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By J Rapkoch, M Cerna

As long as the tendency of Chilean copper ores continues to feature high levels of impurities, the smelters will tend to produce high-impurity mattes. The most notable impurities include As, Sb, Pb and Zn. Producing high-quality copper with such materials is a major challenge to metallurgical engineers and operators. More investigations into process optimisations and/or alternatives are needed, using both theoretical knowledge and operational skill. Converting of matte in Chile depends on the matte grade using established technologies. Mattes up to 66 per cent Cu, such as those from Outokumpu Flash furnaces, are converted in two stages, while typical Teniente Converter mattes, ranging from 70 - 74 per cent Cu are converted in one blow, directly to copper. In this paper thermodynamic data are used to evaluate possible variations in the use of traditional technologies applied to smelt copper concentrates with high impurity levels. The results of this analysis help to predict the impurity distributions between matte-slag-gas during the slag blow, and between copper-slag-gas during the copper blow. For converting high-impurity white metal, the effectiveness of volatilisation in the slag blow is analysed. In the copper blow, the type and the amount of flux (SiO2, CaO and others) are altered with the aim of optimising impurity distribution to the slag and gas.

Jan 1, 2005

By Baafi EY, MacKenzie -Wood P

An experienced and reliable knowledge of fire fighting procedures is necessary for mine emergency situations. Since experts in this area are scarce the technology of expert systems lends itself as a suitable component in the decision making process. This paper describes an expert system that is being developed for this purpose. The expert system. RESCUE. is a knowledge-based computer programme which incorporates the judgement, experience, rules of thumb. mine environmental conditions as well as human intuitions in the mine rescue operation. RESCUE makes decisions such as whether or not the affected area should be sealed.' whether or not rescuemen should be withdrawn, and which fire fighting agent is most appropriate for the situation. The IF..... THEN rules written in the VP-EXPERT shell contains antecedents and conclusions based on environmental as well as other conditions prevailing in the mine. For example, the CO/Oz deficiency ratio indicates the progress of heating; explosibility trends are given by varying flammable gases C CH4,H2,CO) in relation to oxygen concentration, and barometric pressure falls may affect explosibility by increasing CH4 content in workings. The interaction of such numeric-based rules with others rules reflecting the experience and judgement of the experts assist the system to arrive at its conclusions and subsequent course of action.

Jan 1, 1988

The Ausmelt Catalytic Waste Converter (CWC) has been developed for use in the treatment of industrial wastes and for the recycling of secondary materials. Ausmelt Technology uses a top submerged lance system within a versatile and efficient slag bath reactor. High temperature pyrometallurgical reactions are carefully controlled within an oxidised molten siliceous slag such that metals can be extracted from waste feedstock for recycling, with non-volatile elements reporting to the slag, usually as oxides. Modification of the slag chemistry results in a final slag product that is stable, vitrified and is able to pass standard leach tests such that it is safe to discard or be used in civil engineering applications. Toxic components in the wastes such as organohalides can be completely destroyed and are prevented from reforming. Waste to energy conversion is practiced by the addition of a heat exchanger/steam generator in the converter offgas system. The Ausmelt CWC has been used for recovering zinc from residues and slags, treating spent potliner (SPL) from the aluminium industry and a wide range of electronic and other potentially valuable waste materials. Methods of monitoring the exhaust gases at different stages in the CWC gas handling system are discussed. The assay of these gases prior to emission is used to assist in the control of the converter chemistry to ensure the complete oxidative breakdown of the feedstock.

