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By Tapiwa Chenje, Victor Olivas, Peter Radziszewski

"Ore breakage and grinding media wear have always been considered and determined separately in laboratory tests. However the two processes are linked with the ore broken down in any comminution device being responsible for the majority of the steel wear experienced. The Comminution Dynamics Laboratory (CDLab) successfully developed a test methodology that can more accurately predict grinding media wear in tumbling mills than the Bond Abrasion test. This paper looks at the possible application of the abrasive wear methodology to determine breakage parameters of the same ore used in the abrasion test. Results indicate that breakage parameters comparable to t10 can be determined using the Steel Wheel Abrasion Test (SWAT), while using significantly less ore than standard breakage tests.BACKGROUNDThe Rubber Wheel Abrasion Test (RWAT) is an internationally accepted and widely used method for determining the abrasion wear behavior of materials. The abrasion wheel test was developed to primarily utilize a steel wheel (Brinell, 1921). Haworth (1949) criticized using of the steel wheel by arguing that increasing the contact area size in the steel wheel test causes a change in the wear rate with time. He suggested that the use of a rubber wheel instead eliminates this problem, leading to the adoption of the RWAT which was standardized in ASTM G65 (2004).Radziszewski (2002), however, found that the use of the Steel Wheel Abrasion Test (SWAT) was more applicable for wear testing in the mining industry for two critical reasons. Firstly, the major cause of wear in a ball mill, the most frequently used comminution device, is ball-ore-ball contact and also ball-ore-liner which both are metal-ore-metal contact. Therefore, using the steel wheel has the advantage of providing a similar abrasive environment to the one that takes place in a real ball mill. Secondly, the SWAT creates the potential of running experiments at much higher force regimes that are closer to what happens in actual mills, unlike the RWAT which is a low stress test."

Jan 1, 2011

By M. Massinaei, M. R. Yarahmadi, S. Zeidabadi, M. Oliazadeh

"Although the majority of new flotation column installations continue to be for cleaning or recleaning, an increasing number of flotation projects are specifying columns for roughing or scavenging duties. NICICO has recently installed flotation columns operating in rougher, cleaner and re-cleaner circuits at three new copper concentrators; Miduk, Sungun and Sarcheshmeh. Miduk is probably one of the unique operations that use flotation columns in a rougher circuit. The Miduk rougher circuit comprises five CISA parallel columns. The rougher concentrate constitutes 88% of final concentrate and reports to concentrate thickener. The rougher tailings are scavenged with ten 50 m3 mechanical cells. The scavenger concentrate is then reground and cleaned in three 3.2 m columns in parallel. The cleaner tailings are scavenged in six 50 m37mechanical cells. The cleaner tailings along with the rougher scavenger constitute final tailings.In Sarcheshmeh, the cleaner concentrate is re-cleaned in a column. The column tailings are sent back to the cleaning circuit and the concentrate is reported to the concentrate thickener.This paper reviews performance details of the flotation columns utilized in rougher circuits at Miduk and compares their metallurgical performances in an industrial scale with columns at cleaning circuits for copper flotation. Practical limitations for applying the flotation columns in rougher circuits will be discussed in details.INTRODUCTIONThe use of flotation columns has grown rapidly since the first successful commercial application at Mines Gaspe, where columns were used in a cleaning circuit to float molybdenite. Early applications of columns were restricted to replacing or adding final cleaning stages in existing circuits. Columns can achieve superior cleaning as compared to conventional cells due to their ability to support a large froth depth and the use of water for washing froth. Wash water travels down through the froth and crosses the pulp/froth interface, replaces the entrained particles reporting to the froth from pulp and improve the concentrate grade."

Jan 1, 2011

By Terry Keough

Contents for discussion ?Current liner technology ?Innovation of magnetic products ?Development of magnetic wear liners ?Installation and change out method ?Uses and capabilities ?Internal wear liners ?Summary Vulcanized rubber ?Many of you are familiar with using vulcanized rubber to provide wear protection on mining equipment. For years, this was the standard for most mining equipment, and mines spent a lot of money fabricating and lining steel equipment.

