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By N. Waters

"Nickel saprolite ores are normally mined as feed to Fe-Ni smelters or Ni matte smelting operations. The smelting processes typically require high Ni cut-off grades of approximately 1.5 to 2.2% Ni, depending on the operation. These very high cut-off grades result in a significant portion of the saprolite profile being regarded as “waste” and hence having little to no value. The Starved Acid Leach Technology (SALT) was developed to recover nickel and cobalt from nickel saprolites and Caron plant residues. Relatively small amounts of acid are applied to ground saprolites or Caron residues in order to selectively leach nickel and cobalt. The leaching is performed atmospherically under low free acid conditions. Nickel and cobalt may be recovered from the leachate as a mixed hydroxide. The mixed hydroxide may be added directly to a saprolite smelting operation or refined separately. InCoR Technologies is advancing the application of SALT at a number of sites. Bench scale testing has provided a relationship between acid addition and nickel extraction in leaching. Conceptual engineering studies have been completed by SNC Lavalin. The simplicity of the SALT technology provides the benefits of low capital and operating cost and an expected rapid ramp up to full production.INTRODUCTION The recent history of hydrometallurgical nickel laterite treatment plants has demonstrated mixed financial and operational performance. Table 1 summarizes the next generation plants built after the financial and/or technical failure of the Bulong, Cawse and Murrin-Murrin plants in Australia. The Coral Bay plants (Line 1 and 2) stand out (and now Taganito) as relatively low capital cost, simple (no acid plant, production of mixed sulfide product), and modest in scale (10, 12 and 36 kt Ni/a). However, the other plants in the list (Ravensthorpe, Ramu, Goro and Ambatovy) are all characterized by financial and technical challenges. All plants have a very high capital cost ($67,000 to $120,000 USD/annual t of Ni production). Ravensthorpe was sold by BHP Billiton after a poor startup. Ramu has had a steady ramp up but only produces mixed hydroxide for refining by others. Goro has had an extended construction period (since 2001), is high cost and has been very slow to ramp up to design production rates. Ambatovy has had a steady ramp up."

Jan 1, 2017

"SART technology is a useful tool for improving the economics of gold recovery from certain types of complex gold ores. SART liberates cyanide consumed by base metals such as copper, zinc and nickel, and enables the newly freed cyanide to be recycled to precious metals leaching while producing high-grade base metal sulphide concentrates for sale. The benefits of SART include the reduction in cyanide consumption, avoidance of cyanide destruction costs, minimization of risks of environmental non-compliance due to residues of cyanide destruction reporting to mine effluents, and generation of extra revenue from the sale of base metal concentrates. Concerns with SART typically include uncertainties around capital and operating costs and proper integration of SART into the overall metallurgical flowsheet. This paper presents two case studies addressing these concerns. The first involves actual costs of the full scale SART integrated into a gold heap leach operation and treating up to 500 m3/hr of leach solution at a mine in Mexico. The second involves field pilot testing and a preliminary cost estimate for integrating SART into a silver mine in Peru using Merrill Crowe.INTRODUCTION One of the current trends in the gold industry globally is the increasing importance of complex polymetallic gold deposits as discoveries of large Carlin type gold deposits become increasingly rare (Sceresini, 2005). The presence of cyanide soluble copper and zinc in complex gold deposits necessitates changes in traditional gold extraction metallurgical flowsheets. One of the tools available to the industry to help deal with interferences of cyanide-soluble base metals in gold extraction is the SART (sulphidization-acidification-recycling-thickening) process. SART breaks the weak acid dissociable (WAD) base metal-cyanide complexes, precipitates the metals as high-grade sulphide concentrates and makes the freed cyanide available for recycle. Although SART is a commercially available technology, it is still relatively new to the industry. Fewer than ten (10) full scale plants have been constructed in the past couple of decades. Some of these SART plants are small, most are located at remote sites, and the majority have not operated on a continuous basis. This has resulted in a general lack of information in the industry about the true costs, operability and metallurgical performance of SART. BQE Water has been involved in the design, construction, commissioning and operation of large scale SART plants in Mexico, Turkey and Chile and has conducted field testing programs as part of the technical assessment of SART integration into various metallurgical circuits. Having built and operated numerous plants utilizing selective sulphide precipitation of heavy metals, BQE Water has gained unique insight into the design and control of the sulphidization stage of SART to minimize costs and ensure high efficiency in cyanide recovery."

