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Evaluation of Comminution Circuit Design for Sustainability Using EcoNomicsTM

Sep 13, 2010

By D van der Wal, R Dobbe, K Moeller

"Ore mineralogy and texture are primary variables controlling mill recovery efficiency in flotation plants. However, tracking daily variations of key mineralogical characteristics such as species-by-species liberation is not possible with current on stream analysers and assay lab techniques. In addition, traditional plant mineralogical analysis limited by long data turn-around times from central analysis laboratories typically provides only a time-averaged view of mill performance, e.g. by means of monthly composite feed, con or tailings analysis.This paper presents the results of a development and first field test of an on-site Automated Mineralogy solution (MLA or QEMSCAN) with the specific goal of monitoring recovery variation, ore quality and flotation performance on a mineral species-by-species and day-by-day basis, from up to twelve million direct particle observations per month. The trial was performed at a Pb/Zn-Ag operation in the US from November 2012 to April 2013. The focus of the study was three-fold: to validate the robustness of equipment and operational procedures for daily use by mine site technicians at a remote mine site to develop a methodology to boil down hundred-thousands of Automated Mineralogy particle data from size-by-size con and tailings samples to a couple of numbers meaningful to chief metallurgists to monitor recovery trend changes and correlate these to changes in the feed properties and/or flotation efficiency.The study focused primarily on the Pb/Ag rougher-concentrator circuit. Ten polished blocks of two and three size fractions of con and tailings were prepared by mine site technicians during a daily twelve hour shift. Eight hours of daily measurement time by the instrument revealed an estimate of the dayÆs recovery performance, ore quality and flotation performance for Freibergite (Ag-species) and Galena (Pb-species), within 36 hours from initial sampling. Data quality was assessed by means of calculated versus measured assay reconciliation. Cumulative sum curves of recovery performance, ore quality and flotation performance reveal trend changes with a frequency of 1 to 4 weeks. These were correlated to cumulative sum curves of e.g. locked and slimed particle classes of the mineral species of interest, attempting to identify a possible root cause of recovery performance trend changes. Systematic over-grinding and flotation chemistry issues were the primary causes of below average plant operations during the trial.CITATION:van der Wal, D, Dobbe, R and Moeller, K, 2013. Development of an on-site mineralogy solution for metallurgists, in Proceedings MetPlant 2013, pp 126-132 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Jul 15, 2013

By W. F. Cannon

Many high-grade manganese deposits of the world occur in marine transgressive sedimentary sequences deposited on stable platforms. These include the Nikopol and related deposits in the Soviet Union and Groote Eylandt, Australia, among others. We suggest that the Atlantic and Gulf Coastal Plains and the vast area of Cretaceous rocks in the middle of North America are favorable provinces for sedimentary manganese deposits because regionally transgressive units are widespread. North America has 16% of the world's land area but only about 0.2% of known high-grade manganese reserves. This disparity is difficult to reconcile in view of the fact that large areas of North America are underlain by rocks that we consider at least broadly favorable to contain manganese ores, and we suggest, therefore, that important high-grade deposits remain to be found in North America.

Jan 1, 1982

By W. C. Phalen

During the search for deposits of soluble potash salts in the United States, carried on by the United States Geological Survey, much infor- mation was collected on the salt resources and industry of the United States. The more important features of the information thus gath- ered, compiled, and digested may be classified under five headings, as follows: 1. Geology of the salt deposits of the United States. 2. Theories relating to the origin and formation of salt deposits. 3. Chemical composition of saline materials in the United States, principally rock salt and natural and artificial brines. 4. Statistics of salt production in the United States. 5. Technology of salt production. The first four items are not discussed in this report, but their treatment will comprise a separate report published by the Geologi- cal Survey, which will supplement this report, relating to salt- making processes, and will describe comprehensively the salt resources of the United States. Persons desiring a copy of that report should apply to the Director of the United States Geological Survey, Wash- ington, D. C. In addition to the discussion of processes, this report gives a brief description of the more important sources of salt in the United States. This description has been abstracted from the much length- ier description contained in the report to be published by the Geo- logical Survey.

