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By D. P. Fenton

The Phelps Dodge El Paso Rod Mill produces approximately 2.4 million pounds per day of copper rod from a casting and rolling operation. The newly formed rod is treated to remove mill scale and oxides using a sulfuric acid and hydrogen peroxide solution which is bled periodically when the copper concentration reaches 30-35 g/L. The bleed solution is heated to 75° C to destroy the residual peroxide. Copper is then recovered in a 270 cell EMEW electrowinning plant. Clean acid is also regenerated in the EMEW plant and is returned to the rod cleaning circuit. The EMEW plant commissioned in January 2006, has two operators and replaces a copper sulfate plant with fourteen operators. The EMEW plant has a capacity of 1700 kg/day of cathode copper at 2.1 kWh/kg copper deposited. The electrowinning plant operates in closed circuit with the rod mill returning up to 2600 kg/day of sulfuric acid resulting in zero discharge. Use of dimensionally stable anodes (DSA®) ensures that the acid quality is maintained in the closed loop operation. The operating conditions, performance and plant experience of the EMEW copper and acid recovery plant are discussed.

Jan 1, 2007

By E. Roman E.

A novel anode slime purification process was developed and tested at pilot scale in the Chuquicamata Refinery. The process consists of three main stages: First, an atmospheric alkaline leaching at 90°C, under controlled pH and ORP operation parameters where metalloid impurities are preferentially removed from the anode slimes with high efficiency. In a second stage, alkaline washing of the mud leached with addition of reducing agent, with the intention of reducing the silver of the AgCl to metallic silver releasing the chloride, and finally, copper and other remaining impurities are leached out in mild conditions (60°C, one hour in sulphuric acid). In a side process Se, Te, and Sb are recovery with high efficiency from the alkaline liquor as chemical grade products. The global balance shows a high mass loss yielding a final product with high precious metal and low impurities content showing advantages in both a technical and economic point of view with a clear environmental sustainability. This treatment allows either the direct sale of the purified anode slimes or its pyrometallurgical treatment to obtain metal doré without emissions of Se, Sb and As. Chemical mechanisms for this novel process are also described.

Jan 1, 2007

By E. M. Córdoba

The effect of the Fe3+ lFe2+ redox couple on the chemical and biological dissolution of chalcopyrite was studied. All the tests were carried out in stirred flasks with 100 mL of a ferric/ferrous sulphate solution, in the absence or in the presence of bacteria (iron- or sulphur-oxidizing) and at low (35 DC) and high (68DC) temperature. The initial redox potential was controlled between 300 and 600 m V Ag/ AgCI and silver was used as chemical catalyst. The results showed that the oxidizing action of ferric ion on the chalcopyrite was controlled, in all cases, by nucleation and precipitation of jarosites on unreacted particles. The tendency of Fe3+lFe2+ solutions towards equilibrium favours the activities of both ions to be equal. Consequently, the dissolution rate was faster at relatively low redox potentials (between 400 and 500 mY) than at high values (600 mY). In this sense, the presence of ferrous ion in the system is a key factor to control hydrolysis and precipitation of ferric ion. Unlike jarosite, the elemental sulphur produced during dissolution of chalcopyrite was porous and did not act as a diffusion barrier.

Jan 1, 2007

"Background:The recorded coal production in Nova Scotia from 1863 to 1980 was 390, 000, 000 short tons. This extraction was associated with an estimated 60,000,000 short tons of discarded material. This mining discard and coal washing plant reject are located in numerous, varying sized dumps throughout the mining areas. Approximately 70% of these dumps are in the Sydney coal field region of Nova Scotia.The coal content of these dumps varies from 10 to 30% coal with an average of 18%.Energy Costs:The explosion of energy costs in the mid-1970 's greatly increased the sale price of thermal coal which made recovery of coal from some of the dumps economical. The environmental spin-off of these operations will be the rehabilitation of the dumps upon cessation of the coal reclamation operation.Cape Breton Development Corporation, the owner of most of the dumps in the Sydney coal field was receptive to an approach by Selco of reclaiming coal from their dumps. The technology to be used, had been developed by an associate firm in the United Kingdom on similar mine dump situations."

