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By D. Kidby, A. Briggs

"Vitrokele ™ is a synthetic adsorbent, using chelating groups on large polystyrene beads, developed in Canada over 7 years ago, and first commercialised in 1985 to recover noxious metals from plating wastes.Pilot plant trials have been performed in Australia and Canada to demonstrate the recovery of cyanide and removal of metal cyanide complexes from gold plant effluent using Vitrokele1 M 912. The pilot plants comprise a simple adsorption train (similar to a CIP circuit) followed by complete elution facilities, so that loaded Vitrokele™ can be stripped and returned to the adsorption circuit.An account of these campaigns is provided, showing the reduction of total CN levels from over 200 ppm to less than 0.5 ppm and Cu levels from approximately 100 ppm to less than 0.3 ppm in treated tailings.Comparisons between pilot plant results and laboratory test data are given and probable future work on the process and its application to the gold mining industry is discussed.INTRODUCTIONThrough millions of years of evolution, life forms have developed specialised molecules with exceptionally high affinity and selectivity for various metals such as iron, cobalt, zinc and copper.In the early 80's professors at the Faculty of Medicine of McGill University engaged in research on the extremely efficient ways that living cells captured trace metals essential for life.As research progressed, it became evident that the special molecules used by biological systems to capture metals could be synthesized to capture selected metals with similar efficiency from water or other solutions.The technology was first commercialised in 1985 to recover noxious metals from plating wastes with compositions applying the special molecules (chelating groups) on vitreous particles (hence Vitrokele™). To date approximately three commercial Vitrokele™ plants have been installed for treating plating waters in Ontario and Quebec."

Jan 1, 1992

By J. Drelich

We report structural forces measured for 10 nm silica particles deposited on alumina substrate and 5-80 nm alumina particles on mica using atomic force microscopy technique. For nanoparticles forming clusters, oscillation of structural forces was recorded with a periodicity that is close to the size of the nanoparticles used. Additionally, selected force-separation results indicate that the forces involved between the AFM probe and individual nanoparticles can be studied using the nanoparticle-coated substrates.

Jan 1, 2006

By J. P. Thomson

Magnesium alloys are steadily improving their market share as structural components especially in the transportation sector. Therefore, there is a great deal of interest from the automotive and the metal casting industry to develop viable economic casting processes for magnesium-base alloys. This paper summarizes the preliminary results on the continuing projects within CANMET-MTL on casting processes such as gravity and low-pressure casting in sand molds, permanent molds and lost foam.

Jan 1, 2004

By T. C. Murphy, W. Taciuk

In 1966, the Iron Ore Company of Canada commissioned a wet magnetic scavanging plant for the recovery of fine magnetite values p.resent in spiral tailings discharged from a spiral gravity separation process. The plant includes dewatering, grinding, classification, thickening, mini-wedge screening, and primary, secondary and tertiary wet magnetic separation stages. The source of feed varies in quantity and quality, so the original design included variable operational procedures to deal with these conditions.

Jan 1, 1972

By Rhual L. Guerguerian

MINING has been practised by mankind for over sixty centuries (1). In 1876, the "ball mill" was patented, and during the century that followed rotary grinding developed to the state where individual machines are treating tens of thousands of tons of ore per day. This paper gives a brief description of design practices prior to the availability of advanced facilities, followed by modern analytical design development at Dominion over the past ten years.

Jan 1, 1978

By A. Bauer, P. Katsabanis, M. Baker

The principal results from a previous paper presented at the Mine Accident Prevention Association of Ontario in 1987 (1) are summarized here. It is concluded that the selection of explosives in mines experiencing sulphide ignitions is important and that aluminized explosives should be avoided because of their high explosion temperatures and their detonation products. The duration of the blast is also critical and secondary blasts should not occur simultaneously with nearby priroa:ty blasts.

