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By Norman O. Lotter, Simon Yu, Tony Deng, Antonio Di Feo

"Xstrata Nickel’s Raglan operation, northern Québec, achieved paymetal recovery gains in 2007 by switching the collector from potassium amyl xanthate to sodium isobutyl xanthate. To follow on from that position, Xstrata Process Support (XPS) and A. Di Feo of Raglan proposed that a mixed xanthate system be formulated and tested towards further performance gains. This work selected ethyl and isobutyl xanthates as the candidates. An optimized ratio of these was to be determined by a designed experiment. This suggestion was based on an abundance of published literature that reported mixed collector systems outperformed single ones. A partial factorial design was used to configure four test conditions and a mid-square for the flotation work. The testwork was conducted using High Confidence Flotation Testing. The raw data were analyzed and modelled by Design-Expert software. An optimum ratio of 1.6:1.0 by mass (1.32:1.0 in molar terms) of isobutyl:ethyl xanthate was determined. Without this modelling, the optimum ratio would have been missed. Results obtained with the new baseline flotation test using this optimized mixture showed a 3.3% Ni recovery gain in the bypass concentrate and more than 1% recovery gain for PGM over the single PIBX system. This system has been proposed for and accepted as a plant scale trial in the first half of 2010.INTRODUCTIONConcentrator OperationsMilling and flotation of sulphide ores ahead of smelting and refining is a common practice. This choice results in the larger and more variable paymetal loss in the production of saleable metal [Cramer, 2001]. For this reason, it is common to see an ongoing performance improvement programme at the operations level. When successfully performed, these e"

Jan 1, 2010

By K. H. B. Wenzl

"Since the autumn of 1973, the world's attention was captured by the startling revelation that conventional energy supplies were not inexhaustible but were in fact quickly dwindling with future shortages imminent until lagging exploration and technology yielded additional energy sources to catch up with the spiralling increase in demand. This situation was precipitated by the Arab Oil Embargo and the resulting soaring cost of world crude oil.During the past few years there has been tremendous activity in the energy field which has had a direct impact on the Inca Metals Company Ontario Division operations. The company's reaction has been to establish an energy management program which will be described later in the paper. First, a brief description of the Inca Metals Company and the primary energy resources which are utilized will assist in putting the program into perspective.The Inca Metals Company, a unit of Inca Limited, is responsible for the production and sale of primary metals products worldwide. The company's operations in the Sudbury District include mines, ore concentrating plants, a Smelter, Nickel and Copper Refineries and an Iron Ore Recovery Plant. The Ontario Division also has a mine and concentrating plant in Shebandowan near Thunder Bay, and a metals refinery at Port Colborne. Inca is the largest producer of nickel in the non-communist world and is also a major producer of copper and platnium group metals."

Jan 1, 1978

By Camilo I. Morales

At present, many open pit mines are designed to operate and feed a processing plant with ore characteristics that were defined in the design of the mining business, which are not necessarily the same as those found during the operation. This is the case of Spence Mine, whose design was conceived considering the extraction of primary iron sulphides, however, with the extraction of such minerals, it was necessary to mine and process minerals with secondary enrichment. Then it is necessary to work with a greater selectivity degree in the operation, however the capacities of the mine and operational resources were not designed for this. Thus, the changes in the general conditions of the operation should be considered as a series of geometallurgical restrictions to achieve production schedules. The above facts impacts directly in the short-term planning, whose task is to achieve the goals proposed in productive long-term planning because the company does not have the tools necessary to plan with the degree of selectivity required, so it should be done by hand, discretizating and scheduling the production polygons. Naturally, this manual process in the short term planning deviate sharply from the areas in operation, opening new fronts and benches that result in a significant increase in costs and a loss of the value of the mineral resource to miss the exploitation sequence. The research presented in this paper is related to the development of a mathematical programming model to support the short-term planning, so as to integrate the challenge of selective mining with geometallurgy restrictions, to provide the planner a guide to construction of the polygon of exploitation, guiding the fines production to achieve the goals of the proposed production plan.