Jan 1, 1917

Council for 1999/2000 President M.H. Rogers President Elect Dr L.A. Cramer Vice Presidents Senior A.A.B. Douglas Junior S.J. Ramokgopa Immediate Past President J.R. Dixon Honorary Treasurer J.A. Cruise [ ] Annual report In accordance with the current management policy, this report on the activities of the Institute is presented under eight main headings: 1. Interests of Individual Members 2. Technical Meetings 3. Publications 4. Regional Development 5. Engineering Science and Technology in South Africa 6. International Liaison 7. State Liaison 8. Management and Administration.

Jan 1, 2001

By D. Seneviratne

Iron transfer from the pregnant leach solution (PLS) to the electrolyte can have a major economic impact on solvent extraction (SX) operations. High iron transfer will lead to greater operational costs, due to increased reagent consumption through electrolyte bleed and make up, or increased power costs due to decreased electrowinning current efficiency. Bioleaching of low-grade copper sulfide ore from the Kennecott Utah Copper Mine was investigated in a large scale piloting program including SX and electrowinning. Plant data and lab test work conducted throughout the course of operation, show that the unique containing PLS high ferric iron with high pH can lead to lower Cu: Fe selectivity than is typically seen in traditional copper SX operations. The impact of high ferric iron on the plant operation, and methods to reduce iron transfer will be discussed. Special considerations need to be taken for plant operating conditions and selection of SX reagents (including both extractant and aromatic content of diluent) based on the feed PLS characteristics.

Feb 23, 2014

[COUNCIL FOR 1992/93 President J.P. Hoffman President Elect Dr H. Scott-Russell Vice Presidents Senior J.A. Cruise Immediate Past President R.D. Beck Junior D.A.J. Ross-Watt Honorary Treasurer J.A. Cruise Members of Council Dr N.A. Barcza B.R. Broekman G.A. Brown P.M. Craven Prof. R.J. Dippenaar J.R. Dixon* A.A.B. Douglas B.R. Fleetwood Dr R.V.R. Handfield-Jones P.R. Janisch * co-opted P.J. Knottenbelt R.P. Mohring J.L. Nel* K.C. Owen P.D.K. Robinson K.A. van Gessel D.J. van Niekerk C.J.C.J. van Vuuren* P.M.T. White]

Jan 1, 1993

By Alex G. Sciulli

This paper discusses the primary computer programs used by the Mine Safety and Health Administration's Bruceton Safety Technology Center to evaluate coal refuse disposal plans. These programs are currently being used by private consultants, government, and the coal industry for today's coal refuse disposal problems. This paper outlines five programs, their special features, and their importance in the design and construction of coal refuse disposal facilities. The purpose of the paper is to present the general steps necessary in the computer-modeling of each program. The programs that are discussed include BISHOP, STABL, RWE, DAMS2, and HEC-2, which cover the subject areas of slope stability, hydrographs, flood routing, and water surface profiles.

Jan 1, 1983

By Gilbert DJ, Lemon NM

A case history of a two year study of low grade ores in the Middleback Range area with the objective of defining possible areas of interest from a combination of geological- petrological-metallurgical criteria. Covering the general geology of the area and ore types; the results of metallurgical testwork and the pattern of evolution of these tests; the petrological explanation of the results of the testwork; the culmination of the work in the selection of areas of best potential for more intensive work. Jaspilites consisting of magnetite, hematite and limonite with quartz and silicate-carbonate-sulphide minerals are hosts to high grade iron mineralisation but also constitute a large low grade iron Reserve.

Jan 1, 1975

By Joseph G. Wargo

A meteoric rise in selling price has revived gold exploration activity throughout the world. In the United States the effort is, in large measure, channeled toward discovery of disseminated gold deposits such as the Carlin-type, i.e., with size and grade characteristics similar to Newmont's Carlin mine in Nevada. The subtle surface indications characteristic of Carlin-type gold mineralization have been examined by a number of geologists, and the more obvious prospects have been tested by surface sampling and drilling. It is likely that most of these readily recognizable deposits have already been found and, as a consequence, prospectors are now entering a new, second stage of exploration for Carlin-type and related disseminated gold deposits.

