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By J. A. Finch

"A method of sampling and presenting bubbles for imaging for use in full-size flotation cells is described. The device (bubble viewer) comprises a tube attached to a sealed glass viewing chamber. The assembly is first filled with frother-containing water (to prevent coalescence) and the tube immersed at the desired location below the froth. For a few minutes bubbles are collected in the viewer free from slurry and are readily imaged. To reduce bubble overlap and the problem of defining the plane of view, the viewing chamber has a sloped side. Bubbles rise, encounter this slope, spread into a single plane and slide up. This simple expedient virtually eliminates overlap and provides an unambiguous focus plane - the underside of the sloped glass. The bubble image is captured and processed to give size data. The bubble viewer has been employed at several concentrators on different types of flotation cells. Examples of the images are given. The impact of position in the cell and the effect of changing gas rate on bubble size are illustrated. This technique provides a sensitive measure of the effects of process variables on bubble size.INTRODUCTIONDespite the extensive use of flotation in the mineral processing industry, the methodology employed for cell design is largely based on empirical rules rather than on first principles. One of the main reasons for this state of affairs is that the local flow structures encountered in industrial-scale machines are very complex. These flow structures are difficult to simulate under the controlled conditions of the laboratory and the difficulty to solve the mathematical models that treat the randomness of such flows also mean theoretical treatment is limited. Understanding flotation cell hydrodynamics requires reliable data, which involves the implementation of measurement techniques capable of performing both at the laboratory- and the industrial-scale, In addition, it is desirable that such techniques are amenable to automation to reduce extensive manual intervention in the data collection process."

Jan 1, 2002

By L. Hanschar, C. Bwalya, E. Mokola, K. Musonda, A. Makayi

This paper describes the installation, commissioning and operation of porous plugs featuring nitrogen gas purging in both Anode Furnaces at the Kansanshi Copper Smelter (KCS), a greenfield copper smelter which commenced operation in March 2015. The decision to install porous plugs was taken in November 2016 and the facilities were successfully commissioned on both anode furnaces in October 2017. The project was successful and has demonstrated the following process improvements: 12.2% reduction in main burner fuel consumption Larger average charge size, due to fewer accretions; 17 minute decrease in average refining cycle times Improvements in slag skimming operations Improved casting rates INTRODUCTION Porous plugs The application of porous plug technology in copper smelter anode furnaces is well established around the world. Vukovic and Gamweger (2017) and Wallner (2004) noted that the stirring and mixing action induced by the injection of inert nitrogen gas into the molten copper via porous plugs has potential benefits in the following areas: Homogenization of the temperature and composition of the molten copper resulting in Reduced fuel consumption Less tendency to overheat slag (reduced risk of refractory attack) Less slag produced with a lower degree of oxidation (lower rate of refractory wear) Less tendency for buildups to form Improved environmental performance (produce low sulphur blister at Peirce Smith converters) Elimination of buildups inside the furnace and potential for larger charges per cycle Reduced processing times and potential for shorter cycle times More efficient skimming of anode slag Shorter skimming time Less copper carry over to Peirce Smith converters Very little slag remaining in the furnace (reduced potential for buildups to form)

Jan 1, 2019

By Sam Palombo, James José Varela

"Washing can be defined as the process used to eliminate or reduce the dirt (presence of fines or slimes) of one material. It is also the basic and oldest process applied to ore preparation for further concentration. This process, in combination with commnution and screening, form the so called washing plant and in many cases produce end products. This work describes the factors that influence the performance of the washing process and main washing technologies used in the mineral processing industry.The Hydro-Clean represents, since 1998, a state of the art technology in this area and is comprised of one of the most innovative solutions developed at HAVER & BOECKER. HAVER & BOECKER design and manufacture technology for mining and related industries. Today the Hydro-Clean is manufactured and sold throughout the Haver Screening Group (HSG) which is comprised of HAVER & BOECKER Maschinenfabrik Münster, HAVER & BOECKER Latinoamericana – Brazil and W.S. Tyler Canada.The Hydro-Clean is a washing technology based on utilization of high pressure water jets. To follow we will discuss how the Hydro-Clean’s different modes of operation result in several advantages related with mine waste reduction, recovery of saleable product, lower capital costs, superior washing results, less stress for the material, a wider range of application and less maintenance cost. Aside from these positive factors, its lower operation costs related to the consumption of energy and water are presented. It is important to note that the quantities, tonnages, data and management concepts presented in the paper are accurate for the time of writing and are subject to change and modification as operations progress."

