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Flotation Circuit Optimisation - Towards More Sustainable Practice

Sep 13, 2010

By J P. Clark

Industrial minerals contribute about 50% of the NZ$1.2 billion generated annually by the minerals industry in New Zealand. The value is supplemented by a further NZ$500 million of minerals imported to supply our vital agricultural and industrial activity. As globalisation of the world's economy precedes, sources of minerals are being processed by fewer companies giving an ever-increasing control over global markets. If only to protect its primary production New Zealand needs to aggressively develop its mineral resources. The successful development of a deposit requires identification of the preferred market. While low-value aggregates dominate New Zealand industrial mineral production it is more specialised minerals supplied to the manufacturing and industrial sectors that provide more value per tonne. Minerals that have highly desirable intrinsic properties, or through value-added processing provide desirable properties, have the ability to fill niche markets both locally and overseas. Research and development towards enhancement or creation of desirable mineral properties could benefit New Zealand with both increased mineral potential and export of technological information. But, it is nearly always the market not the resource that dictates the viability of an industrial mineral and, with the globalisation of industrial mineral markets resulting in fewer but larger companies, any supplier must be ready to explore niche markets in order to compete on a more global basis.

Jan 1, 2000

By B Vernon, M Whiteley, T Robinson

The Western Australian gold industry has approximately 100 operating plahts, mainly CIP/CIL. The nature of the State's rapidly expanding gold industry gave rise to concerns over management of the  cyanide hazard, in that most plants are remote from major population centres, have a workforce with a high tum over and use highly saline process water. Approximately 4500 workers in the industry have the potential to be exposed to cyanide in the course of their normal work.   This paper outlines the risk management strategy developed by Government and industry to monitor atmospheric HCN gas in the work environment and the role of continuing education and training along with regular site inspections by Department of Mines Inspectors.

Jan 1, 1990

By T. T. Field, M. Gell

MUCH has been learned about plastic deformation behavior in crystals through the use of dislocation and slip band etchants. Slip in nickel and nickel-base alloys has previously been revealed by various etching techniques.l-5 The techniques for nickel-base super-alloys4,5 were successful only in the Udimet 700 composition in specific heat-treated conditions. The objective of this work was to develop a more generally applicable slip-band etching procedure. The nominal compositions of the alloys used in this study are listed in Table I. The low carbon Mar-M2OO alloy referred to in the text is the same as listed in Table I with the exception that the carbon content is less than 100 ppm. Mar-M200 and Udimet 700 were solutionized at 2250" and 2150°F, respectively. The aging treatment for both cast alloys was 32 hr at 1600°F and for wrought Udimet 700 was 4 hr at 1975"F, 24 hr at 1550°F, and 16 hr at 1400°F. The new slip-band etching technique consists of a chemical etch followed by a short electropolish, Table 11. Fig. l(a) shows the best result obtained on an internal section of a plastically deformed single crystal of Mar-M2OO when using a conventional slip-band etching procedure which consists of electropolishing followed by etching. Ghostlike traces corresponding to planar slip bands are observed, but the contrast between the bands and the background is weak. Fig. l(b) shows the same field using the new slip-band etching technique. After the etching step of this technique, the same ghostlike traces of Fig. l(a) are observed, but the subsequent electropolishing accentuates the slip bands and the subgrain boundaries while the rest of the matrix is being polished. Longer electropolishing obliterates the slip bands. The new slip-band etching technique makes use of the etchants and electrolytes that are normally used for a given material. Because of this, it should be possible to slip-band etch other nickel-base superal-loys by using existing etchants and electrolytes for a material and following the procedures outlined in the "Comments" section of Table 11. All the illustrative examples given below show internal plastic deformation in single crystals of regular and low carbon Mar-M200 in the solutionized and

Jan 1, 1970

The Bureau of Mines Minerals Information organization collects worldwide data on virtually every commercially important non fuel mineral commodity. These data form the base for tracking and assessing the health of the minerals sector of the U.S. economy. This data collection activity was instituted by the 47th Congress in an appropriations act of August 7, 1882 (22 Stat. 829), to place the collection of mineral statistics on an annual basis. The most recent authority for the Bureau of Mines Minerals Information activity is the National Materials and Minerals Policy, Research and Development Act of 1980 (Public Law 96-479, 96th Congress), which strengthens protection for proprietary data provided to the U.S. Department of the Interior by persons or firms engaged in any phase of mineral or mineral-material production or consumption.

