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By M Costa, L Polizzi

Process optimisation and continuous improvement are usually acknowledged when making a process more effective, efficient and transparent. During the last few decades, thousands of companies around the world have used total quality concepts in order to establish a continuous improvement process in their companies. Typically these companies apply some kind of Kaizen-type tools and expect results in the short term; however, the great majority of companies are poorly implementing these continuous improvement programs.Usually the most common reasons for failure of the program are lack of commitment from leaders, lack of discipline and engagement from the team to follow process and lack of clear targets for the program. When the results do not come at the expected timeline, it is common to simply drop the current process and apply a different approach from another company or consulting firm.This paper will explore some successful cases of companies that have invested time and effort to establish a reliable and sustainable process of continuous improvement. The focus will be case studies of mines and smelters around the world that use the plan–do–check–act (PDCA) cycle to increase productivity with the best services and lowest costs. The main tools and processes used by these companies will be discussed, as well as results achieved.CITATION:Costa, M and Polizzi, L, 2014. Introducing and sustaining a continuous improvement program in mines and smelters, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 55–62 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Anna Sukhanova, Svetlana Babaeva, Sergey Andreev, Victor Beltenev

"The Zenith-Victoria /1/ and Jubileynoye /2/ hydrothermal fields have symmetrical structural position on the Mid Atlantic Ridge (Fig. 1). In order to compare the evolution of hydrothermal systems, we conducted mineralogical and geochemical studies of SMS from both sites.Radiochemical and geochemical investigations of massive sulfides of the Zenith-Victoria field distinguishes three major stages of evolution: initial, interim and final represented by Fe-S, Cu-Fe and Zn-Fe types of SMS respectively /3/. In this talk, we describe the results of geochemical analysis of massive sulfides from the Zenith-Victoria field. Geochemical varieties of SMS are considered to be indicators of the evolutionary stages of the hydrothermal system."

Sep 1, 2014

By B E. De Gee, N Viviers, A Naidoo

In 2013 the Mopani Copper Mine Mufulira plant in Zambia embarked on a project that was aimed at improving concentrator recoveries. The project commenced with the automation of the milling and flotation circuits. This involved the installation of new instrumentation, namely measurement devices and actuators, and the connection of these to new programmable logic controllers (PLCs).The infrastructure changes were followed by the implementation of basic proportional-integral-derivative (PID) controllers on the PLCs. Supervisory control and data acquisition (SCADA) interfaces were also implemented to allow for switching between controller modes, inputting of setpoint variables and to provide a visual display for process monitoring. The final phase of the project involved the installation and commissioning of advanced process control (APC) solutions on the milling and flotation circuits. This work was carried out by Mintek over 21 on-site days. The APC solutions included the MillStar and FloatStar suites of advanced controllers.The MillStar control suite focused on stabilising the mill feed and mill discharge on the two primary mills as well as the flotation circuit feed. Mintek’s CyLas instruments, which provide a measurement of the hydrocyclone underflow angle, were also installed. The measurements were incorporated into the discharge stabilisation control on both milling circuits. The FloatStar level stabiliser controller provided flotation cell pulp level control on fourteen cells, including two columns.Performance tests showed that the Mintek APC system stabilised the mill feed and mill discharge while ensuring the process remained within operational constraints. The MillStar control system utilised the CyLas instrument to prevent roping on the hydrocyclone underflow. This was not always achieved under normal operation. Additionally, the flotation section was stabilised as a result of improved level control by the FloatStar control system.Performance comparisons showed that the Mintek control system improved the operation of the milling and flotation circuits resulting in a greater copper recovery.CITATION:Naidoo, A, De Gee, B E and Viviers, N, 2014. Implementation of an advanced milling and flotation control system at Mopani Mufulira copper mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 363–368 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By R Wei, Y Peng