Jan 1, 2002

By R G. Alford

Braeside Borefield, located 120 km southwest of Mackay, is owned by BHP Mitsui Coal Pty Ltd (BHP Mitsui). The borefield provides water to BHP MitsuiÆs South Walker Creek and Riverside Coal Mines and communities in the northern portion of the Bowen Basin. Braeside Borefield has also provided water for other users in the region, including the Peak Downs, Goonyella and Saraji Coal Mines owned by BHP Billiton Mitsubishi Alliance (BMA). Water is sourced from alluvial sediments at the confluence of Nebo and Denison Creeks, and transferred a distance of almost 100 km to Riverside Mine and other users. Since commissioning in 1983, monitoring and maintenance programs have been key elements in borefield management. The impact of pumping on groundwater resources is monitored at the borefield, upstream and downstream over a distance of about 50 km. Current annual pumping is of the order of 4000 ML, and in excess of 50 000 ML has been pumped since the commencement of borefield operations. Detailed reviews of borefield performance are conducted every two years. BHP Mitsui actively participates in community consultation on groundwater issues arising from operation of the borefield. Declining groundwater levels from prolonged drought conditions have increased community interest in management of the borefield. Rehabilitation of existing production bores and augmentation of the borefield is currently being investigated to more evenly distribute pumping rather than to increase overall capacity.

Jan 1, 2003

By Teague JK, Read HW

The relationship between the maceral composition of coal and the strength of the coke produced from that coal has received a great deal of attention in recent years. Studies using two Bulli Seam coals, and blends of Bulli and Wongawilli Seam coals, from the Illawarra Measures of the Southern Coalfield of New South Wales were carried out. The optimum range of vitrinite was found to lie between 45% and 60% (mineral matter free). Above and below this vitrinite range coke strength deteriorated. I Coke strength indices increased with rank and the optimum vitrinite content increased with an increase in rank. These changes will require confirmation as trends by testing a third level of rank. It was noted that vitrinite content decreased with an increase in the specific gravity of separation of the coal. . T Use of- petrographic analyses will increase confidence in choosing coals for coking, provided the coals are well known. Such analyses offer the possibility of greater flexibility in coal purchases and the possibility of producing a marketable blend from coals, which have limited market potential. Critical base coals for blends can be conserved. Significantly more work is required before coal reserves can be utilised to optimum advantage. This work would require extension of-the studies discussed in this paper and, in particular, the testing of a wider range of rank.

Jan 1, 1970

By I Gipps

The mining industry has come through a period of major change in community expectations regarding safety and environmental impact and these changes can be expected to continue in the future. These changes are ultimately reflected in Government regulations and industry safety standards and form the basis of the ælicense to operateÆ. Equally, advances in technology have made possible new equipment and processes either available now, or close to completion, that will allow mines to meet these more stringent expectations if properly introduced. Changes in technology provide opportunities for mine management to introduce new systems that will remove people from hazardous areas and lead to improvements in the ætriple bottom lineÆ. In a longer time frame of five to ten years, novel and advanced technologies that are currently being developed will deliver new mining methods and conversion of presently uneconomic resources to ore. This is consistent with the time frame required to develop a new mine from discovery. Strategic decisions can be taken now by mine designers to enable the introduction of these major technology changes. Examples of both practical and strategic opportunities are drawn from the integration of rock cutting/blasting, automation, electronic communications and new mining methods. This paper discusses emerging industry trends, changes to legislative framework and some practical choices for existing and imminent technology.

Jan 1, 2003

By Hindmarsh G

The colliery is owned by the BHP Collieries Proprietary Ltd., the principal shareholders being the Broken Hill Pty. Company Ltd. and Hebburn Limited.It is situated due west of Newcastle and 6 south-east of Cessnock, N.S.W., and is conneeted by 36 miles of railway to the port of Neweastle. Of this mileage, 3 miles are owned by the Company, 3 by Hebburn Limited, 9 by the South Maitland Railways Ltd., and 21miles by the Government Railways.The seam worked is known as the Main Greta Seam of the Greta Coal Measures and is on the southern slope of the Lochinvar anticline.At the shaft, the seam is 1190 ft. below the surface, and the section of the coal measures is:-Upper or Main Seam, . 24 ft. 0 in.Conglomerate and shale 70 ft. 0 in.'Middle Seam 8 in.Conglomerate 25 ft. 0 in,Bottom Seam 1 ft. 2 in.These lie between two marine measures, and are the lower coal series of the permo-carboniferous period.Only the upper seam is workable in this area, the lower seams being too thin for eompetitive working. The section of the workable seam at the shafts is as shown on Fig. 1.Unfortunately, only the lower 12 ft. 5 in. of the seam is saleable.