Oct 1, 2009

By I. G. Townsend, S. A. Buckley, C. I. House

"SummaryBritish Petroleum plc is developing a new gold recovery process known as coal gold agglomeration (CGA) for the recovery of gold from its ores. Liberated gold grains are recovered with high efficiency by adhering to agglomerates of coal and oil. The process is simple, can recover gold grains down to very fine sizes, avoids the large scale use of cyanide and provides the industry with an important new process option.A technical appraisal of the process has been performed on an extensive range of gold bearing materials. Ore types have been identified from which high gold recoveries can be achieved. A spreadsheet based computer program has been used to estimate the preliminary capital and operating costs of the process. Comparison with established gold production costs shows that the process costs of CGA, on the appropriate ore types, are potentially very attractive, which will enable economic treatment of lower grade ores than is currently possible using conventional cyanidation. Treatment of known placer deposits or gravity concentration plant tailings may be the most rapid means of demonstrating the process at a commercial scale prior to more widespread applications.1. INTRODUCTIONWestern world gold production for the 1980s has shown rapid growth sustained by a demand for gold at a favourable price (Fig. 1). Heap leaching and CIP/CIL operations have been responsible for the major part of new production during the 1970s and 1980s with present overall production costs averaging US$200/oz in Canada, USA and Australia and US$265/oz in South Africa [l]. A great deal of research and process development effort in the 1980s has been towards the treatment of refractory ores. Operating costs for the economic processing of these ore types by currently available routes are around US$300/oz [2]."

Jan 1, 1989

By Jr. Blanchette, Claude Bazin, Paul Blatter

"Reporting of the gold production during a month implies to estimate the mass of gold that is processed by a mill, recovered as dorés, lost to the tailings and the change of gold inventory within the plant equipments. Carbon in pulp and/or carbon in leach tanks may contain gold inventory as large as 72 000 g (2 200 troy oz) of gold which needs to be estimated from measurements obtained from sampling the material contained in a tank. Sampling and analysis introduce measurement errors that could be systematic and/or random. This paper examines the effect of measurement errors on the estimation of the gold inventory and on the variation of the inventory in the carbon in leach tanks of the Agnico-Eagle Mines Limited Lapa concentrator. Results of the analysis demonstrate that the inventory is measured with ±10% reproducibility, while the variation of inventory used for mass balance is known with ±300% reproducibility.INTRODUCTIONThe preparation of a production report implies to reconcile measured data with the constraint of material balance over the considered period of production. The sampling and data reconciliation problems were recently reviewed by Morrison (2008) and Jansen (2009a; 2009b). Typically a production report is prepared to cover a period over which the mass conservation hypothesis can be considered valid. In gold processing plants, the change of inventory can seldom be neglected and plays a significant role in material balance calculations. This is particularly true for circuits using carbon adsorption, where the complete cycle of carbon is measured in days.In a 2000 t/d gold ore processing plant, the inventory can be as large as 140 000 g of gold in gravity concentrator bins, carbon in pulp tanks and in the electrolysis circuit. This is equivalent to the mass of gold that fed the circuit during 10 days of operation with 7 g/t feed assays. The change of inventory may therefore strongly impact the production figures and especially the plant recovery at the end of a week or a month. Despite the financial impact associated with gold inventory, few publications are devoted to the subject. Bruington (1991) and Morrison (2008) discussed the problem and stressed the need for the development of reliable methods to estimate the gold inventory in carbon in pulp or carbon in leach circuits."

Jan 1, 2011

By K. V. Konigsmann

"The results of Mr. Klymowsky's research confirm the essential role played by oxidation products in the flotation of base metal sulphides. They invite a discussion on the subject of aeration which I may open by a brief description of the development and current practice of aeration. The first installation of pre-flotation aeration in Canadian milling practice was undertaken during the years 1928 and 29 at the then new Noranda Mill. C.G. McLachlan and his collaborators demonstrated that the flotation differential between chalcopyrite and iron sulphides was enhanced by aeration in soda ash alkaline pulps. The ores treated contained more than 80 per cent sulphides. It was proposed already then that the products of mineral oxidation assisted copper and retarded iron sulphides, at least pyrrhotite flotation. The concentration of thiosulphates was used as a measure of the progress of oxidation. Several papers by C.G. McLachlan elaborate on this subject.The aerator was also used as classifier since it was held that aeration, i.e. controlled oxidation, should go hand in hand with creation of new mineral surfaces. Grinding mills and aerators were placed in closed circuit. Figure 1. This aeration was essential for successful separation at Noranda.Following the application of aeration at Noranda the technique was applied to existing mills in N.W. Quebec. Impressive improvements in concentrate grades and recoveries were obtained. It was observedthat the zinc flotation benefitted from aeration as much as the preceding copper float. In the late forties and fifties the aerator classifier was installed in new mills associated with the Noranda group. A diagrammatic sketch of the Quemont flow-sheet (figure 2) may serve as a typical example."