Jan 1, 2009

By A. D. Hunt

THIS PAPER will review Canada's fossil fuel situation as we understand it today and indicate some of the options available to meet our energy requirements during the next 15 years. It would therefore be helpful to examine Canada's total energy requirements and discuss the un certainties of the data base on which we must base future energy investment decisions. On the world scene, Canada is at the top of the energy-consuming nations, using about 49 bbls of oil equivalent per caput/ year. This appears to be slightly ahead of the U.S. and of course much higher than that of many countries. It is generally accepted that there is a more or less direct relationship between energy consumption and material standard of living. However , as we know, Canada, when compared with other industrialized countries on a GNP, an individual-income or some other standard basis, is lower in the list. This situation may be explained by our more severe climate and a relatively small population distributed over a land mass second only to that of the Soviet Union.

Jan 1, 1977

By Robert J. Kuhne

The Iron Ore Company of Canada has successfully employed advanced process control (APC) to optimize the operation of their induration machines. A significant increase in machine throughput and a reduction in fired pellet quality giveaway were observed following the APC implementation on all six machines. This paper discusses the opportunity for process control optimization in induration, reviews the property estimation and multivariable control technologies, and describes how the IOCC control strategy captured this opportunity. APC performance data is presented. The dependence of APC performance on control room operator acceptance, process equipment and instrumentation is highlighted.

May 1, 2007

By Eric Konigsmann

"Omai Gold Mines is a large scale open pit gold mining operation located in central Guyana, South America with a 12,000 tonne per day milling facility. Mill operations were initiated in December 1992 with commercial production beginning in January 1993. The entire operation employs approximately 120 expatriates and some 800 Guyanese nationals and is expected to produce in excess of 250,000 ounces of gold per year. The total mineable reserves contain 2.5 million ounces of gold with a projected mine life of twelve years.The milling circuits feature an SABC grinding circuit, gravity concentration and a conventional CIP gold recovery circuit. This paper will review the mill start up and ""run-in"" phase during the first year of operation. Emphasis will be placed on descriptions of start up problems and circuit modifications, mill performance trends in 1993, and personnel training and development. An outlook for 1994 is also given.IntroductionOmai Gold Mines is a large scale, open pit gold mining operation located in the Potaro district of Guyana, South America, some 160 kilometers south of the capital city Georgetown. Although there are numerous small scale gold mining ventures in Guyana, particularly with the dredging operations on the rivers, Omai is the first hard rock, open pit mine to be developed in the country. At present, this mining operation is one of the largest gold mines in South America.The Omai gold deposit has been exploited for over one hundred years. In the late 1800's, a German syndicate used hydraulicing with subsequent gravimetric separators such as sluice boxes and trommel screens to recover gold from saprolite, a soft, oxidized, claylike mineral which covers much of the claim area. Through the early 1900's and up until the 1950's, numerous mining companies including Anaconda Mining Co. Ltd. explored and drilled the Omai deposit but the technology and low gold price of the day made the reserve uneconomic to develop."

Jan 1, 1994

By Witold J. S. Ostrowski

The shaft structure being part of an underground mine, depends on programned functional duties, and on geological and hydrological conditions. The majority of Canadian metal mine shafts are in hard competent igneous rocks, which are in an elastic state of equilibrium around the excavation. Others penetrate soft sedimentary or very weak water-bearing rock formations in which the equilibrium varies from plastic to hydrostatic. Knowledge of how to interpret the underground conditions, determine acting forces and design proper structures is essential for the production and safety of the future mine.

