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By K. B. Le Bron, T. van Aard

The empirical pillar strength formulae have been widely, and in most cases successfully, applied to design underground pillars for mines in the Bushveld Igneous Complex (BIC). This paper presents the case for combining the empirical method with numerical modelling when it comes to crush pillar stability analyses. The benefits include an understanding of potential failure mechanisms, which may then be accounted for in the designs. In addition, the impact of weak layers, such as shear zones, the impact of the dip of the orebody, differences in layouts, such as holing widths and the presence of advanced strike gulleys (ASGs) immediately adjacent to the crush pillars, and stress regime (k-ratio) may be studied using numerical modelling, as it is not accounted for in the empirical method.

Mar 5, 2025

By Nicolle Krusberski

Potential errors in XRF analysis are discussed and investigated with specific reference to the analysis of ilmenite samples. A selection of ilmenite samples was chosen and prepared using two XRF preparation techniques: pressed powder pellet and unroasted fusion bead. The merits of the two methods have been discussed in this paper for ilmenite analysis by XRF. Recommendations have been made regarding the use of pressed powder pellets especially with regard to the mineralogical effects that were evidenced during this investigation. The fusion bead technique was found to be far more accurate and able to meet short turnaround requirements provided the calibration methodology used is specific to the grade of samples analyzed.

Jan 1, 2014

By L. Morin, S. Mortazavi, K. Volchek, A. Demers, A. Di Feo

The objective of this paper was to investigate the possibility of reducing process (fresh) water and increasing recycled water (thickener tank overflow water). As part of the investigation, rougher flotation tests were done with the two water types and a mixture of the two (50%/50%). The effect of recycled water on the grade-recovery response and rougher recoveries was investigated. When thickener tank overflow was used (50% and 100%), the nickel+copper grade versus nickel recovery decreased. The decrease in the grade-recovery was due to higher pyrrhotite recovery. Also, there were no effects on nickel and copper recoveries, which was confirmed using multivariate statistical analysis at the 95% significance level. Keywords: Flotation, nickel, copper, water recycling, multivariate statistical analysis, MANOVA, reverse osmosis

Jan 1, 2020

By T. Szendrei, S. Tose

The generally accepted view in rock blasting is that the sources of energy for the fracture and movement of rock reside in the shock wave and gas action resulting from the explosion, and yet the mechanisms by which these sources interact with the rock have remained unclarified. It has also been noted that up to 50% of the work capacity of an explosive released in a blast cannot be accounted for by field measurements of energy partitioning. In this study, we describe a physical model that details the response of rock to both shock wave and gas action. An analytical model based on momentum conservation is derived to describe the dynamics of shock-driven expansion of the blasthole. Radial expansion of the hole is the key parameter that permits the derivation of the following characteristics of rock response to shock loads: hole expansion time; volume of displaced rock; energy consumed per unit volume; expansion energy efficiency; stress wave pulse length; gas pressure in enlarged hole. Soon after the completion of hole expansion, the shock wave degenerates to an elastic stress wave that runs through the burden. Blasthole expansions of between 50% and 300% of diameter are completed in under 1 ms and, depending on rock properties, consume 32% to 42% of the detonation energy or about 55% of the available mechanical (Gurney) energy. Gas pressure in the enlarged holes in five rock types is between 35 MPa and 650 MPa, and drives the mass movement of burden rock.

