Search Documents

By Mario E. Rossi

The full economic evaluation of a mining project requires a block model that provides an estimate of the tons and grades of available resources. The model must be representative of the mineralization to be found at the time of mining for specified extraction periods and within acceptable error margins. In an operating mine, there may be a reasonable understanding and estimates of actual dilution and ore loss. This paper discusses the issue from the perspective of a project at a feasibility or preproduction level of development. Three types of dilution are discussed. Internal dilution (or change of support) is function of the spatial distribution of the mineralization and its relation to the operation?s selectivity. Geologic contact dilution is the unavoidable mixture at contacts or boundaries of material with different geologic characteristics, grades, or metallurgical performance. Operational planned and unplanned dilution should also be considered, sometimes incorporated by factoring the resource model, but more accurately by mimicking the grade control process. The resource estimation process always carries uncertainty, which is sometimes significant, and usually caused by several factors. These include quantity and quality of drill hole information; quantity and quality of geologic data; grade estimation methodology; dilution and mining recovery factors applied; etc. A key decision is to whether estimate as accurately as possible the in-situ geologic resource or to estimate the tons and grade of the material to be fed to the processing plant. The geologic modeling and grade estimation methods used are conditioned by this decision.

May 1, 2009

By Weng Fu, James Vaughan, Stefan Lakemond

Uranium bearing copper sulphide flotation concentrates produced from iron oxide copper gold uranium (IOCG–U) ore contains radionuclides such as 238U, 230Th, 210Pb, 226Ra, 210Po, which have the potential to reduce their marketability, thus posing a challenge to the industry. Thus, a two–stage leach process has been proposed in this study. In first stage, a sulphuric acid leach process effectively dissolve most of the 238U and 230Th into solution, but other radionulclides (mainly 210Pb, 226Ra and 210Po) remain associated with copper sulphide minerals owing to their low solubilities in sulphuric acid solution. In the second leaching stage, the use of methanesulfonic acid (MSA, CH3SO3H) is investigated to selectively dissolve the 210Pb, 226Ra and 210Po from the residue of the first stage. The results indicate that 96% of 238U, 87% of 230Th, 90% of 210Pb, 86% of 226Ra and 17% of 210Po are dissolved using 3 mol/L MSA solution at 90°C for 3 hours, which represents a dramatic decrease in the radioactivity of the copper concentrate. INTRODUCTION Australia is host to one of the largest iron oxide copper–gold–uranium (IOCG–U) deposits in the world. Most of the value in these deposits is associated with copper. In mineral processing, the gangue minerals are separated from copper sulphide minerals that report to a copper flotation concentrate. However, due to the strong association of uranium with copper minerals and hematite, even clean copper concentrates can contain significant amounts of uranium (238U) and its radioactive decay elements, of which thorium (230Th), radium (226Ra), lead (210Pb), and polonium (210Po) are the long life radionuclides. These hazardous radionuclides negatively affect the marketability of the copper concentrates. Customer copper smelters in China, Japan and Europe may consider the radionuclides penalty elements or may not be able to process the feed. Therefore, there is a strong motivation to remove radionuclides from copper concentrates at the mine site before shipping to custom smelters in global market. Hydrometallurgical leaching has been widely employed to remove radionuclides from different kinds of minerals such as copper concentrates (Ragozzini & Sparrow, 1987), zircon concentrates (Aral, Sparrow, McDonald, & Norgate, 2007), and coal ash (Lei, Qi, Sun, Xu, & Wang, 2014). Leaching using sulphuric acid (H2SO4) solutions is the most widely used process for the extraction of uranium from uranium ores due to the relatively low cost and wide availability of the acid (Bhargava et al., 2015; Gilligan & Nikoloski, 2015). The leach process involves treating ground ore slurry with sulphuric acid at elevated temperatures (typically 60–90 °C) under oxidising conditions in order to convert the uranium in the minerals 2+ from the relatively insoluble tetravalent form (UO2) into water–soluble hexavalent state (UO2), which then complexes with SO42- and forms UO2(SO4)22- in solution. The uranium oxidation is generally carried out in the presence of ferric ion (Fe3+), regardless of the reagent and oxidant used. The most commonly used oxidants for uranium include sodium chlorate, pyrolusite and oxygen (Ring, 1980). These oxidants act indirectly by converting ferrous sulphate, formed by the oxidation reaction of UO2 in slurries, into ferric sulphate. The presence of Fe–containing gangue minerals such as hematite in the ore usually provides sufficient Fe required for the oxidation of UO2. After sulphuric acid leaching, the locked thorium (230Th), radium (226Ra), lead (210Pb), and polonium (210Po) elements are chemically liberated from hematite and uranium mineral grains (Ciobanu, Wade, Cook, Schmidt Mumm, & Giles, 2013). However, the extraction rate of radium (226Ra), lead (210Pb), and polonium (210Po) in sulphate solution is very low due to the limited solubilities of (Ra, Pb, Po)SO4 (Bagnall & Freeman, 1956; Liu & Papangelakis, 2006; Nikitin & Tolmachev, 1933).

