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By David Eichenberg

A154S A154N After 3 Years of Mining ?Current mining Level A154S 280RL ?110 Vertical metres of A154S ?Current mining Level A154N 300RL ?100 Vertical metres of A154N ?Variations in Kimberlite Volume ?Ore Types and Plant Production

May 1, 2006

By P. Mageau-Béland, È. -M. Proulx, M. -C. Patoine

Over the past six decades, Hatch has helped several industrial processing facilities in debottlenecking their operations, allowing them to produce more with the same equipment, to reduce and even eliminate expenditure investments, or to increase the return value of their expansion projects. These successes result from the application of a proven analysis approach that can be applied to any industrial facility. A five-stage methodology is discussed and demonstrated with a specific example of a nickel concentrator optimization study. The first stage is an observation stage which allows to meet key actors at the plant, develop mutual understanding of problems, understand operating philosophy, and efficiently collect large amounts of operating and maintenance data. Following is a data compilation stage during which data is analyzed over a representative time period to identify parameters that significantly affect the production, to evaluate data reliability and to define the focus of the upcoming analysis. Quantitative metrics are defined using statistical tools such as pivot tables, histograms, percentiles and MDR (Maximum demonstrated production rate during 3 to 7 consecutive days). Then, the production bottlenecks are identified by a thorough analysis of the facility’s control philosophy, process throughput, equipment capacity, availability, downtime causes, and interaction between components of each circuit. Understanding the maintenance practices and frequency of planned shutdown is also critical to this analysis. Opportunities for improvement are identified in collaboration with the operation, maintenance and engineering teams, ranked as a function of their impact on the bottlenecks and prioritized. The final and most critical stage involves engagement with the plant stakeholders, namely the operators and the maintenance staff members, to present the results of the analysis and obtain their participation in the implementation of the solutions. The benefits of the case study translated into: 10% production capacity gain, improved maintenance planning and avoidance of several million dollars of investment.

Jan 1, 2016

By C. H. Ash

"The Red Chris Cu-Au deposit (522.7 Mt at 0.35% Cu and 0.27 g/t Au), northwestern British Columbia, is one of several pre-accretionary porphyry systems in the Cordillera of westernCanada. It is hosted by an Early Jurassic hornblende monzonite to quartz monzodiorite porphyry which forms part of a suite of dikes and stocks that intrude Late Triassic volcanic strata. Major and trace element chemical data suggest that these Early Jurassic intrusions have compositions which fall on the boundary between alkalic and calc-alkalic compositions. Alteration and mineralization in the Red Chris deposit are more typical of calc-alkaline porphyry systems with abundant potassic, sericitic and argillic assemblages and quartz-rich stockworks. It lacks Na- and Ca-bearing silicate assemblages which characterize the alkalic porphyry deposits of British Columbia. One of the more unusual features of the deposit is the abundance of carbonate alteration and veins which occur throughout the hydrothermal history of the deposit. This type of alteration and veining is more typical of alkalic porphyry deposits.The composition of the carbonates vary both temporally and spatially with different alteration zones. Potassic zones, which are characterized by orthoclase±albite±quartz±chalcopyrite±bor-nite±magnetite±hematite and Au/Cu ratios of 1:1 (g/t Au:% Cu), contain minor siderite veins and alteration. Quartz-sericite-carbonate (QSC) zones overprint earlier potassic alteration and comprisequartz+ankerite+sericite+pyrite+chalcopyrite with Au/Cu ratios of 0.5:1 (g/t Au:% Cu). Ankerite isthe main carbonate in this stage but has a variable composition with a more Fe-rich variety associated with mineralized veins. Localized chlorite-carbonate alteration zones, characterized by chlorite+carbonate+quartz±kaolinite±pyrite±gypsum and high Au/Cu ratios [2 to 3.5:1; (g/t Au:% Cu)],contain predominantly calcite. Late stage carbonate-gypsum veins have an ankerite to dolomite com-position which is very similar to the regional carbonate alteration and veins."