Jan 9, 1979

By J. W. Choung, J. A. Finch

Acid rock drainage (ARD) is a recognized environmental challenge facing mining industries. An ambient temperature ferrite (ATF) process has been investigated for treating ARD. Most nonferrous metal and calcium ions present in typical ARDs were found to be detrimental to the ATF process. Three approaches were examined, including C02 aeration, addition of complex agents and use of magnetic seeds. By introducing magnetic seeds in the ATF process, the interferences were minimized and all the precipitates formed with lime neutralization were magnetically recovered from a simulated ARD. The residual concentrations of major metal ions in the treated water were environmentally acceptable. The XRD pattern confirmed the spinel ferrite crystal structure of the products

Jan 1, 2000

Ore reserve estimates form a basis for strategic mine planning at Argyle Diamonds open pit and alluvial operations. Most ore reserve statements are mainly concerned with resource tonnage and grade. Because diamond deposits are low grade, high value resources, diamond quality ($/carat) is also an important parameter. Relatively large variations in quality and/or grade can occur. These variations must be taken into account before the resource potential can be fully assessed. Computers (HP9000 and PC's) are utilised to compile resource inventories. Resource inventories are then ranked on an economic basis. This paper discusses the methods used to compile resource inventories and explains how these are then used to present ore reserve estimates in terms of resource potential.

Jan 1, 1990

By R H DAVIES

Peak Gold Mine is a new gold and base metal mining project being developed by Enterprise Metals (a 100 per cent subsidiary of CRA) at Cobar in the centre of New South Wales. The Cobar district has a long history of copper and gold mining operations stretching back to the 1870s. Extensive gold and base metal mineralisation was discovered at the Peak in 1981 below a series of gold mines which had been active around the turn of the century. Evaluation of the deposit through the 1980s led to CRA's decision to develop the project for production at a capacity of 450 000 tonnes per annum in late 1992. The project has been developed with a green fields approach despite the long history of mining in the local area. This approach has lead to several innovative ideas being trialed at the site which are expected to result in the operation being a low cost producer of gold and base metals.

Jan 1, 1992

By William K. Tolley

The U.S. Bureau of Mines (USBM) is investigating hydrometallurgical processing techniques to recycle metals from semiconductors and other advanced materials. Cadmium and tellurium were recovered from mixed CdTe/CdS scrap produced in the manufacture of thin-film photovoltaic devices. Selective cadmium dissolution was achieved using oxygen-pressure leaching in dilute sulfuric acid. Leaching the scrap for 90 min at 110° C in 2.2NH2S04 under 400 psig 02 yielded 97% Cd extraction; however, cadmium content of the residue ranged between 4% and 7%. Soluble iron was added to the lixiviant to catalyze oxidation of the CdS component. Tellurium and sulfur remained in the leach residue primarily in the elemental form. The iron and tellurium were removed from the cadmium-rich leach liquor by adjusting the pH to 5.3. The cadmium was recovered as cadmium sulfate crystals by evaporating the solution. Alternative leaching and purification schemes are discussed.

