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By Jeffery S. Thompson, Harry Hinds

Recent advances in the development and application of the DuPont Activator Technology are discussed. Activators are catalysts of gold dissolution in cyanide solution. Plant testing of this technology in the vat leach circuit of the Homestake mine in Lead, South Dakota, showed increased gold recoveries ofup to 5%. Homestake has licensed the technology for this application and is in the process of full commercialization. Results from testing additional ores on a laboratory scale are also presented. These results indicate this technology will also increase leaching at much lower cyanide concentrations while achieving the same gold recovery.

Jan 1, 1997

By J. M. Tranquilla

EMR Microwave has developed several unique processes for the pretreatment of refractory gold and copper ores. This report describes a recent large scale pilot project involving a carbonaceous gold-bearing whole ore. Pilot plant testwork conducted jointly by EMR and Bateman Engineering Inc. has shown that 90+% cyanide soluble gold recovery is obtainable from refractory (sulphide and carbonaceous) Carlin, Nevada gold ores. Typical cyanide soluble gold recoveries for untreated material is 20%. AC energy consumption was found to be between 58.l kWh/ton and 15.5 kWh/t for an assumed heat recovery of 50% and 80% respectively. The plant was operated at reduced temperatures ( 400°C) from previous testwork on similar ore at 600°-700°C.

Jan 1, 2000

By Dianne M. Satalic, Peter A. Spencer

Bacterial leaching is a mature technology and has been applied in six commercial plants with others in the design stage or under construction. Bacterial oxidation is a relatively inexpensive process which uses naturally occurring soil bacteria to assist in extraction of base and precious metals. Bacterial oxidation has ini­tially been applied for gold recovery but the technology is now being transferred to base metal leaching with processes already developed for copper, cobalt and nickel. Bacterial oxidation plants often have capital and operating cost advantages over competing technologies and do not need a highly skilled workforce. The most common species found in the conditions used for bacterial oxidation and bacterial leaching are Thiobacillus fer­rooxidans and Thiobacillus thiooxidans. One common species other than Thiobaci!lus found in the commercial bacterial leach cultures is Leptospirillum ferrooxidans. Mixed cultures of the three species named here have formed the basis of the technolo­gy applied in most of the commercial applications of bacterial leaching to date. These bacterial species already mentioned all belong in the classification of mesophiles and have an operating range from 20 to 43°C. One other culture, a moderate thermophile operating over the range 40 to 50°C, has been used in one commercial plant in Western Australia. Bacterial oxidation takes place in acidic solutions under aer­obic conditions. The oxidation reaction normally produces iron (II) in solution which is ultimately conve1ted into the iron (III) form. The pH value falls naturally as the sulphide minerals are oxidised and the starting pH value can fall as low as pH 0.6 as the oxidation reaction proceeds. This paper examines the impact of the technology selection and its application on the design, engineering and operation of a bacterial oxidation plant. The effect of the changes to these para­meters on the cost of the bacterial oxidation plant is discussed.

Jan 1, 1998

By Lech Bolinski, Joe Shirley

Over two dozen Resin-in-Pulp (RIP) plants have been in operation in the fonner Soviet Union since the beginning of 1970. Currently approximately 50% of the gold produced in Russia, Uzbekistan and Kazakhstan, which equates roughly to 10% of the total world output, is recovered using the RIP technology. An alternative to activated carbon, ion-exchange resin has several advantages for the recovery of gold. Resins are less prone to clay or organic foul­ing and do not require thennal regeneration. They also have poten­tially higher loading capacities, faster adsorption kinetics, and are more resistant to abrasion. The original Russian RIP process was based on engineering expertise developed for uranium ore pro­cessing and has a few major drawbacks. The biggest problem is an 18-30 day resin stripping process, which results in a huge gold lock-up. The problem was recently overcome by the development of a new stripping technology which cuts the time to 12-24 hours. Currently, there is rather limited practical knowledge of the Russian RIP process in the West, but often Western mining com­panies developing gold mines in the fonner Soviet Union are hard pressed by their local joint venture partners to take a serious look into RIP. It is probably only a matter of time before one of these companies will cross Soviet technology with Western engineering and develop a modem RIP process as an attractive option to the current CIP and CIL technologies.

