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By Joseph L. Fournier

Suncor Oil Sands employs delayed coking technology in converting bitumen into synthetic crude oil. Currently up to 10,000 m3 of delayed coke (coke) is produced per day as a byproduct of the upgrading process, of which up to 9,000 m3 per day is placed in dry storage on Lease 86/17. A review was completed to examine the case history of leachate potential experiments from the dry storage of coke and the environmental relevance of coke leachate studies conducted over the past decade. The review included an evaluation of the potential impacts of environmental conditions within the location of coke storage, including precipitation pH, as well as daily and annual ozone trends. Coke leachate potential has historically been characterized using standard leachate testing protocols (i.e., TLCP, SPLP) together with other studies that have employed strong acids and oxidizing agents in the extraction fluids. The present paper highlights prevailing conditions in the Athabasca Valley air-shed with emphasis given to ambient ozone (oxidizers), as well as precipitation pH and acid input deposition rates, and will demonstrate that TCLP / SPLP tests lack the intended environmental relevance relative to the conditions under which coke is stored.

May 1, 2011

By J. R. Goode

"The Las Cristinas deposit contains about 10.2 million ounces of gold at a grade of 1.3 g/t. The deposit comprises a layer of fully oxidized saprolite (SAPO), a layer of sulphide-enriched saprolite (SAPS), carbonate leached bedrock (CLB) and carbonate stable or un-leached bedrock (CSB). Gold occurs at about the same level in all lithological groups. The bedrock units contain minor amounts of copper (about 0.1%) as chalcopyrite, while SAPO contains virtually no copper it having been leached and deposited in the SAPS zone.A previous owner started investigation of the Las Cristinas deposit in Venezuela in 1991. Over the next seven years, 1174 holes with a total length of 159 km were drilled, extensive metallurgical testwork, including pilot plant operations, were conducted and feasibility studies were completed. Construction was started in 1997 and again in 1999 but was suspended.Crystallex has been producing gold in Venezuela since the early 1990’s. In 1997, Crystallex acquired Inversora Mael which had held two of the claims to the Las Cristinas concessions since 1986. In September 2002, Crystallex entered into a definitive agreement with the Corporación Venezolana de Guayana, (CVG), to develop the Las Cristinas deposit.An extensive program of studies and testwork was started in early 2003 to determine an optimum development plan for Las Cristinas. Mine Development Associates, SNC–Lavalin Engineers and Constructors, SGS Lakefield Research Limited, J.R. Goode and Associates, and Professor A. Laplante at McGill University acted as the main contractors.Because of the potential value of by-product copper, earlier flowsheets used carbon-in-leach for SAPO, but processed all other ore types by flotation to produce a gold-copper concentrate with cyanide leaching of cleaner tailings to maximize gold recovery. Cyanide recovery was necessitated by the high copper content of the leach feed. Initial studies of available data by Crystallex revealed that direct leaching of all ore types would provide about 11% more gold recovery than the previously selected flotation route with reduced capital and operating costs.Bench and pilot scale studies have confirmed that a SAG-ball mill-gravity-CIL route is very effective for all ore types and will give about 89% gold recovery. This paper describes the recent testwork, discusses the proposed plant design, and presents economic data."

Jan 1, 2004

By Kosuke Hosoda, Shuji Owada, Hiroyuki Tokuichi, Hirobumi Ohta, Chiharu Tokoro, Moto-o Sato, Katsushi Okumura, Hiroto Ogawa, Hideaki Umezawa

The Japanese government enforced the "Small Domestic Appliances (SDAs) Recycling Law" in 2013. The law targets metals such as Ta, Nd, Dy, Co, and W to be recycled. Considerable amounts of these minor rare metals are mounted on printed circuit boards (PCBs) of the SDAs and/or e-scrap (electric and electronic scraps). Although precious metals and copper can be recovered from the e-scrap in non-ferrous metals smelters, most of the minor rare metals report to the slag in these smelters in non-recoverable forms. These metals are often used in particular types of devices, and therefore it is possible to concentrate them by separating such devices before feeding to the smelters. In previous work we developed technology for "Device Separation" to concentrate several minor rare metals, but some problems remained, such as how to remove the PCBs from e-scrap bodies, and how to detach devices from PCBs after their removal from escrap bodies. This paper proposes a two-stage crushing process in which, firstly, PCBs are removed from the e-scrap body with various crushers, and secondly, devices are detached from the PCBs involving the application of elevated temperatures. It was found that in the first stage, crushers with physically flexible rotating media such as chains, which provide high collision probability with the sample and consume relatively low energy, can quite effectively separate the PCBs from the e-scrap bodies non-destructively. In the second stage, heating was found to be remarkably effective in helping to detach mounted devices from PCBs, also non-destructively. This paper will also discuss the detailed mechanism of the heating effect on the detachment of devices from PCBs.