Oct 9, 2024

By J. -M. Milazzo, T. Wallmach, S. B. Blancher, A. Amalric

In a FeNi electric arc furnace, the physical properties of the slag (chemistry, viscosity, liquid/solid/gas ratio) are of crucial importance in controlling the efficiency of the process. In this paper, we studied the slag crystallised on the walls of a semi-industrial furnace (freeze-lining), the slag rising through the burden during foaming phenomena, and the casted slag. The freeze-lining is the layer of oxides that crystallises on the refractory wall of a furnace, protecting it from chemical and mechanical aggression. It records changes in furnace conditions (slag chemistry, temperature, oxygen fugacity), which makes it possible to observe the impact of these elements. In the high reduction test, the freezing lining is composed of magnesian olivine. Switching to a low reduction process increases the Fe content of the olivine and causes orthopyroxene to appear, making the freeze-lining mechanically and thermally weak. Thermal incidents in the furnace cause significant slag foaming. This foaming is produced by a massive crystallisation of the olivine (due to the drop in temperature), and inducing an exponential increase in viscosity, preventing the free circulation of gases. These foaming episodes are also recorded in the freeze lining and form layers rich in gas bubbles, and therefore mechanically fragile. The slag casted and cooled in a ladle allows the first steps of slag crystallisation to be studied. Olivine is the liquidus phase, with a magnesium-rich core and an iron-enriched rim, contemporaneous with the orthopyroxene phase. The habitus of these phases is very similar to that found in komatiites for the same minerals. FeNi slag is therefore an industrial analogue that is easy to study and compare to komatiites. Keywords: Pyrometallurgy, ferronickel, slag, freeze-lining, characterisation, olivine, mineralogy

Jan 1, 2020

By M. S. Shishvan, S. Klerkx, J. Sattarvand

The inaccurately drilled blastholes from the planned locations cause changes in the spatial distribution of explosive energy; some areas of the blast may receive a surplus of explosive energy, while others see a reduction. This results in less uniform fragmentation, reduces the efficiency of mining operations and increases costs. Additionally, it can lead to slope stability issues, flyrock, and uneven benches. To mitigate these problems, this study attempts to reduce differences in the explosive energy distribution (EED) through an optimization approach that adjusts the height of explosive columns in blastholes. Two optimization algorithms, the Genetic Algorithm (GA) and Tabu Search (TS), are tested. The latter is preferred for its local search neighbourhood strategy that gives superior computation times. Applications on different blast patterns result in improvements of 0.53–1.54%, or 2.14–3.94% when only the affected blocks are considered.

Sep 1, 2021

By L. M. Tavares, H. A. Petit, P. P. Cavalcanti

Iron ore pellets experience degradation during handling due low energy impacts and stresses. These impacts lead to volume or surface breakage of the pellets, creating fine particles that accumulate along the process. Some of the particles are in contact with the air and are dragged as dust into the workplace or into the atmosphere. The aerodynamic size of the particles allows them to be potentially inhaled by the workers or to be carried to nearby communities. Dust emission becomes critical at specific locations, such as transfer chutes and stockpiles. This work models the dust generation that occurs in an iron ore pellet stockyard using a methodology that combines experiments to quantify the degradation of the pellets to mathematical modelling of the dust emission mechanisms in the stockyard. First, laboratory tests were used to characterise the amount of mass and the particle size distribution of the dust generated by degradation under controlled conditions. Second, the flow over a stockpile of an iron ore pellet company was simulated with the aid of computational fluid dynamics (CFD) simulations. Third, semiempirical equations linked the data generated by simulations and laboratory tests to estimate the dust emission in the stockyard. Finally, results were validated with measured field data, obtained with a novel online measurement tool. Results suggest that the approach is able to predict dust emission with sufficient accuracy and can be used for further implementation in the management of operations and decision making in order to reduce the environmental impact of the process. Keywords: Iron ore pellets, abrasion, dust emission, mathematical modelling

Jan 1, 2020

By DeVerle P. Harris, David E. Euresty

"Potential metal supply refers to metals to be produced from as yet unknown deposits. Naturally, to measure potential supply requires, among other things, inference to the number of deposits, their tonnage, and their grade Thus, probability distributions were constructed for each 400-square mile cell in Northern Sonora, Mexico. A computer system was developed that simulated the occurrence of deposits for each cell, exploration for the deposits, and their exploitation. Evaluation was performed for each deposit by discounted cash flow analysis.An objective of this study was to explore the effect of the transportation network and required road or railroad construction upon potential supply. Consequently, the evaluation system was designed to consider the spatial location of a simulated deposit to the existing transportation network and the market destination. The construction of linkages to connect the deposit to existing transportation arteries as well as the carrying of the concentrates to the intended market were simulated. in terms of cost. The selection of the path took into account the existing terrain. This was done by digitizing topographical maps and representing the topography of the area by an orthogonal grid of elevations. The optimum route was selected by dynamic programming, meeting a prescribed gradient constraint. The potential supply of each cell was determined, allowing for the infrastructure effect."

