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By Scott W. Harrison, Richard E. Aaseng

In 1993 Ispat Inland Mining Company began mining its Laurentian ore reserve, which has six distinct ore types that are extremely variable. Initially batch processing was necessary to optimize mining equipment utilization. The variability as found in the ground was compensated for in plant operation, which proved ineffective. When the last of the six ore types was introduced in 1997, production, quality, and cost were seriously impacted. In-pit blending was the solution developed by the process management team to provide the plant feed required to economically process all six ore types in the Laurentian reserve.

Jan 1, 2000

By Ulrich Benatzky

Rheinbraun AG, Germany, is the management company of the mining and raw materials division of RWE AG. Rheinbraun's core business and major functional area is opencast lignite mining in the Rhineland. The characteristic feature of opencast mining is continuous operation using bucket-wheel excavators, belt conveyors, and spreaders. The report gives a survey of the conveyor systems used. In addition to the general performance data of these belt conveyors, this report will deal in particular with major components, such as drive stations and individual mechanical components (e.g., conveyor belts, pulleys, gears, couplings, brakes, scrapers), as well as monitoring systems. Finally, an assessment of the conveyor systems, together with future developments, will be given.

Jan 1, 2000

By M. J. Gula, S. S. Xue, E. P. Horwitz

A study was conducted to remove iron from sulfate solu¬tions using Eichrom'sDipex®extractant, PP'-di(2-ethylhexyl) methanediphosphonic acid (H2DEH[MDP]). It was found that this extractant can effectively and selectively extract ferric ion from highly acidic solutions. Ninety-nine percent of the iron was extracted from a simulated feed solution in a single stage. The separation factor, Fe/Zn, was 106. More than 90% of the iron in a loaded organic can be recovered in an aqueous solution by reductive stripping. This paper presents the experimental results. A new process for iron removal using Dipex extractant is described and discussed.

Jan 1, 2000

By C. A. Fleming, C. J. Ferron, P. T. O'Kane, D. B. Dreisinger

The platinum group metals (PGM's) are typically recovered by flotation, smelting of the flotation concentrate to matte, and matte leaching. Concentrates too low grade to be processed economically by the conventional process require a new treatment route. PLATSOL, a new pressure leach process, was developed for the Northmet deposit and dissolves in one step base and precious metals (PGM's and gold). Various options exist to recover all pay metals from the leach liquor. The preferred option to date involves a solid-liquid separation, followed by sulphide precipitation of gold and the PGM's, and copper solvent extraction using commercial solvent extractants. This paper briefly summarises the process and the effect of the main leach parameters. Application of the PLATSOL process to various feedstocks is also presented.

Jan 1, 2000

By A. R. Laplante

Ten guiding principles in the design and operation of gold gravity circuits are presented: economic impact, applied mineralogy, gold's behavior in grinding circuits, alternate recovery approaches, reliability vs. performance, gold room operation, scale-up, screening, feed rate and recycling. The principles are explained and their application illustrated with case studies. Conflicts in principle application are also discussed.

Jan 1, 2000

By Tim O’Neil

Nearly 4,800 mining professionals and exhibitors occupying 580 booths attended the 2000 SME Annual Meeting and Exhibit, Feb. 28-March 1, in Salt Lake City, UT. The technical program included80 sessions and four specialty symposia: bulk material handling, control 2000, minor elements 2000 and plant operaters. Meeting highlights included the keynote session. Executive shared their perspectives on pivotal issues and approaches to address the challenges of the new millennium. SME has begun planning for its 2001 Annual Meeting, Feb. 26-28, in Denver, CO. The meeting carries the theme “2001 — A Mining Odyssey.” A call for papers has been issued and exhibit space is 80% reserved. For information, visit SME’s website, www.sme-net.org. Or write Box 625002, Littleton, CO 80162-5002,ph 800 763 3132 or 303 973 9550, fax 303 979 3461, or email meetings@smenet.org.

Jan 1, 2000

By R M. Whyte, D McArthur, A Macintosh

In designing a gold extraction circuit utilising carbon­in-pulp (CIP) technology a number of process options can be considered. These include various combinations of leach or pre-leach, CIP or carbon-in-leach (CIL) and conventional counter-current or carousel CIP (or CIL) circuits. Factors affecting the process selection include the project's sensitivity to capital and working costs, the project life, and the mineralogy and head grade. Each process option has it's own advantages and disadvantages. This paper compares both the financial and technical aspects of the flow sheet options. The flow sheet, design aspects and operating performance of Anglogold's West Wits No. 2 and 3 Plants which are leach, pump-cell circuits are described.