With the depletion of high-quality ores, the efficiency of extracting difficult gold ores through flotation and leaching becomes very important in the mining industry. Iron contaminants, sulfide and carbonaceous coatings on the surface of gold and gold bearing minerals significantly hinder the recovery of gold during gold processing. As the surface of gold minerals is easily contaminated, coatings of iron oxides and iron hydroxides originated from the grinding process and oxidation of iron sulfides will cause a retarding effect on both gold flotation and leaching.To mitigate the processing issues caused by undesirable surface coatings on gold minerals, a new technology in treating surface coatings of iron contaminants has been developed. The pulp potential and pH of the slurry are altered to allow dissolution of surface coatings which are further excluded by the use of complexing reagents. The current work shows that iron contaminants can be removed from the surfaces of gold through Eh-pH adjustment and chelation which result in significantly improved gold flotation response. The addition of complexants aids the formation of iron chelates to prevent the iron species in the solution from forming iron oxide and iron hydroxide in the flotation conditions.CITATION:Wei, R and Peng, Y, 2014. Mitigating the effect of surface coatings on gold processing, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 187–192 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Lukasz Maciag, Ryszard Andrzej Kotlinski, Ryszard Krzysztof Borówka, Dominik Zawadzki

Concentration and composition of rare earth elements (REE) and major elements in the sediment samples from the IOM H11 Fe-Mn nodule deposit, eastern part of the Clarion-Clipperton nodule field (located between the Clarion-Clipperton Fracture Zone - CCFZ; tropical Pacific), have been studied. We show the controls on REE concentrations and described vertical/horizontal variability of selected metals in pelagic sediments from the CCFZ. According to Kato et al. (2011), who analyzed 2000 seafloor sediment samples at 78 sites of the Pacific Ocean, deep-sea mud shows high concentrations (2230 ppm maximum) of ?REY and could be potential resource of these elements in the future. However, our work does not fully confirm that sediments in the IOM H11 are significantly enriched in REE.

Sep 1, 2014

By Florian Häckel, Ulrich Schwarz-Schampera, Benjamin Bühring, Katja Schmidt, Dieter Garbe-Schönberg, KoschinskyM Andrea

"The Vanuatu island arc and its adjacent back-arc basins form part of the southern New Hebrides subduction system in the southwestern Pacific Ocean within a triangle defined by the Solomon Islands, New Caledonia and Fiji (Meffre & Crawford 2001). The back-arc region east of the volcanic front is characterized by three structural depressions namely Vate, Erromango, and Futuna (from N to S), also known as the Coriolis Troughs. Earlier studies of lava compositions reveal the occurrence of highly evolved alkali-rich dacites as well as ankaramite basalts within the individual troughs (McConachy et al. 2005).Here we present the first mineralogical and geochemical analyses of hydrothermal fluids and precipitates (sulfides, sulfates, Fe-oxyhydroxides), sediments, and volcanic rocks, sampled during the "Coriolis Volcanism and Vents" (COVOLVE) cruise SO229 in July 2013 aboard the German R/V Sonne. The samples were retrieved during several ROV Kiel 6000 dives directly from the newly discovered active vent sites at the neovolcanic Nifonea Ridge, and from multiple sites at water depths ranging between 200 to 2800 m within the Vate and Futuna Troughs as well as from the shallow water Epi Caldera NNE of the Coriolis Troughs (Fig. 1)."

Sep 1, 2014

By Rolf B. Pedersen, Ana Filipa Marques, Ingunn H. Thorseth, Ingeborg Okland

"Deep sea mining of polymetallic sulphides will change the physical and chemical conditions at the seafloor by creating scars when sulphides are removed, and potentially also by deposition of mine tailings at the seafloor. These changes will impact the existing ecosystems at the seafloor in and around the mined areas. Seafloor Massive Sulphide deposits that have been exposed to oxic seawater weather into Fe-metal-oxyhydroxides. However, the rates of weathering and release of heavy metals and other toxic compounds to the environment from freshly exposed sulphides in a deep-sea environment are not well studied.During a cruise to the Arctic Mid-Ocean Ridge in the Norwegian-Greenland Sea in July 2014 we will initiate in-situ experiments investigating the microbiological and geochemical processes involved in the weathering of freshly exposed massive sulphides deposits in a natural environment. This will be done by creating scars in naturally occurring sulphide deposits and by deploying weathering experiments at the seafloor. The sites will be revisited and re-sampled in 2015. The mobility and fate of heavy metals will be one of the main concerns of the study as well as constraining the time it will take for exposed sulphides to return to the chemical state present prior to mining. In this presentation we will present the experimental framework and the preliminary results from the July 2014 cruise. This project is part of the EU funded MIDAS (Managing impacts of deep sea resource exploitation) project."