May 1, 2010

By R. C. Bryce

"Selbaie is located northwest of Joutel, in what is known as the fourth east-west volcanic sediment group in northwestern Quebec. The main metals produced are copper and zinc, with important contents of both silver and gold. Production comes from an open pit mine on the A-I zone and from two underground mines on the B zone and the A-2 zone. Each mine gave rise to important capital investment programs for construction and mine development, all of which were managed and staffed with company-hired, non-union personnel. Production from all sources now exceeds 7000 tonnes per day, with a workforce of540 regular employees. Of particular interest technically is the high recovery of B zone reserves underneath 40 m of overburden cover, the low-cost capital development of the A-2 zone, the computerized control of open pit mining, and the successful copper-zinc separation of the A-1 zone ore. Due to the low grades of the mineral deposits, efficiency in all aspects of the production process, is essential to the success of the operation.LocationThe Selbaie Mine is located 82 km northwest of the locality of Joutel in northwestern Quebec (Fig. 1). Access to the mine is by an all-weather road, 32 km of which is paved. A second road access to the site is via La Sarre, 134km to the southwest. Employee access, materials transport and haulage of copper and zinc concentrates take place over both of these roads."

Jan 1, 1990

By R. H. Colquhoun, A. W. Bolland, H. J. H. Pieterse

"American Barrick Resources Corporation acquired the goldstrike property in north eastern Nevada in early 1987. Since that time, the company has undertaken an extensive development program. This paper will overview the milling, autoclaving, and heap leaching facilities which are part of the $400-million Betze development plan. Gold production at the Mine has increased from 40,000 ounces per annum in 1987 to more than 500,000 ounces in 1991. And in 1992 Goldstrike will be the single largest North American gold mine when it produces 1,000,000 ounces.1. SUMMARYAmerican Barrick Resources Corporation acquired the Goldstrike property in northeastern Nevada in early 1987. Since that time, the company has undertaken an extensive development program. This paper will overview the milling, autoclaving, and heap leaching facilities which are part of the four year, $440- million Betze Development Plan. Gold production at the Goldstrike Mine has increased from 40,000 ounces per annum in 1987 to more than 500,000 ounces in 1991. In 1992, Goldstrike will be one of the largest North American gold mines, when it produces appro approximately 1,000,000 ounces.2. INTRODUCTIONAmerican Barrick Resources Corporation is in the process of developing the Betze gold deposit, located on Barrick's Goldstrike property in the Carlin area of Nevada, U.S.A.The Goldstrike Mine has 17.9 million ounces of proven and probable reserves and an additional 460,000 ounces of possible reserves. Additionally, the Purple Vein deposit, one mile north of the Mine, is expected to add at least 4 million ounces of reserves by year end 1991.The Goldstrike ore body contains both oxide and sulphide ore. The largest part of the reserves are contained in the high grade, deep sulphide ore. Mining of the sulphide ore contained in the Betze deposit involves the removal of large quantities of overlying oxide ore. Oxide ore is treated through one of the following processes:-"

