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By Peter Erlynne

Rising costs have affected the cost of operating and install­ing crushing circuits, just as they have affected every other area and there is little possibility that the cost cycle is about to be reversed - power costs, wear materials costs and labour costs continue to increase but a basically stable gold price makes little allowance for these cost increases. Additionally, lower grades of ores being worked, and harder feed materials have a significant effect on the potential for higher processing costs. There are, of course, options for size reduction - some of them newer than others - some are suitable for certain types of ores and less suitable for others and it can sometimes be difficult to ascertain the accuracy of anticipated results before plant design and con­struction are completed - by which time the capital outlayed will preclude a change to another method ofreduction. Nordberg's patented WaterFlush Technology has the potential to change the way that Ball Mill Feed production is viewed: Some of the elements that must be considered are: • Capital Cost • Operating Cost • Efficiency • Flexibility • Availability • Control • Support Efficiency • Expertise • Spares availability • Environmental considerations

Jan 1, 1995

By Peter Bourke

It was in 1982 that the first SK-80 flash flotation machine was introduced at Hammaslahti concentrator in Finland to produce a final grade copper/gold concentrate. Since then the size and number of flash flotation units has steadily developed with the SK-240 being introduced in 1984 and the SK-500 unit in 1990. To date over 130 units have been installed worldwide many of which have been used to maximise the recovery of precious metals such as gold and platinum by preventing overgrinding in the grinding circuit prior to flotation. This paper briefly describes results achieved at several major gold mines in Australia and overseas that operate large flash flotation cells.

Jan 1, 1995

By Jeffrey R. Kelly, Paul M. Kubera, Richard A. Howk

Mixing of solid-liquid slurries is a unit operation that is widely encountered in the minerals processing industry. Applications may range from simple slurry storage in open tanks to complex chemical reaction systems under extreme conditions of temperature and pressure. The specific process requirements dictate both the degree of mixing required and the type of agitation employed to achieve the desired results.' Many continuous-flow process applications feature tanks operating in series to provide a discrete number of stages and a known residence time for the slurry. Because these tanks operate at a constant level in an overflow mode, the mixer must maintain uniform solids concentration and size distribution throughout the tank; failure to achieve uniformity results in accumulation of coarse solids in the tank, ultimately leading to a process or mechanical failure. Downward-pumping, axial-flow mixing impellers are widely employed to produce uniform solids suspension. The specific impeller type, number, size, and power draw is a function of each given situation. The use of high-efficiency, fluid-foil impellers (Figure I) has evolved as a recognized standard for these flow­controlled applications. Recent small-scale experimentation and full-scale experience has demonstrated that, when uniformity is required, capital and operating expense can be minimized by employing an additional upper impeller pumping in the upward direction.

Jan 1, 1995

By David Lunt, Evan Kirby, Peter Mason, Ian Ritchie

The treatment of refractory gold ores, in particular the "competing" technologies and their relative advantages and economics, has become a major segment of most mineral technology oriented conferences in recent years. A common theme is the increasing refractory nature of gold ores being treated. This is despite ores such as those at Kalgoorlie having required roasting for liberation since the last century. Papers on refractory gold treatment have examined the characteristics of refractory ores and the causes of reduced recovery (eg La Brooy 1994), the available technologies and their relative economics eg Litz 1990), and the selection of a suitable process route (eg Nicholson 1993, Weston 1994). The most comprehensive collation of data on such processes is provided in the different editions of Randol. A variety of classifications and definitions of "refractory ore" have been published. Due to the many factors which can impact on the recovery of gold it is perhaps not feasible to develop a universal characterisation that can be applied to all gold bearing rocks. La Brooy et al have provided the framework for characterisation shown in figure 1.

