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By J. C. O'Rourke

"Gibraltar Mines Ltd. has been operating its open pit copper mine for fifteen years. In that time over 140 million tons of waste and low grade material has been placed on the mine waste dumps. Laboratory and in-situ testing indicated that enough leachable copper was recoverable from the dumps to justify a leaching operation which would include the construction of a solvent extraction-electrowinning plant. The plant, which was commissioned in October, 1984 was designed to process 3,000 usgpm of dilute copper solution to produce 5,000 tons per year of high quality cathode copper.This paper deals with the start up and initial year of operation of Gibraltar's SX-EW plant. The three areas: leaching solvent extraction and electrowinning are presented with emphasis on the innovations which were made to help overcome the problems unique to die Gibraltar operation.THE LEACHING CIRCUITThe mines waste dumps are leached to produce a pregnant copper solution as feed to the SX-EW plant. To achieve this the dumps are sprinkled with a mildly acidic solution which percolates through the dump. In travelling through the dumps the solution contacts the surfaces of the liberated copper minerals and disolves the soluble copper into the form of copper sulphate. The leaching reaction is achieved by a combination of bacterial action to oxidize the suphides and solublization of the copper into the acid solution.For the bacterial action to occur the dumps must be at or near the ideal pH of 1.9 - 2.1 and the necessary elements of the reaction must be present. Because a bacterial reaction is involved there is a lag time between the time when the conditions for bacterial growth are achieved and when the bacteria are in their active growth phase. Laboratory tests with Gibraltar ore indicated that bacterial action takes two to three months to reach its maximum rate. See figure 1.The expected lag time for the planned rate of bacterial leaching prompted Gibraltar to start irrigating the dumps in late June 1986 for a plant start up in early fall. The lag time proved to be longer than expected and the dumps took until November to start producing copper at the expected rate. See figure 2."

Jan 1, 1988

By J. Koponen, K. S. Stadler, A. Fuerst, S. Gaulocher, Th. von Hoff, R. Veldsman

"Gearless mill drives (GMDs) are the workhorse in the mineral processing industries, more specifically when it comes to grinding crushed ore and cement (in various production stages) in semiautogenous (SAG) mills and large ball mills. They are renowned for their excellent reliability and robustness, long lifespan, and little need for maintenance, and thus yield a low total cost of ownership (TCO).A GMD represents a major investment for a mineral processing plant, and its availability is pivotal for the grinding process. As a basic rule, shut-down periods are to be minimized, but even much more important is that unscheduled shut-downs be avoided. In this contribution, we will present a portfolio of innovative remote diagnostic that consist of the following three key components:1. Trouble shooting is a form of corrective maintenance and is based on state-of-the art remote access technology, thus enabling highly skilled engineers to access the current sensor readings anytime and from anywhere in order to resolve urgent problems together with the GMD user.2. Periodic maintenance reports are a form of preventive and predictive maintenance and aim at continuous improvement based on long-term historical records and analyses of multiple measured signals. These detailed reports highlight the health and operational status of the GMD and are periodically (e.g. 3 months) submitted to the customer.3. Remote condition monitoring spans across preventive and predictive maintenance and is based on continuous recording and automatic analyses of relevant signals using advanced algorithms. The main issue is how to handle the enormous flood of data in an intelligent manner. The results of these analyses are made available to both the GMD user and supplier in real time in order to increase the availability and reliability of the GMD.In this paper, we consider various parts of the GMD, e.g. the cycloconverter, the ring motor, the auxiliary devices (e.g. cooling and lubrication systems), and also phenomena related to the mill itself (e.g. state and quantity of charge). The signal analysis techniques range from simple threshold-based analyses to complex time and frequency domain analyses. We will illustrate the benefits of the proposed approaches with some selected examples."

