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By Michael A. Zappia

INTRODUCTION The San Manuel mine of Magmacopper Company is located approximately 72 km northeast of Tucson, Arizona. The mine, concentrator, smelter, electrolytic refinery and continuous rod casting are located on the west side of the San Pedro River valley. Ore Production: 58 1W mtpd Production To Date: Over 340 000 000 mt since 1956. Ore Grade: 0.70% net sulfide cu. As conceived at the present time, the San Manuel ore body is the lower half of what was originally an elliptical (In cross sect ion) cylinder same 2400 m long with major and minor cross sectional axes of 1500 m and 760 m. After emplacement, the cylinder was diagonally sliced along its long dimension by the San Manuel fault, which separated it into halves, moving the upper half same 2500 m down dip and bringing a wedge-shaped blanket of tertiary conglomerate into position over the lower segment of the cylinder. The lower segment is the San Manuel ore body. The upper part, moved down dip, is the Kalamazoo ore body. Originally, these were one ore body. The San Manuel ore body is a structurally weak and highly fractured quartz monzonite, the principal ore minerals being chalcopyrite, with small amounts of molybdenite. The present mining method is full gravity diagonal retreat panel caving by block. This is shown on Figure 2 , (Block Sequence 56, 57, 58, 59 --on the following page.) The ore mined is hoisted to the surface for transportation to the concentrator. BLOCK CAVING MINING SEQUENCE HISTORY The San Manuel mine was planned and developed as a full gravity block caving mine. It continues as a full gravity block caving mine. Since its initial start, the major changes in mining have been in the areas of ground support, rate of draw and undercut sequence. Ground weight resulting from block caving plays a dual role. It can cause extensive damage to ex- traction openings, yet it is necessary to break the ore into easily handled size. The ground- weight problem resolves itself into finding ways to make it manageable. The initial early ground support in the production areas consisted of timber sets and various combinations of steel and timber sets. This sup- port system proved unsatisfactory and a new support system utilizing concrete was developed. Concrete support, 30 cm to 45 cm thick, proved satisfactory. Rates of draw were experimented with. A draw rate of 45 cm to 61 cm (32 to 45 mt) per draw point per day was determined as optimum in con- trolling ground weight. Undercut sequence or mining sequence was recognized as a major contributing factor to ground weight. This is the most difficult factor to change. The lead time from primary development to undercut can be as much as two years. Initial Checkerboard Pattern The initial undercut sequence was in a checker- board pattern (Figure 2). Blocks Sequence 1, 2, 3, 4, 5, 6--next page.

Jan 1, 1981

By Byron T. Darnton

Gravity concentration at the Pegasus Gold/Montana Tunnels Mine, near Helena, MT, began in June 1991 when a coarse-gold-scalping circuit was commissioned. It processes a small portion of the ball-mill circulating load to reduce the risk of gold particles that are too coarse to float from advancing to flotation. The circuit also cost-effectively enhances overall gold recovery and payable gold ounces. This gravity circuit has been a major success. Since the circuit was commissioned, throughput has increased 30%. Several modifications and improvements were made during the last three years that allowed the gravity circuit to keep pace with the higher tonnage. The overall approach to gravity concentration at Montana Tunnels has always been to optimize production rather than maximize the gold ounces produced. This philosophy has now yielded a circuit expansion and relocation project. It will allow for an estimated 50% increase in gravity gold production, while significantly reducing the unit costs of production.

Jan 1, 1995

By B. T. Darnton

Gravity concentration at the Pegasus Gold Montana Tunnels Mine was initiated in late June, 1991 with the commissioning of a coarse gold scalping circuit that processes a small portion of the ball mill circulating load. The primary objective for the circuit was to reduce the risk of gold particles advancing to flotation that are too coarse to float. The secondary objective was to enhance overall gold recovery and payable gold ounces in a cost effective manner. The gravity circuit has proven itself to be a major success. The above mentioned goals have been achieved, and they have been maintained at record throughput rates that are 30% higher than when the circuit was commissioned. A number of modifications and improvements were made over the last three years which allowed the gravity circuit to keep pace with the higher tonnage, these are discussed in detail in the body of this paper. The overall approach to gravity concentration at Montana Tunnels has always been to optimize production rather than maximize the gold ounces produced. This philosophy has now yielded a circuit expansion and relocation project which will allow for an estimated 50% increase in gravity gold production, while reducing the overall unit costs of production significantly. This paper will review historical gravity circuit performance, improvements, and the current relocation and expansion project.