Sep 1, 2014

By G R. Ballantyne, M S. Powell

A comprehensive Australia-wide survey of comminution energy consumption at copper and gold mines was presented by the authors at the 11th AusIMM Mill Operators’ Conference 2012. The database has been extended to include major overseas mines and used to benchmark comminution energy consumption across the industry. The mines included in this study now represent 15 and 24 per cent of the total global gold and copper production respectively, and almost all Australian production. The comminution energy intensity per unit of saleable metal has been presented in a graphical form similar to a cost curve used in economics. The graphical method has been developed to assess the competitive advantage that can be achieved by reducing comminution energy intensity.This benchmarking tool has been applied to three published case studies to assess its applicability. The first case study indicated that a large reduction in size-specific energy (kWh/t -75 µm) was achievable by converting standard semi-autogenous and ball mill circuits to include high pressure grinding roll and stirred mills. The second case study investigated the metal-specific energy reduction historically achieved by Bougainville with the addition of a preconcentration screening plant. The final case study was conducted by Barrick Gold Corporation and involved incremental efficiency upgrades at three of its gold mines: Cortez, Cowal and Mara North. The application of the benchmarking tool to each of these case studies successfully demonstrated the scale and competitive advantage that was achieved by reducing energy intensity.CITATION:Ballantyne, G R and Powell, M S, 2014. Benchmarking comminution energy consumption for improved efficiency, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 95–100 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By Hyung Jeek Kim, Jongmin Joo, Jonguk Kim, Jai-Woon Moon, Kyeong-Yong Lee

"Co-rich ferromanganese crusts (Fe-Mn crusts) distributed on seamounts in the western Pacific are potential economic resources for cobalt, nickel, platinum, and other rare metals in the future. Evaluation and selection of a mining site can be established based on abundance and grade of Fe-Mn crusts in the site as well as topography that should be smooth enough for mining operations. Therefore, acquisition of shipboard echo-sounding and acoustic backscatter data are prerequisite to the selection of potential mine sites in addition to visual and sampling operations. Acoustic backscatter data can be used to locate crust-covered areas on a regional scale with the understanding of acoustic properties of crust through its correlation with visual and sampling data.During an expedition that took place from January to March 2014, KIOST collected geophysical and geologic data to assess the resource potential for Fe-Mn crusts on three seamounts (guyots) in the Western Pacific. In OSM11, one of the three surveyed seamounts, three camera tows were performed to observe the distribution of Fe-Mn crusts on the summit and slopes of the seamount. Although sediments of various thicknesses generally cover most of summit region of OSM11, several regions with high backscatter signals occur on the periphery of the summit. The occurrence of Fe-Mn crusts, observed during the camera tows, on those high backscattered regions suggests that the backscatter signals of shipboard multi-beam sonar can reflect changes in the geology of the seafloor from sediment layer to Fe-Mn crust deposits. The Fe-Mn crust deposited around the summit region is worthy of notice because of its topographic characteristics, including shallow depth, flat or gentle inclined surface, and smooth relief, which are more suitable for mining operation compared to the flanks of seamount."

