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By Gordon Hubbard, John D'Acierno

The Randgold Resources Ltd. mine operation in Syama Mali performs whole ore roasting followed by CIL gold recovery to produce gold. The roaster has operated continuously since the plant was first commissioned in 1994. The roaster design throughput is 216 tons per hour (5,184 TPD). Roasting provides for the oxidation of the· refractory components, organic carbon and sulfides. The energy balance for the system requires auxiliary fuel oil to be burned in the Circulating Fluid Bed (CFB) reactor. Energy from the 1200-1350 degree F roasted product stream is recovered and recycled back into the CFB using two fluidized bed coolers; one to directly heat the secondary air and the other to indirectly heat the primary fluidizing air. The basis of the design for the roaster was an extensive pilot plant test program, the results of which were scaled up to the full scale plant design. Due to variation in the feed at the mine a number of roaster modifications were necessary following the initial plant start up. During 1998 ore flotation capability was added to reduce the operating cost for the roaster and increase plant throughput.

Jan 1, 1999

By Nick Katsikaros, A H. Gray

Gold concentrates are produced at many mines by a variety of centrifugal and gravity machines, such as Knelson and Falcon concentrators, however the subsequent recovery of gold is relatively inefficient and subject to security problems. The InLine Leach Reactor (ILR) offers a new method to recover over 95% of gold in concentrates using a simple, secure leaching process. The InLine Leach Reactor is of particular benefit in treating slow or difficult leaching sulphide concentrates and its performance can be reliably predicted from simple laboratory tests. The InLine Leach Reactor is now successfully operating in two gold mines providing benefits of high gold recovery, low operating costs, high security and ease of operation.

Jan 1, 1999

By Ian Larkins

The Ruby Hill Mine agglomerates crushed low-grade ore (nominally -1 .5'') with high-grade filtered tailings (filter cake, nominally 80% -65#). Cement is added as a binding agent. The agglomerated ore is then conveyed and stacked on the heap. In 1998 approximately $480 000 was spent on cement for agglomeration. Cement for mill pH control and agglomeration was the largest single reagent cost at Ruby Hill. In an effort to reduce agglomeration costs a test-work program was initiated to investigate alternative binders and optimum binder additions. This paper summarizes the test­work results to-date.

Jan 1, 1999

By Harold Wahlborg, George Owusu

In a study using butyl diglyme as an organic extractant, essen­tially complete extraction of gold from chloride leach solution was achieved. The extraction kinetics are so fast that the process could be completed in 30 seconds. Except for iron, co-extraction of other ionic species was insignificant. Co-extracted iron species were successfully scrubbed from the loaded organic using 10% HCl solution. High grade, >99.9%, gold was recov­ered from the loaded organic using 5% oxalic acid solution as the stripping agent at a temperature of 70°C to 80°C. Over 99% of the organic-loaded gold was stripped from the organic phase. The butyl diglyme extractant is being tested on a variety of gold-bearing feedstocks. Presented here are results obtained from two gravity concentrates.

Jan 1, 1999

By Brian Carr, Craig Brewer, Jeff Grubbs

This paper examines the role of the StemTite Blast Control Plug in explosive energy confinement and explores the benefits of its successful application in gold and silver mining operations. Prior studies involving this device are consolidated.

Jan 1, 1999

By Marcos C. Filgueiras, Thomas A. Post, Michael A. Giralico, Daniel M. Adams

The leaching of copper, gold, and nickel in tanks requires mixing. Minerals require oxygen, acid and/or base [NH3] to assist in the leaching process. Two basic types of tanks are used for this operation. They are either vertical tanks or closed horizontal tanks called autoclaves. This paper discusses mineral leaching, it's mixing requirements, and autoclaves.