May 11, 1988

By D. MacGREGOR, VERA TUREK

The Badgeley Island quartzite deposir in Georgian Bay is worked by lndusmin Limired and was developed in 1969 to produce a high-qualiry silica for use in rhe ferrosilicon and glass industries. The quartzire is part of the Precambrian Bar River Formarion, and is a generally whire, fine-grained rock containing rhin sericire seams. Primary sedimenrary features wirhin the deposit are bedding and ripple marks. Amphibolite and diabase dykes cur the quarr zire body.

Jan 1, 1984

By E. T. C. Spooner, Ioannou S. E.

"Abstract- The Dixie Zone Au-Ag deposit is a low sulfidation (adularia-sericite) epithermal system located 1.4 km from the producing Ken Snyder mine (7.0 M oz Au equivalent reserve/resource), Midas Mining District, north-central Nevada. This WNW striking, steep south dipping, fault system is hosted by mid-Miocene (17 Ma to 14 Ma) felsic volcanic rocks that were erupted from a vent(s) to the northeast. The system was mineralized by approximately 250 ± 20°C (n = 86), near-neutral pH, ascending fluids of predominantly meteoric origin [volatile corrected salinity = 0.52 ± 0.35 eq.wt% NaCl (n = 86)]. Bulk analytical fluid inclusion gas chromatography identified a mineralizing fluid volatile composition of 99.68 ± 0.18 mole % H2O, 0.16 ± 0.09 mole % CO2, 0.11 ± 0.05 mole percent N2, 0.05 ± 0.04 mole % CH4, and 0.01 ± 0.01 mole % CnHn+i (n = 7). Sulfur species were not analyzed due to absorption within the chromatography system; however, a H2S concentration of 16 ppm to 160 ppm molar is estimated. The volatile content contributes approximately 50% of the microthermometrically measured freezing point depression. Cl- concentrations up to approximately 9000 ppm suggest an additional, probably magmatic, fluid component.Ascending fluids were channelled along approximately NW striking faults related to the same primary extension (17 Ma to 14 Ma) responsible for Nevada basin and range physiography. Boiling induced by CO2 effervescence led to precipitation of Au and Ag over a 150 m vertical interval. At the time, this interval was about 460 m below the water table (approximately 38 bars), but because of erosion, it is now within 90 m of the surface. A Ag:Au ratio of 25:1 has been calculated for the Dixie Zone."

Jan 1, 2000

By José J. Suárez

As pressure grows for commodity pricing, new mines are more difficult to develop, the stock markets demand better financial returns from mining companies, resources for the developing and operations are scarce, and developing countries in Asia, and Africa demand more metals, it is important that mining companies effect better utilization of capital to develop capital projects. In the last few years, the costs for Capital projects have been impacted by the following factors:

May 1, 2013

By ByongPil Lee, Changkyu Lee, Jin Gyun Park, Hyung Sub Eom, Sung-Koo Jo, Jae-Young Lee, Gilsoo Han

"A new hydrometallurgical process for nickel extraction from a low grade laterite ore such as limonite has been developed by RIST and POSCO. This POSCO Nickel Extraction Process (PosNEP) consists of five main processes: ore reduction using hydrogen as a reductant; acid leaching at atmospheric pressure and temperature; cementation by the use of reduced-ore seed; production of the main product such as ferronickel or a high purity nickel compound; and production of by-products such as cobalt and iron in the forms of cobalt sulfate and iron oxide. In addition, hydrogen produced in acid leaching and hydrochloric acid regenerated in pyrohydrolysis for iron oxide production can be reused in the process, which makes PosNEP more cost-effective. The performance of PosNEP has been proven through pilot tests, showing that this process is economically and technically viable. In this paper, basic concepts and detailed test results of PosNEP are shown.INTRODUCTIONNickel has been extracted from two types of ore, sulfide and oxide ore. Nickel and cobalt usually occur together in the ores. The principal ore mineral of the sulfide is pentlandite, (Ni,Fe)9S8, which is easily beneficiated to produce sulfide concentrates(Moats & Davenport, 2014). These concentrates are usually treated by smelting and converting to make a matte. The produced matte is then purified through either hydrometallurgical or pyrometallurgical processes to produce high-purity nickel. In general, this process for sulfide ore has been known as a more cost-effective process than that for oxide ore.The oxide ore is laterite comprised of two different ore types, saprolite and limonite. The main nickel-bearing mineral of saprolite is nickeliferrous garnierite,(Mg,Ni)6Si4O10(OH)8, and that of limonite is nickeliferrous goethite (Fe,Ni)O·OH ore (Moats & Davenport, 2014). Since the saprolite has high contents of nickel and slag formers (MgO and SiO2) and a low content of iron, it tends to be treated by a pyrometallurgical smelting process such as calcination and electric furnace techniques to produce ferronickel for use in stainless steel. In this process, the cobalt in the ferronickel does not have any economic value."