Jan 1, 1996

By Neil Jagger, Ian Arbuthnot, Mitchell Gordon

Ultra high density underflow is required in many thickener applications and in mineral processing is typically required for tailings to improve the thickened slurry rheology for either tailings dam development or for paste backfill applications. The improved liquid-solid separation resulting from the production ofultra high density underflow has both environmental and process benefits in the gold industry. Additional cyanide is recovered in the thickener overflow thus reducing plant cyanide costs and perhaps more significantly, a reduced quantity of cyanide is discharged to the tailings thus reducing either the toxic effect on the environment or the costs of cyanide destruction. Many gold and other mineral processing plants are situated in arid regions where the cost of water is high and the quantity often very restricted. Ultra high density thickened underflow results in increased recycle of tailings process water to the plant. In Countercurrent Decantation circuits, the wash efficiency is very dependent on the degree of liquid-solid separation in each thickener stage and the benefits ofultra high density underflow are either increased efficiency or decreased equipment costs as it may be possible to reduce the number of stages in the circuit.

Jan 1, 1995

By David Green

Power point slides

Jan 1, 2000

By Luis Elu, Andy Bolland, Jack Simmons

The gold refinery at Barrick Goldstrike Mines has increased production to more than 2,000,000 ounces poured per year while reducing the labor requirement. Safety and health has not been compromised with this increased production and in fact incident rates and exposures have reduced over the past five years. Streamlining procedures, improving ergonomics and the wise use of unique innovations has accomplished this significant achievement.

Jan 1, 1998

By H. W. Gussmann, R. G. Rohrs, E. van der Merwe

Salinity in Effluents carries a high penalty as a result of toxic­ity, corrosion, limited re-use potential, scaling and environmental impact. Although the high TDS, such as Calcium sulfate, other than metals are still being dealt with a low key non issue basis, they are receiving more and more attention from regulators. Traditional solutions to solve these problems are costly and inefficient and create therefore severe constraints on the prof­itability of mining operations and out-price in general the finan­cial resources for environmental clean up operations. Going up the technology versus cost curve the most econom­ic solution to pollution is dilution but which is difficult in a coun­t1y shoti of water. If this can't be done, the second best, at least in sunny areas, is, to pump the whole effluent on a tailings dam for evaporation. Depending on the contaminants, one may have to pond the efflu­ent to avoid re-dissolution and seepage into the ground. The next most common solution to pollution is the addition of lime to remove and concentrate any dissolved metals and then dump the product, hidden in a mass of gypsum in a convenient place. Again ponding may be required to avoid ground pollution. However the treatment costs start to rise steeply if it is not allowed to discharge the limed overflow solution because of its high calcium sulphate content. Further treatment is then required in the form of high cost and high tech membrane process tech­nology such as reverse osmosis or dialysis or even mechanical driven evaporation.

Jan 1, 1998

By David Wright, Colin Burns

Successful leaching of gold depends on appropriate chemical conditions; contact between leach solution and the gold particles; separation of the leach solution from the solids and extraction of the valuable ion from the solution. Irrespective of the leaching method employed the chemical conditions required are similar as is the dependence of solu­tion/gold contact on liberation. The various leaching methods available vary in the means by which gold/solution contact and solid/liquid separation are achieved. The essential difference between heap or vat leaching techniques and those involving agitation of a slurry is dependence on percolation for effective gold/solution contact. The most significant factor preventing uniform percolation is the presence of fines or clays. The quantity and character of the fines fraction is ore type dependent and may result from crushing, degradation during stacking or leaching, or the natural size distribution of the ore. The problems associated with fines can be aggravated during stacking and preparation of the heap. Segregation during stacking can result in concentration of fine particles at the centre of heaps. Further concentration of fines may also occur during irrigation by the movement of the fine particles with the solution. The end result is that the areas in which fines are concentrated become areas of low permeability. The contact between leach solution and the ore in such areas is, at best, slowed down dramatically and, in some cases, prevented altogether. The consequences of this phenomena are slow leaching and a reduction in recovery. The conventional solution to this problem is well known. Agglomeration of ore prior to heap leaching is practised widely. The effect of agglomeration is to immobilise the fines by causing them to adhere either to each other or to larger ore particles. The net effect is that the ore behaves as if no fines were present. The use of agglomeration is limited only by its cost, the most significant components of which are the cost of binding agent, commonly cement, and the capital cost of the agglomerating equipment.