Jan 1, 2012

By Ken McClure, Alex Day

Located North of Williams Lake British Columbia, Gibraltar Mine is the fourth largest open pit Copper mine in North America. Gibraltar commenced Copper concentrate production in 1972 with a mill throughput rate of 30,000 tons per day. A series of expansion projects, including installation of a second SAG mill with variable speed drives in 2013, has increased mill throughput to 85,000 tons per day. Over the past 24 months, Gibraltar Mine in partnership with Spartan Controls has executed several advanced process control programming projects culminating in the implementation of a Continuous Speed Controller (CSC) for the most recently installed SAG mill. This paper covers development and results for the SAG mill speed controller. INTRODUCTION In January 2016, the price of Copper fell below $2.00 USD per pound, the lowest price in 7 years. Gibraltar Mine faced a significant challenge; how to maximize profit in an environment where capital spending was not an option. An opportunity was quickly identified to improve performance through increased automation and advanced control of the grinding processes. Beginning in March 2016, Gibraltar Mine partnered with Spartan Controls to introduce Advanced Process Control (APC) to the grinding circuits. The collaboration between metallurgical and process control engineering disciplines proved to be effective for achieving gains in throughput, reliability and productivity for the mill process. The Gibraltar milling facilities include 2 grinding-flotation plants for concentration of chalcopyrite ore with throughput rates of 58,000 tons per day (Concentrator 1) and 38,000 tons per day (Concentrator 2). Each of the two concentrators has a 34’ diameter SAG mill powered by 2 GE 4800 kW synchronous electric motors. For SAG 1 (in concentrator 1), power is transmitted through 2 Eaton Airflex clutches. For SAG 2 (in concentrator 2), the motors are driven by 2 TMEIC Variable Frequency Drives (VFDs). All programming is done using DeltaV, which Gibraltar uses as its Distributed Control System (DCS) and Human Machine Interface (HMI).

Jan 1, 2019

By Walter Valery, Lauren Hafla, Megan Tibbals, Adrian Dance, Jeff Snyder

"Newmont Mining Corporation’s Carlin (“Carlin”) operation processes roaster feed through a double rotator, dry grinding mill following secondary crushing. Metso Process Technology & Innovation (“PTI”) was involved in a review of crushing and dry grinding circuit operations in August 2009. A number of opportunities for increased throughput were identified in the PTI study.Extended plant trials were conducted in July 2010 to provide justification for possible circuit modifications and if needed, additional equipment. The trials confirmed that a finer crusher product would reduce the build-up of material ahead of the coarse grinding chamber in the double-rotator. Also revealed were material transport and airflow restrictions in the dry grinding circuit that resulted in a high circulating load.The secondary crushing plant demonstrated it was capable of reducing the amount of +¾” material in the mill feed thus increasing dry grinding throughput. However, wet and sticky feed affected screening efficiency resulting in low utilisation of the existing crusher capacity. The open circuit configuration also made it difficult to control crushing circuit product size.For the dry grinding circuit, changes in grinding media size, transfer grate design and increased airflow were recommended to reduce circulating load issues and increase circuit capacity. This paper summarises the crushing and grinding circuit review, the extended site trials performed by PTI and the improvements in dry grinding operation that resulted from this study."

Jan 1, 2012

By P. Chu, J. A. Finch, R. Li

"Bubble size plays a key role in flotation. In this paper, we examine the possibility of using passive acoustic sending to determine bubble size. Software was developed based on Short Time Fourier Transformation (STFT) to analyze the frequency of the acoustic signal emitted from the bubble formation event. Bubble size was determined from the Minnaert frequency. The acoustic-determined bubble size responded to reagent dosage, but was less sensitive than that given by imaging. The constraints of the current acoustic approach are discussed.INTRODUCTIONBubble size is an important factor affecting flotation performance. It determines the maximum available surface area for collecting and transporting mineral particles. Of interest for process control (Gorain, Franzidis, & Manlapig, 1995), it can be determined by several techniques, such as image analysis (Grau & Heiskanen, 2002; Hernandez-Aguilar, Gomez, & Finch, 2002); conductivity (Barigou & Greaves, 1992); drift flux analysis using gas rate and gas holdup measurements (Banisi & Finch, 1994); and optical sensors (Randall, Goodall, Fairlamb, Dold, & Connor, 1989). However, all these techniques have drawbacks.Acoustic analysis of the oscillatory behaviour of bubbles to extract bubble size is another possibility (Leighton & Walton, 1987; Pandit, Varley, Thorpe, & Davidson, 1992; Al-Masry, Ali, & Aqeel, 2005; Manasseh & Ooi, 2009; Leighton & White, 2012; Spencer et al., 2012). The fundamental basis is the work of Minnaert (1933) who first correlated the bubble size with its natural frequency, Equation 1:"

