Foundation Project DRC

Equipment & Technology

“What is the mining and processing strategy? Something has got to give!”

Factors Which Lead to Success

  • Integrated team effort
    • Geology: resource size and ore characteristics
    • Mining: method, mining sequence, extraction strategy and equipment application
    • Processing: significant technology developments in the last 8 years
    • Recovery: massive advances in technology to optimise recoveries, security focus
    • Diamond specialists: determine optimal process flow
    • Strong diamond and financial controls
  • Water and power are an issue on diamond mines
    • Clay – lock-up, processing bottle neck
    • Waste – screening to pre-concentrate and disposal
    • Processing requirements
    • Influence costs, recoveries and sales

1st Stage: Front End Ore Preparation

  • Objective
    • Reduce downstream plant requirements, enhance waste removal -> reduce water, power use, diamond breakage
  • Process
    • In-field screening and pre-concentration
    • Re-usable and moveable wet front end (alluvial mining tramming distance and clay)
      • No permanent civil infrastructure or retaining walls
      • Technology from alternate applications:
        • Buffalo breakers to reduce clay in the feed (coal mine technology)
        • Advanced screening technology;  high frequency screens and innovative screen panels
        • Hydro-cleaning (alternative scrubbing technologies)
  • Effects
    • INCREASE in washing efficiency
    • INCREASE in diamond liberation
    • INCREASE in ore feed to where it matters most
    • INCREASE in diamond recovery
    • DECREASE in capital expenditure
    • INCREASE in revenue per tonne

Technologies Developed in the Last 8 Years Have Revolutionised Large Diamond Recoveries

“If you can liberate it and you can see it, you can recover it at almost any stage of the process”

2nd Stage: Crushing and Processing

  • Objective:
    • Reduce water and power use, increase efficiency and reduce diamond breakage
  • Crushing (kimberlites)
    • Crushing technology: reduce diamond breakage by correct crusher selection (Kawasaki crushers)
    • Autogenous milling: increase diamond liberation which increases grade and revenue
  • Processing
    • Waste sorting: Near infrared and Optical Sorters
    • XRT: Large diamond recovery: -32mm particle size 50 tph, +32 mm to 55 mm particle size 100 tph
  • Effects
    • INCREASE in washing efficiency
    • DECREASE in waste
    • INCREASE in diamond liberation
    • INCREASE in diamond recovery
    • INCREASE in grade and revenue
    • DECREASE in capital expenditure

3rd Stage:  Enhanced Diamond Recovery

  • Objective  
    • To increase recovery efficiency
  • Process
    • X-ray and XRT technology- can be tailored to needs
    • Single particle sorters
    • Security technology: access to diamonds, diamond controls, “hands-off”
  • Effects
    • INCREASE in diamond recovery and revenues

Sampling plant - 2tph (West Coast, SA)

Mobile plant : Alexkor - 30tph (West Coast, SA)

SETTING UP A TRIAL MINING OPERATION

30 Ton-per-hour Mobile Plant Layout

1. DMS only no pre-concentration

2. Front-end: screening and scrubbing

3. Mobile-wheel or skid mounted

4. Capital: R10 million to R20 million

SETTING UP A HARD-ROCK MINING OPERATION

300 Ton-per-hour Kimberlite Treatment Plant

Crushing and screening – re-circulating load

Jet pumps from DMS to final recovery. XRT Large stones

XRT reduces DMS capacity

Capex: R350-R400 million

AUTOGENOUS MILLING, WASTE SORTING AND X-RAY RECOVERY

Removal of waste and diamond liberation

Ghagoo Autogenous Milling

100 Tph XRT Machine Between Secondary Crusher and DMS – Replaces Coarse DMS

High Frequency Wet Screening at 300 Microns

APPLICATION OF X-RAY AND XRT TECHNOLOGY FOR RECOVERY OF LARGE DIAMONDS

Removal of waste and diamond liberation

XRT Replace DMS

New High-Capacity X-ray Sorters: 2tph per Machine

Containerised XRT: 50 tph – Sort Large Fraction