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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

By P. Gelfi, G. Hill, A. Showell, V. Martins, R. Dunne, R. Jenkins

Carbon attrition losses are not usually a prime consideration for CIP equipment selection and CIP plant design. However, the costs as a result of carbon attrition and associated gold lost with carbon can be high. Recorded carbon losses for Newcrest operating gold plants were shown to vary widely from plant to plant. The Tuckabiana plant recorded an overall loss of only 0.3g carbon /t ore which is very low by industry standards. A comparative carbon management study was undertaken by Newcrest to highlight the reasons for the excellent record of Tuckabiana operation compared to other Newcrest plants. This paper discusses the results of the comparative study and high­lights areas of concern with respect to carbon attrition.

Jan 1, 1995

By Robert J. Storms, David J. Malone, Thomas E. Crandall

Corrosion and abrasion have been present in hydrometallurgical processes for many years. Ceramic lining materials have been used in several applications to protect process vessels from the corrosive and abrasive effects of a wide range of ore slurry processes. This paper reviews the history of ceramic lining systems utilized in hydrometallurgical vessels, the commercial benefits associated with their use, and additional areas of opportunity for the Mining Industry.

Jan 1, 1995

By Stephen Young

The continuous monitoring of free cyanide levels is an important part of gold recovery operations. Accurate and up to the moment knowledge of the free cyanide concentration can result in substantial cost savings by allowing reduced concentra­tions with lower fluctuations, while maintaining or increasing gold recovery. Reduced free cyanide levels also result in lower detoxification costs at the mill discharge which translates into further savings while meeting environmental requirements. As can be seen from the upper curve in Figure 1 (which is based on in-service measurements), without accurate monitoring and control, cyanide concentration fluctuates during the produc­tion cycle, and is maintained at a high level to err on the side of caution. The lower curve illustrates the improved control permitted by the installation of a CY ANCOR, giving a more consistent concentration over the process cycle, and safely allowing use of a lower concentration.

Jan 1, 1995

By Julia R. Budden

The role of bacterial oxidation in the mining industry is becoming more widely accepted. Western Australia has accepted the technology as a pretreatment for refractory gold concentrates more readily than most. The third of such plants has been completed at the Y ouanmi Gold Mine. This is situated approxi­mately 500 kilometres north east of Perth, in the Yilgarn mineral field. Y ouanmi concentrates are produced from underground ore and contain arsenopyrite and pyrite as the main sulphide miner­als. Refractory gold from this deposit is generally associated with the arsenopyrite portion of the material. Gold Mines of Australia Ltd ("GMA") initiated pilot scale testing at the BacTech premises in November 1993. The decision by GMA to use BacTech's technology was announced in February 1994. Design and construction commenced at this time. Bacterial growth on site was initiated in July 1994 and continuous opera­tion began in the October. Concentrate was added at 0.5 tonnes per hour and this has increased to 1 tonne per hour.

Jan 1, 1995

By J. G. Dunn, A. S. Ibrado, D. J. Hollbach

Gold production is one the most important mineral process­ing industries in Western Australia. The gold is usually found in either weathered oxidised zones, or associated with sulfides. In the latter case, oxidation is achieved by some form of chemical processing, such as roasting or more recently bacterial leaching. In all cases, gold is dissolved out of the oxidised matrix by cyanide solution. Pyrrhotite is an iron sulfide generally represented by the formula Fe1_,S where O x 0.125. Three different structural forms ofpyrrhotite are known to occur naturally, stoichiometric FeS (troilite), hexagonal pyrrhotite Fe1_xS and monoclinic pyrrhotite Fe7S8 [I]. Substitution of iron atoms within the pyrrhotite structure by other ions of similar atomic radius such as nickel, copper, cobalt and manganese is also possible [2], and often observed in natural pyrrhotite samples. Pyrrhotite is abundant in Western Australian sulfide mineral deposits which are commonly associated with gold bearing ores. It is generally believed that pyrrhotite has a detrimental effect on gold recovery from such ores, as it is commonly claimed to decompose in alkaline, aerated cyanide solutions to form iron cyanide complexes, thus consuming free cyanide, and to form sulfur/oxygen containing species such as sulfate, through oxidation of sulfur in pyrrhotite, which thus consumes oxygen. From information gleaned from the literature, claims about the high reactivity of pyrrhotite in cyanide appear to be based on early cyanidation studies performed on gold ore samples which have been poorly characterised, and contained impurities such as pyrite, arsenopyrite and chalcopyrite, which may have also contributed to the levels of species observed in solution [3-5]. In addition, the investigations do not take into account that iron atoms in the pyrrhotite structure may have been partially substituted by other atoms that influence the solubility of pyrrhotite in cyanide solution.