Jan 1, 1984

For the past four years, the Department of Mining Engineering at the University of Kentucky has conducted a validation study of the CFD Fluent code, by comparing its results against mining-related benchmark experimental data provided by NIOSH?s Pittsburgh Research Laboratory. This particular study is dedicated to the effect of machine-mounted dust scrubbers on the performance of face ventilation systems using extended-cut mining with a blowing curtain.

Jan 1, 2009

This paper summarizes seven years of Italian ex­perience with the use of large calibration chambers for the calibration, under closely controlled stress and strain conditions, of some in situ testing devices which are used in sand deposits. At the present time two calibration chambers are operating in Italy, one at E.N.E.L.-C.R.I.S. (Milan) (*) and the other at I.S.M.E.S. (Berga­mo) (**). Both chambers can accomodate cylindrical samples 1.2 m in diameter and 1.5 m in height. A detailed description of these chambers can be found in Bellotti, et. al (1982).

Jan 1, 1987

By A Yame, P J. Pollard, E Atase, J Garu, M Tangwari, D R. Hastings, R W. Smillie

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Townsville prospect is situated approximately 4 km north of the Ok Tedi copper-gold mine in Western Province, Papua New Guinea. Drilling in the 1990s delineated a resource of >1 Moz of gold within shallow, skarn breccia-hosted mineralisation associated with quartz-carbonate infill, together with pyrite, chalcopyrite, pyrrhotite, sphalerite, galena, tennantite-tetrahedrite, arsenopyrite, marcasite, and a variety of Au-, Ag- and Bi-telluride minerals. The deepest of these historical holes (TVL034) also intersected copper-gold-silver mineralisation more than 100 m below the gold-rich zone that is associated with calc-silicate skarn breccia. Although copper-gold-silver mineralisation in DDHTVL034 is associated with clinopyroxene-rich skarn, it was also noted that garnet in the skarn breccia became progressively darker in colour with depth, ranging from green at shallow levels to dark red-brown at depth. This indicated that the skarn breccia is zoned, with more proximal garnet skarn at depth possibly indicating an association with porphyry-style copper-gold mineralisation.Based on this skarn zonation model, recent drilling at the Titan prospect, located approximately 500 m south of TVL034, was targeted at potential copper-gold silver mineralisation beneath shallow skarn breccia-hosted gold mineralisation. DDHTVL 081 intersected 46 m at 6.36 g/t Au from 68 m and 80.7 m and 1.67 per cent Cu, 1.27 g/t Au and 20.32 g/t Ag from 184 m. Exploration is now attempting to define the extent of copper-gold-silver mineralisation by defining structural controls on the skarn breccia together with paragenetic and mineral zoning data.CITATION:Smillie, R W, Pollard, P J, Hastings, D R, Yame, A, Tangwari, M, Garu, J and Atase, E, 2015. Exploration of the Townsville Cu-Au-Ag skarn, western province, Papua New Guinea – preliminary observations of paragenesis and zoning, in Proceedings PACRIM 2015 Congress, pp 593–600 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By D. Harrington