Sep 1, 2014

By Se-joon Kim, Jong-hwa Chun

"‘Gas hydrate’ is the common term for a solid material formed from the combination of various gases as ‘guest’ and water as ‘host’. A series of large-scale scientific drilling and coring programmes conducted since 2000 revealed that natural gas hydrate exists in a wide variety of accumulations in the sediments. The scaled-up onshore and offshore field production tests during the last decade show that gas production technology will be realized to make gas production from gas hydrates viable in the future, recognizing its potentials as one of the future sustainable energy resources.The total produced gas was approximately 470 m3 by the hot water circulation method over 6 days of operation in the permafrost-associated Mallik 2002 project in the Mackenzie Delta of Canada. In the Mallik 2007-2008 project, the gas was successfully produced stably by the depressurization method for 6 days, up to 13,000 m3 cumulatively. The depressurization method applied in the Mallik test was shown to be an effective way to produce gas from gas hydrates. The Alaska field trial to inject mixed gas of CO2 and N2 to exchange CH4 in 2012 was successfully done for the first time to produce maximum 1,270 m3 per day. A remarkable achievement was made by Japan when it completed its first offshore production test in the Eastern Nankai Trough, producing approximately 120,000 m3 of methane by the depressurization method over 6 days in March 2013. The technical challenges and scientific uncertainties obtained from Nankai Trough production test provide Korea with more considerations as to the aspects of well completion, reservoir formation and seafloor stability, sand control, flow assurance, environmental monitoring, and etc., due to the different geological setting and geomechanical properties of the Ulleung Basin in Korea."

Sep 1, 2014

By Irina Melekestseva, Beltenev. Victor, Victor Ivanov

"One of the major problems discussed over the last years is a possibility of mining of seafloor massive sulfide deposits. In spite of the pessimistic points of view on their commercial development, they are still of great interest and continue to be studied (Hannington et al., 2011). Recently, Barriga (2012) paid special attention to the underestimated amount of massive sulfide hydrothermal fields and pointed to the importance of the buried fields and subseafloor mineralization.This study examines the geochemistry of seafloor and subseafloor precipitates collected at the Peterburgskoe (19°52´ N) and Irinovskoe (13°20´ N) hydrothermal fields (MAR) during the 34th cruise of the R/V Professor Logatchev in 2011. These fields were discovered by the Polar Marine Geosurvey Expedition in 2010 and 2011, respectively (Shilov et al., 2011; Beltenev et al., 2012). The Peterburgskoe field, associated with basalts, is located 16 km west of the main rift valley at the depth of 2800-3100 m at the junction of a large non-transform discontinuity with the second rift ridge parallel to the rift valley. The Irinovskoe field occurs at depths of 2700-2850 m and has a northwestern satellite sulfide site, both confined to an oceanic core complex (MacLeod et al., 2009), which includes mafic and ultramafic rocks. The details of geological structure of the fields may be found in the relevant papers.Diverse samples were collected from the hydrothermal fields: seafloor massive sulfides, Fe-hydroxide crusts, SiO2-rich sulfide-bearing precipitates, and subseafloor mineralized rocks (Melekestseva et al., 2014a). Massive sulfides may be subdivided on the Fe-rich and Cu-rich types. The marcasite-pyrite, pyrite, hydroxide-marcasite, and chalcopyrite-pyrite (Fe-rich) mineral types are dominant in the Peterburgskoe field at lesser amounts of sphalerite-hydroxide-chalcopyrite and pyrite-covellite-chalcopyrite (Cu-rich) massive sulfides. The mineralized sulfide-talc-carbonate-chlorite, chlorite-sulfide-quartz, and hematite-sulfide-quartz rocks host stringer-disseminated sulfides including chalcopyrite, covellite, and pyrite."

