CIRCULATION

Jan - June 2015

PRINT CIRCULATIONLocal Africa

3 529 303

Total audited 3 832

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iningA F R I C A N U P D AT E S O N T H E G R O U N D A N D U N D E R G R O U N D

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23%

5%

16%

21%

10%

8%

3% 2%

4% 7%1%

Underground Mines

Institutes & Associations

Mining Houses

Surface Mines

Exploration Companies

Consulting Companies

Civil Engineering Contractors –Infrastructure & ConstructionFinancial & Insurance Companies

Government: National, Provincial & Municipal

23%

5%

16%

21%

10%

8%

3% 2%

4% 7%1%

Underground Mines

Institutes & Associations

Mining Houses

Surface Mines

Exploration Companies

Consulting Companies

Civil Engineering Contractors –Infrastructure & ConstructionFinancial & Insurance Companies

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54 274

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iningA F R I C A N U P D AT E S O N T H E G R O U N D A N D U N D E R G R O U N D

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structures to facilitate adequate froth drain-age to minimise chromite entrainment into the concentrate. Coupled with this concept was the realisation that one should not re-cycle any streams to the rougher circuit and that one should minimise the recycle loads in the cleaning circuit to ensure high overall PGM recoveries. It was felt that the highest probability of � oating the slow � oaters was during its � rst pass through the cleaning circuit and every e� ort should be made to recover it and, if allowed to recycle, it would probably be lost to an eventual bleed out to the � nal tail. At the same time, it was also realised that, to run long residence times in the cleaning circuits, one needed very tight control of froth height and air rate to ensure that the pulp carry-over into the � otation concentrate was minimised. Out of this knowledge, Mintek developed the Floatstar platform, which controls operat-ing � otation pulp levels more consistently than previous manual attempts.

After a quiet period where the then producers continued development inde-pendently, Mintek reactivated its inter-est in PGM mineral processing � owsheet development when Craton Resources ap-proached Mintek in the mid-90s on behalf of Aquarius, an Australian junior mining company, to assist in the evaluation of some UG2 orebodies in the Kroondal-Rustenburg area. As a small potential PGM producer, with limited access to capital, Kroondal needed to be innovative in its approach to the mining and metallurgical aspects of the project.

Mintek was intimately involved with Dowding Reynard and Associates with re-gard to the metallurgical performance of the process. � rough various pilot plant campaigns, it was shown that dense me-dia separation was a viable process for the rejection of barren waste rock. It was also shown that rod mills could be used e� ec-tively to produce grinds of 35% (75 µm) and that the bulk of the PGMs was liberat-ed at this grind. It was also shown that the plant could start up with a single-stage mill rather than the more expensive option of two-stage milling. As Kroondal had di� cul-ties in � nding a market for its concentrate, attritioners were installed to enhance the product quality.

A signi� cant database of experience at Mintek has indicated that there is no ge-neric UG2 deposit or � owsheet, hence validating the need for piloting testwork. During pilot campaigns, spirals, attrition-ers, dense medium separators and � ne grinding mills were integrated into UG2

INSIDE MINING 04 | 2015 5INSIDE MINING 04 | 20154

THE STRATEGIC vision in the 70s, within the industry, was that there was going to be an in-creased demand for platinum to

support the expected growth in the auto-catalyst industry, as environmental issues became more important. It was considered unlikely that the demand could be met by the depleting Merensky reserves or from the Eastern Bushveld, where signi� cant infrastructure investment would be re-quired. Attention was thus focused on the extraction of the PGM values from the UG2 ore. At the time, the major concern about the UG2 ores was that it would be di� cult to treat the concentrate in a traditional matte sul� de process, as the Cu-Ni sul� de values were low and the chromite values high. Furthermore, the poor association

High-calibre research by Mintek enables the effective utilisation of natural resources through the development and adoption of new technologies, as well as the reapplication of existing technologies in new operations.

in certain cases of the PGMs with the base metal sul� des (BMSs) and the small PGM sizes was interpreted as indicating that the concentration of the PGM values into a � o-tation concentrate would be di� cult.