Jan 1, 1973

By P. Choquet, F. Miller

"The development and testing of a simple low-cost gauge for measurement of tension in a cable bolt grouted in a borehole are presented. Its principle is based on a resistance wire which is wound on a 70 cm length into the spiral grooves of the wire strand cable bolt. Readings are then taken by a robust automatic data logger with a several day autonomy or by a portable readout. In order to have a complete profile of tension along the cable bolt, a number of tension gauges can be installed along its length.This paper provides a description of the development and laboratory calibration of the tension gauge and addresses the two modes of loading for a cable bolt in a rock mass, namely pure tension and shearing at a joint location.In the second part of the paper, four field tests in underground and open pit mines are reported. The first test was used to substantially modify both the gauge and the readout unit principles while the other tests which are still on-going show a very satisfactory behaviour of the modified version of the tension gauge. IntroductionCable-bolting is often used as ground support in Canadian mines for a variety of applications. In underground mines, cable bolts can be installed vertically at the back of cut and fill stopes or in an inclined fashion in the walls of large open stopes. Alternatively, cable bolts at Mines Gaspe (Noranda Inc.) are used in a fan-shaped pattern from a drill drift to stabilize the inclined roof in 25 m wide open stapes. This new application oriented our research efforts toward the design of a novel instrumentation to monitor the efficiency of most commonly used 5/8-inch cable bolts."

Jan 1, 1988

By J. Z. Cui

In this paper a statistical multi-scale method for the mechanics parameter prediction of the rock mass with random distribution of multi-scale cracks/joints is presented. First the micro-structure of the rock mass with random distribution of multi-scale cracks/joints is represented. Then the statistical second-order two-scale method for the mechanics performance predictions of the rock mass structure with random cracks/joints distribution is presented, including the statistical second-order two-scale expression on the vector-valued displacement, strain tensor and stress tensor, and the algorithm procedure of statistical multi-sale computation for the mechanics parameters. Finally some numerical results for mechanical parameters for the rock mass with random distributions of multi-scale joints/cracks by statistical multi-scale method are shown.

May 1, 2009

By S. Foged

Umicore and MWH jointly demonstrated that mechanical dewatering of goethite and neutralised tailings significantly increased the life of a 30 ha tailings pond and improved the operation of the pond. Umicore operates one of its zinc production plants in Balen, Belgium. As part of its production process, an excess of neutralised and goethite¬containing tailings is generated. These have historically been stored inside large lined ponds. As the storage area of the current goethite pond was nearing its capacity, Umicore studied the potential for an extension to the existing embankment. However, this extension would face intense regulatory scrutiny, because the environmental and safety impacts were considered important. Together with Umicore, MWH suggested and investigated an alternative treatment approach consisting of mechanical dewatering prior to storage. A feasibility study was prepared where wet storage was compared to dry storage. Differences in safety risks, environmental impacts and economic costs were outlined. The study demonstrated that the life of the tailings pond could be increased from 6 to 22 years, seriously reducing the environmental impacts and safety risks at no significantly higher cost than would have been incurred with the continued operation of the existing pond. The results of the study are presented in this paper.

