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By Eugene Larochelle

The serpentine of the Eastern Townships of Quebec is more or less seamed and impregnated with chrysotile asbestos, of which we note two types: the cross-fibre and the disseminated fibre. The cross-fibre type always appears in fibres or crystals arranged parallel to one another, and disposed at right angles to the walls of the matrix serpentine. The length of fibre of these veins, which run in every conceivable direction, even crossing ?one another, varies from microscopie dimensions to three and sometimes four and even five inches. It is the principal form of asbestos found in the serpentine of Thetford Mines, Black Lake, Coleraine, and Asbestos. The disseminated-fibre type, which is the main product of the serpentine of Broughton township, in which ate located the mines at East Broughton, does not form veins, but occurs in the serpentine without any definite arrangement. There is a difference in the toughness and hardness of the rock of the two types, the Broughton serpentine being softer than that at Thetford. The disseminated-fibre section of the serpentine belt is probably more regular in its content than is the cross-fibre section. Nevertheless, it contains no 'crude,' which is the most valuable of asbestos, and the fibre is usually shorter than the cross-fibre average.

Jan 1, 1928

By M. Clotilde Apua, A. F. Mulaba-Bafubiandi

"The efficiency of hydrochloric acid (HCl) leaching of gold from low grade gold-bearing material has been investigated in the presence of sodium hypochlorite (NaOCl) to produce in situ chlorine gas which is an oxidizing agent able to oxidize gold metal to its soluble forms. The effect of concentrations of HCl, NaOCl, and mixtures of HCl + NaOCl was sought. Iron and potassium present in the feed were leached and consumed all the HCl. Gold found as inclusion in pyrite was not exposed to the lixiviant. Therefore, leaching of gold from low grade gold-bearing material in aqueous chlorine solution is not an effective process for now.INTRODUCTIONHydrometallurgy of gold is commonly based on cyanide leaching solution. Due to the environmental concerns related to cyanidation and mercury processes, and inefficiency of cyanide gold leaching to dissolve refractory ores, sustainable alternative lixiviant systems, capable of generating gold (I) and gold (III) complexes must be studied. Amongst non-cyanide gold lixiviants there is the chloride/chlorine system (Hilson and Monhemius, 2006; Senanayake, 2004; Pilsniak and Trochimczuck, 2007; Wang et al., 2007; Reeves et al., 1999; Khodadad et al., 2008).In practice, the most oxidizing agents utilized for the leaching of gold as chloride, are chlorine (Cl2) or hypochlorite (HOCl) which are either generated in situ by suitable reaction or added in solution (Adamson, 1972). The dissolution of gold concentrate using hydrochloric acid, sodium chloride and sodium hypochlorite (Cl-/HOCl system) were studied (Puvada and Murthy, 2006). The effect of NaOCl and NaCl concentrations were also investigated. The leaching was performed under the following conditions; time: 4h, solid–liquid ratio = 1:4, at room temperature. It was found that the increase of the NaOCl concentration from 25 to 75 g/L did not have any meaningful effect on the recovery of gold which was about 30% (experimental conditions; S/L ratio = 1:4, NaCl concentration: 25 g/L, HCl concentration: 0.35 M). It was also found that from 25 g/L to 200 g/L NaCl, the recovery of gold rose from 30% to 40% (experimental conditions; S/L ratio: 1:4, NaOCl concentration: 25 g/L, HCl concentration: 0.35 M)."

