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By V. V. Getman, V. A. Chanturiya, T. N. Matveeva

Most of the Au and PGM ores in Russia are characterised by a thin mineral impregnation of noble metals in sulfide minerals, and a large variety of mineral forms that lead to high loss of precious metals with fine fractions during flotation. In modern flotation technology, the rational choice of reagents is one of the main trends for selective separation of minerals and effective metals recovery. New data on the selectivity of the thermo-sensitive polymer with specific functional groups (TMPPh) as a flocculant and collector of Au and Pt fine fractions are available. The selective modified collector (DEDTCm) for the recovery of Au and Pt from complex ores is discussed in this paper. Scanning electronic microscopy (SEAM), laser SIM and AFM microscopy, UV and IR spectroscopy were applied to study the adsorbed layer of new reagents on the mineral surface. Flotation tests of TMPPh on the gold-bearing ore of the Olimpiada deposit showed an increase in Au extraction and Au content in the concentrate of the rougher flotation. Using a combination of reagents TMPPh and ButX, the quality of the Au and Pt concentrates increased in 1.7 time with an increase in recovery up to 15 % compared with the traditional reagent mode. Testing of TMPPh polymers in flotation of Pt-Cu-Ni ore at Norilsk Nickel has shown the ability to obtain a concentrate with a higher Pt content. Recovery of platinum is 17% higher than recovery in an experiment without polymer. Application of DEDTCm helped to achieve higher technological parameters in flotation of lowgrade Rt-Cu-Ni ore. Compared to the basic mode Pt recovery was plus 13%, Pd recovery was plus 9% and the content of precious metals in the rougher flotation concentrate increased in 2,5 - 4 times. The studies have been supported by Grants of the President of RF “Scientific School of Academician V.A. Chanturiya” NSh-220.2012.5, NSh-748.2014.5. Keywords: Au and Pt complex ores, flotation, flocculation, thermo-sensitive polymer TMPPh, modified collector

Jan 1, 2020

Exxaro installed their first ultra fines treatment plant at Leeuwpan Coal mine. The plant is now fully operational and results already show that the plant has great potential. The plant was designed and installed by DRA. Several challenges were faced during the installation due to the space constraints in the Leeuwpan plant. Efficiency tests were conducted on both modules after commissioning and showed very promising results. A lower ash product with a higher yield can be produced with the fine coal dense medium cyclones compared to the spirals previously employed.

Jan 1, 2010

By А. А. Vasiliev, Y. G. Seredkin, А. V. Aksenov, А. Y. Senchenko

Refractory gold-containing concentrates usually contain gold enclosed in sulphides as well as in rock-forming minerals. Another difficulty is that gold often occurs as very fine inclusions of several micrometres, and even smaller than 1 micrometre, or can be part of the mineral composition at the structure level. Processing of such concentrates is a challenge. Ultrafine grinding and further oxidation are applied for gold liberation. The paper deals with the results from the study of gold deportment using Qemscan, and atmospheric oxidation testwork involving Albion Process™ on a gold-containing concentrate with a high content of refractory gold in sulphides and gangue minerals. Albion process testing was performed at Institute TOMS with the participation of Glencore Technology Pty Ltd (Australia). Additionally, conventional cyanidation testwork was carried out for the concentrate processing. As an alternative technology of gold liberation, oxidising roasting with arsenic stabilisation was used. The results from the study make it possible to assess the efficiency of the above-mentioned methods of gold liberation, and applicability of Albion technology to recover gold from the refractory concentrate. Key words: Gold, refractory concentrate, Albion Process, atmospheric oxidation, oxidising roasting, leaching

