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Retreating Cu-Mo Rougher Tailing by Flotation for Concentration of Copper and Molybdenum

Sep 13, 2010

Thank you for the invitation to address The AusIMM Young LeadersÆ Conference here today. When I first saw the conference theme û æadvancing technologies and their future applications in the mining industryÆ û my interest was sparked because there is little doubt that technology and technological advances will determine the relevance of this industry in the future. And the people seated here today are major players in determining the minerals industryÆs destiny.During my 20-year association with the mining industry, I have observed a number of significant changes that have been delivered as a result of the vision of technical specialists. These changes have built a more competitive industry, a more socially acceptable industry and most importantly an industry with ever-improving safety performance. The purpose of my address is to attempt to provide a context and foundation for other presenters over the following two days. Today, I wish to try to answer the question, æWhy do we invest in new technology in the mining industry?Æ, via: a brief history lesson, a review of the needs of the business, a look at the process for improvement, and finally an example from WMC ResourcesÆ current technology portfolio. I would like to take a very brief walk back in time. During the iron and bronze ages, whilst our ancestors IÆm sure never spoke the phrase ænecessity is the mother of inventionÆ, I am sure they lived by it. Undoubtedly more so than we do today. The roots of geology, mining and extractive metallurgy grew out of the need for better tools in order to get access to the basic necessities of life. It was their superior ability to generate and deliver these ætechnologyÆ improvements that underpinned great civilisations such as the Egyptians, Romans and Incas. The application of mineral technology improvements by these civilisations was crucial to their success, it was their competitive advantage at the time. Many historical texts include detailed descriptions of both mining and processing fundamentals that formed the basis of many of todayÆs operations and processes. However, it is technological improvements to these fundamentals, as well as the development of new technologies, that have preserved the fundamentals as viable options for the industry today. Even in my time in the industry, there have been substantial improvements in the way business processes operate. When I first started working in a gold mine in WA in the late 1980s, the office had one PC (a 286 processor). All data was managed by paper and then often re-typed into other databases. Electronic mine design and process control was in its infancy. Today, massive amounts of data are recorded, analysed and acted upon almost without any human interaction. Our industry today has far different challenges than those described by Argricola. These are many and diverse, but new technologies are required to address three distinct classes of need: 1. Societal needs: physical needs for food, shelter, recreation and leisure; community and political needs for less waste, less emissions, better safety and working conditions, less energy consumption and sustainability. 2. Individual needs: intellectual needs to create innovative technical and organisational ideas. 3. Wealth generation needs: investor needs for maximising operating efficiency and value growth. Each new technology, to varying degrees, fulfils one or all of these needs. In many cases, the driver of a technological development was to fulfill only one of these needs, but after it was implemented, the development actually fulfilled each need. I would like to expand on these needs.

Jan 1, 2003

Platiniferous horizons such as the Merensky Reef that are mined chiefly for their PGE contents constitute one end member of a continuum of Ni-Cu-PGE sulfide deposits; Ni-(Cu) sulfide deposits in which the PGE may or may not be by-products represent the other end of this continuum. Although it has long been thought that PGE-rich sulfides can only be developed by magma mixing in large magma chambers, new PGE data for the Bushveld Complex suggests an alternate model to account for origin of mineralization in the worldÆs most important Pt producer. Briefly, this model suggests that PGE-rich sulfides were initially deposited at depth below the Bushveld Complex as a result of interaction of a S-undersaturated mantle magma with S-rich crustal rocks. These PGE-rich sulfides were subsequently re-dissolved by a second magma, which introduced the PGE into the Bushveld Complex magma chamber, where the PGE-rich reefs were formed due to cooling of these magmas. If this model is correct, it means that large layered mafic/ultramafic intrusions are not a prerequisite for the formation of economic PGE-rich deposits. Exploration for Merensky Reef-type PGE deposits can be greatly facilitated by documenting variations in the background PGE contents of non-mineralized rocks collected on traverses across mafic/ultramafic intrusions; the mineralized horizons occur at cross-overs in ratios such as Pd/Cu, Pd/Se and Pd/S.