Jan 1, 2017

By Stephen Stone, Kerby Dobbs, G. Richard Whittecar, W. Lee Daniels, Zach Agioutantis, Tess Thompson

A common result of Environmental Impact Assessments associated with mining projects is the construction of new wetlands in areas disturbed by mining operations. Where appropriate, this mitigation may be considered an integral part of the mine reclamation process under the principles of sustainable development in the minerals industry. Wetbud is a new tool for estimating wetland water budgets using available weather data and site-specific topographic, soil and geohydrologic data, coupled with mass balance mathematics. Wetbud is primarily intended as a planning tool for use in the design of created wetlands, but it can also be applied to native wetlands or wetland restoration sites where the required input parameters can be specified. Wetbud can be run in its basic form where wetland topography, soil parameters and groundwater flux are simplified, or in the advanced form, where these parameters are included in a more complex approach via integration of the MODFLOW package, a free 3D program that was developed by the United States Geological Survey. Both versions can also include overbank flow hydrology sources and the advanced form can also model sloping and irregular topography. The program downloads weather data from the nearest applicable station and selects appropriate wet-normal-dry (W-N-D) years following a modest user data clean-up step. Wetbud also has the ability to utilize existing short-term (e.g. 6 to 9 months) groundwater data from an up-gradient well to simulate longer-term groundwater level inputs for the selected W-N-D years. In addition, Wetbud features a “Wizard” version that comes pre-loaded with 14 pre-selected weather data sets for all areas of Virginia that can develop a simple monthly water budget in less than 15 minutes – a feature that could be expanded anywhere geographically with historic weather data.

Jan 1, 2017

By R. Barbaroux, J. -M. Lalancette, D. Lemieux, K. Nasrallah, G. Garcia Curiel

"Arsenic released from the lithosphere by mining and metallurgical activities is a growing global environmental concern. Dundee sustainable technologies (“DST”) has developed a processing technology to sequester arsenic by means of vitrification. This method can effectively sequester arsenic trioxide without the need to oxidize from As (III) to As (V). Arsenic oxide is incorporated within a silica glass matrix that is stable as per the Toxicity Leaching Characteristic Procedure (“TCLP”) or EPA Method 1311. In this paper, the conventional treatment of arsenopyrite, commonly referred to as “two-stage roasting”, is discussed along with the options traditionally available for the remediation of the arsenic trioxide by-product. The drawbacks limiting the adoption of this processing flowsheet are discussed and a new processing route is presented for the treatment of arsenopyrite. This new flowsheet outputs an auriferous aluminosilicate highly amenable to gold extraction (> 96%) while eliminating the sulfur dioxide production associated with the second-stage roasting of pyrrhotite and ultimately uses vitrification as a definitive sequestration solution to arsenic trioxide.INTRODUCTION Faced with the depletion of conventional gold ores, the gold industry has witnessed a trend towards the exploitation of arsenical deposits. Arsenic is a naturally occurring metalloid often found in mineralogical association with gold. Many northern Canadian regions, from the Northwest Territories to Northern Manitoba, Northern Ontario and the Abitibi region are facing significant arsenic challenges. Projects are deemed uneconomic or prevented from going into operations due to the costs associated with handling arsenic material and there are penalties imposed to complex concentrates by smelters. In addition, Canadian mining operations have left an environmental legacy of gold tailings with grades typically of up to 9 grams per tonne with no processing solution as they also contain significant arsenic contamination at grades of up to 20%. Table 1 presents a list of Canadian deposits known to contain arsenic."

Jan 1, 2017

By B. Hilscher, P. Nayak, N. Yoon

"The mining industry is currently facing challenges with declining feed grades and is struggling to find solutions to improve the project’s economic value. By means of pre-concentration, ore sorting aims to separate the barren material from the valuable ore to reduce energy consumption and tailings generation, while increasing the feed grade, concentrate grade, mill recovery, and revenue. In addition, ore sorting allows the modification of deposit geometallurgy in order to allow the creation of an optimal mill feed.This paper evaluates the applicability and challenges of ore sorting by utilizing the results from four different mines, and reviews them in detail. The mines include two underground and two open pit mines that are base metal and precioius metal operations. In order to understand the applicability of ore sorting in these operations, initial rock-by-rock test results and different types of assays (atomic adsorption [AA], inductively coupled plasma [ICP], and fire assay) are utilized. Using the assay results, the grade recovery curves for ore sorting are generated and they are further improved by using and developing an ore sorting algorithm, which is discussed in this paper. The application and evaluation of ore sorting in greenfield and brownfield properties will also be discussed.The state of the art ore sorting technologies for both rock-by-rock and bulk sorting are reviewed in this paper. The future technologies on the horizon, including different combinations of sensors, are explained. The sorting technologies include, X-ray transmission (XRT), X-ray fluorescence (XRF), colour, infrared, electromagnetic, and laser induced breakdown spectroscopy (LIBS).IntroductionOre sorting is a sensor-based sorting technique introduced between the excavation stage and processing stage, where the unwanted waste is diverted to the waste dump and only the ore is sent to the mill for further processing. As a result, the quality of the material entering the mill is improved and the dilution of the ore is reduced. In greenfield projects, sensor-based ore sorting provides an opportunity to reduce the capital cost of the project and increase the return on investment (ROI). With most operations currently facing the challenge of finding a high grade deposit, having a sorting unit provides several advantages while keeping the cost at minimum."