Jan 1, 1935

A laminar-flow furnace technique was used to study the combustion of 37-53 µm size fraction of Woodlawn copper concentrate containing 7.4 per cent zinc, 5.0 per cent lead and 22.5 per cent copper. Factors studied included the effect of time, temperature and the distribution of volatile elements between the panicles and the fume. Air was used for most of the work but a few tests were carried out using 1 per cent oxygen in nitrogen. Chemical analysis, X-ray diffraction, and scanning electron and optical microscopy of polished sections were used to characterize the reaction products.When the concentrate was combusted at low temperatures (800-900°C), the fume was rich in lead. At higher temperatures, this was diluled by increasing amounts of zinc and copper. 70 per cent of the zinc, 60 per cent of the lead and 40 per cent of the copper were found in the fume after oxidation at 1400°C. Lead, zinc and copper were present in the fume as anglesite (PbSO4), zincite (ZnO) and cuprite (Cu2O) respectively. The major phases present in the panicles were magnetite (Fe3O4) and/or cuprospinel (CuFe2O4), with some zincite and cuprite.Elemental copper was found in the particles oxidized in 1 per cent oxygen. Possible vapour species responsible for the vaporization are discussed.

Jan 1, 1985

By Dyne GD

From experience in the design and operation of power station combustion facilities in most mainland Australian States, involving a wide range of black coals and lignites, and in the specification and procurement of coal supplies for power station use, techniques for the optimisation of coal resource development and power generation utilisation have been developed to ensure compatibility between characteristics of the selected coals and power station design. These techniques include computer data bases for resource data handling and computer simulation of coal-fired boilers for determining coal property cost effects. Data Base Systems allow results of coal analyses to be efficiently handled, to assist in the review of the relevance of resource data to the coal sections proposed to be mined and the coal fractions proposed to be marketed. Data Base Systems also facilitate the marshalling of coal quality data into basic utilisation format to enable a proper utilisation review and analysis of the certainty and scatter of coal properties. Computer simulation of the effects of different coal properties on the capital and operating cost of power stations is achieved by establishing conceptual design parameters of the major items of plant to relate the variations in coal specification to equipment size and type. Variations in power station budget costs can then be determined using the computer model for variations in coal specification.

Jan 1, 1983

By Nye P. B, Fisher N. H

At the second Empire Mining and Metallurgical Congress held in 1927, the Empire Council of Mining and Metallurgical Institutions was formed and it was proposed that the Council take steps to prepare a "Review of the Mineral Resources and Industries of the Empire." At the third congress in 1930, it was resolved that the proposal to institute the review should be submitted to the Imperial Conference held in 1930. This was done, and the Minerals Committee, of the Imperial Economic Committee compiled, an interimreport which was based on statistics of imports and exports, and did not consider resources and consumption.In 1942 the Institution of Mining and Metallurgy, London, wrote to the Empire Council and stated that it was desirable that the Council should be in a position to take part in decisions affecting the future of the mining and metallurgical industries. The Council communicated with the constituent Institutions regarding the nominations of two members then in England. Subsequently the Mining, Geological and Metallurgical ,Institute of India prepared a review of the mineral resources and industries of India and their post-war development, and the Empire Council forwarded a copy to the Australasian Institute of Mining and Metallurgy and asked if that Institute would submit a review on simjIar lines for Australia. The Australasian Institute arranged that the Australian review should be prepared by...

