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By K. A. Natarajan, Namita Deo

Strains of Bacillus polymyxa, preadapted and grown in the presence of corundum, were found to be capable of the efficient separation of hematite from alumina. Results of tests performed using binary hematite-corundum and ternary he- matite-quartz-corundum mixtures in the presence of cells and metabolic products separated from the adapted bacterial culture indicated that more than 99% of the hematite could be efficiently separated through selective flocculation after desliming. It was found that alumina-specific bioproteins and other nonproteinaceous compounds were secreted by bacterial cells after adaptation to the mineral. The utility of this bioprocessing is demonstrated in the removal of iron from bauxite ores through selective

Jan 1, 2000

By K. Norrena, E. Magri

An important problem in mine operations is the classification of material as waste, low-grade stockpile and ore. This classification must often be made with blasthole data that are widely spaced and that have sampling errors. Geostatistical-simulation techniques combined with basic economic principles allow a procedure for classification that maximizes the expected profit. Geostatistical-simulation methods (Gaussian, indicator or annealing-based) allow the integration of hard and soft data in the creation of alternative, equally probable realizations of the mineral grades. At each location, for each realization one calculates the "profit" if the block were to be classified as ore or waste. The optimal classification is the one that maximizes expected profit (a maximum profit selec¬tion or MPS procedure). In this paper, the authors discuss the theoretical justification of the method and implementation details. The use of blasthole data from different types of mineral deposits, that is, different levels of continuity, are considered. The authors also show the efficacy of the procedure with different levels of sampling error. The increased revenue due to the MPS procedure and improved sampling is shown. The paper shows the geostatistical-simulation procedure and the uncertainty in block grades that result from incomplete and imperfect sampling. The optimal classification is presented. Optimal block classifications are transferred to realizable dig limits by hand-drawing polygonal boundaries. The results of the proposed method are compared to classification based on kriging. Limitations and areas of future work are identified.

Jan 1, 2000

By P. H. Willis

Since the 14th CMMI conference, held in Edinburgh in 1990, at which a paper was presented by the author (Willis, 1990) reviewing the role of integrating new technology as a survival strategy for South African gold mines, considerable change has occurred in the South African mining industry. This paper reviews the current state of the industry and provides an update on the technologies discussed ten years ago. It reviews available technology and provides a broad economic assessment of these technologies if they were to be introduced in an integrated mining system with a focus on deep level mining below 3000 m. It also reviews possible future technologies currently being researched and developed by CSIR: Division of Mining Technology (Miningtek).

Jan 1, 2000

By D E. Langberg, J S. J va, D R. Swinbourne

Specifications on the types and levels of impurities tolerable in metals are becoming increasingly stringent, and are pushing the limits achievable with conventional refining technologies. Particularly difficult is the removal of electrochemically noble elements with low volatilities, such as copper, from more active host metals such as lead, iron and aluminium. Electrochemical refining, utilising the ability of certain solid electrolytes to selectively transport copper or other impurity cations away from the molten host metal into a separate refining phase, may provide an answer to this problem. Numerous studies on solid electrolytes used in concentration sensors have been reported, as well as a limited number on metal refining. Oxygen anion conducting solid electrolytes have been applied to the deoxidation of copper and steel while cation conductors, eg ¯ -alumina and Nasicon materials, have been used to remove lithium and sodium from aluminium. However, solid electrolytes have yet to be applied to the removal of noble elements. The behaviour of solid electrolytes under the extreme conditions of molten metal refining is not well understood. This paper will examine the potential use of solid electrolytes to remove noble metals such as copper from active host metals such as iron. The suitability, and selection criteria of available solid electrolytes for implementation in the metal refining industry in the future will be discussed. In particular, the stability of Cusicon, a copper superionic conductor potentially suitable for use in metal refining, has been assessed and the results of the experiments are presented.