Jan 1, 1992

By R. E. Whitehead

"Alkali/alumina and MgO/alumina molar ratio plots graphically portray both chemical and mineralogical changes accompanying potassic, phyllic, argillic, chloritic, and alunitic alteration of quartz monzonites and granodiorites hosting porphyry (as well as lode and greisen) ore deposits. The molar ratio plots can be used to identify different types of alteration. In most cases, the identification based on molar ratios coincides with petrographic data. In those instances where the molar ratio and petrographic identifications do not agree, the mineralogy might need to be re-examined. Hydrothermal alteration studies using trace elements could benefit from the application of complementary alkali/alumina molar ratio plots.Le diagramme des rapports molaires alkali/alumine et MgO/alumine illustre clairement les changements chimiques et minéralogiques qui accompagnent les altérations potassique, phyllique, argillique, chloritique, and alunitique des monzonites à quartz et des granodiorites encaissant les gîtes de type porphyrique, ainsi que des veines et des greisens qui leur sont associés. Les diagrammes de rapports molaires peuvent être utilisés pour identifier divers types d’altération. Dans la plupart des cas, l’identification basée sur les rapports molaires est en accord avec celle basée sur les données pétrographiques. Là ou il y a désaccord entre les rapports molaires et les données pétro-graphiques, il peut être nécessaire de réexaminer la minéralogie. Les études de l’altération hydro-thermale accompagnées d’une étude des éléments traces auraient avantage à utiliser un diagramme des rapports molaires alkali/alumine."

Jan 1, 2009

By Lloyd W. Trevoy

Titanium and zirconium heavy minerals occur in the tailings streams from processing plants which use the hot-water extraction process for recovery of bitumen from tar sand. In a research program conducted by Syncrude Canada Limited, the crude tailings stream was upgraded to produce quality zircon and titanium mineral products. To process the tailings through conventional upgrading equipment, bitumen residues must first be removed from the mineral grains. Then, by gravity separation, fines and coarse sand grains were removed and a 71% heavy minerals concentrate was prepared which was further separated by high-tension equipment into zircon and titanium minerals concentrates. The zircon concentrate was upgraded by gravity, magnetic and high-tension cleaning to produce a high-quality 98% zircon product. The titanium minerals concentrate was separated into rutile, leucoxene and ilmenite fractions. Heavy minerals distribution in tar sand drilling core samples has been evaluated for various locations on Syncrude Lease 17, and expected annual production levels of heavy minerals have been estimated. A preliminary evaluation has been made of the potential for zircon, leucoxene and rutile production and for further upgrading of ilmenite and leucoxene to synthetic rutile for titanium dioxide pigment production.

Jan 1, 1978

By R. Tipman, T. C. Burnett

"A general computer program has been written to calculate material balances using multiple regression techniques. The program can handle metal assays or size distribution data obtained in multiple surveys of the flotation circuit. The ""best fit"" weight split is calculated between the input and product streams by minimizing the sum of squares of the residual errors using all of the available data. The program includes an assay adjustment feature in which each assay is recalculated to fit the ""best fit"" mass balance. Thus assay or sampling errors can be easily identified. Also the assays can be statistically weighted so the most precise measurements are given the most influence on the material balance. The computer output reports the mass balance, the actual and corrected assays, the percent metal recoveries and the significance and confidence levels for the weight splits.The program enables a rapid and accurate evaluation of mass balances from large masses of data obtained in multiple surveys around a flotation circuit. The effects of changing process variables can be quickly evaluated with statistical confidence."

Jan 1, 1978

By Tim Hughes, A. H. (Sandy) Gray, Jennifer Abols

"The selective recovery of gold and silver from solutions containing other metals such as copper is possible using AuRIX®100 resin in conjunction with the Gekko Resin Column. Selectivity is driven by controlling the solution pH, which enables activities such as loading copper, gold and silver and then selectively stripping copper before gold and silver. Alternatively gold and silver can be loaded and the copper left in solution. The selective loading of gold while reducing the silver loading has also been demonstrated opening the possibility of producing high grade gold doré from high grade silver pregnant leach solutions. This paper reviews the AuRIX®100 resin and Gekko Resin Column Technologies, discusses the uses of AuRIX®100 in the recovery of gold and silver and the chemistry relating to several projects for which AuRIX®100 is being tested.INTRODUCTIONGekko SystemsGekko Systems specializes in the design, development and distribution of innovative mineral processing equipment and systems with a particular focus on gravity separation for the gold and diamond industries. The company, which has been around since 1996, has five main products: the InLine Pressure Jig, the InLine Spinner, the InLine Leach Reactor (ILR), Gekko Resin Column and Modular Systems.The InLine Leach Reactor is an intensive cyanidation reactor that uses high cyanide (0.5 – 2 % NaCN) and high oxidant (20 ppm dissolved oxygen as O2 or hydrogen peroxide) to dissolve gold from medium and high-grade gravity or flotation concentrates. The ILR, which typically replaces a shaking table in the gold room, is available in both batch and continuous models. There are 42 installations worldwide. Further details on this technology can be found in papers written by Gray et al (2003) and Longley, McCallum and Katsikaros (2003). By replacing a shaking table with an ILR, the overall gravity and plant recoveries can be increased significantly. Other advantages include reduced security risks, lower operating costs, reduced operator involvement due to the automatic process and increased safety for gold room operators."