Jan 1, 1995

By M. J. Virnig, J. M. W. Mackenzie, M. W. Johns

The properties of Henkel's Aurix® resin which uses a guanidine functionality to recover gold by ion exchange have been described in publications of the International Mineral Processing Congress and Randol International (1)(2). The purpose of this paper is to provide an update on the results of further testwork using Aurix®. Specifically, this paper presents the first results of resin in pulp testing, all the results previously reported were for testwork carried out using synthetic gold leach solutions.

Jan 1, 1995

By Hans von Michaelis

It is difficult to fail if one has a great deposit, but 'great' ore deposits are few and far between. More often one hears that a mine has been 'made' rather than found. This is particularly true for industrial minerals and for gold and silver projects. Even the best ore deposit can often be improved through innovative technology, e.g. the Escondida copper mine in Chile, where a novel ammonia leaching process is yielding a fabulous DCFROI. Consider the case of a small high grade gold mine. Previous owners had found inadequate reserves to justify the capital cost of developing the mine and installing a mill. Lower grade resources had been ignored because the owners were looking only for grades that would be high enough to support a small underground mine and mill. Randol, assisted by Kappes Cassiday & Associates, determined that the ore was amenable for heap leaching. Secondly, existing drillhole data indicated a significant lower grade resource that appears to be accessible to open pit mining methods. In this case, the appropriate selection of off-the­shelf technologies has literally 'made' the mine. At the Randol at Vancouver '94 conference on Latin American Mining Opportunities, papers on innovative technolo­gies for exploration, mining, metallurgy and environmental management were presented in non-technical terms for managers and resource developers. It was surprising how few of the exploration- and finance-oriented delegates participated in these sessions. Numerous technologies were presented that could be added to one's arsenal of tricks to 'make' a mine, i.e. to convert resources into ore reserves through knowledge.

Jan 1, 1995

By Stephen C. Everett

Why? This is the first question that everyone asks. Why did Renison give away such a valuable asset? What is the problem with Mt Lyell? No doubt this question was asked of Denehurst regarding Woodlawn, MPI at Stawell, Golden Shamrock at Cobar, Western Metals at Cadjebut and Poseidon with the Big Pit. Whilst it is not possible to second guess the rationale behind Renison's strategic withdrawal from an operation that they considered to be uneconomic, the Renison/Mt Lyell deal has certain specific perspectives:

Jan 1, 1995

By Hugh K. Herbert, R. John Watling

Laser Ablation-Inductively Coupled Plasma-Mass Spectrom­etry (LA-ICP-MS) has been used successfully to "fingerprint" gold in forensic investigations within Australia and abroad. By comparison of the elemental associations it has been possible to relate gold to specific mineralising events, mines, bullion samples and fabricated articles. The methodology facilitates identification of the provenance of gold thereby providing definitive scientific evidence in criminal investigations. "Gold" samples for analysis span a wide range of materials with many requiring exhaustive prior separation and treatment to present the contained gold in a chemically "unmodified" state, and in a form, suitable for LA-ICP-MS fingerprinting. The quality of the fingerprint, and hence its value in evidence, is directly related to the rigours of prior sample preparation and evaluation, to an appreciation of the history of the gold under investigation, and to the skill of the analyst.

Jan 1, 1995

By Hans von Michaelis

The current exploration boom in Central and South America shows no sign of abating and, if anything, is growing. This is despite an inevitable cooling in the recent frenzied buying of resource stocks on the Canadian exchanges which have funded much of the Latin American exploration. Several factors appear to be driving the boom. Firstly, the resource potentials in this vast under-explored regions are nothing short of phenomenal. Secondly, after decades of stifling nationalization and restrictions that stood in the way of foreign investment, especially in mining, emerging nations the world over now suddenly find themselves competing with each other to be the most attractive.