Jan 1, 1973

By W. S. Dyer

The lignite deposit at Onakawana on the Abitibi river is of particular interest at the present time, since the Ontario Government has recently decided to proceed with the extension of the Temiskaming and Northern Ontario railway to James bay. Forty-five miles of steel will be laid this year to the crossing of the Moose river. This will cross the lignite field. It has been known for many years that lignite occurred in the Moose River basin, but it was not until drilling was commenced at Blacksmith rapids (or Onakawana, as the camp is now known) in June, 1929, that a seam of economic thickness and extent was found. Early in 1929 the Ontario Legislature voted $25,000 for the carrying out of a drilling programme in the Moose River basin. This came as a culmination of two summers' exploratory work by the Geological Branch of the Ontario Department of Mines, and as the result of a report which said; in effect, that further information concerning the mineral resources of the basin could only be obtained by drilling, and that such a drilling programme was well worth while in order to establish once for all whether lignite, fire-clay, or oil or gas did or did not exist in economic quantities in the region.

Jan 1, 1930

By Johnna Muinonen

"The Thompson Mill processes ores from the Thompson and Birchtree Mines. While the Thompson ore has very little magnesium containing gangue, the Birchtree orebody consists of veins of massive sulphide in a rock matrix that contains a high proportion of magnesium silicate minerals. A significant fraction of the magnesium is floatable, which lead to MgO levels varying from 3-11 wt% in the Birchtree concentrate. The magnesium in the concentrate causes a higher operating temperature in the smelter, reducing furnace life.Birchtree ore represented 20-30% of the mill ore receipts prior to October 2003. Since then the fraction of Birchtree ore has increased to 50%. A reduction of the MgO in concentrate to less than 3% in the total mill concentrate was required to allow safe and economic smelter operation.In October of 2002 a miniplant was set up to simulate the Birchtree plant circuit. Several flow sheet modifications were tested that led to a proposal for a circuit having increased cleaning capacity for the scavenger concentrate and a recleaner on this concentrate. Addition of CMC in rougher cleaner feed was also found to be required. The solution was confirmed through pilot plant testing in the mill in December of 2002. A full-scale installation was designed, engineered, and installed between February and September of 2003 with commissioning in September and October of 2003. Target metallurgy was achieved one week after start-up on slurry to coincide with the Birchtree Mine tonnage increase. This paper highlights the development, design and commissioning stages of the project.The new MgO rejection circuit has successfully allowed the processing of Birchtree ores producing concentrate consistently below 3% MgO. In addition, the new circuit increased overall nickel recovery in the mill.INTRODUCTIONThe Thompson Nickel Belt located approximately 700km north of Winnipeg was discovered in the early 1950’s. Inco first produced nickel from the area in 1960. Over the years the mill has processed several ores from different ore bodies in the area. Currently the Thompson Mill processes two significantly different ores from two mines, Thompson and Birchtree. The Thompson ore is a massive sulphide orebody hosted in schist, containing feldspars, quartz and biotite. Thompson Ore is characterized by high nickel recoveries and clean, low MgO containing concentrates (<2.5% MgO). The Birchtree ore is ultramafic and contains a high percentage of Mg-silicates such as serpentine, chlorite, biotite, amphiboles and talc. Some of these Mg-silicates report to the nickel concentrate and prior to commissioning of the MgO rejection circuit the Birchtree nickel concentrate typically contained 5-8% MgO"