Jan 1, 2006

By Jr. Blanchette, Claude Bazin, Paul Blatter

"Reporting of the gold production during a month implies to estimate the mass of gold that is processed by a mill, recovered as dorés, lost to the tailings and the change of gold inventory within the plant equipments. Carbon in pulp and/or carbon in leach tanks may contain gold inventory as large as 72 000 g (2 200 troy oz) of gold which needs to be estimated from measurements obtained from sampling the material contained in a tank. Sampling and analysis introduce measurement errors that could be systematic and/or random. This paper examines the effect of measurement errors on the estimation of the gold inventory and on the variation of the inventory in the carbon in leach tanks of the Agnico-Eagle Mines Limited Lapa concentrator. Results of the analysis demonstrate that the inventory is measured with ±10% reproducibility, while the variation of inventory used for mass balance is known with ±300% reproducibility.INTRODUCTIONThe preparation of a production report implies to reconcile measured data with the constraint of material balance over the considered period of production. The sampling and data reconciliation problems were recently reviewed by Morrison (2008) and Jansen (2009a; 2009b). Typically a production report is prepared to cover a period over which the mass conservation hypothesis can be considered valid. In gold processing plants, the change of inventory can seldom be neglected and plays a significant role in material balance calculations. This is particularly true for circuits using carbon adsorption, where the complete cycle of carbon is measured in days.In a 2000 t/d gold ore processing plant, the inventory can be as large as 140 000 g of gold in gravity concentrator bins, carbon in pulp tanks and in the electrolysis circuit. This is equivalent to the mass of gold that fed the circuit during 10 days of operation with 7 g/t feed assays. The change of inventory may therefore strongly impact the production figures and especially the plant recovery at the end of a week or a month. Despite the financial impact associated with gold inventory, few publications are devoted to the subject. Bruington (1991) and Morrison (2008) discussed the problem and stressed the need for the development of reliable methods to estimate the gold inventory in carbon in pulp or carbon in leach circuits."