Jan 1, 2002

By AMIRA P588 Research Team

This contribution summarises new knowledge and data, obtained during a three year ARCAMIRA funded research project, on the mineralogical and geochemical characteristics of hydrothermal alteration associated with low sulfidation, gold-silver epithermal deposits. These data are used to develop exploration vectors for use at both deposit and district scales, plus techniques have been established to distinguish ore grade epithermal systems from barren or low grade systems. Deposits investigated were Ladolam, Papua New Guinea, Gosowong and Mt Muro, Indonesia, Cerro Vaguardia, Argentina and Bimurra and Twin Hills, Australia.

Jan 1, 2005

Open pit mining has considerable damaging effects on the environment of the mining region. These harmful influences have to be controlled during mining operation until mine closure. Different sections of mined land, such as; pit(s), waste dump(s), tailing pond(s), roads, areas for onsite facilities and free land zones which are not mined, have to be reclaimed through treatment of environmental pollution and implementation of a permanent post mining land use (PMLU) after mine closure. Implementation of a permanent optimal post mining land use (OPMLU) is one the most decisive criterion which effects on reclamation procedure, mine closure and their costs. Therefore to define ultimate pit limit (UPL), mine closure and reclamation costs should be entered in the calculation iterations same as the other variable costs of the projects. Estimation of closure and reclamation costs of a mining project is carried out based on the attained OPMLU and the specifications of the mine site. In this paper, a model is developed to provide OPMLU for pit area through fuzzy multi-attribute decision making (FMADM) technique. The model was implemented on a hypothetical copper mine in northwest of Iran as a case study. Lumber production was selected as OPMLU for the pit area. It is finally concluded that through the developed model, OPMLU for different sections of mined land in an open pit mine project is defined. Also closure and reclamation costs are estimated based on the defined OPMLU to achieve a more accurate UPL.

Dec 6, 2010

By H Sofatzis, J Kinal, J Siliezar, B Kirkwood

Ernest Henry Mining (EHM) is a copper, gold and magnetite mining and processing operation located 38 kilometres north east of Cloncurry in the Mount Isa - Cloncurry mineral district of north west Queensland, Australia. The EHM ore body is an iron oxide copper gold deposit with an average grade of 1.1 percent copper, 0.5 g/tonne gold and 22 percent magnetite.At the end of 2009, after a series of promising laboratory test work, EHM converted the ball mill media charge from forged steel to high chrome media. Laboratory test work also indicated that with the use of high chrome media, the pH was able to be reduced with no negative impact on plant performance. At high pH values (above 10.5), the forged media is passivated, so as the pH of the system drops the media corrosion rate increases and floods the system with corrosion products, affecting flotation. As the high chrome media is much more inert, pH has less of an effect on copper flotation response.This paper provides an overview of the effects of reducing the pH in the EHM copper rougher flotation circuit. The pH in the roughers was dropped from 10.6 to 9.6 to determine the impact on the rougher performance and the subsequent performance of the whole copper flotation circuit. It was found that there was a slightly increased improvement in copper recovery and no statistical change in either the rougher or final copper concentrate grades for copper and gold.With the reduction in pH, there was a noticeable reduction in lime usage from 0.85 kg of lime per tonne of ore processed to 0.55 kg/t. This reduction in lime is equivalent to approximately $700,000 per annum at current production rates.CITATION:Kirkwood, B, Kinal, J, Siliezar, J and Sofatzis, H, 2013. Low pH trial in the Ernest Henry Mining copper rougher flotation circuit, in Proceedings MetPlant 2013 , pp 371-377 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By K Gordon