Jan 1, 2016

By N. Molaei, E. R. Bobicki

The continued demand for mineral products, coupled with the depletion of high-grade ore resources, has led to the mining of lower grade ores, which often require fine grinding to achieve mineral liberation. Regrinding of low-grade ores results in the production of fine gangue mineral solids and produces vast quantities of fluid fine tailings which are difficult to separate from water, particularly if they are composed of clay minerals. Organic synthetic polymers and inorganic salts have been widely applied in flocculation of colloidal suspensions in the treatment of mining tailings. However, there are growing concerns regarding their impact on the environment and human health. Recently, extracellular biopolymer flocculants or bioflocculants have attracted much attention as alternative reagents. In this study, much effort has been devoted to considering the effectiveness of protein and polysaccharide-based biopolymers for the dewatering of clay slurries. The interaction between kaolinite and illite clays and biopolymers was investigated via settling tests at pH 7 and 10. Zeta potential measurements were also conducted as a complementary technique. Results showed that protamine and lysozyme protein- based biopolymers were generally the more effective bioflocculants. Pectin, a polysaccharide-based biopolymer, showed a dispersing effect and has the potential to be used as a dispersant and/or depressant for clay minerals in froth flotation. INTRODUCTION With the depletion of high-grade ore resources, the need for mining of low-grade ores has increased over the past few decades (Bourgès-Gastaud, Stoltz, Dolez, Blond, & Touze-Foltz, 2014; Chen, Walshe, Fru, Ciborowski, & Weisener, 2013; C. Wang, Harbottle, Liu, & Xu, 2014). Low-grade ores often require fine grinding and contain clay minerals, leading to the generation of fluid fine tailings (FFT). It is a challenging process to separate suspended clay particles from water (Craciun, Manaila, & Stelescu, 2013; Dompierre, Lindsay, Cruz-Hernández, & Halferdahl, 2016; Kasperski & Mikula, 2011; Mercier et al., 2012). Clay minerals form stable dispersions in water due to their anisotropic nature, non-spherical morphology and colloidal size (Lagaly & Ziesmer, 2003; Olphen, 1977). The difficulty in separating clay minerals from water has led to the accumulation of vast quantities of FFT in oil sands, phosphate, copper and nickel operations, representing a huge liability for mining companies (Chen et al., 2013; Mercier et al., 2012)

Jan 1, 2019

By M. A. Nadar

Harsh and dynamic construction sites are generally equipped with cranes in order to rapidly and conveniently move heavy loads from one location to the other. If not properly inspected and managed, this operation can be very hazardous and lead to accidents. As such, a reliable and self-contained monitoring system that can update construction and safety personnel about the status of the crane, the weight of the load lifted, the location of the boom with respect to nearby buildings and other tower cranes, and the weather conditions under which the crane is operating, is deemed necessary. This can lead to significant time and cost savings as well as safety and productivity improvement due to the accuracy and immediacy of relevant on-site crane information delivery. This paper takes the initial steps and presents research targeted at evaluating the capability of wireless sensor networks (WSN) for monitoring tower crane operations in construction environments. A reliable long range WSN system is implemented and information is obtained from various special-purpose sensors (temperature, wind, proximity, etc.) mounted on special motes that relay data to and from each other and a central hub. The latter continuously monitors and manages network performance and relays incoming data to the host application. This application, in turn, displays the received data, and maps it onto a user-friendly visualization scheme, triggering alarms when a set of pre-programmed rules and safety conditions are crossed. The components of the proposed system have been tested through proof of concept experiments and preliminary results highlighted the potential of WSN systems for improving monitoring of tower cranes and reducing related accidents on construction sites, especially in Lebanon and the Middle East region where safety precautions are usually not properly implemented.

Aug 1, 2013

By Osvaldo A. Bascur

Industrial complexes rely on measurements of flow rates, qualities, and concentrations for monitoring and optimizing their operation. Corporations use the data from the various sensors and measurements to make business decisions, which affect the profitability of the operation. However, gross errors, due to a variety of reasons like faulty sensors, bad instrument calibration, or incorrect process models may corrupt the actionable information supplied to operations, quality managers, and maintenance personnel. The solution is to use the sophisticated new tools to model the process, sift through the available data to locate the gross errors, and use statistical data reconciliation to validate the sensors and instruments. In this way the data are unified to give the most accurate plant information for use by the monitoring and decision making processes. Most mining and metallurgical plants use predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis, and oil and lube analysis for critical equipment. Process control strategies are installed in several metallurgical sites. All of these depend on reliable and accurate data. The data unification methods validate the individual measurements by using the concept of balances and statistical techniques where each instrument is no longer independent of the other measurements in the facility. This paper refers to the data unification and analysis methods required for profitable plant operations. Continuous improvement and monitoring of the measurement system at the plant and analysis of the reconciled data provide the best information for the decision-making process. On-line gross error detection and elimination methods are required to ensure efficient evaluation of process performance and process optimization. An open discussion of the new methods for gross error detection and data unification will be presented.