Jan 1, 2006

By P. Wells, P. Quinn

"A moveable flotation miniplant was designed and constructed at the research laboratory of Inco Technical Services Ltd. to address the need for flowsheet development with a limited amount of ore (such as drill cores). It consists of one rod mill, two regrind ball mills, one vibratory screen, 24 flotation cells of various sizes and two Venturi aerated flotation columns. The setup has continuous monitoring capability for pH, dissolved oxygen, oxidation-reduction potential, conductivity and temperature in conditioning tanks and flotation cells. Various options regarding flotation reagents, circuit configurations, and fineness of primary grind and regrind can be readily evaluated. The throughput of the miniplant is 20 – 30 kg/hour ore.Unit operations such as flash flotation, magnetic separation and gravity concentration can also be evaluated as an integral part of an entire flowsheet development.This communication describes the basic design features of the miniplant and some examples of applications are given.INTRODUCTIONInco operates numerous mines in Sudbury and Thompson and will shortly bring the Voisey’s Bay mine into production. It has long been recognized that the ores from different mines or from different depths of the same mine can give different responses in flotation. There is a growing need to properly evaluate the ores before feeding the mill to maximize the return of the mine/mill operation. Inco Technical Services Limited at Sheridan Park, Mississauga, Ontario has developed a batch laboratory procedure to address this issue. The results are considered in the overall economical assessment of new mine operations.For ores that cannot be processed by the existing mill operations or that will be processed by a new mill, it is necessary to develop a flowsheet that can maximize the economical return of the mine/mill operation. While recognizing the importance and contribution of the laboratory batch flotation procedure, it does not generate reliable data for flowsheet simulation and design. A full-scale pilot plant campaign is normally required to obtain the design data but often this is not possible due to a limited amount of ore obtainable from the drill core. A small-scale pilot plant (mini pilot plant or miniplant) capable of processing 20-30 kg/h ore can provide this data prior to a full-scale pilot plant campaign. A miniplant can also be used to optimize the circuit configurations, reagent additions and recycle options of process water before pilot plant work and can be used to test a different flowsheet configuration for an existing mill before re-piping a plant circuit."

Jan 1, 2003

By P. A. Selvadurai

This paper presents the results of a research investigation leading to the development of a technique for the measurement of the surface permeability of Indiana Limestone. The tests are conducted on a cuboidal block of the limestone with a flat surface that can be sealed to create a circular aperture through which water influx can take place. Computational results for Darcy flow are used to interpret the results of the experiments. The water entry area can be moved over the surface area of the block to investigate, quite conveniently, the distribution of permeability across the surface of the limestone block sample.

May 1, 2009

By L. J. Vincze

The high cost of constructing mineral processing plants in remote locations warrants a close examination of the alternatives available for reducing the amount of on-site construction work. Among the alternatives are portable process plants, modular design and barge mounted plants. Each alternative has certain advantages as well as limitations depending upon specific conditions. On the basis of practical experience and engineering analysis, the paper examines the potential benefits to be realized by these techniques and summarizes the conditions required to obtain them. The potential savings indicated by such studies should encourage consideration of innovative design features for new plants located in remote areas.

Jan 1, 1980

By Alain Langlais, Caroline Boudrias Chapleau, Claude Bazin, Ahmed Bouajila

"Slurry «viscosity» has been recognised for several decades as a variable that significantly influences the operation of grinding mills. This paper describes an instrument that can be used in a laboratory or a plant to measure and monitor the flow properties of mineral slurries. Laboratory results obtained for two different ore samples are consistent with results obtained during a full scale trial. The results provide a basis for analysing the effect of the solids concentration and particle size distribution on the slurry flow properties. Grinding tests were also conducted in an attempt to link the grinding efficiency to the rheological properties of mineral slurries.INTRODUCTIONThe flow properties, or incorrectly called «viscosity», of a slurry influence the operation of mineral processing devices. Work has been conducted for instance to assess the effect of this variable on the operation of hydrocyclones (Kawatra et al. 1996; Klimpel, 1982a) and dense media separators for coal (Napier-Munn, 1996). However, most of the research effort has been oriented toward the grinding processes which is still the most energy demanding operation for ore dressing (Fuerstenau et al., 1995).Results of investigations of the influence of slurry flow properties upon grinding performances are presented regularly in the literature since 1950. In the 70's, most of the research work was conducted with the aim of using slurry flow properties for the control of grinding mill and to analyze the effect of that variable upon the population balance model breakage and rate functions (Austin et al., 1984; Hemmings et Boyes, 1977). In the 80's, most of the litterature dealing with slurry rheology was devoted to the use of viscosity modifiers to adjust the slurry flow properties, allowing an increase of grinding mill throughputs (Klimpel, 1982b; Fuerstenau et al., 1985). Although laboratory and pilot plant results show the benefits of adding these modifiers to the slurry, few plants have published results concerning the advantages of such addition (Fuerstenau et al., 1985). It is felt that the use of these modifiers introduce operating difficulties with the concentration circuits, especially flotation (Kawatra et Eisele, 1988)."

