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By Victor C. Storhok, Batric Pesic, Marlyn D. Ballain

No1ihwest Alloys produces magnesium from dolomite by reduction with ferrosilicon and aluminum. This process produces alkaline by-products in quantities that allow their consideration for use as commercial products. Two such products are dicalci­um silicate, termed as Di-Cal, and magnesium oxide, termed simply MgO. The alkaline properties of these materials offer acid neutralizing power, comparable to traditionally used lime. Thus, the materials warrant study for their use in various appli­cations where neutralization of acidic waters or process solutions are required. One such application is the treatment of acid mine waters with the objective of removing heavy metals. The chem­ical stabilities of the produced metal precipitates are critically important, from an environmental point of view, for their safe disposal in tailing ponds. The EPA regulates waste material dis­posal according to the results from TCLP testing. In this ongoing study, three mine waters were selected for treatment with Di-Cal and MgO. Lime was used as the control for these experiments. The waters were collected from the Bunker Hill mine, Berkeley Pit, and the Blackbird Mine. In addi­tion to testing the chemical stability of produced metal precipi­tates by the TCLP procedure, two other parameters were studied as well. They are: 1. the effect of water pH on stability, and 2. the effect of pH on the stability of resulting precipitates. In the first three months of study, it was found that neutral­ization with Di-Cal results in precipitates that range from equiv­alent to superior in performance as compared to those produced using lime for the waters from all three mines. An additional beneficial characteristic of precipitation with Di-Cal is the fast filtering characteristics of produced precipitates, when compared to the precipitates produced by lime. This property may be of significance when considering the improvement in drainage of tailing ponds and the volume of solids produced. This paper will discuss in detail the stability of metal precipitates with respect to various pe1iinent metals found in mine waters of Berkeley Pit (Cu, Zn, Mn, etc.), Bunker Hill (Zn, Mn, Ni and Co), and Blackbird Mine (Cu, Co).

Jan 1, 1998

By R. W. Lawrence, P. B. Marchant

Biohydrometallurgy is now forty years old. Since the discovery of the role of microorganisms in the oxidation of sulphide minerals that gives rise to acid mine drainage, many workers in industry, research organizations and academia in many countries have been active in attempts to develop practical commercial processes which exploit microbiological reactions in mineral processing and extractive metallurgy. Reactions which have potential and are being actively researched include:

Jan 1, 1998

By A. Goulsbra, S. McAllister, R. Dunne

Since 1992, a tailings gravity re-treatment plant has been in operation at the New Celebration Gold Mine to recover aurifer­ous pyrite (Martins, Dunne and Gelfi 1991; Martins, Dunne and Delahey 1993). The gravity pyrite concentrate is ground in a Tower mill to liberate gold (average particle size around 25µm) prior to cyanide leaching. Although the re-treatment plant has met the predicted gold recovery, based on original laborat01y testwork, there is still room for improved gold recovery. This requires enhanced pyrite recovery, especially in the finer size ranges. The application of centrifugal gravity separators would seem to be an ideal means to achieve this criterion. In particular, the Falcon continuous centrifugal separator (Series C machines) would appear to be ideal for this particular duty. A testwork program to evaluate the application of the contin­uous Falcon to recover pyrite from New Celebration ores was unde1iaken over a six month period during the later part of 1997. The work involved laboratory batch testwork, followed by con­tinuous testing of the Falcon Cl0 (2tph to 3tph) and Falcon C40 (l00tph) units. A summary of the results from this evaluation program are provided in this paper.

Jan 1, 1998

By Gregory Owen Lewis

The use of gravity concentration as a means of recovering the 'free' gold component from alluvial and milled ore products is widely used and is receiving increasing attention, particularly with the introduction of the centrifugal-type concentrating units. Because of ever-increasing mining and processing costs and a decline in the gold price, it has become important that the recov­ery efficiency from concentrates is improved so as to increase the yield of bankable gold from this primary recovery step. This paper outlines an alternative hydrometallurgical approach aimed at achieving overall gold recoveries in excess of 98%, together with the elimination of any secondary residue streams which, in the case of conventional treatment methods, require re-processing. An adaptation to the Minataur™ Process technology is being applied with the proposed method, incorpo­rating the pre-treatment of the concentrate, oxidative leaching of the pre-treatment residue, followed by precipitation of a high­purity gold. This route is seen to have application in all scales of operation. Selected results from laboratory-scale testwork are presented to highlight the discussion.