Jan 1, 1983

By S. Koski, M. Schmalzel, D. A. Jacobson, S. Crosby, P. Cook, M. Mular

"Mining operations, whether new or existing, are constantly looking for ways to maximize production and improve energy efficiency, while keeping the footprint required to a minimum. The Nordberg MP1250 cone crusher was designed with these three goals in mind. A series of side-by-side evaluations comparing an MP1250 to an MP1000 were completed at two Freeport-McMoRan operations. The first evaluation began October 2009 in a tertiary position and the second began March 2010 in a secondary position, where it remains in full production today. Utilizing 25% higher power capacity than the existing MP1000 tertiary crushers, the MP1250 had 29% higher capacity and 17% lower specific energy, adjusted for differences in feed and product size. The MP1250 compared to the existing MP1000 secondary crushers achieved 30% higher capacity at a slightly reduced specific energy, while achieving a finer product.The MP1250’s higher capacity and energy efficiency may have application in many crushing plants. Depending on site specific economic factors, greenfield projects may benefit from a smaller footprint and less ancillary equipment, whereas brownfield projects may benefit from higher capacity or a finer product within the same footprint."

Jan 1, 2012

By J. D. Stinnette

Traditionally, airflow requirements for diesel equipment operating in underground environments such as mines and tunnels were determined by multiplying the vehicle power by a ventilation rate that was either mandated by regulations(s) or determined empirically from known quantities. In some cases, utilization factors were further used to adjust (reduce) the total airflow calculations for a diesel equipment fleet. However, in light of the drastic reductions to diesel equipment emissions mandated by the US EPA Tier IV and EURO Stage 4 regulations, there is currently a great deal of uncertainty in the underground mining industry among those responsible for the ventilation of planned new mines or the expansion of current mines. Tier IV engine standards mandate a reduction of DPM and NOx of approximately 95%, but can ventilation rates at mines with Tier IV equipment (or equivalent) really be reduced by a factor of twenty? This paper outlines some of the factors that affect the airflow required for the ventilation of modern diesel-powered equipment and examines how they can be applied in determining a reasonable ventilation rate for Tier IV compliant equipment operating in subterranean environments.

Aug 1, 2013

By Andrew D. Lapworth

The use of geological and grade models has been standard practice in mine design for many years now, with a wide range of software available to create and analyze the models. Although geotechnical parameters are also of vital importance for mine planning, there has been very little in the way of commercially available systems for integrating geotechnical data into the mine planning and design process. Sirovision is a new technology based on digital photography for automated, safe and accurate 3D mapping of geological and geotechnical features in rock faces. Datamine has integrated this capability into its product range so that Sirovision becomes an integral part of day-to-day face mapping, mine geology and geological / geotechnical modeling in both open pit and underground mines. This results in improved fragmentation for loading, hauling and processing, and for open pits local geotechnical conditions can be taken into account to improve slope design and control. This paper describes some of the ways that geotechnical modeling can be used to create more refined and cost effective mine designs and then discusses the role of Sirovision in enabling the raw data required for such modeling to be collected quickly, safely and reliably.

May 1, 2007

By H. Tokuichi, H. Ohta, K. Sato

A physical separation technique of tantalum capacitors from waste print circuit boards is in a development phase in Japan. A tantalum capacitor consists of an exterior coating of resin (epoxy resin) mixed with silica fillers and a sintered tantalum compact, the latter of which is impregnated with manganese dioxide (MnO2). In this study, we developed a process to recover tantalum oxide from tantalum capacitors by roasting, fluidized-bed separation, and hydrometallurgical treatments. Our aim was to recover tantalum oxide with high purity from waste tantalum capacitors. In this process, the exterior resin was selectively decomposed by roasting without oxidation and pulverization of the sintered tantalum compact at a proper temperature. Furthermore, the decomposed resin with silica filler on the surface of the sintered tantalum compact was mostly removed by fluidized-bed separation. The surface of the sintered tantalum compact was cleaned by ultrasonic irradiation in an acid solution to remove the MnO2 paste as well as residual Ag paste and silica filler. The impregnated MnO2 in the sintered tantalum compact was leached as Mn(II) ions using acid solutions via the reducing effect of tantalum metal to recover purified tantalum oxide.