Jan 1, 1995

By David Muir, Slobodanka Vukcevic

Gold is commonly associated with copper minerals, particu­larly in the more geologically recent rocks of Northern Australia, Chile and the Pacific Rim. Traditionally, oxidised copper-gold ores are selectively mined and processed for gold by cyanidation, ensuring that levels of reactive copper in the ore are kept low to minimise cyanide consumption; whilst sulphide copper-gold ores are floated and gold is ultimately recovered as the by-product from copper smelting and refining (La Brooy, 1992). Very few process­ing options exist for treating copper ores which cannot be selec­tively mined or floated, and for treating floation tailings which often contain significant gold (Muir et.al.,1989). The ammonia-cyanide leach system stands out as a unique method of selectively extracting gold without copper using economic levels of cyanide (1-2 kg/t NaCN) and ammonia (1-5 kg/t). Although first patented in 1904, it proved difficult to control and predict per formance with different ores. However, recent research and development in Western Australia by Ruane (1991), Hayes and Corrans (1992), La Brooy et.al.(1991), Muir et.al.(1993), Muir and La Brooy (1993), has led to an under­standing of the mechanism, and the commercialisation of the process at the Paris Dump (W.A.), Akjoujt (Mauritania), and in the Eastern Transvaal (Laxen,1994). Efforts are now underway to pilot and develop a tailings treatment plant at Telfer following successful laboratory trials. To date, process optimisation has relied on trial and error and large numbers of tests covering a range of conditions. Thus the results are specific to the ore. At Murdoch University, process optimisation is now focused on measuring and control­ ling Eh, pH, NH3 [Cu(II)], and Cu-CN species at the optimum levels identified from the recent mechanistic studies. In this way, the optimum composition required to process any ore should be readily established and maintained.

Jan 1, 1995

By L. D. Gehi, A. W. Khair, M. Ahmad

This paper presents an analysis of the dynamics of bit wear on the productivity of continuous miners. Two field surveys were carried out. The first survey assessed the impact of bit wear on productivity and production cost. The second survey studied the wear characteristics of the cutting tool (i.e., magnitude, forms, and mechanisms of bit wear, Primary factors affecting bit wear were identified. Laboratory experiments were carried out to study in detail the effect of some of these primary factors on wear. Results indicate, that bit wear has a significant effect on the productivity a continuous miners. Furthermore, under severe geologic conditions (i.e. cutting rock partings in roof and floor) bit wear not only hampers the productivity, but also increase the production cost due to a higher consumption of bits. This study also indicated that beyond 20% of the conical height loss (which corresponds to 7% of the weight loss) the rate a bit wear accelerates. This increased rate of wear is an indication of higher abrasion between bit body and cutting material, resulting in a dustier environment.

Jan 1, 1995

By X. P. Zheng, H. K. Lin

Barium fluorophlogopites were synthesized in the laboratory to investigate the effects of composition and crystal parameters on surface properties and floatability. The negative surface charge of mica is determined by the barium content, the crystal cell volume, the distance between the layer structure and the Ba-O bond length. The higher the barium content, the larger the cell volume and distance between the layer structure, and the longer the Ba-0 bond, the more negatively charged the surface is, and, hence, the more easily adsorbed are cationic collectors. When an anionic collector (sodium oleate) is used, barium oleate forms on the mica surface and hence chemical adsorption occurs.

Jan 1, 1995

By W. A. Van Dyk

Hydrophobic particles with diameters between 1 and 3 mm are poorly recovered by conventional flotation techniques. A novel reverse flotation technique is described whereby coarse particles with surfaces rendered highly hydrophobic, repel the bubble films in a froth and thus drop through the froth under gravity, to be recovered as a sink product. Conversely, gangue or hydrophilic particles are supported by the bubble films in the froth and are therefore recovered as a floating product. Tracer tests were conducted in the cell in order to study the dynamic behaviour of solid particles in the froth. The effects of hydrophobicity, density, particle size and particle shape were investigated experimentally. The higher the hydrophobicity of the particles, the lower the recovery of particles as a floating product, while the recovery of particles as a sink product increases with an increase in particle density. Furthermore, a decrease in particle size results in an increase recovery of hydrophobic particles as a floating product. When treating particles of the same mass-to-surface-area ratio in the froth, flat particles would be recovered as a floating product in preference to cubic, disc-shaped, cylindrical and spherical particles, in that order.