Jan 1, 2017

By Sazol Das, Hany Ahmed, Ganesh Bhaskaran, Zhuoru Wu

"Friction stir welding (FSW) process in lap configuration for dissimilar materials has been developed and tested for steel to aluminum joining. A novel cylindrical tool was designed for improved material flow. The joining of steel to high strength 5xxx and 6xxx aluminum was carried out by FSW technique using optimized process parameters. The microstructure, micro-hardness, joint strength and corrosion properties at the weld interface have been investigated. Optical and scanning electron microscopy reveled a well layered structure at the interface and lap shear tests of the welds showed excellent fracture resistance. Neutral salt spray tests for up to 500 hours (ASTM B117) were carried out on the bare steel to aluminum FSW joints, which did not show neither evidence of corrosion at the weld interface, nor any degradation of the weld strength. The FSW lap configuration was applied to prototype commercial vehicle structural component whereby a steel stiffener insert was friction stir welded to high strength 6xxx aluminum alloy. The interface microstructure showed layered root without any steel shattering in aluminum side. A finite element study was carried out to quantify the benefits where it was found that the stiffness increases by 76% under bending loads and 36% in torsion loads.INTRODUCTION Energy preservation and environmental issues, namely carbon footprint and legislation around emission in transportation industries has led to a growing need to use of lightweight materials such as aluminum and magnesium alloys along with various grades of steel in structural application, while still maintaining their strength and crashworthiness. Assembling dissimilar materials within integrated structure is thus a stringent requirement related to optimum performance. In order to achieve an efficient technology of joining dissimilar materials such as aluminum to steel, it remains difficult to select an effective welding process for a given joint configuration. The use of aluminum in transportation industries for structural component is not exclusive in a design and is almost always used along with various steel grades for a mixed materials solution, thus dissimilar aluminum/steel lap joining is of great interest since this is widely used in the assembly of parts (e.g. pillar, frame rails, chassis, body in white (BIW), CAB, etc.)."

Jan 1, 2018

By R. N. W. DiLabio

"In a continuing program of mapping glacial dispersal trains, near-surface till samples were collected down-ice from a copper-silver-gold prospect at Onaman River, Ontario, and down-ice from the past-producing gold district at Oldham, Nova Scotia. The program is designed to aid exploration by illustrating glacial dispersal from various types of known occurrences and by identifying postglacial processes that control drift composition at a detailed scale.Native gold was mined at Oldham from arsenopyrite-bearing saddle reef quartz veins in a dome in Early Paleozoic slates of the Meguma Group. Gold abundances greater than 10 ppb in till form a dispersal train at least 1900 m long. Gold abundances between 40 and 100 ppb occur in clusters up to 600 m down-ice from gold-bearing bedrock. Anomalous arsenic abundances in till form a broad train 1100 m long that is significantly different in shape from the gold train.At Onaman River, subeconomic amounts of Cu-Ag-Au occur in quartz lenses in Archean mafic volcanic rocks. A dispersal train defined by the distribution of mineralized boulders and increased abundances of Cu, Ag and Zn in till extends 600 m down-ice from mineralized bedrock. Gold abundances between 10 and 70 ppb do not define this dispersal train, but occur instead in clusters 300 to 600 m down-ice from mineralized bedrock. In vertical sections in the upper 2 m of copper-rich till, Au abundances vary sympathetically with Ag and Cu levels; however, there seems to be no preferential site of Au enrichment in the mineral portion of the soil profile.Several of the mineralized boulders at Onaman River are richer in Au and Ag than the mineralized bedrock from which they were derived. Although some of the high Au and Ag assays were caused by biased sampling of sulphide-rich portions of the boulders, many were caused by leaching of sulphide minerals from 'the boulders, which left a limonitic boxwork that is enriched in Au and Ag. A few of the Au-rich boulders may have been derived from an unknown bedrock source."