Over an extensive period, Mintek, in con-junction with Lonmin, was able to show that a process could be developed to exploit the UG2 ore commercially. In the process, Mintek developed expertise in characteris-ing the UG2 ore, developed mineralogical and assay techniques, and demonstrated pro� cient pilot plant building and oper-ating capabilities. As the UG2 ore became an increasingly important resource in the industry, Mintek continued to invest in understanding the mineral processing of this orebody. Extensive research work in understanding the interaction between the

gangue minerals and rea-gents was undertaken.

An innovative approach to UG2 processing plant design was the introduc-tion of the mill-� oat-mill-� oat (MF2) concept, and the removal of a chromite fraction from the primary rougher tail. Both devel-opments were based on mineralogical observations that indicated that the bulk of the PGM values in the ore were liberated at a coarse grind of 35% (75 µm), and there were signi� cant as-sociations of PGMs on the grain boundaries of base metal sul� des. A signi� cant

portion of the PGMs were locked in the sil-icate phases and required � ne grinding for liberation. It was also shown that the chro-mite grain size enabled the production of a high-grade chromite product by spirals that did not contain signi� cant PGM values. From laboratory work on plant cleaner tail streams, it had been demonstrated that the PGMs could be recovered by the addition of high depressant dosages and the use of long � otation residence times.

From this observation was born the con-cept of the ‘Mintek Process’, which uses a single integrated cleaning circuit with the production of high- and low-grade concen-trates to improve the PGM recovery to the overall concentrate by up to 5%. � e con-cept that there were fast and slow � oating PGM and gangue values in an ore was used to design the � otation plant con� guration such that the fast � oating PGM values were removed to the high-grade concentrate, and the slower � oating PGM values to the low-grade concentrate. � e subtleties of the process were the realisations that one needed to accentuate the di� erences be-tween the slow � oating PGMs and gangue through depressant addition, but that one also needed to create the appropriate froth

COVER STORYCOVER STORY

A focus on

� otation circuit � owsheets, each being sup-ported by the speci� c mineralogy of the ore or stream being treated. As the experience in processing technology for UG2 matures, process optimisation, to make marginal incremental improvements in recovery and reduce costs, continues. Some of the technology improvements include the move to open-circuit secondary milling and the use of sensor-based sorting technology.

Commercial milling circuits saw many mills being operated in closed circuit, with the mill discharge being classi� ed and the coarse product re-turned to the mill to be reground. Op-erating mills in this manner achieves energy e� ciency while also achieving product speci� cation. Mineralogical and chemical analysis of the second-ary � oat tails showed that it con-tained a signi� cant portion of coarse, unliberated silicates that contained

SOME OF THE HIGHLIGHTS OF THE WORK CONDUCTED INCLUDE:• development of the ‘Mintek Process’

for maximising PGM recovery for UG2 ores

• development of a fl otation predictor, based on detailed autoSEM characterisation

• conversion of the UG2 milling circuits to open circuit

• development of a robust pilot plant facility for use in plant design studies

• use of dense medium separation as a waste rejection option

• use of attritioners in fl otation circuits • development of a fl owsheet for

Platreef ores• use of sensor-based sorting

technology for upgrading platinum ores

• use of a mini-plant for reagent optimisation studies.

upgrading UG2 oresupgrading UG2 oresupgrading UG2 oresupgrading UG2 oresMarikana platinum mine

TOP Platinum fl otation at Impala Platinum

BELOW A rock driller in action

PGMs either locked or attached to grain boundaries. Size and assay investigation of the secondary mill discharge indicated that the chromite had a � ner particle size distribution than the silicates and was be-ing over-ground due to a dense media e� ect occurring in the classifying cyclone.

As a result of the high recirculating load of the chromite to the mill, the silicates were being displaced in the secondary mill, lead-ing to ine� cient milling of the silicates and hence increased PGM losses to the � nal tail. Upfront waste rejection in a UG2 plant has two potential bene� ts, which, for an oper-ating plant, in which the plant is the bot-tleneck, is the ability to increase the PGM ounce production for a relatively � xed op-erating cost. � e second bene� t is to mine more economically and safely by using mechanised and wide mining techniques. Recent technology advances have allowed sensor-based sorting to be considered for this application. Further developments of this technology, exploiting optical as well as multi-sensor technology, exist and are presently being developed and tested.