Jan 1, 1998

By William M. Clark

In 1988, the Chemical Manufacturers Association (CMA) launched Responsible Care®, a program of guiding principles created to address the publics' concern about the manufacture and use of chemicals. The Product Stewardship Management Practice code is a key component of the program. Along with the other five comple­mentary codes - Community Awareness and Emergency Response (CAER), Pollution Prevention, Employee Health and Safety, Process Safety, and Distribution - it has been initiated to protect the health and safety of member companies employees, neighbors, customers, the public and the environment. Possibly no other Management Code requires greater collec­tive effort or comprehensive commitment to implement than Product Stewardship. With its mandated cradle-to-grave control, every employee is required to consider all of the potential cir­cumstances involving product and processes, from raw material supply to customers final use or consumption of product. Degussa Corporation, a long time CMA member, fully endors­es the Responsible Care initiative and is most active in imple­menting the various codes. In fact, the guiding principles of the program are an integral part of the company's business strategy. Degussa recognizes that its long-term success and the health of each of its products, the company and the chemical industry itself, is contingent on the successful implementation of the program. Furthermore, the company believes its role in society and the economy can only be justified and sustained if it improves the overall quality of peoples' lives. Consequently, it is a dictum that Degussa products must provide a net benefit over their entire life cycle - from inception to final disposal - both in terms of their utility and their impact on health, safety and the environment.

Jan 1, 1998

By John C. Schneider

During the past decade, operators and researchers have worked toward a better understanding of the mechanisms operating in flotation. As reported by W. J. Trahar in 1981, this work commenced with the operators determining a relationship between recovery and particle size. They defined three particle size ranges, that being fine, intermediate and coarse. It was noted that the fine and the coarse ranges had slower flotation rates than the intermediate range as demonstrated by their lower recoveries.

Jan 1, 1998

By Paul Chamberlin

Although performing a heap leach test is inherently simple, a lot of information beyond extraction, leach time, and reagent consumption can be obtained from a well designed test program. The following is a list of information to look for and acquire when performing column tests and field heap leach tests.

Jan 1, 1998

By M. S. Hunter, Al Bishop

In 1994, Lone Tree Mine invited Hunter Hawk to participate in a problem-solving arena at their mine located in Valmy, Nevada. Lone Tree was experiencing consistency problems with autoclave valve component quality and delivery. Based upon a prior working relationship at Homestake Mining Company's McLauglin Mine, located in Lake County, California, both customer and vendor enjoyed a measure of rap­po1i and trust - the keys to problem solving communication. This paper is an overview of the problem solving process that has contributed to Lone Tree's excellent record of 95 per cent autoclave availability since 1995.