Jan 1, 2017

By Claudio Asioli

"The project’s goal was to construct the Al Ghazala Intercontinental, a multi-use development in the bay area of Tripoli overlooking the Mediterranean Sea. The site of the project is located approximately 500 ft (150 m) from the Mediterranean coast, near the Al Ghazala roundabout in the town center of Tripoli, Libya. The investor of the project was Magna Properties Group, Ltd. – Libya, the main contractor was Man Enterprise S.A.L., and the design and construction management was performed by Dar Al-Handasah Engineering. Trevi S.p.A. was contracted to perform the design and construction of the anchored diaphragm walls and dewatering systems for the excavation of a two-level basement car park, which extends across the full footprint of the site.The site was approximately 640 ft by 230 ft (195 m by 70 m) in plan and nearly flat. The groundwater level typically varies from about 11 ft to 23 ft (3.4 m to 7.0 m) above mean sea level. To construct the required raft foundation, it was necessary to excavate the area down to El. -15.7 ft to -26.3 ft (-4.8 m to -8.0 m), which resulted in an excavation depth ranging from about 27 ft to 39 ft (8.3 m to 12.0 m) below the existing ground surface.Subsurface ConditionsThe subsurface site investigation was performed in three phases by Al-Tamier Engineering Consulting Bureau. During Phase 1, a preliminary investigation was undertaken during the early stages of the project to obtain information about the general stratigraphy and groundwater level at the site. Phase 2 was performed to obtain subsurface information and design parameters, and Phase 3 was performed as a supplementary ground investigation to investigate unexpected ground conditions identified during Phase 2. In total, 14 boreholes were drilled to depths ranging from about 80 ft to 180 ft (24 to 55 m). The generalized subsurface profile is quite heterogeneous, and is predominantly composed of sand with silt and gravel that is underlain by limestone, calcarenite and claystone"

Jan 1, 2017

By Fazel G. Jahromi, Ahmad Ghahreman

"Atmospheric leaching of arsenical sulfide concentrates, and especially enargite leaching, is one of the major challenges within the current hydrometallurgy research area. One of the recent processes developed for sulfide ore treatment is atmospheric leaching in the presence of AF 5, a novel carbon based catalyst, in chloride media. The quantification of different ion concentrations during enargite and chalcopyrite leaching in the presence of AF 5 were measured and the copper recovery rates of 97% and 96% were achieved. The objective of this study is to shed light on the leaching mechanism of the sulfide minerals. Based on the speciation of iron and copper by different titration methods, the AF 5 catalyst first reduced ferric and cupric ions and then oxidized ferrous, cuprous and arsenite ions. The oxidation behavior of the catalyst enhanced the leaching results. The AF 5 catalyst also caused in situ precipitation of scorodite in leaching experiment. The speciation of ions in the chloride media were simulated by Phreeqc software and the dominant species in the leaching solution were determined.INTRODUCTION The hydrometallurgy of copper has been used for several decades and is still under development for more complex copper sulfide minerals due to their refractory nature. Most of the world copper reserves are in the form of chalcopyrite; and enargite is known as a major contaminant. Pyrometallurgical processing of enargite is problematic due to arsenic release and tight environmental regulations (Peacey, Gupta, and Ford n.d.). On the other hand, lower recoveries in the hydrometallurgical processes make most of these processes impractical. Several leaching processes have been developed for the leaching of copper sulfide minerals. Some of the common treatment methods for copper sulfide minerals are pressure oxidation leaching (POX), CESL, Activox, Albion process, atmospheric ferric sulfate leaching, Dynatec, Galvanox, and Hydro copper process (Barr, Defreyne, and Mayhew 2005; Conner and Anderson 2013; D.G. Dixon, Mayne, and Baxter 2008; Hyvärinen and Hämäläinen 2005; Palmer and Johnson 2005; Rohner, Bartsch, and Ngoviky 2012). Generally it is not viable to dissolve copper sulfide minerals at ambient pressure in mild acidic media and dissolution of these refractory minerals requires harsh conditions in the presence of oxidant materials (Biswas and Davenport 2002). Ferric ions have been used as an oxidant in different media in copper sulfide leaching processes. U. S. Bureau of Mines’ Reno Metallurgy Research Center in 1969 (Haver and Wong 1971) investigated ferric chloride leaching of chalcopyrite. Dutrizac and Macdonald (1972) studied ferric sulfate leaching of enargite. Based on this study, 50% of the copper was recovered at 80-85 ºC after 7 days of leaching. Cupric ions can also be used as an oxidant. Parker, Paul, and Power (1981) stated that cupric/cuprous couples are more effective than ferric/ferrous couples in chloride media because they are rapid and reversible. The Hydro Copper process leaches copper sulfide minerals in chloride solution catalyzed by cupric ions. In this process, copper dissolves as cuprous ions in presence of cupric ions (about 10 g/L) (Hyvärinen and Hämäläinen 2005)."