Jan 1, 2012

By John A. Allan

The subject chosen for this paper is not a new one, but the subject matter is so extensive that something new can always be said .about it. We are just beginning to realize how little is actually known about the character of Alberta coal, except for a few general facts. The object of this paper is not to explain that our previous information, in whole or in part, on the coal resources of Alberta, has been incorrect, but rather to present some new facts obtained as a result of recent study in the field and in the laboratory. As field investigation continues the problem of determining the character of a coal seam for any great distance laterally becomes more and more complex. Our present knowledge of Alberta coal deposits should not be discussed before due reference is made to those great pioneers who blazed the trails for later geologists, by recording their observations on the general geology of Alberta. Geologists, to-day, particularly those of us who are striving, year after year, to unravel the mysteries of stratigraphy, palaeontology, and structure, in so far as these are related to the coal resources of Alberta, fully realize our indebtedness to those three trail-makers, Dawson, McConnell, and Tyrrell. Had these geologists not recorded their observations correctly, nor interpreted the broad geological facts contained in Nature's book, with still uncut pages, how much slower would have been the progress of our coal knowledge in the succeeding years. It is true that many of the interpretations given to observations by these pioneers have had to be changed as a result of closer studies, but we must also expect that the geological interpretation from present day observations will be changed by future workers, as Nature's book is read and re-read.

Jan 1, 1925

By G. A. Davidson, P. G. Williams

"New developments in centrifugal slurry pump technology are discussed in relation to their importance for improving pump operation and reliability.Experimental data obtained by measuring the velocity of liquid flows in a slurry pump casing using Laser Doppler Velocimetry are presented. This demonstrates the importance of selecting pumps with the proper hydraulic design to provide optimum efficiency, maximum part life and minimum operating cost.The paper also discusses the use of new wear resistant materials, such as ceramic/metal composites, which can significantly improve the life of parts exposed to abrasive media. The results of laboratory attrition tests are presented. IntroductionCentrifugal slurry pumps are of primary importance for the hydro transport of abrasive and corrosive media in the mineral processing industry. As for all process equipment, slurry pumps must be carefully selected and operated to provide optimal performance. To achieve this, it is necessary to select equipment which will provide efficient and reliable operation for the specific service conditions and incorporates the best materials available to obtain maximum parts life.Abrasive wear of liquid end components is the most important aspect that distinguishes the design and application of slurry pumps from other types of pumps. It is therefore necessary to have a fundamental understanding of the mechanical interaction between pump components and the media being handled, as this will impact significantly on hydraulic design, mechanical reliability and selection of wear resistant materials. Recent advances in computational approaches'» have greatly improved the prediction of wear rates in pump casings by facilitating the solution of complex equations which describe the wear mechanisms mathematically. In conjunction with this, new experimental techniques allow researchers to measure flow fields in pump casings using non-invasive devices such as Laser Doppler velocimeters."

Jan 1, 1992

By B. D. Frater

Geometallurgy or process mineralogy is an integrated part of the scoping, pre-feasibility and feasibility phases of a project as well as an existing operation. A well planned and executed geometallurgical testwork programme during the early phases, will result in a more accurate decision making process during the selection phase. The better this integration between geological, mining and metallurgical data gathering during the early phases, the more accurate the predictions will be with regards to throughput and recovery during modelling and process and equipment selection in later phases. This will enhance and improve the mine and process scheduling and subsequent NPV. Geometallurgical information gathered during plant operation and testwork can for example be used to statistically model the pit optimisation, plant throughput and optimise the plant for certain feed material (characterised by statistical models).

Jan 1, 2017

By Gordon Nelson

The Homestake gold mine is one of the largest and oldest continuously operating gold mines in orth Ame rica. To date this mine has produced in excess of 128.000.000 tons of ore containing almost 34 million ounces of gold . Gold mine ralization is restricted to the Homestake Formation. This unit is a metamorphosed iron-formation which is enclosed by pellitic metasedime nts below (Poorman Formation) and a pellitic to qua rt zitic unit (Elli son Formation) above. The e ntire Precambrian sequence. in the Lead area. has been subjected to a multi-stage defo rmation episode which ha c reated an extremely complex structural setting for the Homestake orebodies. Metamorphic grade inc reases from greenschi st ro amphibolite in a northeast d irecti on acros the mine area. Present thickness of the Home take fo rmation va ric from O to »400 fee t. The amount of thicke ning and th inning which is attributable to tectonic deformation or original sedimenta ry di fferences is not known. Orebodies constitute onl y a small pe rcentage of the Homestake Formation and do not occur along a pa rticul ar stratigraphic pos ition within the unit. Gold i assoc iated with inc reased py rrhotite and a rsenopyrite concentrations within the iron formation. Inc reased \ cin qua rt z development and chl oritic alteration usuall y accompany this minerali zation. Local remobilizati on of mine ralization due to metamorphi sm has occurred. Homestake mine ralization has been shown to be of sy ngeneti c origin . Because no feeder zones have yet been recognized a di stal source for the mine ralization is inferred .