May 1, 2001

By J. L. Jambor, M. J. Baker, M. J. Logsdon

"Abstract - Prior to the development of the Diavik Diamonds Project, baseline studies were conducted to determine the geochemical characteristics of four kimberlite orebodies as an aid in the design of both the water-management system and the facilities for containment of processed kimberlite and ore stockpiles. Materials tested included field samples of volcaniclastic and pyroclastic kimberlite, processed kimberlite (i.e., kimberlite ore which had been screened and washed as part of the processing procedure), and sedimentary mudstone (a minor xenolithic unit which was assimilated during kimberlite emplacement). Approximately 200 samples of kimberlite materials were collected as part of the geochemistry program. Test-work included whole-rock chemical analyses, acidbase accounting, kinetic leach tests using columns, and mineralogical analyses. Diavik kimberlite has major oxide and trace-element concentrations consistent with global averages for kimberlite. The mean total-sulfur content of the kimberlite material is 0.22 wt% S, but with a significant range. The kimberlite has an excess of carbonate minerals over sulfide minerals (average CO2 = 4 wt%, present mainly as calcite), and has a mean neutralization potential of 311 kg CaCO3 equivalent/tonne. A reactive form of framboidal pyrite associated specifically with the mudstone xenoliths is the primary source of sulfide-sulfur. Long-term kinetic tests confirmed the preliminary interpretations that were made from the static-test results. Kimberlite and processed kimberlite are net acid-consuming materials that produce alkaline drainages and have low but detectable leaching rates for SO4 and specific trace metals such as Al, Co, Cu, Ni, and Zn. If segregated from the kimberlite, mudstone xenoliths are acid-generating (pH = 3) and produce an effluent with elevated concentrations of SO4, Fe, Al, Cu, Ni, and Zn. The study demonstrates that xenolithic units in Diavik kimberlites have an important effect on the environmental geochemistry of the ore rock. The mineralogy and aqueous geochemistry of the kimberlite materials are such that they may not be suitable for general earthworks or as an alkaline agent and should report to an engineered facility to protect site water quality."

Jan 1, 2001

By Laxman M. Amaratunga, Nuri Hrnidi

"Reactive pyrrhotite tailings were agglomerated using the Cold Bond Tailings Agglomeration (CBTA) process with low cost binders; Portland Cement and fly ash. Various chemical additives, were used to retard acid mine drainage (AMD), including acid neutralizers, surfactants, sealants, and bactericides, which were encapsulated into the agglomerates. The choice of these additives was based on their low cost, low toxicity, and environmental friendliness. The main objective of the study was to examine the long term stability of these reactive tailings agglomerates towards AMD when used as aggregates for disposal in underground paste backfill.A carefully controlled kinetic stability test was carried out using specially designed humidity cells suitable for testing pellets. Using the humidity cell test method a 20-30 year AMD test may be accelerated to 50 weeks. During this period the following parameters were monitored: pH, redox potential, conductivity, sulphate, acidity, and dissolved metals.Results indicated that most of the encapsulated additives were successful in retarding AMD, while the control samples produced significant amounts of acid generation. The water soluble surfactant Enviroseal, and the sodium silicate sealant were very effective as a long term retardant for acid generation reactions in the sulphidic tailings when exposed to oxygen, water and iron-oxidizing bacteria.IntroductionThe sulphidic material discharged from concentrators becomes reactive upon exposure to air and/or water. Pyrrhotite (Fe0 S0_1) and pyrite tailings in particular which are discharged from the beneficiation process in the mining and mineral processing activities consist of finely ground particles. Upon exposure to oxygen and moisture, the tailings become reactive due to the instability of the metal sulphide minerals present which undergo spontaneous oxidation, thereby producing a weak sulphuric acid. Therefore, the long-term behaviour of the tailings can have a significant impact on the environment, due to acid mine drainage (AMD). AMD is created during natural atmospheric weathering when leaching action (natural and bacterial) conditions are present in the process wastes discarded during the mining and milling of sulphur bearing ores, and consequently it plays a major role in surface water chemistry."