Jan 1, 1982

By R. Agius, A. Nacu

"Cyanide destruction technologies are implemented at gold and silver operations to comply with the International Cyanide Management Code and meet ever more stringent discharge limits. Currently, the most common chemical cyanide destruction processes used in industry are sulfur dioxide/oxygen, hydrogen peroxide, and Caro’s acid. The cyanide destruction process used at an operation must reliably generate streams of acceptable quality at all times, and depends on numerous factors, including permit discharge requirements, tailings chemistry, location, site-specific climatic conditions and size of the operation. Selecting the most appropriate cyanide destruction process and determining the process design criteria requires accurate laboratory testing. This paper presents and discusses the results of a number of cyanide destruction evaluations that have been conducted to reduce cyanide concentration in process solutions or cyanidation tails. Laboratory testing provides important insights into reagent consumption and other factors required to achieve the target residual weak acid dissociable cyanide (CNWAD) levels.INTRODUCTION Process solutions associated with the extraction of gold and silver contain several forms of cyanide. The most toxic form of cyanide is free cyanide, which can be present as a dissociated cyanide anion (CN-) or gaseous or aqueous HCN. Weak or moderately stable cyanide complexes such as those of zinc, copper and nickel are classified as weak acid dissociable (CNWAD). Although less toxic than free cyanide, weak acid dissociable cyanide complexes are considered “ecologically sensitive” forms of cyanide and are regulated in most jurisdictions. In practice, reported WAD cyanide values comprises both free cyanide and weak acid dissociable cyanide complexes. Cyanide complexes with gold, mercury, cobalt and iron are referred to as strong acid dissociable complexes (CNSAD) and are much more stable, even under mildly acidic conditions. Another term commonly used in cyanide chemistry is total cyanide, which represents all cyanide compounds present in solution. Total cyanide levels in solutions are always equal to or higher than WAD cyanide values and the difference between the two usually indicates the presence of iron-cyanide compounds. Typically in Canada, CNTOTAL levels cannot exceed 1 mg/L in solutions discharged to the environment."

Jan 1, 2017

By John Stoten

"The 1980s have proven extremely difficult years for many resource-based organizations. Mining companies have learned how to weather the negative effects of inevitable economic cycles. However, with some notable exceptions, such as gold mining companies, the mining industry has faced a broader and deeper round of cutbacks than any experienced since the 1930s. Downsizing has been a major issue for many mining companies as they have faced the need for dramatic staffing cost reductions in the recent past.The continuing current rapid rate of change in technology and the marketplace, coupled with increasing merger and acquisition activity, will provide an on-going need for some companies to face major reorganization. This inevitably will involve down-sizing activity in some instances.Given this scenario, it is worth reviewing the industry's past experiences to identify approaches and techniques that could prove of value in handling a future staff downsizing challenge. This paper is based upon a downsizing consultant's experiences with the mining industry and other sectors, and highlights what appear to be key staff reduction planning and process issues.Planning for DownsizingA review of companies' downsizing activities of the last few years reveals four key activity stages which need to be addressed to ensure a successful transition. These stages are:1. organization planning;2. developing cost reduction strategies;3. implementing downsizing; and4. building for the future.A business situation that is severe enough to require drastic staff cuts typically affects all aspects of a company's operations. Most mining companies have reviewed cost efficiencies in many operational areas. However, these reviews often have been short term in focus . As a result, some companies have experienced multiple downsizing; each event a response to an immediate economic threat. This has sometimes resulted in an unstable organizational environment, with severe stresses on staff morale and productivity.In the long term it is more efficient and less stressful to the organization to adopt a more comprehensive and longer-term strategy. Especially in capital intensive mining operations, it makes sense to review all areas of business activity, not just staffing."