Educational campaigns conducted by the manufacturers of explosives, the Bureau of Mines, mining companies, and safety organizations have contributed greatly in reducing accidents caused by explosives arid blasting. Despite these campaigns and the dissemination of information, accidents from explosives and blasting continue to be the direct cause of scores of fatalities and hundreds of nonfatal accidents annually, not only in the mineral industry but essentially wherever explosives are used. The experience of many mining companies and other users of explosives has proved that accidents from explosives can be prevented or averted by the proper training of employees in the handling and using of explosives and by the enforcement of definite rules and instructions for their use. Unfortunately, throughout the years numerous false impressions and ideas have grown up and around the use of explosives. Many of these can be traced back to the manner in which the users of explosives were originally taught, if instructed at all; and as with many types of misinformation in nearly all walks of life, those false ideas are decidedly persistent and being so cause much damage. Many if not most of the users of explosives gained their knowledge of explosives and blasting by watching others and more or less "absorbing" the procedures and thrones of the other fellow, who acted unconsciously as teacher or instructor. A study of explosives accidents reveals the results of such "teachings" when the causes of the accidents are determined, and as might be expected the results very often are far from good. One of the most persistently erroneous impressions or ideas is concerned with the burning rate of safety fuse. Many men with

Jan 1, 1944

By J. A. Finch, Zhenghe Xu, Z. A. Zhou

A particle-bubble collision model was used to investigate the minimum recovery zone height, H(r,min) required for flotation columns. The criterion used to define H(r,min) is that height which gives unit collision probability. It is shown that H(r,min) is determined by particle and bubble size, gas hold-up and bubble-bubble interaction. Under typical operating conditions, for flotation of particles less that 10 micrometres in size H(r,min) is greater than 10 m, but it reduces to less than 1 m for particles greater than 100 micrometres

Aug 1, 1995

By M. Jele

? Sulphuric acid plant in umbogintwini. ? Double absorption plant, capacity of 550MTPD. ? Build by simon curve during the year 1973. ? Side stream plants such as: ? Liquid SO2 Plant, ? Liquid SO3 and ? Oleum plant

Jan 1, 2009

By C. O. Brawner, J. Kalejta II

The classical approach to control rock fall and ravel in open pit mining has been to use catch benches. The width and volume of benches is most dependent on the bench height, size of loading equipment, blast damage to the face and mining regulations. This was compatible with open pit slopes of less than about 45°. As our understanding of rock mechanics and blasting control has improved over recent years, much steeper rock slopes can be developed at many open pit mines. However, narrower benches result with less rock fall capacity. The transportation industry has been very successful in using catch fences to protect highways throughout North America and Europe for years. The authors recommend that cable and ring net fences have a potential major application in open pit mining to allow steeper rock slopes with significant economic benefit. This paper outlines the application, design and operation of catch fences in surface mining for specific conditions. Typical case examples are presented.

Jan 1, 2002

By Alan D. Curtis

A standard planning block model for Phelps Dodge North America Operations has been developed to improve mine planning efficiency and performance in a skill starved environment. The model saves time on software management and training, consolidates data and standard information/output, enhances evaluation and strategic process, and improves communication between sites.

May 1, 2007

By F. -J. Wodopia

Sustainability of energy supplies has been an issue of general interest for a long time. Whilst in the past the continuous productive use of natural commodities was in the fore, its compatibility with the environment and climate and ultimately also social aspects have recently gained more and more attention. Today many discussions focus on the climate compatibility of individual options to act. Fossil fuels, in particular coal and lignite, are generally challenged because coal use makes a significant contribution to global man-made CO2 emissions. The drastic increase in the consumption of fossil fuels is not explained by the fact that coal utilisation technologies are not or cannot be sustainable but rather by the growing world population and the endeavours numerous national economies trying to catch up economically. Coal is the world’s No. 1 fuel and, in the view of many experts, will keep this position also in the foreseeable future. The access to its deposits plays a significant role for the economies of the emerging countries. Consequently the aspects of energy security and economic efficiency need to be considered at eye level with climate compatibility. In Germany, however, the public acceptance of fossil fuels and of large industrial projects is in the focus of attention.