Jan 1, 1998

By M. Leroux, C. J. Martin, S. R. Rao, J. A. Finch

"The effect of nitrogen on the flotation separation of sulphides from complex ores from Brunswick Mining and Smelting (New Brunswick) and Mattabi Mines (Ontario) was investigated. The most significant finding was enhanced pyrite floatability after as little as 3 minutes nitrogen conditioning. This was used in a novel sphalerite/pyrite separation process developed on the Brunswick ore. After aeration and Cu/Pb bulk flotation in air using xanthate the slurry was nitrogen conditioned, xanthate added and the pyrite floated in nitrogen. As an example up to 70% pyrite recovery with about 20% sphalerite recovery was achieved. Sphalerite was recovered from the pyrite tailings and the pyrite concentrate by copper-activation, raising the pH to 10 and floating in air. About 65-70% recovery at 35-40% Zn grade was achieved compared to 25% Zn grade by the conventional route. The process offers a promising alternative to current practice which seeks to depress pyrite at all stages. A possible mechanism of the effect of nitrogen is presented. INTRODUCTIONUse of gases other than air in froth flotation has been reported from time to time. [Podobnik and Shirley, 1982; Lin and Metzer, 1975]. Of all the gases, nitrogen would appear to hold the greatest practical promise because of its easy availability and chemical inertness. It is used in froth flotation in chalcopyrite-molybdenite separation [Redfearn, 1983]. The use of nitrogen in polysulphide chalcopyrite. this case is mainly to reduce the oxidation of a compound (Nokes reagent) used as a depressant for There is no reported use of nitrogen in the flotation of other sulphide minerals."

Jan 1, 1988

By Alan B. Morrow, William A. Poe

"Minerals processing operations are constantly challenged with improving production rates, yields, energy efficiency and process stability. Advanced Process Control has proven to be an effective tool for improving operations by capturing the full process capabilities consistently. However, the velocity of applying the technology as well as the sustainment of these significant benefits has been hampered by the usability of the software and adaptability of the applications.Some of the new technology developments that improve the usability and adaptability of advanced process control include:• modern and intuitive user interfaces,• customizable models to support unique process behavior,• fast and flexible OPC connection tools,• automated model building,• integration with first principles dynamic models and• improved performance monitoring.This paper will briefly discuss the new technology developments that have improved the usability and adaptability of advanced process control and how this can affect minerals processing operations.In today’s environment, Minerals Processing plant managers continuously face new challenges and requirements including:• higher energy efficiency,• increased run lengths,• reduced product quality variability,• reduced emissions,• higher availability, and• lower operating costsOperating a unit to meet these challenges in real time is not easy for operators and conventional process control systems. However, innovatively using existing technologies in Minerals Processing plants can improve operations on a minute by minute basis and reap significant benefits.Advanced Process Control (APC) can extract the maximum performance benefits from existing equipment while respecting plant operating constraints. Expensive capital projects to upgrade equipment are not always necessary. Advanced Process Control can deliver significant economic benefits by maintaining the plant at its most profitable point as conditions change."

Jan 1, 2016

By T. Gonzales, S. Thakurdin

The conducting of risk reviews is an essential activity in ensuring safe operating conditions, both during project design phases and for existing facilities. The following paper presents a structured approach to the conducting of risk reviews for existing operations, including descriptions of supporting documentation and guidelines for on-site review activities. The conducting of regular site risk reviews and safety audits is crucial in ensuring the continued safe operation of existing facilities, particularly in the copper industry where numerous processes and unit operations can present catastrophic risks, both in terms of loss of life and financial liability. The structured approach presented aims to provide a logical and comprehensive analysis of risks to align safety-related facilities and procedures with current industry best practice and ensure consistency across multiple client operations. INTRODUCTION The production of copper, whether by pyrometallurgical or hydrometallurgical process routes, carries significant inherent safety risks. Production volumes are relatively large, often requiring complex processing routes, multiple production trains and a variety of supporting ancillary facilities. Furthermore, considering the relatively large size of ore reserves, copper production plants can have operational lives well beyond the typical design duration of 20 years. In this context, the conducting of regular risk reviews is essential in ensuring safe operating conditions and aligning facilities with current industry best practices. Risk reviews and safety audits can take various forms and have various areas of focus. The methodologies and approaches described below relate specifically to catastrophic risks, defined broadly as risks that carry the potential for multiple fatalities and significant financial losses. Focus is given to existing facilities and does not consider the risk-related activities such as hazard and operability (HAZOP) studies conducted during plant design. The structured approach presented aims to provide a guide for effective site- based audits and a logical analysis of risks identified. RISK CLASSIFICATION Table 1 provides a typical summary of the classification of risk types and the associated consequence categories and descriptions. It illustrates the descriptions of a catastrophic risk in terms of the broad categories of Health & Safety, Environment, Financial, Image & Reputation and Legal & Compliance. In terms of the Financial category, numeric costs ranges are often prescribed depending on the financial characteristics of the specific operation and the associated parent company.