Jan 1, 1997

By J. Kang

Large-scale land reclamation has been undertaken in Singapore since the 1960s. In the early years, the fill materials excavated from the hills. In recent years, sea sand is the main source of the fill materials. The contractors used to import the sea sand from the neighbouring countries such as Indonesia. However, in early 2000, the sea sand import from Indonesia and Malaysia was banned. Cambodia, Myanmar, and Philippine therefore became the alternative sources for sea sand. Distance between the jobsite and these countries is over 1,200 km, and transporting sea sand from these areas became a critical issue that could affect the contractor?s performance. Figuring out the right combination of transportation means for a longdistance sand transportation would be challenging because of uncertain situations. We developed a stochastic simulation model, using ARENA, to figure out the right quantity of small-size barges, bulk carriers, and loading/unloading equipment, which could help project managers yield the most production for sand transportation. This paper presents how we developed the simulation model, how it was applied to figure out the optimum combination among various size barges, different bulk carriers, and various types of loading/unloading equipment, for the sand transportation project in Singapore.

Aug 1, 2013

This paper describes the results of a laboratory study on the upgrading of Algoma siderite by the amine flotation of silica and silicate gangue. The experiments indicate that a virtually complete removal of silica is possible in a rougher flotation con-ducted in tap water at natural pH, without prior desliming of the ore. Grinding considerably finer than the apparent liberation size is essential for maximum silica rejection. A cationic collector, Aeromine 3037, gave best results when used in combination with a modifier. Of the several modifiers tested, a Dutch potato dextrin, Dextrin 4356, was found to be the most effective. Both iron recovery and the grade of the final iron product are enhanced by floating the pyrite contained in the ore prior to the amine flotation of the silica, and by scalping the magnetics from the silica concentrate. F OR over twenty years, the Algoma Ore Properties Division of The Algoma Steel

Jan 1, 1963

By F. E. Goodwin

Since the last CIM Zinc and Lead Conference ten years ago, significant technical and market forces have influenced how these metals are used, and the geographic distribution of their uses. Unprecedented price fluctuations have opened competitiveness issues, while the rapid growth of the Chinese market has created challenges both inside and outside China. Recent technical developments in battery energy storage, coatings, castings and chemical applications of lead and zinc will be reviewed together with the influence of these trends on end use markets.

Jan 1, 2008

By Mari Yamamoto

Controlled thermolysis of gold(I) complex, [Au(C13H27COO)(PPh3)], at 180 °C for 5 h under an N2 atmosphere affords the new type of monodispersed spherical gold nanoparticles capped by myristate and a small amount of PPh3 ligands (average diameter 23±1.5 nm), in spite of no use of solvent, reducing agent and stabilizer. Much attention has been paid to the preparation and structure determination of transition metal nanoparticles, because of their widespread use in technological applications.1 In general, the chemical reduction of metal salts and organometallic complexes2 by the use of reducing agent is carried out to prepare gold nanoparticles. In some cases, a large amount of solvent and stabilizers such as surfactants,3 polymers4 and ligands5 are used to prevent agglomeration of particles and control the particle size. For instance, Brust et al. reported a two-phase reduction of AuCl4 - by NaBH4 in the presence of dodecanethiol as stabilizer to prepare gold nanoparticles.6 On the other hand, O?Brien et al. recently reported an one-phase preparation of gold nanoparticles by the reduction of AuCl4 - by NaBH4 in the mixture of tri-n-octylphosphine oxide and octadecylamine which act as both solvent and stabilizer, but this procedure also needs reducing agent.7

Oct 1, 2003

By C. R. Edwards

"Equity Silver Mines Limited owns and operates an open pit silver 111ine located 37 km southeast of Houston in the Omineca District of British Columbia, Figure l. The property is approximately 300 km west of Prince George and 417 km east of the Port of Prince Rupert. This is the largest silver mine in Canada and one of the five largest silver producers in the western world.Equity is a subsidiary of Placer Development Limited, which owns 70 of Equity's issued and outstanding Common Shares. Placer was responsible for financing and developing the property and now provides general management and administrative services.All mining is by open pit methods, using three 1600 P&H shovels, eight 45 t Caterpillar and three 77 t Wabco trucks, three 40R rotary drills, two D8 dozers, one 9888 front-end loader and other ancillary equipment. We are now phasing out the Southern Tail pit and bringing the Main Zone into productior; see Figure 2.Comminution in the concentrator is achieved via primary, secondary, and tertiary crushers followed by rod and ball mills. The flotation circuit, with Southern Tail ore, produces a concentrate containing between 3 000 and 6 500 g of silver per tonne, 201 copper, and 25 g of gold per tonne. Running Main Zone ore, concentrate grades will decrease to about 4 500 g of silver per tonne, 17% copper, and 18 g of gold per tonne. Design milling capacity is 5 300 tpd, which is often exceeded.The flotation concentrate contains relatively high levels of antimony and arsenic. Because of these impurities Equity was unable to obtain economically acceptable long-term sales contracts for flotation concentrate. For this reason a leaching process was developed, and a plant designed, built and placed in operation. Due to the complex and unique technology involved, many start-up problems were encountered but by March 1983 the leach plant was considered ""fully operational."" This paper describes some of our progress and problems in bringing the Equity leach plant through its start-up period."