Jan 1, 2011

By M Fallon

The full history of exploration successes, failures and related costs from initial greenfield exploration in 1987 to the current brownfield stages was analysed for the Plutonic Marymia Gold Belt of Western Australia. This belt, which had escaped the attention of turn-of-the-century prospectors and had not produced any gold until 1990, is an ideal area for a collectively exhaustive, progressive value and risk case study of expected return on gold exploration. The study analyses the progressive screening of over 200 greenfield and near mine prospects, through various stages of exploration to the establishment of 38 mining sites, ranging from a few large mines to small satellite operations. It provides empirical estimates of the historical Bayesian probability of projects advancing to successive stages of exploration, eg from reconnaissance, to systematic drill testing, resource delineation, feasibility and mine development, given a successful outcome in any exploration phase. The ratio between the estimated value of the gold discovered and the corresponding historical exploration expenditure in each year and cumulatively, ie the average cost of discovery per ounce of gold, are then computed as measures of historical return on the exploration investment in this belt. These, together with an estimate of the æresidualÆ gold endowment, ie of the number and size of possible as yet undiscovered deposits, generated through the use of rank statistics (ie ZipfÆs law), provide a basis for future strategic consideration in exploration targeting in this and similar geological terranes.

Jan 1, 2009

By Roger S. Jackson

"This study interprets vibrations produced by single underground shots, recorded on surface by 135 digital seismographs laid out in four linear arrays. Several vibration anomalies were observed and are investigated. A novel method of displaying the blast-induced vibration iso-contour data relative to the three-dimensional representations of the geological rock units and structures leads to the following interpretations:• The identified faults commonly dampen or amplify vibrations, on the evidence of the peak particle velocity,• Strong anisotropy of geologic formations produces different vibration attenuation in the various directions of interest,• Low-vibration “depressions” can be related to the presence of faults, and• Higher vibration levels than expected based on ‘scaled-distance’ principles are observed close to intersecting faults.The interpretations from this study document a better understanding of the geotechnical influences on blast induced stress wave propagation in a geologically complex area. The practical benefit of this understanding is better control of surface vibrations, experienced from underground mining activities."

Jan 1, 2010

By Abigail Styer, Paul Holmgren, Josh Calnan

Detonating cord is a staple of the explosives industry, used widely in the civil and defense industries. Detonating cord is a thin, flexible plastic tube filled with pentaerythritol tetranitrate (PETN). It has many applications in mining, construction and military disciplines. For civil applications, it is used to connect and initiate a series of blastholes in a desired pattern. In the defense sector, it can be used as a detonating agent, a priming agent or alone as an explosive charge. Research has been done to understand the initiation and detonation physics on the detonating cord. However, its sympathetic detonation characteristics needed to be further analyzed. The sympathetic detonation of the detonating cord can lead to the poor performance of production shots in mining or civil applications and unsafe conditions in defense applications. This paper focuses on the analysis of different factors involved in the sympathetic detonation of various sizes (grain weights) of detonating cord. The variables analyzed include the minimum distance between segments of detonating cord and grain weights. These variables were analyzed by securing segments of detonating cord at measured distances apart on a steel plate and detonating them. The physical examination of the aftermath of this detonation included a qualitative recording of data. Applications of detonating cord that could be affected by this research include mining and construction blast initiation, explosives disposal, and breaching.