Jan 1, 1995

By S. R. LaBrooy, M. C. Costello, A. C. Bax

Nickel is present in a number of gold ores in Australia, Africa and the United States. The effects and behaviour of the nickel during the cyanidation and adsorption processes, and also during the elution and electrowinning processes have been examined by a number of researchers, usually as a part of a larger investigation. This paper examines the available data on the behaviour and effect of nickel during cyanidation and its associated unit processes. The presence of nickel is often not considered to be particu­larly important as it does not cause the same degree of problems across the circuit as those experienced in the presence of copper. It can however lead to increased cyanide consumption during leaching, and reduced adsorption of gold onto carbon. A proportion of nickel cyanide may be removed from carbon prior to elution by carrying out a hot (90° C) acid wash. The nickel which remains on the carbon will be partially eluted during the main elution step, and, dependent on its concentration in the pregnant solution, part of it may be deposited during electrowinning. There is always a risk that any nickel remaining on the carbon after the elution step will be reduced to metallic nickel during the regeneration step. This may ultimately result in an increasing base level of nickel on the carbon, as metallic nickel is insoluble in both cyanide and hydrochloric acid.

Jan 1, 1995

By Kunibert Hanusch

Copper in recycling material is accompanied by various groups of metals: 1) Metals which are much more negative than copper, such as Fe, Al, Si, P, Be They are mainly removed by fire refining during the recovery of copper and leave the process in form of slag. 2) Metals which are more positive than copper or difficult to separate by fire refining and which are partly reduced together with the copper. These metals are for example As,. Sb, Ni, Ag, Pb, Zn, Sn. They are enriched in intermediate products and recovered from these or remain for their major part in the fire-refined copper and can be separated by electrolytic refining and recovered from the electrolyte or anode slime. This report describes the process of Hüttenwerke Kayser AG in Germany and illustrates how considerable returns of material are partly required to separate or recover associated metals. They are finally removed in saleable products.

Jan 1, 1995

By H. M. Castrantas

Caro's (peroxymonosulfuric) acid has been reported to destroy WAD (weakly acid dissociable) CN-but, until recently, the technology has not been demonstrated in other than a laboratory setting. During the last two years, Caro's acid has been shown to successfully detoxify WAD CN-in tailings at two large North American gold mines. Using on-site FMC generators, Caro's acid reduced the WAD CN-from 40-55 ppm to below 20-35 ppm WAD CN-, the target range for the two mines. The detoxification costs using Caro's acid were less than 50% of the treatment cost of using hydrogen peroxide, the previous oxidant of choice. In addition to the considerable savings in CN-detoxification costs, lower WAD CN-values were achieved and the detoxification time with Caro's acid was greatly reduced compared to hydrogen peroxide.

Jan 1, 1995

By James F. Holzbach

Although Disputes Review Boards have been used for some time, they had not received wide publicity at the time Monroe County first used one. Public owners frequently resist adopting new contracting practices. This paper discusses an owner's experience with Dispute Review Boards, from learning about them to their use on two (2) projects. The experiences of potential and actual contractor claims are compared to a claim on an earlier contract and the ensuing litigation. Suggestions for possible use for Owner-Engineer disputes and recommendations for use are provided.

Jan 1, 1995

By Brian V. Roulston

Potash is Canada's leading industrial mineral in terms of value of production, with 11.1 M tonnes of muriate of potash produced in 1992 for a value in excess of $1 billion U.S. Each tonne of potash produced generates about 2 tonnes of waste salt, together with slimes and brine. The disposal of these waste products, particularly the salt and slimes which are discharged on the surface, has recently become an environmental concern. This concern is forcing companies and regulatory authorities to review disposal practices. In New Brunswick, on Canada's east coast, Potash Company of America operates a mine at which 2 M tonnes of potash ore and 0.5 M tonnes of rock salt are mined each year. The mine is situated in an environmentally sensitive area, noted for its dairy farming and salmon angling. In such an area it was recognized that the storage of waste on surface would be unacceptable, and the mine was designed around this principle. Three main waste streams - salt, slimes, and brine - must be managed as an integral part of the mining system. Around 1.5 M tonnes of fine salt tailings from the milling process and the rock salt screening operation, are sent directly to the active cut-and-fill potash stopes to be used as backfill. Slimes and excess brine from the mill are piped underground as a slurry to be discharged into one of the basin shaped stopes created by mining of the rock salt. While the slimes settle out, the clarified brine is withdrawn from part of the stope to be pumped to surface as a feedstock for the evaporator - a process which recovers the contained potash values in the brine. By designing a system which integrates the mining, processing and disposal of all product streams, and by careful production planning, it has been shown that zero effluent potash mining is possible and points the way for the industry in the future.