Jan 1, 2010

By K. Heasley, A. Yassien, A. Khair, S. Peng

There are three major components of a fully grouted roof bolt which primarily determine its ability to develop and sustain load: the steel rebar, the resin annulus, and the rock/grout interface. The untensioned, fully grouted roof bolt is subjected to loading only when the surrounding rock deforms. Vertical rock deformation is generally a result of strata sagging and bedding plane separation, whereas horizontal deformation is typically a result of bedding plane sliding. These two types of deformation create different types of internal loads with-in the roof bolt, tensile stress for vertical rock deformations and shear stress for horizontal rock deformations. Also, as a result of the mutual load transfer between the rock and bolt, shear stress will be developed along the grout/rock interface. According to the exact bolt loading conditions, different failure modes may occur: bolt axial failure, bolt shear failure, and shear failure along the grout/rock interface. Understanding these possible failure modes and their root causes is the key to eliminating roof failures in underground mines employing fully grouted resin bolts. Using ABAQUS 5.8, a finite element model was developed to simulate the components of the fully grouted bolt and its interaction with the surrounding roof strata. Several models were conducted to investigate how load transfer occurs between the rock and the bolt under different geological and mining conditions. The effects of bed-ding plane location and properties, and strata sequence on bolt stability were studied. Also, the effects of hole roughness on bolt stability were discussed. Bolt axial failure was not observed within the range of the studied parameters; however, a combination of high overburden depth, a bedding plane located at 2 to 3 ft from the roofline or a low coefficient of friction along the bedding plane caused strata sliding and shears failure in the bolt. Also, in the case of a weak immediate roof, the shear stress at the grout/rock interface could exceed its ultimate capacity lead to slippage.

Jan 1, 2004

By R. W. Crocker, H. H. Clark

The purpose of the investigation discussed in this bulletin, one of a series dealing with the use of electricity in mines, was to study the various means and methods used to confine the flashes that occur when a switch carrying electric current is opened. The flash result- ing from the opening of a 250-volt direct-current circuit carrying more than half an ampere will ignite explosive mixtures of mine gas and air. An equally dangerous flash may be produced by even less cur- rent from a 500-volt circuit. Few mine electric circuits carry less than half an ampere when in use. The need of protecting the switches of such circuits in places where gas is likely to be present is therefore obvious. Two general methods have been proposed for preventing switching flashes from igniting gas surrounding the switch. One method is to inclose the switch in a casing provided with openings that are covered with wire gauze or otherwise designed and equipped for preventing the passage of flames from the interior to the exterior of the switch casing. Switches so protected are called explosion-proof switches. The second method is to immerse the switch contacts in oil to a depth sufficient to quench any flash that may occur when the switch is operated. Switches so protected are called oil switches. The success of the first method of protection depends upon the proper design and construction of the switch casing. It is essential to the successful operation of the second method that the switch contacts be surrounded by the proper kind of oil in good condition. There are several ways in which an oil switch may be deprived of its protective feature. The oil tank may not be filled or, if filled, the oil may leak out or be spilled. The oil tank may be removed (in some designs) and not replaced or through neglect the condition of the oil may become such that it is no longer an efficient protection. While such contingencies are not likely to occur, and although oil switches may be so designed that the loss of oil is not probable, nevertheless, as compared with oil switches, explosion-proof switches seem to

Jan 1, 1913

By A. L. Field

This general subject has been so thoroughly discussed by Dr. Herty and his associates, especially with regard to the degree of oxidation of the metal at the time that the silicon pig or spiegel is added, that I am not going to spend much time on that today. I should like to propound a question, which is based on my own observations made some years ago while with a large alloy-steel company which had two open-hearth furnace plants. It is true that one of these plants was not engaged particularly in making alloy steels, but there were certain relations between slag and metal composition which appeared to me to be entirely different in the two plants. I have an explanation for it that is more or less incomplete, but possibly Dr. Herty or Mr. Reinartz or some of the others may be able to complete it. Suppose we take our three layers; the metal on the bottom, on top of that the slag, and on top of the slag, the gas. We cannot overlook the gaseous phase. Regardless of the effect of the iron oxide in the slag on the rate of carbon elimination—and that, of course, is rather important in alloy practice since it is not desirable to have the carbon dropping too rapidly at the time the deoxidizing is had in the furnace—it will probably be admitted that it depends on the iron oxide in the metal for a given carbon oxide. I have seen cases where with approximately identical metal and slag compositions one furnace would work twice as rapidly as another in removing carbon. Of course, there is some explanation of this in what others have already said, that the question of the exact lime and silica content of the slag determines the activity and viscosity of the slag; but I am convinced, without having reviewed the actual records since I was asked to make this talk, because they were not available at the time, that the slags in these two furnaces were not materially different. Putting it another way, one furnace would have