Jan 1, 1989

By D. Gaboury

Most hydrothermal gold deposits contain quartz with fluid inclusions that record composition and temperature of the mineralizing event. Quartz has strong chemical and mechanical resistances to weathering and abrasion. Hence, quartz fragments occurring on weathered surfaces or in till cover have the potential to be used for gold exploration as far as we know what is the signification of the volatile content of the fluid inclusions for gold mineralization. In this perspective, fluid inclusions were analyzed in pure quartz by solid-probe mass spectrometry from gold deposits hosted in the Archean Abitibi (Canada) and Paleoproterozoic Birimian (Western Africa) belts. This approach provides the relative abundance of volatiles from families of fluid inclusions decrepitating at specific temperatures (Td). Fluids in gold deposits are aqueous-dominated with CO2 and minor H2S in accordance with their fundamental role as gold-ligands (H2S) and for pH-buffering (CO2) of the gold-bisulfide solubility. However, there is no correlation between CO2 and H2S contents of fluid inclusions with the gold grade of the samples. This suggests that trapped fluids represent a marginal portion of the fluid history recorded by the veins. However, in barren quartz veins away from known mineralization CO2 or H2S are commonly absent. Wide ranges in H2O Td from 250 to 450°C and CO2-H2O Td offsets are common, indicating phase separation. The content of other volatiles seems to be more dependent on the geological setting. Helium content may suggest proximity to a crustal-rooted fault, a critical parameter for gold mineralization. Methane and especially C2H6 appear to be indicative of fluid buffering by organic-rich material such as graphitic-shale. These rocks may provide an important primary gold reservoir from sedimentary metal-rich pyrite. Nitrogen-bearing fluids may be related to a magmatic component but can also be derived from organic-rich sedimentary rocks. For gold exploration, quartz containing CO2- H2S-bearing fluid inclusions and having H2O-CO2-Td offsets within 250 - 450°C has strong vectoring potential.

Jan 1, 2011

By P. Hajiani

"Feasible and sustainable separation of lanthanides outside of China has been a dilemma for the past few years. The present technique uses REE electrophoretic mobility (Ui) variation in an electrical field to separate them. The present invention relates to a system and a method to separate and refine rare earth elements/compounds produced in hydrometallurgical processes while they are dissolved in an acidic medium, without any intermediate precipitation step. This process uses free-flow electrophoresis to isolate REE from the concentrate simultaneously without any pre-treatment or intermediate steps related to the nature of elements.INTRODUCTIONRare earth elements (REE) invariably occur together in nature, and any given mineral contains several or most of them. Production of high purity individual rare earth (RE) elements/compounds from their ores generally requires two stages of processing, including mineral processing and hydrometallurgy.Depending on the ore, mineral processing and hydrometallurgy treatment of the ore before REEs purification is relatively simple and quite achievable though conventional methods. However, producing individual REE from mixed REs compounds is tremendously tedious. RE processing often requires dozens of steps, each resulting in minute improvement in the complex RE streams. Separating and extracting a single REE requires a great deal of time, resources, and expertise. Today, advanced RE refinery facilities cost hundreds of millions of dollars to build. The high purity RE concentrates are separated into individual REE using solvent-based or ion exchange methods. Although there are several techniques to separate REEs, most of them suffer from different types of drawbacks. For instance, solvent extraction requires a great number of steps to achieve high purity REEs. The process which uses ion-exchanger for separation and refinery operates with low REE concentration in solution which leads to very large liquid volume quantity, bulky tanks, dehydrators, pumps, etc. The low concentration will adversely affect the water consumption as well as other chemicals. Similar chemical properties of those three valent elements do not allow them to be isolated easily one from one another using conventional separation techniques. Solvent extraction has been successfully applied for rare-earth refining (lanthanide, scandium and yttrium) for the past few decades in China. Since then, efforts have been dedicated to develop other techniques which could be applied industrially around the world."