Jan 1, 2014

By D. Bois, F. P. Hassani, M. Hossein

"A growing environmental awareness hos prompted the mineral industry to seek innovations in waste management and technology. It is estimated that over 500 million metric tonnes of solid waste each year are rejected by the Canadian mineral industry. This waste hos to be disposed of in the most environmentally and economically acceptable manner.An extensive study has been conducted to estimate the cost of implementing total tailings fill from a waste disposal point-of-view as an alternative to large-scale surface disposal of tailings. The cost of waste disposal at the surface (tailings pond), and underground (total tailings fill) for three Canadian mines which have taken part in Quebec Mine Survey conducted in 1992 are analyzed. Surface disposal is the most economical and common method of mine waste disposal in Canada. Total tailings backfill as a method of waste disposal is technically feasible but cannot be regarded as more economic than surface disposal in all . It is important to remember that while surface disposal costs are rising, due to tighter legislation and more environmental pressure on governments; the costs of preparing and placing total tailings backfill is still falling as the technology improves."

Jan 1, 1994

By J. E. Danoczi

Shore Gold Inc. (Shore) is presently designing a diamond processing plant for the Star and the Orion South kimberlite deposits in the Fort à la Corne area kimberlite field in central Saskatchewan. The first step in the plant is diamond liberation and occurs in the comminution section. Diamond liberation is the process of breaking up the kimberlite rock, as ?gently? as possible since essential to the diamond liberation process is the minimization of diamond damage, particularly for the larger, high value diamonds. The Southern African diamond mines traditionally use Jaw and Gyratory crushers as their primary comminution method. However, these diamond mines generally process the harder, competent kimberlite that is located in the diatreme zone as well as the root zone of the volcanic pipe. Softer kimberlite is typically located in and around the crater area of a volcanic pipe and it is this source of kimberlite that makes up the majority of kimberlite for both the Star and Orion South deposits. These softer kimberlites can be readily broken up using abrasion and attrition imparted by AG mills, this being the preferred method of comminution for minimizing diamond damage.

Nov 1, 2011

By Barry W. Schmitke, J. M. Marino

"Cigar Lake Mining Corporation is presently operating an underground test mine in northern Saskatchewan, with a view to developing a high grade uranium deposit. The mining test is intended to demonstrate that the innovative mining methods designed are safe and economical. Two vertical mining methods are considered for the test:• box hole boring from the lower level;• blind boring from the upper level.In both cases, it is anticipated to freeze the ground before excavation to ensure hole stability and limit the inflow of water. Special care will be taken to minimize radiation exposure of personnel.Remote controlled equipment will be used where applicable.The access to the orebody was an important component of the test. After shaft sinking to a depth of 500 m, development work commenced at the 420 level in fractured sandstone which was grouted to restrict the inflow of formation water. The drifting continued in a section of poorly consolidated sand, clay and sandstone; this area was frozen to allow stabilization prior to excavation. At the 480 level relatively little water was encountered in the altered basement gneiss and grouting was not necessary; however, extensive ground support was required in the soft ground areas."