Jan 1, 2017

By R. Barbaroux, B. Dubreuil, D. Lemieux, K. Nasrallah, G. Garcia Curiel

"As conventional, base or precious metal ores are being depleted worldwide, the mining industry is being faced with an increasing exploitation of arsenical sulfidic ores. Enargite is a common example. The downstream processing of these ores poses several problems ranging from high smelter penalties to finding economical and environmentally acceptable means of disposing of the arsenic. Several hydrometallurgical processes have been proposed for extracting arsenic from enargite concentrates, notably using alkaline sulphide leaching (ASL). However, few alternatives exist for removing the arsenic from solution and stabilizing it in an approach that is both economical and environmentally acceptable.Dundee Sustainable Technologies (“DST”) has developed a technology for the sequestration of arsenic by vitrification. Originally optimized to cost-effectively stabilize arsenic trioxide (As2O3), DST has shown that vitrification could be successfully extended to the stabilization of other arsenical products, such as calcium arsenate (Ca3(AsO4)2) and sodium arsenate (Na3AsO4). In this paper, the vitrification of arsenic in the context of an enargite leaching was newly explored and demonstrated successfully.Two processing routes are being proposed by DST for the removal of arsenic from enargite concentrates and their stabilization by vitrification. In one route, arsenic is extracted by ASL and is then precipitated under atmospheric conditions and with minimal use of reagents and time. The resulting precipitate is an unstable hydrated ferric arsenate (FeAsO4•2H2O) that is then vitrified in a non-dilutive method, significantly increasing the stability of arsenic and meeting the TCLP guideline. Unlike is required for scorodite, stabilization was successfully achieved without concern for the crystallinity of the precipitate."

Jan 1, 2017

By Adam T. Young

This paper will describe the process of using low density bulk emulsion as a means to maximize the production of an oversize or “rip rap” aggregate size range (8 inch to 72 inch) that the quarry customer has a market demand for. It will also discuss the pre-blast and post-blast metrics used during the product trials and evaluation.