Jan 1, 1986

By Garth A. Maki, Douglas M. Smith

"The largest Canadian Lamella thickener installation to date, with 13,600 square feet of effective clarification area, is being successfully operated at the Rocanville Division of the Potash Corporation of Saskatchewan. This paper describes the operational principles and design features of the Lamella thickener, the testwork leading to its specification f or the Rocanville phase two expansion project and a review of the performance of the full- size unit which was ultimately installed.IntroductionThickening equipment operating in the Saskatchewan potash industry is generally situated within the main refinery building or a separate insulated an d he a ted structure due to the harsh winter climate and the need to closely control plant brine temperatures to en sure good flotation circuit performance Because these thickeners process large volumes of slurries, conventional basin-type designs tend to be large, ranging up to 46 metres 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 LamellaTM thickener and one other type of ‘High Rate' thickener as alternatives to a conventional design for the phase two expansion project.This paper describes the operational principles and design features o f the Lamella thickener (manufactured by Axel Johnson lnc.), the testwork leading to the specification of a Lamella for the Rocanville expansion project and are view of the performance of the full size unit (1486 m2 of the effective settling area) which was ultimately installed and is now successfully operating in the Rocanville plant."

Jan 1, 1983

By L. Xia, B. Hart, K. Douglas1, S. C. Chelgani

Development work to optimize a flotation flowsheet for rare earth element (REE) recovery is underway. The original approach used alkyl phosphates and phosphoric acid ester as collectors to concentrate REE minerals. To improve REE recovery, hydroxamates as alternative collectors were investigated. In this paper, micro flotation of REE minerals using salicylic, benzoyl and naphthoyl hydroxamates is reported. Unlike phosphonic collectors, slime removal does not show a significant effect on REE recovery when using hydroxamates as collectors. Among the three hydoxamates, the grade of La, Ce, and Nd for concentrates produced by salicylic hydroxamate is the highest. The recovery response with naphthoyl hydroxamate is similar to that of salicylic hydroxamate; good grades for La, Ce, and Nd, less effective for Nb, Y, and Zr. The data indicated an affinity by salicylic and naphthoyl hydroxamtes for LREE over the HREE minerals. In comparison, benzoyl hydroxamate indicated an affinity for Nb, Y, and Zr. Temperature effects on REE recovery were also studied. The grade and recovery of REEs generated by flotation using a mix of salicylic and benzoyl hydroxamates at room temperature was almost identical or even better relative to the recovery using naphthoyl hydroxamates at elevated temperature.

Jan 1, 2014

By K. R. Wood, G. W. McDonald

"The tailings disposal system at Les Mines Selbaie includes dewatering of tailings in a high-capacity thickener, followed by point discharge of the thickened solids to form a stable conical pile. Tailings water drains to ponds formed behind engineered dams, prior to either recycling f or process use or discharge to the environment. Design and economic considerations of the system are discussed. Construction, start-up and operating experiences are also presented.Introduction Les Mines Selbaie is located in the Abitibi region of northwestern Quebec, approximately 700 km north of Toronto and 150km south of James Bay. More locally, the Detour gold mine is 60 km to the west while the Noranda smelter is 220 km to the south.The deposit was discovered as a result of a Questor INPUT Mark VI geophysical survey in 1973, followed by diamond drill programs from 1974 to 1976. Three mineralized zones were delineated and underground exploration was carried out on all three. A production decision for the 'B-zone' copper-gold-silver orebody was made in July 1979. The underground operation started in July 1981, with full production of 1500 t/d being achieved in May 1982.During the planning phase, every effort was made to ensure that the operation would be environmentally sound . The design included the provisions of the then newly proposed provincial environmental guidelines. The tailings disposal system formed the most significant part of the environmental program due to the large volumes of solids and water effluent. In addition, the design allowed for future expansion of the system to accommodate mining of the other zones, thus minimizing future costs and disruptions."