Jan 1, 1984

By S. Ng, Peter Stapleton, Paul Mankowski, J. Spence, R. Siy

"Syncrude has developed a low energy extraction process for the recovery of bitumen from oil sand. This new process operates at a temperature of 25 °C, resulting in substantially lower energy costs and lower capital costs, especially for the thermal energy generation equipment. The process will be used in Syncrude’s Aurora Mine, which is scheduled for startup in mid 2000. The flowsheet for Low Energy Extraction includes hydraulic transport of oil sand slurry, and bitumen separation using collector and frother chemicals and air as process aids. A number of flow sheet innovations and optimizations have been included, resulting in the next generation of extraction technology. Experimental pilot plant results, engineering progress to date and areas of ongoing work will be discussed. SUMMARYThe Low Energy Extraction Process has been successfully developed for commercial implementation at Aurora. The 1996 100 tonne hour Field Pilot demonstrated that the bitumen recovery target could be met with an 11.1% grade oil sand. However, pilot plant bitumen recoveries for a lower grade oil sand were not acceptable. The subsequent flowsheet optimization study led to a new flowsheet for Low Energy Extraction, which includes a primary separation vessel, a flotation circuit for PSV middlings, and the use of middlings displacement in the PSV cone bottom with flotation underflow. A test program conducted in 1997 showed that the new flowsheet could significantly improve the bitumen recoveries for lower grade oil sands. Engineering work on process scale-up led to selection of a 30 meter diameter PSV, with a tangential feedwell. The successful development and commercialization of Low Energy Extraction for the Aurora Mine Project is a major enabling step in the Syncrude 21 program. The low energy requirements of this process allow Syncrude to develop the Aurora leases more cost effectively. The use of this process results in major capital cost savings, predominantly in the thermal energy infrastructure and also provides long term operating cost advantages for Syncrude."

Jan 1, 1999

By China University of Mining & Technology, Yuemin Zhao, Bo Zhang, Liang Dong, Zhenfu Luo, Chenlong Duan

"In China, approximately 65% of coal reserves are in the west region, where water shortage is a serious problem: high-efficiency dry coal beneficiation technology is desired. Using magnetic powder and fine coal as heavy medium, and using air as the fluidizing agent, a novel air dense medium fluidized bed separator is proposed for coal preparation. Coal can be efficiently separated according to density in the fluidized bed, where bed density is steady. The separator is highly reliable, the circulation quantity of heavy medium is low, and the gas distributor cannot be easily easily. The world’s first industrial modularized dry coal preparation plant was built by China University of Mining and Technology. Dry coal beneficiation technology was first used to produce low-ash coal. Results of industrial production show that the ash content of clean coal is 3.46%, the probable error E value is 0.055 g/cm3, and the organic efficiency is over 90%. The advantages of the modularized dry coal beneficiation system are the high separation accuracy, the simple process flow, the low operation cost, low energy consumption, and so on. This technology provides a new effective method for coal separation in acid region and coal tending to sliming.INTRODUCTIONCoal is the most important primary energy source in China, where coal output reached 3.68 billion tons in 2013 and represents approximately 68% of the primary energy consumption. Coal has made a great contribution to the development of the Chinese national economy, but it also brings serious environmental pollution. However, approximately 65% of coal reserves are in the arid west region in China where water shortages present a challenge for wet coal preparation technology. In addition, the abundant lignite resource, because it is easy to mud in the water, should not be treated with the wet separation method. Therefore, it is critical to develop highly efficient dry coal preparation technology to meet the demand in arid areas. Further, water resource shortages are a global problem, thus the development of efficient dry coal preparation technology in has potential application in other water-short countries like South Africa, Brazil, India and Turkey."