Jan 1, 1992

By M. Abumiya, N. Onodera

"The synthesis of large scorodite particles in non-ferrous metallurgical industries usually requires a high-cost operation involving heating and high-pressure autoclaving. To overcome these obstacles, an atmospheric-pressure process for scorodite synthesis (DMSP®) was developed, in which ferrous ions were oxidized by oxygen gas in the presence of pentavalent arsenic ions. This process gives scorodite of good crystallinity with particle sizes as large as 15-20 µm. The solutions used for scorodite synthesis in the DMSP® are prepared from various residues containing arsenic from non-ferrous smelters. The solutions may be contaminated with Cu, Sb, and Bi, for example, and therefore the effects of such impurities on the formation of crystalline scorodite need to be investigated. In this study, the effects of Cu, Sb, and Bi contaminants on the formation behaviors of scorodite particles in the DMSP® were investigated systematically.INTRODUCTIONThe synthesis of crystalline scorodite (FeAsO4·2H2O) is a suitable method for arsenic (As) stabilization and storage of As-containing by-products such as flue gas dusts in non-ferrous smelters. It is expected that the formation of large, highly-crystalline scorodite particles would be an ideal method for avoiding the release of arsenic to the environment. Generally, autoclave methods under pressurized oxidation conditions at temperatures above 100°C have been used for the formation of arsenic minerals such as scorodite. However, the autoclave method requires sealed vessels that are resistant to high pressure, heat and acids. This process is also unfavorable on account of the high construction expenses, and high running costs as a result of vapor heat loss. Processes for synthesizing scorodite under atmospheric conditions at temperatures below 100°C which do not need an autoclave have therefore been extensively investigated (Demopoulos, Droppert, & VanWeert, 1994; Demopoulos, 1996; Demopoulos, Lagno, Wang, & Singhania, 2003; Droppert, Demopoulos, & Harris, 1996; Filippou & Demopoulos, 1997).Recently, Fujita et al. (Fujita, Taguchi, Abumiya, Matsumoto, Shibata, & Nakamura, 2008a, 2008b, 2009; Fujita, Taguchi, Kubo, Shibata, & Nakamura, 2009; Fujita, Taguchi, Shibata, & Nakamura, 2009) developed a new method for producing large scorodite crystalline particles with improved filtration and washability properties at normal atmospheric pressure and temperatures below 100°C. In the new method, oxygen gas (O2) is blown into solutions containing a high concentration of arsenic ions (As(V)) and ferrous ions (Fe(II)). The Fe(II) ions were subsequently oxidized to ferric ions (Fe(III)), resulting in the formation of large scorodite particles. High supersaturation of solutes such as Fe(III) will result in excessive nucleation, and the formation of poorly crystalline phases. The scorodite formation must therefore be conducted in a manner that avoids the critical supersaturation level being exceeded. It is supposed that the oxidation of Fe(II) to Fe(III) by O2 gas in the new method suppressed the supersaturation of Fe(III) during scorodite formation. The low Fe(III) supersaturation resulted in formations of highly crystalline scorodite particles of size of around 20 µm. In June 2008, based on the developed process described above, DOWA began experiments to verify the industrial capability of a plant with a capacity of 30 MT/month of As. It was successfully proven that it is possible to produce crystalline scorodite industrially on a commercial scale. This process was named and trademarked as DMSP® (Kubo, Abumiya, & Matsumoto, 2010)."

Jan 1, 2012

By Y. X. Li, L. R. Xiao, S. Gong, S. S. He

Porous copper and porous copper based alloys with controllable pore structure have been manufactured successfully by sintering evaporation process. This process consisted of mixing copper or copper based alloys with NaCl powders, hot pressing and final high-temperature sintering to evaporate the filler material of NaCl powders. NaCl was eliminated completely during vacuum sintering, and strong metallurgical bonding in the walls was achieved. The pores’ structural parameter (pore size, shape, and direction) and porosity can be controlled effectively. These porous copper and porous copper based alloys with controllable pore structure have great potential in many fields. Including heat dissipating materials, heat absorbing materials, chemical catalyst carriers, electromagnetic shielding materials, filtering materials, damping materials, silencing materials, battery electrode materials. INTRODUCTION The development of porous materials began in the 1960s. The research of activated carbon with high specific surface area made porous materials enter the stage of material research (Belyakov et al., 2008; Ferey et al., 2008). With the rapid development of science and technology, porous materials play an important role in material research, and gradually become an indispensable part of the material research field (Wu et al., 2012). The research of porous materials has gradually extended to metal, ceramics, plastics and glass and other fields. It has been successfully applied in many fields, such as functional materials, industrial production, aviation, medical materials, biochemistry and electronics, which fully shows that porous materials have considerable development prospects. Porous silicon, plastic porous materials and glass porous materials are the most widely used in the field of non-metallic porous materials (Capelle et al., 2012). Compared with non-metallic porous materials, metal porous materials have developed rapidly in the late 1980s and become new materials with good mechanical properties and excellent physical properties. Porous metal materials have many advantages, such as large specific surface, small specific gravity, good silencing effect, high stiffness, high electromagnetic shielding performance, good shock absorption performance, etc (Li et al., 1999; Ferey et al., 2008). Among its many applications, metal porous materials can be used as both functional materials and structural materials. In some cases, metal porous materials have dual functions and structures. It is a multi-purpose engineering material with excellent performance. At present, porous copper, porous aluminium and porous nickel are the most concerned materials (Chen et al., 2002; Yang et al., 2017; Liu et al., 2018). The preparation methods of porous copper and copper-based alloys mainly include self-propagating high temperature synthesis (SHS), capsule-free hot isostatic pressing (CF-HIP), spark plasma sintering (SPS) (Kvanin et al., 2008; Takahashi et al., 2008; Zhang et al., 2014). However, these methods can not accurately control pore structure parameters (including pore size, shape, orientation, distribution, etc.). In porous materials, pore structure plays an important role in the overall performance of materials. In order to control pore structure parameters accurately and optimize material performance, it is necessary to explore and develop new preparation technology. In this paper, the sintering evaporation process (SEP) was introduced for the preparation of porous copper and copper-based alloys. The core process of the preparation method is hot pressing and evaporative desalination. Hot pressing can make the pore orientation consistent. Evaporative desalination can ensure the complete removal of NaCl in the form of vapor in a short time, thus eliminating the corrosion of residual NaCl on the matrix metal (Gong et al., 2011).