Jan 1, 1998

By J. H. Tu

The technical paper correctly points out that the kriging variance is not a good measure of the uncertainty of the estimated (i.e., kriged) value of individual blocks. The au thors claim that their proposed jackknife method, which is a rekriging of each block by eliminating, in turn, one sample from the original sample set and then taking the average of the rekriged estimates, not only gives good block estimates, but the resulting jackknife kriging standard deviation is a useful indicator of the "true uncertainty associated with block estimates." However, they immediately abandon the idea of using the block-by-block standard deviations, reasoning that these standard deviations are not independent and that there is no easy way to utilize them. There may be another reason for not using them. The jackknife standard deviations for individual blocks given in their example are mostly in the range of 0.004 to 0.005 oz/st (0.14 to 0.17 g/t) with only one block having a high value of 0.012 oz/st (0.41 g/ t). These individual block standard deviations are as low as the jackknife standard deviation for the mean grade of the entire shape, i.e., 0.0041 oz/st (0.14 g/t). Do they represent the "true uncertainty" of the individual block estimates? Could the authors explain this? In a global shape consisting of a large number of blocks, any given sample will affect the kriged estimate of only those few blocks within its vicinity. This is the rationale for the authors' selective rekriging, making the jackknife algorithm more efficient. On second thought, why not do away with jackknifing altogether? Just cumulate and normalize, if necessary, the kriging weights of each sample used during the ordinary block kriging process, and then compute the global variance from these kriging weights and their respective sample grades? After all, isn't the global mean grade nothing but the weighted average of the samples used in the estimation? Reply by G.S. Adisoma and M.G. Hester The jackknife is one of the many tools in a practitioner's toolbox to solve estimation problems. The strengths of the technique lies in its simplicity, i.e., it uses the concept of mean and standard deviation and the fact that it can be easily combined with other tools, in this case kriging. Because the jackknife kriging (JK) estimate is also the mean of the pseudovalues, the JK standard deviation is attractive just as the standard deviation of the mean explains the variability of the data. The difference is that the pseudovalue calculation in jackknife kriging uses the ordinary kriging (OK) weighting scheme instead of simple arithmetic averaging. The data used to illustrate the jackknife technique in the paper consist of high values that are roughly three times the low values. The resulting JK estimate of the block grades show that the highest estimate is roughly twice the grade of the lowest estimate. The contrast between the low and the high estimate is more evident in the JK estimate than in the OK estimate, even though the mean grades of the blocks for the two estimates are very similar. Nonetheless, in this paper, we are concentrating more on the need for a more realistic measure of uncertainty, or precision, for the estimate. Unlike its OK counterpart, the JK standard deviation of the blocks clearly reflects the original data variation. The highest JK standard deviation of the blocks is three times its lowest value. This follows our intuition that, when the samples used to estimate a block is more variable, the resulting estimation variance (or standard deviation) should be higher than the case where the samples are more uniformly valued. However, block-by-block standard deviation or variance is of little practical value in reserve estimation and classification, as well as in mine planning. One is usually more interested in quantifying not the variance of the individual block estimate, but the uncertainties associated with a much larger dimension, such as the minable reserve. Thus, the thrust of the paper is to find a simple way to obtain a single estimation variance or standard deviation associated with the reserve grade estimate. The discussion by J.H. Tu did not mention how one would obtain the global variance from the OK weights and the sample grades. As a technique that offers a data valuebased measure of uncertainty for its estimate, the "leave-one-out" jackknife fills this need nicely through the block kriging shortcut approach described in the paper. Note: The first column and the last two columns of Table 3 in the paper should have contained a single number each, namely, an OK estimate of 0.0317, a JK estimate of 0.0333 and a JK standard deviation of 0.0041 oz/st, respectively, for the shape, as are obvious from the text. ?

Jan 1, 1998

By V. B. Achanti

This paper deals with the effect of various bit geometric parameters on failure characteristics of rock material. Improvement of rock cutting efficiency of continuous mining machines has been an interesting research topic for the last few decades. In the current study, an automated rotary rock cutting simulator, duplicating a continuous miner, was utilized to study these parameters in the laboratory. Improvement of bit performance in terms of its life, cutting efficiency, dust production and energy consumption has drawn wide spread attention over the years. Research shows that optimizing bit parameters can result in efficient fragmentation of rock. Indiana limestone rock material was utilized in this study while bit tip angle, bit tip size, bit spacing, depth of cut and cutting velocity of rotary drum were varied to investigate the failure characteristics. The cutting pressure, penetrating pressure and the depth of cut were monitored on the simulator during the cutting process. Air borne dust and settled dust were measured for each experiment. Then, the specific airborne dust and specific energy were determined for the each type of bit. Triaxial tests were carried out to correlate the failure angle of the rock in static case to dynamic cutting process failure. The physical and mechanical properties of the rock were also determined in order to assess their influence on the wear characteristics of each bit.