Jan 1, 1986

By R. Druffel, P. Wittke-Gattermann, M. Wittke

"The two tubes of tunnel Hirschhagen along the highway A44 in Germany, underpass the federal road B7, a railway line and the valley of the river Losse close to the city of Hessisch Lichtenau. The ground in the area consists of Triassic sand- and siltstones (""Buntsandstein"") as well as tertiary clays. Prior to tunneling, the groundwater in the area is planned to be lowered by means of a gallery of deep wells. As a basis for the design of this dewatering gallery, two large pumping tests have been carried out. The results of these tests have been evaluated by means of 3D-Finite Element analyses. By means of the large-scale model, the influence of the anisotropy resulting from jointing and bedding and the influence of fault zones in the area have been taken into account, which lead to a thorough basis for the design of the dewatering gallery.INTRODUCTIONThe 4.2 km long Tunnel Hirschhagen of the highway A 44 crosses below the federal road B7, a railway line and the river Losse close to the city of Hessisch-Lichtenau in central Germany. Both tunnel tubes are located in a subrosion depression in which Triassic sandstone and tertiary clay prevail. It is planned to lower the groundwater table in the area of the meadow of the Losse prior to tunnel heading [1]. Groundwater lowering is planned to be achieved by means of a series of large pumping wells. The bottom of the river Losse will be sealed in order to avoid direct inflow of water from the river into the ground (Fig. 1 and 2)."

Jan 1, 2015

By E. Stansfield

Coal samples are sometimes taken from a wet spot in a mine, or from an open car or pile shortly after rain, and submitted for analysis in a dripping wet condition. Other samples are taken from a dry spot in the mine, or from an open car or pile after a period of dry weather. Comparison of the analyses obtained in the two cases would be absurd, although the samples might be of essentially the same coat apart from the surface moisture on the one. The analyst therefore attempts to reduce all samples to an equal basis by the operation known as air-drying. Air-drying is practised by the chemist for three reasons: (1) To make it possible to grind the coal to powder. (2) To bring the coal sample to a condition in which it will not change in weight rapidly whilst portions are being weighed out for analysis -in other words, to bring it into equilibrium with the air in the laboratory. (3) To determine the water-retaining power of the coal. Any kind of drying is satisfactory for (1); the coal should be dried more or less according to the humidity at the time in the laboratory for (2); whilst it should be always dried to the same extent for (3). In other words, no method can be satisfactory for both (2) and (3). In this paper the only question considered is (3) -that is, air-drying the coal under standard conditions so that strictly comparable results can be obtained for the water content of coals after air-drying. After a sample of wet coal is exposed, it loses moisture until it is in equilibrium with the air at the time: thus the coal will loose distinctly more water in air of 20 per cent relative humidity, for example, than it would in air of 80 per cent.