Jan 1, 2000

By Barrick Pierina, John Frostiak, Igor Gonzales, Kenneth G. Thomas, Ken Manning

"1.0 SummaryThe Pierina deposit was acquired in August 1996 when Barrick Gold Corporation purchased Arequipa Resources, a junior mining company with extensive land positions in Peru. At the time of acquisition, Arequipa had developed two exploration tunnels and drilled 9 exploration holes on the property. Metallurgical tests, conducted on samples taken from the tunnels and the exploration holes indicated that the ore was amenable to heap leaching. Barrick’s exploration team recognised from the outset, the potential of the mineralisation and convinced Barrick’s senior management that this was indeed a world class deposit that should be pursued. On November 25, 1998, the first dore was poured at Pierina, 27 months from the time of acquisition. During that period Barrick completed its exploration programme, prepared a development plan including capital and operating costs, production profiles and cash flow forecasts, and a schedule to develop a mine and construct a leach pad and gold recovery plant, including all supporting infrastructure. All permits and environmental approvals were obtained and all necessary land was acquired. The project was completed on schedule and under budget. This was the first greenfield mine development for Barrick outside of North America.This paper details, mainly, the research and development, engineering, construction and commissioning of the metallurgical process facilities.2.0 The Develonment ProgrammeImmediately after the acquisition, Barrick began the process of gathering information required to prepare a project development plan. Kilborn Engineering was retained to assemble all of the information collected and collated into a development plan document. This document was completed by June 16,1997. The objective was to bring the mine into production as quickly as possible with critical activities identified as follows:"

Jan 1, 2000

By John R. Twining, Michael D. Lawton, Ross A. Jeffree

The Finniss River system in tropical northern Australia has received 'acid-drainage' contaminants from the Rum Jungle uranium/copper mine site over the past 4 decades. Following mine-site remediation that began in 1981-82 the annual contaminant loads of sulfate, Cu, Zn and Mn have declined by factors of 3, 7, 5 and 4, respectively over 1990-93, compared to the 1969-74 pre-remediation loads. Comparison of the frequency distributions of contaminant water concentrations over these pre- and post-remedial periods have shown varying degrees of reduction in the highest levels following mine-site remediation, that are consistent with reductions in their annual-cycle loads. Among the three selected major metal contaminants the reductions in maximum water concentrations are most pronounced for Cu. The demonstrated reductions in the highest water concentrations of all four contaminants are also associated with previously reported ecological improvement in the Finniss River system, compared to the benchmark of environmental detriment established in 1973fl4, prior to the beginning of remediation at the mine site.

Jan 1, 2000

By S. Chander, S. W. Musselman

The molecular structure of hydrophobic and hydrophilic groups in nonionic surfactants has been related to the wetting and dispersion of selected pigments. The nonionic surfactants included in this study are acetylenic diol based surfactants and ethoxylated alkyl phenols. The Langmuir model could be used to fit adsorption data. Further analysis of the data showed that the free energy of adsorption was a function of adsorption density of the surfactants at the interface. The change in free energy with adsorption density could be interpreted by considering a change in the orientation of the adsorbed molecules. Acetylenic diol based surfatants were found to have an area per molecule of 2-3 times that of similarly ethoxylated alkyl phenols. The wetting and dispersion properties of lamp black, a model hydrophobic surface, by these surfactants were investigated by contact angle measurements and particle size analysis. Acetylenic diol based surfactants with ethylene oxide contents between3.5 and 10 moles per molecule and alkyl phenol based surfactants with approximately 9 moles of ethylene oxide per molecule were found to provide superior wetting abilities. Longer ethylene oxide chains were required for superior dispersion capabilities within each family of surfactants. Complete wetting and dispersion was found to occur above the critical micelle concentration of the surfactants.

Jan 1, 2000

Many mining operations generate seismic signals. They come from blasting and from underground mine failures such as rockbursts, longwall first caves, coal bumps and pillar collapses. Traditionally, seismic motions have been of concern on a local scale because they could create damage to structures at the mine site or at neighboring locations. Recently, there has been much interest in the Comprehensive Nu-clear-Test-Ban Treaty (CTBT). It prohibits any kind of nuclear explosion, anywhere. So distinguishing signals of mining operations from a possible nuclear explosion becomes important. An international monitoring system (IMS) is being implemented to verify the Treaty when it is ratified. It includes a large number of seismic stations capable of recording signals at regional (200 to 2,000 km or 124 to 1,240miles) and teleseismic (more than 2,000 km or 1,240 miles) distances.