Jan 1, 1995

By B. J. S. Sceresini

The Filblast Cyanidation Process incorporates the advantages of intense high shear mixing, high dissolved oxygen concentra­tion and high pressure to achieve extremely rapid gold dissolu­tion rates. This is made possible without suffering from high energy or wear rates by the unique design of the Filblast gas shear reactor. The reactor is a rugged and compact in-line device which can be constructed from a variety of wear and chemical resistant materials. High temperature tolerance is also possible so that the device can be incorporated into a pressure leach circuit with significant capital cost savings because of the high capacity to volume ratio that is an inherent feature of the device. For cyanidation applications the outer casing is protected by a polyurethane coating and the internal parts are of wear resistant polymer. The largest unit built to date has overall dimensions of 1200 mm length by 300 mm diameter and has a capacity of about 150 dry tonnes per hour at 40-45 % solids. Service life at this throughput is at least three months. Six mines are currently employing the Filblast Process and another six are conducting plant trials. The ore types range from highly reactive, almost impossible to treat, pyrrhotite/ arsenopy­rite to deeply weathered clay ore which forms a highly viscous pulp. It has been found that the effect of shear thinning has resulted in improved leaching and adsorption kinetics resulting in higher carbon loading and reduced soluble gold loss. Total tonnage treated is approximately eight million tonnes per annum. This paper presents the operating benefits and cost savings which have been achieved in four plants, two treating oxide/ sulphide ore blends and two treating highly reactive sulphide ore and concentrate. Filblast leasing and maintenance charges and pump operating costs are about ten percent of the benefits. A conceptual cyanidation circuit based on the Filblast Cyanidation Process is also discussed. The Filblast System is an in-line pressure leach aerator/ reactor which generates very high shear and greatly enhances mass transfer rate by generating extremely small gas particles where oxygen gas is required for oxidation reactions and/or utilising the high shear characteristics to minimise the diffusion boundary layer. Both of these rate limiting factors effect the rate mechanism for gold cyanidation. Initially two multi-stage Filblast aerator cartridges formed a leach train but now the trend is to install a single submersible cartridge of equivalent perfor­mance. This design simplifies installation and minimises change-out times. However the in-line concept can be employed where high pressure leaching or pressure oxidation is required. The reactor is submerged in the leach tank so that the mass of gas micro-bubbles contained in the discharging slurry is entrained in the agitator vortex and is thoroughly dispersed throughout the tank. A diagrammatic representation of a leaching circuit incorpo­rating the Filblast Reactor is shown in Figure 1. The recirculation pump takes new feed directly from the cyclone overflow trash screen either under gravity or pump fed and recirculates the balance to maintain 250 - 270 m3/h total slurry flow. All of the leach feed slurry gets at least one pass through the Filblast thereby eliminating short-circuiting. Typically a 6/4 EAH Warman pump drawing 60-70 kW is required to circulate 250 m3/h through the system. The back pressure generated by the Filblast is in the range of 400-500 kPa depending upon pumping rate, pulp density and slurry rheology. The high shearing rate effectively negates the viscous effect of slurries and the addition of a gas further reduces the pulp density by virtue of the intensely aerated, homogeneous medium. The gold leaching Filblast cartridge elements are made of polyurethane but stainless steel, ni-hard, rubber or ceramics can be used depending on the operating temperature and design duty. The efficiency of the Filblast Leach Reactor in gold cyani­dation is due to the extremely efficient mixing, oxygen dissolu­tion and surface polishing action of the Filblast design. Either air or oxygen may be used but Atomaer recommend the use of oxygen because of the rate benefits gained from cyaniding at [02] significantly > 20 ppm D O in the reactor. Very high DO concentrations have been measured; in excess of 50 ppm. There is some debate as to whether the value is a true measure of the DO or the oxygen meter sensor is measuring the effect of a mass of very fine bubbles of free oxygen. Regardless of the fact the reactor has registered some amazing gold dissolution rates commonly in excess of 80 % during transit of the pulp through the reactor. The elapsed time is less than half a second!