Sep 1, 2014

By A Rantala, C Cruickshank, I Muzinda, O Haavisto, J Timperi

The production at First Quantum Minerals’ (FQM) Kevitsa Mine, located in northern Finland, commenced during the second quarter of 2012. Presently, the mine processes approximately five and half million tonnes of ore annually, producing nickel, copper and platinum group metal (PGM) concentrates. In order to support fast production ramp-up and optimise the performance of flotation thereafter, an extensive advanced flotation control solution was implemented by Outotec in collaboration with FQM Kevitsa.In addition to basic process instrumentation and process control, each of the 14 Outotec 300 m3 and another 26 cells, ranging from 20–160 m3, have been equipped with state-of-the-art systems providing froth image analysis and automatic froth speed control. Also, the flotation cell levels are stabilised with advanced feed-forward level control.The online analyser provides key feedback information of the process performance for the advanced process control (APC) system. Based on this information, APC system defines grades and recoveries according to rules defined by Kevitsa process metallurgists. This system executes the control strategies for optimising the production of concentrates.Throughout the implementation and support phases, specific and intensive attention was paid to ensure plant personnel gained full understanding of interacting with the system and how to incorporate their process experience and skills to optimise the APC strategy. This level of expertise is also a valuable asset in understanding the APC system’s contribution to the overall performance of the plant as well as providing the ability and confidence to define key performance indicators used for continuous assessment. The experiences and results from site achieved so far are discussed in this paper.CITATION:Rantala, A, Muzinda, I, Timperi, J, Cruickshank, C and Haavisto, O, 2014. Implementation of advanced flotation control at First Quantum Minerals’ Kevitsa mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 369–378 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By G Pasin, F Wirfiyata, G Khomaeni, W Valery, A Maclean, A Jankovic

The grinding circuit at PT Newmont Nusa Tenggara (PTNNT) – Batu Hijau mine consists of two SABC (semi-autogenous milling, ball milling, pebble crushing) trains, including four 20'?×?33'6? ball mills that have been lined with steel liners since the commissioning of the plant in 1999. During 2011 and 2012 an industrial trial was conducted to evaluate Poly-Met liners (a combination of rubber and steel liners). These new liners were installed in two of the ball mills (ball mills 1 and 2) and operated in parallel with ball mills 3 and 4 with steel liners.The objective of the trial was to compare the plant performance with the Poly-Met and steel ball?mill liners with regards to wear life, mill throughput, grind size and total unit costs. The trial was conducted over the entire life of the liners. The evaluation methodology implemented consisted of frequent spot sampling around the ball mill circuits, complete surveys/audits in both ball mills, and detailed analysis of process data. This paper presents the results of the industrial trial and main conclusions.CITATION:Maclean, A, Wirfiyata, F, Khomaeni, G, Jankovic, A, Pasin, G and Valery, W, 2014. Ball mill Poly-Met liner evaluation at PT Newmont Nusa Tenggara – Batu Hijau mine, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 255–262 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By M. I. F. S. Cruz, R. Pedersen, F. J. A. S. Barriga, A. Dias, A. F. A. Marques

"Underwater hydrothermal vents are known since the 1970s and their importance for the global economy is growing as new discoveries and new assessments are made each year (Cherkashov et al., 2010; Corliss et al., 1979). The similarities of seafloor massive sulfides, representing the younger versions of the well exploited on land volcanogenic massive sulfides, bring an increased awareness to the potential of the sea (Ajan G. Galley, 2007; Hannington et al., 2011; Herzig and Hannington, 1995). The Arctic Ocean presents itself as an opportunity to study new interest areas and numerous hydrothermal systems (active and inactive) were discovered along the Arctic Mid Ocean Ridge (AMOR) (Pedersen et al., 2010b). The Mohns ridge is an ultraslow spreading ridge of the AMOR (Vogt, 1986) where two hydrothermal vent sites were recently discovered, the Jan Mayen and the Loki’s Castle (Pedersen et al., 2010a; Pedersen et al., 2009; Pedersen, 2005). Here we compare these two Arctic hydrothermal systems, which represent two well-differentiated end-members of hydrothermal fields in the region."

Sep 1, 2014

By A. Yu. Lein, V. V. Maslennikov, S. P. Maslennikova, I. Y. u. Melekestseva, Yu. A. Bogdanov