Mintek has maintained its position as a leader in the PGM mineral processing � eld by application of its early research and the continued investment in projects to im-prove the e� ectiveness of these circuits. � e project areas on UG2 ores that have been identi� ed for active research are: the production of very high PGM grade, and low chromite grade concentrates; � otation using non-mechanical type � otation cells; improving recovery from plant streams using ultra-� ne grinding techniques; sec-ondary mill energy e� ciency improve-ments through improved classi� cation and milling conditions; and the development of sorting and concentration technologies.

A F R I C A N U P D AT E S O N T H E G R O U N D A N D U N D E R G R O U N D

www.miningne.ws

WOMEN IN MINING Overcoming prejudice

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 8 • No. 04 • April 2015

IRON & STEEL Supply exceeds demand

MINING 2015Mergers & acquisitions

IN THE SPOTLIGHT

Setting the pace of

innovation

MINTEK

GREENFIELD

SIMANDOU

AFRICA Dormant opportunity

IRON & STEEL Supply exceeds

MINING 2015acquisitions

GREENFIELD

SIMANDOU

Dealing with trees

The El Dorado of iron ore

FRONT COVER + 2-PAGE ARTICLE

All branded content in the magazine gets extensive online exposure. Your content will be featured in the newsletter, on the home page of the www.miningne.ws website, and in our social media.

This provides your brand with substantially more exposure across various platforms.

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PANEL DISCUSSIONSPosition yourself as an expert in the industry. Share your knowledge and showcase your company, products and services, and how they can be used to provide solutions to market needs. The panel discussion includes a one-page

editorial piece and another full-page display advert.

HOT SEATShare important information and hot news with your industry. The Hot Seat, written by our editorial team, includes two pages of editorial, in question and answer format. The photo of the person interviewed will be published on the front cover of the magazine along with a pull quote.

INSIDE MINING 10 | 201356

I dentify the main IT trends in the mining sector MVA These are: • data warehousing• auditable, quality

management of data life cycles

• overall automation and integration of data from disparate sources such as laboratories • data security• data quality• software as a service.

What IT solutions does SABLE Data Works offer to meet these trends?• Data warehousing – The fifth and sixth generations of the SABLE product suite have been built on a rugged client server architecture that manages and supports one customisable data standard across multiple servers. Each server holds the data

for a particular business unit but the data structures and relationships, data conventions, dictionaries and data processes remain the same across the separate databases.Auditable, quality management of data life cycles – SABLE provides functionality around its databases to track the movement of data sets and entities. Data ownership is promoted through security. Changes to data can be tracked to particular logins, user roles and timed sessions. If part of the data’s life cycle is outside of the database, its integration back to its position is tracked and managed auditably.Overall automation and integration of data from disparate sources such as laboratories – SABLE has tackled the issue of receiving analytical data from multiple laboratories in variable formats by supplying a managed process that conforms the data before subjecting it to quality control functions. Once the quality control has been passed, the data can be loaded to the data warehouse through a firewall.Data security – In order to prevent the risk of intellectual

property residing in user applications such spreadsheets and user data stores, remote data capture functionality is provided at the point of data collection. This data is then migrated straight to the mother database using a secure data format. This means that data cannot change during transportation. The integration of this data within the governed data warehouse environment is strictly managed.Data quality – I believe that it is better to have no data than bad data! SABLE’s Data standard provides measurable quality assurance for the data in our databases. We deal with descriptions that are qualitative in nature. They must be quantified in order to be captured into a database. SABLE provides the tools to support and manage this transformation. User licensing for data capture has been provided at no additional cost to our clients since 1996. I remember a year when Anglo American Platinum’s exploration team logged 250 km of drill core into SABLE in one year.