Jan 1, 2019

By R. V. Typliski, G. J. Labarre

"Hudson Bay Mining and Smelting Co., Limited, Flin Flon, Manitoba, Canada, has developed a metallurgical wastewater treatment system employing two-stage lime neutralization, sludge recirculation and conventional mechanical thickening.Laboratory investigations, initiated in 1970, led to the construction of a pilot-scale minewater treatment plant, at Schist Lake Mine, in early 1971. This plant, treating 600 cubic meters/day wastewater containing 30-60 mg/l zinc, demonstrated metal extraction efficiencies of 99% under normal operating conditions.On the basis of this pilot work, a second pilot-scale treatment system was established in 1975 at the Flin Flon metallurgical plant to treat zinc refinery process waste water. Through numerous improvements, including automatic control equipment, the system has evolved to a full-scale operation capable of treating 800 cubic meters/ day wastewater containing 4-11 gm/l zinc. Treated effluent contains 0.2-20 mgll zinc. Hydroxide sludge produced returns to the metallurgical process for recovery of metals while clarified effluent discharges to waste.With the system, Hudson Bay Mining has achieved its original goal: the reduction of environmental contamination, while realizing ii return from metal recovery."

Jan 1, 1980

By J. Schick, V. Granger

Nowadays, all French former uranium mining sites are remediated and redeveloped. If needed, mining waters containing radium have to be treated before discharged into the environment. Classical radium treatment consists in a (Ba,Ra)SO4 salt precipitation and radium monitoring was carried out using a time-consuming analysis called emanometry. Three zeolite samples have been tested to remove 226Ra from mining water. In batch experiment, radium was totally (R=100%) and quickly removed after 2 minutes contact time. Continuous sorption experiments were carried out through a vertical column at lab scale. Chabazite is the most efficient zeolite with an 226Ra activity below 0.2 Bq/L until 60000 Bed Volume. Chabazite is always efficient although radium content in material reaches 150 Bq/g. 226Ra uptake was also tested at semi-industrial scale on a pilot plant. More than 3000 m3 were successfully treated with a radium content below 0.1 Bq/L. The environmental impact assessment of Ra-chabazite was characterized by using batch leaching tests made according to the NF EN 12457-2 standard as applied on all wastes. Ra-chabazite stability is excellent during this test: radium leaching is very low, less than 0.005%. A new 226Ra measurement method was developed by ICP-MS for a better analysis reactivity. This new method was carried out in a couple of minutes with a lower sample volume than emanometry. The validation was performed according to the French NF T90-210 standard for the calibration function definition, the limit of quantification, the accuracy and the interferences.

Jan 1, 2020

By L. J. Heaslip, J. M. Toguri, T. R. Meadowcroft, R. L. Addinall

"""Pilot Plant Operations"" is a final-year core course given to the Metallurgy and Materials Science students at the University of Toronto. This course involves a laboratory study of an industrial project at an industrial site. Details of this program are discussed and reviewed after eight years of experience. IntroductionEducators in the field of Metallurgy and Materials Science have long agreed that ""hands-on"" experience is an important component in the education of metallurgical engineers. This philosophy is reflected in the undergraduate curricula of most metallurgical schools. The major problems encountered with laboratory-associated courses are the requirements for equipment, space and funds for both purchase and maintenance of equipment. For example, consider an exercise in crushing and grinding treatment in a mineral processing laboratory. Such operations require the handling of tons of material and often equipment of large size. The problems of storage of ore, methods of handling and maintenance of equipment are a few of the concerns facing the department. Considering that metallurgical departments at universities are, in general, relatively small, the support to purchase and maintain largescale equipment becomes an annual budgetary concern. In reality, universities today are not geared to operate mini-pilot plant equipment, either in terms of space or personnel.For the above reasons, in 1972an undergraduate core course called ""Pilot Plant Operations"" was introduced to the fourth year curriculum in Metallurgy and Materials Science at the University of Toronto. This course consists of I to 2 full weeks (8 hrs per day) of pilot plant laboratory study at an industrial site on a project of mutual interest with the industrial organization whose facility is being used. The first 5 years of the program were carried out at the pilot plant facility at the Ontario Research Foundation; Stelco's Research Centre in Burlington, Ontario, was used for the last 3 years. The nature of the projects undertaken during the 8-year period is shown in Table 1."