Jan 1, 2000

By T. Tamagawa, S. H. Tabaian, I. Iwasaki, N. X. Fu, M. Kobayashi

A gaseous chlorination process for the hydrometallurgical treatment of a chalcopyrite concentrate was investigated. The overall process is visualized to consist of low-temperature chlorination -selective oxidation, followed by aqueous chloride leaching and SX-EW for producing electrolytic copper, elemental sulfur and ferric oxide. In this article, the chlorination phase of the process is described. Initially, the chlorination behavior of chalcopyrite concentrate micropellets was investigated using a small batch-type fluidized bed reactor. The optimum conditions thereby established were used in continuous chlorination tests. The chlorinated products thus prepared were used in the selective oxidation phase of the investigation.

Jan 1, 2000

Change is inevitable but learning from change is an option. Willingness to learn is one of the first lessons that a leader must learn. Get comfortable and get left behind. I propose to outline the main social changes which are taking place and their impact on the Minerals Industry. Also the changing way we do business and what are the skills needed to manage that change and diversity. How are Associations and Institutes responding to this ever changing environment? More specifically, what is my Vision for the Institute to assist professionals to achieve greater and continuing professional excellence in their chosen professions?

Jan 1, 2000

By 1980, the US mining community had reached a broad consensus regarding coal pillar design. The pillar load could be estimated from tributary area theory, and the pillar strength could be estimated from empirical formulas and laboratory coal strength testing. Then the growth of longwall mining required new thinking. Recently, powerful design methods have emerged from analysis of large databases of real-world pillar successes and failures. These include the analysis of retreat mining pillar stability (ARMPS), the analysis of longwall pillar stability (ALPS), the Mark-Bieniawski rectan¬gular pillar strength formula and guidelines for preventing massive pillar collapses. Sophisticated numerical models have also helped transform the pillar design landscape. In the process, the understanding of pillar mechanics has been greatly enriched. A new paradigm identifies three categories of pillars according to the types of failure that are associated with them. These categories are slender pillars (w/h < 3.0), which are subject to sudden collapse; intermediate pillars, in which pillar squeezes seem to be the most common failure mode; and squat pillars (w/h > 10), which are dominated by entry failure (rib, roof or floor) and coal bumps.

Jan 1, 2000

By J L. Mauk

Golden Cross is a volcanic-hosted, low-sulfidation, epithermal Au-Ag deposit in the Hauraki Goldfield. Irrespective of the rock type (andesite versus dacite), hydrothermally altered wallrocks are enriched in K, Rb, As and Sb around Au-Ag mineralised veins of the Empire vein system and stockwork. Sodium and Sr are strongly depleted around these veins, whereas Mg and Fe are locally depleted. Calcium and Si display mixed behaviour, varying from unchanged to depleted to enriched. Other elements including Al, Ti, Mn, Zr, Y, and Nb show little change or are immobile during hydrothermal alteration. Element enrichment and depletion trends are directly related to the degree of alteration and the alteration mineralogy. Addition of K and Rb and converse loss of Na and Sr in intensely altered wallrock surrounding veins corresponds to the replacement of igneous plagioclase by hydrothermal adularia. Sodium and Sr occur in moderately altered rocks on the margins or in æhard barsÆ that contain plagioclase. Locally, elevated Si concentrations and depletion of Mg adjacent to the Empire vein system reflects intense silicification of the wallrocks and the replacement of mafic minerals by quartz rather than by chlorite. The geochemical zonation patterns at Golden Cross are very similar to those at the McLaughlin deposit California, and shallow levels of the active Broadlands Ohaaki geothermal system. Therefore, determination of K, Na, Rb, Sr, and Ca enrichment and depletion patterns provides insight into alteration intensity and mineralogy that is complimentary to traditional trace element analysis of As, Sb, Hg, Au, Ag, Zn, and Pb used in the exploration of shallow level (&lt; 500 m) epithermal Au-Ag deposits.