Jan 1, 2016

By Mahmood Alemrajabi, Ake Rasmuson, Kerstin Forsberg, Kivanc Korkmaz

"In the present study, the recovery of rare earth elements (REE) in the nitrophosphate process of fertilizer production is investigated. The apatite has been recovered from iron ore tailings by flotation. After digestion of apatite in concentrated nitric acid, Ca(NO3)2.4H2O is first separated by cooling crystallization and then the REEs are recovered by precipitation. Optimum conditions in these steps have been determined in a previous study. The precipitate mainly consists of CaHPO4.2H2O and REE phosphates.In the present study, selective dissolution and re-precipitation have been studied in order to obtain a precipitate that is more concentrated in REEs. The precipitate was selectively dissolved in nitric and phosphoric acid at different acidities (pH 6 to 0) with the liquid /solid ratio of 100 mL/g. It is shown that most of the CaHPO4.2H2O and other calcium containing compounds will be dissolved at pH 2 while the REE phosphates are not dissolved above a pH of approximately 2. Thus, by partial dissolution of the REE precipitate at pH 2.5 most of the solid calcium phosphates will be dissolved and the remaining solid phase, which is more concentrated in REEs, can be filtered off as a fairly concentrated REE solid mass and the liquor can be recycled back to recover more P nutrients. Alternatively, the REE enriched precipitate was dissolved completely in nitric acid and re-precipitated again by addition of ammonium hydroxide to pH 1.2. A chemical equilibrium software, MEDUSA (Puigdomenech, 2013) has been used to evaluate the experimental results and to estimate the optimum conditions for selectively dissolving the precipitate."

Jan 1, 2016

By D. Kong, A. Klyashtorin, L. McGilp, I. Wilson

This work reports on applying iron oxide coated sands media in an experimental permeable reactive barrier to remove uranium species from uranium containing water. A field experiment was conducted at the legacy Gunnar uranium mine & mill site that was abandoned in the 1960s with limited to no decommissioning. The flooded Gunnar mine pit presently contains about 3.2 million m3 of water contaminated by dissolved U (1.2 mg/l), Ra-226 (0.4 Bq/l), and minor concentrations of other contaminants (As, Se, etc.). The water is seeping over the pit rim into Lake Athabasca posing environmental and health concerns. Iron oxide coated sands can be used to immobilize uranium species through an adsorption process. Methods for preparation of hydrous ferric oxide sorbents and their supported forms onto silica sands are described. Fourier transform infrared spectroscopy (FTIR), and powder X-ray diffraction (pXRD) were used to characterize the physical-chemical properties of the sorbent. The monolayer uranium uptake capacity (Qm) was estimated through the Langmuir adsorption isotherm. Adsorption kinetic experiments were performed in a lab environment before moving to a field trial. Based on these lab results and the input on field-scale appropriate geometries, a pilot permeable reactive barrier was fabricated and a field test conducted near the Gunnar pit in June 2019. This pilot test provided technical data and information needed for designing a full-scale permeable barrier based on the iron oxide coated sands, which may be applied for in-situ water treatment at Gunnar and other legacy uranium sites.

Jan 1, 2020

By C. G. Anderson

Industrially proven and applied nitrogen species catalyzed (i.e. NSC) acidic pressure leaching has been utilized to treat a number of ores, concentrates and recycled materials. This versatile technology offers many advantages including low temperatures, low pressures, low capital costs, low operating costs, faster throughput and less costly materials of construction than conventional pressure oxidation. This paper will elucidate the application of this technology for production of gold, silver, palladium, rhodium, zinc, germanium, gallium, cobalt, copper and nickel. Recycled material applications will also be elucidated. In addition, details of an application for treatment of a refractory chalcopyrite copper and gold bearing ore will be presented and pertinent economics discussed.

Jan 1, 2004

By V. G. Papangelakis, S. Peters

Pressure oxidation of refractory gold ores can be conducted on ores with high carbonate content using just water or water with alkaline reagents to promote fast kinetics, and suppress the formation of elemental sulphur and CO2. In this work, a fundamental study was conducted to explore the silica-pyrite interaction in the presence of calcium and sodium carbonate. It was found that an alkaline environment increases the pyrite decomposition kinetics on one hand, but on the other dissolves silica, which encapsulates the dissolving pyrite thus hindering ultimately its complete decomposition.