Jan 1, 1980

By Mohamed Ourriban, Yongjun Peng, Qi Liu, Denis Cotnoir

"In the flotation of fine particles, there are two difficulties in general: low recovery of valuable minerals and high recovery of gangue minerals. The low recovery of fine valuable minerals is attributed to low bubble-particle collision and attachment efficiencies, while high recovery of fine gangue minerals is attributed to mechanical entrainment through water films between gas bubbles. Over the last five years COREM has been actively developing fine particle flotation techniques with the objective of improving fine particle flotation separation efficiencies.The fine particle flotation techniques with both generation of micro bubbles and enlargement of sizes of fine particles have been developed to increase bubble-particle collision efficiency. For oxidized fine sulphide minerals, both physical and chemical techniques have been developed to modify the hydrophilic surfaces and therefore increase bubble-particle attachment efficiency. To reduce mechanical entrainment of fine gangue minerals, a new approach, polymeric depression and flocculation, has been developed. By selecting the high molecular weight polymeric depressants to make fine gangue minerals hydrophilic and also enlarge their sizes, entrainment can be minimized. By combining these techniques, we are able to improve both flotation recovery and selectivity in some fine ore flotation systems.INTRODUCTIONWith depleting mineral resources and their declining grades, ores leaving grinding circuit for froth flotation are becoming increasingly finer to achieve mineral liberation. Together with the increasing demand for minerals, ever-increasing tonnages of fines are being produced. Therefore, flotation of fine particles is an immense challenge to be tackled by researchers all over the world today."

Jan 1, 2006

By René Lefebvre

Numerical simulations of the physicochemical processes related to acid rock drainage (ARD) in the Sugar Shack South rock pile of the Questa Mine were performed with the TOUGH AMD simulator. The objectives were to 1) identify the main processes responsible for observed present-day conditions, 2) provide an estimate of gas phase humidity transfer, and 3) give a preliminary indication of the potential impact of closure involving the installation of an alluvial soil cover. Modeling results indicated that the mine rock geometry (thin layers placed along steep mountain slopes) favors the onset of strong thermal air convection. Simulations also indicate that resloping the piles would not significantly reduce convection and oxidation. For simulation purposes, a potential cover with the permeability range of a local alluvium was investigated and found to be of questionable effectiveness since its permeability can exceed the value of 3x10-13 m2 required to prevent thermal air convection and reduce ARD.

Nov 1, 2002

By A. T. Robles, L. Buckingham

"When certain gold ores containing pyrite, graphite, humates and fumates or other organic compounds which are possibly adsorbed on clay minerals are treated with aqueous solution of alkali metal cyanide, the aurocyanide complex which forms is adsorbed by these ""pregrobbing"" species in the ore. Dissolution of gold proceeds until chemical equilibrium is attained between the cyanide complex adsorbed by the ore and in solution.Sodium lauryl sulfate (SLS) may be used to decrease the adsorptive activity of the prerobbing species in the ore. It has successfully improved recovery at Holt-McDermott Mine and is highly biodegradable.INTRODUCTION Precious metal-bearing ores containing preg-robbing species are poorly amenable to standard cyanidation techniques. The ""preg-robbing"" impurities with which they are associated tend to adsorb the gold cyanide complexes and carry them through the circuit to the tailings. Also, gold may be associated with these impurities in the ore and not be leached by the cyanide complexing agents used in conventional cyanidation techniques.Methods for dealing with the problem of preg-robbinq impurities in gold ores are:Carbon-in-Leach (CIL), in which granular activated carbon is added to compete with preg-robbing species for the gold cyanide complexes. This process can improve gold recovery in mildly preg-robbing ores especially when fine carbons with very high activities are used. However, with severely graphitic ore, the carbon associated with the rock may outperform the granular activated charcoal.Chemical Oxidation, in which the ore is subjected to preliminary chemical oxidation techniques to oxidize carbonaceous materials using such diverse reagents including ozone, sodium hypochlorite, calcium hypochlorite, chlorine gas, permanganates, perchlorates, chlorates and oxygen prior to subjecting the oxidized ore to standard cyanidation treatment to extract gold. This is generally a costly method and will not prove economical on a low-grade ore."