Jan 1, 1995

By Ian Larkins

The Ruby Hill Mine agglomerates crushed low-grade ore (nominally -1 .5'') with high-grade filtered tailings (filter cake, nominally 80% -65#). Cement is added as a binding agent. The agglomerated ore is then conveyed and stacked on the heap. In 1998 approximately $480 000 was spent on cement for agglomeration. Cement for mill pH control and agglomeration was the largest single reagent cost at Ruby Hill. In an effort to reduce agglomeration costs a test-work program was initiated to investigate alternative binders and optimum binder additions. This paper summarizes the test­work results to-date.

Jan 1, 1999

By A. H. Reitsema, Hans E. van Dam

In CIP, CIL, and Heap Leach gold recovery operations, a sub-optimal activated carbon performance invariably causes a significant loss of revenues. In this paper it is shown, how dedicated analyses of carbon samples can be used as a guide in plant performance optimiza­tion. Firstly, a brief outline is given of the most important methods of analyses, including the specialized methods not normally used by mining operations, but provided by carbon manufacturers. Then, a number of practical cases are discussed in which carbon sample analyses provided insight which allowed significant improvements.

Jan 1, 1995

By H. G. Linge

The Australian gold industry currently contributes some $4bpa to the national economy [l]. Some 40% of the total gold is produced in the region centred on Kalgoorlie known as the Eastern Goldfields of Western Australia. This region is the largest single centre of production with an output of some 100 tpa of gold [2]. In the Eastern Goldfields, refractory arseno­pyritic gold ore is an increasingly significant source of gold, feeding several operations utilizing bio-oxidation as the pre­carbon in pulp/leach (CIP/L) treatment process [1]. This paper desribes an alternative pre-CIP/L treatment option for use in the Eastern Goldfields based on the chlorination of arsenopyrite by chlor-alkali technology [3] using the salt resources available from saline water present in abundance in the region.

Jan 1, 1995

By Richard M. Crowell, John W. Shield

GeoBiotics has developed a biooxidation technology (patents pending) which involves coating refractory precious metal sulfide concentrates onto a support material and biooxidizing the sulfides in a heap configuration. The concentrates are produced from low or high grade sulfidic refractory ores or existing mine tailings. The process has been found to achieve high gold recoveries asso­ciated with stirred tank biooxidation, but at the low operating and capital costs associated with whole ore heap biooxidation. Improved gold recoveries of up to 98% after biooxidation are reported for 4 representative mines or deposits. The sulfide flotation concentrates were studied using 3 and 6 in. diameter columns or 3 in. drained vats. The refractory sulfide concen­trates biooxidize rapidly in 3 to 12 weeks with substantial increases in subsequent gold recovery.

Jan 1, 1996

By Rosa H. Harris

The world's largest gold dump leach operation, Minera Yanacocha S.A., has installed community assistance programs in Peru concerned with health, education, electrification, agricultural assistance and road improvements. The programs are conducted in a joint venture fashion in association with various organizations.

Jan 1, 1998

By V. I. Lakshmanan, Chris Dodson

Refractory gold ores or concentrates are pretreated in general by physical, chemical and biological oxidative pretreatment processes prior to cyanidation for the economic recovery of gold. The thermal treatment processes generally include fluid bed pro­cessing(!>, chemical with pressure<') or atmospheric (Caro's< ·'>, 3 Nitrox1')) pretreatment leaching and physical with ultrafine grinding!"). Roasting and aqueous pressure oxidation pretreat­ment methods have several commercial applications (Homestake, Barrick) and biological oxidation methods have recently found industrial applications in Africa. The roast pretreatment methods to treat refractory sulphide ores or concentrates transform iron sulphides generally to a porous iron oxide matrix assisting the lixiviant cyanide to effectively diffuse the calcine for cyanidation and hence with improved gold recovery. Jha and Kramer<') made an extensive review of roasting chemistty and practice to tt·eat refract01y gold ores. Industrially two stage pretreatment roasting is generally employed. During the first stage roasting is carried out under oxygen deficiency conditions to provide a low arsenic calcine, mainly magnetite and in the second stage magnetite is trans­formed to haematite under oxidizing conditions.