Jan 1, 2014

By Mike Robotham

When RFQ?s are received they often contain detailed technical specifications which suggest a departure from the suppliers own customary approach to the design. Both client and end user are quite rightly influenced by their own experiences. The question is who is right, the client and his consultant, the supplier or perhaps a combination of these. This paper looks at some of the fundamental variances that often occur in the approach to the mechanical design of drum hoists, based on our experiences of recent years. Director of Engineering, Mike Robotham is a chartered engineer and has been with DavyMarkham for over 30 years. Having completed a craft apprenticeship he later joined the engineering department as a junior engineer. He has a wealth of experience of working on medium to large engineering projects in the field of mechanical, electrical and hydraulic equipment

May 1, 2011

By C. P. Patel

"The Sturgeon Lake Joint Venture volcanic massive sulpide deposit was discovered in 1970. Milling was started by Falconbridge Copper Ltd. at Sturgeon Lake in September 1974. The Sturgeon Lake pit and mill are located 88 kilometers by road northeast of Ignace, Ontario. IgnE1ce is a town of some 2800 people located on the Trans-Canada Highway, 241 kilometers west-northwest of Thunder Bay. The mill is treating an average of 1100 TPD producing separate concentrates of copper, lead and zinc. Initially, difficulties were experienced in achieving accept-able concentrate grades and recoveries but these were eventually overcome. This presentation describes current metallurgical strategy as practiced at the Sturgeon Lake mill.But first, a few words about the type of ore being treated. In geological terms the ore is classified into two main categories. They are the massive sulphides with underlying zones of stringer sulphides as illustrated in Fig. 1. The plan view is shown in Fig. 2. The areas of East-limb and North-limb are as shown. These last two ores have suffered enough alteration to cause problems during treatment. The massive sulphides consist of chalcopyrite, sphalerite, galena, tetrahedrite and small amounts of pyrrhotite among other gangue materials. The stringer ore is comprised of predominantly chalcopyrite intrusions into rhyolite and has lesser amounts of sphalerite and tetrahedrite. At present we are treating a predetermined blend of massive and stringer ores from zones that have been metallurgically tested to ensure compatibility with current treatment procedure in the plant. Ore responding to this treatment is classified as normal ore while the ore proving incompatible is classified as north-limb ore or east-limb ore."

Jan 1, 1980

By Mario E. Rossi

The full economic evaluation of a mining project requires a block model that provides an estimate of the tons and grades of available resources. The model must be representative of the mineralization to be found at the time of mining for specified extraction periods and within acceptable error margins. In an operating mine, there may be a reasonable understanding and estimates of actual dilution and ore loss. This paper discusses the issue from the perspective of a project at a feasibility or preproduction level of development. Three types of dilution are discussed. Internal dilution (or change of support) is function of the spatial distribution of the mineralization and its relation to the operation?s selectivity. Geologic contact dilution is the unavoidable mixture at contacts or boundaries of material with different geologic characteristics, grades, or metallurgical performance. Operational planned and unplanned dilution should also be considered, sometimes incorporated by factoring the resource model, but more accurately by mimicking the grade control process. The resource estimation process always carries uncertainty, which is sometimes significant, and usually caused by several factors. These include quantity and quality of drill hole information; quantity and quality of geologic data; grade estimation methodology; dilution and mining recovery factors applied; etc. A key decision is to whether estimate as accurately as possible the in-situ geologic resource or to estimate the tons and grade of the material to be fed to the processing plant. The geologic modeling and grade estimation methods used are conditioned by this decision.