Jan 1, 2019

By R. Tessier, R. Grant, C. Bazin

"Brunswick Mining has investigated grinding media optimization for the purpose of improving the flotation feed and regrind product size distributions to enhance metal recoveries. The paper presents findings in the on-going testing of various sizes and shapes of grinding media. Breakage rates are used as an aid to assess the effect of grinding media. Results of empirical and phenomenological analyses demonstrate the importance of adequate selection of media sizes on the milling operation.INTRODUCTIONBrunswick Mining and Smelting operates one of the world's largest lead and zinc mine near Bathurst, New-Brunswick. The No. 12 ore body is an extremely fine grained volcanogenic massive lead, zinc, copper, silver, iron sulphide body between two metamorphosed sedimentary and felsic volcanic rock units. Pyrite content is about 60% with 20% non-sulphide minerals, mainly silica and chlorite. The operation is currently processing 10,500 tonnes of ore per day in conventional crushing, grinding, differential flotation and dewatering circuits. Details on the circuit can be found elsewhere (e.g. Hendriks and Ounpuu, 1985; Grant et al., 1991).The mill has operated for more than 25 years and despite the past milling experience, there has been much disagreement as to the required grind size. Since 1964, fineness of the flotation feed ranged from 60% to 80% passing 400 mesh (37µm) and averaged slightly over 71%in1992. Results from mineralogical analysis (Petruk and Schnarr,1981; Coleman, 1988), Brunswick metallurgical laboratory (Grant et al., 1991; Shannon et al., 1992) and Lakefield pilot plant tests (Hendriks, 1984; Hendriks and Ounpuu, 1985) clearly indicate that improved metal recoveries can be achieved by an increase in the fineness of grind, and more specifically by maximizing the amount of material in the 15-25µm range."

Jan 1, 1993

By K. A. Lewandowski

Agglomeration of ore used in heap leaching allows for the immobilization of fine particles that would otherwise migrate and cause permeability problems in the heaps. For copper ore, binders are needed in order to make stable agglomerates. However, the majority of binders break down when introduced to an acidic environment, allowing fine particles to be released from the agglomerate surfaces. These particles migrate through the heap impeding solution flow, leading to a decrease in metal recovery rates. The authors have developed a series of testing procedures to determine the acid resistance of several binders. Only five binders were shown to be acid resistant in soak tests, decreasing fines migration by up to 93%, compared to tests which were agglomerated with leach solution, raffinate, as a binder. Flooded percolation column testing also showed that these binders were able to reduce the "slump" of the ore by up to 82% and increased the hydraulic conductivity by up to 90%, when compared to agglomerating with leach solution alone. The use of binders in the agglomeration of copper ore also showed no negative effects on the bacterial populations throughout a leach cycle.

Jan 1, 2007

By C. W. Chao, M. Melashvili, F. Hilário

The processing of a bulk concentrate containing copper as chalcocite, enargite, bornite and chalcopyrite along with pyrite and precious metals of silver and gold was studied. A leaching study was undertaken to examine the application of the atmospheric acid leaching process to a bulk copper concentrate for copper recovery followed by cyanidation or thiosulfate leaching for gold and silver recovery. The extraction of copper exceeded 90% under some conditions and the recovery of gold and silver reached a maximum of 44 and 45%, respectively. A sample of bulk concentrate was roasted in air to oxidize the sulfides with release of sulfur dioxide followed by acid leaching of the roaster calcine and cyanidation of the acid leach solution. The copper extraction reached over 92% and the gold extraction exceeded 88%. The sulfur dioxide may be captured for acid production. INTRODUCTION The processing of a large primary copper deposit in Indonesia is under investigation. One of the possible routes for processing involves flotation of a bulk copper-gold concentrate followed by treatment by an atmospheric leach/SX-EW process for copper recovery. The atmospheric leach residue would then be leached for recovery of gold and silver. A second route involves roasting of the concentrate followed by acid leaching and SX-EW for copper recovery. The leach residue from the roaster calcine would then be leached for recovery of gold and silver. The roaster off-gases could be used for sulfuric acid manufacture, enabling the production of a valuable by-product. The Cobre Las Cruces (CLC) process (Munoz, Garcia, & Delgado, 2017) was designed to treat a resource of copper discovered close to Seville, Spain. The process was developed by Outotec with MK Gold (original project owner). INMET Mining subsequently purchased the deposit from MK Gold and built the copper processing facility. The CLC process is similar to the Mt. Gordon Copper process; except that OKTOP reactors have been installed instead of a low temperature, low pressure autoclave process. The plant was designed to treat 1.3 mtpa of ore at a grade of 6.2% Cu to produce 72,000 tpa of cathode copper over a 15 year project life. The main gangue mineral at Cobre Las Cruces was pyrite. The Cobre Las Cruces ore is therefore similar to a rougher flotation concentrate containing copper minerals and pyrite. The roasting of a rougher flotation concentrate can be designed to produce hematite, basic copper oxides and sulfur dioxide off gas. The acid leaching of the basic copper oxides may produce soluble copper for SX-EW recovery of copper. The sulfur dioxide off-gas may be used to make sulfuric acid.