Jan 1, 2011

By Todd Smith, Brigitte Lacouture, Greg Anderson, David Lin

"The lead and zinc flotation circuits at Red Dog Mine are preceded by a preflotation circuit which recovers naturally-floating organic carbon contained in the ore. Organic carbon is a potential contaminant in the lead concentrate and is detrimental to lead-zinc selectivity. Prior to 2007, the Red Dog preflotation circuit consisted of a single stage bank of tank cells which floated the organic carbon. The preflotation concentrate was discarded directly to tailings, however, this stream contained significant amounts of lead and zinc. Zinc loss to preflotation ranged from 2% to 6%, relative to the zinc in the mill feed and was proportional to the amount of organic carbon in the ore. The main mechanism of the zinc loss was entrainment.Pilot plant and modeling testwork were conducted to examine the use of a Jameson Cell to clean the preflotation concentrate. Results indicated that up to 90% of the zinc deporting to preflotation concentrate could be returned to the flotation circuit for recovery. The installation of a 5.4 m Ø Jameson Cell with 18 downcomers was initiated in June 2006. The new preflotation cleaning circuit was commissioned in March 2007. Conservatively, preflotation cleaning has resulted in zinc and lead absolute recovery gains of 1.0% and 1.5%, respectively. The $9.1M project has a payback period of approximately 1 year at current metal prices.INTRODUCTIONRed Dog Preflotation CircuitRed Dog Mine is located above the Arctic Circle in northwest Alaska. It is the world’s largest zinc concentrate producer with a production rate of more than 1.0M t/yr. Red Dog is operated by Teck Cominco Alaska Incorporated under an operating agreement with the Northwest Alaska Native Association (NANA). Due to the remote location of the mine, it is accessible only by air, or seasonally, by ocean-going barges.The Red Dog deposit is a rich sedimentary exhalative (sedex) zinc-lead-silver deposit. The major sulphides, in decreasing order of abundance, are sphalerite, pyrite, galena and marcasite. Due to the complex nature of the ore body, run-of-mine ore is blended in stockpiles before being crushed and processed through the concentrator. The average mill feed grade for 2006 was 6.1% lead, 20.6% zinc, 8.0% iron and 0.67 % organic carbon."

Jan 1, 2008

By Buse Florian

This paper presents the specific features of the large-scale production and transportation systems (LSPTS), describing the main notions and characteristics of the LSPTS elements. A methodologically unitary approach of the formulation, formalization and solution of the problems regarding the planning of the LSPTS structure development is offered, based on the system description by the aggregation-decomposition method, as weil as on the complex of interreloted models for the planning optimization. The paper describes the characteristics of the complex of dynamic models for investments, utilized in solving the planning problems of the LSPTS structure development.

Oct 1, 2009

By P. K. Naik, B. Das

Flotation studies were carried out to recover carbon values from blast furnace flue dust containing ~30.34% carbon, 4.6% volatile matter (VM), and 65.03% ash. The variables chosen for the experiments were dispersant (sodium hexametaphosphate), pH, collector (diesel oil), and frother (MIBC). The experiments were designed according to a 24 full factorial design method and regression equations for the recovery of carbon and product grade were determined from the data. Experiments were performed to optimize recovery and grade using the steepest ascent method. The maximum recovery of carbon was 90.0% with a concentration of 56.5%, whereas the maximum obtainable grade of carbon was 66.35% with 50.45% recovery.

Jan 1, 2005

By J. P. Sancho, L. F. Verdeja, J. I. Verdeja

"This paper analyzes the present state of the different processes competing to keep their market shares within the future iron and steel business sector.The continuous transformations in the steel making process are also studied here. These transformations have happened especially during the two last decades obviously favouring steel price, properties, quality and environmental compatibility in the new millennium. IntroductionIn the early 1980s, world steel production reached a historic figure; specifically in 1982, the amount was 645 Mt (Verdeja et al., 1993). This might have been one of the reasons why the United States, Japan and the European Community drew up a declaration of principles after which the leading industries and sectors in the following century’s development would be: advanced materials, also known by the very diffuse term of new materials; information technologies; and biotechnology (Eager, 1998).On the threshold of the 21st century, it can be inferred that information technologies (computers and telecommunications) have progressed spectacularly. Nevertheless, there have been downsides too; technology develops so quickly that after a few months the products are obsolete. Environmental problems may also appear in a few years due to storing so many useless devices. At the same time, the achievements of biotechnology did not meet the optimistic forecasts made in the early 1980s.On the other hand, it is also curious that some solutions for the environmental problems generated by star technologies of the new millennium, such as computers and biotechnology, are closely linked to the iron and steel industry. For example, blast furnaces in Germany and Japan are prepared for burning residua by introducing polymer materials from computers and other electronic prepared devices through their tuyeres, while cement tube furnaces can destroy any organic residua from different origins."

