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By Ashma Singh, Nichole Maistry

Due to declining iron ore grades, low-grade ores with complex mineralogy — namely, banded iron formation (BIF) — are being explored to maximize iron ore resources and increase the life of mine. Flotation is the standard global process used for the beneficiation of BIF ores, as it is a complex ore reserve, and liberation is typically achieved below 1 mm. This study focuses on the flotation of a South African BIF, evaluating its response to different collectors, as well as effect of grind. As flotation is an expensive process and South Africa ranks high on the production cost curve, preconcentration by gravity or magnetic separation is performed prior to flotation. Thus, flotation was also performed on a gravity concentrate to determine if a grade suitable for steelmaking (approximately 63 percent) is achievable. The results indicate that the use of an alkyl ether amine-based collector partially neutralized with acetic acid is suitable for separation of hematite from illite and quartz at high pH values. Further optimization tests are being pursued to improve overall recovery and grade.

May 1, 2025

By David A. Milligan, William Cobb

2.1 INTRODUCTION This chapter provides the reader with a sense of how a heap leach project may make an orderly, and hopefully non-traumatic, transition from discovery or acquisition to project construction. In making this transition a project can pass through several project development phases (i.e. ore definition and delineation, conceptual engineering, detailed engineering, and ultimately on to project construction and operation). "Go" or "no go" decisions may occur at any point in each of these phases. The transition from ore definition to detailed engineering should be accomplished via a well thought out program of interdisciplinary studies and an integrated, interdisciplinary project team. This chapter also describes, in general terms, a "roadmap" approach to the project evaluation process that must occur as project planning and development progress. It is the experience of the authors, as well as a myriad of companies who have been through the heap leach project development process, that a systematic approach will save many headaches, and many dollars. In fact, it is safe to say that a project with no formalized system of "objectives setting" and "milestone charting" may well flounder along the way, even if an economic ore body exists. Many papers and technical articles have been written about various aspects of mineral resource appraisal, economic evaluation, and mine development. Most of these invoke the same general philosophy of a systematic approach to project evaluation and development, although methods cited for attaining goals are quite variable. This is undoubtedly appropriate, given the fact that there is great variation in approach to project development (e.g., climatic considerations, ore body size and physical ore characteristics, permitting constraints, etc.). For the purposes of this chapter, two primary sources of information have been used to highlight the "road map" approach previously alluded to. These sources are cited throughout the text as Mackenzie (1980) and Snow and Michel s (1986). A brief summary of each of these sources is provided below: Brian GJ. Mackenzie of Queens University (Mackenzie, 1980) has developed a wealth of information concerning project development topics. Much of this information is synthesized in his notes for a short course entitled : "Mineral Exploration Planning and Economic

Jan 1, 1988

By Gus H. Goudarzi

The apatite deposits in east-central Bahia, Brazil, are about 50 km east of Serra do Jacobina, between lat. 11° and 12° S. and long. 39°40' and 40° W. Apatite was found and examined at 15 localities in a mineralized belt that strikes about N.25° - 30 W. over a distance of about 100 km, but the size of the deposits has not yet been determined. Rocks of the region consist of a sequence of Precambrian migmatites and quartz feldspar paragneisses containing units of pyroxene-rich rocks, lenses of sillimanite-bearing quartzite, amphibolite zones, and calc-silicate marble lenses. Pegmatites and granites of probable anatectic origin (anatexite) are abundant. Faults are numerous. Clastic sediments of Tertiary and Quaternary ages cover most of the area; thus, outcrops of the Precambrian rocks are sparse. Trenches and pits have exposed mineralized zones as much as 10 m wide at some localities within the region. A layer of apatite at least 1 ½ m thick is exposed in a trench at Lagoa do Mel. At Rio do Peixe, vertical shafts have penetrated a mineralized zone, to a depth of as much as 13 m, of which about 25 percent is apatite. Apatite is massive or forms minute crystals, stringers, and disseminated grains in alkalic host rocks. At Apolinario, euhedral crystals of apatite are as much as 50 cm long and 30 cm in diameter. Associated minerals include vermiculite, biotite, scapolite, opal, chalcedony, epidote, montmorillonite, chlorite, kaolinite, sericite, magnetite, and limonite. Apatite is everywhere intimately associated with pyroxene-rich rocks, alkalic syenite pegmatites, and alkalic granite pegmatites. At Panelas-Retiro, apatite is associated with pegmatites, crystalline calcite (vein calcite), vermiculite, and pyroxene-bearing rocks. Analyses of samples show that the apatite is radioactive and rare-earth-bearing. Traces of vanadium and titanium were detected by spectroscopic analysis. The apatite was probably derived from phosphatic zones in the original Precambrian sedimentary rocks and has been crystallized and some mobilized by high-temperature regional metamorphism (higher amphibolite facies) into veins, pegmatites, and along certain preferred beds and fractures. Radiometric and geophysical surveys, in addition to conventional geological investigations, are planned to further investigate the nature and economic potential of the deposits.