Software as a service – We have identified the need to supply the product as a bundled service. Each package delivers a well-defined set of functionality and everything required to make it work for the client or site. Packs are independent of each other and can be added or dropped easily.

What IT infrastructure requirements need to be in place to ensure they are used and function optimally? We require stable Microsoft Windows

PCs for field data capture into a locally hosted database on the PC. Rugged PCs are recommended for harsh environments, local or wide area networks for database connectivity and database servers hosting Microsoft SQL Server to host the data warehouse.Remote sites can make use of external cloud hosted services (which require internet access) or internal hosted servers (which can be accessed via VPN).

Data captured offline can be emailed or uploaded for incorporation into the mother database by the administrator. What is the average time frame for return on investment for your IT packages/solutions? SABLE is easily motivated within a drilling and sampling programme because the cost of the product and service is a small fraction of the cost of obtaining the data. Return on investment is obtained within three months. You do, however, need a six-month programme to justify new software implementation. If you already have an

established implementation, you can get up and running within one month.

What training is required to operate your systems and how user-friendly are they? We provide hands-on training using the client’s customised data standard and perform data management and administration of databases using SABLE tools. Training courses support our packaged functionalities to ensure quality assurance and quality control of data.We make sure that the users know why they are doing what they are doing and how to do it. Clients’ data managers are able to train the data loggers themselves using our training material, if required.

PANEL DISCUSSION | I T I N N O V A T I O N S I N M I N I N G

SABLE DATA WORKSPANEL EXPERTMarcia van Aswegen – MD

SABLE software helps mines unveil their true potential

INSIDE MINING 05 | 2014 11

INSIDE MINING 05 | 201410

HOT SEAT

HOT SEAT

Guideline for water-use licensingGolder Associates has

developed a guideline

for water-use licence

application for a key

mining client that it hopes

will become an invaluable

resource for the industry,

Riana Munnik tells

Gerhard Hope.

SOUTH AFRICA’S legislation in

terms of water use is the most

progressive on the continent,

says Munnik, who is the divi-

sional leader of the Integrated Water &

Waste Management Planning Division

at Golder. “We have fine legislation, but

while we are more advanced than other

countries, it is the efficient implementa-

tion that is the big challenge.”

It is for this reason that Golder worked

with one of its key mining clients to ad-

dress the inevitable grey areas in apply-

ing for a water-use licence by develop-

ing a risk-based guideline to facilitate

the process. “The risk-based approach is

something that is supported by the De-

partment of Water Affairs (DWA),” con-

firms Munnik. Indeed, Golder was ap-

pointed by the DWA to revise and update

Regulation 704, known as GN 704, made

in terms of Section 26 of the National Wa-

ter Act, which relates specifically to the

protection of the water resource in min-

ing and related activities.

Munnik explains that the National

Water Act, 1998 (Act No 36 of 1998)

mandates the DWA to protect, use, de-

velop, conserve, manage and control

the country’s water resources in an in-

tegrated manner. Therefore water users

such as mines are required to submit

water-use licence applications to the

DWA for the authorisation of water uses

associated with planned and/or existing

mining operations.

Water uses that require authorisation

Examples of water uses that require such

authorisation are the abstraction of wa-

ter, whether from a borehole or river,

or even transferring contaminated wa-

ter from underground workings into a

treatment plant. “What is important

from a mining perspective is that pollu-

tion and stormwater control dams and

mine-residue disposal facilities, such as

tailings dams, all require authorisation in

terms of the Act,” explains Munnik.

However, the problem is that while the

Act was developed as long ago as 1998,

the DWA only ever brought out a single

guideline in 2007. “There is no clear in-

terpretation of what constitutes a water

use,” notes Munnik.

“Recently we saw the DWA regarding

dust suppression on mine roads as a wa-

ter use, whereas previously it was not.

This leads to a situation where a client

may have to consult a lawyer to argue

that this is not a water use. That is the di-

lemma: should mining clients contest the

DWA’s interpretation, or simply abide by

its rulings?

Industry practice

“In many instances, mining clients just

concur and fill out the forms and apply.