Jan 1, 2019

By Walter I. Nelson

THE geology of the Copper Mountain mine has been ably described by Dr. Victor Dolmage in Memoir 171 of the Geological Survey. Reference is invited to that paper for a more extended description of the geology of the ore deposits than will be given here. The important orebodies of the mine occur in fragmencal volcanic rocks, parallel with and adjacent to the gabbro of the Copper Mountain stock. In the mine area, the contact strikes N.45°W. and dips either vertical or steeply co the southwest. For a distance of 500 feet or more from the contact, the fragmental rocks have been intensely metamorphosed both dynamically and hydrothermally. The dynamic effects are reflected in the foliation and fracturing parallel with the contact, which occurs throughout the mine, and the volcanic rocks within this foliated zone are, in places, highly schistose. Superimposed upon thi.s structure is a system of fine, straight, parallel frac-tures that strike nearly normal to the foliation (and contact) and dip between 65° and 75° to the north; it is with this last-described fracture system that the ore minerals are structurally associated. The fractures are mineralized with bornite and, to a considerably less extent, with chalcopyrite and some pyrite. A notable characteristic is the extreme fineness of the fractures; even in high-grade ore they are rarely larger than pencil lines. The tenor of the ore, therefore, varies directly with the fracture spacing. Replacemcnr of the host-rock between two or more fractures, varying in degree from finely disseminated sulphides to masses of nearly solid bornite up to 18 inches wide and 2 to 3 feet long, is not uncommon in the higher-grade portions of the orebodies. Two structural types of orebody are recognized in local nomenclature: the 'contact' orebodies, so-called because they occur along the contact; and 'outlying' orebodics, which are enclosed in the volcanics. The former arc tabular or lenticular bodies elongated along the strike and dip of the contact. The 'outlying' orebodies are coniform, chimney-like masses roughly elliptical in plan; with depth, their roots plunge at steep angles toward the contact. All of the orebodies are cut by a number of light-coloured granophyre and felsite porphyry dykes. These dykes-the so-called 'mine' dykes -enter the mine area from the north, curve gently southeasterly across the orebodies, and then cross the contact into the gabbro at the south end of the mine. All the dykes dip vertical to steeply east.

Jan 1, 1941

By C. Pichler, C. Benigni, J. Antrekowitsch

"The recycling of steel mill dust results in zinc oxides which are sold to the primary industry in or-der to recover zinc in its metallic form. Due to the contained impurities - chlorine and fluorine - these sec-ondary oxides are usually charged into the roaster together with primary concentrates. Appearing problems in this furnace limit the application of secondary materials. Based on the zinc amount, a direct leaching, assumed that a low halide concentration is present, would be possible. To use the zinc solution directly in the electrowinning stage, the concentration of impurities, first of all iron, is limited. Iron can be found in secondary zinc oxides due to carry over during the recycling process. In order to reduce the iron content in the solution, the leaching has to be pH-controlled. This leads to a limited number of simple purification steps before the solution enters the electrolysis. Various trials were performed to evaluate the influence of temperature, time and sulphuric acid concentration on the iron dissolution. This paper deals with the results and also focuses on other impurities such as halides. Additionally, the soda washing process, usually done with secondary zinc oxides to remove most of the halides, and the challenges within this step are discussed.INTRODUCTION Recycling of steel mill dust, which is the main zinc containing residue, in the Waelz process dis-plays the common method worldwide. The product of the process is a secondary zinc oxide which is con-taminated with different elements like lead, iron and halides due to mechanical carry over or evaporation. Depending on the feeding material the concentration of each element in the dust is varying. The zinc con-tent of the product, also called Waelz oxide, lies around 65–68%. Based on these values it presents an al-ternative to the primary concentrate for the production of metallic zinc. The contained halides limit the direct utilization in the leaching stage and therefore have to be reduced. State of the art is a soda washing process but also solvent extraction gives a possibility to remove chlorine and fluorine but the desired con-centration for the electrolysis is hardly reachable (Antrekowitsch et al., 2016) Iron is present as an undesirable component of such secondary zinc oxides due to carry over. During the hot acidic leaching of the secondary concentrate, iron is dissolved too. Based on the higher electrical potential iron has to be removed before the zinc solution enters the electrowinning stage. It is usually removed by precipitation as goethite, hematite or jarosite, which is the common precipitation residue (Ismael et al., 2003)."