By R. J. Anderson, A. V. Castelli

In 1986, United States' barite production fell 48.9%, consumption - sold or used by grinding plants - was off 47.3%, and imports were down 63.8%. Meanwhile, world mine production decreased 29.6%, according to the US Bureau of Mines. However, value of US-produced barite FOB mine increased 46.51%, according to USBM figures. The declared value CIF US port of all imported unground barite decreased from $41.94/t ($46.23 per st) to $39.02/t ($43.01 per st). Nevada continued to be the leading US producer of barite with 69% of the total. It is followed by Georgia, Missouri, Tennessee, and California. The USBM estimates that 65% of the barite mined was used as a weighting agent in drilling fluids. The remaining 35% was used in the production of barium chemicals and as a filler. Most of the production from Missouri, Georgia, and Tennessee was used in the non-oilfield sector. This sector made up a larger percentage of the US produced barite in 1987 than it did in 1986, increasing the overall value per ton of barite. Barite consumption was at its lowest since 1963. It is estimated that 80% of the barite was consumed in the drilling fluid market. The remaining 20% was used in barium chemicals, glass, and as filler in plastics and paper. The decline of barite used in drilling fluid followed the decline in the average number rotary rigs operating - 964 versus 1968 in 1985. This was the lowest average number of rotary rigs operating since 1971. The non-oilfield market was up 5.3% in 1986. This increase can be attributed to the increased use as a filler in plastics. Imports of crude barite, though down nearly two-thirds, still made up 65% of the barite consumed in the US. China was the leading exporter to the US with 58%, followed by India, 15.4%; Morocco, 11%; Thailand, 5.4%; Mexico, 4.6%; Chile, 3.9%; and Ireland, 1.7%. Less than 1% of the imported ore was used in the nonoilfield sector. Imports of ground barite dropped from 64.4 kt (71,000 st) to 19.8 kt (21,800 st) in 1986. Of this amount, 14.1 kt (15,500 st) were used in drilling fluids in 1986 and the remainder for non-oilfield use. During 1986, more of the grinding plants supplying the drilling fluid market were closed. Dresser Magcobar and IMCO Services, a Halliburton company, formed M-I Drilling Fluids Co. Mine production in the US will probably decrease in 1987 due to the lower cost of imported ore. No significant change is expected in the drilling fluid market. The average number of operating rotary rigs is estimated at 950 in 1987 versus 965 in 1986. The nondrilling fluid markets (chemicals, glass, and filler) will follow the overall US economy. Bauxite and alumina R. J. Anderson, Ohio State University US bauxite production in 1986 dropped to a pre-World War II level, continuing a decline that began a decade ago. 1986 production totaled 450 kt (496,000 st), compared to 674 kt (743,000 st) in 1985. World production of bauxite also decreased in 1986. This reflected the soft market in alumina, aluminum, and related products. Total mine production worldwide came to 79 Mt (87 million st), down from 85 Mt (94 million st) in 1985. For the sixteenth consecutive year, Australian production of bauxite led all other sources. No other country approached the 28 Mt (31 million st) mined in Australia in 1986, despite a 4.4-Mt (4.9-million st) drop in its output from 1985. Other major producers in 1986 were: Guinea 11 Mt (12 million st), Brazil, 6.5 Mt (7 million st), Jamaica, 6.5 Mt (7 million st), and Suriname 2.8 Mt (3 million st). Despite weakness in world demand for bauxite, Venezuela, heretofore an alumina producer, is now pushing development of a new mining venture near the western border of the state of Bolivar. Plans call for barging bauxite down the Orinoco River to the Ciudad Guyana alumina plant, a distance of 650 km (400 miles).