Jan 1, 1992

By V. Lakshmanan, Dan Mackie, J. Melnbardis

"Crystalline Flake Graphite is a strategic mineral. Since 1954 nearly all North American consumption has been imported from offshore. The Bouthillier Project in Quebec, Canada, is Orrwell Energy's bid to enter the market, with plans to begin production of a 500 TPD operation in 1984.Milling of flake graphite is considered easy, yet more problems have been encountered in flowsheet and plant design than in most other minerals. A fresh approach to existing technology was taken, giving results that are highly satisfactory. The key to graphite liberation without flake deterioration is found to be in autogeneous grinding. In addition to producing marketable coarse graphite by such autogeneous grinding, flotation and tabling, super purity fines can be produced using repeated regrinding, elutriation and flotation. This paper discusses the design of a 500 TPD plant based upon the results obtained from bench and pilot plant studies. INTROOUCTIONWhen the Black Oonald mine at Calabogie Ontario ceased production in 1954 nearly all North American crystalline flake graphite had to be imported from offshore. Orebodies in the United States were too small or too low in grade to be exploited economically.The Houthillier Township near Mont Laurier in Quebec (Figure 1) was a known graphite-bearing area The Orrwell property in that area was delineated in 1957 Some test work including minor footage of diamond drilling was carried out by Italia Copper and the MHM Syndicate prior to 1981 when Orrwell acquired the property"

Jan 1, 1984

By J. Lovering, M. Allan

"INTRODUCTIONThe Afton Mines property is located 180 air miles east-northeast of Vancouver and nine miles west of Kamloops, a city of 60,000 people in south central British Columbia. The deposit is located adjacent to the Trans-Canada Highway at an elevation of 2,231 feet above sea level.Interest in the property dates back to 1898, when a 330 foot shaft was sunk on the Pothook claim immediately south of the existing operations. Since that time many companies and individuals have investigated the possibilities of the area but it was not until 1972 that Afton Mines Ltd. located a significant zone of copper mineralization. The feasibility study was completed in the period 1974-1975, by Teck Corporation Ltd., who control Afton through 50% direct ownership and 65% ownership of Isa Mines, who own a further 23%. Construction began in March, 1976. Ore production started in August, 1977, and the first ore was fed to the mill on December 8. This was the third mine to be brought into operation by Teck since 1975, the others being Newfoundland Zinc and Niobec.The orebody is a porphyry copper deposit which has undergone supergene alteration. It is 1,700 feet long in a west-northwest by east-southeast direction, 300 feet wide and dips at 55° to the south. The mineralization in the supergene zone, which accounts for two-thirds of the known deposit, is rather unusual in that the copper is present primarily as native copper and chalcocite. The grade is one percent with the distribution: 70% native, 25% chalcocite, and 5% chalcopyrite with bornite, covellite, and cuprite."