That leads to a certain practice within

the industry that is not aligned with the

original intent of the law,” argues Mun-

nik. “The interpretation of the Act has

grown organically, but it has never been

a framework, or been proactively thought

through; that is why it is so difficult for

mining clients, in particular.” Munnik

says the solution to this dilemma lies in

the water-use licence application. “This is

a critical component in defining upfront

which water uses are under considera-

tion,” says Munnik.

Getting the application right from the

get-go is particularly important, as the

DWA does not have a regulated time-

frame for the issuing of water-use licenc-

es. In practice, the DWA assessment pro-

cess can take 11 months (if it is quick),

two years realistical-

ly and up to six years

in other cases. “We

refer to this process

as the art of water

licence application”.

“This really places

a restriction on new

developments in the

mining industry, as

any new water use

cannot commence

without the necessary authorisations

(that is, a water-use licence) issued by

the DWA. Therefore it is very important

to provide the correct technical sup-

porting information to the DWA in the

format of an integrated water and waste

management plan (IWWMP) to sup-

port the water-use licence application,”

says Munnik.

Dedicated team of experts

Golder has a dedicated team of experts

specialising in the compilation of IWW-

MPs, with Munnik herself having been in

the sector for 20 years. The IWWMP pro-

vides a short-, medium- and long-term

water and waste management frame-

work for a mine, specifically in terms of

storm water, groundwater, process water

and waste.

“The action plan of an IWWMP is an

excellent management tool to guide an

industry such as mining for the imple-

mentation of a range of measures to im-

prove its environmental performance and

to save costs by implementing pollution

prevention instead of treating water or

waste at a high cost,” says Munnik.

Again a major stumbling block is that

the DWA does not have a document that

provides clear guidance related to the

exact legal definition of water uses. “This

has resulted in the DWA regulating on-

site activities, such product stockpiles,

by means of the water-use authorisation

process. It is therefore possible that the

water uses associated with a particular

mining operation can change based upon

the latest interpretation of the Act by

DWA officials.

Consistent approach

“In many instances, the DWA officials

responsible for managing catchments

and associated mines and industries are

inexperienced, and do not have the le-

gal insight into the original intent of the

NWA,” argues Munnik. “On a national

level, there is also not always a consistent

approach between the various regional

offices of the DWA related to water-use

authorisation and the definition of

water use.”

Thus it is entirely possible for a mining

client to apply for water-use authorisa-

tion for activities not legally defined as

water uses in the Act. “This has resulted

in unnecessary delays and a huge back-

log in the water-use licensing process,”

points out Munnik. This led to Golder

working closely with one of its key min-

ing clients “to take a proactive approach

and document legally defensible defini-

tions of water use to prevent the client

from applying for authorisation of activi-

ties not deemed to be water uses.”

The resultant guideline developed by

Golder incorporates “a risk-based ap-

proach to deal with water uses that are

either not legally defensible or clear-cut.”

This risk-assessment process was devel-

oped further to determine the risks asso-

ciated with mining activities that may be

considered a water use by the DWA, but

for which there is no legal backing.

Risk assessment

Munnik says that Golder’s key mining

client will utilise the water-use identifi-

cation guideline and accompanying pro-

cedure and the outcome of the activity

or project-specific risk assessment to in-

form management decisions related to

the water uses associated with an activity

or operation for which the client will ap-

ply for authorisation in the future.

“Another solution to the dilemma of

the delay in the issuing of water use

licences by the DWA is the continual

follow-up with the DWA during the as-

sessment phase. The DWA periodically

requests additional information from

applicants. Due to the potential change

in departmental requirements, it does

seem that the goalposts keep on moving,

which is why it is critical to maintain con-

tact with the DWA during the process,”

says Munnik.

This is why it is important for mining

clients, in particular, to approach a sea-

soned consultancy like Golder, which

has not only established a close working

relationship with the DWA, but also has

an intimate understanding of its require-

ments, in addition to submitting applica-

tions of a sufficiently high quality, with

the required technical supporting infor-

mation.” Golder Associates will also be

exhibiting at the upcoming WISA Bienni-

al Conference (see sidebar).