Jan 5, 1987

By E. A. von Hahn, T. R. lngraham

The rates of cementation of pd11 on electropolislzed copper cylinders were studied in aqueous perchloric acid solutions at pdII concentrations from 0.02 to 0.1 mM. The cylinders were rotated at various high speeds to reduce the diffusion layer to a minimum thickness. In 0.1 M HClO4 solutions, the cemented palladium is dense, adherent, and shiny. The rate data indicate that there are two stages in the deposition. In the initial stage, the rate of cementation is first order with respect to the pd11 concentration. The second stage is much slower. The first stage is consistent with rate control by the diffusion of pd11 ions to the copper surface, and/or chemical reaction at the surface, and the second stage is consistent with rate control by the diffusion of copper ions from the cop-per surface through the deposit of cemented palladium, out to the main body of solution. In 0.001 M HClO4 solution, only the first stage is evident and the rate is more rapid than at higher acidities. This rate enhancement is attributed to PdOH+ ions that predominate at low acidity and aye more reactive than unhydrolyzed pdII. The deposit is porous and loose. All of the cemented deposits are Pd-Cu alloys rather than pure palladium. Activation energies are 9.5 kcal per mole in 0.1 M HClO4 and 7.4 kcal per mole in 0.001 M HClO4. CEMENTATION or displacement reactions occur between aqueous solutions of metal salts and immersed metals according to the general equation: where M1 is electrochemically the more noble metal. Although these reactions find considerable application in metals recovery processes (e.g., the cementation of copper192 or gold3), in electrorefining processes (e.g., solution purification before electrolysis4,5), and in plating and metal finishing processes,6 few studies have been made of the kinetics of such reactions.7-9 The rates of cementation reactions will depend on one or more of the following factors: a) chemical reactions at the metal-solution interface; b) ionic transport to or away from the interface;'-' and c) the character and adherence of the cemented deposit on the substrate metal,6a,10 because the deposit will inhibit the rate of transport of dissolving ions (M2m+) into the solution. In this investigation, the kinetics of the early stages of cementation were studied to obtain an understanding of the reaction mechanism under conditions in which the deposit was sufficiently thin that its inhibiting effect could be disregarded. To achieve this, very dilute solutions in Mn+ were used. Cementation rates are often fast in the initial stages and transport-contr01led.9 To find conditions under which transport control would shift to chemical control, very high stirring velocities were used to minimize the diffusion-layer thickness. Of the many possible cementation reaction systems, the palladous perchlorate-copper system was chosen for this investigation because it was believed to involve simple ion-for-ion exchange. In addition, there are no interfering side reactions, such as the reduction of hydrogen ions, and anion effects are usually absent in perchlorate solutions. EXPERIMENTAL Materials. Reagent-grade chemicals and redistilled water were used in all experiments. Palladous perchlorate stock solutions (0.02 M) were prepared by dissolving 99.5 pct Pd sponge (Johnson Matthey and Mallory Ltd.) in concentrated nitric acid, adding concentrated perchloric acid, evaporating twice slowly (to prevent PdO precipitation) to a small volume, and diluting in a volumetric flask. To prevent gradual hydrolysis of PdII, the stock solutions were made 0.4 M in HC104. Tests for pdIV (Ref. 11) and C1- were negative. Copper strips were cut accurately from 0.025-in. electrolytic tough pitch sheet, Sample 1 (Mines Branch stock or Canadian Copper Refineries Ltd., Montreal), or from oxygen-free, high-conductivity sheet, Sample 2 (American Metal Climax O.F.H.C. brand, sold by Utility Brass and Copper Corp., Brooklyn). The strips were annealed for 1 hr at 335°C in a stream of purified nitrogen (Union Carbide, Linde Division) which had

Jan 1, 1967

By Wilson D, Kirkland J

Compressed air energy storage (CAES) uses low cost off-peak energy to compress air and pump it into pressurised underground storage. Expanding the air through a modified form of gas turbine generates electrical energy when required. While generating power, a CAES station consumes approximately one-third of the gas required for the equivalent installed capacity of a conventional gas turbine. Air can be stored in underground rock caverns, caverns in salt domes, or in aquifers. Existing CAES power stations use caverns mined out of salt domes. Aquifer storage for CAES has been proposed, but not yet implemented. The groundwater in the aquifer would be displaced during air injection and when required the air would be extracted using the natural hydro-static pressure. Victoria has no salt domes, but has aquifers onshore in the Gippsland Basin with geological dome structures of suitable depth, discovery pressure, porosity, permeability and caprock for CAES development. Field tests costing several million dollars would be required to prove the suitability. The most suitable aquifer is near Seaspray, where several dome structures exist. The aquifer, comprising of coarse sands capped by coal and mudstone, is some 600 metres deep with a hydrostatic pressure of 6.3 MPa. Computer simulation of injection and extraction of air from the aquifer under various combinations of horizontal and vertical wells, permeability and tubing head pressures indicated the largest aquifer structure had the capacity to sustain a 300 MW station. A well field comprising of 24 directionally driven wells with a horizontal exposure to the aquifer would achieve the air flow rates required. Using plant similar to that recently installed at McIntosh Alabama USA, would mean high capital costs compared to standard gas turbine plant. However, a review of modem gas turbines indicated that they could be easily and economically adaptated to CAES duty. Adapting a 120 MW gas turbine would give 344 MW output. A separate air compression plant would be used. Economic evaluations indicate that, for gas prices above $1.95 per GJ, a 344 MW CAES plant is more economic for intermediate/reserve load duty than simple cycle gas turbines.

Jan 1, 1992