Jan 1, 1935

By A. L. Field

This general subject has been so thoroughly discussed by Dr. Herty and his associates, especially with regard to the degree of oxidation of the metal at the time that the silicon pig or spiegel is added, that I am not going to spend much time on that today. I should like to propound a question, which is based on my own observations made some years ago while with a large alloy-steel company which had two open-hearth furnace plants. It is true that one of these plants was not engaged particularly in making alloy steels, but there were certain relations between slag and metal composition which appeared to me to be entirely different in the two plants. I have an explanation for it that is more or less incomplete, but possibly Dr. Herty or Mr. Reinartz or some of the others may be able to complete it. Suppose we take our three layers; the metal on the bottom, on top of that the slag, and on top of the slag, the gas. We cannot overlook the gaseous phase. Regardless of the effect of the iron oxide in the slag on the rate of carbon elimination—and that, of course, is rather important in alloy practice since it is not desirable to have the carbon dropping too rapidly at the time the deoxidizing is had in the furnace—it will probably be admitted that it depends on the iron oxide in the metal for a given carbon oxide. I have seen cases where with approximately identical metal and slag compositions one furnace would work twice as rapidly as another in removing carbon. Of course, there is some explanation of this in what others have already said, that the question of the exact lime and silica content of the slag determines the activity and viscosity of the slag; but I am convinced, without having reviewed the actual records since I was asked to make this talk, because they were not available at the time, that the slags in these two furnaces were not materially different. Putting it another way, one furnace would have

Jan 1, 1935

By Danuta Szyszka

This paper presents results of tests performed to determine minimum concentration of a surfactant used at which coalescence of air bubbles during flotation has low probability to occur. The measurements of the critical coalescence concentration, also known as CCC, were carried out in a device consisting of glass cell into which air was pumped by peristaltic pump through capillaries. The flotation foam was recorded with a high resolution digital camera. Basing on the video records, average diameters of the air bubbles were measured and the values obtained were subsequently used to determine the CCC values. The author of paper determined the CCC values of surfactants tested using the linear regression method, and subsequently analyzed the results obtained. To define initially the capability of a tested surfactant to flotation, efficiency of multiparticle model flotation and flotation of individual size fractions were determined in a flotation apparatus for laboratory use in the presence of only foam making agent at CCC value pre-determined during the tests previously carried out. The tests of coalescence phenomenon were carried out with use of selected flotation frothing agents.

Jan 1, 2014

By H. H. Lowry

Science attracts the attention and interest of an individual or an industry in general only in proportion to the apparent direct application to its immediate welfare or benefit. Engineering accomplishments, as aphlied science, therefore receive more recognition than the scientific discoveries on which they are based. Even self-evident truth needs endless repetition before recognition: engineering as applied science cannot advance beyond the science on which it is founded. Scientific research, and discovery, is sometimes forced by the limitations recognized by those active in its development for the use of society and industry and sometimes results from an apparently superficially illogical curiosity about natural phenomena. Research has received inadequate support except in industries born in the laboratory, the chemical and electrical industries, from which many lessons might well be drawn by their elder associates. The rapid growth of these industries has been largely due to close cooperation of scientists and engineers. Most rapid advance is made when the research worker and the engineer keep in close touch with each other's ideas and problems. Many of the developments of modern industry are based on discoveries buried for years in scientific journals because the "time was not ripe" at their discovery. The situation with regard to utilization of coal is quite the oppositre. The fundamental facts in regard to the scientific aspects of the problem of developing the energy from coal are scarcely known. The engineer, without much scientific cooperation, has accomplished much in increasing the number of kilowatt-hours per pound of coal from 0.31 in 1919 to 0.69 in 1934, in increasing the 1000 gross ton-miles of freight hauled from 12.2 to 16.4 per ton of coal in the same period, in fuel economy in production of coke, and in developing the production of motor fuel in Germany and England by hydrogenation of coal. This lack of scientific research on the utilization of our most important natural resource, coal, has been due undoubtedly in large part to the reluctance of investigators to study the interrelationships involved in the complicated processes in which coal is used. These complexities are made

Jan 1, 1936