Jan 1, 2002

By T. C. Cheng, G. P. Demopoulos

It is the object of this paper to discuss various options for improving the hematite process in terms of increased throughput hence lower capital cost and production of saleable quality hematite. With reference to increasing the throughput of the process, it has now been determined via the analysis of Akita Zinc Co's continuous industrial autoclave performance data that the process kinetics is limited by the rate of the hydrolytic precipitation reaction. By correlating the hydrolytic precipitation rate to supersaturation ratio, it is shown that accelerated kinetics can be achieved via the following measures: (1) in-situ neutralization with addition of zinc calcine; (2) elevation of temperature; and (3) dilution of feed; of which, the first one was retained for further evaluation. According to presented estimates, addition of calcine, amounting to only 2.6% of the total zinc calcine processed, can allow for shortening the retention time by at least 50%. Such drastic shortening of retention time may be either used to increase the throughput of a given autoclave circuit or alternatively to release autoclave capacity for clean hematite production. Hydrothermal treatment of the crude hematite product proved effective in producing clean hematite as according to laboratory tests, hence allowing the sulphur content of hematite to be reduced from around 4% to less than 1%. A conceptual flowsheet incorporating in-situ neutralization for accelerated kinetics with hydrothermal upgrading of crude hematite without sacrificing production capacity and with minimum upset of the plant's water balance is described.

Jan 1, 2004

By K. H. B. Wenzl

"Since the autumn of 1973, the world's attention was captured by the startling revelation that conventional energy supplies were not inexhaustible but were in fact quickly dwindling with future shortages imminent until lagging exploration and technology yielded additional energy sources to catch up with the spiralling increase in demand. This situation was precipitated by the Arab Oil Embargo and the resulting soaring cost of world crude oil.During the past few years there has been tremendous activity in the energy field which has had a direct impact on the Inca Metals Company Ontario Division operations. The company's reaction has been to establish an energy management program which will be described later in the paper. First, a brief description of the Inca Metals Company and the primary energy resources which are utilized will assist in putting the program into perspective.The Inca Metals Company, a unit of Inca Limited, is responsible for the production and sale of primary metals products worldwide. The company's operations in the Sudbury District include mines, ore concentrating plants, a Smelter, Nickel and Copper Refineries and an Iron Ore Recovery Plant. The Ontario Division also has a mine and concentrating plant in Shebandowan near Thunder Bay, and a metals refinery at Port Colborne. Inca is the largest producer of nickel in the non-communist world and is also a major producer of copper and platnium group metals."

Jan 1, 1978

By M. J. Allan

"The paper describes the author's experiences in the startup of autogenous and semiautogenous grinding circuits gained over the last twenty years on both large and small grinding circuits. Typical phases in commissioning from construction to startup with ore are covered. The paper also describes experiences with material handling systems, slurry pumping, vibrating screens, trommel screens and pebbles crushing systems. INTRODUCTIONThe commissioning of any new mineral processing plant is an important and exciting milestone in any project. It is at this point in time that the efforts of developers, design engineers, equipment suppliers and operators culminate in a finished product. The successful completion of any project requires that the plant achieve design throughput as quickly as possible. The success of any startup can generally be anticipated by the amount of careful planning which takes place before equipment is operated. The first part of this paper describes the steps in going from construction through to introduction of ore. The organization and planning of startup activities is also covered.The second part of this paper describes some typical problem areas and past experiences in the startup of semi-autogenous grinding circuits. Semi-autogenous grinding circuits present some special challenges in the startup phase. The description of some of these problems and experiences will hopefully provide other operators with suggestions on how to avoid (or at least prepare for) these problems."