Tellurium is a high-tech and also toxic element. This element shows sufficient contents in Fe-Mn crusts and nodules in the modern ocean to be involved in future industrial processes [Hein et al., 2003]. Tellurium minerals and contents are not well recorded in modern and ancient black smoker systems. Tellurides are rarely found in sulfides from the modern oceans [Iizasa et al. 1992; Maslennikov et al., 2010]. The previous common opinion that tellurium is scarce in active seafloor hydrothermal systems can be revised due to the recent discovery of abundant tellurides in chimneys from Brothers Volcano vent site [Berkenbosch et al., 2012]. We found abundant tellurobismuthite, hessite, and native tellurium in chimneys from Su Su Knoll vents sites (West Pacific). So, tellurides can be found in some chimneys but absent in others. The causes of this are poorly understood. These conflicting data create numerous questions and require an explanation. The problem can be resolved by research at different scales including analysis of relevant genetic features of host sequences, systematic textural and paragenetic studies of different types of chimneys, and their rare mineral assemblages. Paragenetic models, compositional analyses and ranges of tellurium-bearing minerals and the physicochemical interpretation of chimney diversity in different types of VMS deposits are the main subjects of our research. The data on tellurides in chimneys from ancient VMS deposits should also be useful to resolve this problem.

Sep 1, 2014

By A Cranley, A Giblett, S Thacker

The Newmont Tanami Operations are located in the Northern Territory, approximately 550 km north-west of Alice Springs. The Granites process plant commenced operations in 1986 as a 300?000 t/a ball mill / carbon-in-leach (CIL) plant and has undergone numerous expansions between that time and the current day, with project-to-date gold production exceeding 6.5 Moz. Annual plant throughput has exceeded 2.8 Mt/a while processing a blend of open pit material and ore from the Callie Deeps underground mine, with annual gold production exceeding 400 koz. In 2013 the operation processed 1.8 Mt of underground ore for the production of 323 koz of gold.This paper reviews the operation and expansion of The Granites process plant since the mid to late 1980s with particular focus on the gravity gold recovery circuit. The Tanami ores contain significant levels of free gold, and gravity recovery has long been an integral component of the metal recovery process at the Granites plant. The results of ten years of gravity circuit performance analysis and optimisation are presented.CITATION:Giblett, A, Cranley, A and Thacker, S, 2014. Three decades of gold production at the Newmont Tanami operations, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 209–216 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By D Atheis, S Williams, A Dance, D Taplin

"Resurrected from its former life at the Big Bell operation, the grinding circuit at Evolution Mining’s Edna May operation in Western Australia has many a story to tell. The task of optimising a plant designed for another orebody provides as many challenges as opportunities. Initially faced with a blend of primary and oxide ore, the circuit achieved in excess of 320 t/h until the oxide was depleted, leaving only the much harder primary feed.The 2.0 MW semi-autogenous grinding (SAG) mill and 3.7 MW ball mill were assisted by a 150 kW pebble crusher, but the power limitation of the SAG mill resulted in a drop in throughput. Edna May personnel have been involved in a number of progressive improvements to restore the design capacity of the concentrator and work towards 3 Mt/a or even higher ahead of the gravity and leach recovery circuits.These improvements include: a crush forward configuration of the SAG mill scats partial to full secondary crushing variable speed drive upgrade of the SAG mill lifter and grate design changes ball mill circuit grinding efficiency.This paper summarises the chronology of events that has resulted in significant improvements in throughput by conventional (and in some cases, novel) methods of reconfiguring the existing grinding mills. Lessons learned and hindsight perspectives will be summarised, sharing this educational experience with other operations in a similar situation.CITATION:Dance, A, Atheis, D, Williams, S and Taplin, D, 2014. Grinding circuit improvements at Evolution Mining’s Edna May operation, in Proceedings 12th AusIMM Mill Operators’ Conference 2014, pp 63–70 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Sep 1, 2014

By B Murphy, S O’Connell, J L. Heath

In the 1989 best-seller The 7 Habits of Highly Effective People, the author, Stephen Covey, highlights the importance of maintaining not only ‘production’, but also, ‘production capacity’. When operating a modern flotation concentrator, production is often measured in terms of concentrate tonnage, tonnes milled and plant utilisation. There are very few metrics that focus directly on flotation equipment condition in relation to performance, which is analogous to Covey’s production capacity principal. It is evident on many mine sites that flotation equipment condition is not monitored on a proactive basis and that the prevailing culture is to wait for a failure, before addressing an issue.This paper discusses examples of how poor equipment condition can lead to production loss through poor metallurgical performance. Actual examples are given where these problems have occurred in operating plants. An outline is provided on how metallurgical and maintenance departments can work together to protect production capacity and gain more from existing equipment.CITATION:Murphy, B, O’Connell, S and Heath, J L, 2014. Maximising value through maintaining your flotation equipment, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 71–76 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By P Thompson, D Rose, S Yu, W Baum, R Zahn, D Meadows, G Hall