Jan 1, 2006

By Aparup Chattopadhyay, Barun K. Gorain

"Porphyry copper deposits are the most important source of copper and also gold within the orogenic belts. These deposits are characterized by low grade copper ore (0.2% to 1% copper) and host precious metals like gold, silver and platinum. A characterization tool has been developed for complex porphyry type copper-gold deposits with an aim to quantify copper and precious metal deportment. This quantification is a challenging task due to low grades and also due to the presence of both visible and invisible precious metal content in different sulphide and non-sulphide phases. Studies were initiated on various complex ore deposits and also on samples representing various processing streams such as flotation and leach products. This paper presents the development of a systematic approach to diagnostic metallurgy using state-of-the-art optical and automated mineralogy, micro-probe, dynamic SIMS and TOF-SIMS analysis for quantification of invisible and visible precious metals content in various species. The relevance of this characterization to metallurgy will also be briefly discussed in this paper.INTRODUCTIONA novel characterization tool has been developed for double refractory gold ores and complex copper-gold ores using state-of-the-art technology for quantitative gold and copper deportment study. The characterization of these ores is a challenging task due to low copper and gold grades in ores, presence of both primary and secondary copper sulphide phases and variable proportion of visible and invisible gold in different sulphides phases (pyrite, chalcopyrite, chalcocite and bornite) and iron oxide phases (magnetite, hematite and goethite). A study was initiated on various ore deposits and also on samples representing various processing streams of pilot plant batches such as flotation concentrates and tailings. This paper attempts to discuss the deportment characterization methodology through presenting results from investigations on four samples from a flotation circuit viz, Feed, Final concentrate, Cleaner Scavenger Tail and Rougher Tail samples. These four samples represent the key streams for a typical copper-gold flotation flow sheet. The key objective of this investigation was to identify and quantify visible and invisible gold along with understanding the morphology and liberation of gold associated with various sulphides, Fe- Oxides and non-sulphide gangue species. In addition, the aim of this study was also to relate this mineralogical and gold deportment information to metallurgical performance."

Jan 1, 2013

By C. Gosselin, G. M. Payenzo, C. Bazin, M. Desnoyers, G. Chevalier

"ArcelorMittal Mines Canada operates hydraulic classifiers to reduce the silica content of an iron oxide concentrate from 4.5% to less than 1.2% SiO2. Sampling campaigns were conducted to develop a preliminary model for the hydraulic classifier. Results show that iron oxide and quartz are respectively concentrated in the coarse and fine size fractions of the classifier feed. The mineral partition curves in the classifier and the size distribution of the minerals in the feed are used to simulate the classifier operation in order to identify the source of variability observed in the daily plant production data. Results indicate that most of the variation is probably caused by unsteady operating conditions of the classifiers.INTRODUCTION Hydraulic classifiers are a class of gravity separation devices (Wills, 1992) used to classify particles according to their size and specific gravity. Hydraulic classifiers also known as density separators (Hearn, 2002) combine hindered settling and upward flow of water to selectively entrain light particles to an overflow stream. Denser particles settle to an underflow stream. Hydraulic classifiers are used for various purposes ranging from cleaning of coal (Das, Sarkar, & Mehrotra, 2009), recovery of chromite from plant tailings (Kumar, Tripathy, & Rao, 2009) to upgrading iron oxide concentrate (Hearn, 2002). ArcelorMittal Mines Canada operates several hydraulic classifiers to upgrade an iron oxide concentrate by removing fine quartz and other light minerals from hematite that is the main iron oxide mineral. A project was initiated to analyze the operation of the classifier in an attempt to identify the source of the variability in the production results and to assess the potential of increasing iron recovery in the classifier. One possible disturbance for the classifier operation is the change in the classifier feed composition and size distribution, while the other considered disturbance is the operation of the classifier. The paper is divided into five sections. The first section summarizes the ore processing sequence for the production of iron oxide pellets to identify the position of the hydraulic classifier in the process. The second section describes the hydraulic classifier. The third section discusses the sampling campaigns conducted on the hydraulic classifier. The method used to process the data from sampling, the results of the data processing and simulation of the classifier are discussed in the remaining sections."

Jan 1, 2012

By R. R. Klimpel

"SYNOPSISA discussion of the importance of flotation rate in the analysis of mineral flotation is presented. In particular, the highly interactive nature of the flotation ""system"" is emphasized where there are components of chemistry, equipment, and operating conditions simultaneously involved. It is further shown that: 1) flotation rate must be measured in order to economically optimize the performance of an industrial flotation circuit, 2) that consistent patterns exist in both flotation rate and equilibrium recovery when changing various settings of the system components, 3) that knowledge of these patterns is necessary in order to avoid making system changes that are either self-compensating or dramatically re-enforcing in some particular aspect of performance, and 4) the rate related role of the chemistry component (e.g.frothers and collectors) is often much bigger than is sometimes realized (especially in a negative sense involving overdosing of reagents). INTRODUCTIONFroth flotation is widely usedl-6 in mineral beneficiation processes as a method for separating different types of finely divided solids present in a liquid (usually aqueous) suspension. The approach is based on the contacting of solids with upward moving air bubbles in an agitated vessel where the solids are exposed to chemicals (collectors) which create a condition favoring the attachment of a certain portion of the solids to the air bubbles. This selected portion is then removed in a froth stabilized by chemicals (frothers) and subsequently recovered from the flotation vessel. Depending on the settings of the various components of the flotation ""system"" (see Figure 1) it is possible to achieve a wide range of flotation performance."