Jan 1, 2017

By K. Avarmaa, P. Taskinen

"The solubilities of rhodium (Rh) in a molten silver alloy in doré-smelting conditions for treating copper refinery slime at temperatures of 1,000 to 1,300 °C were measured using a high-temperature equilibration-quenching technique and direct phase analysis by electron probe X-ray microanalysis. The results obtained indicate that the solubility of rhodium in molten silver is very limited: only 0.04 to 0.26 weight percent at 1,000 and 1,300 °C, respectively. The thermodynamic properties of rhodium in molten silver were estimated from the solubility data. The compositions of the solid rhodium alloys in equilibrium with molten silver-rich doré metal were also measured in this study. The excess rhodium in the doré alloy will precipitate during the refining as solid, greater than 99 weight percent Rh.IntroductionSilver refining is a core step of the processes of anode slime treatment and precious metals recovery in copper refineries (Hait, Jana and Sanyal, 2009; Ludvigsson and Larsson, 2003). It separates the oxidic materials, such as nickel oxide (NiO) and barium sulfate (BaSO4), from metallics after the de-coppering and de-selenation steps of the anode slime, and refines the silver bullion from the undesired elements present (Cooper, 1990; Hyvärinen, Lindroos and Yllö, 1989). Doré metal is a silver-rich alloy which after the smelting step will be refined electrolytically, and the remaining constituents of gold as well as the platinum group metals (PGM) will be subsequently recovered in their own processing stages.Because of low concentrations of PGMs in copper, they are typically soluble in the doré metal in anode slime treatment. This can be concluded from their binary phase diagram data with silver (Massalski et al., 2007). One exception is sometimes encountered in the anode slime smelting operations if the smelter feedstock is rich in rhodium, as may be the case if the raw materials contain secondary raw materials such as e-scrap. The solubility of rhodium in solid silver is less than 0.04 weight percent (Królas and Sternik, 1995), and its solubility in molten silver is highly uncertain. The only experimental information in the literature (Królas et al., 1993; Elliott, 1985) suggests that the silver-rhodium alloy system at 960 °C forms a eutectic, which locates less than 2 °C below the melting point of pure silver (Arblaster, 2015). Early observations (Rössler, 1900) propose that rhodium is insoluble in molten silver even if solid silver-rhodium solutions have been recently produced on a nanoscale (Kusada et al., 2010).The aim of this study is to measure experimentally the solubility of rhodium in molten silver at doré metal smelting and refining temperatures. The silver alloy used to mimic the doré alloy contained silver and about 1 weight percent of the alloying elements copper, gold, palladium, rhodium and tellurium. The experiments were carried out in metal-slag equilibria with nitrogen-oxygen mixtures as the atmosphere, employing an equilibration-quenching technique and using direct phase composition analysis by electron probe X-ray microanalysis (EPMA) (Jak, Hayes and Lee, 1995)."

Jan 1, 2017

By Dominic Fragomeni

"The mineral processing industry has had a long history of innovation that is recognized but not often celebrated. These include significant advances in mineral measurement, testing, comminution, mineral separation and process control technologies that have transformed mineral assemblages into ore.This presentation presents some of the major mineral processing innovations and the impact they have had on our industry. As we look to the future, it is critical that we innovate and change. We will explore some examples of the next developments and how they can be catalyzed in the face of risk management, lower metal price cycles, resource constraints, inertia and the challenge of short term value delivery."

Jan 1, 2017

By John P. Turner, Benjamin J. Turner

"Tieback anchors are now used routinely for landslide stabilization in the USA and abroad. It is generally understood by design engineers that friction loss over the unbonded length of a tieback anchor is inherent to the system, and such loss is permitted as long as it does not exceed a certain threshold, typically 20 percent of the post-tensioning load. However, recent experience from projects utilizing tieback anchors with unbonded lengths in excess of 150 feet has demonstrated that this criterion may be difficult to achieve, particularly in certain ground conditions. Furthermore, anchor friction loss, even if below the 20-percent threshold, has important implications for the stability of the slope that are often ignored in practice. This paper presents the results of a study in which friction loss is quantified from load test data for projects in a variety of ground conditions by means of a “wobble coefficient.” Factors that may influence the wobble coefficient are examined, and recommendations for addressing this issue in practice are presented. A recent instrumented load-test program for a landslide stabilization project in Southern California is examined, demonstrating that with appropriate monitoring controls, uncertainty with regard to friction loss can be minimized. IntroductionSteel-strand tieback anchors have been used by the geotechnical community to support shoring systems for many decades, and more recently as a means to stabilize landslides. For strand encased in grease-filled plastic sheathing, which is intended to allow the strand to elongate freely, some load can still be transferred by friction between the strand and the grease and between the grease and sheathing. The sheathing then transfers load to the surrounding grout and, in the case of ground anchors, to the surrounding soil or rock. The resulting decrease in load over the length of the unbonded zone is known as “friction loss.”A widely used criterion for ground anchor acceptance based on load testing is that the measured anchor elongation must achieve a minimum value of 80 percent of the theoretical elastic elongation, or in other words the actual elongation can be up to 20 percent less than the theoretical value. This ensures that the majority of the load applied at the anchor head is reaching the bond zone behind the assumed failure surface, since load shed within the failure mass does not contribute to stability. This criterion acknowledges that friction loss is an inherent feature of the anchor system which cannot be eliminated completely, only minimized."