Jan 1, 2003

By V. Coffin, T. Cienski

"(Figure 1) Reagentized pulp enters into the column at about 1/4 of the distance from the top. Inside the column it meets with a downward flowing stream of water and with an upward flowing mass of air bubbles. Flotation takes place in this counter current system while at the same time fine gangue particles are washed off the froth before it reaches the overflow lip at the top of the column. The main operating features of the column flotation are as follows:a) No moving parts. Solids are kept in suspention not by an agitating action of a propeller but by settling down against the rising air bubbles.b) Wash water. Spray pipes are installed a few inches below the froth surface and deliver required volume of water. The purpose of this water is twofold:(i) it keeps in balance the flow of material through the column and(ii) it washes rising froth in the froth layer as well as removes unwanted fines attached to the bubbles at the lower flotation section. As a result the concentrate produced is of higher purity than in the conventional flotation. Column is characterized by very high up-grading. However, even temporary disruption of wash water supply results in a drastic drop of concentrate grate.c) Flow balance. (Figure 2) For the correct operation volume of the underflow (tail) is larger than that of the feed. The difference is made up by the wash water. This difference called bias is predetermined and ranges from some 4 to 15 USGPM depending on the size of the unit and process requirements."

Jan 1, 1981

By Tony Lipiec, Greg Gosson

"When it comes to new mines being developed, there is a general industry consensus that most low-hanging fruit has been picked. Many projects currently in the mine development pipeline have been around for decades, but were held back because of technical challenges. Future development of these deposits will likely require access to the public capital markets, and in Canada that means providing scientific and technical disclosure on these deposits in compliance with NI 43-101. As many of these “challenged” projects have metallurgical issues, the companies that own the projects need to ensure their metallurgical Qualified Persons provide transparent disclosure regarding proposed solutions to those issues.This paper provides an overview of the disclosure requirements under NI 43-101 that are pertinent to metallurgists, and other Qualified Persons who prepare technical disclosure regarding the metallurgical characteristics of a mineral project. It lists the triggers for a technical report under NI 43-101 and Canadian stock exchange policies, and identifies the sections of the report that should involve input from a metallurgist or process engineer. It briefly outlines new civil liabilities under Canadian securities laws that increase the possible consequences for not complying with the technical disclosure standards.These materials are provided for general information purposes only and do not constitute legal advice. Readers are advised to seek specific legal advice from their own legal counsel in relation to any decision or course of action contemplated."

Jan 1, 2010

By Ike Isagon

Backfilling has become an integral process in underground mining operations, with varying cost-effective forms of application. This study is a part of an overall investigation into the backfill practices at Copper Cliff North Mine (CCNM). The mine is well-diversified in terms of backfill methodologies and practices. The mine employs different fill methods such as cemented and un-cemented rock fill, slag fill, and cemented hydraulic fill (or a combination of them) in order to fill the voids created by mining activities. The history of backfilling at CCNM has been dominated by cemented and un-cemented slag fill. Each fill method requires operating and engineering guidelines for a cost effective quality control system. The purpose of this paper is to briefly discuss the backfill methods and applications, operating guidelines, and engineering requirements at CCNM.

May 1, 2011

By Alain Blouin, Mohamad Sabsabi, Aissa Harhira, Paul Bouchard, Greg Lithgow

"The objective of this study was to demonstrate the application of Laser-Induced Breakdown Spectroscopy (LIBS) to the continuous analysis of online monitoring of Al, Mg, Ni, Mn, Si and Fe in nickel ore limonite and saprolite slurry samples. Analysis was performed on slurry samples in air at atmospheric pressure. Two pure samples of limonite and saprolite were used. Mixtures of the two samples in varying proportions were used to build calibration curves, study the influence of solid/liquid ratio, and evaluate short and long term reproducibility. The LIBS measurement of these elements is independent of the water content (from 70-85%, the range allowed by our setup). Repeatability of the measurement and long term reproducibility (from day-to-day) were below 1.2 % and 2% respectively for all the elements studied in our conditions. The results obtained showed that an industrial LIBS analyzer could provide the chemical composition of the six elements Al, Mg, Ni, Mn, Si and Fe within 1-2 minutes.IntroductionThe metal-producing industry faces the major challenge of increasing productivity, reducing costs, and maximizing benefits from existing equipment. By pyrometallurgy, metal making involves the basic steps of charging the furnace, melting the charge and refining. By hydrometallurgy, the metal refining is carried out through the dissolution of the metal by chemical reaction and electrolysis. During refining either by pyrometallurgy or hydrometallurgy, it is critical that operating parameters be adjusted and controlled so that the chemistry of the melt or the solution is within predetermined limits. Presently, the complete turnaround time for sampling, sample transfer, analysis and communication of the results to the operators is often 30 minutes or more."