Jan 1, 2000

By J. W. Choung, J. A. Finch

Acid rock drainage (ARD) is a recognized environmental challenge facing mining industries. An ambient temperature ferrite (ATF) process has been investigated for treating ARD. Most nonferrous metal and calcium ions present in typical ARDs were found to be detrimental to the ATF process. Three approaches were examined, including C02 aeration, addition of complex agents and use of magnetic seeds. By introducing magnetic seeds in the ATF process, the interferences were minimized and all the precipitates formed with lime neutralization were magnetically recovered from a simulated ARD. The residual concentrations of major metal ions in the treated water were environmentally acceptable. The XRD pattern confirmed the spinel ferrite crystal structure of the products

Jan 1, 2000

By J. W. III Leonard, T. E. Wilson

In addition to coalbed thickness and basic coal quality data, coal drill cores can produce design data for coal beneficiation processes. To generate design data, a coal drill core should be reduced from its original cylindrical form to a particle size distribution and composition that represents (with the possible exception of top size) a raw coal process stream. Reducing a coal core with a crushing machine rarely accomplishes this representation. This investigation employs drop-shatter impact breakage followed by dry batch tumbling in a steel cylinder rotated about its transverse axis to characterize the core in terms of first-order and zeroth-order break- age rate constants, which are indices of the propensity of the coal to degrade during handling. To reduce composition variables and conserve difficult-to-obtain coal cores, the initial drop-shatter and dry-tumbling tests were done with synthetic cores. Then, cores from three coal beds, Illinois No. 6, Upper Freeport and Pocahontas No. 5, were tested. Comparison of a crushed drill core and a drill core prepared by drop-shatter and tumbling indicated that the size distribution and size fraction composition of the drop-shattered/tumbled core more closely resembled the plant feed.

Jan 1, 2000

By A. J. Friedrich

Conveyor belts are designed to go unnoticed. When they work well, they attract little attention. When they are not doing the job right, it is noticeable, and they need to be fixed immediately. Vulcanising contractors compete for the maintenance of belts in mining/quarrying and general materials handling worldwide. Damage repair is approached in similar fashion. The damaged section of belting is normally cut out and discarded, and the belt re-spliced using hot vulcanising, Cold splicing, or mechanical fasteners/clip joints. However, there is a cost-effective alternative, alleviating the need to remove damaged sections which are often perfectly recoverable. This is the use of cold-curing repair resins and adhesives.

Jan 1, 2000

By H. Y. Sohn, M. Pérez-Tello, J. Löttiger

An investigation of the oxidation reactions of two industrial copper mattes was performed using dflerential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) at heating rates of 20°C and 8°C/min, respectively. The temperature of incipient reaction, the total exothermic and endothermic heats of reaction and the weight change during the oxidation process were measured as functions of the oxygen concentration in the oxidizing gas, matte grade and matte particle size. The temperatures of incipient reaction measured from the DSC experiments were found to increase monotonically with all three input variables. TGA experiments showed that Cu2O and CuO CuSO4 are formed before the complete oxidation of Cu2S to CuO.

Jan 1, 2000

By B. Bergmark, O. Guyot, A. Broussaud, C. Bouché

The Boliden Aitik concentrator in Sweden processes 2,000 t/h (2,200 stph) of low-grade copper ore. The plant consists of five grinding lines that feed four bulk-flotation banks with a scavenger-concentrate regrind mill und a column cleaner circuit with a regrind mill. The authors installed a model-based expert optimizing control system to maximize copper recovery in the bulk-flotation circuit while maintaining an appropriate copper grude in the cleaner feed. The optimizing control system uses on-line assays and calculates and implements set points for cell pulp levels, air rates and reagent- addition rates. It combines the power of a dynamic population-balance model that estimates mineral liberation in each stream, an optimizer that computes appropriate set points and a rule-based module that implements the strategy. The benefits have been evaluated over a period of three months. The model-based expert optimizing control system generates a measurable increase in copper recovery, around 0.5%, and an optimized bulk-concentrate grade. The need to maintain the optimizing control system and other practical aspects are discussed.