Jan 1, 2017

By H. Sato, Y. Sato, T. Ooishi, K. Sakamoto

"Sumitomo Metal Mining Co., Ltd.(SMM)'s Niihama Nickel Refinery(NNR) produces high quality Nickel cathode, Cobaltcathode and other by-products using hydrometallurgical refining process called “MCLE”(Matte Chlorine Leach and Electro-Winning). In 2005,NNR started to use nickel and cobalt mixed sulfide (MS) produced by one of the SMM’s subsidiaries Coral Bay Nickel Corporation(CBNC)’s HPAL plant in Philippines, although its main and the only raw material until then was nickel matte. With start-up of the second HPAL plant at Taganito in 2013, NNR expanded its production capacity of nickel cathode from 41,000 to 65,000 tpa and finally achieved its target in 2015 by producing 65,980 tpa. SMM developed the technologies to improve poor reactivity of MS and installed new facilities to cope with increased Cobalt and Sulfur production at that time. This paper describes the technical approach to increase MS treatment with high efficiency.INTRODUCTIONThe Sumitomo Metal Mining Co., Ltd.(SMM)Niihama Nickel Refinery(NNR) produces Nickel cathode, Cobalt cathode and other by-products using Matte Chlorine Leach and Electro-Winning (MCLE) process technology. SMM uses nickel matte and nickel & cobalt mixed sulfide (MS) as raw materials for the MCLE process. Table 1 shows typical composition of these raw materials. Nickel matte had been only raw material until 2005, and with start-up of Coral Bay Nickel Corporation (CBNC) operation in the Republic of the Philippines, MS became major part of it. In 2009, when CBNC doubled its production capacity, NNR also expanded its plant capacity of electrolytic nickel from 36ktpa to 41ktpa, keeping an eye on the possibility of 65ktpa with oncoming SMM’s second HPAL in Philippines. Poor reactivity of MS was the prime concern at that time because our intention was to increase production with MS. Nickel extraction rate deteriorated with increasing usage ratio of MS in raw materials. To keep high nickel extraction rate under high ratio of MS, NNR developed a new leaching technology. Another concern arising from treatment of MS was Cobalt and Sulfur contents that are much more than those of nickel matte as shown in Table 1.NNR introduced new technology of solvent extraction process as to Co/Ni separation process in order to keep cost competitiveness instead of the conventional cobalt oxidation–neutralizing method. As to sulfur products, new sulfur productive facility was installed to improve the exposure to sulfur dust and the hot working conditions for workers. As a result of process development and installation of new facilities against the problem with MSusage,65 ktpa production was achieved in 2015."