Jan 1, 2016

By Xing Jin, Dan Graffi, Glenn MacPherson, Dan Rioux

"The complexity of a modern flotation circuit makes it susceptible to disturbances such as changes in feed, ore mineralogy, equipment degradation, poor measurements and faulty instruments. Good measurements and a robust control system are critical to create and maintain a stable and optimum flotation process.This paper focuses on the development and implementation of process control applications in the flotation circuits at Xstrata Nickel’s Strathcona Mill ( referred to as the mill hereafter ) in Sudbury, Ontario. Following the path of ‘stabilize-improve-optimize’, basic controls to stabilize process variables such as flotation cell pulp level, air and reagent addition rates, cleaning-column feed and wash-water rates have been established. Factors such as best practice in pulp level and valve position measurement, feedforward control and the application of an appropriate control philosophy, have contributed to the significant reduction in process variability. For instance, standard deviation reduction of 79% for the Ni impurity in the column Cu concentrate grade was experienced and is shown. The variability reduction of the flotation circuits’ key process-variables paves the way to further improve and optimize flotation performance. A grams-per-metal unit reagent addition control scheme has been improved upon, particularly for different operating scenarios and better robustness. In addition, following significant stabilization of the primary controls and columns feedrates, Cu/Ni separation cleaning-column bias-control (cascaded to the wash-water rate) and hold-up control (cascaded to air flowrate) have been developed and tested. This strategy – from stabilization to optimization - is expected to achieve a more consistent control of final concentrate grades and improve recoveries.INTRODUCTIONFlotation is considered the most important and value-added process in the milling metallurgical plant and is still undergoing continuous evolution to treat greater tonnage and different ores (Wills, 2006). Starting over three decades ago, with the advent of on-line slurry content analysis devices, flotation automatic control has received persistent interest and a large number of applications have been reported (Thwaites, 1983, 1986 ; Mckee, 1991). Bergh and Yianatos (2011) reviewed different aspects of process control in flotation circuits and have evaluated the applicability of model predictive control to the process. Mckee (1991) analyzed the difficulty in developing lasting/robust process control applications for flotation circuits and stated that the path of stabilization-refinement-optimization would more likely lead to successful flotation circuit process control. Best practice on column process control was discussed by Bouchard, etc. where a multi-layered approach was proposed, provided that the measurement of column process variables ( i.e. bias, froth depth, hold-up, etc. ) are measured reliably (Bouchard & Thwaites, 2008). Wills (2006) stated that the best practice for flotation automatic control starts with fulfilling basic control objectives, such as stabilized flotation cell level, air flow, pH, reagent flow etc., before considering more advanced, or even optimal, control of metallurgical targets, which are more closely linked to economic performance."

Jan 1, 2013

By S. Cossio, J. L. Noyola, R. Espinosa

"Minera Penmont’s La Herradura is a joint venture between Industrias Peñoles, S.A. de C.V. and Newmont Mining Corporation. The mine is located in the northern Mexican state of Sonora. La Herradura consists of an open pit mine with a two-stage crushing plant and heap leaching facility. Gold is recovered from the pregnant solution using the Merrill-Crowe process; production began in July 1998. La Herradura produces about 130 000 oz gold per year and its treatment capacity is approximately 22 000 t/d. Ore mineralization occurs in a shear zone with quartz and native gold. Gold distribution is quite heterogeneous due to coarse visible gold, which in some cases ranges from 100 to 600 microns.Sampling and assaying protocols were established during exploration and prior to start-up of operations, based on nomographs developed from early heterogeneity tests. However, as the coarse gold problem became noticeable, it was necessary to develop new sampling protocols to have an acceptable relative standard deviation to control the fundamental error within ± 15%.An experimental program was developed and conducted on a selected ore block consisting of 195 blastholes; regular ore grade control procedures were applied to both sets of data to evaluate the difference in results between the protocol established prior to start-up of operations (existing) and the new protocol (leaching). In the existing protocol, sub-sampling is done through riffle splitters, and coning and quartering. Fire assaying was used to estimate the gold content on a 50 g sample. In the leaching protocol, a 12 000 g sample of bottle-rolled cyanide was leached, and the leach residue was assayed on a 50 g sample using fire assaying, and a weighted average total gold content was calculated. Currently, a new alternative method is being evaluated, where sub-sampling is done using rotary splitters, and fire assay on a 50 g sample; in this rotary sampling protocol and for comparison purposes, gold assays were also repeated using the leaching protocol.Test results were compared in three groups: < 0.3 g/t (below cut-off), 0.3 to 0.8 g/t, and >0.8 g/t. Overall, results show that the protocol established prior to start-up of operations underestimates the gold assays. Detailed technical results, alternative options, and their implications are discussed in the paper."