Jan 1, 1998

By J. G. Groppo

Froth flotation has been shown to be an effective method for reducing Loss-on-Ignition (LOI) of ponded or landfilled fly ash. Reduction of LOI is required for many fly ashes, particularly those produced from low-No, burners, in order to meet ASTM requirements for use as a mineral admixture in Portland cement concrete. An additional ASTM requirement, fineness, is critical in determining end use applicability, and in many cases, classification of fly ash is necessary to produce an acceptable product. Hydraulic classification has been shown to be a simple, cost-effective method for classification of a variety of minerals including silica, phosphate, mica, coal, etc. and has shown to be similarly effective on fly ash. The combination of froth flotation and hydraulic classification facilitate the production of a high quality pozzolan that meets or exceeds ASTM specifications. This combination has been rigorously evaluated and results of pilot-scale testing are presented. Pilot scale testing was conducted on fly ash from two active utility storage ponds and demonstrated that high quality, consistent pozzolan could be produced using APT's Fast Float? Technology. Along with the pozzolan, additional production of aggregate for masonry mortar and a low sulfur, medium Btu fuel were also demonstrated. The Fast Float? process incorporates several simple unit processes to ensure pozzolan consistency; classification controls particle size distribution which is critical to achieving early strength, flotation controls the grade with respect to L.O.I. (Loss on Ignition) while dewatering controls the moisture content.

Jan 1, 1998

By B. W. Cavender

Capital investments are made for a variety of purposes, from providing incremental capacity at existing operations to developing and implementing new technologies intended to radically improve a company's capabilities. These projects generate very different business opportunities and create value in distinctive ways. For incremental improvements, the capital budgeting process assures at least a loose fit between short-term goals and readily available resources. However, the criteria used to evaluate capital projects often prevent a company from committing to more aggressive goals that lie beyond the firm's current abilities or resources. Such projects may not have clearly identifiable future cash flows, and the degree of interaction with other projects and the nature of the risk incurred may be difficult to estimate. Additionally, by focusing only on quantifiable benefits, the budgeting process often fails to recognize "soft" improvements such as increased operating flexibility or new knowledge generated by such projects. By rejecting these projects, the capital budgeting process may actually harm the company's future competitive position.

Jan 1, 1998

By Ian Hutchison, Michael C. Salmon

TRC'S INNOVATIVE EXIT STRATEGIES™ FOR MINE CLOSURE , MINE "EXIT STRATEGIES™", WHAT IS AN EXIT STRATEGY™?

Jan 1, 1998

By Kwadwo O. Adutwum, George M. Potter, Todd J. Harvey

Ashanti Goldfields Company (AGC) is the largest gold mining company in Western Africa. Their jewel operation is a highly inte­grated set of mines and plants situated in Obuasi, in the Ashanti region of Ghana. This operation is responsible for mining 5.5 mil­lion tonnes of ore at 4.6 git annually from a series of open pits and underground mines. The sulphide ore is highly refractory with untreated gold recoveries in the range of 30-40%. The milling facilities are quite varied and include an oxide treatment plant (OTP), a heap leach, a sulphide roaster circuit (PTP), a tailings treahnent plant (TIP) and the most recent, a sulphide treatment plant (STP). The sulphide treatment plant, the world's largest stirred tank biooxidation circuit, was commissioned in early 1994. This plant treats approximately 800 tonnes of refractory gold con­centrate per day with overall recoveries of75-85o/o(ll, Biooxidation was selected for its ease of operation and less exotic maintenance requirements as well as its ability to achieve comparable gold recoveries. Unfortunately, despite stirred tank biooxidation being one of the lower cost methods of treating refractory ores, it is still too costly for low grade refractory materials. GeoBiotics, Inc. has developed a proprietary technology that allows the economic treatment of lower grade refractory gold ores through heap biooxidation. AGC has a significant resource of low grade refractory sulphide ore. This ore is too low grade to warrant BIOX™ sulphide treatment and its oxide plant recov­ery is low at 35-45%. GeoBiotics and AGC have completed pre­liminary testing and economic analysis of heap biooxidation for this material. Additionally, the feasibility of producing a gravity concentrate from the tailings of the sulphide treatment plant has been explored. This concentrate would be coated onto the low grade sulphide and biooxidized concurrently. Gold recoveries for the biooxidized low grade sulphide have increased to 75% and the gravity recovery from the STP tailings has achieved 80% uti­lizing a Falcon concentrator. The preliminary economics of the proposed full scale plant are very favourable with a pre-tax IRR of 233% and a payback period of 6 months. This paper details the biooxidation testing, flow sheet devel­opment and preliminary economics of employing heap biooxi­dation for low grade refractory ore treatment at Ashanti Goldfields' Obuasi operation.