Jan 1, 2014

By H. Manurung, I. M. Bendiayasa, W. Astuti, and H. T. B. M. Petrus, F Anggara, K. C. Wanta

The leaching kinetics of cerium (Ce) and yttrium (Y) in sodium-hydroxide-digested non-magnetic coal fly ash using acetic acid were investigated. The variables analysed were pH, solid-to-liquid ratio (S/L), and temperature. The results show that cerium and yttrium's maximum recovery was 57.33% and 58.36%, respectively, under leaching temperature of 90°C for Ce and 60°C for Y at pH of 1,74 and 10 g/mL solid-liquid ratio in 240 minutes. Increasing the leaching time to more than 120 minutes did not significantly improve the results. After the magnetic separation process, the ICP-OES analysis shows a slight increase in the concentration of cerium and yttrium on nonmagnetic components. The XRD and ICP-OES analysis for the sample before and after silicate digestion shows that 40% silicate was dissolved. The calculation of apparent activation energies of leaching using the Arrhenius law for the leaching of cerium and yttrium gives 22.72 kJ/mol and 35.84 kJ/mol, respectively. The kinetic leaching model of cerium and yttrium all fit Dickinson's new shrinking core model. The calculation results show that the leaching reaction is controlled by combining interface transfer and diffusion across the product layer.

Nov 6, 2024

By J. Hadjigeorgiou, G. Knox

There is a considerable wealth of information on the behaviour of rockbolts under axial loading conditions both in situ and under controlled laboratory conditions. However, there is comparably less data on the behaviour of rockbolts in shear. Several authors have contributed to the understanding of the behaviour of conventional rockbolts’ performance under shear loading. Much of this data have been gathered through experimental programmes conducted on sections of the rockbolt. Considering the continuous coupling between the rockbolt and borehole interface, the approach is justified. Due to the design premise of energy-absorbing rockbolts with discrete couplings, full scale testing is required to quantify the behaviour of the rockbolts. This paper reviews published results obtained from two testing facilities, which are the SINTEF rockbolt pull test rig in Trondheim, Norway and the Epiroc Combinations Shear and Tensile test rig in Johannesburg, South Africa, both capable of conducting full scale testing of rockbolts. Based on this high-quality database it was possible to identify three distinct responses of rockbolts in shear. The behaviour under load is controlled by the presence or absence of an encapsulation medium (resin/cement grout), the reinforcement mechanism, and whether the rockbolt is continuously or discretely captured. As a reference the results are compared to the performance in shear of conventional grouted rockbolts.

Nov 24, 2025

By B. P. Watson, D. P. Roberts, R. A. Lamos

The Upper Group 2 (UG2) chromitite reef is a shallow-dipping stratiform tabular orebody in the South African Bushveld Complex, which strikes for hundreds of kilometres. Mining is extensive, with depths ranging from close-to-surface to 2 500 m. Pillars are widely used to support the open stopes and bords. Little work has been done in the past to determine the strength of pillars on the UG2 Reef and design was done using formulae developed for other hard-rock mines. This has led to oversized pillars with consequent sterilization of ore. In this paper we describe a back-analysis of stable and failed UG2 pillars on the Bushveld platinum mines, and provides a strength formula for UG2 pillars. The formula may be used cautiously on all Bushveld platinum mines with similar geotechnical, geometrical, and geomechanical conditions to the pillars in the database.