A methodology for assessment and remediation of acid mine drainage (AMD) developed at the Sullivan Mine in the West Coast Region has been applied to the closed Blackball Mine, Blackball, West Coast Region. AMD from the Blackball Mine has low pH, high acidity, and elevated levels of iron, aluminium, manganese, nickel, zinc and arsenic. The AMD flows at a variable rate (36 - 101 L/s) into adjacent Ford Creek, causing an increase in acidity and trace element concentrations in the creek. To test the effectiveness of treatment with a simple limestone-based treatment system, a column leaching experiment was conducted over a nine day period. The results show effective removal of acidity, reduction in the concentrations of iron, aluminium, manganese and zinc, and production of alkalinity. To determine if this treatment method reduces the toxicity of the AMD to aquatic invertebrates, a 96 hour ecotoxicity experiment was conducted. The results show a significant decrease in mortality in the treated AMD compared to untreated. The column experiment, in conjunction with the ecotoxicity work, suggest that a passive treatment system consisting of a limestone leaching bed and an open limestone channel may be sufficient to treat the AMD from the Blackball Mine. Further work, such as large-scale treatment trials, is recommended.

Jan 1, 2004

By R L. Brathwaite

The epithermal gold-silver deposits wall poster is one in a series of posters on different mineral deposit types being produced by GNS Science to raise awareness of the characteristics of New Zealand mineral deposits and their prospectivity. Epithermal deposits consist of quartz veins, quartz vein stockworks and hydrothermal breccias that are mainly hosted in subaerial andesitic or rhyolitic rocks of Tertiary age. The deposits were formed at depths of typically less than 1 km and at temperatures between 180¦ and 320¦C, although ore grade mineralisation was generally deposited at less than 270¦C.   In New Zealand, epithermal deposits occur in association with late Cenozoic volcanic rocks in the Northland, Coromandel and Taupo volcanic regions. All of the past and present gold production, estimated at greater than 380 t (along with 1300 t Ag) comes from the Miocene-Pliocene Coromandel Volcanic Zone, where about 50 epithermal gold-silver deposits occur over a 200 km long belt. In Northland, silver and mercury have been produced from hot spring type epithermal deposits, and several gold-silver prospects have been identified. Ore grade gold-silver mineralisation is currently being deposited in several active geothermal fields of the Taupo Volcanic Zone, and extinct geothermal systems occur on the western side of the zone. The active systems have provided natural laboratories to help understand the processes of epithermal mineralisation.

Jan 1, 2005

By L-B Fu and J Tan, J H. Wei, N Tian

"An EXTENDED ABSTRACT is available for download. A full-length paper was not prepared for this presentation. The Kendenggaoer-Kuokuqueke region lies in the western part of Chinese North-western Tianshan. New laser ablation inductively coupled plasma mass spectrometry zircon U-Pb geochronology for five separate granitic plutons for this region reveal two distinct intrusive periods: late Devonian (367~361 Ma) and late Carboniferous (315~301 Ma). These intrusions all share an arc-like geochemical affinity (ie enrichment of large ion lithosphere elements and negative anomalies of Nb, Ta and Ti). In situ zircon Hf isotopic compositions further differentiate the magmatic cycle, with the late Devonian intrusions yielding more depleted eHf(t) (+1.47~+6.54) composition than the late Carboniferous intrusions (eHf(t) = +4.95~+9.79). These geochemical data suggest that they might be mainly derived from different source regions and the tectonic setting was transformed into post-collisional in the late Carboniferous. As in many significant porphyry-ore districts, this dramatic tectonic reconfiguration, combined with melting of an evolved crust, resulted in genesis of metal-bearing melts. Furthermore, we can show that Neoproterozoic mafic juvenile lower crust intruded by mantle-derived melts and/or partial melting of slab material generated hybrid primary magma during subduction of the Palaeo-Junggar oceanic crust in the late Devonian. Whereas underplating of mantle-derived magma contributed more to the Late Carboniferous post-collisional magmatism.CITATION:Tian, N, Wei, J H, Fu, L-B and Tan, J, 2015. Timing and geodynamic setting of the late Palaeozoic polymetallic mineralisation in Chinese north-western Tianshan – insights from geochronology and petrogenesis of granitoids , in Proceedings PACRIM 2015 Congress, pp 171–174 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Mar 18, 2015