Jan 1, 1998

By Roy Norcross, Stephen Gos

For over 100 years Degussa has worked together with the min­ing industry not only providing quality products but also develop­ing technologies to support these products through value added goods and services. For cyanide, these technologies include leach enhancement processes such as PAL™ and Solidox™, and cyanide detoxification with peroxygen based processes such as SILOX™ and Caro's acid using our DegOX™ technology. Degussa has also made important advances in how sodium cyanide is packaged and shipped with our liquid NaCN plant joint venture with MSI, CYANCO in Winnemucca, Nevada, and our Advantage SLS™ solid to liquid cyanide delivery system. All of these innovative technologies developed to support NaCN in mining, provide value to our customers and show Degussa's commitment to Responsible Care·11.1 and dedication to product stewardship. With Responsible Care and the customer in mind, Degussa has developed Advantage CCS™ cyanide control system, which will soon be available for the North American market. Currently there are several CCS units in service installed by Degussa AG (Germany), and we are in the process of designing the next gen­eration of the CCS which should be completed by late '98. Based on our experience working with gold and silver mines all over the world, there appeared to be an opportunity to further assist our customers by providing a better more automated way to control their cyanide additions. By providing the mine with an accurate method for maintaining their desired cyanide levels in their leach circuits, we could help them avoid underdosing and the associated gold and silver losses, and overdosing the cyanide which not only wastes cyanide but may increase treatment costs as well. In the early 1990's, when we began to introduce our CCS units, there were several cyanide controllers and on-line analyzers avail­able. However, they appeared to be too complicated and not made to stand the harsh conditions inside a mill. This resulted in exces­sive downtime and poor analytical results. We also found that many units would be installed but not commissioned by the sup­plier. Based on these observations, along with filtration and con­trol problems on some existing units, Degussa decided to design its own cyanide control system based on our extensive knowledge of cyanide chemistry, using the best components available worldwide.

Jan 1, 1998

By John A. Lombardi

The solutions used in the heap biooxidative treatment of sulfidic refractory Au ores and concentrates generally load free mineral acid and metals and, in time, become bacteria activity inhibiting due to increased acid and/or metals concentrations. The metals­acid loaded, bacteria action inhibiting, solution must then be: (a) processed, prior to re-use, to reduce its metals and/or free acid mineral acid components to bacteria activity compatible levels; or (b) neutralized prior to discharge. The most common solution processing method to adjust acid-metals contents is liming to effect the precipitation of dissolved metals and neutralization of acid sufficient for solution discharge or re-use. The lime treated solution is high in suspended, colloidal precipitates and requires clarification before reuse. Most often the "bleedstream" of biooxidation solution that is lime treated is discharged and req­uisite volumes of fresh water added to the process inventory. Depending on the level of bacterial action in a heap and the acid consumption characteristics of the ore/concentrate being biooxi­dized, the bleedstream taken from the circulating, irrigation on­off, solution, can be large (e.g., 10%-20% and sometimes as much as 50% of the daily solution flow requires treatment-dis­charge). The lime charge for bleedstream treatment is commen­surately large and represents a major operating cost of the bioox­idation process. The patented HW Process Technologies (HWPT) Engineered Membrane Separation (EMS™) method is an alternative biooxi­dation bleedstream treatment method. EMS™ processing removes the multivalent base metals ions in an acid solution to a small volume EMS™ "concentrate" (typically 25% of the feed­stream volume). The EMS™ method coincidentally makes a "clean acid" EMS™ "permeate" (typically 75% of the feed­stream volume). In general, EMSTM processing enables 75% of the bleedstream volume to be recycled; allows up to 2/3 of the bleedstream acid to be recovered as a 10% solution; and delivers dissolved metals in a highly concentrated stream suited to a. metals recovery or b. reduced cost lime neutralization for a given metals precip­itation relative to full bleedstream neutralization (typically a 30% lime use savings). Implicit in the recovery of process water for re-use and reduced reagent addition requirement for metals precipitation is a significant reduction in wastewater-sludge dis­posal facility size.