Jan 1, 2000

Atlas Copco Wagner launched its ST1010 Scooptram load haul dumper. The ST1010 replaces the company’s Wagner ST-1000 Scooptram. The improvements to the Wagner ST1010 include increased reliability, ease of maintenance and driver comfort or ergonomics. The ST1010 has been redesigned and has added several new features and options not offered in the earlier model. These include anew boom design with side stops. Heavy reinforcements to the bogie offer better protection against the harsh working conditions in underground mining and tunneling. An auto lube system has also been added as has paint-on grip tread to reduce slips and falls during maintenance checks or repair work. Other features include a heavy-duty, auxiliary-fan motor, an isolated transverter, remote diagnostic pressure taps, a bolt-on battery box, raised air-intake, improved fuel-filter access for easier maintenance, larger wear-bars around the engine tub, and smaller, higher output batteries

Jan 1, 2000

Introduction Surface mining is a business, and the objective of most businesses is to make as much money as possible within certain responsible constraints. Businesses normally measure their potential to make money by estimating the discounted cash flow rate of return on new projects or the net present value for ongoing projects. These estimators of profitability are calculated using the following well-known equation: [ ] where i is the year, n is the total number of years, A, is the after tax net cash generation in year I, r is the discount rate and NPV is the net present value. In its simplest form, when the value of r makes the NPV equal to zero, the discounted cash flow-rate of return (DCF-ROR) is defined. The maximum economically recoverable reserve is identified at the point where the NPV or DCF-ROR is at a maximum. Depending on the measure used (DCF-ROR or discount rate) for calculating the NPV, the definition of recoverable reserve will be different for exactly the same deposit. Maximization of the measure of profitability and the economically recoverable reserves should not be separated from the mining method and sequence of exploiting the reserve. The surface mining methods may involve multiple-pass development of the resource, mining to the ultimate limit in one pass or a combination of the two methods with backfill. Multiple-pass development When planning a multiple-pass mining operation, it is important to determine the width of pit expansions that are appropriate for a specific situation. Production personnel typically want wide, open work areas where operations can be set up to run at peak efficiency. While this is understandable, the trade-off between highly efficient production operations and an overinvestment in stripping should be carefully weighed. As long as safety is not compromised, a few cents per bank cubic yard increase in operating cost due to lower productivity by working in more confined spaces may well be offset by a decrease in the overall short-term stripping requirements. A mini study on productivity and cost should help quantify this cost before deciding on minimum phasing requirements. The bigger challenge associated with establishing smaller work areas is securing operations and management buy-in to marginally lower productivity when reporting results. When cost reduction is the important management goal and everyone is focusing on unit costs, one sometimes loses sight of the goal of total cost management and, even more importantly, maximum profitability. The first pit should be defined by the first grouping of recoverable mineral that has the highest after-tax unit value and forms a feasible mining unit. The assumed mining of the first pit should be followed by the assumed mining of the second most profitable practical pit or pit expansion. If this process of grouping and sequencing is followed until the profitability approaches zero, the general sequence required to extract the maximum economically recoverable reserve is identified. The curve in Fig. 1 is constructed for a rate of production, R, and a quality management strategy, Q, by calculating the NPV for a series of sequences, with each sequence assuming that the operations are terminated on successively lower profit pits. These values are plotted to form the curve in Fig. 1. If the operation ceases on a pit that has too high of a profit, opportunity is lost, and the NPV is lower than the maximum. The NPV curve peaks and starts to decline before the zero-profit pit is assumed mined. This occurs because the money invested in advanced stripping would have made more money invested at the discount rate than by mining the next pit expansion. Therefore, the maximum economically recoverable reserve is defined by the pit limit corresponding to the maximum NPV. There may be an opportunity to refine the definition of the "ultimate pit" around the maximum-value point. The precise definition of the ultimate pit early in the mine life may or may not be important today, depending on how far off in the future these limits will be reached. By the time an operation must decide on its last increment of economically recoverable reserve. much of the

Jan 1, 2000

By D. Royston

Curved pulp lifters have been incorporated in SAG and AG mills in Australia. The aims have been to ensure complete discharge, at high throughput, of both slurry and coarse solids, especially at high mill rotational speeds. Curved pulp lifters can overcome incomplete discharge and back-flow of solids down the pulp lifter that can occur in straight-radial pulp lifters (and is a major cause of wear). They can be designed to prevent reverse flow of pulp via grates back into the mill. Experience with curved pulp lifters now extends to three years over three mills, in one mill as an installation from new and two as retro-fitted installations. Curved pulp lifters, relative to conventional designs, offer improved discharge and wear performance and well as high impact-resistance and wear life of the curved pulp lifter grates.

Jan 1, 2000