Jan 1, 1979

By J. S. Roberts

"Campbell mines has been in operation since 1948. Part of the process consists of roasting of a flotation concentrate which contains arsenopyrite.At present operation level the milling rate averages about 850 t.p.d. and about 48 t.p.d. of concentrate is roasted. The gas emissions at present contain between 3 and 3.5 t.p.d. of arsenic trioxide, about2 - 2.5 t.p.d. of particulate matter and between 19 - 25 t.p.d. of sulphur dioxide. The particulate is extremely fine calcine dust and it assays about 4 oz. Of gold per ton.Until 1974 the gas was discharged untreated through a 125' stack.UntreatedThe decision was made in 1972 to erect a gas treatment plant, construction ran through 1973 and operation began in 1974. The cost of the installation was about 1.3 million dollars.On investigation the process technology, it was apparent that the plant operated by giant Yellowknife for the same purpose was the model we should study. I would like to acknowledge the fine cooperation we had from giant, the plant that emerged is very similar to theirs and incorporates some improvements suggested by them and based on their operating experience.The plant is designed to remove arsenic and solid dust and it has no provisions to remove sulphur dioxide.We depend upon the 125' stack to assure adequate dilution. Because of the nearby airport the stack cannot exceed 125'. A stack burner is provided that can ""y used to heat the stack gas and carry it higher into the atmosphere when there is an inversion condition.The removal of arsenic from hot gas is fairly simple. The sublimation point is about 425°f, a few degrees above this point the arsenic is a gas and a few degrees below it condenses into a solid form. The arsenic could have been removed by simply dropping the temperature below the condensation point and collecting all the solids in a baghouse. This would have removed the possibility of recovering the gold in the calcine dust and would have produced an impure and more bulky arsenic material to be placed in safe storage. The decision was made to collect the solid dust in a hot electrostatic precipitator operating above the sublimation point and subsequently lower the temperature below the condensation point and collect the arsenic in a baghouse."

Jan 1, 1976

By Dave Bulled, Chris Bennett, Glenn Kosick, Glenn Dobby

"Mining companies around the world are embracing geometallurgical modeling at a rapid rate, as senior executives realize that inputs must be properly measured if the output is to be managed effectively. Geometallurgical modeling is used to scientifically manage risk in project evaluation, for plant design and production forecasting, and optimization of production planning and mineral processing/metallurgical unit operations. The technology also provides a solid foundation for implementing broad corporate strategies with respect to intelligent asset utilization and metal sales. Over the past five years, MinnovEX Technologies Inc. has been actively engaged in developing, promoting and applying geometallurgical modeling technology for major mining companies around the world. This paper describes the methodology for successfully applying the technology for the unit operations of comminution and flotation in the mining industry.INTRODUCTIONGeometallurgical modeling (referred hereon as geomet modeling), in theory, can be applied to its full potential on all unit operations in mineral processing; however, this paper will concentrate on two of the largest unit operations, namely comminution and flotation, where the technology is actually being practiced by many large mining companies. For concept studies and prefeasibility studies, aspects of geometallurgical technology are regularly applied but in a less rigorous manner than for final feasibility studies where justification for funds is sought. This paper will focus on the final feasibility stage of a project and on existing operations or planned expansions, where the full power of geometallurgical technology is brought to bear in a cost effective manner.One of the unique aspects of geomet modeling, when used to its potential, is the ability to design plants, and forecast and plan production with a quantifiable degree of precision, something that was unattainable in the past. This means that when new comminution and flotation plants are designed, the mining companies and financial institutions involved in the project can measure the precision of the design and therefore better understand and manage project risk. It means that for existing and new operations, metal sales personnel can carry out their sales strategies with a much better understanding of the degree of error associated with production forecasts of concentrate/metal and quality of concentrates. For mine and mill managers, geomet modeling allows the effect of the mine plan on the downstream processes to be quantified; thereby allowing the mine plan to be recast in a more optimized manner. Finally, existing concentrator personnel can optimize their unit operations based on a more definitive understanding"

Jan 1, 2004

By Bryan A. Bartley

"Jim Macdonald was promoted from Waterworks Engineer to Streetworks Engineer for the Wellington City Council. He thus took over the City quarry and responsibility for its performance. The crushing plant needed upgrading and he thought it would not be difficult to make a crusher to overcome a problem. If he had a longer association with the quarry industry he would have used conventional methods and equipment, so his invention arose from a fresh view of crushing.He invented the Barmac Rotopactor after observing a wear resistant chute with a lining of dead stone trapped above a piece of angle. This idea led to a rotor lined with trapped stone, rotating on a vertical spindle. In trying - a model rotor he observed the impact against a circular rill of stone in half an oil drum and thus was started a very fertile new area of developement in comminution. The writer helped in the developement and shares in the patents. Jim died in January 1982, just as the machine was becoming known and some 200 were in use in various countries. Most were working in hard rock quarries et that time but recent uses have carried the machine into the mining and mineral processing field. This paper is directed at that industry."