Jan 1, 2020

1. Book reviews Mining and metallurgical practices in Australasia. Melbourne, Australian Institute of Mining and Metallurgy, 1981. $40 (incl. surface postage). Reviewer: M. G. Atmore Coal mine ground control, by Syd. S. Peng. 1978. Reviewer: C. F. Engelbrecht Sixth Annual International Conference on Coal Gasification, Liquefaction and Conversion to Electricity, July 31 -August 2, 1979. Pittsburgh, School of Engineering of the University of Pittsburgh, 1980. Reviewer: S. T. J. van Rensburg This book is a useful general reference volume on the topics covered provided a great deal of technical detail is not required from it. It consists of 29 papers, which are arranged under 6 headings. Flotation agents and processes. Technology and applications, edited by M. W. Ranney. Park Ridge, D.S.A., 1980. $48. Reviewer: R. P. King 2. New books Project control manual, by Sven R. Red. 250 pp. in loose-leaf binder. U.S. Al47. (Obtainable from the author at Bray Studios, Windsor Road, Windsor SL45 UG, England.) Manganese deposits, by Supriya Roy. London, Academic Press, 1981. 400 pp. Joint preparation for welding (set of overhead-projector transparencies). Abington (England), The Welding Institute, 1980. £34 per set. Electron micrographs of clay minerals, by T. Sudo,S. Shimoda, R. Yotsumoto, and S. Aita. Amsterdam, Elsevier, 1980. 228 pp. Dfl.150. Weld pool chemistry and metallurgy. Abington (England), The Welding Institute, 1980. 357 pp. $27. 3. New journal ...being known as Gliickauf + Translation, at an annual subscription of 396 DM for 24 issues per year. It is available from Verlag Gliickauf GmbR, D-4300 Essen I, P.O. Box 103945, Federal Republic of Germany. 4. Canadian MRI publications During 1980 the Mineral Policy Sector introduced a new series of reports identified by the prefix MRI. These cover internal studies and analytical works on a wide variety of subjects, that for one reason or another, do not reach the publication stream of the regular series yet may be of interest to readers in this 'unpublished form'. Twenty-four such titles are listed below. Exploration planning A series of professional advancement seminars for the mineral industry is to be held at Rhodes University from 12th to 20th August, 1981. The series, entitled 'Economic Guidelines for Exploration Planning', will be conducted by Professor B. W. Mackenzie, and the attendance will be limited to 30 participants. The seminars are intended Seminar on Geostatistics A seminar for mining executives on Geostatistics and Decision Making in the Mining Industry is to be held in Toronto from 23rd to 25th September, 1981. v

Jan 1, 1981

By R. W. O. Kersten

"The aim was to investigate stable pillar design procedures currently in use on chrome and platinum mines, subject them to a critical appraisal, and review some of the alternatives proposed in the literature. It is concluded that these pillar design methodologies suffer from drawbacks that can be detrimental to the mining industry and that an improvement is essential.It was decided that the increased availability of analytical models and failure criteria could be exploited to update the empirical to an analytical/empirical method. The proposed methodology adopted FLAC2D simulations using the Hoek-Brown failure criterion to calculate full stress-deformation curves for typical pillars. The mine stiffness concept was introduced to determine the pillar load, integrating the influence of the pillar and strata stiffness and mining geometry.The proposed methodology was calibrated by comparing experimental and predicted deformations and failure depth of pillars in one hard-rock mine. The conclusion was that the methodology is an improvement over the one currently in use. An improved factor of safety is given by the intersection point of curves for the stiffness of the system and the pillar strength. IntroductionThe paper describes part of the findings of a PhD thesis (Kersten, 2016) on an alternative stable pillar design methodology. This publication contains sufficient information to implement the method for further interpretation and testing. A detailed comparison of measured and predicted data is dealt with in the thesis, and the results show that there is promise in the methodology.The design of stable pillars in mining is of fundamental importance, not only in the Bushveld Complex mines but throughout the mining industry. Wherever mining occurs, pillars are formed at some stage and it is essential to predict their behaviour, i.e. whether they will burst, yield, or remain stable. Although of crucial importance, pillar design still suffers from major shortcomings and weaknesses."