WISA BIENNIAL CONFERENCE

Golder Associates will be exhibiting

and presenting at the WISA Biennial

Conference from 25-29 May at

Mbombela in Mpumalanga.

Golder will facilitate workshops on:

• mine water

• integrated water resources

management and regulatory

performance measurement

system (RPMS)

• biomimicry

• waste discharge charge systems.

A presentation will also be

given on the environmental

mineralogy of Ghanaian gold belts

and the implications for mine

water management.

For more information contact

Lucinda Scholtz on +27 (0)11 313

1151, or email lscholtz@golder.co.za.

“Getting the

application

right from

the get-go is

of particular

importance.”

Riana Munnik, Golder

Acid mine drainage

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iningA F R I C A N U P D AT E S O N T H E G R O U N D A N D U N D E R G R O U N D

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COVER STORY

INSIDE MINING 02 | 2014 5INSIDE MINING 02 | 20144

WEIR MINERALS

Supplying business excellence

COVER STORY

SUPPLY CHAIN IS the beating heart of the business, says Van Vliet, who is supply chain director: Middle East and Africa at Weir

Minerals. “If this heart stops beating, the entire business will feel it immediately.” He attributes Weir Minerals Africa’s impres-sive growth to regional MD Dave Athey, “who identified that if we were to go grow as planned, which meant doubling the business by 2014 – which we have done, and in less time than anticipated – we would need an ef-fective supply chain.”

It is at this point that Van Vliet was ap-pointed in his current position at Weir Min-erals Africa, where he immediately brought about a number of changes, restructuring the supply chain and introducing a more cen-tralised business model.

“Essentially it was Athey who identified the opportunity, necessity and strategic impor-tance of the supply chain. That was in 2010, and since then the supply chain has grown in leaps and bounds. I think the value we have brought to the business speaks for itself.”

Simple maximVan Vliet ascribes to a simple maxim: If the supply chain is not effective, then you are not going to be able to deliver in accordance with customer expectations. “We needed to be-come a lot more visible, making sure that our internal customer base understood the value that we can contribute.”

In upgrading its supply chain, Weir Miner-als Africa has built a brand new warehouse, as well as implemented a number of new technologies under the guidance of Van Vli-et. Perhaps most significantly, a fragmented team was centralised.

“We have brought them all together under one roof, so we can leverage those synergies. It has been a very exciting three years. This

Weir Minerals Africa has achieved its target of doubling the business in the five years to 2014 with the support of various supply-chain initiatives, explains Wim van Vliet.

business is extremely  dynamic.” As a quali-fied mining engineer, Van Vliet fully under-stands the requirements of an effective sup-ply chain from a customer’s perspective.

“I built up this team over the past three years, and it is a highly competent team in its own right. If you do not have a good team backing you up, you will not get anywhere.”

Successful transformationKey to the successful transformation of the supply chain at Weir Minerals Africa has been the deliberate distinction between sup-pliers and partners. Van Vliet says the tradi-tional way of dealing with suppliers centred on dictating the terms of supply. “It was a very adversarial relationship that lead to a breach of trust.” The first step in changing this was to acknowledge the importance of the supply base and its impact on the busi-ness as a whole.

“We have about 800 suppliers in our suppli-er base. There are many suppliers with goods that are viewed as being non-strategic to the business, with wide market availability from other suppliers. Then we have strategic sup-pliers, which I regard as partners, as these are an extension of our own business. We deal with them on a daily basis, as I would deal with anyone within Weir Minerals itself. That is how critical they are. There has to be

“If this heart stops beating, the entire

business will feel it immediately.”

Wim Van Vliet (right, seen here

with Dave Athey), supply chain

director, Weir Minerals Africa

EDITORIALEditor: Mientjie Kleinhans+27 (0)11 233 2600

insideminingeditor@3smedia.co.zaSALESAnnemarie Prins t +27 (0)11 233 2600 c +27 (0)76 795 7870annemarie@3smedia.co.za

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