Jan 1, 2011

By Marcel M. Djivre

The paper will outline the destructive test methods and test procedures including the evaluation criteria currently used at the Materials Testing Laboratory (MTL), Sudbury, Ontario, Canada, a laboratory approved by the Ontario Minister of Labour for the purpose of testing or examining mine shaft ropes or other hoisting appliances. For the evaluation of the mechanical properties of rope samples used in "ultra-deep" single-lift shafts, additional discard criteria used in Ontario, Quebec and South Africa shall be presented. Most of the methods and test procedures currently used at MTL can also be found in the current CSA G4-00 Standard, Steel Wire Rope for General Purpose and for Mine Hoisting and Mine Haulage, published in November 2000. In this latest or sixth edition of CSA Standard G4-00, a new Clause 14 has been added outlining the requirements for in-service destructive testing of steel wire ropes for mine hoisting applications. The CSA G4-00 Standard is also intended for the manufacturing of new ropes, and includes requirements for raw materials and construction features for round strand and flattened strand rope, and locked coil rope in bright and galvanized finish. To-date the Ontario Mining Regulations require only that destructive test of new ropes be performed in accordance with CSA Standard G4-00, but does not require conformity to the Standard, and on the other hand the inservice wire ropes are required to be tested in accordance with CSA G4 and thus require conformity. The author recommends that the Ontario Mining Regulations (and regulations of other mining jurisdictions) be improved in order to ensure quality control in the manufacturing of wire ropes destined for mines in Ontario (and Canada). Also, the author recommends the revision of the CSA G4-00 Standard by the technical committee in order to address manufacturer?s concerns with respect to compliance, and harmonize the Standard with Internationally recognized Standards.

Apr 1, 2005

By M. Barati

A collaborative research between University of Toronto and Hatch was conducted to understand and optimize the process conditions pertaining to a novel steelmaking technology. In this technology, known as CRISP, direct reduced iron is continuously melted and refined in a stationary electric arc furnace. The major challenge against continuous operation of the electric furnace was identified to be minimizing the corrosion of the refractory in order to achieve uninterrupted operation for a minimum of one year. Theoretical analysis and bench scale experiments together with two pilot runs resulted in defining an operating window for slag chemistry that would minimize chemical attack to the refractory while satisfying the oxidizing conditions required for sufficient decarburization. An analysis of the process in terms of energy consumption and emission of greenhouse gases revealed that it is superior to the current batch DRI-based steelmaking technologies.

Jan 1, 2011

By R. Salimi

Tricalcium aluminate hexahydrate (TCA) is used as filter-aid for security filtration in the Bayer alumina process. TCA is typically produced on-site by mixing Bayer liquor with slaked lime. Specific properties are required from the TCA to ensure adequate filter throughput, lifetime and importantly effective reduction of solid/colloidal impurities from the solution. The effect of reaction time on morphology and particle size distribution of tricalcium aluminate was studied for a batch experiment at simulated process conditions. It was found that reaction time plays a critical role on the morphology, crystal structure (diameter and crystallinity) and particle size distribution. In the early stages of the reaction, nucleation dominates the crystallization process followed by growth dominated by agglomeration up to a mean particle size of 10 µm. The particle morphology shifted from an irregular shape to more spherical throughout the course of the reaction.