By E Skinner, G Lane

Project delivery strategies are determined by project context, business case requirements, scale of project, market conditions, ownerÆs capability and preference, contractorÆs experience, resource and skill availability, project location and type of project or facility.Successful project management requires the setting of coherent, effective and realistic business objectives and success criteria. The management team needs to lead, prioritise, resource, align, plan, track and communicate the processes that enable the realisation of these business objectives and success criteria.For any given project there is a unique balance between selection of a simple project delivery strategy that minimises interfaces and a complex strategy that necessarily engages the use of expertise and experience from numerous parties. The right balance for a project between these "book-end cases" is a function of how the project owner or managing contractor defines its objectives and chooses to manage risk, cost, schedule and project quality, in the context of the conditions affecting the project.Selection of an effective project delivery strategy requires a detailed appreciation of the range of external and internal environmental / shaping factors which influence the project. These factors include the project constraints imposed by the business, market or operational environments and the selection of an effective mix of primary (head contract), secondary (mix of vertical and horizontal packages) and tertiary (type of individual contract) strategies. The selection of the primary, secondary and tertiary strategies also shapes the project, the size and responsibilities of the ownerÆs team and the framework for delivery of outcomes.How does an owner or prime contractor decide? What is the optimum for a given project? Those with operations management backgrounds will have different views to those with project and construction management backgrounds.Is the simplest practical approach the best approach? Each and every interface needs to be managed.The owner will want a very experienced team that is engaged directly with the owner. The team will have a track record of successfully performing projects using contractors skilled in their respective disciplines and selected using competitive tendering on brilliantly designed scopes of work and good contract terms, with a fully defined project scope and appropriate schedule, for which all significant risks have been addressed and no scope changes are outstanding. Budget and schedule will be expected to have been developed with a full understanding of the scope, situation, risk management requirements etc.The problem is that these conditions rarely exist. The challenge in selection of a project delivery strategy is to resolve how best to address the inadequacies between the ideal case and the present reality. The mechanism for addressing the inadequacies defines the likely outcome of the project.CITATION:Lane, G and Skinner, E, 2013. Project delivery, in Proceedings MetPlant 2013 , pp 50-65 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

Drill blasting is a widely used method for rock fragmentation in mining, quarrying and construction industries. Environmental effects such as air shocks, dust, flying rocks and ground vibration are unavoidable results and undesired effects of blasting. Among these ground vibrations can have a damaging effect and may influence on long distances. Therefore various researchers have developed mathematical models to predict ground vibration after blasting. These models take into account the amount of explosive, distance and several coefficients related to the field under investigation. The developed models to predict ground vibration may yield different results for the same case. Selection of the most suitable model requires engineering judgment and evaluation of models. At this point, a computerised system helps the engineer to evaluate and select the most suitable model in order to design and plan a blasting pattern. The safe charge of explosive and magnitude of vibration after blasting should be predicted beforehand. Therefore a computer program namely 'prediction of blast induced vibration' (P-BIV) has been developed. This paper introduces and presents a computer program (P-BIV) which includes the set of models developed to estimate ground vibration to provide blasting engineers a tool to determine the amount of explosive for safe blasting.

Dec 6, 2010

The Significance of Internal Recycle in Froth Flotation

Sep 13, 2010

By R Young, D OÆSullivan

When Centaur Mining and Exploration produced nickel metal fromlaterite ore at its Cawse nickel project in January 1999, a new era in the nickel industry was heralded in. One of three new laterite projects commissioned that year, new technology and a unique process design has been combined at Cawse to launch what will be amongst the worldÆs cheapest nickel production. However, the road to success has proven to be long and challenging. This paper explores CentaurÆs approach to the Cawse start-up and discusses a number of issues that have been confronted and overcome. * Originally published in the Proceedings of the Seventh MillOperatorsÆ Conference, published by The AusIMM.