May 1, 2019

By Mike Rogers

Platinum production in Southern Africa amounted to 80% of world production in 2005with a small increase from 5 117 000 ounces to 5 275 000 ounces. For the seventh consecutive year the platinum market is on course to record a moderate deficit in supply. This is reflected in the price increase from a trading range US$860 to US$880 in June 2005 to an excess of US$1 200 in September 2006. Southern Africa, with its extensive platinum reserves, will continue to be the dominant platinum producer and has a number of new mines in an advanced stage of planning. The slogan ?Platinum Surges Ahead? was selected to describe the exciting and vibrantnature of all aspects of platinum mining, beneficiation and marketing. This conference will cover these aspects from exploration and orebody delineation, through mine design, development and operation to mine closure; mineral beneficiation, marketing and compliance with the Mining Charter will also be subjects for discussion and debate. It is also anticipated that the issue of overall increases in productivity, through the introduction of technology, will demonstrate Southern Africa?s status as a premier mining district. It is my pleasure to welcome delegates from abroad and locally, on behalf of the SAIMM, to the Second International Platinum Conference ?Platinum Surges Ahead?. I trust that you will find the proceedings informative and value adding and will participate in the discussions and debate in order to obtain maximum benefit from the conference. I am sure that the post-conference tours will be interesting and of great benefit to participants. Finally, a big word of thanks to the members of the Organising Committee, the management and staff of the SAIMM, and to our willing sponsors, without all of whom this conference would not have been possible.

Jan 1, 2006

By C. C. Pretorius, S. Ramjee, R. J. Mostert

The study investigates the effect of prior corrosive exposure on crack growth resistance behaviour of thin sheet (3 mm thick) aluminium alloy 2024-T3 at slow strain rates. Compact tension specimens were exposed to standard corrosive environments that simulate accelerated atmospheric corrosion attack. Two corrosive environments were considered – an exfoliation corrosion (EXCO) solution and a 3.5 wt% sodium chloride solution. The unloading compliance R-curves of the two-hour EXCO-exposed specimens revealed a significant degradation of approximately 11% in the crack growth resistance behaviour (Kc_e values) compared to the baseline (air-exposed) values. Furthermore, secondary intergranular crack formation was also revealed in the plastic zone ahead of, and adjacent to, the crack tip of these specimens; which formed during the crack growth resistance loading. It is postulated that the observed degradation of the Kc_e values of the EXCO-exposed material is due to hydrogen embrittlement since the exposure times for the EXCO evaluation were limited to ensure that uniform corrosion dominated; that is, significant penetration of corrosion damage and pitting due to localized corrosive attack did not occur. The sodium chloride-exposed specimens revealed a similar degradation (13%) after 24 hours exposure. However, slight intergranular corrosive attack and isolated pitting were observed on the exposed surfaces prior to crack growth resistance loading, resulting in notch effects that could assist in crack growth. Pitting and intergranular corrosion were, however, not observed at the pre-crack tip. The relative contributions of the notch effects and the hydrogen embrittlement during the degradation of the KR performance are, therefore, unclear.

Apr 1, 2021

By Mark Dangerfield

[Power-Point Presentation]