Jan 1, 1946

By Jones M

The concept of precise, accurate timing with Electronic Delay Detonators (EDDs) was first seriously addressed in the mid-1980s and much was made of the cheapness and profusion of digital watches in terms of the likelihood of EDDs also being cheap and easy to produce. Ten years later, with every major explosives company and many electronics groups having instituted projects to capitalise on the promise of these devices, production devices are still to come into general use. In South Africa, Expert Explosives units have been used in most applications during proving trials and more recently for production blasting in underground ring stoping and open cast coal. The outcome has been valuable learning both as to the benefits and technical requirements for electronic delay blasting, and especially, safety aspects. Examples are shown of production blasts which utilised the power of EDDs. It is evident that it is not delay accuracy alone which determines the value of these systems, but the whole robustness, flexibility and ease of delay allocation when harnessing blast engineering knowledge. Muckpile movement and shape, fragmentation and vibration frequencies have shown to be greatly influenced by designs which can be implemented no other way. The flexibility of a system and the power of the software controlling it are crucial in capitalising on blasting potential, which lies in integrating control of blast timing with other developing electronic Technologies.

Jan 1, 1995

By H Beucher

The uranium grade in roll front deposits is the result of successive processes that can be summarised in two steps. First a sedimentary phase, which gives the deposit support, then an oxidation-reduction phenomenon, which leads to the uranium deposit itself. In order to simulate such a deposit, it is important to mimic these different phases. The final aim of such a study is to localise the uranium itself and to reproduce the internal heterogeneity of the orebody in order to simulate the recovery process. The idea in this paper is not to reproduce a genetic approach but to consider the final image of the deposit. Three approaches are proposed. The first one consists of simulating the facies of the sedimentary deposit. The second approach reproduces the distribution of facies resulting from oxidation phenomenon (reduced or oxidised facies). The third approach consists of simulating the mineralisation at the interface of reduced and oxidised areas using the definition of a new data set determined by the grade values. At the end of each approach, the uranium grade could be simulated facies by facies according to the corresponding distribution characteristics. The plurigaussian method dedicated to random set simulations is well-suited for the facies simulations of deposits resulting from several sedimentary processes whether correlated or not. In this paper, the benefit of this method is demonstrated in an actual case study.

Jan 1, 2006

The Drake-Rivertree area lies in the far north east of the New England district of New South Wales. Drake is some 500 miles north of Sydney by road and 36 miles west of Lismore. Rivertree is situated 24 miles north of Drake.The Drake deposits were first worked in 1878 for gold which occurred in a very fine state in ferruginous gossan but at depth copper ore became more significant. The lodes at Rivertree, discovered in 1887, were worked for silver but mixed sulphides became more prominent in deeper levels.Several mines operated at each centre and each locality smelted its own ore.The mines at both centres were operated sporadically for many years though production was not particularly substantial.A number of the larger mining companies have shown a recent interest in this mining field with special emphasis on the Drake locality.GENERAL GEOLOGYThe two mining centres are situated to the north and south respectively of a belt of Permian marine sediments and volcanics similar to, and probably representing an easterly extension of, the rocks of the Emmaville district further west.E. C. Andrews (1907) recognized two stratigraphic units within what he called the Drake Series. The Lower Division consists of rhyolite flows, tuft's, breccias and agglomerates, followed by trachytic and andesitic tuft's containing cladochonns, thanmopora willcinsoni and other Permian forms.

Jan 1, 1962

Epithermal gold mineralisation was discovered at the Muyup prospect during regional reconnaissance exploration in 1986. Further exploration utilising routine techniques of stream sediment, panconcentrate, rockchip sampling and geological mapping resulted in the discovery of five auriferous vein systems located along northwest-trending fault zones. Scout diamond drilling was conducted on two of the vein systems. Mineralisation is hosted by a poorly exposed, mid-Tertiary volcanic inlier composed of intermediate and minor felsic volcanic rocks intruded by intermediate hypabyssal por- phyries. Gold is wholly contained in narrow steep-dipping hydrothermal breccias and quartz vein stockworks in which chalcedonic silica and fine grained quartz is the predominant gangue with minor adularia, carbonate, and sulphides. Alteration zoning is manifested as intense fracture-controlled silicification mantled by narrow clay-rich envelopes which in tam grade outward and downward into propylitic alteration or unaltered host rocks. Late advanced argillic alteration is superimposed on the vein-related altera- tion assemblages. Alteration assemblages and fluid inclusion data suggest that gold mineralisation occurred in response to episodic hydraulic fractur- ing and boiling of low to moderate temperature, dilute alkali-chloride fluids. The Muyup prospect represents the shallow eroded remnants of an epither- mal gold deposit enriched in Au, Ag, As, Sb and Hg. Low sulphur fugacities reflected by vein and alteration assemblages support an adularia-sericite classification (Heald et al, 1987) for this epithennal gold deposit.