Jan 1, 2017

By J. Sliwinski, H. Kikutani, J. Atwood, D. Larimer, J. Pyecha

"The Pogo mine start-up milling targets of 2005 are vastly different than the targets of today. Improvements have been driven by unintentional design oversight, continual circuit optimization or optimization due to changing mineralogy. The more significant process improvements to date have occurred in the gravity, flotation and leach/CIP unit operations. Details of the significant improvements are presented along with the impacts to the process.INTRODUCTION Deposit Overview Pogo mine is located along the Goodpaster River, southeast of Fairbanks, Alaska. This deposit sits in the center of the Tintina Gold Province (Figure 1), a region of similar Intrusion Related Gold deposits in Interior Alaska, the Yukon and British Columbia Canada (McCoy et al., 1997). The Pogo deposit is hosted in a rock sequence of amphibolite-grade gneisses intruded by mid-Cretaceous granitic plutons and dikes, which in turn, were cut by and host the auriferous quartz veins of the Pogo deposit.The Pogo deposit is comprised of three distinct zones of auriferous quartz veins spatially adjacent to each other. These are the Liese Zone, North Zone, and the East Deep Zone. The Liese Zone consists of three stacked, massive quartz veins, designated the L1, L2, and L3. Vein thickness averages 3.0 m, with variations from 0.3–18 m thick. The North Zone mineralization is comprised of four veins with more consistent thickness, between 1 and 1.5 m. The East Deep deposit lies northeast of the Liese Zone ore body. It is separated by a post mineralization, quartz diorite pluton. The East Deep Zone is comprised of two stacked massive quartz veins with similar orientation as the Liese Zone."

Jan 1, 2017

By D. Paul Bishop, Kevin P. Plucknett, Hung-wei Liu

"Spark plasma sintering (SPS) process has been evaluated for producing the commercially pure (CP) Ti, TiAl and a TiAl-B4C composite. Comparisons were made between the materials in terms of the sintered density, resultant hardness and microstructures. In the present work, the titanium aluminide powders (Ti-48Al, producing a mixture of y-TiAl/a2-Ti3Al) were synthesised „in-house? using a simple reaction-sintering and mechanical attrition approach. This allowed various size distributions to be generated. The powders were then blended with a fine boron carbide (B4C) powder (up to 6 wt.%), and the resulting mixtures were consolidated using spark plasma sintering (SPS) under vacuum in graphite dies. An applied stress of 50 MPa was used for all SPS runs. The SPS parameters were varied in terms of the ultimate sintering temperature (up to 1300°C) and hold time (up to 10 minutes) for each material. It is demonstrated that high densities can be achieved this approach (exceeding 95% of theoretical, with optimised samples close to full density). Microstructural characterisation was conducted using optical microscopy, scanning electron microscopy, and X-ray diffraction. The B4C additions were seen to partially react with the TiAl to form reinforcements, such as TiCx and TiBx. Preliminary mechanical property assessment will also be briefly discussed.INTRODUCTION Titanium- and titanium aluminide-based alloys possess many unique properties, such as excellent corrosion resistance and high temperature strength, respectively (Cardarelli, 2001; Leyens & Peters, 2003). Compared to many other competing materials (e.g. stainless steel or Ni-based alloys), Ti- and TiAl-based alloys also have relatively low densities (~4.5 and ~3.9-4.1 g/cm3, respectively), which is critical for performance in aviation and automobile applications. However, the manufacturing cost is high, due to the expensive raw Ti material and difficulties in machining. TiAl-based alloys are particularly difficult to produce because of their limited ductility (Lütjering & Williams, 2007). To overcome those problems, powder metallurgy (PM) technologies have shown great potential as near-net shape processes for Ti- and TiAl-based alloys. The general PM process largely avoids laborious post-machining and minimises material use. In industrial production, the PM approach has been successfully utilised to manufacture aluminium- and iron-based alloys (Huo & Heath, 2008)."