Jan 1, 1999

By Mike Jahraus

The topic I would like to throw out for discussion this morning concerns the metallurgical solution management of operating a valley fill leach facility where ore depths approach 250 feet and deeper. We are currently beginning to experience solution transport times through our heaps on the order of 60 to 70 days as our heaps approach 250 feet. Incorporating a two-stage leach scenario, or solution enrichment, these times are nearly doubled. Concurrent with the increased solution transport times, the solution tenors being produced by our heaps are being diluted slightly as percolation occurs through the lower lifts. I feel the best way to handle these situations is to closely monitor solution application rates, and carefully manage ore stacking. Also, as heaps become deeper, metallurgical and hydrologic characteristics of the ore become inter-related, i.e. if channeling or preferential flow is taking place, lowering cross-sectional flow rates to older leach panels with help re­institute capillary flow while helping to prevent solution tenor dilution.

Jan 1, 1999

By Richard M. Crowell, John W. Shield, Todd J. Harvey

Facing lower gold prices, gold mine operators throughout the world are seeking ways to reduce costs for treating refractory sulfide ores. Many gold mines, currently producing oxide ores, have underlying refractory sulfide deposits and the operators could extend the mine life by processing these sulfides. Fortunately, oxidation technologies for refractory ores need not be complex nor costly. GeoBiotics, Inc. has developed heap biooxidation technologies (GEOCOAT™) for treatment of refractory gold ores and concentrates. GEOCOATTM uses simple low cost unit operations common to heap leaching of gold and copper ores. The cost effectiveness and flexibility of GEOCOAT™ heap biooxidation allows mining companies to expand operations to include refract01y ore. In addition, GEOCOAT™ can be utilized to supplement or replace existing oxidation processes such as roasting, autoclaving, or agitated tank biooxidation, and to treat a lower resource grade than is currently economic. The GEOCOAT™ technology involves coating sulfide concentrates onto sized support rocks and biooxidizing the sulfides in a heap configuration. After biooxidation the concentrate is stripped from the support rock, neutralized and leached in conventional cyanidation facilities. Ashanti Goldfields Company Ltd. (AGC) produces over 885,000 ounces of gold per year from oxide and refractory ores at its Obuasi operations in Ghana. Refractory flotation concentrates are treated in roasters and in the world's largest stirred tank biooxidation facility. In August 1998, AGC and GeoBiotics jointly constructed and operated a field demonstration heap of the GEOCOATTM process at the Obuasi operations. The heap contained I 082 tonnes of support rock and 125 tonnes of concentrate. The heap was approximately 19 meters square at the base and 3.8 meters high, and ran for 88 days after which the concentrate was reclaimed. Average gold recovery after biooxidation was 91.5% with a NaCN consumption of 8.6 kg/t. Baseline gold recovery by direct cyanidation of the concentrate was 53.8%.

Jan 1, 1999

By Michael J. Virnig, Murdoch W. MacKenzie, Michael R. Davis

The objective of this paper is to present preliminary capital and operating cost estimates (±25%) comparing conventional carbon-in-solution (CIS) with resin-in­solution (RIS) using AuRIX® 100 for the recovery of gold and silver from typical heap leach solutions. Preliminary testwork was carried out with AuRIX® 100 using real and synthetic leach solutions to determine the technical viability of the resin for gold/silver recovery and to provide process design parameters for the preliminary RIS circuit. The scope of the resin testwork was sufficient to support the level of accuracy applied in the capital and operating cost estimates. No parallel testwork was carried out with activated carbon. Industry standard design data and operating data from existing CIS operations were used as a basis for the comparison. Both the capital and operating cost comparisons indicate a substantial savings for a RIS circuit using AuRIX® 100 (- 14 to 18% in terms of capital and 25 to 35% in terms of operating costs) over a conventional CIS circuit depending upon solution flows and grade.