Jan 1, 2017

By J. Zhou1

"The extractive metallurgy of gold ores is largely driven by their grade and mineralogy. The concentration of gold in the crust is extremely low and highly variable, resulting ore variability in many gold and copper-gold deposits. More importantly, gold in an ore may occur in two or three forms (i.e. microscopic gold, submicroscopic gold and surface gold), making gold ore processing extremely challenging. Geometallurgy is a technique to document variability within an orebody and quantify and evaluate the impact of many factors including geology and mineralogy on grinding, flotation, leaching and metal recovery processes. The objective of gold geometallurgy is to reduce and minimize the technical risk in project evaluation, plant design, mine planning and production forecasting through geometallurgical modelling, representative sampling and subsequent systematic mineralogical and metallurgical testwork. Gold deportment study is a powerful tool in characterization of various gold ores. Effective and quantitative gold deportment results are critical and useful for predicting gold recovery and building geometallurgical models of gold ores. This paper provides an overview of geometallurgy fundamentals and applications in gold processing, with a focus being on the ore characterization and gold deportment study.INTRODUCTION Geometallurgy is an inter-disciplinary approach which links the geological, geochemical and mineralogical characteristics to the metallurgical performance of an orebody. Combined with mine planning, it has been used in scoping, prefeasibility and feasibility studies, process design and optimization of gold, copper-gold, copper-moly, nickel and iron projects among others (Williams & Richardson, 2004; Dobby, Bennett, Bulled, & Kosick, 2004; Bulled, 2007; Bulled, Leriche, Blake, Thompson, & Wilkie, 2009; Kormos, Sliwinski, Oliveira, & Hill, 2013; Muinonen, Sciortino, Korczak, & St-Jean, 2013; Leichliter & Larson, 2013; Leichliter, Jahoda, & Montoya, 2013; Hatton & Hatfield, 2013; Baumgartner et al., 2011, 2013; Hoal, Woodhead, & Smith, 2013; Zhou, 2013). The goal of a gold or copper-gold geometallurgical program is to characterize and understand the metallurgical variability of an orebody, such as comminution, gravity, flotation and cyanidation parameters and metal recoveries, and to build a geomet model which can be used to assist in mine planning and to predict the plant performance. In any geometallurgical program, representative sampling is the key to ensure the results of a geometallurgical study will reflect future performance once the plant is commissioned. Geometallurgy compliments, but does not replace, the traditional mineralogical and metallurgical approach during the development and operation of a gold or copper-gold project. Geometallurgy is a methodology for testwork design and a framework for mine planning. The first part of this paper provides an overview of geometallurgy fundamentals and application in gold ore processing."

Jan 1, 2017

By Andrew Artzer, Michael Moats, Jack Bender

Antimony and bismuth in copper electrorefining electrolytes can cause cathode contamination, leading to the careful control of their concentrations. This study examined the laboratory scale removal of bismuth and antimony from an electrorefining electrolyte using a solvent extraction mini-pilot plant. The ability of a proprietary phosphonic acid ester extractant (REX-2) in a commercial diluent was studied in a simulated commercial setting. Antimony and bismuth were both extracted effectively from the electrolyte (72% Bi and 70% Sb removed) and Bi was effectively stripped (92% Bi recovered) with 400 g/L sulfuric acid. A final strip solution was obtained from the SX circuit containing 0.36 g/L Bi, 0.043 g/L Sb, 1.3 g/L Cu, and 0.18 g/L As. Unfortunately, most of the extracted Sb remained in the organic phase. Following the pilot study, experiments were performed to examine the precipitation of bismuth from the aqueous strip phase and the removal of antimony loaded on to REX-2. INTRODUCTION For many years, antimony and bismuth have been some of the most problematic impurities in copper electrorefining (ER) (Bardwell & Lapee, 1933). Along with surface roughening, high concentrations of Sb and Bi can contaminate the copper cathode and precipitate at the copper grain boundaries. This drastically reduces the drawing ability of the metal (Bender & Emmerich, 2016). For these reasons, it is necessary to control Sb and Bi concentration in the cathode, which is done by controlling their concentration in the electrolyte. Conventionally, Sb and Bi concentrations are controlled by maintaining a proper As/(Sb+Bi) molar ratio in the anode and arsenic concentration in the electrolyte. Antimony and bismuth are removed during electrolyte purification using liberators (electrowinning cells) and/or ion exchange. Liberators treat an electrolyte bleed stream from the ER circuit and electrodeposit increasingly impure copper as the copper concentration of the solution decreases. Traditionally, first stage liberators reduce the copper concentration from ~45 g/L to ~15 g/L and produce saleable copper. Second stage liberators decrease the copper concentration to ~8 g/L (Biswas & Davenport, 1980) which results in contaminated cathode that is returned to anode production (Biswas & Davenport, 1980; Wang, 2004). Further electrolyte purification is not always required but third stage liberators can be used to reduce copper concentration below 2 g/L which results in significant removal of As, Sb and Bi and very impure deposits which are recycled to a smelter or used for As production. However, liberators do not have very high energy efficiency (Acharya, 2014; Ando & Tsuchida, 1997) and below 0.5 g/L copper, highly toxic arsine gas may form (Biswas & Davenport, 1980).