Jan 1, 2017

By M. Rylatt, E. Legault-Seguin, C. Mohns

"With energy costs increasing and ore grades diminishing, the role of preconcentration in hard-rock mining operations has gained greater interest. Dense medium separation is a process that can be conducted at particle sizes from 250 to 0.50 mm with high separation efficiency, depending on liberation characteristics of the valuable minerals. Pilot-plant case studies conducted at the SGS Lakefield site are presented, including mineral systems such as spodumene, sulfide-bearing gold ores, and complex sulfide ores. These case studies demonstrate that, for amenable ores, mass rejection of 20–60% is possible while maintaining recoveries of greater than 90%.RÉSUMÉ Au vu de la hausse des coûts liés à l’énergie et du déclin de la teneur des minerais, le rôle de la préconcentration dans les exploitations minières en roche dure présente un intérêt croissant. La séparation (ou concentration) en milieu dense est un processus pouvant être mené sur des calibres de grains de 250 à 0.50 mm avec un rendement élevé de séparation, en fonction des caractéristiques de libération des constituants des minéraux métallifères. Sont présentées dans cet article des études de cas menées dans des usines pilotes du site de Lakefield de SGS, lesquelles incluent des systèmes de minéraux tels que le spodumène, les minerais aurifères sulfurés et les minerais sulfurés complexes. Ces études de cas montrent que pour les minerais présentant les caractéristiques de libération appropriées, il est possible d’atteindre un rejet en masse de 20 à 60 %, tout en maintenant des récupérations supérieures à 90 %.INTRODUCTIONPreconcentration is the process of rejecting gangue minerals while ensuring recovery of valuable minerals prior to more intensive, downstream processing. Preconcentration has been practiced in the industry for many years, and is gaining greater interest as the industry copes with processing lower grade, more difficult ores, which typically require finer grind sizes and incur higher energy costs.The benefits of preconcentration are:• lower mining costs, which allows for nonselective mining;• lower process capital and operating costs (e.g., resulting from reduced grinding, flotation, and fines disposal stages);• increased ore reserves, which provides the potential to treat lower grade ore;• increased mine production without expansion of the existing plant or concentrator;• reduced overall tailings impoundment by converting the reject into a byproduct (e.g., underground backfill or aggregate);• improved efficiency of downstream processes (e.g., silica removal in electric arc furnace feed, removal of softer sliming minerals prior to grinding);• potential application to brownfield operations and greenfield projects; and• a “green” process option, which reduces processing energy consumption;– reduces mill feed;– increases stage metal recovery (higher grade feed);– increases mill metal output per tonne processed;– reduces surface plant, tailings dump, and tailings pond requirements because the plant has a small footprint and can be installed underground; and– can be applied to retreatment of old tailings dumps to recover metal values and reduce environmental impacts (e.g., dissolved metal runoff, acid drainage)."

Jan 1, 2017

By D. Brand

"The risk management objective of the AMIRA Code of Practice for Metal Accounting has seldom been systematically investigated in the literature up to the authors’ knowledge. Risk is defined in the Australian Standard on Risk Management (AS/NZS 4360:2004), as “the chance of something happening that will have an impact on objectives”. The simplified economic analysis performed in this paper has lead to define “something happening” as measurement non-representativity and “impact on objectives” as NSR loss from the optimal NSR. This has pinpointed a missing link being the establishment of a relation between NSR in flotation plants and measurement representativity. The proposed framework, referred to as the total cost of representativity, answers the previously unanswered question of how much accuracy/reproducibility is fit for purpose in a given flotation plant. Authors readily acknowledge that it is way easier to assess the cost of accuracy/reproducibility than the cost of inaccuracy/irreproducibility. However, this exercise not only answers previously unanswered questions but also establishes an essential link with operational excellence. This paper exposes why such operational excellence could neither be attained nor proved without a state of the art metal accounting system. This should impact not only how metal accounting systems are audited/designed/refactored, but also how flotation plants are designed.IntroductionBecause representative metal accounting is a vital source of information for the financial accounts of a mining/metallurgical company, the need for a code on metal accounting was recognized in 2001 and a team was formed in 2003, under the sponsorship of several major mining houses, to produce such a code. Table 1 exposes the two main objectives of this AMIRA Code of Practice for Metal Accounting."

Jan 1, 2017

By R. Holmwood, M. Faris, P. Holloway, M. Collins

Sulphuric acid addition is a major driver of the economics in the processing of nickel laterite ores by high pressure acid leaching (HPAL). Understanding the optimal acid addition rate is essential for the success of any HPAL operation, and this is especially true at Ambatovy, where the composition of the feed tends to vary significantly on a day-to-day basis. Most studies on the effect of acid on nickel extraction in HPAL have used laboratory testwork as their basis. Although these studies are invaluable in assessing the economics of a new project, they are limited by the range of ore composition that can be tested and the differences between the operation of the laboratory equipment and the commercial plant. To enable optimization of the acid addition at Ambatovy, operating data from the HPAL operation were obtained using OSISoft’s PI system and the data from several periods were examined to develop relationships between acid addition and nickel extraction. The initial relationships from 2014 focused on the acid required to achieve a target nickel extraction of 95%, with aluminum and magnesium in ore and feed slurry solids content as the major variables. As Ambatovy ramped up through 2015 and 2016, the calculated acid requirement was further refined to address the effects of HPAL temperature and retention time, and the oxidizing/reducing characteristics of the ore, and to generate acid requirement relationships as a function of ranges of nickel extraction. These relationships supported raising the target nickel extraction to 96% and enabled the development of an economic model between acid addition and nickel extraction.