Jan 1, 1992

By Jan W. Merks

"The settlements between mines and smelters are based on the mass of metal contained in concentrate lots. The mass of contained metal is a function of the wet mass of a lot, and its moisture content and metal grade while the variance of the mass of contained metal is a function of the same variables and their variances. Uncertainties in the measurement procedure applied to estimate each variable are quantified in terms of precision and bias. The absence of bias and an acceptable degree of precision are the keys to effective risk analysis and loss control.ISO Technical Committee 183-Copper, Lead and Zinc Sulfide Concentrates, has developed standard methods for sampling and weighing, estimating precision and testing for bias, the determination of mass loss on drying, the calculation of the mass of contained metal and its variance, and various analytical methods for major and minor metals. The variance for wet mass is calculated from the precision of the scale while the total variances of moisture and grade are estimated from pairs of interpenetrating primary samples. The variance of contained metal can be calculated either from mine data or from smelter data but the risk associated with the settlement is largely determined by the absence or presence of bias and the variance of differences between exchange assays.ISO/TC 183 does not deal with precision and bias for exchange assays but is developing guidelines to determine realistic splitting limits. Given that the exchange of assays between mines and smelters accounts for a large part of the risk associated with the settlement, precision and bias for exchange assays should be measured and monitored. The need for umpire services can be reduced by applying statistical quality control (SQC).Calibrating static scales, moisture balances and analytical balances, bias testing of sampling methods and sample preparation procedures, estimating the variance of a single variable or the variance of a function that a set of variables defines, and monitoring precision and bias for exchange assays, are the quintessence of metrology, the science of measurement, when applied in mining and metallurgy."

Jan 1, 1995

By Andrea M. Ouchi

A major focus of ground control research presently being conducted by the Geomechanics Group in the University of British Columbia Mining Engineering Department is to incorporate weak rock masses (RMR76 less than 50) into existing empirical design relationships. An emphasis is being placed upon the updated span design curve/critical span graph originally developed at UBC. The original database has been augmented by mapping of one mine in Montana and of several mines within the Carlin and Getchell Trends of Nevada. In addition, a neural network analysis has been performed and modifications of the span design curves at the lower RMR76 range have been made. The common factor in all the above mentioned mines is a weak back and/or walls. In most cases, the ore zone is the weakest rock unit and must be dealt with to safely extract the mineral bearing rock. This work attempts to provide rock mechanic tools that will enable a mine operator to make economic decisions that will also ensure a safe working environment.

May 1, 2004

By James Anstey

BHP Billiton?s Cannington facility is a mining and minerals processing plant near Mt. Isa in Central Queensland, Australia, producing silver, lead and zinc. Mine ore is processed in a concentrator, which consists of grinding, flotation, thickening and filtration. Grinding is carried out in a fully autogenous (AG) mill. The mill operates in closed circuit with a pebble crusher. Throughput is approximately 380 tph. Cyclone overflow from the grinding circuit is fed into a flotation circuit for the recovery of lead, zinc and silver. Two concentrates are produced (lead and zinc), which are then thickened and filtered. The filtered concentrate is transported by road to a rail receiving station. From here the concentrate is railed to port in Townsville for shipment to the smelter. Matrikon and Engineers at BHP Billiton?s Cannington Mine have used ProcessACT to develop a flexible, nonlinear dynamic simulator for the grinding circuit to further enhance process understanding, as well to investigate various optimization strategies. An online charge volume estimator was also developed for the AG mill to aid in the understanding of overload conditions, which for the previous two months had been the primary contributor to downtime. The models were developed using a combination of first-principles modeling along with input-output dynamic responses. Examples of models used include: Morrell ?C? model for power and charge shoulder/toe angle prediction; Whiten?s mixing model for breakage and hold-up; Nageswararao cyclone model for predicting cut size; slurry recovery and water recovery. The composite model simulates system dynamics starting from the stockpile reclaim system and finishing at the feed for the flotation process. The objective was to provide a tool that assisted Cannington in understanding their Grinding Circuit and allowed them to develop and evaluate circuit optimization strategies. BHP Billiton Cannington Mine is now considering development of a Grinding Circuit Optimizer utilizing the models developed for the simulator.

Apr 1, 2005