May 1, 2009

By K. Meyer

"The largest cost centres of the David Bell Mine concentrator are grinding, leaching and effluent treatment. Optimizing results during the 6th year of operation are listed below: o SAG mill slurry density control and operating strategies improved liner life and media consumption by 10 and 25%, respectively.o Poly-met liners clad the SAG mill except for the feed end. Lower noise levels and reduced mill downtime have resulted in an improved and more efficient workplace (time required for liner changes is 2 to 3%).o A comparative grinding media study using seven different marked media at the same time showed media wear rates range 120 to 198 mg/kWh and ball mill charge replacement frequencies of 8.3 to 13.1 per year, and that a meaningful wear test must include all media to be tested at the same time in the same mill. High quality carbon steel cylinders had the best economics.o Pre-aeration, using pure gaseous oxygen is accomplished in pipe reactors. Small bubble generators provide oxygen in the first three leach tanks. 1500 to 3000 kg of oxygen is consumed per day. Leach kinetics have improved and trends indicate increases in gold recovery of three to seven ounces per day at reduced costs. Effects of reduced cyanidation of accessory metals on the effluent treatment plant will be discussed in a separate paper."

Jan 1, 1991

By Tapiwanashe Chenje, David Hewitt, Peter Radziszewski

"Steel media wear is a major cost component in mineral processing. In the case of existing operating mill, steel media wear prediction can be used to help compare the performance of steel media from different suppliers before completing marked ball tests. It can also be used to investigate how ores from different site of a given mine affect steel media wear. In the case of Greenfield cases, steel media wear prediction can be used to estimate the cost of steel media for a given feasibility study.This paper presents a wear testing and prediction methodology that ties together abrasion wear and corrosion wear testing results through the use of a simplified discrete element charge motion model. The experimentation dimension to this methodology takes samples for steel media, mine site ore and water to determine abrasive and corrosive wear parameters of a given media, ore, water set.The test methodology development is illustrated along with a comparison of wear predictions with observed wear rates in some operating mills. A case study is included that illustrates how this methodology was used to estimate steel media wear performance. The paper closes with a discussion on the use of parts of the experimental methodology to investigate other abrasive wear conditions such as liner wear, paste backfill piping and ore breakage as well as avenues for future test development.INTRODUCTIONThe cost of comminution processes represents a significant part of the overall costs of a mining operation. Grinding media/liner wear alone accounts for 15-25% of the total operating cost. The annual steel grinding media consumption is approximately 2.5 mtpa or 0.3% of total world steel production [Smorgon Steel Group, 2005]. Using an estimated grinding media cost of about US$0.75/kg [Halbe and Smolik, 2002], gives a media cost of over US$1.875 billion per annum. Mining continues to shift towards exploitation of lower grade ores as the higher grades get depleted. These low-grade ores require finer grinding for the liberation of the value minerals, and hence it can be assumed that grinding media consumption will also continue to rise.The Bond abrasion test, dating back to 1963, [Weiss, 1985] is still used to estimate the total mill media wear. This is a purely empirical test based on the ore. From Bond abrasion index tests, it is possible to determine a wear rate using the following function:"

Jan 1, 2009

By G. J. Knighton

Introduction The Sullivan concentrator treats the complex lead-zinc-iron ore from the Sullivan mine of the Consolidated Mining and Smelting Company of Canada, Limited, to make a lead and a zinc concentrate for its metallurgical plants at Trail. Three miles separate the mine and mill, which are situated near the town of Kimberley, in the East Kootenay district of British Columbia. The orebody consists typically of banded sulphides, mainly galena, sphalerite, pyrrhotite, and pyrite. Important factors in the concentration of the ore are its exceedingly complex and its high specific gravity. It should be remembered throughout the paper that results and figures are based on Consolidated's experience with the Sullivan ore. The present mill feed rate is 8,500 dry tons of ore per 24 hours, for an operating week of five and a half days. Grinding and classification of the ore are carried out in three stages and, in addition, there is a re-grind section which re-treats the zinc middling. It is the purpose of this paper to discuss the classification in the various stages and to give the results o comparative tests which have been carried out for the purpose of improving operations in the mill. The Primary stage consists of six units, each made up of a ball-mill and classifier (see accompanying flow-sheet). Four units operate in open circuit and two in closed circuit. The secondary stage consists of eight ball-mills operating in closed circuit with twenty-one classifiers. In the Tertiary stage are two ball-mills in closed circuit with eight classifiers. The re-treatment section for re-grinding the zinc middling comprises one ball-mill in closed circuit with two classifiers.