Jan 1, 1998

By Robert Dunne

Over the last eighteen months, there has been a dramatic r decrease in the gold price fom US$450/oz to a low of US$275/oz. The prospect of low gold prices, around US$300/oz, appears to be a reality the gold mining industry will have to face over the next couple of years. Already some high cost operations have closed and at others, cost cutting measures and rationalisation have been or are being undertaken. This paper reviews the operating cost of some Australian mines and highlights the potential for cost cutting and demon­strates individual impacts on the dollar's reduction in the cost per ounce of gold.

Jan 1, 1998

By D. Scott Barr

The Zarafshan/Newmont Joint Venture operates the Muruntau heap leach project, located in the Kyzylkum desert of central Uzbekistan. The mine produces more than 12.4 t/a (400,000 oz/year) of gold from low-grade oxide ore stockpiles adjacent to the Muruntau open pit. It is op¬erated by the Navoi Mining and Metallurgical Combine and is one of the largest gold resources known (Fig. 1). Since commissioning in 1995, total heap leach production has exceeded 21 t (675,000 oz). The joint venture uses four-stage crushing and screening to produce a final product for heap leaching, Merrill-Crowe processing and local refining.

Jan 1, 1998

By Terry McNulty

DOUG HALBE: I've decided that we're going to change tactics here and we're going to be nice to people from now on. [Co-chair makes gesture of intense disbelief; laughter] I've also decided who's not going to be a co-chair next year. [laughter] We thought we'd get a couple of experts for our next presentation: some people with a lot of experience. We've asked them to tell us some of the things that all of you operators out there might be able to apply immediately to your plant. Our next two speakers have a tremendous amount of experience, and I think you'll find what they're going to say is highly pertinent to most plants. I looked through their paper and found some things that I could have used in the plants I operated in the past. Our first speaker is Terry McNulty. A lot of you know Terry. He was with Anaconda for a number of years as director of research. He then was president of Hazen Research. I'm going to continue with our new custom of saying nice things. Terry is the guy that I call when I don't know something, and he's always got the answer. SPEAKER: Who do you work for, Doug? [laughter] DOUG HALBE: Remember that we're being nice to people here, Joe. I know that's a stretch. [laughter] TERRY McNULTY: Thank you, Doug. I'm a little bit mystified by this sudden switch of tactics just before I get to the podium. Doug's been a good friend for a lot of years so I guess I do have to be nice. I won't say anything deprecatory about him, but I would have to comment that the observations made by earlier speakers have been far too generous. [laughter] During nine years of consulting as a mineral processor and extractive metallurgist, I have often conducted audits of the performance of client's plants. Usually these audits have been ordered by the plant management in hopes of identifying opportunities for improving processing efficiency or reducing costs. Some of the audits, however, have been financed by the Electric Power Research Institute (EPFU) and member utilities with the objective of

Jan 1, 1998

By William P. Blacutt

This paper describes the strategy, the struggles, and the obstacles encountered during the last two years in the ongoing process to capitalize Vinto. The effort involves the offering of a vertically integrated business package composed of the tin and antimony smelters along with the two principal tin mines of the country. Capitalization: Bolivia's Innovative Approach for Privatization, the Vinto Case provides a summary of hard-earned lessons. These experiences can be success- fully implemented in other nations committed to transforming their state natural resource sector.

Jan 1, 1998