Jan 1, 2016

By Dr. Rory Cameron, Dr. Terry Cheng, Dr. Nadia Mykytczuk, Ian Bedard, Kristie Tarr, Ruth Joseph

Pyrrhotite-rich tailings from Sudbury, Ontario mining activities are known to contain significant amounts of EV metals, such as nickel and cobalt.  CanmetMINING has developed a novel bioleaching process for recovering the nickel and cobalt (both critical for vehicle electrification) from tailings that incorporates partial neutralization and iron removal in the bioleaching circuit; bench- and pilot-scale tests have resulted in excellent nickel and cobalt recovery over a range of temperatures.  However, this process generates a new bioleach residue, which is heavier and more voluminous than the original tailings due to pyrrhotite oxidation and jarosite formation during the bioleaching process. This residue can be problematic for long-term disposal. A possible solution being studied for this issue is using mine backfill as a disposal mechanism.  Underground backfilling allows for effective re-purposing of mine waste, however the backfill must also be able to withstand a certain load, since in most cases it is used as an underground construction material, such as in cut-and-fill mining methods.  Therefore, the composition of the mill tailings must be such that when combined with a binding agent and pumped underground, the slurry or paste is then able to withstand a certain load within a certain period of time.  Unfortunately, high-pyrrhotite content tailings, commonly found on mine sites in Ontario and Quebec, are reactive and can easily oxidize and produce acidity and/or metal-laden drainage under some disposal conditions. This means that the pyrrhotite in the tailings can lead to acid mine drainage if stored on surface, however, it can also cause strength degradation if re-purposed in too high a concentration in underground mine backfill.  The research being done at CanmetMINING related to the bioleaching process is aimed not only at recovering nickel and cobalt from mine tailings, it is also being used in an attempt to neutralize the tailings to reduce acid mine drainage and backfill strength degradation. This paper reports on research designed to evaluate different options for transforming the bioleaching process residue into iron oxide phases, for better environmental footprints if stored on surface, as well as increased disposal possible, if re-purposed as underground mine backfill material.  

May 4, 2025

By Jörg Fischer-Bühner

Conventional 22ct Au jewellery alloys are comparably soft in the as-cast and soft-annealed state and hardening by cold-working is the only way of giving strength to the jewellery. The paper first focuses on hardening of 22ct jewellery alloys by conventional means, i.e. solid solution hardening with base metals (aiming particularly at an increased as-cast hardness) as well as precipitation hardening by alloying with base metals beyond the solubility limits and subsequent age-hardening heat treatment. Co-additions of ~2% turned out to result in most pronounced solid solution hardening up to ~100 HV1 in an investment cast & quenched state. Subsequent heat treatments, consisting of solution annealing at 850°C for 1h followed by water quenching and ageing at 300°C ? 400°C for ~ 1h lead to pronounced age-hardening with a peak hardness of ~ 260 HV1. In contrast, 22ct Au alloyed with Ni, Fe or Sb display no age-hardening effect within the same range of heat treatment parameters. The 2nd part of the paper reports on some preliminary trials to enhance the hardening effect of the base metals by additions of suitable elements, which possess a strong tendency to phase formation with the added base metal during ageing treatments. It is shown, that the age-hardening behavior of 22ct and 990/995 Au alloyed with Co or Ni can be remarkably influenced by additions of Sb. A total of only 10wt%0 of CoSb or NiSb-additions lead to a peak hardness of ~ 150 HV1 for a 22ct Au and ~ 100-120 HV1 for 990 Au , which is obtained already after very short ageing times (20-40min) at 300-400°C after solution annealing at 700°C / 1h / water quenching. It is suggested that the age-hardening mechanism in these alloys consists in precipitation of intermetallic CoSb- and NiSb-phases.