Jan 1, 1984

By Laurence McGonagle

"The Highland Uranium Project (HUP) is located approximately sixty miles northeast of Casper, Wyoming and is owned and operated by Power Resources, Inc. (PRI). With an annual production of680 tonnes (1.5 million lbs) U308, HUP is one of the largest uranium producers by in-situ leach (ISL) in the western world. Uranium is currently produced from four wellfields with a total flow rate of approximately 1,135 m3/hr (5,000 gpm). The carbonate leach solutions are processed by anion ion exchange at two satellite facilities located in close proximity to the wellfields. The loaded resin is transported by truck to a central processing facility for elution of the uranium. Uranium in the pregnant eluant is precipitated and washed prior to calcining.Wastewater from the satellite facilities is treated and used for irrigation at a Land Application Facility. The wastewater generated at the central processing facility is injected into a 2,750 m (9,000 ft) deep waste disposal well.When economical mining of the orebodies is complete, restoration of the groundwater is initiated. There are currently two wellfields at HUP undergoing ground water restoration. Phase I restoration consists of removal of the carbonate leach solution from the ore body. Phase II includes treating the withdrawn fluid with reverse osmosis and reinjection of the permeate into perimeter wells.Future plans include construction of additional satellite facilities at the Gas Hills Project and other economical deposits located within 240 km (150 mi) of HUP. The capacity of the central processing facility will be increased to 1,815 tonnes (4 million lbs) U308 per year by late 1999."

Jan 1, 1998

By M. Kalin

"SUMMARYWaste management in general, and the water treatment of mine and mill effluents, has become an ever increasing burden for mining operations. A reduction in these expenditures would undoubtedly be desirable if this could in fact be achieved within effluent guidelines and monitoring requirements.A brief summary is presented of the research which has as its aim the development of methods which would reduce such costs and lead to solutions for environmentally acceptable close-out conditions for acid generating mine waters. The basic concepts of Ecological Engineering and Biological Polishing are presented, together with an indication of the present state of these research efforts. Details are provided of the progress of various experiments which aim to promote reducing conditions, organic matter production and the establishment of biological filters which remove metals from the water which are then retained within the waste management areas. These conditions should lead to a curtailment of acid drainage and an improvement in effluent quality.A description is provided of the first pilot demonstration using this approach to achieve a walk-away condition for the close-out of a massive sulphide tailings resulting from 10 years of operating a copper/zinc concentrator in Northern Ontario.1.0 INTRODUCTION1.1 Waste management and close-outIt is recognized that the achievement of a cost-effective and competitive mining operation, from the commencement of exploration for ore bodies through to the day-to-day efficient operation of the mine, requires a certain expertise and sophistication. However, the environmental effects of these activities are considered peripheral issues and their importance as an integral part of the planning and development of the mine/mill, is not always appreciated."