Jan 1, 1985

By Douglas M. Smith, G. A. Maki

"The initial development of the massive potash deposits of the prairie evaporite formation took place over a decade ending in 1970. The potash mining and refining facility near Rocanvi11e, Saskatchewan was the 1ast of ten mines to come into production during that era. This operation, known as Sylvite of Canada Ltd., was designed to produce 1. 2 million short tons per year of KCl product in granular, coarse, standard and special standard grades.In 1977 the parent company, Hudson Bay Mining and Smelting, sold the Sylvite property to the Potash Corporation of Saskatchewan. Shortly thereafter PCS slated its new Rocanville Division for a two phase program of expansion. The first phase, completed in the spring of 1979, was relatively small, involving mill debottlenecking and additional equipment in the compaction circuit and the product and ore storage areas. The second phase was a major undertaking which included additional mining equipment and a new 300 STPH milling circuit. This work was completed during the fall of 1981 and has increased the Rocanville Division's nameplate capacity to two million STPY.Thickening equipment operating in the Saskatchewan potash industry is generally situated within the main refinery building or a separate insulated and heated structure due to the harsh winter climate and the need to closely control plant brine temperatures to ensure good flotation circuit performance. Since these thickeners process large volumes of slurries, conventional basin type designs tend to be large, ranging up to 150 feet in diameter or more. As part of the general effort to minimize capital costs, the potash industry has begun investigating the use of alternate high capacity, compact thickener designs. In this regard, PCS Rocanville undertook a program in 1978 to evaluate a Lamella™ Thickener and one other type of 'High Rate' thickener* as alternatives to a conventional design for the phase two expansion project."

Jan 1, 1983

By G. M. Hughes, J. Ellis

"IntroductionHydraulics has been considered a science for thousands of years. Applications included water wheels, dam; and slice gates but today the term ""hydraulics"" commonly refers to ""power hydraulics"" in which fluid is used under controlled pressure to do work. The mining industry employee’s hydraulics in practically every aspect of its operations, on such equipment as trucks, front end loaders, LHD units, crushers and hydrostroke feeders. The many benefits of hydraulic drives such as ease of variable speed control, high power: weight ratio low envelope size of hydraulic actuators and ease of maintenance have been extensively developed in the pulp and paper, chemical, steel, and other basic industries, but until quite recently, concentrator operators have not taken advantage of the versatile methods of power transmission offered by hydraulic systems.After some preliminary testing at the Lynn Lake concentrator Sherritt Cordon Mines Limited installed several hydraulic system; at their Fox Mine concentrator to drive slurry pumps and conveyors. The systems used at Fox and the systems which will be installed at the Ruttan concentrator are briefly described in this paper. Since acceptance is based mainly on understanding a few basic principles of hydraulics system; including pumps, motors, circuitry and central methods are also presented in the paper.PRINCIPLES OF POWER HYDRAULICSBasicsHydraulic systems provide an uncomplicated, versatile means of power transmission. The basic system is quite simple. It consists of five main elements, as shown in Figure 1, which are:1. Prime Mover - generally an electric motor.2. Hydraulic Pump - fixed or variable positive displacement type such as a piston or vane p.mp which displaces a constant amount of fluid for ead1 revolution - this unit converts mechanical energy of the prime mover into fluid energy.3. Oil Reservoir - a standard tank to operate under atmospheric pressure which has a capacity of 2 - 3 times the maximum gpm outp.it of the hydraulic pump."

Jan 1, 1972

By J. A. Finch, A. R. Laplante, R. Espinosa-Gomez

"The Niobec concentrator rejects up to /5% of the Nb as slimes (-10u.m). The recovery of Nb from these slimes by column flotation is being studied. An essential condition for selective flotation is slimes dispersion. A particle size analyzer, the Sedigraph 5000D, was used to monitor dispersion in plant waters with combinations of organic and inorganic dispersants and flotation reagents. Flotation reagents were particularly detrimental to dispersion with sodium silicate. The best dispersion conditions were selected for column flotation tests. These tests revealed that reagent combination had a pronounced effect on froth stability. Careful frother selection achieved good froth stability under conditions of good dispersion. Plant water increased the required dispersant concentration causing mineral depression.IntroductionSlimes (-10 u.m) rejected at Niobec contain up to 15070 of the over-all Nb content . Recovery of Nb from these slimes would significantly increase over-all recovery. A suggested recovery route involves two phases: (1) carbonate flotation (to remove most of the carbonates) depressing silicates and pyrochlore (as currently done at Niobec); and (2) selective (direct) pyrochlore flotation from the silicates. Phase 2 has been addressed and several routes to achieve selective flotation are available. Phase I was attempted with the selective reagent scheme used at Niobec but a considerable amount of pyrochlore floated with the carbonates due to poor slimes dispersion."