Jan 1, 1999

By David Green

Power point slides

Jan 1, 1999

By Ron VanRiper, Ben W. Burdett, Randy A. Ynchausti, Jeff D. McKay, Dan Lampshire, Thomas W. Toronto

An adaptive process control system was installed in Cortez Gold Mines Mill #2 Grinding Plant in Nevada. The installation, commissioning, and testing of the system took approximately 80 manweeks, but final test results show that the system paid for itself through increased throughput within two weeks of commissioning. Both crisp and fuzzy rules are used in the expert rule base which is also integrated with continually adapting neural network models. The expert rules and models are used by predictors, and optimizers to allow the control system to provide optimum process performance under continually varying feed conditions. The selection, installation, rule and predictor configuration, and statistically verifiable testing of the control system in the Cortez Gold Mines Mill #2 Grinding Plant is described in the paper.

Jan 1, 1999

By Andy Cole, Stanley Bunk, Steve Dunn, Thom McCord

In 1994, Goldstrike initiated a research program to investigate processing options for treating what was then the small amount of carbonaceous ore identified in the reserves. The focus of the research was on developing a process which incorporated the autoclave technology already utilized at Goldstrike. Over the next two years, Barrick pursued the development of an ammonium thiosulfate leaching (ATS) process. During the period in which the ATS research was being conducted the amount of carbonaceous ore in Goldstrike's reserves increased substantially and continued growth was projected. By 1996, significant advancement was made on the development of the ATS process. The work culminated in a series of integrated pilot plant runs incorporating autoclaving, ATS leaching, resin in leach, stripping and cementation. Several questions about the process chemistry remained unanswered, preventing commercial development. Barrick was committed to producing gold from the carbonaceous ore reserves by 2000. A due diligence review of carbonaceous ore processing options was initiated during the second half of 1996. Processes considered in addition to ATS were fine grinding/autoclaving, as practiced then by Santa Fe, and whole ore roasting as practiced by Independence Mining and Newmont. The objective by year-end was to recommend the most robust and economical process for Goldstrike's carbonaceous resources. In the fall of 1996, a detailed review of roasting as a processing alternative for Goldstrike was initiated. Throughout the ATS development period, whole ore roasting was used as the benchmark. All the ATS metallurgical and financial results were compared to roasting bench top test results. It was clear this data was too imprecise for use in due diligence study, a more definitive recovery value was needed to complete the carbonaceous ore review. The primary goal of the roasting review was to conduct pilot plant roast tests to gain a more thorough understanding of Goldstrike's carbonaceous ore's response to roasting and its effects on gold recovery. Using the test facility at Hazen Research, four pilot plant campaigns were conducted to determine optimum roast conditions and further define metallurgical design parameters. Conventional two-stage fluid bed technology based on Freeport­McMoRan's roasting patent was the specific process basis for testing. The ore's response to roasting exceeded expectations. In January 1997, a preliminary economic evaluation comparing ATS and roasting was presented, and the outcome was approval to proceed with a roasting prefeasibility study. In July 1997, approval for Goldstrike's Roaster facility was received and basic engineering started immediately thereafter. Detailed engineering _began in January 1998 and plant construction commenced in October 1998,t, Goldstrike's Roaster facility is designed to treat 12,000 tpd of a refractory gold ore, which contains both pyrite and organic carbon. Circuits in the facility include primary and secondary crushing, dry grinding, roasting, gas handling, neutralization, thickening and standard CIL. Gold desorbtion and recovery is carried out at Goldstrike's existing refinery. Plant start-up of the first dry grinding and roasting train is scheduled for March 2000, with the second train coming online in May 2000.