Jan 1, 2005

By E. Garab, M. Pillalamarry, E. Develo

"Recent geological exploration at Rosh Pinah mine revealed that the mine’s major production is shifting towards the western orefield, which will increase the demand for air flow to be supplied to this area. A snapshot of the ventilation survey carried out in December 2014 at the western orefield drill drive B (WOF-DDRB) showed that the air flow was well below the required standards. In order to improve the existing conditions, possible options were considered and simulated using Ventsim™ software.The best option found was to replace the existing western orefield fans with the larger fans from the inactive southern orefield workings, to increase the air flow in the DDRB district. Simulation showed that as much as 20 m3/s of air can be received at the working faces of WOF 30, compared to the previously received amount of 1.37 m3/s. The economic analysis indicated that the above option can reduce the ventilation cost by N$1.9 million annually. It was also noticed that after implementing this option together with other projects, the ventilation conditions in the mine were greatly improved and currently give no cause for concern. IntroductionA good mine ventilation system should be capable of providing adequate quantity and quality of air to all working faces, and is critical to the occupational health, safety, and comfort of underground employees (Luxbacher and Ramani, 1977; Exikis and Kapageridis, 2006). No ventilation system can remain adequate indefinitely; as the mine workings are extended, the ventilation characteristics such as system pressures, air volumes, leakages, and airway resistances change considerably. Continuous improvement of the ventilation system is needed to ensure compliance with health and safety regulations (Lovejoy, 2010). It also ensures that the right quality and quantity of air is delivered to all the necessary areas at the lowest possible cost. This can be achieved by identifying inefficient airways and poorly ventilated areas in the mine and planning how best to upgrade them.The latest geological exploration shows that the focus of production at Rosh Pinah mine is shifting towards the western orefield (WOF). As mining progressed, the working areas have advanced away from the main fans, which increased the resistance to air flow drastically and resulted in increasing demands being imposed on the main fan in order to supply an adequate air flow. This process also created more leakage paths between the fan and the working areas, which has caused the air to short-circuit before it can reach the faces. Consequently, a much larger quantity of air has to be circulated by the fan so that the stipulated quantity reaches the face, which increases operating costs (Singh et al., 2004)."

Jan 1, 2016

By M. S. Shishvan, J. Sattarvand, R. S. H. Meij

Navigating miners during an evacuation using a smart evacuation technology can significantly decrease the evacuation time of an underground mine in case of an emergency. This paper presents a mathematical programming model to calculate the most efficient escape path for each miner as a critical component of the smart evacuation technology. In this model, the total evacuation distance of the crew is minimised and scenarios with blocked pathways, and stamina categories for the miners are simulated. It was found that all the tested scenarios are technically feasible. Using the feature that filters out blocked pathways has no downsides, as safer routes are calculated, and there is no penalty in the computation time. The paper also discusses the social and technical issues that need to be overcome before the algorithm can be implemented as an actual escape solution.

Sep 1, 2021

By M. E. Rossi, C. Badenhorst

Conditional bias occurs when the expected value of the true grade conditional on the estimated grade is not equal to the estimated grade. It is a quantification of how the average of estimates differs from the true value. Conditional bias is present in all resource estimates due to the unavoidable properties of kriging, and indeed all linear estimation (regression) methods. In a mining resource estimation context, the degree of conditional bias is dependent on the spacing of the conditioning data; more data leads to the expectation of less conditional bias This paper discusses conditional bias from two perspectives: 1. 2. Estimates seeking to eliminate, as much as possible, conditional bias; and Estimates that accept a larger amount of conditional bias in resource models, in order to achieve a specific outcome. The problem of conditional bias in estimation can only be fully appreciated if the objective or purpose of a resource model is understood. There are instances where conditional bias should be avoided because it is not reasonable to make decisions using estimates that are known to be wrong in expected value; for example, when making a final decision in grade control with respect to the destination of the material. In most instances in the mining resource estimation context, however, the estimated values will not be “final estimates”, but “interim estimates”, meaning that in the future more data will be obtained, and the ”interim estimate” will then be updated. In this context, the most useful resource model is an interim model that is able to predict the final model estimates, despite not having all the data available that will be collected in the future. This is the objective, for example, of a recoverable “long-term” model developed prior to operating a mine, for example at the feasibility stage. It attempts to predict the ore that a processing plant will receive, well into the future. In such cases, it can be unequivocally demonstrated that conditional bias is not only unavoidable, it is a necessity.

Sep 1, 2021

By B. Litt, D. L. Van Coller

Job evaluation and the changing wage pattern by D. L. VAN COLLER, B.A.(Cape Town), M.A., B.Litt.{Oxon.) (Visitor) This paper sets out to show how changing forces are affecting the techniques that have been used in the evaluation of Black jobs on gold mines in the Anglo American Group since the introduction of job evaluation in 1961. Initially, job evaluation was essentially a management tool designed to differentiate jobs in a limited skill spectrum and thereby permit the establishment of a 'many stepped' job ladder for Black employees to climb. With the changing wage pattern, job evaluation is becoming an industrialrelations tool aimed at recognizing the skill and effort contributed by the worker so that the pay relationships between jobs are seen to be equitable by the employees.