Jan 1, 1998

By Ian J. Corrans, Gary Johnson, John E. Angove

Activox® is a hydrometallurgical process used to oxidise sulphide concentrates. The process is based on two relatively simple, established unit operations; i.e. fine or ultra-fine milling (UFM) and pressure oxidation under mild conditions. An under-standing of, and ability to control the pulp chemistry during oxidation has resulted in the successful Activox® treatment ( on a batch scale) of a wide variety of sulphide flotation concentrates; • pyrite/arsenopyrite + gold • pyrite/chalcopyrite + gold • pyrite/chalcocite + gold • pyrite/enargite/tetrahedrite + gold Oxidation rates are rapid (1-2 hours retention time) and gold

Jan 1, 1995

By Kevin Phelan, Gary Johnson, Peter Sperring

The vast majority of tailings in the Western Australian Goldfields are deposited in purpose-built storage facilities. At mine-sites with open-pit mining operations there is also the requirement to mine and stack large volumes of waste rock, usually into surface waste dumps. As these dumps have typically 30% of their gross volume present as voids, there is the potential to use this void space for the storage of tailings. The concept of co-disposal is to store the tailings material in the void space of the waste dumps, eliminating the need for a separate tailings storage facility. Dominion Mining Limited have been investigating the possibility of using co-disposal as a means of tailings storage. Laboratory testwork has been used to understand some of the issues associated with the concept, and assist in the design of an on-site demonstration of the concept. Co-disposal offers a number of potential advantages, and despite a number of practical hurdles to overcome, considerable economic and environmental benefits could be realised if this concept can be demonstrated on a commercial scale. The major advantage of such a system is to remove the need to build, operate and rehabilitate a separate tailings storage facility. Rehabilitation can be incremental throughout the mine life as the co-disposal site will be virtually indistinguishable from a current waste dump in both size and form. Other potential advantages include more stable waste dumps, less land area disturbed on the project site, and better water recovery from the tailings.

Jan 1, 1995

By Harold Wahlborg, George Owusu

In a study using butyl diglyme as an organic extractant, essen­tially complete extraction of gold from chloride leach solution was achieved. The extraction kinetics are so fast that the process could be completed in 30 seconds. Except for iron, co-extraction of other ionic species was insignificant. Co-extracted iron species were successfully scrubbed from the loaded organic using 10% HCl solution. High grade, >99.9%, gold was recov­ered from the loaded organic using 5% oxalic acid solution as the stripping agent at a temperature of 70°C to 80°C. Over 99% of the organic-loaded gold was stripped from the organic phase. The butyl diglyme extractant is being tested on a variety of gold-bearing feedstocks. Presented here are results obtained from two gravity concentrates.

Jan 1, 1999

By V. Fred Swanson, J. Patrick Glynn

The environment for process engineers today is very different from 20 years ago. The ideas and mathematical description of models for a multitude of different unit operations is an ongoing development. The computer tools to deal with the mathematics are readily available and specialist companies have developed, tested and verified their models. The challenge for the process engineer is to know which package to use and to know whether a particular application is the most accurate for the specific process. Metallurgical simulation programs today are well known and proven. Certain programs are specialized while others are broader based. The needs of each user are dependent on the application. Typically, most users require the following operations: • Comminution • Flotation • Hydrometallurgy • Pyrometallurgy • Additional requirements could be defined as: • Thermodynamic capabilities for solids, phases, and gases • Dynamic simulation • Data analysis tools • Coal oriented operations • Diamond oriented operations

Jan 1, 1997

By Timo Niitti

Within the minerals industry, flotation is the predominant method when processing sulphide ores. There is hardly any competition in this area because of the high efficiency and low costs of flotation. When processing other ore types magnetic or gravity• methods are commonly used and sometimes leaching methods are selected. The wide variation of the properties of gold (high value, low ore grades, softness, high specific gravity etc.) sets challenging requirements to the processing methods and particu­larly for flotation machines, which should be able to effectively recover free fine gold, coarse gold and gold bearing minerals throughout the full size range. In gold processes the amount of concentrate is usually low, but in some cases large amounts of gold bearing sulphides e.g pyrites has to be recovered. In gold processing seldom does only one method provide the optimum results, but the recovery is usually made using several complementary technologies: gravity separation, leaching and flotation are the most common ones. Mineralogy is the determin­ing factor when selecting the method or methods to be used.

Jan 1, 1995