Jan 1, 1995

By Hans von Michaelis

Very little has been published about Cia de Minas Buena­ventura. Don Alberto Benavides Quintana, now in his seventies, founded the company in 1953. This venerable gentleman is a Doyon of the Peruvian mining industry and more has been known about him than about his company. Buenaventura is a highly profitable gold producer with excellent potential to expand gold production in joint ventures with Newmont, Southern Peru Copper (ASARCO), and BRGM as well by developing their own new gold mines. On September 15, The Wall Street Journal published an article titled "Peru's Big Rebound Sets Off Foreign Investors' Enthusiasm."

Jan 1, 1995

By Luis Tondo, Gary Johnson, Steve Morell

High pressure grinding rolls have been demonstrated by numerous researchers, and at a number of commercial installa­tions to be power efficient comminution devices. They have become almost "standard equipment" in the grinding of cement clinker. However, the technology has been relatively slow to catch on in the mineral processing industry. Part of this may be due to the fact that this relatively expensive machine has not been incorporated into the plant flowsheet so as to fully exploit its power efficiency, and therefore realise the maximum economic benefit. This paper describes the results of a pilot scale test program designed to evaluate the performance of the device with the aim of developing a circuit configuration that better exploits the inherent power efficiency of the machine. The results of the test program clearly show that power savings of about 50% over conventional technology are achievable when the machine is made to produce the final product grind size.

Jan 1, 1995

By David Martin Menne

Carbon or attrition can be expected to be affected by • Agitation power • Vessel volume • Carbon and Suspension densities • Kinematic viscosity of slurry • Carbon particle size • Impeller diameter • Impeller rotational velocity • Fractional carbon [volume] concentration • Gravitational constant

Jan 1, 1995

By C. A. Fleming, R. G. Williamson

Process development for Eskay Creek began in early 1990 at Lakefield Research, and was initially focused on producing a high-grade/high-recovery concentrate for sale. Owing to the significant base metal sulphide (Cu, Zn, Pb) content of the ore, such a product would have made an attractive feed to a copper smelter, while a gravity and/or flotation flowsheet would have circumvented many of the environmental permitting problems that were anticipated. In the event, it was found that neither gravity nor flotation (nor even a combination of the two) was able to produce a discardable tailing and, in late 1990, attention shifted to the development of a hydrometallurgical flowsheet.

Jan 1, 1995

By Mike Wardell-Johnson, Chris Campbell-Hicks, Craig Bitmead

Faster, simpler, cheaper and more accurate cyanide ex­tractable gold procedures are now available for grade control assay. Cyanide 'bulk leach extractable gold' or BLEG assays have previously been seen as desirable, due to the large sample size that can be treated, but not in common use due to the 24hr total assay time required. Sample sizes from 50g to several kilos can now be accurately assayed in less than 4 hours total time with the larger sample size increasing accuracy, without loss of precision, while greatly reducing the 'nugget effect' or coarse gold bias. Typical assay size is 200g, equivalent to 4 x 50g Fire Assays or 10 x 20g Aqua Regia Assays. Ongoing modifications and refinement of the procedures and reagents used also indicate applicability to the treatment of coarse gravity gold where substantial savings in both capital and operating costs for these circuits are possible. The successful use of this cyanide assay at the Bannockburn and Windine Well operations are cited to-gether with a compre­hensive comparative testwork program by Newcrest. Testwork at Gidgee and Lynas Gold operations is currently being initiated. Other operations using the method include Red Dome and Kidston; with Placer(Granny Smith) and PMA's Palm Springs operations to commence shortly.