Jan 1, 1999

By Ken Deter

I have some general comments on optimizing profitability based on working in heap leach operations in tropical environments. Many of my planned comments this morning have been stated earlier in the Conference. I get the opportunity to say only a few words, and follow up on some specific comments and concerns. In normal operations, stack the ore higher, where possible. The surface area of the stacked ore controls the total solution volume that can be sprayed on the pad at a specific time period. With higher lifts, solution will contact more ore particles as it percolate through the lift, and therefore the solution grade flowing through the base will be increased, whether it is freshly stacked or almost completely leached ore. This also allows more tonnage to be stacked per lift on the pad, decreasing conveyor movement and downtime. Increasing from 6 to 8 meter (20 to 26 feet) lifts have worked successfully, and some mines are using 10 meter (33 feet) lifts in 10,000-15,000 dmtpd plants. The same concept will work with smaller plants, but initial 6 meter lifts should be used until the start-up period has shown the leaching is working as planned. As the stacked ore lifts get higher, the solution flowing through the highest lift is diluted by solution retained in the lower ones. Eventually no real increase is noted from putting fresh ore in service, and gold production rate suffers. To address the dilution problem, an HDPE liner should be installed between each 2 to 4 lifts, depending on each site specific lift height, recovery, % slump in the lift, recovery rates, and grade treated, among others. The surface of the previous lift should be leveled and sloped to control the effluent draining from the planned lift, then the liner is placed, including berms and discharge pipes. The intermediate HDPE liner does not need to be completely sealed as would be the case with the base liner, and can accept some solution penetrating into the lower lifts. A one-mm (40-mil) thickness liner can be used. This intermediate liner allows the upper lift(s) higher-grade effluent to report to the pad discharge point. This will maintain higher gold solution grades going to the ponds. The slopes of the previous lifts should not be covered with HDPE in this concept, and precipitation falling on the lower lift slopes and benches can be directed to barren or surge ponds.

Jan 1, 1999

By Steven Schurman

Acid Rock Drainage (ARD) is one of the most serious and persistent pollution problems facing today's mining industry. ARD is formed when pyrite (FeS) is exposed to natural weathering conditions. Pyrite weathering, formally the oxidation and hydrolysis of pyrite, leads to the generation of soluble, hydrous iron sulfa-salts and the production of acid in the form of H+. The resulting effluent is water that is characterized by high levels of iron (and any other metal contained in the rock undergoing weathering) as well as high concentrations of sulfate and a low pH (acid). Rocky Mountain Remediation Services, L.L.C., has developed a patents pending Envirobond'™ product, Envirobond™ ARD, to treat acid rock drainage. Treating pyrite with Envirobond™ ARD inhibits the oxidation and hydrolysis of pyrite thus curtailing the pyrite oxidation cycle.

Jan 1, 1999

Caterpillar recently held two, two-day demonstration programs for its mining customers. The event, billed as MineDemo by Caterpillar, consisted of two sessions held on consecutive weeks at the company's Tinaja Hills proving ground south of Tucson, AZ. The program included several classroom sessions that focused on Caterpillar equipment applications, including the VIMS (vital information management system) and the CAES (computer-aided earthmoving system). Also included were field demonstrations and the opportunity to test drive mining-related heavy equipment, including dozers, trucks, graders, shovels and loaders. Featured at the event were the recently upgraded 785, 789 and 793 C-Series trucks. Caterpillar recently announced the availability of the 136-t (150-st) 785C and the 177-t (195-st) 789C. The upgraded haulers have replaced the respective B-Series models. The 218-t (240-st) 793C was introduced in 1996. It, too, has been upgraded but retains the C-Series designation. While attending the press event, the author had the opportunity to test drive the 793C at the Tinaja Hills test site. It was amazing how well the machine handled. The operation was smooth and the braking system was precise. The cab was extremely comfortable. To see a C-Series truck in action, the author also visited Newmont Mining's Mesquite Mine, located in Cali¬fornia, across the border from Yuma, AZ. The Mesquite Mine operates a new model 785C truck. At the mine, temperatures have been measured as high as 58° C (138° F) in the pit. Needless to say, the ability to operate dependably in extreme heat is an important consideration for the mine operators. An interview with the driver and later with management confirmed that the 785C has worked out well. The driver praised the comfort of the cab and the ease of operation. Management reported significant fuel savings and was impressed by the truck's maintenance features.