Aug 1, 2021

COUNCIL The following served on Council during the year under review: Office bearers: Messrs V. C. Robinson (President), Prof D. D. Howat and Dr J. P. Hugo (Vice-Presidents), J. K. E. Douglas (Immediate Past President) and D. G. Maxwell (Honorary Treasurer). Ordinary Members of Council: Dr M. G. Atmore, Dr J. M. Bereza, H. P. Carlisle, W. W. Malan, C. E. Mavrocordatos, Prof R. P. Plewman, Dr R. E. Robinson, Dr M. D. G. Salamon, P. W. J. van Rensburg, L. W. P. van den Bosch, P. A. von Wielligh. Branch Chairmen: J. Meintjes, J. M. Meyer (Acting), J. N. Saunders (Retired). Past Presidents serving on Council: R. J. Adamson, M. Barcza, H. Britten, R. C. J. Goode, P. Lambooy, Prof J. de V. Lambrechts, Dr J. T. Mclntyre, J. F. Reid, H. Simon. Ten Council meetings were held during the year with an average attendance of eighteen and the standing committees held forty-six meetings. FINANCE The annual accounts, which are attached to this report, show an excess of income over expenditure of R5 051 compared with an excess of expenditure over income last year of R4 608. This major reversal of fortunes is due in the first instance, of course, to the increased subscriptions. There were, however, other important contributors, particularly sales of the Proceedings of the Symposium on Open Pit Mining and profits on the operation of symposia and colloquia. It would appear from a study of the accounts that there has been a substantial drop in expenditure on secretarial fees. In actual fact, however, our total expenditure on secretarial fees was higher. A portion of this expenditure was charged against the administration of the Symposium on Open Pit Mining and, in addition, the charge against the Journal accounts for secretarial fees was increased. It will be recalled that in last year's annual report it was mentioned that subsequent to the new arrangement for publication of the Journal, the expected improvement in the finances of the Journal had been slow in materialising. After a total period of 18 months there was still no sign of improvement and it was accordingly decided to end the arrangement. As a result, the drain on the finances of the Institute was considerably lessened in the second half of the year. During the course of the year Council became concerned about the rapid depletion of our accumulated funds and gave careful and detailed attention to all aspects of the Institute's financial affairs. Particular attention was given to: 1. The fact that the Institute does not have a solid financial backing and must appeal for funds every time any special event such as a symposium is held. 2. The responsibilities of the Institute to the profession and the community, with particular reference to the desirability of establishing Institute bursaries and participating in other educational activities. 3. The rapidly rising cost of living. 4. The immediate financial position of the Institute. 5. The rapidly increasing cost of publishing the Journal due to the increasing number of papers available. In the meantime the immediate financial position of the Institute has improved but as this is due largely to non-recurring or irregular items of revenue, it should not be given undue weight. After careful consideration it was decided that an appeal should be made to industry for financial assistance, which would be used to cover the cost of symposia and other unusual expenditure and also, if possible, to build up the capital resources of the Institute so that there is a solid foundation for the future. Before appealing to industry, Council wished to be quite certain that there could be no criticism of the Institute for not having done our best in a personal capacity. Furthermore, Council examined many comparative statistics, including those circulated to members, which showed that, while expenditure per member has risen at an average annual rate of 7,5% over the last fifteen years, subscription revenue per member has risen at only 3,4% per annum. It was with this background that your Council decided to raise the subscriptions. Initial approaches have been made to the big mining groups and there has been a very generous response, although the details of how financial assistance will be provided have not yet been worked out. It seems likely that some form of affiliated company membership will be the most suitable method of achieving this. When these details have been fixed, it is the intention to extend the appeal to all corners of the mining industry as well as manufacturing and metallurgical industries. It is believed that these measures will ensure that the finances of the Institute are placed on a firm foundation on which the expanding activities can be planned. The MacArthur Forrest Memorial Fund shows an excess of income over expenditure of R73 and the total fund was, therefore, increased by this amount to R4 411. The balance sheet shows that the market value of quoted shares and debentures increased during the year fron R6 540 to R9 160. The market value is now almost exactly the same as the book value. Accumulated funds now amount to R23 010 compared with R17 959 a year ago.