Jan 1, 2019

By Laxman M. Amaratunga, Glen G. Hein

"Most mining operations utilize the tailings coarse fraction for backfilling while the fines have been traditionally disposed on surface in tailings ponds. Recently, paste fill has been developed which uses a fraction of the fine tailings (10-30% w/w of <45 µm) in the fill (Brummer and Moss, 1991). This development allows a mining company to use a portion of the fines for backfill, but still requires surface impoundment of the unused tailings. Reactive tailings have the added problem of generating acid after being oxidized in the presence of air and water. Treating acid mine drainage (AMO) from these ponds has proven to be a costly environmental problem and a long term liability.One practical method to reduce the environmental impacts associated with the tailings pond is to modify the physical and chemical prope1ties of the fine tailings so that they can be utilized in an environmentally safe manner. This was accomplished by agglomerating the tailings into pellets and using theses pellets as a coarse aggregate in a total tailings paste fill. This technology does not require any supplemental sand or gravel to be added to the fill.This paper presents the ongoing research into utilizing these tailings agglomerates as a coarse aggregate fraction, in order to create a total tailings paste fill which has supe1ior strength characteristics.IntroductionThe Canadian mining industry produces more than 500 million tonnes of tailings and waste rock annually. The waste rock is usually returned underground for use as rock fill in underground support with the tailings remaining to be disposed of in tailings ponds. Tailings consist of a coarse and fine fraction, and can be either reactive (acid generating) or non-reactive. In an effort to minimize tailings disposal, the coarse fraction has been used underground in backfill along with alluvial sands. This diversion of the coarse fraction, however still requires that the fine fraction be disposed of in tailings ponds. This disposal creates the potential for acid mine drainage (AMO), since in the presence of air and water, reactive sulphide tailings can generate acid. It is therefore an important goal in the mining industry to minimize the disposal of fine tailings into tailings ponds since the treatment of AMO is a costly and long-te1m environmental liability."

Jan 1, 1997

By H. E. (Buzz) Neal

"Abstract - The Labrador Trough contains world-class iron deposits which have been mined since 1954. The direct shipping of Knob Lake ores were mined at Schefferville from 1954 to 1982. Concentrate production began in 1961 in the southwest end of the Trough, with three mines currently producing concentrate and pellets at a rate of 35 Mt per year. West and north of Schefferville, several billion tonnes of taconite have been outlined in fine-grained, cherty magnetite iron formation. Several deposits of highly metamorphosed magnetite-specularite iron formation are located west of Ungava Bay. Numerous studies have shown that this medium- to fine-grained iron formation can be beneficated to 66% to 68% iron. In the area from Wabush Lake to Mont-Wright, a medium- to coarse-grained friable specularite-quartz iron formation is repeated by folding to form several large deposits. In this area, three mining operations are located with reserves and resources in the order of 5 billion tonnes.The iron deposits occur within iron formation in sediments in the extensive Proterozoic geosyncline called the Labrador Trough. Several facies of iron formation within the Sokoman Formation reflect variations in chemical composition and depositional conditions. The correlation between the mineralogy and textures is discussed to illustrate the development of different types of iron ores. This band extends for about 1100 km southeast of Ungava Bay through both Quebec and Labrador. Further south, it turns southwest past the Wabush and Mont-Wright areas to within 300 km of the St. Lawrence River. The iron formation is essentially folded and faulted along most of its length. The degree of metamorphism is variable, ranging from intense in the northern and southern portions to greenschist facies in the central portion.The stratigraphy, structure and mineralogy of the producing mines are described along with the history of discoveries. Geological input is required to achieve the strict specifications of the international iron ore market."

