Comminution Laboratory Services

Laboratory-scale comminution techniques followed by computer simulation are becoming increasingly popular. Laboratory or bench-scale tests are relatively inexpensive, much quicker than piloting, and require only a small sample. Mintek offers a whole range of laboratory facilities and testwork to the mining and minerals industry. The results from these tests are used for general characterisation of ores, simulations, scale-up studies, and techno-economic evaluations.
Equipment and scale of operation
Bond Work Indices for rod and ball mills. JKTech drop weight tester and abrasion mill the test provides information on the breakage and abrasion properties of rocks, which can be used to simulate and design mainly crushing equipment and AG/SAG mills. SAG Mill Comminution (SMC) test, developed as a lowercost precision technique to determine the impact breakage characteristics of drill core samples. SMC generates a drop weight index, which is a measure of the rock strength when broken under impact. Advanced Media Competency tests these tests are conducted to evaluate the competency of the ore as the grinding medium. Grindmill tests batch mill used for estimating breakage and selection function parameters, which can be used as an aid in mill design. Stirred milling tests generally used for ultrane milling, i.e. when product sizes below 10 m are required. Scrubbing tests these tests are normally conducted to remove coatings such as oxide coatings or clay layers from particles. Various scrubber parameters such as residence time, L/S ratio, scrubber speed, and charge level can be evaluated. The results obtained from the laboratory-scale scrubbing tests indicate the residence time and scrubbing parameters required to obtain a clean product. Conrmatory pilot-scale scrubbing tests may then be undertaken to verify and ne-tune the scrubbing conditions. relative abrasiveness of an ore on a standard metal sample. The results can be used to estimate the relative steel ball, mill liner, and crusher liner consumption. Uniaxial Compressive Strength tests - The uniaxial compressive strength is a function of the maximum force recorded at the point of ductile-brittle transition of a sample under slow compression. The results are generally used in the selection of primary crushers and mineral breakers. Mintek has established a strategic alliance with Orway Mineral Consultants (OMC) of Australia. Mintek conducts a suite of testwork as specied by OMC, and the results are used in conjunction with OMCs large database of ore types to characterise the likely behaviour of the ore in a mill, thus enabling a choice to be made on the type of milling circuit required.

Projects
Scrubbing projects on several kimberlite ores to determine the optimal residence time required for efcient scrubbing. Testwork using the OMC procedure for several gold projects in South Africa and West Africa, particularly Ghana. General characterisation tests on gold ores, PGMs (UG2 and Merensky), base metals (copper, zinc, iron) and industrial minerals. Bench-scale comminution testwork for Everest South (Aquarius Platinum), Two Rivers (Avmin), Blue Ridge (Cluff), Kalplats (Harmony). Grindmill testwork and simulation for BHP Billiton, Kumba Resources, Gold Fields and Polysius Krupp. Feasibility studies for Barrick Gold (Tanzania) and the Langer Heinrich uranium deposit in Namibia.

Particle density and bulk density of samples

A major partnership has been established with CSIR Miningtek and Rocklab, who carry out the following tests: Bond Crushability (Impact) Work Index this test provides the energy requirements for a given crushing operation. The information is used by crusher manufacturers for crusher design and selection.

A Symantec Particle Size Analyzer is used for particle size analysis from 850 m to 0.1 m in dry and aqueous suspensions.

Key Staff

Jan Lagendijk - Chief Engineer. More than 15 years experience in the process industries. Musa Sadiki, National Diploma in Chemical Engineering, 6 years experience. Philemon Shalang - Chief Operator. More than 24 years experience in various mineral processing techniques.

Bond Abrasion Test this test is used to obtain an indication of the

For further information contact Jan Lagendijk - Chief Engineer, Comminution Laboratory Services Telephone +27 11 709-4550, Fax: +27 11 709-4427, e-mail: janl@mintek.co.za Agit Singh - Manager: Minerals Processing Telephone +27 11 709-4339, Fax +27 11 709-4427, e-mail agits@mintek.co.za

Mintek 200 Malibongwe Drive, Randburg, South Africa Private Bag X3015, Randburg 2125 South Africa Tel: +27 11 709 4111 www.mintek.co.za

Specialists in mineral and metallurgical technology

Comminution Pilot Plant

simulations, scale-up studies and techno-economic evaluations.

Mintek offers both bench- and pilot-scale testing facilities. The results from these tests are used for
Equipment and scale of operation
Concrete drying pad for ore drying and sizing, capacity up to 500 t of material. Trommel screen for continuous classication of ore from 150 mm to 50 mm. Crushing and blending facility, consisting of a 20 by 10 inch jaw crusher followed by a 2-foot standard head Symons cone crusher in closed circuit with a vibrating screen. Kilowatt-hour meters are used to measure the power consumption of the jaw and cone crushers. Access points are available to take belt cuts of all the streams in the circuit.