Jan 1, 1995

By Ishwinder Grewal, Michael Fullam

Many factors affect the overall performance of a gravity circuit beyond that of the primary gravity recovery device. It is critical to examine the gravity circuit in its entirety in order to determine the dominant operating variables that affect overall performance. Knelson has developed a mathematical model which has been used to assist in the design of gravity circuits, and in particular, in making accurate predictions of plant scale gravity recovery. More recently, inclusion of recovery by particle size class and additional data from various mine sites and research studies has made the model more robust. The model is now able to predict GRG (gravity-recoverable-gold) recoveries using various devices such as centrifugal concentrators, shaking tables, jigs and flash-flotation within the grinding circuit. The benefits derived by these recent advancements in modeling capability are two-fold; the first is as a tool to assist in circuit design and correct equipment selection and the second is as an analytical tool to help to evaluate and enhance the performance of existing gravity circuits.

Jan 1, 2006

Traditionally, the gravity cleaning of coal has been evaluated in pilot plant tests. Attention is now turning to the development of empirical models of gravity cleaning equipment that can be used for the design and evaluation of circuits. This paper presents some preliminary information for spirals and water-only cyclones treating fine coals. Also discussed is how such information gives a better understanding of the operating and performance characteristics of this equipment, how realistic comparisons can be made between different types of equipment, and how small mobile plants could be designed for treating the fine coals 'stockpiled' at many NZ mines.

Jan 1, 1985

By R. O. Burt

The paper examines the role of gravity concentration in both an historical contest and within the modern mineral processing industry. It discusses the principles of the process on both a theoretical and practical level. The importance of ore mineralogy and its effect on the choice of the wide range of equipment available is discussed. The paper concludes with a discussion on the relative merits of gravity concentration to other forms of processing and seeks to answer the classical question - "Quo Vadis?"

Jan 1, 1982

By Frank F. Aplan

Introduction Gravity concentration may be defined as that process where particles of mixed sizes, shapes, and specific gravities are separated from each other by the force of gravity or by centrifugal force. The nature of the process is such that size and shape classification are an inherent part of the process in addition to separation on the basis of specific gravity from whence the process got its name. Mother nature has long practiced this form of mineral concentration by concentrating such heavy and relatively indestructible minerals as gold, platinum, cassiterite, ilmenite, zircon, and diamonds in placer or beach sand deposits. Once freed of their host granitic or other rock through natural weathering processes, these minerals are then subjected to stream or wave action producing a natural classification and concentration of the heavy minerals. Gravity concentration dates back to antiquity and was certainly the first ore concentration process used when selective mining and hand sorting would no longer suffice to produce the quality of concentrate desired. Forerunners of the present day sluice box and panning techniques were undoubtedly used by the ancient Egyptians on the upper Nile to separate gold from stream gravel. By the second century BC the extraction of gold from veins in quartz was well detailed by Agatharchides, but there is evidence that gold was brought into Egypt from the south as early as the XI1 Dynasty (~1900 BC).1 Most assuredly gravity concentration devices were used during the later Bronze Age to separate the heavier tin and copper minerals from their lighter gangue minerals. The Athenians used an elementary form of Rowing film concentration at their lead-silver mines at Laurium,2 and elementary jigging using wicker baskets was also probably developed at this time. Agricola's famous treatise De Re Metallica3 demonstrates that by the 16th century gravity concentration technology was well advanced and a large number of devices had been developed. Chinese