Jan 1, 1972

By I. Tsolas

This paper presents the use of non-parametric approach (i.e., data envelopment analysis, DEA) for the development of environmental sustainability indicators in mineral processing using environmental, economic and/or integrated indicators (i.e., indicators that interrelate two dimensions of sustainability). A case study based on real publicly available data is presented to illustrate how the proposed approach can be implemented in practice. The merit of this approach, which is based on the productive efficiency framework, is that it provides environmental sustainability indicators that can be used internally for benchmarking purposes and externally for sustainability reporting.

Jan 1, 2008

By M. Irish, M. Jahraus

Accurate prediction of gold (or other metal) production from a heap leach operation is essential to the economic vitality of any such operation. However, this is also one of the most challenging issues facing managers of these facilities. Three approaches to modeling gold production from the Valley Leach Facility (VLF) at Anglogold’s Cripple Creek & Victor Gold Mining Company are presented. Evolution of these modeling methods has been necessary as ore heights and volumes have increased. In addition, the complex geometry of the VLF presents additional complications to production modeling, Comparison of actual and predicted gold production are presented

Jan 1, 2001

By Peter Amelunxen, Craig Lockhart

Significant effort was made in 2003 and 2004 to upgrade the existing instrumentation and process control infrastructure at the Phelps Dodge Bagdad copper concentrator. Specifically, • cameras were installed on the feed belt for online image analysis data, • ultrasonic level sensors were installed for froth height and sump level control, • a trial froth image system was installed on one of the rougher rows, and • a new expert system to tie everything together was integrated and tuned in-house. Control philosophy, observations, opinions, and general tips and tricks are discussed with the hope of assisting other plant personnel and expert system integrators.

Jan 1, 2005

By J. Brent Hiskey

Thiourea is a reagent capable of complexing gold and silver. With the proper oxidant, thiourea can effectively dissolve metallic gold and silver. A thiourea leaching system possesses potential advantages over conventional cyanidation including acidic solutions instead of alkaline, cationic complexes in contrast to metal-cyanide anoionic complexes, and faster leaching rates with acidic solutions of thiourea. Generally, the rate of metal dissolution in thiourea solution is fastest when ferric ion is employed as an oxidant. Acidic thiourea solutions for certain applications could offer a nontoxic and noncorrosive option for processing gold and silver. This paper provides information regarding the fundamental chemistry of the acidic thiourea system, and reviews the dissolution of both silver and gold in acidic solutions of thiourea. The recovery of gold and silver from acidic thiourea solution is discussed.

Jan 1, 1981

By P. Koh

A novel approach incorporating computational fluid dynamics (CFD) and flotation modelling has been used for investigating flotation cell designs. CFD modelling has increasingly been employed to enhance understanding of the cell hydrodynamics in mineral and coal flotation. Opportunities for improving the flotation cell performance can be identify by modelling. The CFD-flotation model from CSIRO incorporates cell hydrodynamics that affect particle-bubble interactions. Information from the model includes velocities, turbulent dissipation rates, gas hold-up, particle-bubble attachment and detachment rates. The attachment and detachment rates have been found to be effective measures of cell performance for cell design.

Jan 1, 2011

By John T. Crawford

Open pit limit analysis techniques of various types have been utilized for many years to design ultimate pit surfaces. In the last 15 years there have been many advances in the development of sophisticated computer methods to aid this process. The extensive capability of the computer has led to multiple alternative approaches to problem solving. Computerized open pit limit analysis methods can be applied to a broad scope of long-range and intermediate-range mine planning and design questions. A single computer run develops a pit design from a set of data. A set of nonsequential runs is used to evaluate changes in pit slopes, property restraints, and mineral model variables. Ore reserve economic sensitivity and intermediate-range mining plans can be developed using sequential computer runs. Present value methods are incorporated by using iterative sequential techniques. Multiple ore processes, dump leaching credits, and the trade-off between open pit and underground mining can also be handled. Many of the applications described are representative of current practice. The remainder are suggested extensions.

Jan 1, 1979

In May 1993, SME contracted with The Dolecek Companies of Denver, CO to conduct a salary survey and a study of Mining Engineering. A written, four-page survey was sent to a random select sample of 1897 current SME members from the United States and Puerto Rico and to 40 current SME members from Canada. A total of 621 survey responses were input and analyzed, to guarantee the validity of the survey findings. The findings are representative of the entire SME membership. And the survey is within a statistical range of accuracy of plus or minus 5%. Salary survey SME members currently earn an average of approximately $60,000 a year. Some 45% earn less than $60,000 and 49% earn more than that. About 24% of all SME members earn $80,000 or more each year and 13% earn $100,000 or more. Not surprisingly, a statistically greater number of owners (27.5%) and those in senior management (30%) have a current income or salary of $100,000+ a year.