By K. Barani, F. Moradpouri, M. Godarzi

A sampling campaign carried out on the lead flotation circuit at Lakan lead-zinc processing plant demonstrated that the Pb recovery was only about 68-69%. Characterization of the Pb flotation tailing showed that 61.4% of the Pb is in the –37 μm size fraction, which is difficult to recover by flotation. Batch flotation experiments were carried out on a plant sample of the lead flotation feed and high-intensity conditioning (HIC) was used to improve flotation recovery. The results showed that increasing the collector conditioning time from 1 to 3 minutes significantly increases the Pb recovery from 42.5% to 57.3%. Further increases in conditioning time to 5 to 7 minutes decreased the Pb recovery. With a collector conditioning time of more than 3 minutes, due to the surface cleaning effect, increasing collector and frother dosage improved the flotation selectivity and recovery, even at higher collector dosages. The Pb recovery increased from 69.1% to 79.8% with increasing impeller speed from 600 to 1250 r/min. HIC increases the flotation kinetics and greatly improves the flotation recovery and concentrate grade.

Apr 2, 2022

By D. Rankin, H. J. Stucke, W. K. B. Loftus

SYNOPSIS Planning for the Finsch opencast mine is described with particular reference to the proposed stages of mining, the method used to determine the limits of surface waste rock stripping and the derivation of the waste rock mining rate. Actual mining practice is described and the possibility of installing a skipway into the open mine at a later date is discussed. In addition, the waste dumping policy is referred to: this includes the cutting of slots through the hill on the west side of the pipe to increase tramming speeds. The crushing, washing and recovery sections of the treatment plant are described together with the various changes being made to the circuit. The most important of these are the installation of X-ray sorters for the final recovery of + 7 mesh diamonds, and the vibrating grease belt for the recovery of - 7 mesh diamonds. INTRODUCTION The Finsch Mine, a subsidiary of De Beers Consolidated Mines, Limited, is situated approximately 90 miles west of Kimberley, and some two miles from the village of Lime Acres, in the Northern Cape. Lime Acres is a company village shared with the Northern Lime Company which operates a limestone quarry and works near the township. The mine is near the southern end of a well mineralized belt producing limestone, asbestos, diamonds, manganese and iron ore, and the whole area has developed rapidly in the last 20 years. Power for mining operations is drawn from the Electricity Supply Commission. The mine is conveniently close to the main Kimberley-Postmasburg railway line. Water is drawn from the Vaal River through a 57 mile State-owned pipeline at present temporarily operated by mine staff. DISCOVERY AND PROSPECTING OPERATIONS The diamondiferous orebody is situated on the farm Brits, which is State-owned ground that has been leased to the Company for the period of mining operations. There are indications of interest in the area by prospectors (Richter, de Bruin and others) over a period of some 30 years and the discovery would possibly have been made years earlier but for a law preventing prospecting for precious stones on State-owned land. Although the pipe formed a clear depression on the hill where it was situated, it was overlain by some 5 to 40 ft of banded ironstone rubble which was washed into the depression from the hillside above the pipe and obscured the deposit. In 1958, Mr Allister Thornton Fincham applied for, and was granted, the right to prospect for base minerals on the farm Brits. Asbestos is known to occur in the area and, initially, was Mr Fincham's primary interest. However, during the prospecting operations, garnets were discovered and it was realised that diamonds might be present. In 1960, when the Precious Stones Amendment Act was passed, a company