Major projects completed in the past few years

Evaluation of AG, SAG, ball or pebble milling circuits for base metal ores: Nkomati nickel project for Avmin, South Africa. Agua Rica copper ore project for BHP Copper, Chile. Pilot-scale testwork to evaluate AG, SAG, ball or rod milling circuits on South African PGM ores: Impala Platinum UG2 and Merensky ores. Two Rivers (Avmin). Everest South UG2 (Aquarius Platinum). Ngezi (Zimbabwe Platinum Mines). Winnaarshoek UG2 (Impala Platinum). Target gold project for Avgold, SA - evaluation of AG, SAG, ball and pebble milling circuits. Metallurgical audits of comminution circuits (Impala Platinum and Lonmin Platinum). Sampling campaigns, mass balance reconciliation, laboratory and pilot-scale testwork, steady-state computer simulations to evaluate possible circuit modications to increase throughput and maintain or improve neness of grind.

AG/SAG pilot mill

Internal dimensions: 1.7 m diameter by 0.6 m length. Typical throughput: 0.5 to 1.5 t/h, depending on type of ore. Accurate instrumentation for feed rate, charge mass and mill power.

Pebble, ball, and rod mills

Internal dimensions: 0.86 m diameter by 1.5 m length (smaller mills available). Typical throughputs: 0.3 to 1.0 t/h depending on feed material. Accurate instrumentation for feed rate and mill power. Various classiers are used with these mills, including hydrocyclones, screens, and spiral classiers. Pebble crushers are frequently used in certain AG circuit options.

Key Staff
Adrian Hinde - Specialist: Particulate systems. More than 25 years experience in comminution R&D. Jan Lagendijk - Chief Engineer. More than 15 years experience in the process industries. A team of 7 operators headed by Patrick Tshisikhawe and Philemon Shalang, each with more than 15 years experience in the operations of metallurgical pilot plants and laboratory. equipment.

For further information contact Agit Singh - Manager: Minerals Processing Telephone: +27 11 709 4339 Fax: +27 11 709 4427 e-mail: agits@mintek.co.za

Mintek 200 Malibongwe Drive, Randburg, South Africa Private Bag X3015, Randburg 2125 South Africa Telephone: +27 11 709 4111 www.mintek.co.za

Specialists in mineral and metallurgical technology

Flotation
Mintek can develop and evaluate otation procedures for new ores, according to specic
product grade and recovery requirements, by applying our expertise on the selection of plant conguration, reagents, and conditions, and by running extended pilot-scale testwork. We also offer a consultancy service to help existing plants improve their operations.

Equipment

Fully equipped otation laboratories for routine and specialised testwork. Six Denver D-12 laboratory otation machines. Leeds-design otation system. Wemco and Agitair otation machines. Full range of otation cells from 1 to 10 litres. Facility to measure and record parameters such as sulphide ion concentration, redox potential, pH, oxygen levels, xanthate concentration, and temperature. Procedures for conducting rougher rate otation tests and tting to rate models. An extensive range of modular pilot-scale equipment for use on small (60 kg/h) and large (up to 1 t/h) otation plant runs for parameter investigations and plant design data-gathering exercises. Autogenous mill (a bleed stream is fed directly into the otation plant). A wide range of pilot-scale mills, that can be run in rod or ball mode, with capacities from 250 - 1000 kg/h. Two smaller mills, 0.6 m diameter by 1 m long, are used for smaller scale testwork. Stirred mill detritor. High Pressure Grinding Roll (1 t/h). A range of classication systems (microscreens, spiral classiers, sieve bends, and cyclones), conditioner types (Sala and Denver), and peristaltic pumps sizes for reagent delivery. Flotation cells for specic on-site applications. One 18 l OK ash otation cell. One Maxwell-type cell. Two modied single Sala 80 l cells with extra-large impellers. Six 180 l tank cells, skid-mounted for on-site testwork. Jameson cells and Multotech column otation cells can be hired as required. Flotation cells, modular, for general work. Eight banks of 80 l Sala cells for rougher and scavenger otation, each bank comprising four or six cells, all equipped with automatic level controllers. Six banks of 30 l Sala cells, usually used for cleaner otation, each bank consisting of two, four, or six cells. Six banks of Denver 11 l cells. A dedicated 100 kg/h milling and otation plant is available for reagent evaluation and comparative testwork. A full range of in-house analytical facilities is available, with turnaround times of between 3 and 8 hours. Plant runs can be scheduled for periods ranging from a few hours to continuous runs over several days.
For further information contact Mike Bryson - Specialist Telephone +27 11 709-4446, Fax: +27 11 709-4427, E-mail: mikeb@mintek.co.za Agit Singh - Manager: Minerals Processing Telephone +27 11 709-4339, Fax: +27 11 709-4427, E-mail: agits@mintek.co.za

A dedicated, experienced team is available to run the pilot plant and to manually measure all plant parameters. The plant is usually sampled manually every hour, and the data is processed through commercial mass-balancing packages. The pilot plant is set up so that air owrates and bubble sizes in the cells can be measured. This is useful for modelling purposes. The plant is controlled via the Mintek FloatStar system, which reduces start-up time and allows tight level control at setpoints. This reduces variations in the data due to plant disturbances, and allows study of the effects of small level changes.