Jan 1, 1988

By John G. Payne

The Pebble deposit contains three contiguous zones. In the Pebble West zone, granodiorite stocks intrude gently warped volcanosedimentary rocks that had been intruded by diorite sills and two felsic intrusion breccias. In the Central zone, volcanosedimentary rocks are cut by diorite and granodiorite sills; the latter are genetically associated with the granodiorite stocks. In these zones, widespread potassic alteration consists of brown biotite and K-feldspar, with abundant quartz-carbonate-sulphide vein stockworks. Chalcopyrite/pyrite ratios range from 2/1 to 1/20. Diorite hosts the highest-grade mineralization, with much of it being disseminated. Patchy, later phyllic alteration is moderate and commonly depleted in copper. The Pebble East zone occupies a granodiorite stock and intruded host rocks below an eastwardly thickening wedge of barren Tertiary volcanic and sedimentary rocks up to 600 m thick. Brown biotite alteration and copper mineralization are strong, with chalcopyrite/pyrite ratios commonly over 1/1. The zone extends to a depth of at least 1200 m below surface; some drill holes bottomed in strong mineralization. Later, weak to moderate sericitic alteration removed some chalcopyrite and locally remobilized gold. The Pebble deposit has a Measured/Indicated resource of 3 billion tonnes grading 0.28% Cu, 0.32 g/t Au and 0.015% Mo (= 0.5% copper-equivalent) and an Inferred resource of 1.13 billion tonnes grading 0.30 g/t Au, 0.27% Cu and 0.015% Mo (0.55% copper-equivalent). The Pebble East zone has an Inferred resource of 2.13 billion tonnes grading 0.55% Cu, 0.34 g/t Au, and 0.037% Mo (0.97% copper-equivalent). The Pebble East zone is open to the east and to a lesser extent to the north, south, and to depth.

May 1, 2006

By A. Takala, B Nielson, J. Schunicht

"Pre-concentration in minerals processing presents clear advantages in energy efficiency, water efficiency, reduction of consumables and minimization of capital and operating costs. Outotec’s sorting solutions are powered by Tomra Sorting in order to achieve pre-concentration of concentrator feed in a variety of mineral processing applications. Sensor based sorting combines advanced sensors with rapid computational evaluation and mechanical separation of valuable material from waste and/or gangue. Modern sensor based sorting machines typically use fine air jets to propel individual rocks, thus optimizing recovery and minimizing “mis-sorting”.Gold is generally present in such low concentrations that sensors suitable for ore sorting cannot directly detect it. Therefore, in order to sort gold ore, properties of associated host rock are used. Free and sulphidic gold is often hosted on the quartz-host rock contact zone. Laser scattering effect can be used to detect the surfaces of quartz and composite quartz-host rock particles for subsequent sorting with very high recovery of 95 to 99%. In addition, ore often preferentially fractures along the quartz-host rock contact zone in the crushing circuit. This behavior helps because it liberates more quartz for detection.The feasibility of sorting is investigated for four gold projects in Northern Europe with similar mineralogy. This includes geometallurgical evaluation, amenability testing, small scale “mini-bulk” factory testing in full scale sensor based sorting. The results of the various tests are presented and basic feasibility demonstrated with information on flow sheet development. In addition, the amenability process is evaluated and recommendations made for future projects."

Jan 1, 2017

By Costa

The fly-in-fly-out (FIFO) mining model has significant implications for the industry as it plays an important role in fulfilling the economic, social and workforce needs of the contemporary mining industry. It has increasingly been adopted in countries such as Canada and Australia, but is the current nature of the FIFO model challenging the place women have achieved in the mining workforce? Research in the mining and oil and gas industries reveals that major sources of stress for fly-in-fly-out mining workers are the times of parting and of reunion, the challenges in defining roles within the family, parenting, and conflict between spouses over the use of the leave time and money. So how are women in the industry coping with the FIFO schedules and consequent intermittent relationship with families and partners? How is the mining industry adapting to recruit and maintain female employees in FIFO operations? This paper describes an exploratory study conducted in Canada, which intended to provide some initial insights that might help us answer the questions above. There are several inferences made from this exploratory study. It is clear that FIFO poses significant challenges for both female and male workers. It is largely seen as rigid, extremely challenging for employees with young families and workers who are single mothers, and it is generally incompatible with starting a family and caring for small children. FIFO creates severe stress on relationships and on workers psychological well-being. It seems to be indeed harder for women, since they are often in lower paying positions and therefore have less financial reward for the FIFO lifestyle. On the other hand, FIFO creates the opportunity for young women, including Aboriginal women, to jump-start their careers, as well as opportunities for mature women to work while pursuing other personal interests during their time off. This paper concludes with recommendations to improve the FIFO system in order to increase the ability of mining companies to hire and retain women