Jan 1, 2004

By G. H. Babcock, D. A. Knight, V. G. Medina

"Production commenced at the Golden Sunlight Mine in 1983 and at Kidston Gold Mine in 1985. These projects were both constructed under the management of the Placer Dome Inc. (Technical Services) group of Vancouver, B.C.Golden Sunlight uses a conventional rod mill/ball mill grinding circuit while Kidston uses a SAG /ball mill, and later on, SABC circuit. Since the hardness of the ore and the fineness of the primary grind in both mines are about the same, a meaningful cost comparison can be made. The comparison is made on the basis of capital and operating costs.The result of this study indicates that a significant capital cost savings can be achieved in favour of the SAG /ball mill circuit when the ore is amenable to semi-autogenous grinding. With a good maintenance program, the operating cost for the SAG /ball mill circuit could also be lower that the conventional rod mill/ball mill circuit.HISTORYGolden Sunlight MineGolden Sunlight is a 5 530 t/d gold mine located near Whitehall, a small town 60 km east of Butte, Montana. Originally optioned by PDI U.S. in 1958, the development of the property waited until 1981 when economic conditions became favorable for the project to proceed.Semiautogenous grinding tests were conducted during the final stages of the feasibility study. The hard near surface ore was not quite amenable to semi-autogenous grinding. The best result produced from a series of tests using a 1.83 m diameter mill was a semiautogenous work index of 39. This is substantially higher than the 22 Bond work index of the sample used in the testwork. A conventional SAG/ball mill circuit for this ore will be extremely inefficient, and for this reason, this circuit was rejected in favour of a conventional rod mill/ball mill circuit."

Jan 1, 1991

By Bradford C. Wesstrom, Ricardo Parra

The Freeport McMoRan El Paso Refinery uses co-generation to produce some of its electricity and all of its steam. This paper will cover the operation of the co-generation plant natural gas turbine at a fixed RPM for blade longevity and energy output. The by-product heat from the turbine passes through boilers with additional heat from a duct burner to produce steam for the Tank House and auxiliary operations. The steam demand varies dramatically throughout the day based on unloading activities in the Tank House. The use of an automated steam control system within the El Paso Refinery will help stabilize line pressure by incrementally controlling steam consumption based on electrolyte temperature. This will minimize steam line pressure fluctuations. INTRODUCTION In the mid 1920’s the Nichols Copper Company of Laurel Hill, New York recognized the need for a modern copper refining facility in the southwest. Due to the many railroad heads, affordable power and abundant labor supply, and the close proximity to regional copper smelters in Mexico, Arizona, and New Mexico, El Paso became the logical location. In December 1928, ground was broken for the joint venture refinery between the Nichols Copper Company, Phelps Dodge, and the Calumet and Arizona Mining Company. In September 1930, Nichols Copper Company became a part of Phelps Dodge Corporation after a stock exchange. In July 1938, Nichols Division officially became Phelps Dodge Refining Corporation. In March 2007, Freeport McMoRan Copper & Gold acquired Phelps Dodge. Energy costs (electrical and thermal) are critically important in the viability of modern copper electrorefineries. The El Paso Refinery produces electricity and steam through its cogeneration system. The El Paso cogeneration facility is a natural gas, 15-megawatt facility containing five turbine generators and associated waste heat recovery boilers. The facility is divided into two phases. Phase I consists of two Allison 2.2-megawatt turbine generators. Phase II consists of three Solar Taurus 3.5-megawatt turbine generators. Presently three units in Phase II are operated. The Phase I units were purchased and installed in 1986 and the Phase II units in 1992 (Solar 1991). The facility operated at full capacity until 2003 when steam demand was significantly reduced due to decrease in cathode production and closure of the copper sulfate and precious metal operations. Phase I units were taken out of service and put on care and maintenance status.

Jan 1, 2019