Jan 1, 1947

By F. Hassani

This Paper describes a sudden spill of rock waste used for backfilling from a waste pass at one of the underground mine in Canada thus causing a major failure/accident. The mine operator immediately launched a detailed investigation to understand the causes of this accident and develop procedures to prevent any recurrence of such events in future. The investigators from McGill University were invited to collaborate with the engineers at the mine to examine this accident. The events leading to the accident were studied and appropriate measurements were taken and samples of the waste material was collected for further test and analysis. The field visit and the interview of the witnesses allowed a detail documentation of the events. The sequences of events related to the incident together with the experimental results obtained in the course of the investigation is detailed. The waste material was characterised in the laboratory with regard to its behaviour in the presence of water. This information is then discussed and the failure mechanism involved in this accident is identified. The full recommendation as well as the immediate operational measures implemented by the mine to prevent future occurrence of such events are discussed and presented.

May 1, 2003

By Tanveer Jahir

With increasing energy costs and mounting government pressure to adopt low emission, green sources of energy, it has become imperative to develop long-term sustainable underground infrastructures that exhibit low power consumption. Underground mining environments are mandated to have ventilation systems in place to replace polluted air with clean air. Continuously running air ventilation systems have proven to be an expensive solution for this requirement. Ventilation-on-demand (VOD) is a cost effective method for not only reducing energy consumption and greenhouse gasses, but also ensuring the safety and well-being of the miners beneath the surface. VOD is achieved by monitoring the air quality in target areas of the mine, and based on variables such as the number of personnel in the area, the number of emission-emitting vehicles, the air leakage around doors and entrances, dust levels, and other key environmental details, the speed and angles of the fan blades are adjusted to increase or decrease the volume of air flow. For over 40 years, Conspec Controls has been developing systems capable of VOD through the use of controllers, gas monitors and personnel/vehicle tracking equipment, providing inexpensive, reliable solutions for underground ventilation.

May 1, 2011

By S. Fuentes, J. Cáceres

"During the past fifteen years, mines utilizing the block caving method have improved performance and systematically reduced total mining costs.This paper describes improvements in mine design, mine planning, and mine management, including methods enabling the Chilean and international mining industry to ensure cost savings and productivity growth while using the block caving method. These improvements have encouraged the re-evaluation of underground operations at operating and closed open pits, and challenge surface mining applications as the only low-cost mining method. This paper describes a strategy to estimate the optimum open pit to underground transition time during the life of a mine. IntroductionDuring the last fifteen years, block caving mines have experienced huge changes in designs, planning and administration. These changes have permitted operators to drastically reduce costs, improve equipment productivity, and improve overall business performance. As a consequence of this situation, the block/panel caving mining system is challenging actual open pit operations to maximize the net present value (NPV)."

Jan 1, 2004

By P. W. Godbehere

"INTRODUCTIONMagnetic mill linings have been developed from an invention by Mr. Bertil Brandt, the originator of the Skega rubber lining. The OREBED magnetic mill lining is a concept in which rubber covered strontium ferrite permanent magnets are arranged on the inside wall of a mill shell so that they attract magnetically susceptible material be it ore, media or tramp, to form a protective layer over the magnets and to serve as an operating surface with indefinite life.Noranda Mines Ltd. through its associate Norcast Division of Noranda Metal Industries formed a joint venture with the inventors to market magnetic mill linings in North America. For the past twelve months trials have been undertaken in conjunction with Orebed Inc. to test and develop these linings for grinding mill applications at the Horne Concentrator. Two independent milling circuits are currently being operated, one treating a siliceous gold ore and the other a copper slag.This paper presents the results of the magnetic lining test programme to date."