Jan 1, 1923

By A. Mellek, M. Pischtschan, M. Perrucci

ABB has received an order for one of the most challenging mill drive projects in its history. With one SAG mill and one ball mill to be added at an iron ore mine in Sweden, the customer’s plant managers wanted to have the most efficient solution for driving their mills but had the budget limitations typically faced by the majority of mining companies during periods of market downturn. To find the best balance between cost of acquisition and highest performance throughout the lifetime of the plant, ABB was selected to deploy a synchronized bypass solution, in which only one drive system is used for two different mills in series. However, being one of the first grinding mills in the world with such a solution was not the only challenge the ABB team faced: The inclusion of some mill application functions - e.g., frozen charge protection, automatic positioning and creeping mode - brought the demands on the engineers to another level. With only one frequency converter and one mill application controller available, the configuration logic and interlocks had to be meticulously designed and thoroughly tested to ensure a smooth and safe startup. The solution offers a footprint reduction and more operator flexibility at a reduced investment as each mill can be run in both directions, and wear on the mechanical components can be greatly reduced due to ABB’s premium ring-geared mill drive (RMD). This paper will describe the details of the project, the configuration developed and the tests performed to guarantee correct software functionality. Mill startup is scheduled for January 2016.

Jan 1, 2016

By Heidi Fauser

The aim of the project was the development of an electroforming process for the production of medical implants out of gold. To prove the applicability of this technology, tympanostomy tubes were chosen as demonstrators. These barbell-shaped tubes are usually produced mechanically; of silicone or, for higher therapeutic demands, of metal ? gilded silver or gilded stainless steel. Gold electroforming of the tubes as an alternative manufacturing process would reduce the expenditures for the mechanical preparation and lower the corrosion susceptibility significantly. To obtain electroformed gold tubes of the desired shape, the following steps are necessary: fabrication of a negative template by drilling holes with countersinks in an insulated aluminium sheet, electroforming process, removal of the aluminium by using a sodiumhydroxide solution. For the optimisation of the shape and surface quality of the tubes respectively the simplification of the manufacturing process, various parameters were tested, e.g. aluminium quality and sheet thickness, type of insulation layer, substrate processing, hydrodynamic conditions, type of electroforming electrolyte, electrodes position, etc. The manufactured tubes were characterised in view of thickness distribution, hardness, surface roughness and purity in comparison to mechanically produced reference tubes. From the results obtained during the project it can be concluded that electroforming processes can be easily adopted for the manufacture of medical implants. The time-consuming electroforming process is by far compensated by the simultaneous production of an arbitrary number of implants.

Oct 1, 2003

By H. W. King

"Cryogenic engineering is concerned with components and machines which operate for long periods of time at temperatures within a few degrees of absolute zero. The absence of a ductile-brittle transition is thus the prime component of the specification for a suitable low-temperature alloy. The word "" cryo"" means ""frost-forming"" , and this leads to the second component of the alloy specification, which is resistance to corrosion in humid atmospheres. Further, although most early applications of low-temperature alloys were limited to the storage or transportation of liquified gases, an increasing proportion of alternative energy storage and conversion technologies are being based on the availability of high-field superconducting solenoids. The third basic component of the specification for a low-temperature alloy is thus the absence of a low-temperature ferromagnetic transition.Although the firs t two of these components of the specification can be met by using austenitic stainless steels, many of these supposedly "" non-magnetic"" alloys have been found to undergo martensitic transformations to ferromagnetic phases at very low temperatures. In addition, steels which remain structurally stable may still exhibit other magnetic transitions, e.g. to antiferromagnetic or superparamagnetic states. The successful application of these alloys in cryogenic engineering has thus required an initial basic study of the types of magnetic transition that can occur in such concentrated solid solutions, followed by a more applied study directed at an alloy formulation which will induce beneficial magnetic states at low temperatures."

Jan 1, 1981

By Daniel L. Cluff

The Canadian mining industry needs to find viable alternatives to the conventional cemented pastefill/hydraulic methods of backfilling open stopes for underground mines located within a permafrost zone. The harsh environment and the isolated location of a mine north of 60° impose additional challenges to standard backfill methods and opportunities to the technological and operational issues related to the use of frozen fill. Underground open stoping mining methods require the placement of fill material to enable the controlled recovery of ore from secondary and tertiary stopes. The typical design of the fill material requires the specification of inert material, water and binder. The permafrost conditions provide the additional parameter of subzero temperatures for backfill design and process control. The paper presents the results of an experimental field study, using large size samples, to determine the strength capacity of frozen backfill. The experimental work was performed utilizing rockfill and tailings material with moisture content consisting of water and ice crystals. Preliminary results indicate that the mixture of rockfill, tailings and moisture, develops strength that meet the demanded requirements for open stoping. A thermal equilibrium modelling analysis is presented in the paper.