Jan 1, 1985

By C. Mills, A. O. Burt

"The paper examines the role of gravity concentration in both an historical context and within the modern mineral processing industry. It discusses the principles of the process on both a theoretical and practical level. The importance of more mineralogy and its effect on the choice of the wide range of equipment available is discussed. The paper concludes with a discussion on the relative merits of gravity concentration with other forms of processing.IntroductionIt is an unfortunate, albeit popular, misconception among otherwise enlightened engineers in the mineral processing industry that gravity concentration was a process developed in the dark ages, perfected in the middle ages, and abandoned in the modern ages.Gravity concentration was developed in the dark ages - long indeed before that. Agricolau: cited examples of gravity concentration, crude examples admittedly, being practiced over 3000 years ago. However, gravity concentration is not dead. Far from it. As recently as 1978 it was reported that the total mineral tonnage treated by this process in the United States was greater than that processed by flotation. Coal represents the bulk of the or e treated by gravity separation in the U.S.A., with iron ore representing a major portion of the balance."

Jan 1, 1985

By Barry Cloutt

Western Mining Corporation Limited owns and operates the St Ives Gold Plant located near Kambalda, approximately 90 kilometres south of Kalgoorlie in Western Australia. Production commenced in March 1988 at a design capacity of approxi­mately two million tonnes per year. The plant was quickly expanded as a result of new ore discoveries in the district and has been processing ore since 1993 at the rate of three million tonnes per year. The plant has recovered over 50 tonnes of gold since the operation began, The plant was able to maintain acceptable recoveries throughout the plant expansion phases. Further gains in recovery were possible since there was still free gold in the tailings after approximately 24 hours of leaching. Testwork carried out on prospective orebodies showed that some contained considerable quantities of free visible gold, while others were seen to be semi­refractory using a conventional grind - leach circuit. Alternative treatment techniques were considered because a substantial amount of revenue was lost with the treatment of these ore bodies using conventional milling techniquies. The basis for all the investigations was to maximise the gold recovery from each orebody while minimising the effective cost per ounce of gold produced,

Jan 1, 1995

By J. A. Folinsbee

Placer Dome Canada owns and operates the Campbell Mine at Balmertown, in the Northwestern corner of the Province of Ontario, Canada. The mine operates at 1500 stpd and produces in excess of 300,000 oz of gold annually. Recent changes to the gravity concentration circuit have resulted in a 10-15 % increase in gravity recovery. The circuit changes responsible for these improvements will be the focus of this paper.

Jan 1, 1997

By Brad Hewitt

Since Campbell Mine began processing ore, there has been a gravity gold recovery circuit. From 1947 to 1982, gravity gold was concentrated through the combination of jigs and mercury amalgamation. In 1982, jigs with concentrating table upgrading commenced and was utilized until the end of 1994. As of January of 1995 to the present, Knelson Concentrators in com­bination with concentrating tables have been employed to achieve a refinable product. An evaluation of the justification used for the last change is the focus of this paper.

Jan 1, 1996

By Steve Lloyd, Mary Anne Antonioli, Byron Darnton

Pegasus Gold Corporations' Montana Tunnels mine began oper­ation in March 1987. The process plant at startup consisted of a bulk flotation circuit followed by leaching of the reground bulk concentrate. The leach residue then advanced to selective Pb/Zn flotation. This original circuit had its share of problems, and the leach circuit was abandoned after six months. The bulk flotation circuit was modified to selective Pb/Zn flotation at this same time. Gravity concentration was researched early on, prior to selecting bulk flotation with leach as the flowsheet of choice. Flotation was deemed to be more practical than gravity due to the lower capital and operating costs. No further work was done concerning gravity concentration until 1990 when it was decid­ed to investigate ways to diminish the occurrence of free gold reporting to the flotation tailings.