Jan 1, 2017

By Y. Qin, X. Fu, T. Qi, H. Tang

"The FASTMELT ® process was developed as an alternative to blast furnace ironmaking; in this process, high-quality molten iron is produced using direct reduction followed by high-temperature slag/metal separation. In this study, iron recovery and phosphorus removal from oolitic highphosphorus haematite using the FASTMELT® process was investigated. The performance of two reducing agents, coal and wood char, was compared. Direct reduction experiments indicated that with optimized reductant addition, the ore-char and ore-coal briquettes attained metallization values of 82% and 78%, respectively, and residual carbon contents of 0.24 and 2.35%, respectively. The slag/metal separation experiments revealed that molten iron containing 0.41% phosphorus and 0.021% silicon (by mass) was produced from optimally reduced ore-char briquettes, and molten iron containing 0.78% phosphorus and 0.91% silicon from optimally reduced ore–coal briquettes. The study indicates that carbonaceous materials with high CO2 reactivity are suitable for use in the FASTMELT ® process for phosphorus removal and iron recovery from oolitic high-phosphorus haematite. IntroductionIn China, the general depletion of iron-rich mineral reserves has led to many efforts to exploit low-grade and refractory ironcontaining resources for ironmaking (Liu et al., 2014). The efficient utilization of the highphosphorus oolitic haematite resources in central China has received considerable attention. The available resources of this material total approximately 3.0 billion tons. The oolitic units in the ore exhibit an onionlike structure with phosphorus-containing gangue layers of 2–10 µm thickness. The best concentrate produced from these resources contains approximately 50% iron (Fe) and 0.8–1.2% phosphorus (P) (by mass) (Ai, Yu, and Wei, 2009; Song et al., 2013; Wu, Wen, and Cen, 2011). Further removal of phosphorus from these ores using conventional beneficiation methods is not possible."

Jan 1, 2017

By Dave Rose, Jacques McMullen

"The Detour Lake mine is located 200 km northeast of Timmins, Ontario, Canada.The mill processes a free milling gold ore using both a gravity circuit and leaching with a state-of-the-art carbon-in-pulp circuit. The grinding circuit is a conventional SABC circuit with a tonnage of 55,000 tpd at 95 microns with the addition of pre-crushing upstream of the SAG mill.The Detour Lake mine has one of the largest gyratory crusher in the world (60"" x 113"") and over the years, many improvements have been made to this crusher with the result of improving plant throughput. This paper will present how choke feeding the gyratory crusher has been found to be one of the main influences on crusher product particle size and plant throughput. It will explain how the effect of choke feeding the gyratory was measured and from that, the various changes made to improve choke feeding of the gyratory crusher.IntroductionOre is hauled from the open pit mine and dumped directly into a single 60"" x 113"" primary gyratory crusher. The live capacity of both the feed and discharge hoppers of the gyratory crusher are designed for two (2) truck loads each, assuming a nominal payload of 300 tonnes per truck. The surge bin under the primary crusher feeds an apron feeder that controls the ore feed rate at approximately 4,200 tph onto a 227 metres long x 1.52 metres wide belt conveyor with a nominal capacity of 4,200 tph.The primary crusher is operated at an open side setting of 172 millimetres to produce a F80 feed to the secondary crushing circuit of 135 millimetres."

Jan 1, 2017

By Baohua Guo, Xuelin Yang, Tingkan Lu, Hailin Sun

The work presented in this paper mainly involves two parts. Firstly, the fundamental characteristics of the high pressure carbon dioxide gas fracturing technique (CO2 technique), including, a proposed method of TNT equivalence calculation, which is used to calculate the TNT equivalence of discharge of CO2 technique, and the comparison of the explosion volume generated by dynamite and expansion volume of liquid carbon dioxide is conducted to show the differences of fragmentation capacity between the two of them. Secondly, the coal seam fragmentation mechanisms of CO2 technique are proposed, including, 1) Gas jet cutting and penetration by shaped charge, 2) Gas volume expansion by changing phases of carbon dioxide, 3) Coal seam softening by destress blasting and 4) Coal seam fragmentation by discharge vibration, associating with the mechanisms, the equations for calculating fragmentation radius are developed and verified.

Jan 1, 2017