Jan 1, 1993

By Neville T. Moxen, Stuart K. Nicol, Malcolm D. Engel

Ion flotation is a process in which ions of interest are complexed with a suitable surfactant molecule. A dilute solution containing these complexes is then aerated, under which circumstance the surface-active complex concentrates at the air-water interface and is transferred to a froth. The present work describes some of the phenomenology of this process and experimental work leading up to the design and use of a pilot scale laboratory facility. Early experiments suggest that selective recovery of gold can be obtained in a manner at least equivalent to conventional CIP processing at low capital cost. Under favourable conditions, upgrade ratios of gold ions of the order of 180: l have been achieved from reclaimed residue dam water with as low an initial gold level as 0.2ppm. Successful development of countercurrent ion flotation for concentrating solids-free gold solutions may offer a lower cost alternative to existing gold ore processing technologies, or in more secondary applications such as concentrating dilute gold solutions or heap leach runoff. The technology may also have more generalised applications to other heavy metal processing.

Jan 1, 1990

By V. I. Lakshmanan, Chris Dodson

Refractory gold ores or concentrates are pretreated in general by physical, chemical and biological oxidative pretreatment processes prior to cyanidation for the economic recovery of gold. The thermal treatment processes generally include fluid bed pro­cessing(!>, chemical with pressure<') or atmospheric (Caro's< ·'>, 3 Nitrox1')) pretreatment leaching and physical with ultrafine grinding!"). Roasting and aqueous pressure oxidation pretreat­ment methods have several commercial applications (Homestake, Barrick) and biological oxidation methods have recently found industrial applications in Africa. The roast pretreatment methods to treat refractory sulphide ores or concentrates transform iron sulphides generally to a porous iron oxide matrix assisting the lixiviant cyanide to effectively diffuse the calcine for cyanidation and hence with improved gold recovery. Jha and Kramer<') made an extensive review of roasting chemistty and practice to tt·eat refract01y gold ores. Industrially two stage pretreatment roasting is generally employed. During the first stage roasting is carried out under oxygen deficiency conditions to provide a low arsenic calcine, mainly magnetite and in the second stage magnetite is trans­formed to haematite under oxidizing conditions.

Jan 1, 1998

By J. Finch, W. Petruk, R. G. Pinard

An investigation was conducted to determine the minimum number of samples that must be studied by image analysis of polished sections to characterize a mill product and determine the apparent mineral liberation. It was found that a representative polished section cannot be prepared from an unscreened sample that has a wide size range of particles. Similarly, individual screened fractions are not representative of the sample because minerals are partitioned during screening, and the quantities of soft brittle minerals are increased in fine grained fractions, whereas the quantities of hard minerals are increased in coarse grained fractions. It is assumed that results obtained by combining data for a series of narrow size range screened fractions (one Tyler size range) are representative of the sample, and relatively accurate apparent mineral liberation data can be obtained for a mill product by analyzing each fraction and combining the data. Somewhat less accurate data would be obtained by analyzing a series of screened fractions that have a wider size range of particles (five Tyler size ranges).

Jan 1, 1987

By Bruce A. McKinstry

Introduction For many major mining projects the time frame from initial planning to production can be measured in decades. Hecla&apos;s Silver Shaft project, scheduled to go into production by the end of this year, includes a complete surface facility, shaft with an ultimate depth of 2.4 km (7,700 ft), complete ore pass and loading pocket system, and 610 m (2,000 ft) of development drifting and stope preparation. The project was conceived in the fall of 1979, and the duration of a mere four years from conceptual engineering to production is testimony to what can be accomplished when a mining company and a contractor work as a team rather than developing into two warring camps, as often happens. Engineering In 1979, Hecla Mining Co. awarded a contract to J. S. Redpath Corp. to perform feasibility investigations and design engineering related to a proposed new shaft facility at the Lucky Friday Mine. The Lucky Friday, in Mullan, ID, is a major producer of silver, as well as significant quantities of lead and some zinc. In late 1979, stoping was in prog-

Jan 10, 1983

By Howard A. Jongedyk, Jerry Wachtel

Advancements in tunneling technology and underground construction, plus rapidly rising costs of land, and a higher priority being placed on urban esthetics, make tunnels a more attractive option for certain portions of the highway construction program. Recent emphasis placed on fuel conservation reinforces the need for tunnels as a means of shortcutting circuitous routings designed to avoid potentially undesirable environmental impacts on any given area. Larger and more complex tunnels which have been constructed in recent years attest to this greater interest. More than 100 major highway tunnels are in operation in the United States. Highway tunnels commonly have much higher initial cost compared to surface routes. Where extensive cut and cover is involved, temporary disruption of the surface area may prove costly. In exchange for these costs, certain environmental advantages result. The purpose of this paper is to discuss some of the environmental advantages of highway tunnels and some of the unsolved problems related to obtaining maximum use of highway tunnels and research underway to help solve these problems.

