optimization method were employed to solve an inverse heat conduction problem. Erosion profiles could be obtained when calculated temperatures at sensor locations agreed well with measured temperatures. The model was validated by comparing the heat loss through the linings, which was calculated by BEM and integral operation after erosion profiles were obtained, with the value calculated from industrial data such as actual power consumption, tap-to-tap time, and ferronickel output. The optimal solution for the erosion profile could be acquired when the difference in heat losses calculated by these two methods is at a minimum.

Jan 1, 2014

By P. He

Abstract This paper introduces the test results of dark-gray calcium-shale, discusses the infection of strength characteristic and deformation characteristic due to the angle between structural planes. Keywords calcium-shale, failure form, strength, deformation characteristic, structural planes. Zusammenfassung: basier auf der Anwendung von Problematik des Felsenbauprojektes und Beschaffenheit Felsen unter Beaugnshme auf den Zustand des Druckes von einzeler Welle legt dieser Text dar, wie der Winkel der Schichtstrukturflaeche des schwarzgrau kalziumhaltigen Schieferblocks auf die Zerstoerungs-, Intensitaets- und Deformationseigenschaften einwirkt. Schluesselwoerter: schwarzgrau kalziumhaltigen Schiefer, Zerstoerungseigenschften, Intensitaetseigenschften, Deformationseigenschaften, Flaeche dar Schichtstruktur. Résumé – En fonction de la configuration du massif rocheux sous l’état de la contrainte de pression axiale simple et de la pratique de l’ingénierie de roches, le présent article fait la déscription concernant l’influence de l’inclinaison ? de la couche de structure stratifiée du bloc de schiste calcaire gris noir sur ses caractéristiques de destruction, sa spécificité de résistance ainsi que sa nature de déformation. Mot clés – Schiste calcaire gris noir, Caractéristiques de destruction, Spécificité de résistance, Nature de déformation, Couche de structure stratifiée

Jan 1, 2003

A Seismic Hazard Scale (SHS) has been developed to provide a practical seismic hazard assessment tool applicable to mine site personnel. It has been applied to seismic data sets from numerous Western Australian mines. The SHS is applicable when quantifying seismic hazard on a mine wide scale, on a mining block scale, and on a local cluster-by-cluster scale. Spatial mapping of variations in seismic hazard is a particularly powerful application of the scale. The SHS is sensitive to temporal increases in seismic hazard. It has also been shown that the SHS can be applied to estimate seismic hazard when seismic monitoring data are not available. The SHS is a simple derivation of the Gutenberg-Richter relation. There are assumptions and limitations to the SHS that need to be considered when applying it to mine seismicity data.

Jan 1, 2004

The gold concentration profiles which develop inside the activated carbon particles during the adsorption process were measured, so as to obtain additional direct proof of intra-particle mass transfer rate-control and to determine how individual carbon particles in a population vary in their gold uptake behaviour. The observed gold concentration profiles inside the activated carbon particles were typical of situations where an intra-particle mass transfer mechanism is rate-controlling. Gold di-cyanide penetrated the carbon particles with a wave-like front until it was uniformly distributed throughout the particle. This corresponds with the profiles predicted by the film and surface diffusion model. However, the rate with which gold di-cyanide was transported inside the individual carbon particles varied within the population of carbon particles. This variation was characterized by a lognormal distribution in surface diffusivity. Because the estimated variances of these surface diffusivity distributions were small, the dynamic adsorption behaviour of the carbons used in the present study did not deviate significantly from that predicted by a model based on film mass transfer and a single surface diffusivity. Van Deventer (1984, 1985 and 1986a) reported data that could not be adequately described by a model based on film mass transfer and a single surface diffusivity. In this study a model based on film mass transfer and a wide lognormal distribution of surface diffusivity values was applied to his data. It was shown that a population of carbon particles with a wide distribution in surface diffusivity values could offer an alternative explanation to the mechanism proposed by Van Deventer which was based on film mass transfer, with partitioning of the carbon into micro- and macropores with surface diffusion in the macropores and slow mass transfer into the micropores.

Jan 1, 1997

By G. C. Smith

Process control applications in the minerals processing industry have grown extensively over the years due to the many benefits derived, both financially and operation-wise. Although control theory is widely known, conventional control does not address many of the problems posed by minerals processing circuits. Some of these problems include interactions between process units, large dead times, few and sometimes unreliable measurements of process variables, non-linear systems, disturbances entering the process, processes with varying dynamics, and many more. For the past 26 years Mintek has been active in the field of providing specific, customized solutions for the minerals processing industry. This paper focuses specifically on applications in milling and flotation control. The underlying control principles have been applied to a wide range of other processes including submerged arc furnaces. Advanced control application is implemented on a common advanced control platform, called the PlantStar. Much innovation has been brought to the fore in terms of adapting theoretical techniques and developing new methods to resolve specific milling and flotation circuit issues by using process control. The general approach adopted by Mintek when implementing advanced control is to enforce stabilization of the process as a solid foundation for optimization strategies to be built upon. In doing this, a robust control solution is presented, and the end result is flow and level stability, better product quality regulation, increase in throughput and a stable feed to downstream processes. The MillStar advanced milling control system ensures that the milling circuit is at all times easy to operate while achieving optimum product quality and throughput. Stabilization should include product size regulation and sump level control. Another important aspect of stabilization control is the handling of milling circuit constraints without introducing cyclical behaviour and with minimal disturbance to the final product quality. Process constraints may include factors such as process water limitations, cyclone feed density, and cyclone underflow angle. An optimization strategy should be developed to increase the mill throughput without affecting product quality or introducing mill overloads. The relationship between solids feed and power draw is examined and manipulated for optimization. The interactive nature of flotation circuits and the presence of recirculating streams tend to make satisfactory control almost impossible with conventional techniques such as PI (Proportional plus Integral) or PID (Proportional, Integral and Derivative) control. The FloatStar Level Stabilizer simultaneously considers all the flotation levels in a circuit by use of a multivariable algorithm, and takes compensating action in anticipation of disturbances. The FloatStar Flow Optimizer is an optimization strategy that controls the concentrate flow rate between various sections of a flotation circuit (e.g. Rougher ?Cleaner; Cleaner ?Recleaner). By controlling the concentrate flow between the sections, the mass pull, circulating loads and residence times of the circuit can be stabilized, thereby enhancing the performance of the flotation process. Optimizing grade and recovery are coupled with the dynamic optimization of circulating flows. The FloatStar Grade-Recovery Optimizer will maximize the grade in a section, whilst ensuring that recovery or any other process specific limits remain within predefined limits. With successful applications on several milling and flotation plants worldwide processing amongst others PGMs, gold, copper and nickel, Mintek has shown that it is a leader in milling and flotation control innovation

Jan 1, 2004