Jan 1, 1991

By L Chaffey, M Buckland

The minerals industry has enormous potential to positively contribute to sustainable development and many leading companies have concluded that their long-term success is directly linked to their ability to leave a lasting positive legacy. While there are many examples of success, there have been failures as well and much work has been done in recent years to define the role of the minerals industry in sustainable development and identify the key elements for success. In the past, our sector could point to the taxes and royalties it paid, the exports it generated and employment it created and felt confident that its contribution would be recognised and duly acknowledged. This is no longer the case. Critics of the industry have highlighted resource-rich countries that have failed to capitalise on their resource wealth and have arguably lower standards of living than their resource-poor peers û the æresource curseÆ hypothesis. Recent research has done much to clarify the factors that contribute to a countryÆs success or failure and all stakeholders in the industry now need to include these learnings in their approaches going forward. We know that our long-term success relies on embedding a company- wide approach to sustainable development into all aspects of our business operations. In this paper we highlight BHP BillitonÆs experience in the development and implementation of policies and systems designed to enhance our contribution to sustainable development. We detail the business drivers for excellence in this area and the key external codes and initiatives that have shaped our approach. The values-based BHP Billiton Charter, Sustainable Development Policy and associated Health, Safety, Environment and Community (HSEC) Management Standards are central to our approach. Implementation is reviewed through our HSEC audit program. One area in which we have placed particular emphasis is our approach to community development. BHP Billiton has a corporate target to contribute one per cent of its pre-tax profit on a three year rolling average to voluntary community programs. As our profit stream has increased with the minerals boom this is approaching an A$100 million commitment. In our paper we detail how we are working to ensure we maximise the value of this contribution for our communities and our shareholders.

Jan 1, 2006

By D La Rosa, K Caron, H Mamani, W Valery, R Diaz

The Gold Fields Cerro Corona copper-gold deposit in Peru has heterogeneous rock characteristics in terms of its mineralogical, geological and geotechnical properties. Blast design variations in these conditions directly impact the run-of-mine (ROM) fragmentation, which in turn influences downstream process efficiencies. In particular, when harder ore is processed, throughput and circuit performance may be limited.To evaluate the potential to increase throughput and improve overall plant performance by optimising blasting practices and comminution circuit operation, Gold Fields La Cima engaged Metso Process Technology and Innovation (PTI) to conduct a full process integration and optimisation project at Cerro Corona. Blasting, crushing and grinding processes were reviewed to identify the potential to achieve substantial improvements in productivity when treating the most competent ore types.Site-specific models of the blasting, crushing and milling processes were developed using SmartTagTM ore tracking technology for calibration and validation. Ore tracking permitted locations in the blast volume to be queried against the geotechnical block model to determine the hardness and structural parameters of the feed to the comminution circuit. They also ensured surveys were conducted when ore from the audit blast was flowing through the crushing and grinding circuits.The predictive models developed enabled PTI to demonstrate how changes in blast design influenced both ROM fragmentation and the performance of downstream comminution processes. Outcomes of the project suggested changes to blast designs and comminution practices, and these were partially implemented for a validation trial. The trial demonstrated a 14.8 per cent increase in mill throughput for the specific ore selected for the study, and an average increase of 5.7 per cent for all ore types. There is potential to further increase throughput and process performance if all recommendations are implemented. This paper describes the methodology used and benefits to the operation from the mine to plant.CITATION:La Rosa, D, Caron, K, Valery, W, Diaz, R and Mamani, H, 2015. Blast fragmentation impacts on downstream processing at Goldfields Cerro Corona, in Proceedings 11th International Symposium on Rock Fragmentation by Blasting, pp 333–342 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 24, 2015