Jan 1, 2001

Detachment of Particles from Bubbles in a Stirred Cell

Sep 13, 2010

The quantity, quality and detail of project information increases as project development moves from initial scoping level studies, to pre-feasibility and option studies, then definitive feasibility study and basic engineering stages. Data accumulates from metallurgical and vendor testing from various ore types and composites carried out to assess physical characteristics and processing responses of the ore. Over-simplification or assumptions about the orebody for flow sheet development can result in using æaverageÆ information for design. Use of averages of data can have adverse implications on sizing of plant and equipment and consequently on definitive study cost estimates and detailed engineering. In practice, the treatment plant workforce is faced with managing a non-homogeneous or non-average orebody in a variable operating environment that is not always predictable. This paper presents views on how to use the data generated from testwork in project development and for process and plant design. Examples of process design risk or operating risk are presented. Although this topic is applicable to the broad range of process design decision making in the minerals industry, this discussion references comminution, flotation and extraction processes for gold and base metal ores.

Jan 1, 2004

This paper examines the integration of risk management into the design philosophy of a project to produce a æzero baseÆ design, which targets a minimum capital cost without adversely impacting upon the operating costs of the resulting plant. The concept of zero base design is similar to zero base budgeting and the desired outcome is to improve the economy of the design. Design requirements are questioned in an attempt to distinguish preference, prejudice and myth from necessity. Where doubt remains a risk management approach is adopted. The key to risk management is not risk elimination, but risk mitigation. Risks can be managed by designing them out, but often this involves considerable capital cost penalties and it is more attractive to accept the risk and design an operating strategy to deal with it. The paper discusses this with some examples of real world risk mitigation strategies that resulted in substantial capital cost savings. The paper concludes that as much as a quarter of project capital costs can be eliminated by a combination of zero base design and carefully crafted risk mitigation strategies.

Jan 1, 2004

By C Hall, J L. Mauk

New 40Ar/39Ar dates of vein and wall rock adularia from seven epithermal deposits and one porphyry copper prospect help constrain the ages of mineralisation in the Hauraki Goldfield. Vein adularia from the Paritu region yielded a single 40Ar/39Ar plateau date of 16.315 ¦ 0.066 Ma. Five 40Ar/39Ar plateau dates of three samples of vein adularia from the Opitonui deposit overlap within error to yield a preferred age of 13.149 ¦ 0.016 Ma. Two samples of vein adularia from the Night Reef at the Broken Hills deposit yield exceptionally flat 40Ar/39Ar plateaus, and all dates overlap within error to provide an age of 7.121 ¦ 0.010 Ma. Two 40Ar/39Ar plateau dates of one sample of vein adularia from the Wharekirauponga deposit overlap within error to provide an age of 6.318 ¦ 0.061 Ma. Four 40Ar/39Ar plateau dates of three samples of vein adularia from the Maratoto deposit overlap within error to provide an age of 6.411 ¦ 0.022 Ma. Two samples of adularia from altered wall rock at the Sovereign deposit yield three 40Ar/39Ar plateau dates that range from 6.547 ¦ 0.021 to 6.806 ¦ 0.028 Ma. This suggests that mineralisation formed around 6.6 Ma, but the results are complicated because the adularia contains minor illite that post-dates adularia formation. Results from the Karangahake deposit are complex. Two samples of vein adularia yield three 40Ar/39Ar plateau dates that range from 6.116 ¦ 0.116 to 6.901 ¦ 0.101 Ma, whereas one sample of wall rock adularia that contains minor late illite yields two 40Ar/39Ar plateau dates that overlap within error to provide a date of 5.734 ¦ 0.041. The range of dates indicates that more work is necessary to understand the history of mineralisation at this deposit. Two samples of vein adularia from the Tui deposit yield four 40Ar/39Ar plateau dates that overlap within error to provide an age of 5.714 ¦ 0.017 Ma. These results confirm previous work that indicates that the ages of epithermal deposits young southward in the Hauraki Goldfield. These results are also consistent with previously postulated different ages for deposits hosted in Kuaotunu Subgroup rocks in the northern goldfield (>10 Ma), and deposits hosted in Waiwawa Subgroup rocks in the southern goldfield (7.1 to 5.7 Ma).

