By:Miningreview

 Mineral processing, a cornerstone of the mining industry, is evolving rapidly with the advancement of new technologies aimed at maximising efficiency, reducing environmental impact, and ensuring economic viability. Africa, rich in mineral resources, is at the heart of this transformation. As the global demand for metals like gold, copper, and graphite grows, the continent’s mining sector focuses on adopting cutting-edge innovations to improve recovery rates, enhance productivity, and optimise sustainable practices.

Africa’s abundant mineral resources, from gold to platinum group metals, copper, graphite, and rare earth elements, require advanced processing technologies to unlock their full potential. Traditional mineral processing methods, while effective, face limitations in terms of recovery rates, energy consumption, and environmental sustainability.

Today’s mining companies face increasing pressures to improve operational efficiency, reduce water consumption, minimise waste, and comply with stringent environmental regulations. Technological advancements in screening, dewatering, and fine particle separation are critical for modern mineral processing.

Derrick Corporation, a global leader in fine separation screening technology, has played a pivotal role in driving these advancements across Africa.

Revolutionising high-capacity screening

One of Derrick Corporation’s most significant contributions to mineral processing in Africa is the SuperStack technology, a high-capacity screening system. The SuperStack is designed to handle the demands of large-scale mining operations, offering increased capacity without compromising efficiency or performance.

It features up to eight screening decks, compared to the industry standard two to four decks, effectively doubling or tripling screening capacity within the same footprint. This innovative design allows mining operations to process more material at a faster rate, improving throughput and reducing bottlenecks in processing circuits.

The SuperStack has been successfully deployed in multiple African mining operations, offering solutions for both wet and dry applications. Due to its versatility, the SuperStack technology has been deployed across the continent in various projects. For instance, at a Namibian Gold Mine, Derrick replaced a cyclone cluster with four 5-Deck units nearly seven years ago, which significantly improved the efficiency of closing the milling circuit.

An additional set of four 5-Deck screens has been ordered, reflecting the continued success of this installation. In a phosphate application near Cape Town, South Africa, Derrick supplied four 8-Deck units in 2021 for milling circuit closure, a successful deployment positioning Derrick as the preferred supplier for their upcoming project in Congo, which will be double the size of the South African operation.

This success has been mirrored at a Liberian iron ore project, where Derrick supplied 27 8-Deck units in 2023 to protect Reflux Classifiers. This installation, currently being commissioned, marks another milestone in the application of Derrick’s advanced screening solutions for iron ore processing.

Addressing water scarcity challenge

Water scarcity is one of the most pressing challenges for mining operations across Africa. In arid and semi-arid regions, water-intensive mineral processing techniques place significant stress on local water resources, creating environmental and operational challenges.

To address this issue, Derrick Corporation’s dry screening technology has emerged as a game-changing solution for African mining operations, offering a water- free alternative to traditional wet screening methods. Dry screening technology is designed to separate materials based on particle size without water.

This is especially beneficial in regions where water is scarce, or mining operations must meet stringent environmental regulations regarding water usage and waste management. One of the most remarkable examples of Derrick’s dry screening technology success is in Mauritania, where 60 single-deck dry screens were installed, back in 1984.

Remarkably, these machines are still in operation 40 years later, a testament to Derrick’s reliability and durability. At a new Mauritanian project, Derrick has positioned itself as the preferred supplier for an upcoming project, having submitted a bid for 18 5X14 Dry Screens, with an expected PO around mid-2025. Meanwhile, a third project, also in Mauritania, is scheduled for late 2025, where Derrick is set to supply 88 Dry Screens.

Overcoming the challenges of carbon management in gold processing

Another major innovation driving success in Africa’s mineral processing sector is Derrick Corporation’s G-Vault interstage screens, LMS, and Trilogy Surface Technology. These technologies have proven particularly effective in addressing the challenges of carbon management, a critical issue in gold processing circuits.

In traditional gold recovery processes, carbon management plays a vital role in separating gold from cyanide solutions in carbon-in-pulp (CIP) and carbon-in-leach (CIL) systems. High-viscosity solutions and frequent carbon changes can cause operational inefficiencies, increasing both the cost of production and the time required to recover gold.

The G-Vault interstage screen, with its smaller and tapered openings, reduces carbon consumption and provides improved flow rates. The technology’s robust design minimises the risk of screen blinding, ensuring uninterrupted operation even under the most challenging conditions.

By embracing innovation and adopting advanced screening and processing systems, African mining companies can unlock more value from their resources, reduce costs, and improve their environmental performance.

Future expansion and technological innovation

As Africa’s mining sector grows, so does the need for innovative technologies to improve productivity while minimising environmental impact. Looking ahead, the continued evolution of mineral processing technologies will be critical in shaping the future of mining in Africa.

Projects like the Phosphate expansion in Congo and the upcoming partnerships in Mauritania’s iron ore sector showcase the potential for further growth, with Derrick Corporation poised to remain at the forefront of this technological revolution.

Derrick’s technologies address key challenges such as throughput limitations, carbon management, and water scarcity, helping African mining operators achieve higher recovery rates, lower operational costs, and improved environmental performance. As the continent continues to develop its mining sector, these innovations will be instrumental in driving sustainable growth and unlocking Africa’s full mineral potential.