By U. Atici, R. Comakli

"Understanding rock properties is of vital importance in mining and civil engineering. Rock properties are generally determined through laboratory tests, which require a large number of uniformly shaped samples and technicians who use indirect methods to determine rock properties. The texture coefficient (TC), which represents various textural parameters including the size, shape, orientation, and relative proportions of grains and the matrix, is an efficient means for indirectly evaluating the mechanical behaviour of rocks. In this study, 12 different rocks (ten granites, one diorite, and one gabbro) were collected and their engineering properties. including specific gravity, porosity, P- and S-wave velocities, Schmidt rebound hardness, uniaxial compressive strength, and elasticity modulus, were investigated. Relationships between TC and these measured properties were assessed. Statistically significant (at the 95% confidence level) correlations were found between the TC and compressive strength, elasticity modulus, sound velocity (both compression and shear waves for dry and saturated samples), but no significant correlation was found with Schmidt rebound hardness. The results suggest that it is possible to use the relationships between TC and the mechanical properties of rocks in rock classification. IntroductionIn every aspect of rock engineering, knowing rock properties is essential for determining and predicting the behaviour of rocks and rock masses. Mechanical properties of rocks are important parameters in mining, geology, and engineering, and they are affected by textural characteristics such as grain size, grain shape, cement type, degree of cementation, mineral content, and the ratio of the grain area to the matrix area. The effects of textural properties on the physical and mechanical properties of rocks have been investigated for a long time, and previous studies revealed close relationships between single parameters related to rock texture and mechanical properties of rocks (Akesson et al. 2001; Gunsallus and Kulhawy 1984; Merriam, Rieke, and Kim, 1970: Onodera and Kumara 1980; Prikryl 2006; Ulusay, Tureli, and Bider, 1994; Tugrul and Zarif 1998). Rock properties are usually determined using mechanical tests, which require uniformly shaped and relatively large samples. However, it is not always possible to obtain such samples. Furthermore, rocks with similar textural and structural properties may exhibit different mechanical behaviour. Howarth and Rowlands (1987) developed a texture coefficient (TC) that expresses all the main textural parameters of a rock in a single dimensionless quantity based primarily on statistical assessment. The TC makes it possible to understand the effects of a rock’s textural properties on its mechanical properties using thin sections instead of large, uniform samples. Ersoy and Waller (1995) investigated the relationship between strength and TC for limestone, sandstone, and siltstone; they also examined the effect of rock properties and TC on drilling performance. Ozturk, Nasuf, and Bilgin (2004) explored the relationship between rock quality and TC by evaluating the uniaxial compressive strength (UCS) values of limestone, basaltic andesite, and tuff. Gupta and Sharma (2012) evaluated TCs as well as the petrophysical and mechanical properties of quartzite from the lower and higher Himalayas and found a strong relationship between TC and UCS. Similarly, Ozcelik, Bayram, and Yasitli (2013) investigated the relationship between TC and various parameters in marble by applying the statistical analyses developed by Ozturk, Nasuf, and Kahraman (2014)."

Jan 1, 2019

By L Dyer, G. J. Wilkie, P. Walters, B Tadesse, L. Keeney

Grade Engineering® is a term trademarked by the Cooperative Research Centre for Optimising Resource Extraction (CRC ORE) and includes five key levers for upgrading ores and rejecting waste prior to expensive downstream comminution and mineral processing. These five levers include natural deportment, induced deportment, bulk sorting, particle sorting and gravity separation. Over the past ten years, CRC ORE has progressed a range of technologies that exploit these levers from laboratory proof of concept through to large scale demonstration and validation. This paper details the work carried out by CRC ORE and Curtin University for assessing the amenability of an ore for its natural deportment and particle sorting attributes in an Integrated Screening and Particle Sorting (ISPS) Grade Engineering® process. ISPS is seen as a preferred method for Grade Engineering® as compared to individually operated unit operations as the benefits of each can be complementary. Furthermore, it is suggested that integrating the two levers has two important impacts: 1. Firstly, there is a risk that isolated particle sorting test results will be misinterpreted as being representative of the full sample without considering the mass balance impact of high-grade material that might have been lost in the fines fraction. This fine fraction will not be detected through the particle sorter. 2. Secondly, and potentially of more valuable impact, is that the opportunity may exist to upgrade the feed first through determining if there is a concentration of high grade to the fine (or coarse) fraction which can be separated through screening. Undertaking screening in the preparation stage of the particle sorting process will enable analysis and separation of the fine or coarse fractions of a rock mass. The result of this study provides the mining industry with an independent framework for undertaking an Order of Magnitude (ISPS) Grade Engineering® assessment on a range of constituent ore types. Keywords: Grade engineering, particle sorting, grade by size fractionation

Jan 1, 2020

By K. G. Lomberg

The density used to covert volume to tons is critical in determining the real in-situ tonnage of Mineral Resources. However, the methods used to determine density and the use of different technical terms are seen to be inconsistent throughout the industry. Probably the best discussion addressing the determination of density was presented by Lipton (2001). This paper does not try to replicate this excellent work, but rather to review current industry practice and present a comparison of the approach to density in public reporting. Some of the technical terms used in reporting and the common methods applied are also discussed.