By M N. Mian

The Cayeli volcanogenic massive sulphide deposit is located in Black Sea region of Turkey. Cayeli Bakir Isletmeleri (CBI) was formed as a joint venture between Inmet (Canada) and Eti Holding (Turkey). CBI is processing complex copper/zinc sulphide ores. The Cayeli concentrator was commissioned in 1994, with a design capacity of 600 000 tonnes/year. The grinding circuit was a classical rod mill/ball mill combination. The rod mill was converted to a primary ball mill in May 1997. The reasons for conversion were to use mill power more efficiently and eliminate feed interruptions during rod charging. The grinding circuit now has a primary ball mill in open circuit, and a secondary ball mill in closed circuit with hydrocyclones. Classification was originally done in two stages with hydrocyclones. Both mill discharges were combined and pumped to a primary cyclopack having two, 500 mm diameter cyclones. Primary cyclone overflow was pumped to a secondary cyclopack for further classification. The secondary cyclopack had ten, 200 mm cyclones. Both unit underflows were fed to a secondary ball mill by gravity. The secondary cyclone overflow, typically 62-64 per cent passing 36 ¦m, at around 42 per cent solids (w/w) was fed to flotation circuit. In order to increase circuit capacity to 1 000 000 tonnes/year and to improve control over the grinding circuit, it was decided to convert the classification circuit from two stage to one stage. For this purpose, six Warman Cavex cyclones having 400 mm diameter were installed. Now, the combined primary and secondary ball mill discharge was classified in single stage with the Warman cyclones in closed circuit with the secondary ball mill. The cyclone overflow goes directly to the copper rougher circuit as flotation feed. The grinding circuit is producing a flotation feed of 70 per cent passing 36 ¦m. The change over to single stage classification at Cayeli was successful. A mill throughput of 1 000 000 tonne/year is being achieved with better control over classification, and improved grind size. Results and comparison between the two classification circuits are presented in the paper.

Jan 1, 2003

The Sao Chico gold project is located on the Tocantinzinho trend which is the most mineralised zone in the Tapajos Mineral Field of Brazil (see Figure 1). The Tapajos goldfi eld was the site of the biggest gold rush in Brazilian history in the late 1970s and 1980s when approximately 500 000 garimpeiros (artisanal miners) rushed to the area to exploit extensive areas of newly discovered alluvial gold. Approximately 20 - 30 million ounces of gold were produced from these operations before the easily won alluvial gold deposits were largely depleted. The Tapajos region has had little exploration by modern exploration methods compared to any other equivalent gold fields in the world. The gold occurs in sulfide veins developed in shear zones within Proterozoic granites. Gold grades vary from approximately 15 g/t in the hard rock veins, to up to several ounces per tonne in the supergene weathered upper portions of the veins. Goldbearing vein zones in the weathered profile are free digging. In addition, tailings dumps from previous mining operations contain gold grades of approximately 1 g/t. Metallurgical test work conducted to date indicates that gold recoveries of at least 70 per cent can be achieved via gravity concentration. Gold Anomaly, via its 100 per cent owned Brazilian subsidiary, Gold Aura Do Brasil Mineracao Ltda (GOAB), plans to mine the tailings and weathered vein material by open cut methods to generate a quick cash fl ow and to provide a better understanding of the mineralisation as part of a feasibility study for mining the underlying sulfide zone mineralisation (see Figure 2). Mining will utilise locally hired excavators and trucks and ramp up to a rate of 100 tonnes per day. To treat the gold-bearing material, GOAB has purchased an integrated 'state of the art' gravity concentration processing plant from Gekko Systems of Australia. The processing plant includes a scrubber for clay and oversize removal, coarse gold gravity separation via an inline pressure jig and an inline spinner; and fine gold gravity separation via a Falcon Concentrator. The plant is expected to be operational by late 2010. This is an ABSTRACT ONLY. No paper was prepared for this presentation. 