Jan 8, 1974

By J. C. Vreugdenburg, B. A. Dippenaar, J. Muller, T. L. de Vries

Iron ore fines are agglomerated in the sintering process to produce sinter: an important feed material for blast furnaces worldwide. A model of the iron ore sintering process has been developed with the objective of being representative of the sinter pot test, the standard laboratory process in which the behaviour of specific sinter feed mixtures is evaluated. The model aims to predict sinter quality, including chemical quality and physical strength, as well as key sinter process performance parameters such as production rate and fuel consumption rate. The model uses the finite difference method (FDM) to solve heat and mass distributions within the sinter pot over the sinter bed height and time dimensions. This method can further be used for establishing empirical relationships with measured sinter properties. Inputs into the model include the feed material physical properties, chemical compositions, and boundary conditions that vary over time. Sub-models describe relationships between applied pressure differential and gas flow rate through the bed of granulated fine ore particles, combustion of carbonaceous material, calcination of fluxes, evaporation and condensation of water, and melting and solidification. Four sinter pot tests were performed and the model predictions validated against temperatures measured at depths of 100, 230, and 420 mm. Differences between predicted and measured temperatures indicated the need for optimization of some model parameters that are uncertain. Optimization resulted in an improvement in the correlation between the predicted and measured temperatures for all tests, although an acceptable level of agreement was not achieved in all cases. Using these parameter values, reasonable agreement was found in terms of typical performance parameters for three out of the four tests.

Jan 1, 2014

By L. Xingwana

"The purpose of this study is to understand how ore loss and dilution affect the mine call factor, with the aim of subsequently improving the quality of ore mined and fed to the mill. It was necessary to know the relationship between ore mined and delivered for processing in order for the mine to operate efficiently. A review of the literature suggested the mine-to-mill integration approach as a standard intervention to address declining mine call factors. A case study was undertaken at a gold mine in the Free State on the influence of the fragment size distribution on ‘free gold’, the effect of ore loss and dilution on the mill efficiency, and time tracking of ore movement from source to the plant. The study revealed that fragmentation, underground accumulation of ore, and dilution have a significant influence on the mine call factor and mine output. It was difficult to quantify the total ore loss due to the time lag between mining and milling, which is extremely variable, when estimating the mine process inventory. However, it was possible to estimate the total dilution with some degree of precision by analysing the daily blast and head grades. It is therefore recommended that mines accept that some gold loss and dilution will always occur during blasting and transport of broken ore, and this loss must be minimized.IntroductionThe mining of high gold grades is obviously very beneficial for the economic viability of an operation, but optimum recovery of the product is required to maximize profits (Chapman and Bindoff, 2010, p. 13). Although integrating these two requirements is very difficult, due to the various activities occurring between mining and processing, it is indispensable. The main driver of this integration is the impact that different ore types and characteristics have on head grade. According to Isokangas et al. (2012, p. 871), mining and processing operations involve a series of well-defined sequential stages that are complementary in an efficiently operating mine, with the performance of one operation affecting that of another. An attempt to optimize each function separately without considering the whole extraction process will not result in the optimum efficiency of the entire mine. Several researchers have developed a proven methodology for revealing these inefficiencies (Dance et al., 2006, p. 1)."