Jan 1, 2005

By D Wyatt, J Domenico, W Kow

Over the past few years developments in heavy minerals processing have concentrated on the mineral separation portion of the business. The best example of this would include new developments in rare-earth magnetic separators and associated flowsheet modifications. Except for some minor modifications in spirals, the æwetÆ side of the separation business has lagged behind the ædryÆ side. Basic concentrator design has not changed in 20 years. Recent pilot trials by Outokumpu Technology have shown the benefits of a new gravity flowsheet that combines density separation and spiral concentration on a variety of heavy mineral deposits. This concept is already well utilised within the iron ore industry. The synergistic combination of these two technologies allows smaller, simpler, and controllable gravity concentrators to be built while providing equivalent or better grade and recoveries of valuable heavy mineral. This is contrasted to the all spiral flowsheet characterised by the diminishing returns of multiple stages of spirals and associated recirculating loads. Examples of the flowsheets and associated benefits will be presented from a variety of cases.

Jan 1, 2001

By M J. Andrews, P J. White, I Bogie

Active geothermal systems occur widely in Sumatra and in the Taupo Volcanic Zone (TVZ) ofNew Zealand. There are also many occurrences of epithermal gold mineralisation in Sumatra, some of which are economic. Minor sub-economic occurrences of gold have been reported in the TVZ but none have yet been mined. There are both similarities and differences in the nature of the active geothermal systems and mineral deposits in Sumatra and New Zealand, which can be systematically related to the tectonic setting. The thicker crust and consequent predominance of silicic volcanism in New Zealand leads to hydrothermal systems which are little eroded and with limited lateral outflows. The systems in Sumatra are of mixed character, with some of the characteristics of those in andesitic island arcs such as Java or the Philippines, e.g. a higher proportion of systems with identifiable acid magmatic volatiles, a greater potential for deep erosion and lateral outflows than in New Zealand; but modified by the more oblique component of subduction and thickened crust so that some are localised in volcano-tectonic depressions and consequently have high piezometric levels of primary hydrothermal fluid. The unusual occurrence of calcic zeolites in veins associated with gold mineralisation in Sumatra is thought to be indicative of æsatelliteÆ boiling zones along de-gassed hydrothermal outflows.

Jan 1, 1995

The history of mining is rightly proud of its achievements in improving productivity and cost improvements over the years. No matter what measure is used, tonnes per manhour, cost per tonne, etc vast improvements have been made over the last hundred years. In fact over the last ten years in Australian coal mines raw coal output per employee has increased by 60 per cent. When one examines why these improvements have taken place the principal reasons have been technological advancement in mining equipment, excavator and dump truck capacity increases, longwall and continuous miners continually improving in reliability and size. Of course all these improvements are correlated to an increase in capital cost. Even with the above-mentioned advances the pressure for increased performance is as strong as ever. The international mining and mineral-processing sector is currently operating in a recessive market with some traditional commodities, eg gold trading at 20 year lows. During recessive times senior management will demand greater returns on capital employed: the obvious choices being reducing costs or increasing throughput. In addition, head office environments will often place a capital freeze on operational management so the opportunity to take advantage of technological change is not available. The challenge is, therefore, to increase throughput and cut costs without the need for capital. The answer is to optimise the existing labour and plant. If done systematically a result in productivity improvement, in our experience, as high as 45 per cent can be achieved with the average across South East Asia and Australasia being 21 - 23 per cent. The intention of this paper is to present a systematic approach to labour and machine utilisation thereby gaining the greatest possible return on the existing capital base.

Jan 1, 1999