Aug 1, 2010

During the past Two years in reef gold mining, "indicators" have received great attention at the hands at the Victorian gold seekers. Many years ago, what was caned the" indicator lode," was struck in Ballarat East, on the course of which extremely rich deposits of gold were discovered but as to its being a .qeneral experience in reefs or leaders no one ever dreamed. Now, however, we find that these "indicators" are frequently to be met with, though they differ very much in different localities, making it, therefore, a difficult matter for other than a careful minel' to follow them. The necessity of following "indicators" for the purpose of developing gold is now recognized, and the policy of following them up has been attended with much success in this field. In the case of Messrs Shaw and Sons, at Wedderburn, those gentlemen began to work on an "indicator" here five years ago, and immediately thereafter more by accident than anything else they being at that time inexperienced as regards "indicators " came upon gold bearing quartz, which continued payable so long as the" indicator" aud the stone were in conjunction with each other, but as soon as they parted company the stone ceasedto be of any value then, by following the" indicator," as the latter intersected fresh bodies of stone they proved again more or less payable, until a fortnight or so ago the Messrs. Shaw turned out 4 tons of stone, which yielded £1,825, with also profitable workingup to the present moment. Where they are now working is a mile north of their original find thus proving that "indicators" travel considerable distances and have something to do with the gold deposits found in reefs. On the direct course of Shaw's "indicator," as high as hundreds of ozs to the ton was obtained from the stone but, just a few inches from either side in the same" leader," not a colour could be got. Whatever the cause-whether by electricity or some unknown force in nature-the gold is found on the course of these" indicators" and nowhere else, and-as each of the Victorian Government Geologists admit-their value to the gold-seeker as a means of leading to' gold cannot be over-estimated.

By C Maloloy-on, S Morgan, M Deiparine, H Mackie

There is a strong focus in the mining industry to limit its impact on water quality and usage. This is even more evident in developing countries, where mining companies operate within local communities and have to be diligent not to affect them negatively. In mineral processing operations, the vast majority of water reclamation occurs at the tailings thickener area and tailings storage dam. It is often more effective to maximise water recovery at the tailings thickener before material transport to the tailings dam. Tailing dams are relatively inefficient, and experience a high degree of water loss due to evaporation, seepage and water retention. In addition, tailings dams present the biggest environmental liability for mineral resource projects, so it is beneficial to limit their size and loading.In the past, it was common for tailings thickener areas to have a significant footprint with several large diameter conventional thickeners, producing underflows of between 45-55% solids (w/w). At times, these multiple thickeners were difficult to operate, leading to inefficiencies in water recovery and quality. The development of High-Rate Thickeners (HRT) has resulted in improved settling properties and HRTs usually operate at significantly higher solids loadings (= 1.2 t/m2.h) when compared to conventional thickeners (= 0.1 t/m2.h). Subsequently, thickener diameters have reduced in size and HRT technology has become the preferred option for thickener circuit design in both new and existing operations. HRTs also produce higher water recoveries with increased underflow densities = 55% solids (w/w).The Carmen Copper Corporation (“Carmen Copper”) circuit upgrade is a recent example of these HRT benefits, where one, 39 m diameter, Outotec HRT treats the solids flow rate of five 76 m diameter conventional thickeners. This has allowed operations to increase dry plant tonnage by 50%, maintain key performance targets and provide a framework for further plant expansion. This paper details the sustainable approach to the Carmen Copper tailings thickener upgrade, where metallurgical performance, cost-effectiveness and environmental impact were key considerations.CITATION:Morgan, S, Mackie, H, Maloloy-on, C and Deiparine, M, 2015. Carmen Copper – a sustainable approach to tailings thickener upgrades, in Proceedings MetPlant 2015, pp 416–430 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015