Jan 1, 2016

By N. Naude, W. P. Roux, O. Kaba

Ceramic filtration plates are used for dewatering slurries with high solid concentrations and particles in the size range of 30 μm to 150 μm. After extensive operating times, the ceramic filter plates at Minas Rio in Brazil begin to blind due to the precipitation of barium sulphate on the surface of the ceramic filter plate, which reduces the overall efficiency of the filtration process. Further research is needed to identify the barium precipitate phases on the blocked filter plates and its thermodynamic and kinetic behaviour in the system. A crystallography analysis was performed on the sample and the results showed that there are two different sets of precipitates formed on the filter plate: grey crystals which were large and scatted on the filter plate and red micro crystals that covered the entire surface of the filter plate. The red microcrystals on the sample were identified with XRD, which indicated that the sample contained barium sulphate in the mineral form barite. Experiments were conducted to determine the optimum conditions under which barium precipitation will occur. The conditions tested as a possible driving force for barium sulphate precipitation were the effect of temperature, pH and concentration. The pH and temperature ranges were pushed to both the lower and higher boundaries. The effect of temperatures as low as 15oC was studied and pH levels of 7 and upwards. The first nuclei started appearing at a pH of 7 but significant growth is promoted at higher pH levels. The X-Ray diffraction analysis confirmed the phase of the precipitates formed, and the orthorhombic crystallographic structure formed is a characteristic of barium sulphate. Keywords: Iron ore, barium sulphate, temperature, pH, concentration, morphology, and ceramic filter plate

Jan 1, 2020

By D. Hu, J. Xu, N. Liao, C. Wu, J. Ye

The vertical stirring mill’s fine grinding equipment is affected by the operating conditions during the grinding process. The grinding media has a great influence on the energy consumption and particle size distribution. This paper investigates the fine grinding performance of nano-ceramic balls and steel balls of the same weight for magnetite by a wet grinding process in a vertical stirring mill, where 15 mm nano-ceramic balls and 12 mm steel balls are used as grinding media to carry out batch grinding tests. We have observed that the newly qualified particle content of the nano-ceramic balls is higher than steel balls of the same weight at the same specific energy. The reason may be the advantage of a greater surface area and volume filling rate with the nano-ceramic balls. Moreover, the specific energy of nanoceramic balls is less than steel balls of the same weight under the same grinding fineness. In addition, energy efficiency indicates that the nano-ceramic ball has a higher energy efficiency than a steel ball of the same weight. This is due to the light bulk density of nano-ceramic balls. The application of a nanoceramic ball in a vertical stirring mill will improve iron ore grinding performance. Keywords: Steel balls, nano-ceramic balls, vertical stirring mills, fine grinding, particle size distribution, energy consumption

Jan 1, 2020

By K. C. Corin, M. S. Manono

The drive to reduce water usage globally has led to the mining industry reassessing its water usage - owing to past environmental degradation due to effluent discharge, tailings disposal and process water seepage into the water-table (Haggard et al., 2015). Factors such as water scarcity and environmental restrictions have created the necessity for recycling of process water in mining and other industries. Water recycling, however, causes an accumulation of ions in the process water, which may affect the strength of reagent action on the target mineral and in turn critical aspects of flotation may be impacted. Prior studies have shown that certain ions have specific effects on flotation: for example, calcium and copper have been found to enhance the adsorption of depressant onto gangue (Feng et al., 2013, Wang et al., 2016). Calcium and sulfate ions have been seen to give a higher concentrate grade than other ions present in process water (Manono et al., 2012). An increase in ion concentration will increase the mineral grade due to a decrease in entrainment (Corin et al., 2011). This study considers the impact of ion accumulation on reagent action and flotation response. Keywords: Flotation chemistry, water quality, ionic strength