Jan 1, 2000

By P Simpson, P Bundo

The Eureka Mine is situated in the Guruve district of Zimbabwe, some 150 km north of Harare. The mine was first worked in 1895 and until recently was operated as a typical Zimbabwean "smallworking" with a single owner­operator and small labour force mining at up to 50m depth and processing 50 tonnes per day of ore via grind, gravity recovery and CIP. The gravity circuit comprised a Knelson 12" Centre discharge Concentrator from which a significant but variable portion of production was recovered. In 1996 exploration was commenced by Delta Gold Zimbabwe (Pvt) Ltd (DGZ), a wholly owned subsidiary of Delta Gold NL of Australia, with the aim of testing mineralisation and establishing a large-scale open pit operation. A feasibility study was completed in April 1998. Construction began in August 1998 and first gold was poured in June 1999. The mine is designed to produce 65 000 oz/annum of gold from 1.5 million tonnes of opencast ore grading 2 git Au.

Jan 1, 2000

By Steve Rule, Jose Roberto Vago, Walter de Moura

Cerro Vangaurdia Gold Mine is a joint venture between AngloGold (the operator), Perez Companc and Formicruz and is situated in the southern province of Santa Cruz, in Argentina, approximately 2,150 km south of the capital, Buenos Aires. The mine is located in a severe, semi-arid environment with very cold winters and little annual rainfall (200mm). It is an open-pit operation, mining several narrow, shallow epithermal quartz veins with . gold and silver mineralisation. Commissioning of the plant commenced in September 1998 and the first dore bar was poured towards the end of the same month. The nominal capacity of the plant is 55,000 tonnes per month, with a design capacity of 60,000 tonnes per month. Prior to finalising the design, an extensive testwork programme was undertaken at Nova Lima, in Brazil, in which all parts of the process were evaluated together on a pilot-plant scale. The process flowsheet selected at Ce1rn Vanguardia is quite novel, in that it includes milling in cyanide, as well as a cyanide recovery and recycling plant on the tailings section of the treatment plant is included. The cyanide recovery process selected was a version of the acidification - volatilization - reabsorption (AVR) process, known as Cyanisorb™. The selection of the Cyanisorb™ process in the plant design was as a direct consequence of two factors:

Jan 1, 2000

By Malcolm Wills

Boddington Gold Mine commenced operation in 1987 with an initial production of 3.0 Mt/y at a grade of 3.5 git. Head grade has reduced over the life of the mine and the major response to the drop in grade has been to increase mining rates and increase plant throughput. A capital expansion was carried out in 1996 increasing the throughput to 6.0 Mt/y and since that date tonnage has been increased without major capital expenditure. BGM's current mill throughput is 8.77 Mt/y ( 1999). In 1999 the combined basement plant and direct leach plant processed 8,770,055 tonnes to produce 233,507 ozs or 7.262882 tonnes of gold at an average head grade of 0.83 git. With grades of 0.83 git, and gold price at record lows, $US251.95loz in August 1999 or $A393.67loz it has been necessary to make and maintain major cost savings to remain profitable. Boddington Gold Mine has achieved this by a number of steps including a productivity study by outside consultants.

Jan 1, 2000

By Tony Treasure, Ian Ewart

The EMEW® cell has been developed to overcome a number of inherent limitations in conventional electrowinning technology, particularly the high cost and restricted process windows characteristic of conventional hardware. The EMEW technology has been widely demonstrated to achieve high performance for various metals under chemical conditions well outside the limits required for efficient operation of conventional cells. In particular application of the EMEW cell for recovery of silver offers significant operating and capital cost advantages over conventional Merrill Crowe technology used for cyanide based solutions. The cell also offers process advantages for direct silver recovery from nitric acid solutions. The performance of the EMEW® cell on silver cyanide solutions, producing high grade silver metal in a single step, is accomplished by providing a physical mechanism which presents metal ions to the cathode on a highly efficient and continuous basis. The simplicity of design and operation of the EMEW cell offers the following advantages for silver recovery from cyanide or nitrate based solutions: • High grade product in a single step. • Selective for silver over other metals in the electrolyte. • Wide operating concentration range (100,000 - 5ppm). • Ability of the cell to operated in a variety of acid or alkaline electrolytes. (Cyanide, Nitrate). • Simple liquor reticulation. • No pretreatment required - Clarification, deaeration or zinc dust. • High cmTent density and current efficiency compared to conventional electrowinning cell. • Modular design allows for flexible operation and production rate. • Pilot plant results using full scale cell result in accurate scale up design. • Easy/fast installation - cell banks are delivered pre configured with piping and wiring. • Enclosed cell minimizes corrosive vapor and liquid losses in the circuit.