Jan 1, 2014

By André Chagnon, Michel Malo, Benoît Dubé, Chantal Pelchat

"Abstract- In the southern Gaspé Appalachians, gold mineralization is spatially associated with the Acadian dextral strike-slip Grand Pabos-Restigouche fault system. Two different structurally-controlled gold prospects, the Lac Arsenault and the Saint-André-de-Ristigouche, are described to unravel the genesis of gold mineralization in this part of the Canadian Appalachians.At the Lac Arsenault gold prospect, gold mineralization consists of Au-As-Pb-Zn-Cu-(Ag) polymetallic fault-filled quartz veins with laminated textures emplaced in brittle-ductile sinistral X shear fractures. Mineralized veins are hosted by Middle Ordovician graywacke of the Arsenault Formation, belonging to the Dunnage Zone, the Early Paleozoic oceanic domain of the Appalachians. Terrigeneous rocks of the Arsenault are regionally metamorphosed at the lower greenshist facies and the mineralized veins are included in a zone of Fe-carbonate alteration.The Sb-Au-As mineralization of the Saint-André-de-Ristigouche gold prospect, in the southwestern Gaspé area, comprises extension veins in the extension direction emplaced in brittle conditions. Mineralized veins are hosted by calcilutite and laminated silty and argillaceous limestone of the Early Silurian part of the White Head Formation, which belongs to the Gaspé Belt, the Middle Paleozoic successor basin in the Gaspé Appalachians. Metamorphic grade of the White Head Formation in the southwestern Gaspé area is very low, but the gold mineralization is included in a zone of hydrothermal propylitic alteration which includes two Cu-skarn mineral occurrences. The Lac Arsenault gold prospect has many characteristics of "greenstone-hosted quartz-carbonate vein" deposits whereas the southwestern Gaspé area, which includes the Saint-André-de- Ristigouche gold prospect, shows affinities with the geological setting of sediment-hosted gold deposits (Carlin-like deposits). The two gold prospects are controlled by the Grand Pabos- Restigouche fault system but they were not emplaced at the same level in the crust. Acadian strikeslip fauting played a major role in their respective genesis in providing channelways for ore-bearing fluids. The recognition of the analogy of the geological setting of the southwestern Gaspé area with that of Carlin-like mineralization gives new ideas for exploration in the area and elsewhere in the Appalachians.Résumé - Dans le sud des Appalaches de la Gaspésie, on trouve des minéralisations aurifères spatialement associées au système de failles de coulissage dextre acadien de Grand Pabos-Restigouche. Deux indices très différents, Lac Arsenault et Saint-André-de-Ristigouche, sont décrits pour évaluer la genèse des minéralisations aurifères à contrôle structural de cette partie des Appalaches canadiennes. Au Lac Arsenault, la minéralisation aurifère comprend des veines polymétalliques à Au-As-Pb- Zn-Cu-(Ag) en remplissage de failles. Ces veines à texture laminaire se retrouvent dans des zones de cisaillement fragiles-ductiles senestres de type X. Les veines minéralisées sont encaissées dans les grauwackes d’âge Ordovicien moyen de la Formation d’Arsenault appartenant à la zone de Dunnage, le domaine océanique du Paléozoïque précoce des Appalaches canadiennes. Les roches terrigènes de l’Arsenault sont métamorphisées régionalement au faciès inférieur des schistes verts et les veines aurifères sont dans de larges zones d’altération dolomitique (Fe-carbonate).Dans le sud-ouest de la Gaspésie, la minéralisation à Sb-Au-As de Saint-André-de-Ristigouche est dans des veines d’extension comprises dans la direction d’extension et mises en place dans des conditions de déformation fragile. Les veines minéralisées sont encaissées dans les calcaires argileux et les calcilutites de la partie silurienne de la Formation de White Head qui appartient à la ceinture de Gaspé, le bassin successeur du Paléozoïque moyen des Appalaches de la Gaspésie. Le degré métamorphique des roches du White Head est très bas, mais"

Jan 1, 1998

By R. Hans

Removal of toxic anions from aqueous solution was studied using a Magnetic Ion Exchange (MIEX) resin which is a polyacrylic, strong base resin. Gravity based settling is made more efficient due to the magnetic nature of the resin which is advantageous over conventional ion exchange resins. In addition, the magnetic microspheres of MIEX have larger surface area in comparison to conventional ion exchange resins. Over the years MIEX has been successfully used and has gained significant popularity for efficiently removing dissolved organic matter from wastewater and groundwater. In the present study the efficiency of the MIEX resin was tested for the removal of chromium(VI), molybdenium(VI), vanadium(V) and arsenic(V) anions. Effects of pH (2-10) and temperature (25oC-55oC) were examined. In general, low solution pH values were favorable for anion uptake by MIEX. Except for chromium(VI), the metal ion uptake was significantly increased by the increase in solution temperature. The adsorption data were analysed on the basis of chemical speciation and heterogeneous kinetic models.

Jan 1, 2014

By D. Lunt

Telfer bulk concentrates typically contain 8% chalcopyrite, 8% chalcocite, 45% pyrite and 80-120 g/t gold. Although very high copper and gold recoveries can be obtained by subjecting the concentrate to a "conventional" high temperature pressure oxidation step followed by copper recovery by solvent extraction and electrowinning, and cyanidation of the leach residue for gold recovery, the cost of lime required for neutralisation and power for oxygen generation was such that the process was uneconomic in terms of operating costs. The challenge therefore was to develop an alternative flowsheet that maximised copper and gold recovery in which the reagent costs were commercially attractive. An additional objective was to reduce the capital cost so that the overall NPV and IRR values would enhance the economic viability of the total project. Following a series of batch and locked cycle testwork programs, supported by Metsim modelling, it was established that the same high levels of overall copper and gold recoveries can be obtained by use of a novel two-stage split leaching circuit in which the chalcocite component is leached in a low temperature (90-110°C) circuit with the chalcopyrite component treated in a high temperature (220-250°C) circuit. This split circuit has a number of advantages, including minimising the required capacity of the high temperature autoclave, as well as reducing the overall lime consumption and simplifying the total process water balance. The paper outlines the basis for the development of the flowsheet and discusses the integration of the leaching stages into the overall circuit.

Jan 1, 2004