Jan 1, 1995

By A. R. Biggart

Twenty-sixth Sir Julius Wernher memorial lecture, presented at the Tunnelling '94 symposium held in London, 5-7 July 1994. In describing 18 projects with which he has been involved over a period of 36 years, the author aims to illustrate how technological change and an increase in scientific knowledge have influenced tunnelling practice, which he nevertheless maintains does continue to be an art. Tunnels discussed are: the Silver Street, Blackfriars, Whitechapel, St. Paul's and Waterloo Post Office tunnels, 1958-1969; metro tunnels on the Victoria Line, London, 1962-1970; the introduction of tunnel boring machines (TBMs), 1971-1978, in the Empingham reservoir diversion tunnels in Rutland, the bentonite tunnelling machine experiment at New Cross, the Southern tunnel water main section of the London Ring Main and the Warrington sewer in Cheshire; tunnels in rock 1975-1981, for the Lune Wyre and Megget Manor aquaducts, Weymouth sea outfall and Bristol interceptor sewer; Priestley TBM tunnels 1969-1982; the Greater Cairo wastewater project 1983-1987; Anacostia River crossing, Washington DC 1985-1987; the Channel Tunnel 1987-1992; and the Storebaelt eastern tunnel in Denmark, 1992-1994.

Dec 1, 1994

By P. J. O'Connor, V. Gallagher

examined analytically in relation to the ratio of the

Dec 1, 1994

By G. Zhan, P. Mousset-Jones, G. Danko, J. J. K. Daemen, C. Mezei

Paper presented at the conference Risk assessment in the extractive industries, held in Exeter, 23-24 March 1994, and first published London: IMM, 1994, preprint volume. 18pp., 12 refs. (Originally entitled: Tunnel roof diagnosis using a robotic sensor test bed.) An integral roof diagnosis method is proposed to assist in assessment of risk regarding the stability of an excavation. A Robotic Sensor Test Bed (RSTB) is being developed for the characterisation of roof stability. The sensor test bed consists of a sonic/ultrasonic wave response sensor, a laser surface profiler and a surface temperature sensor. These sensors are mounted on an articulated robot manipulator for performing remote-controlled or fully automated diagnoses. A number of laboratory and field sonic/ultrasonic tests were conducted. A high-energy ultrasonic transducer and an impact device were used to resonate rock slabs. The fracture depths of the slabs were found to be inversely related to the measured resonance frequencies. The agreement between identified and actual dimensions was acceptable. Field tests also showed that loose rock on the surface can be clearly distinguished from solid formation by comparing their wave responses. The robotic laser profiler part of the RSTB was used to measure surface geometry. Different scanning methods are being developed to achieve the fastest and most precise measurements and to provide pertinent information about rock joints and major fractures

Dec 1, 1994

By J. L. Robson, C. M. Bristow

mass flow rates of particles and air (the loading ratio).

Dec 1, 1994

By L. D. Smith

Paper presented at the conference: Risk assessment in the extractive industries, held in Exeter, UK, 23-24 March 1994, and first published London: IMM, 1994, preprint volume. 22pp., 15 refs. The concept of risk is well established in the mining industry but it is difficult to provide a quantitative assessment of risk. A discussion is presented of the significant sources of risk in a mineral project and how they are addressed. The discount rate is examined as a fundamental means of reflecting risk in discounted cash flow evaluations. Current industry practice is discussed and a methodology for the analysis of risk levels is proposed which assesses the constituent components of the discount rate (real interest, mineral project risks and country risk)

Dec 1, 1994

By G. E. Pearse, comp.

Questions from the conference delegates and replies by the papers' authors are summarised for sessions on hydropower, metro/rail and water/waste tunnels, tunnel-boring machines, environmental issues, research and case histories, design, and tunnel machinery, with reference to papers on tunnels in Lesotho, Nova Scotia, Italy, UK, Sweden, Kenya, Massachusetts, Germany, Norway, Taiwan, Switzerland, Greece, Malaysia, Australia and Texas.

Dec 1, 1994