Jan 1, 2019

By Vishal Shukla, Prateek Singh, D. P. Chakraborty

"Continuous thickening by an operation called sedimentation is the separation of suspended solid particles from a liquid stream by gravity settling. The primary purpose of thickening is to increase the solids concentration of the feed stream. High rate thickeners are designed specifically to maximise the flocculation efficiency. A detailed investigation has been carried out to understand the influence of ore type and operating parameters such as bed level, bed mass, rake arm torque and flocculent concentration on thickening operation. Tata steel’s Noamundi plant data shows that variation in ore type, and operating parameters are major contributors to fluctuation in thickener performance. A lot of research has been done earlier on thickening operation but effect of ore type and operating variables by using plant data was never touched before.In this context, the performance of thickener was evaluated by daily data to study the influence of ore type and operating variables on thickener operation. Investigation shows that friable ore % in feed mix is proportional to slime density because friable ore is porous & brittle in nature. As a result, friable ore generates more fines/ultrafine during communition process in wash plant. Increase in flocculant concentration and bed mass is showing a positive change on high rate thickener performance Investigation shows that optimum bed mass and flocculant concentration is required to achieve desired pulp density in thickener underflow at different feed pulp density (g/cc).INTRODUCTIONOver the years, Iron Ore Beneficiation at Tata Steel, Noamundi has seen varied changes. Depletion of high grade iron and with increasing iron ore throughputs coupled with lowering of the hard ore a subsequent increase in slime generation, slime management and clear water requirement for wet Plant has thrown up myriad challenges. To overcome these challenges, many improvements initiatives were taken by Tata Steel in last decade. One of the major changes is the recent High Rate Thickener commissioning at Tata Steel Noamundi to cater the high iron ore throughput requirement. Slime reporting to Thickener has increased from 1.4 MTPA 2.5 MTPA over the last few decades. The above changes further aggravate the poor settling and dewatering characteristics of the slurry which is being feed to HRT. Considering the above mentioned constraints and stringent environmental implication proper water management has become a major challenge to reckon with. The thickener is used to increase the concentration of the suspension by sedimentation, accompanied by the formation of a clear liquid. In most cases the concentration of the suspension is high and hindered settling takes place."

Jan 1, 2016

By F. Habashi

"While bioleaching of pyrite concentrates has been successfully used in industry to liberate gold from the sulphide matrix for subsequent cyanidation, the same technology cannot be recommended for leaching chalcopyrite concentrates for copper recovery. It will be shown to be uneconomical and cannot compete with pressure leaching technology. Data on the pilot plants that were constructed for this purpose and were shut down will be given.INTRODUCTIONBacterial leaching has been successfully applied for heap leaching of low-grade copper ores (Habashi, 1978, 1999). One of the major operations is that at Bingham in Utah (Figure 1). The leach solution collected at the bottom of the heap is extracted by organic solvents and the strip solution is electrolyzed to get high purity copper. The process was extended to treat auriferous pyrite concentrates to liberate gold and render it amenable to cyanidation by a process known as BIOX (Marsden & House, 2006; Lunt & Briggs, 2005).BIOX plants currently or recently in operation are the following:??Ashanti Goldfields Company, Ghana. Designed with an initial capacity of treating 720 tonnes of concentrate per day, the Sansu plant has since been expanded and currently has four modules processing 960 tonnes per day in all. It is by far the largest biooxidation plant in the world. The capital cost of the plant totalled US $25 million (1994 terms) and the operating cost is currently US $17/tonne milled.??Fairview, South Africa. The plant at the Fairview mine in Barberton, which was the initial pilot plant, has been fully operational since 1986. It was originally designed to treat 10 tonnes/day of concentrate but with the success of the project this has been increased to 55 tonnes per day. With the purchase of Fairview by Avgold’s Eastern Transvaal Consolidated, Avgold concluded a licensing agreement with Gold Fields, formerly known as Gencor, entitling it to use the BIOX technology to treat itsconcentrate.??Saõ Bento, Brazil. A BIOX plant was recently in operation in Brazil at the Saõ Bento Mine where a pressure oxidation circuit is used to treat the refractory flotation concentrate. This plant has confirmed the viability of combining bio-oxidation with pressure oxidation as a cost-effective method ofincreasing capacity at an existing oxidation plant.??Wiluna, Australia. The plant at Wiluna Gold Mine, Western Australia, was commissioned in 1993. Although originally designed to treat 115 tonnes per day of concentrate this has subsequently been increased to 158.??Other plants at Tamboraque in Peru, Harbour Lights and at Youanami in Australia have been commissioned recently."

Jan 1, 2012