Jan 1, 1996

By John A. Folinsbee

Placer Dome Canada owns and operates the Campbell mine and mill at Balmertown, in the north western corner of Ontario. The mine operates at 1.3 kt/d (1,500 stpd). It produced more than 9.3 t/a (300,000 oz/year) of gold during the last three years. Changes to the gravity concentration circuit have resulted in a 10% to 15% increase in gravity recovery. The mill head grade at the Campbell Mill is relatively high, averaging 18.5 g/t (0.54 oz/st) over the total reserve tonnage. During the past several years, the head grade was averaging close to 20 g/t (0.6 oz/st). Before 1994, gravity concentration was achieved by using a combination of conventional mineral jigs and tables. Jig concentrates were upgraded on shaking tables to produce a concentrate, which was refined to bullion. In May 1994, management decided to buy two Knelson CD 760-mm (30-in.) concentrators. The objective was to replace the existing jigs and increase gravity gold recovery by up to 15%. Gravity recovery with jigs averaged between 30% to 35%. Gravity recovery was anticipated to increase to about 50% with the Knelsons.

Jan 1, 1997

By A. Goulsbra, S. Gregory, P. Gelfil, V. Martins, R. Dunne

As a general rule for gold treatment the presence of reasonable amounts of 'coarse' free gold will dictate the use of a gravity circuit. The actual particle size of gold that constitutes the por­tion of' coarse' free gold can vary widely. The larger its size the more troublesome it is, mainly because of the tendency for this gold to quickly settle out from slurries in regions of relatively low velocities. There are a multitude of places where 'coarse' gold can find a resting place, namely, in chutes, between and behind lines, in pump hoppers and in pumps themselves. Fortunately, the problems associated with recovering very 'coarse' free gold, say greater than Imm, is rare on most gold mines that have grinding and cyanide leaching circuits. For these operations it is common practice to have a gravity circuit situated within the milling circuit to recover 'coarse' free gold. Should the 'coarse' free gold constitute 15% to 20% of the total gold in a deposit then its recovery by gravity separation is seri­ously considered. As a gold mine 'matures' the availability of soft oxide ore decreases and the likelihood that harder ore having sulphide gold association increases. To maintain gold production rates in this situation either the gold grade of the treated ore must increase or more ore needs to be treated. In the latter case this is achieved by installing more grinding capacity, an expensive option, or coarsing the grind, with the downside of loss in gold recovery. In general the less expensive capital options is fol­lowed. There is, however, some upside to improve recovery when reasonable quantities of sulphide containing gold are pre­sented that can be recovered by flotation or gravity separation. Concentrates produced from these unit operations can be finely ground and reintroduced to the cyanide leach circuit to improve gold recovery. This scenario is a much less costly option than one where all the ore is ground finer. In this paper the experiences of recovering gravity gold from the Telfer Gold Mine, and gold associated pyrite from the New Celebration Mine will be discussed.

Jan 1, 1996

By Shawn Healey

The Mineral Hill Mine, owned and operated by TVX Gold Inc., is located in the Beartooth Mountains, 5 miles north of Gardiner Montana, U.S.A., which is the north entrance of Yellowstone National Park. Mining is carried out underground using ramp attack cut and fill as well as room and pillar mining. The mine currently employs approximately 145 people and is producing 550 tons per day at a grade of around .21 oz/ton.

Jan 1, 1996

By Richard H. Johnson

The Castle Mountain Mine (CMM) is located in the eastern por­tion of San Bernardino County, Southern California, 70 miles south of Las Vegas. The CMM is a joint venture between Viceroy Gold Corp. (75% and operator) and MK Gold (25%). The CMM initially started gold production with an 8,000 tpd cyanide heap leach operation in February, 1992 when the first ore was crushed and delivered to the leach pads. Even during construction and commissioning, design work was under way to engineer and construct a 1,200 tpd Mill circuit to process the higher grade fraction of the ore through use of pulp agglomera­tion. The need for a grinding circuit became evident with the quantity of high grade material delineated during drilling and the amount of visible gold that the geologists were finding in the drill core and R.C. cuttings. Viceroy did not want to stack the higher grade ore on the heap, and it was clear that permitting a tailings pond would, at best, be a long drawn-out affair. An alternative to a tailings facility had to be found.

