EXTRACTIVE METALLURGY AND MINERAL BENEFICIATION WORKSHOP

Mr Basdew Rooplal

Metallurgical and Business Consultant

Mr Basdew Rooplal is a Mineral Processing Engineer with over 20 years of experience gained in the mining and related industries in the operational, research and development, project management (plant design and commissioning) business development and consultation fields. His experience spans over hard rock underground mining of the Witwatersrand, large open cast mining of Botswana and alluvial mining of the west coast of Southern Africa.
During his career Basdew has facilitated several workshops for the Mineral Processing environment. He is currently working together with international partners (ex JKMRC) on the development and distribution of user friendly (excel based) plant monitoring and optimisation software for the minerals industry. He holds a HND in extractive metallurgy and a Post Graduate Diploma in Management Studies (SAQA NQF level 8)

Overview of presentation.

The success of extraction of minerals and their subsequent beneficiation is not only dependent on the metallurgical unit processes (comminution, mineral separation and refining) but also relies on an integrated series of stages which eventually culminate to the refinement of these unit processes. Extensive exploration work is carried out which involves sampling and processing to determine the viability of the ore body. Various levels of financial as well as technical studies are carried out thereafter. An integrated approach between geology, mining, metallurgical processing, finance, etc. then manifest into a final feasibility study which is used as a tool to confirm investor interest which results in a mine.

Proper sampling methods, up to date laboratory testing, proper economic evaluations, and a collaborated effort between mining, geology, engineering and processing will result in a suitable design of the plant to extract the mineral from the ore body at an economically viable and efficient rate to satisfy the market demand in an environmentally friendly manner. Mistakes made at this stage can result in the loss of large sums of money in terms of capital and working cost over the life of mine. Herein we discuss some of the important processes.

Who should attend?

  • Mineral Processing Engineers
  • Plant Superintendents
  • Mine Planners and mining engineers
  • Exploration and Mine Geologists
  • Plant Operating Personnel ( Middle Management level)
  • Research and development metallurgists
  • Production Metallurgists.

Key Learning areas:

  • The delegate will learn the stages involved in performing a feasibility study.
  • Learn to perform an economic analysis of an ore body
  • Learn the importance and relevance of sampling during the prospecting and design stages of a project.
  • The relevant bench scale tests that need be performed for design purposes
  • Become aware and use modern tools like computer simulation to reduce costs and enhance efficiency both a pre and post feasibility stages.
  • Developing a Plant auditing system including safety and hazards identification.
  • Developing an overall control strategy for plant management and optimisation tools for improved production performance.

Topics under discussion.

  1. Design Criteria for a mineral processing plant – The formal basis of design of Mineral Processing Plants.
  2. Sampling
  3. Sampling of Mineral Deposit for Feasibility Studies
  4. Sampling a deposit for Metallurgical Testing and the design of Comminution and Mineral Separation processes
  5. Bench Scale and Pilot Scale testwork
  6. Overview of Metallurgical Testing Procedure and flowsheet development
  7. Guiding process development by using automated Mineralogical Analysis
  8. Modelling and Simulation of Mineral Processing Plants
  9. Mineral Processing Plant Circuit Simulators - An Overview.
  10. Reducing Maintenance Cost using process and equipment event management
  11. An overview of Newly developed plant monitoring system
  12. Financial Management and Feasibility Studies for mineral processing plants
  1. Guide to feasibility studies
  2. Major Mineral Processing equipment costs and Preliminary capital cost estimates
  3. Process operating costs with application in Mine planning and risk analysis
  4. Financial Analysis and economic optimisation
  5. Mining project financing
  6. Specification and purchase of equipment for mineral processing plants
  7. The management and control of costs of capital of mineral processing plants

  1. Equipment selection and characterisation and plant Hazards
  2. Factors influencing the selection of crusher circuits
  3. Types and characterization of crushing equipment and circuit flow sheets
  4. The basic layout and design of crushing plant
  5. The selection and sizing of Primary and secondary crushers
  6. Hazards associated with a Crushing and Screening Plant
  7. Metallurgical Accounting and Auditing
  8. Sampling, Sampling Management, Measurement and Analysis for Metal Accounting
  9. Developing a Metal accounting auditing system.
  10. Plant Optimisation and Control
  11. Process Evaluation and control
  12. Case Study: Real time information management infrastructure for asset optimization.
  13. Process Strategy Development
  14. Principles and Practice of Automated control systems
  15. The Benefits of Dynamic Simulation for the Minerals Industry
  16. Taking mineral processing plant simulation to a new level – Inclusion of mine plan and financial performance