Jan 1, 1995

By P. Whincup, T. Showell, B. Marchant, R. Dunne

An oversupply of copper on world markets in the early 90' s, coupled with a decrease in demand, resulted in a "tight" market for the sale of copper concentrate. In these conditions small producers of low grade copper concentrates found it difficult to sell their products. The situation was exacerbated for those producers also having reasonable quantities of penalty elements (e.g. As, Bi). The Telfer Gold Mine bulk copper gold concentrate, produced from treating underground sulphide ore, fell into this category (i.e. 16% to 20% copper, 30% to 35% sulphur and 3500ppm to 4500ppm arsenic). The concentrate sulphide minerals are predominately chalcocite and pyrite. Although a higher grade copper concentrate was attainable a substantial decrease in gold recovery ensued. Under the prevailing market conditions a decision was made to stockpile concentrates pending either an easing of market conditions or alternatively finding an on site method for treating the concentrate to recover both the contained gold and copper.

Jan 1, 1995

By Peter Erlynne

Rising costs have affected the cost of operating and install­ing crushing circuits, just as they have affected every other area and there is little possibility that the cost cycle is about to be reversed - power costs, wear materials costs and labour costs continue to increase but a basically stable gold price makes little allowance for these cost increases. Additionally, lower grades of ores being worked, and harder feed materials have a significant effect on the potential for higher processing costs. There are, of course, options for size reduction - some of them newer than others - some are suitable for certain types of ores and less suitable for others and it can sometimes be difficult to ascertain the accuracy of anticipated results before plant design and con­struction are completed - by which time the capital outlayed will preclude a change to another method ofreduction. Nordberg's patented WaterFlush Technology has the potential to change the way that Ball Mill Feed production is viewed: Some of the elements that must be considered are: • Capital Cost • Operating Cost • Efficiency • Flexibility • Availability • Control • Support Efficiency • Expertise • Spares availability • Environmental considerations

Jan 1, 1995

By Peter Bourke

It was in 1982 that the first SK-80 flash flotation machine was introduced at Hammaslahti concentrator in Finland to produce a final grade copper/gold concentrate. Since then the size and number of flash flotation units has steadily developed with the SK-240 being introduced in 1984 and the SK-500 unit in 1990. To date over 130 units have been installed worldwide many of which have been used to maximise the recovery of precious metals such as gold and platinum by preventing overgrinding in the grinding circuit prior to flotation. This paper briefly describes results achieved at several major gold mines in Australia and overseas that operate large flash flotation cells.

Jan 1, 1995

By Jeffrey R. Kelly, Paul M. Kubera, Richard A. Howk

Mixing of solid-liquid slurries is a unit operation that is widely encountered in the minerals processing industry. Applications may range from simple slurry storage in open tanks to complex chemical reaction systems under extreme conditions of temperature and pressure. The specific process requirements dictate both the degree of mixing required and the type of agitation employed to achieve the desired results.' Many continuous-flow process applications feature tanks operating in series to provide a discrete number of stages and a known residence time for the slurry. Because these tanks operate at a constant level in an overflow mode, the mixer must maintain uniform solids concentration and size distribution throughout the tank; failure to achieve uniformity results in accumulation of coarse solids in the tank, ultimately leading to a process or mechanical failure. Downward-pumping, axial-flow mixing impellers are widely employed to produce uniform solids suspension. The specific impeller type, number, size, and power draw is a function of each given situation. The use of high-efficiency, fluid-foil impellers (Figure I) has evolved as a recognized standard for these flow­controlled applications. Recent small-scale experimentation and full-scale experience has demonstrated that, when uniformity is required, capital and operating expense can be minimized by employing an additional upper impeller pumping in the upward direction.

Jan 1, 1995