Jan 1, 1983

By Andy Cole

Barrick Gold recently implemented an oxygen roasting process to treat carbonaceous ore from its Goldstrike property in Nevada. One of the key project challenges was the design of the roaster gas cleaning system, which was driven by the requirements of a strict air permit and the need to achieve very high reliability. The roaster gas systems include multiple stages of wet particulate collection, a dual-alkali SO2 scrubber, mercury scrubbing, CO oxidation and NOx reduction. This paper describes the gas system, the influence of regulations on project implementation, and performance of the system.

May 1, 2002

By D. Kidby, A. Briggs

"Vitrokele ™ is a synthetic adsorbent, using chelating groups on large polystyrene beads, developed in Canada over 7 years ago, and first commercialised in 1985 to recover noxious metals from plating wastes.Pilot plant trials have been performed in Australia and Canada to demonstrate the recovery of cyanide and removal of metal cyanide complexes from gold plant effluent using Vitrokele1 M 912. The pilot plants comprise a simple adsorption train (similar to a CIP circuit) followed by complete elution facilities, so that loaded Vitrokele™ can be stripped and returned to the adsorption circuit.An account of these campaigns is provided, showing the reduction of total CN levels from over 200 ppm to less than 0.5 ppm and Cu levels from approximately 100 ppm to less than 0.3 ppm in treated tailings.Comparisons between pilot plant results and laboratory test data are given and probable future work on the process and its application to the gold mining industry is discussed.INTRODUCTIONThrough millions of years of evolution, life forms have developed specialised molecules with exceptionally high affinity and selectivity for various metals such as iron, cobalt, zinc and copper.In the early 80's professors at the Faculty of Medicine of McGill University engaged in research on the extremely efficient ways that living cells captured trace metals essential for life.As research progressed, it became evident that the special molecules used by biological systems to capture metals could be synthesized to capture selected metals with similar efficiency from water or other solutions.The technology was first commercialised in 1985 to recover noxious metals from plating wastes with compositions applying the special molecules (chelating groups) on vitreous particles (hence Vitrokele™). To date approximately three commercial Vitrokele™ plants have been installed for treating plating waters in Ontario and Quebec."

Jan 1, 1992

By Elmer Stewart, Richard May

"The Central Mukur deposit was discovered by the Semipalatinsk Geological Exploration Expedition (GEE) during detailed searches from 1977 to 1980. Andas Altyn Ltd., a Kazakhstanian gold mining company acquired the property and commenced mining in 1995. In 1998, Andas-Altyn Ltd. became a wholly owned subsidiary of Eurasia Gold Corporation.The Central Mukur gold project covers a linear series of parallel, discontinuous zones of near surface oxide gold mineralization that covers a distance of 7 kilometers and extends past the property boundaries. The oxide gold mineralization is a result of the regional oxidization of a primary sulfide gold mineralization emplaced in a series of shallow dipping thrust faults. Resources as calculated by the GEE are 3.45 mt at an average grade of 1.84 gmt Au in the C1 +C2 category and 7.52 mt at an average grade of 1.80 gmt Au in the P1 category. The Central Mukur Gold Heap Leach Mine consists of an open pit, heap leach pads, and an ion exchange resin gold recovery plant. Limited gold production (<2,500 ounces/year) has been achieved over the past three years leaching run of mine oxide gold mineralization. Gold recovery utiling cyanide to dissolve the Au and ionic resin technology to recover the Au for the leachate is approximately 60%. Loaded resin is shipped to a treatment plant at Almaty where the gold is stripped from the resin, refined and sold.This paper will describe the geology, mining, and processing of the Central Mukur ore. In addition, it will describe what it is like doing business in Kazakhstan and the transition from a Soviet style operation to a more western style operation.INTRODUCTIONThe Central Mukur Mine is owned and operated by Andas-Altyn Ltd. a Kazakhstanian gold mining company located in northeast Kazakhstan. Andas-Altyn is a wholly owned subsidiary of Eurasia Gold Corp., a Canadian public company listed on the Alberta Stock Exchange. The Central Mukur mine consists of a small open pit, and a heap leach operation that utilizes ion exchange resin to recover gold from pregnant solutions. In addition to the Central Mukur mine, Eurasia also owns the Myaly heap leach gold project which is also operated by Andas- Altyn Ltd."

