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Blasting Masterclass 30 September 2014
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Improving metallurgical performance with chemical technology through the development, manufacture and seamless application of reagents
Dr Stephen Foster
A GLOBAL LEADER IN MINING CHEMICALS
MINING
COMMINUTION & LIBERATION
BENEFICIATION
METAL RECOvERY / SMELTING
THE FOUR PLATFORMS OF ExTRACTION TECHNOLOGY
CONvENTIONAL MININGGEOLOGY
AND GRADE
SHAPE OF MUD PILE
(FINE/LUMPY)
SIzE DIS-TRIBUTION FOR
CRUSHER
CONvENTIONAL MINING
BLASTING CONTROL TO
OPTIMISE ENERGY
AvAILABILITY OF SERvICES AND
RESOURCES
SURFACE AND UNDER-
GROUND
OPTIMAL BLAST CONDITIONS TO GUARANTEE A MEASURED RESULT
CRUSHED AND MILLED OREINPUT POWER
COST AND AvAILABILITY
LOW ENERGY FOOTPRINT
MILLING MEDIA
COMMINUTION/ LIBERATION
HARDNESS/ BRITTLENESS
OF ORE
MANY DESIGNS TO CHOOSE
FROM
USE OF GRINDING
AIDS
OPTIMISED SIzE FRACTION FOR BENEFICIATION
THE BENEFICIATION PLATFORM
METAL GRADE AND RECOvERY
GRADE (IN AND OUT): LOW
GRADE-HIGH GRADE
MAkE-UP, APPICATION,
DOSE CONTROL AND qUALITY OF
REAGENTS
WATER RECOvERY
AND SLIMES DISPOSAL
BENEFICIATION
METAL OR PRODUCT RECOvERY
MIxED AND COMPLEx ORE MINERALOGY
REAGENT SELECTION
(SUITE)
SUPPLY A qUALITY PRODUCT TO THE MARkET
METALS OR FINAL PRODUCTSMELTING CAPACITY
SAFETY ACROSS
THE ENTIRE PROCESS
ENvIRONMENTAL ACCOUNTABILITY, EFFLUENT, WATER
USAGE AND LICENCE ISSUES
FINAL PRODUCT TO MARkET
PRODUCED WITH LOWEST COST
AvAILABLE
POWER AND REFINERY
COSTSPURITY (qUALITY)
INvOLvEMENT IN MINERALS PROCESSING
Mining Crushing
Grinding
Thickening Smelter
Electrolysis
Precipitation
Agglomeration andBriquetting
Tailings Thickening
Disposal
Electrode Ingot
CCD Wash Train
Flotation Concentrate
Heap or vat Leach
Solvent Extraction
• Oreisnothomogeneous• Maycontainmoreorlesswasterockandgangue• Affectsbeneficiationprocess• Highproportionsofsilica,sulphidesandoxidesaffect flotationprocess• Impactgradeandrecovery• Dosageandtypeofreagent• Liberationduringgrinding• Thickeningandwaterrecovery
NOT ALL BLASTS ARE THE SAME
AREAS OF ExPERTISE
• Aluminum• Coal• Cobalt• Copper• Diamonds• GoldandSilver• Iron
• Nickel• PlatinumGroupMetals• Phosphate• Titanium• Uranium• Zircon
REAGENT SUITE
A range of water-soluble products, such as carboxymethyl cellulose,
guar gum and other natural polymers for gangue depression
SENDEP (depressants)
REAGENT SUITE
A range of polyelectrolyte flocculants and coagulants for
improved solids thickening, water recovery, clarity and
rheology modification
SENFLOC (flocculants)
• Bench scale/metallurgical evaluations• Statistical evaluation and data validation• Product development and optimisation• On-site product management• Site-specific account management• Supply chain control (e.g. telemetry and bulk distribution)• Plant safety audits FIT-FOR-PURPOSE SERVICES
• Ownership of the reagents area • Agreed monthly KPI’s• Quality control on incoming reagents• Reagent mixing to the right
concentration• Availability of plant and reagents and
reporting of engineering faults• Ordering and stock reconciliation
• Dosing Optimisation• Overall plant performance
measurement (grade, recovery reporting and reagent usage)• Safety management• Audits• Improvement initiatives
FULL SERVICE MODEL
RESEARCH AND DEVELOPMENT
• Research and Development Centre• AMIRA International
• South African Minerals to Metals Research Institute (SAMMRI) • University of Cape Town