May 1, 2008

By G. Dubé, A. Leclerc, P. Quinn, G. E. Agar, J. Y. Clouthiér, J. D. McLaughlin

"Gold dissolution by cyanide requires the presence of oxygen which is usually supplied by sparging compressed air into the gold containing slurry. For those ores that contain certain obnoxious substances that consume oxygen, maintaining the required minimum level of dissolved oxygen can be troublesome. One of the most economical solutions to the problem of low dissolved oxygen, especially in plants that have air compressors installed, is to enhance the rate of oxygen mass transfer.The oxygen mass transfer rate was measured in a two phase system using two different sparger arrangements, and with addition of a frother that is known to reduce the bubble size produced by the sparger. The common sparger system was shown to be inefficient compared to a readily available but under utilized method of gas dispersion which introduces air directly below the reactor turbine. Transfer of this technology to an operating plant confirmed the beneficial effect of the improved sparger system. The addition of the frother did decrease the bubble size, but it also reduced the oxygen mass transfer rate."

Jan 1, 1993

By W. de Klerk, M. B. Thorpe

Golden Star Resources Bogoso operates in Ghana’s Western Region. The gold recovery plant includes; a flotation circuit producing a concentrate for the BIOX® process that oxidizes sulphides before a CIL circuit; and a dedicated CIL circuit. BIOX® uses bacteria, therefore water from the BIOX® and CIL plants remained separated; CN water could not be introduced into the flotation / BIOX® circuit. The operation built a process water inventory with high TDS and installed a process water treatment plant (PWTP). Water was released in compliance the permits but containing some thiocyanate. The PWTP brine was returned to the TSF, further exacerbating the TDS. The operation experienced a drought removing the traditional water sources; the team evaluated the options to maintain production - various water streams were laboratory tested provided options for water use. The paper presents the story (treatment chemistry and process chemistry) of continued operations by treating stored water and PWTP discharge water with peroxide; brine usage within the CIL circuit, which increased gold recovery (laboratory testing) and reduced the TDS. Water flows were further modified to include hydraulic tailings re-mining to a CIL circuits. Details of the recovery, basic chemistry and costs savings are provided.

Jan 1, 2014

By D. Embury

The construction and utilization of oil and gas pipelines is a vital aspect of the Canadian economy. The evolution of materials for this application can be considered as part of an evolutionary process in which the processing of the materials is linked to the design requirements of the pipeline. The evolution of both materials and designs will be considered in terms of parameters such as yield strength, work hardening characteristics including strain path changes such as the Bauschinger Effect and toughness. The final portion of the presentation will consider the possible uses of non-metallic materials, composites and 'smart 'systems in pipeline construction.