Jan 1, 2000

By Fernando Canales

In the last decade a great dealt of attention has been paid to the chemistry of polynuclear gold derivatives with a central heteroatom, not only from the experimental and structural but also from the theoretical standpoint (1). Interesting hypercoordinated species of the type [C(AuPR3)5]+, [C(AuPR3)6]2+, [N(AuPR3)5]2+, [P(AuPR3)5]2+ and [P(AuPR3)6]3+ have been described (2), apart from other complexes with more conventional stoichiometry, and all have in common the presence of gold-gold interactions of ca. 3 Å. Usually, the chemistry of the first row elements of the p-block is known to follow classical rules of bonding, and only in cases of extreme electron-deficiency has the traditional electron count to be reconsidered to account for special types of molecular or solid state structures. Many of these heteroatomcentered complexes are electron-deficient and the gold-gold interactions provide a significant contribution to their stability. The attraction between these closed-shell systems has recently captured the attention in inorganic and organometallic chemistry (1). P. Pyykkö has summarized the available theoretical and experimental evidence of intra- and inter-molecular interactions between heavy metal atoms, such as Au(I) (3). In general, when heavy metals are involved in such interaction, the closed-shell attractions are of metallophilic or van der Waals type, as has been found for d8, d10 coinage-metals, and d10s2 centers. Experimental evidence for the aurophilic Au(I)???Au(I) attraction is available from crystallography, NMR and Raman spectroscopies, and optical spectroscopic measurements of the interaction strength (4). It is manifested in molecular conformations with relatively close Au???Au interactions of ca. 3 Å, whose strength has been estimated at ca. 25-50 kJ/mol (5). These attractions are weaker than most covalent or ionic bonds, but stronger than other van der Waals bonds and comparable in strength to typical hydrogen bonds. The phenomenon cannot be satisfactorily explained by classical theories such as hybridization (3). From a theoretical point of view, the attractions close to equilibrium distances are caused by dispersive interactions together with relativistic effects (6). The attractive contributions are dominated by pair-excitations from the heavy metal, such as gold, strengthened by relativistic effects. In all the cases where there are inter- or intramolecular metal-metal attractions, the correlation effects are essential; if they are omitted, at the Hartree-Fock (HF) level, repulsive interactions are obtained (6). Hence, it is necessary to use at least second-order Møller-Plesset level (MP2) methods for the dispersive forces, which are included in the electronic correlation effects (7).

Oct 1, 2003

By Samantha A. Beeson, Colin Poole

"A selective flocculation-floe flotation technique is already in use in the Canadian potash industry for the removal of water-insoluble slimes, but the process is currently limited in its application and reagent consumption is high. The work described in this paper details investigations into the separation of sylvite and halite from water-insoluble slimes by selective flocculation utilising other commercially available polymers.Preliminary flocculation performance tests were undertaken on pure sylvite, halite and water-insoluble minerals to establish the importance of a number of experimental parameters. The data from these single mineral tests was then used to establish optimum parameters for the separation of sylvite and halite from a synthetic mixture similar in composition to a typical potash ore. Under optimum conditions, separation was achieved with high recoveries using dispersant and flocculant dosages significantly lower than those currently used in plant practice.IntroductionAlthough solar evaporation and solution mining are used in some operations, most potash is extracted by conventional underground techniques and is then processed by froth flotation, in order to separate the valuable sylvite (KCI) from halite (NaCl) and water-insoluble gangue minerals. Flotation is usually preceded by a desliming stage to remove water-insoluble fines, but this also results in high potash losses and affects process brine requirements. To overcome these problems, one plant operated by Cominco in Saskatchewan uses a selective flocculation -floe flotation process (Banks, 1979/1980), in which a polyacrylamide flocculant is added to produce floes of water-insoluble material with minimal incorporation of halides. A collector is then added to render the floes hydrophobic and suitable for removal by froth flotation.A number of workers have also investigated the use of selective flocculation in potash processing, but these too have been concerned with developments in the removal of water-insoluble slimes (Williams, 1960; Brogiotti et al, 1974; Chan et al, 1986; Thompson et al, 1979; etc.). This paper provides results of novel investigations into the selective flocculation of sylvite and halite from water-insoluble minerals and discusses the possible mechanisms involved."

Jan 1, 1995