May 1, 2006

By Michael Li, Arie Moerman

"Paste backfill as a means of supporting underground mining is gaining popularity. Despite this trend, engineering and design of mine paste backfill systems are still largely based on empirical methods rather than established scientific principles. Because of a lack of sound understanding of mineral paste flow, some degree of trial and error is often involved during commissioning and operating of new paste fill systems. New operations often have to be built with flexibilities and contingencies, escalating the overall project costs.Disciplines that can lend some science to mineral paste flow include slurry transport, fresh concrete rheology, and soil mechanics. This paper reviews the applicability of some scientific and engineering principles found in those related disciplines to mineral paste flows. Examples are given to illustrate important points. The phenomenon of mineral paste flow is examined from new perspectives. Gaps in our understanding of mineral paste rheology are identified and from those some future research directions naturally emerge. Status and problems of the current engineering and design practice are also briefly discussed.INTRODUCTIONPaste backfill as a means of supporting underground mining is gaining popularity. Despite this trend, engineering and design of paste fill production and distribution systems today are still largely based on empirical methods rather than established science. One of the weaknesses of such empirical methods is the lack of scalability and transferability of rheological data from pre-engineering test phases to production phases. It is not uncommon that flow fiction data generated from expensive loop pumping tests turn out to be uncharacteristic of the paste in fullscale production. In such a case the operators have to re-climb the learning curve, sometimes with expensive disruptions to the mining operation."

Jan 1, 2002

By L. Flett, S. Woods, C. Deredin

"Following a significant reduction in world Imperial Smelting Furnace (ISF) capacity from 2003 to 2008, a major optimization initiative was successfully carried out on the lead upgrading and bulk (zinclead) flotation circuits in the Brunswick Concentrator.This paper describes the process improvements that have taken place in order to reduce the quantity of bulk concentrate:•,Increase in lead upgrading rougher flotation circuit capacity•,Installation of a closed-circuit bulk regrind utilizing MillPebs and 150 mm Cavex hydrocyclones•,Installation of two additional cleaner flotation stages on the bulk circuit•,Optimization of the manipulated variables in the lead upgrading and bulk circuitsINTRODUCTIONThe Brunswick Mine (Xstrata Zinc Canada) is located near Bathurst, New Brunswick and is one of the world’s largest lead/zinc mines. Milling of ore commenced in 1964 from the No. 12 orebody, with an expansion in 1966 to accommodate ore from the No. 6 open pit mine. The planned closure of the mine will take place at the end of the first quarter in 2013. The ore is a complex massive sulphide, consisting of approximately 20% valuable minerals, 60% pyrite and 20% silicates.A simplified flowsheet for the concentrator is given in Figure 1. The overall flowsheet involves SAG milling, secondary ball milling, selective flotation, and dewatering by thickening, filtering and drying. The complexity of the flowsheet evolves from the requirements for fine grinding and the production of four concentrates: zinc (sphalerite), lead (galena), copper (chalcopyrite) and bulk (sphalerite plus galena).Primary hydrocyclone overflow feeds the copper-lead aerator-roughers for flotation at pH 9.0 with soda ash. Plant xanthate (80-20 sodium isopropyl and potassium amyl) and AP407 are used as collectors in the copper-lead circuit. The rougher concentrate is directed to the copper-lead regrind circuit and the tailings are fed to the secondary grinding circuit. The secondary hydrocyclone overflow from the secondary grinding circuit feeds the copper-lead rougher-scavenger banks. Rougher concentrates are reground to a P80 of 28 µm prior to three stages of copper-lead cleaning. The first stage of cleaning is done in an open circuit with the tail reporting to the cleaner scavenger. The cleaner scavenger concentrate reports to the regrind circuit and the cleaner scavenger tail combines with the rougher/scavenger tail to feed the zinc circuit. The second and third stages of cleaning are performed in closed circuit with the cleaner tail being recycled to the copper-lead regrind circuit. The average final concentrate grades 23% Pb, 3% Cu and 704 g/t Ag, and is fed to the copper separation circuit."

Jan 1, 2013