Opportunities to improve mill operations are often cited by mining companies and recognised in many concentrators spread throughout the world but are not always followed through. Copper-molybdenum concentrator operations are challenged by a continuously increasing list of detrimental factors. They include deteriorating ore characteristics and poor mineralogical information on deeper ores, water quality and availability, steel wear and increasing power costs. Rapidly declining productivity, sustainability and environmental factors, new taxes, mining industry global skill set shortages, to name but a few, must also be considered. The days of maximising value by just increasing production or simple cost cutting are fading and will not be sufficient for the future of more complex mineral processing operations and larger plants. As a result, FLSmidth’s Global Process Technology Group has launched a plant and process optimisation program based on mineralogical and metallurgical surveys.Copper-molybdenum concentrators of the future need a paradigm shift. Modelling and simulation tools alone are not the answer to complex mineralogical associations and larger scale equipment and operations. Detailed area by area review aimed at identifying process constraints in terms of equipment and operating practice in conjunction with robust diagnostic work, ie mineralogical and metallurgical characterisation, are mandatory for process optimisation. The navigational beacon, for all operations who want to remain competitive, will be ‘process efficiency’. Since the use of automated mineral analysers has become more readily available and reliable, mineralogical-metallurgical plant surveys have proven themselves as the most efficient tool for optimising plant performance.The following paper will illustrate how operations can move toward eliminating under-performing flow sheets, fixing run-away flotation conditions, maximising individual process equipment performance, preventing shortcuts in Bond work index testing which may cause the failure of comminution models and minimising costly and time-consuming ‘debottlenecking’. As previous plant surveys have shown, the net project cash flow can be increased by 50 to 200 per cent if a combination of robust ore characterisation and plant process mineralogy is performed. The combined plant survey approach has been demonstrated successfully in a multitude of operations. This includes the use of key ore types in concert with statistically sampled process streams, bench-scale metallurgical tests and automated mineral analysis on a size-by-size basis.CITATION:Meadows, D, Hall, G, Rose, D, Thompson, P, Baum, W, Zahn, R and Yu, S, 2014. Copper-molybdenum concentrator surveys using mineralogy and process benchmarking tools to improve overall plant performance, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 315–322 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By J Hartog, V Beehan, D Beeson

Treating an ore blend from five different deposits at Newgold’s Peak Gold Mine (PGM) has always been a challenge due to the inherent variability between each of the orebodies.Operating the processing plant at PGM with a ‘normal’ level of process control and a good operations and metallurgical team has allowed the processing plant to achieve above the name plate design at 102 t/h and recoveries in the order of 92.8 per cent for gold and 88.4 per cent for copper.With a company value and culture of striving for continuous improvement, PGM implemented the Manta Cube® system, an advanced process control system, for the semi-autogenous grinding (SAG) mill, gold leach circuit and tailings thickener over a 12-month period throughout 2012 and 2013.The overall benefits of implementing the Manta Cube® system has led to an increase in mill throughput of at least two per cent, improved SAG mill liner life, a ten per cent decrease in cyanide consumption and a reduction in flocculant of at least 30 per cent with no detriment to the gold and copper recoveries.The entire project had a payback period of less than two months, and the combined benefits resulted in an overall increase in revenue of at least $5 million per annum. This is quite significant for a processing plant the size of PGM.This paper describes the methodology, overall results and economic benefit of applying the Manta Cube® system on-site at Newgold’s PGM.CITATION:Hartog, J, Beehan, V, Karageorgos, J and Beeson, D, 2014. Optimisation of the Peak Gold Mine’s processing plant through advanced process control, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 335–344 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014