Recent projects
Nkomati (Ni-Cu-PGMs) - major pilot-plant campaign to derive concentrator design parameters for expansion. On-site piloting (at Tati Nickel) to recover precious metals from Activox residues. Bindura Nickel process design. Marakand Minerals Cu-Pb-Zn recovery.

Base metals

Platinum-group metals

Bushveld Complex Process development for Mototolo (Anglo Platinum/Xstrata), Blue Ridge and Shebas Ridge (Ridge Mining), Everest South (Aquarius Platinum), Leeuwkop (Afplats), Boikgantsho (Anooraq/Anglo Platinum), Elandsfontein (Eland Platinum), Smokey Hills (Platinum Australia), and Tussenkomste (Platmin).

Other deposits

Process development for Kalplats (Platinum Australia/ARM).

Miscellaneous testwork

Independent evaluation of gangue depressants for a reagent manufacturer. Continuous rougher testwork on UG2 ores. Comparison of PGM otation recoveries from DMS concentrates and ROM material.

Key Staff

Mike Bryson - Specialist. PhD in Chemistry on otation reagents. Ten years R&D experience on the fundamentals of otation chemistry before taking responsibility for all sulphidemineral otation process development work at Mintek. Has supervised many major pilot-plant projects on the otation of sulphide, gold and PGM ores. Dhiraj Maharaj. BSc Chem. Eng. Five years experience in developing process owsheets for a range of PGM and base metal projects. Ravi Roy. BSc Chem. Eng. Four years experience in fundamental aspects of otation processes.

Mintek 200 Malibongwe Drive, Randburg, South Africa Private Bag X3015, Randburg 2125 South Africa Tel: +27 11 709 4111 www.mintek.co.za

Specialists in mineral and metallurgical technology

Physical Separation
MINTEK has 70 years experience in developing techniques for the physical separation of metallic and non-metallic minerals. South Africas andalusite industry was founded on work done at Mintek. More recently, densemedia separation (DMS), has been incorporated into platinum-group metals owsheets, to separate barren waste rock from ore prior to milling. The beneciation of chromite using gravity separation and DMS, and vermiculite upgrading by dry separation techniques, have become important activities.
Services
Heavy Liquid Separation and Dense Media Separation
A laboratory is set up to carry out preliminary sink-oat separations up to densities of 4 g/cm. Density classes with intervals of 0.05g/cm can be evaluated. The data is used to construct washability curves. From these tests, investigative projects are designed to treat bulk samples in the 2-5t/h DMS cyclone plant, which operates, using either cyclones 250 mm or 350 mm in diameter. The plant is able to treat samples from 100 kg to 100 t in the larger pilot applications. Both density beads and Heavy Liquid Separation analyses on the sink and oat fractions are used to conrm the separation density. Projects on diamondiferous gravel, andalusite, iron, PGMs, gold, copper-nickel, and chromite ores have been run successfully.

Electrostatic separation
Mintek has a bench-scale Ultrastat separator, an improvement on the standard plate separator, which is available for laboratory scale testwork.

Magnetic separation
Mintek has a laboratory rare-earth oxide permanent high-intensity roll separator for dry separation, with barium ferrite, samarium cobalt, and neodymium boron iron rolls. A pilot separator with two rolls treating a nominal 300 kg/h is also equipped with barium ferrite and neodymium magnets. Wet, ne magnetic separation is done on bench and pilot scale, using low-intensity drum separators. Wet, high intensity magnetic separation (WHIMS) is done at both laboratory and pilot scale (Jones pilot-scale separator).

Other Gravity
Mintek has a range of bench and pilot-scale equipment, including: Wiley shaking tables (one-eighth and half-size). A variety of spiral concentrators, including a large diameter coal spiral that can be run either in batch mode or continuously at solids feed rates from 1 t/h to 4 t/h. Fines separators such as the Falcon, 3 inch and 7 inch Knelson concentrators, as well as a laboratory Superbowl laboratory and pilot jigs. The pilot units use the unique Apic air-pulsed technology. They operate at up to 35 t/h and can treat material as coarse as 35 mm. These jigs are electronically controlled, and are mobile. Mineral Density Separator for characterising samples into closely spaced density fractions. The results could be used to assist in plant performance, as well as to evaluate the amenability of using Jigging as a processing option. laboratory and pilot Linatex T-type classier treating up to 1 t/h solids, and Eriez Crossow. Laboratory Mozley multigravity separator. Kipp Kelly pilot air (pneumatic) table feed rate 100-300kg/h.