Jan 1, 1999

By J. A. van Huyssteen, P. H. Radcliffe

With the profit squeeze of recent years and indeed the survival of many mines at risk due to low gold prices and declining grades, many inventive solutions have been found of increase production and decrease cost. One of these is the application of process auditing methodology which is essentially a tool to determine systematically whether a process is delivering optimally and, if not, to identify the basic causes. Then a prioritized action plan can be developed with the client. Our experience has shown that problems are seldom what they appear to be and that most processes can operate far more efficiently with relative little effort. A process auditor requires good facilitation skills to overcome initial suspicion, and for sustainable solutions client involvement is essential. Process auditing as it is being applied in Anglogold has evolved over many years to reach its current format. The lessons learned and insights gained in the process are shared here with the reader.

Jan 1, 1999

By G. R. Harrod

Effective mine operation demands that the right people have the right information at the right time. Caterpillar's Mining and Earthmoving Technology System (METS) meets this demand by providing "real-time" information transfer between the mine offices and machines equipped with the Caterpillar Computer Aided Earthmoving System (CAES). Transfers of mine plans from the mine planning software to CAES-equipped machines give operators access to current mine plans within minutes of their creation. Additionally, office personnel have access to a current digital terrain model (DTM) of the mine site as it is updated in "real-time" by CAES-equipped machines. METS provides mine personnel in operations, planning, and management the information they need when they need it.

Jan 1, 1998

By A. F. Stewart

Slope design in an open pit mine includes the determination of a number of parameters, including bench height, bench face angle and berm width. By way of a case history of two highwall slopes (160m and 220m high) excavated in dipping strata in an operating coal mine, this paper illustrates the influence that bench face angle can have on the stability of an entire slope. The two highwall slopes, the lower of which experienced significant instability, were excavated in essentially the same lithologic and structural environment, with the main differences between the slopes being the angle at which the bench faces were excavated and the excavating methods that were employed. In addition to describing the instability that occurred on one of the pit walls, relevant aspects of the engineering geology, slope design and excavation procedures are described.

Jan 1, 1998

By David M. Spatz

Anyone who scans the modern literature will realize that concepts of leadership have changed during the past few years. And like change in so many areas of our culture, change has been rapid in the perception of leadership. Many traditional leadership traits are still highly regarded and many of the longstanding personal qualities that improve leadership abilities continue to be effective. In the past, though, leaders could rely on dominance, intimidation and fear to accomplish their goals through the actions of others. In contrast, effective leaders today build relationships, provide vision and guidance, and strive for communication, cooperation, trust and employee satisfaction. Earnest leadership involves moral issues like honesty, integrity, fairness, empathy and respect. Modern leaders guide, facilitate and coach, rather than command and direct. But how well equipped are managers in the mining industry to meet the leadership challenges that lie ahead? More importantly, is he or she becoming a better leader? This article outlines steps to becoming a more effective leader. Management consultants stress that the changes that lie ahead will demand swift organizational adjustments and managers who are equipped to lead during times of change (Boyett and Conn, 1991; Hesselbein et al., 1996; White et al., 1996 and Kotter, 1997). Becoming a better leader begins with self-assessment and a commitment to unify all who depend on one's leadership abilities. Simply defined, leadership is leading others. Contrary to common practice, leadership is not about advancing one's own career but about bringing out the best in others. The beauty of modern leadership, however, is that the path of serving others creates synergies. They benefit everyone, including the leader, those the leader manages, upper management and company shareholders.

Jan 1, 1998

By R. H. Derammelaere

With renewed interest in coal slurry pipelines in China, Indonesia, Australia and Canada for electric generation, it appears worthwhile to update the relative economics of transporting coal by slurry pipeline. Three slurry pipeline technologies are evaluated for the commercial transportation of 3.0, 6.0, and 9.0 million tonnes per year (MMT A) example cases, over distances of 250 km, 500 km and 1000 km.

Jan 1, 1998