Jan 1, 1974

By M. Takayasu, J. Y. Hwang, F. J. Friedlaender, G. Kullerud

Al unite has been used as raw material for producing alumina and potassium sulfate fertilizer in Russia for many years. In the United States, this mineral has not been commercially processed though reserves of 5 to 10 billion tons of alunite ore have been estimated. Major constituents of these ores are quartz and alunite. The minerals are finely intergrown and liberation occurs below 10 µm. Adequate separation techniques for such ultrafine particles have not been developed. A new method for the beneficiation of al unite ore is proposed in this study. This method utilizes a small amount of fine magnetite upon which the liberated quartz is selectively flocculated. The co-flocculated magnetite and quartz are then separated from the alunite in a high gradient magnetic separator. Clean products, e.g., an al unite concentrate of 90% grade with 80% recovery, has been obtained from Utah ore. Techniques for selective co-flocculation of magnetite and quartz, separation of the carried quartz, and recovery of magnetite after separation are discussed.

Jan 1, 1987

By Edward F. Fries

Computerized, real -time monitoring had its beginning in the U.S. coal industry in the early 1970&apos;s. Over the last 10 years, developments in technology have made systems available that are capable of monitoring and controlling many mine parameters that can increase safety and production. However, situations currently exist where computerized monitoring systems are not being utilized to their fullest capability. They produce reams of printed output that are not sorted in a useful format, and human operators are not able to react fast enough in emergency situations tn tile large amount of information that the systems generate. A solution is the application of an expert system as the interface with real-time monitoring. An expert system would use an extensive knowledge base and human-type reasoning ability to make decisions on optimum strategies. Expert systems have been applied successfully to problems in other industries, and could provide significant benefits to mine information management systems. The use of an expert system with real-time mine monitoring is discussed in this paper.

Jan 1, 1986

By A. G. Belova

Conversion of coal into high-value gases via gasification offers significant pollution reduction and efficiency improvement benefits associated with controlled combustion of clean gases for power generation. However, current gasification-based electricity production technologies, such as IGCC do not address carbon dioxide emissions. The focus of the study is CO2 capture on CaO prior to combustion of coal-derived gases. To overcome kinetic and stability limitations associated with its utilization, CaO is distributed on high-surface area -Al2O3 and supported on a ceramic honey-comb monolith. The proposed method allows for efficient capture of CO2 from a gas mixture, as studied in a flow-through reactor system. This novel method of CO2 capture is used here to argue for pre-combustion capture of CO2 in coal gasification-based power plants. When CaO is present during the steam reforming of coal gasification gases, continuous withdrawal of CO2 from the system provides for higher yields of reforming products (hydrogen gas) by influencing the thermodynamic equilibrium of the entire system.

Jan 1, 2009

By S. Svoronos, B. Moudgil, R. Stana, A. El-Midany

Due to their similar surface properties, it is not always easy to separate carbonate minerals from other salt type minerals by froth flotation. A particular example is the difficulty of separating dolomite impunities from phosphate minerals. Such challenging fundamental and practical problems have inspired several research efforts in various laboratories around the globe to find methods for economically removing the dolomite. However, a universal and cost effective process is not in commercial use. In this paper, a new process for separation of carbonate minerals (dolomite or calate) from other associated minerals is presented. Differential solubility of carbonates in slightly acidic solution is utilized to generate micro GO, bubbles at the carbonate mineral/ water interface. Particle (e.g., dolomite)/ bubble aggregates float to the surface leaving phosphate concentrate with low MgO content. Interestingly, up to 6.0 mm particles can be floated by such micro bubble/particle aggregates. Different sutface-active agents were tested to stabilize the bubbles. Results of these tests are presented and the mechanisms involved are discussed.

Jan 1, 2005

By G. A. Kosick, L. Kuehn

The design of an information management system (IMS) for a mineral processing plant requires prior consideration of many factors, which can be broadly categorized into two domains, process plant considerations and IMS considerations. The process plant considerations include: plant characteristics, management and personnel issues, existing organizational standards and policies, and the level of existing hardware and software systems. The IMS considerations include: system functionality, system sizing and desired performance, hardware components, software components, and system support issues. All of these aspects must be addressed in order to achieve a functionally successful and cost effective system. The purpose of this paper is to lay out these design issues and, in doing so, to provide process engineers with a guideline with which to tailor a system that is best suited to their specific application. The paper is completed by presenting an approach that has been used in two Canadian concentrators. Both of these plants have incorporated MillEX, a software system designed specifically as the central component of a mineral processing IMS.

Jan 1, 1993