Sep 1, 2021

By T. Bezuidenhout, J. D. Visagie

In recent years the requirements for a barrier system between the waste body of tailings storage facilities (TSFs) and the natural ground (NG) has necessitated the use of HDPE-lined TSFs in South Africa and other countries. The addition of an HDPE liner creates an interface between, inter alia, the tailings and surrounding soils on the footprint of the TSF. It is known that low-strength materials beneath slopes can cause slope instability. One method which can theoretically mitigate this instability of a lined TSF is the addition of stability bunds along the footprint of the TSF. Altering the profile of the footprint to include slope changes which oppose the direction of the failure creates passive slices in a limit equilibrium analysis. The passive slices actively oppose the movement of active slices, resisting the mobilization of tailings, thus greater active slice forces are required to develop a failure surface running along the liner interface. Two scenarios are presented and compared. The first scenario retains the ground profile unaltered and the second scenario includes stability bunds along the ground profile. An in-depth assessment is made of the interslice forces and the interface shear stresses for each scenario. The theoretical background is discussed in greater detail to determine the mechanisms of reinforcement provided by the bunds.

Jun 2, 2022

By M. Saghaeian, R. Hejazi, V. Sheikhzadeha, A. H. Baladastian, A. Dehghani Ahmadabadi

This paper describes research done to remove apatite (phosphorus) from hematite ultrafine (70% finer than 25 micron) concentrate, recovered by electromagnetic separators at the FST Tailing Recovery Plant located in Chadormalu Iron Ore Complex through reverse froth flotation. As a result, iron and phosphorus content in magnetic concentrate (flotation feed) were 53.52% and 0.58%, respectively. Therefore, to increase the Fe content and decrease the P content of the sample, reverse flotation tests were applied. Chemical reagents used in this research consisted of sodium silicate as a depressant, sodium hydroxide and sodium carbonate as pH regulators, Alke & Dirol as fatty acid collectors and MIBC as frother. Process parameters including dosages of collectors, depressant and frother, preparation times of depressant and collectors, steps and time of frothing and pH range were selected. After doing flotation tests, in optimum condition, dosages of collectors were 1200 g/t, depressant 1200 g/t, pH in the range of 9.5 to 10, preparation time of collectors in the first step was eight minutes and at the other steps, four minutes; the number of frothing steps 4 and frothing time in each stage was three minutes. In this case, it was observed that the amount of phosphorus in the final concentrate was reduced to 0.05%, the Fe content increased from 53.52% to 61.66% and the Fe recovery achieved was 82.21%. Keywords: Iron ore, hematite ultrafine concentrate, iron and phosphorus content

Jan 1, 2020

By N. T. Beukes

An engineering house?s perspective of required inputs in designing a copper electrowinning tank house and ancillary equipment calls for both understanding of the key fundamental controlling mechanisms and the practical requirements to optimize cost, schedule and product quality. For direct or post solvent extraction copper electrowinning design, key theoretical considerations include current density and efficiency, electrolyte ion concentrations, cell voltages and electrode over potentials, physical cell dimensions, cell flow rates and electrode face velocities, and electrolyte temperature. Practical considerations for optimal project goals are location of plant, layout of tank house and ancillary equipment, elevations, type of cell furniture, required cathode quality, number and type of cells, material of construction of cells, structure and interconnecting equipment, production cycles, anode and cathode material of construction and dimensions, cathode stripping philosophy, plating aids, acid mist management, piping layouts, standard electrical equipment sizes, electrolyte filtration, impurity concentrations, bus bar and rectifier/transformer design, electrical isolation protection, crane management, sampling and quality control management, staffing skills and client expectations. All of the above are required to produce an engineered product that can be designed easily, constructed quickly and operated with flexibility.

Jan 1, 2009