Oct 1, 2003

By Luke Keeney, Stephen Walters

"The start up of a new mining and metallurgical facility is a crucial step in the life of any mining project. The mining industries record is poor when evaluating processing plant operation relative to design capacity predictions made during feasibility studies. Multivariate geometallurgical orebody characterisation, using principle component analysis, is a method developed for improving predictive processing performance models during feasibility stages of mine development. This paper outlines the application of multivariate geometallurgical characterisation to the Cadia East deposit located in New South Wales, Australia. Cadia East is a low grade high tonnage copper-gold porphyry system in advanced stages of feasibility analysis. A dataset of ~32000 measurements and 150 comminution parameters (A*b and BMWI) has been used to develop class-based characterisation and modelling methodologies. The results of this study outline the development of class-based ore characterisation and provide a technique for analysing and interpreting large and complex geometallurgical datasets for prediction and optimisation of processing performance. The results enable sophisticated population modelling to be conducted which displays deposit scale processing variability, aiding circuit design specifications and predictions during feasibility studies.INTRODUCTIONA feasibility study is the major technical report on which the decision to proceed to production and on which financing is based (Shillabeer & Gypton, 2003). The mining industry’s record is not very good when actual construction time, costs, and operating performance are compared to the projections made in feasibility studies (Ballard, 1983; Gypton & Ward, 2000; Gypton 2002). A study by McNulty (1998) found that of 41 mineral processing and chemical plants built between 1965 and 1995, only 56% achieved design capacity within two years of commissioning and three were closed after failing to achieve design capacity within 36 months of start up (Shillabeer & Gypton, 2003). McNulty (1998) related this underachievement and failure of start up performance to the use of innovative process technology without appreciating and managing technical risk. Factors contributing to technical risk include inadequate pilot plant testing, scaled up prototype equipment without backup, design flaws and poorly understood complex process chemistry."

Jan 1, 2009

By David Minson

On many occasions, operators have seen that high density and paste thickener performance does not meet the initial design expectations, and the installed equipment produces lower than expected thickener underflow solids content. This lower-density tailings slurry leads to more water and lower beaching angles being seen at the tailings storage facility (TSF). This not only reduces storage capacity, but also increases the risks of non-compliance with environmental permit constraints. Reasons for the shortfall in performance can be many, but perhaps the main problem is inadequate understanding of the critical components of thickener design and operation, with too much reliance placed on standardised design terminology; such as tph/m2. This paper discusses additional factors that influence high-density thickener operation and presents test work that defines “Dynamic Slurry Fluidity”, “Bed Compaction Rates”, and “Natural Slump Angles” for these high yield stress/viscosity slurries. Finally, the paper uses this data to define thickener geometry, drive torque, floor slope(s), rake blade configuration and how this can be used to provide engineers with more tools for in depth evaluation of a High-Density thickener design. INTRODUCTION Generally copper mines are high tonnage operations, with copper flotation concentrators producing high volumes of tailings slurries of milled solids and water. As a result, Tailings Storage Facilities (TSF) become very large and this, along with potential scarcity of water, favours a design that maximises storage space. In theory, the use of filtration equipment that achieves immediate water recovery, high TSF in-situ densities and high stacking angles are preferred for this duty. However, large tailings filter units are uncommon, and have high operating and capital costs that favour the use of thickeners. The use of high-density thickeners to produce a thick or near-paste like slurry with high un- sheared yield stress values above 100 Pascals, is becoming more common. The higher thickener underflow is required to not only maximise water recirculation within the mill, but to also increase beaching angles, maximise tailings storage capacity and minimise evaporation losses arising from large areas of superficial water. However, the reliability of this equipment is also under scrutiny and there is perhaps a need to better define these designs.

Jan 1, 2019