Jan 1, 1987

By R. Dahlke, J. A. Finch

"A campaign was undertaken during the greater part of 2001 at Noranda’s Brunswick Mine Concentrator to investigate the role of gas (air) superficial rate distribution (Jg profile) to the cells in the final Zn cleaning stage (bank of seven cells). Three profiles were tested: Balanced (each cell with same Jg), Increasing (from cell 1 to 7), and Decreasing, along with an “as found” profile in a parallel control bank. The experimental design allowed for two confounding factors, changes in ore type and circulating load. The Increasing profile consistently gave the best metallurgy (down-the-bank grade / recovery). The reason for improved performance was traced to the response of the first few cells. The Increasing profile gave the highest selectivity of sphalerite against non-sulphide gangue (NSG) in these cells with relatively even recovery per cell down the bank (10-15% based on feed to each cell). The other profiles gave lower selectivity and higher zinc recovery in the first cells (up to 25% in cell 1), which combined to reduce overall bank performance. The increased selectivity with the Increasing profile is attributed to the low gas rate in the first cells reducing water recovery and hence limiting entrainment of NSG gangue. The Increasing profile was subsequently configured for all four stages in the zinc cleaner circuit.INTRODUCTIONThe performance of a flotation circuit is largely the result of the operator’s response to visual clues. This includes manipulation of the gas (air) input and how it is distributed to cells in a bank. A lack of sensors prescribes this approach. Over the past ten years the Mineral Processing Group at McGill University have developed a set of gas dispersion sensors including one to measure gas superficial rate (or simply “gas rate”), i.e., volumetric gas rate per unit cell crosssectional area, Jg (Gomez and Finch, 2002). The device collects bubbles in a tube immersed in the pulp and infers Jg from the pressure-time curve generated after a valve is closed and air starts to accumulate. The usual units are cm/s. It is robust, reliable and suited for plant use.A version of the Jg sensor was tested extensively during 2000 at Noranda’s Brunswick Mine Concentrator (Dahlke et al., 2001). The results were sufficiently encouraging that a sensor was fabricated to suit local requirements (Insta-Jg). The sensor detected malfunctioning field instruments and flotation mechanisms, and demonstrated that gas distribution to cells in a bank “as found” had no particular pattern, or profile. Preliminary testing suggested that a balanced profile (i.e., all cells with the same gas rate) gave superior metallurgy (grade / recovery down the bank) than the “as found” profile. This observation prompted a focused campaign to explore the impact of the gas rate (Jg) profile, introducing the notion of “gas distribution management”."

Jan 1, 2004

By Brian Flintoff

"When I was first asked to prepare this paper and presentation in late June, I thought it might be fun to ""step back and paint the bigger picture."" Having attempted to do this, fun is not the first descriptor that now comes to mind, and speaking dyslexically, I've had 'nuf.'Unlike Nostradamus, or even Orwell, I've discovered that I'm ""clairvoyantly challenged"" and not even the psychic hot-line was of much help, at least with respect to process control! I am somewhat comfortable speculating on evolutionary change, but the radical developments that will arise from revolutionary changes are well beyond my mortal capabilities. Even with evolutionary change, I'm reminded of the lessons of time series analysis which show the prediction error to grow exponentially as the horizon moves into the future. As Macluhan is reported to have said: ""Predicting the future based on the past is a little like driving your car while looking in the rearview mirror!""Having honestly presented my qualifications, allow me to try to look at process control and to offer some conjecture on where we're probably headed. In the end, it is said that: ""The plant of the future will have only two employees, a man and a dog. The dog will be there to keep the man from touching the equipment.1""IntroductionA little less than a decade ago Andy Mular and I co-edited a monograph entitled ""A Practical Guide to Process Control in the Minerals Industry."" The work was commissioned by the senior management of a consortium of Canadian mining companies, since it was widely perceived that control was an area of great economic potential, but one that had not been effectively tapped. The concern was that if the industry could not soon deliver on the ""potential"", the term may well have appeared in the epitaph of what was, to these men, a very attractive investment opportunity. I think it is fair to say that over the past few years process control has clearly established itself as an essential technology in plant operation and optimization. That isn't to say that we get it all-right, all-the-time, but, the circumstances are much different than they were. In the eyes of many, process control has attained the distinction of being considered a mature technology, even though there are still countless avenues for exploration."