Optical sorting
A novel optical sorting technology has been successfully tested for the cost-effective upgrading of gold, platinum-group metal (UG2), base metal and industrial minerals ores. A full-scale unit is on site, capable of handling particle sizes of 20-100 mm at throughputs of up to 30 t/h.

Coal preparation
Mintek undertakes testwork on the upgrading of coal to a saleable product using dense media, centrifugal separation, jigging, spirals, and T-classiers, using either bulk or laboratory-scale samples. Other services include process simulation, total plant audits, and coal laboratory audits.

Recent Projects

Picobello Andalusite - Spain. Mooinooi Chromite - testwork to upgrade recovery plant following changes in mining methods. Kumba Resources - characterisation of iron ores during development of the Mineral Density Separator. Saudi Arabia - pilot-scale testwork on phosphate ore upgrading in conjunction with Bateman.

Classication
Wet and dry classication is carried out using a variety of equipment: Standard laboratory sieve shakers. Pilot screening facilities, including a number of 36 inch diameter Sweco screens and double deck Rotex screen. Hydrocyclone pilot plant incorporating 25 mm, 65 mm, 100 mm, and 150 mm diameter cyclones. Air classier used for dry classication down to 5 m.

Key Staff

Heloise Thiele - Group Head. Eight years experience in projects on industrial minerals, including heavy mineral sands, andalusite, chromite, iron and manganese ores. Carl Bergmann - Specialist. Danie van Wyk - Specialist. The Physical Separation Group consists of ve engineers, and about 15 technicians and operators.
Mintek 200 Malibongwe Drive, Randburg, South Africa Private Bag X3015, Randburg 2125, South Africa Tel: +27 11 709 4111 www.mintek.co.za

For further information contact Heloise Thiele - Group Head Telephone : +27 11 709-4469 Fax : +2711 709-4427 e-mail : heloiset@mintek.co.za Carl Bergmann - Specialist Telephone : +27 11 709-4529 Fax : +2711 709-4427 e-mail : carlb@mintek.co.za Danie van Wyk - Specialist Telephone : +27 11 709-4455 Fax : +2711 709-4427 e-mail : danievW@mintek.co.za

Specialists in mineral and metallurgical technology

Sample Preparation
Mintek has a fully equipped sample preparation facility. Its function is to provide support for small, medium, or large-scale operations both inside and outside Mintek with respect to sample preparation. This includes crushing, milling and blending of samples.
Facilities
Concrete drying pad for bulk sample drying and sorting maximum capacity 500 t. Pilot-scale crushing and screening plant, consisting of a 20 inch by 10 inch jaw crusher followed by a 2-foot Symons cone crusher in closed circuit with a vibrating screen. The maximum reduction ratio is from -150 mm to -6 mm. A variety of small crushers are also available - jaw, roll, cone, and pulverisers for handling small samples up to 50 kg. Samples up to 2 t can be treated with jaw crushers and roll crushers. In large-scale testwork, screen analysis can be carried out using large screens or a rotary trommel screen. In small-scale testwork, particle size can be determined using normal wet and dry screening techniques down to 38 mm. Sub-sieve sizing to produce size fractions for chemical analysis is performed using a Cyclosizer. A Particle Size Analyser is used for size analysis down to 1 m. Ceramic and steel mills are available for dry batch milling. Samples up to 200 kg can be blended using a double cone blender. Larger samples up to 100 t have been blended using a layering technique similar to the stacker/reclaimer system used in industry. This technique is recommended for preparing representative feed for pilot plant campaigns.

Facility Capacity
Grind ROM ores to below 38m. Handle 3 tons per day. All types of ores can be handled and processed in this facility.

Other Capabilities
Viscosity measurements. Particle density and bulk density of samples. Preparation of standard analytical samples. Air classication.

Key Staff
Walter Coko - Group Head. Seven years experience in minerals handling and sample preparation. This includes both bulk and laboratory samples.

For further information contact Walter Coko - Group Head Telephone: +27 11 709-4437 Fax: +27 11 709-4427 e-mail: walterc@mintek.co.za

Agit Singh - Manager: Minerals Processing Telephone: +27 11 709-4339, Fax: +27 11 709-4427, e-mail: agits@mintek.co.za

Mintek 200 Malibongwe Drive, Randburg, South Africa Private Bag X3015, Randburg 2125 South Africa Tel: +27 11 709 4111 www.mintek.co.za

Specialists in mineral and metallurgical technology