Jan 1, 2020

One of the main bottlenecks in the carbon-in pulp process for the recovery qf gold is the elution procedure, which typically requires the heading of caustic cyanide eluants to high temperatures for 16 to 24 hours. The present work demonstrates that sodium sulphide solution as an alternative eluant can effect complete elution in about 4 hours at ambient temperatures. Elution efficiencies of around 100 per cent were obtained in 4 hours with a single pass of eluant containing 0,2 M Na2S and 0,4 NaOH about 10 bed-volumes of eluant The initial rate was slow over the first hour of elution, probably because the activated carbon catalysed the oxidation of sulphide to polysulphide. Elution efficiencies of around 100 per cent were also obtained in less than 4 hours during the batch elution of carbon at liquid-to-solid ratio of about 100. Lower liquid to solid ratio resulted in the re-adsorption of gold, probably owing to the oxidation of sulphide to polysulphide, with the resultant formation of gold complexes that were eluted less readily. Improved rates of elution were obtained at higher sulphide concentrations and pH values greater than about 13. Higher temperatures increased the initial elution rate, but lowered the overall extraction efficiency, probably because of the deposition of elemental gold on the carbon. Variation of the ionic strength by the addition of NaCl had no defect on the elution, which confirms that the elution mechanism in the case of sulphide is different from that when cyanide or I1)1droxide is used as the eluant. It is proposed that the elution of gold by sulphide solutions proceeds by means of an initial step that involves the reaction of polysulphide ions with the adsorbed aurocyanide speeds, forming AuCN on the carbon and thiocyanate in solution. This step is followed by the formation of poorly adsorbed complexes with sulphide ions, such as [AUS3-2]-The presence of polysulphides, whether generated in situ by the catalytic oxidation effect of activated carbon or by the addition of elemental sulphur, reduces the elution rate and efficiency dramatically. This is probably due to the formation of complexes such as AUS-3 and AUS-2 , which have a high adsorption affinity.

Jan 1, 1994

By J. F. Lupo

One of the earliest records of metal recovery by solution leaching is described by Agricola as 'juice of rock' in the 1550s. In these early years of hydrometallurgy and civil engineering, few controls and systems were employed to enhance recovery and protect the environment. Since that time, leaching (dump or heap) operations have made significant strides in increasing metal and solution recovery while protecting the environment, all goals of a sustainable operation. It is now recognized that the design and operation of modern heap leach facilities requires contributions from many fields of study, including hydrometallurgy, civil engineering, geotechnical engineering, unsaturated-flow hydrology, mine planning, geosynthetics engineering, geochemistry, process engineering, mechanical engineering, and electrical engineering. While advancements in these fields have resulted in more sustainable heap leach operations, challenges in the industry still exist. A number of heap leach operations exhibit poor or lower-than-predicted metal recovery, loss of solution flow and control within the ore heap, loss of ore heap stability under leach, failure of liner and/or solution recovery systems, and overtopping of process water ponds. A number of these issues may be the result of several compounding conditions. For example, poor metal recovery may be due to an inadequate scale-up assumption (scaling laboratory tests to field-size heaps), lack of control of the in-heap geochemical environment, changes in ore mineralogy from the original design, changes in mechanical and hydraulic properties of the ore from the original design, ore handling and pre-treatment, inadequate solution management system, and inadequate solution application. The purpose of this paper is to present and discuss issues that may affect the sustainability of a heap leach operation. Since sustainability encompasses a broad range of topics and issues, the focus of this paper will be on issues affecting metal and solution recovery, solution flow and containment, and stability of the ore heap.

Jan 1, 2012

By C. L. E. Swartz, I. J. Barker, J. H. Schubert

A dynamic simulator of the leaching and adsorption cascades of a gold plant was developed and used to compare the effect of various disturbances on the overall efficiency of the plant. These comparisons show which disturbances most critically need to be controlled to optimize plant performance. The simulator was based on an existing gold plant. Dynamic and steady-state data were collected on the plant and were used in the modeling of the process. Simple dual-rate models are used to describe the leaching and adsorption processes. Mole-balances of various species take into account the changes of concentrations in the leach, and also the movement of pulp and carbon up and down the adsorption cascade. Fluctuations in the flow rate, density, and cyanide concentration of the feed to the leach have a negative effect on the efficiency of the leach, while carbon attrition was found to be an important factor in decreasing the efficiency of the carbon-in-pulp (GIP) section. Badly regulated transfers contribute towards the decreased efficiency of the GIP section, but overflows and carbon leakage have only a limited long-term effect. Various carbon profiles and transfer schemes were studied, and the results indicated that a slightly heavier loading at the bottom of the cascade is beneficial, while the type of transfer is relatively unimportant.

Jan 1, 1993