Jan 1, 1998

By Glenn Clarke, Ben Holloway, Barry Lumsden

"BHP-Billiton’s Cannington mine in Northwest Queensland produces a silver-rich lead concentrate and a zinc concentrate. The plant has the capacity to treat 3.1 mta and for the year to June 2006 mean feed grade was 10.3% Pb, 461 g/t Ag and 3.7% Zn. Recovery losses of lead and silver are primarily in the fine fractions. In 2001, the plant was modified when it was determined that splitting the lead feed into two size fractions, and floating the two fractions separately increased fine lead and silver recovery. The fine lead fraction (called the split float) is 80% <16µm and about a quarter of the lead and silver is in the finest fractions. In 2006 to further improve lead and silver recovery a statistical plant trial of magnetic aggregation conditioning of the split float feed was undertaken. While pure galena is diamagnetic the Cannington galena contains iron within the galena mineral resulting in the galena having a paramagnetic, magnetic susceptibility. The trial demonstrated to greater than 98% statistical significance an increase in lead recovery, and to 99% statistical significance an increase in silver recovery, and to greater than 97% significance an increase in the lead in concentrate in the split float circuit. These economic recovery benefits with magnetic aggregation of the split float feed, has led to the incorporation of this technology in the plant.INTRODUCTIONThe BHP-Billiton owned Cannington silver, lead and zinc mine is located in the Australian state of Queensland about 800 kilometres west of the coastal city of Townsville. This is a pastoral area characterised by large cattle farms, low population density and very little infrastructure. The area has two seasons, a wet, hot summer and a dry, mild winter. Because of its isolation and lack of infrastructure the mine has always operated on a fly in fly out basis.Geological drilling defined the resource as 43.8 million tonnes grading 11.6% lead, 4.4% zinc and 538 ppm silver (Walters and Bailey, 1998). At times during its history Cannington has held the crown as the single largest lead and silver mine in the world (Torrisi and Smith 2003). Another unique characteristic of the operation’s history is the rapid progress from discovery to operation. The first drill to intersect the ore body was in 1990 and the mine and plant was commissioned in 1997."

Jan 1, 2008

By J. A. Finch, T. Weber

"Bubble size in flotation is strongly influenced by frother concentration in the pulp liquor. There is no accepted method of judging the dosage and thus how effectively frother is being distributed to control bubble size is not known. This will hamper certain plant test work where constant bubble size (e.g., when comparing reagents) is implicit. Bubble size is not easy to measure in plant and gas holdup is suggested as a surrogate in the development of a proposed “meter” to estimate frother concentration. The meter is calibrated to enable frother concentration to be estimated on samples drawn from any location in the flotation circuit. The meter and its calibration are described.As general background the action of frothers in reducing bubble size by retarding coalescence is discussed and the bubble generation systems for which the effect will be important are considered.INTRODUCTIONBubble size is an important variable in flotation. The flotation rate constant k has been related to mean bubble size Db by k % Db -n with n ranging up to 2 (Ahmed and Jameson, 1989) and even 3 (Yoon, 1993). Recent work has introduced k % Sb, the bubble surface area flux, given by Sb = 6 Jg / Db (where Jg is the superficial gas velocity or volumetric gas rate per unit cell cross-sectional area), i.e., n = 1 (Gorain et al., 1998). Regardless of the exact value of n, the significance of bubble size in flotation remains. In many plant trials it will be implicit that bubble size has not changed and attention will focus on other process variables. The measurement of bubble size, or a surrogate, would be useful addition to any test work.The size of the bubbles is influenced by several variables, gas rate, gas injection system (e.g., impeller design and rotation speed in a mechanical cell) and pulp composition (chemicals added, percent solids), but the most important is frother concentration (Harris, 1976). The frother functions by retarding coalescence (see appendix), which acts to preserve the small bubbles generated in the pulp (and permits a stable froth to form on top of the pulp). The measurement of bubble size is thus related to measuring frother concentration. The distribution of frother and whether sufficient (to control bubble size) is reaching the intended parts of the circuit then become important considerations. At present there is no simple way to judge frother concentration in a plant. In this communication we introduce a possible methodology, a “frother concentration meter”."

Jan 1, 2003