Jan 1, 1996

By R. O. Burt

"Gravity Concentration, the oldest form of Mineral Processing, remains of major importance to the Industry. Current applications of Gravity Concentration are briefly examined.The Paper details one approach to the development of a Gravity Concentration Plant, from laboratory and mineralogical techniques, through Pilot Plant testing, where applicable, to the actual design of the plant.INTRODUCTIONGravity Concentration, once the major method of concentrating minerals has, for much of the twentieth century been regarded, like the dodo bird, as obsolete. However, in more recent years it is enjoying something of a renaissance, and is once again being treated as a useful, economic alternative in the Mineral Processing Engineers' arsenal.An indication of the broad application of gravity concentration is the variety of minerals presently recovered. A list is given in Table 1; this list is not exhaustive."

Jan 1, 1984

By Thunaes, Arvid

Pilot plant test work in 1942 and 1943 showed that by a combination of desliming, fine-size classification, and Sullivan deck concentration it is possible to recover heavy minerals such as cassiterite at least as fine as 10 microns in size. This appreciable improvement in gravity concentration practice has been substantiated by several full-sized plants.

Jan 1, 1950

By Carlos G. Rudolp, Julio C. Videla, Mario Zuleta

"The present paper summarises the results of gravity pneumatic concentration of a borax ore with 17.5 % B2O3. The sample was extracted from the Tincalayu ore deposit located in the Salta Province of Argentina.The applied methodology was based on a former study (Zuleta, 1985). It consisted of sample characterization by means of physical and mineralogical determinations, chemical analyses as well as pneumatic table concentration tests. In this, a simplified concentrating flowsheet was utilized.A concentrate with 30.6 % B2O3 and 74.7 % recovery was obtained. The recovery was 8.8 % less than previously reported and that was of 30.6 % B2O3 with 87 % recovery. Nevertheless, the simplified flow sheet presented processes only two granulometric fractions, - 6.4 mm + 0.3 mm and - 0.3 mm, compared to the three granulometric fractions used in the previous study: - 6.4 mm + 1.4 mm; - 1.4 mm + 0.3 mm and . 0.3 mm. This would simplify industrial implementation."

Jan 1, 2003

By N. Duru

"Gravity concentration is still a challenging area in the mineral industry. This is mainly because of the fine size valuable mineral losses to the tailings during its application. But the recent developments in centrifugal separation methods and their mutual application with conventional separation techniques has increased mineral recoveries. In this paper, field application of conventional gravity separation methods with the combination of 2” diameter hydrocyclone cluster unit and a multi gravity separator (MGS) was discussed. Additionally, particle size distribution and chromite content of the plant streams is presented and initial laboratory test results were compared with the actual plant data throughout the paper. As expected, field data showed derivations from the laboratory tests but the combination of MGS and conventional gravity separation techniques resulted in gravity separation of -0.1 mm chromite particles. INTRODUCTION The purpose of this mineral processing plant project was to investigate the possibility of upgrading chromite ore from 12% to 48% Cr2O3 and having final tailings assay as 2% Cr2O3. For this reason, initially a set of laboratory gravity separation studies were conducted to evaluate the performance of combination of 2” diameter hydrocyclone cluster and multigravity separator. After obtaining successful results from the laboratory work, a feasibility study was initiated. Economical results of the feasibility study showed that an achievable high net present and return on investment values. Following the investment decision; engineering, equipment procurement, construction of the processing plant was completed in eighteen months. This paper focuses on the initial laboratory test work results, operational data of the 2” diameter hydrocyclones and MGS units; resulted chromite recoveries. Processed ore has the chromite associated with serpentine and olivine minerals. The chromite particles are generally in round shapes with sizes between 50 µm to 1600 µm and average size of 450 µm. The microscope images of the chromite and associated formations are presented on Figure 1.Chromite is formed in mixture with iron oxides, with varying amounts of magnesium, aluminum. The average chemical composition of the representative drill core samples of the ore deposit is given on Table 1."

Jan 1, 2017