Jan 1, 2005

By D. R. Schmitt, N. Ong, R. S. Kofman

Shales and mudstones comprise about 75% of all the sedimentary rocks. In, particular, organic rich shales are considered as a petroleum source rock and more recently with the advent of hydraulic fracturing technology to be a reservoir in their own right. In this sense, the aforesaid motivates our work with laboratory measurements of elastic properties of these geologic materials, which are known to be anisotropic. As such, assuming Vertical Transverse Isotropy (VTI) symmetry, the dynamic and static moduli of a series of cores from various geological formations in Alberta, Canada are simultaneously investigated as a function of confining pressure using the ultrasonic pulse transmission method and strain gages. Dynamic moduli were obtained from ultrasonic P- and S-wave velocities measured on a prism cut with faces perpendicular, parallel and oblique to the assumed vertical axis of symmetry. Static moduli were calculated from strain-stress curves obtained along the directions perpendicular and parallel to the assumed axis of symmetry as well. Velocity measurements show that samples are highly anisotropic, but that the pressure-dependent behaviour of the wave speeds differs. VP(90°) and VSH(90°) both with layer parallel propagation and polarizations change little with pressure while VP(0°) and VS(0°) (both with layer perpendicular propagation) display significant nonlinear responses particularly at pressures < 25 MPa. These characters transfer to the derived full set of elastic constants. In order to effect a proper comparison of the dynamic and static moduli, we convert the dynamic elastic constanst to linear compressibilities pependicular (Kdyn1) and parallel (Kdyn3) which are directly comparable to the static tangent compressibiities obtained by differentiation of the observed strains. Both sets highlight the anisotorpic nature of the material but most interestingly Kdyn1 _ Ksta1 but Kdyn3 > Ksta3 by nearly 40% for one of the samples. The other samples measured respond similarly suggesting that conceptually the structure of such materials could be considered to be constructed of alternating stiff or compliant layers. This finding has implications in the response of the formation to stress particularly during hydraulic fracturing and the interpreation of acoustic logs in providing appropriate measures of elastic properties for engineering purposes.

Jan 1, 2015

By E. Yan, M. Mankosa, E. B. Wasmund

Mechanical cells are the dominant unit operation in base metal rougher flotation applications worldwide. As economic demand for metals increase, and as the feasible ore grades decrease, the installed capacity of mechanical flotation units worldwide has greatly increased, adding significant capital and operating cost. One opportunity to improve this situation is to use fundamental knowledge to make the industrial flotation process more efficient. A key insight is that the flotation process can be optimized by dividing the processing of the pulp into two distinct fluidic environments; a collection cell where air and pulp mix in a highly energetic compartment, and a low energy gravity separation cell. This is the basis of the “2-stage flotation device” that has been patented by Eriez and marketed under the tradename StackCell™. Two industrial case studies will be presented to highlight the potential metallurgical and commercial advantages of the StackCell. In the first, a train consisting of three pilot scale StackCells (each 0.6 metre diameter) was run in parallel with a train of conventional mechanical cells in a major copper concentrator and benchmarked against a batch Denver test. In the second, the performance of a 3 metre diameter StackCell in a nickel sulfide cleaning application was benchmarked against a batch Denver test. The flotation kinetics observed in the StackCells were 2.4 to 2.9 times faster when compared with the lab Denver test. In the first case study, the kinetics of the StackCell was about six times faster than conventional mechanical cells. It is hypothesized that the efficiency improvement in kinetics is because of reduced “drop-back” during the froth recovery phase, which is reduced because of the reduction in the shear that is present in a conventional mechanical tank cell. This result suggests that a 2-stage flotation system can be used to reduce the working volume of flotation units by five to six times. This would allow operators to significantly reduce the size of their flotation lines for a comparable flotation objective. Some discussion will follow about the scale-up criteria, maintenance and operability issues, comparisons of layout, and possible cost savings. INTRODUCTION The solution that most equipment suppliers have offered to reduce the cost of mechanical flotation equipment over the last 30 years has been to increase the size of the flotation unit cell (Mankosa, 2017). For example, three 100 m3 machines with three smaller motors, mechanisms and control valves could be replaced with a geometrically similar 300 m3 with a larger version of each ancillary component. While there are some efficiencies and cost improvements to be gained by this approach, it does not take advantage of fundamental insights into the flotation process, and it does not represent a step-change in terms of process design or economic benefit for the customer. The advantage of the “bigger is better” approach is that there is past experience of incremental improvements by making cells larger and there is a well-established scale-up method, which allows practitioners to estimate equipment capital costs based on very simple laboratory test- work. A different paradigm, which is gaining interest rapidly is to use a unit operation in which it is easier to optimize the flotation process, which will be described in this paper. This approach is often referred to “2- stage flotation”. Because this approach is new, it is important to benchmark it against existing conventional technology and to demonstrate a robust methodology for sizing equipment and flowsheets. This paper aims to address these issues with two case studies.

Jan 1, 2019