Jan 1, 1999

By Jim Truskoski, Alain Bouchard, Andy Kerr, Germain Labonté, Jim Barrett

"Improving mill grade recovery relationships is always good business. INCO’s Clarabelle Mill has just undergone a $16 million process upgrade that was designed to improve nickel recovery by 2%. The “Mill Redesign Project” was completed on time, under budget and delivered the promised improvement in recoveries.This paper describes the methodology of the Mill Redesign Team, details of the process improvements and the critical success factors that helped the team deliver on its promises.With a payback of under one year, the Mill Redesign Project will play a key role in ensuring a competitive edge as INCO embarks on its second century of operation.INTRODUCTIONIt is not uncommon in milling operations to encounter a crisis. That is the point when the process does not behave as expected and fails to respond to the increasingly desperate efforts of the metallurgists and operators. Flowsheet and process changes are attempted and abandoned. With luck, one or more of the changes achieves some mitigation of the original problem or more usually, the original cause of the problem disappears. Regardless, the metallurgist can sit back and bask in the apparent success of his or her endeavours.Less common is when a problem is carefully diagnosed, a team put together to explore all avenues and recommend a path of action that is implemented on time, on budget and immediately delivers on the promises which are sustained over time. This is one such story. It is the story of the Mill Redesign Project at INCO’s Clarabelle Mill in Copper Cliff, Ontario.BACKGROUNDThe Clarabelle Mill was built in 1971 on the southern rim of the Sudbury basin. At that time it was one of four mills operated by INCO in the Sudbury area. During the 1970’s, 80’s and 90’s, the need for increased process efficiency, higher levels of sulphur rejection to tails and the concurrent development of high capacity mills and flotation cells, resulted in the consolidation of INCO’s Sudbury area milling operations into a single, expanded facility at Clarabelle."

Jan 1, 2003

By Andrea M. Ouchi

A major focus of ground control research presently being conducted by the Geomechanics Group in the University of British Columbia Mining Engineering Department is to incorporate weak rock masses (RMR76 less than 50) into existing empirical design relationships. An emphasis is being placed upon the updated span design curve/critical span graph originally developed at UBC. The original database has been augmented by mapping of one mine in Montana and of several mines within the Carlin and Getchell Trends of Nevada. In addition, a neural network analysis has been performed and modifications of the span design curves at the lower RMR76 range have been made. The common factor in all the above mentioned mines is a weak back and/or walls. In most cases, the ore zone is the weakest rock unit and must be dealt with to safely extract the mineral bearing rock. This work attempts to provide rock mechanic tools that will enable a mine operator to make economic decisions that will also ensure a safe working environment.

May 1, 2004

By Patrick F. R. Murphy

The mechanization of platinum group metal (PGM) underground reef mining in South Africa has posed a challenge to mining engineers for several decades. This is primarily due to the shallow dip angles and narrow thickness (<1.1m) of the tabular orebodies mined, and the issues faced in developing reliable drilling, bolting and loading machines suitable for such hard-rock mining applications. Presently, mining is typically conducted using hand drills and scraper shovels. These methods, however, are intensive in terms of manual labor, and limited in terms of productivity, and improved methods are desired. This paper will review the technical features of a 4 tonne, low-profile, LHD for narrow-reef PGM mining, developed by EJC Loaders Division.

May 1, 2003

By A. M. Childs, R. F. Mather, K. R. Rawling

"The challenges encountered in the design and construction of mines and their process facilities today are becoming more intense and the engineering more competitive. The need to incorporate new techno1ogy to compensate for ever rising costs is always present, but its application in the harsh environment of Northern Canada increasingly requires the inclusion of new proven methods and innovative approaches to arrive at economically attractive projects.This paper deals with the development of the process design for the Cullaton Lake Gold Mine in the Northwest Territories. Particular emphasis is given to the interaction of the imposed construction and testwork schedules, and their effect on certain process decisions.The challenge that faced the project team may be defined by the following factors:1. A schedule which required that metallurgical testing, engineering, and procurement and delivery of all equipment and construction supplies should be complete within a period of ten months.2. Transportation of all personnel, equipment and supplies to the site by airlift, as no road was available or affordable.3. A six week period when transportation to the site was impossible.4. The extremes of temperature beyond the tree line in the Northwest Territories.5. A complete lack of infrastructure in the area."

Jan 1, 1983