Jan 1, 2000

By Michael Drozd

The operation of an activated charcoal system has five separate unit operations. These unit operations have common points for CIP, CIL and CIS system, which vary widely in application. a. Absorption b. Desorption (Stripping) c. Acid Washing d. Reactivation e. Carbon Handling ( carbon transportation, sizing, de­watering, etc.) Cost optimization starts with the basic operating parameters (design philosophy) set down at the time of engineering design. This parameters undergo almost immediate change due to site specific ore requirements, throughput changes, operator requirements or reagent availability. Activated charcoal is sometimes viewed as simple, uncomplicated reagent that requires not optimization. To some extent, this statement is true, but under most circumstances, if the time necessary to optimize the use of activated charcoal is available, the effort is rewarded with significant savings. CPL-Carbon Link has embarked upon a program of supplying technical support with its activated charcoal. Several operation in the United States have under taken to have CPL-Carbon Link do an operational survey to determine if potential savings are possible. CPL-Carbon Link has offered to do these surveys for projects that are clients or simply would like to have CPL-Carbon Link review their operation. The information accumulated by CPL-Carbon Link is being used to attempt to fashion industry standards so that a common reference point came be establish for activated charcoal usage.

Jan 1, 2000

By Daniel W. Kappes

This paper examines the issue of heap leach cash flow based on some recent operational examples. After the first six months of operation, single-lift continuous heaps produce into salable bullion only 70% of the total recoverable gold stacked. This compares with "batch" heaps and lab columns which achieve 100% in two to three months. Multiple-lift heaps often experience a second cash flow depression as a result of the holdup of gold in the heap. Heap leach projects seldom fail based Oil technical pe1for111ance, but they often fail in the sense that they gmerate cash flow at a much slower rate than expected.

Jan 1, 2000

By Gregory Owen Lewis, Wendy Bouwer

Various processing strategies have been implemented in an effort to limit the loss of gold, during leaching, to the naturally-occurring carbonaceous 'preg-robbing' constituents present within certain gold bearing ore sources. Certain processing routes include complex and costly pre­treatment steps to reduce the negative effects of the preg­robber prior to dissolution, while others adopt a simpler direct leach/recovery approach. Process selection is largely dependent upon the gold deportment and the nature of the preg-robbing constituents within the particular ore. In the case of carbonaceous ores in which the bulk of the contained gold is available to direct cyanidation, carbon-in­leach (CIL) technology is generally applied with varying degrees of success. The effectiveness of the CIL route is governed by the competitiveness of the preg-robbing constituents in relation to activated carbon for the preferential adsorption of the solubilized gold. Trials have shown that the DOWEX MINIX strong-base gold-selective ion exchange resin has gold loading characteristics superior to those of activated carbon. The faster gold loading kinetics, together with the higher capacity of this resin, favour its use in an in-leach application as a more effective adsorbent for complex ores. This paper introduces the alternative resin-in-leach (RIL) technology, compares the metallurgical responses to RIL processing of different problematic ore sources, and discusses the interaction between various process conditions. Selected results from laboratory and pilot-scale testwork are presented to highlight the discussion.

Jan 1, 2000

By Gus Van Weert, Roy van Lier

It has been demonstrated for two totally different silver bearing and cyanide refactory concentrates that the formation of silver jarosite can be prevented through the addition of iodide to the autoclave feed. A molar ratio of r/ Ag+ of no more than 1 was sufficient to raise silver extractions in a subsequent cyanide leach from 4% after autoclaving without iodide addition to 98% for the sulpho-salt concentrate and from 15% to 97% for the pyritic acanthite concentrate. Flowsheet proposals will be discussed to prevent loss of the iodide additive. The use of chloride instead of iodide will also be reviewed.

Jan 1, 2000

By Wayde Esplin

At the Barrick Goldstrike processing facilities in northeastern Nevada, sulfide ore is pressure-oxidized at a temperature of 440° F and 420 p.s.i. in six autoclave circuits. The low pH, high temperature, and abrasive characteristics of the oxidized slurry present many new and unique maintenance challenges. To meet these challenges, the Barrick Goldstrike autoclave department formed a reliability group in August 1998. One of this group's critical missions is to reduce both maintenance costs and unscheduled downtime through the application of predictive maintenance technologies and Reliability Centered Maintenance Analysis. This paper discusses some of the successes of the reliability program at the Barrick Goldstrike autoclave.

Jan 1, 2000

By Mike Schaffner, Pieter Van Aswegen

There are a significant number of refractory sulfide deposits that cannot be economically treated with conventional roasting, autoclaving, or tank biooxidation technologies. Echo Bay and Biomin have developed the Integrated Tank/Heap Biooxidation Process (T/H process) to allow treatment of these deposits. This paper reviews the flowsheet development, pilot plant results, and economics of the T/H process.

Jan 1, 2000

By John G. Banker

Titanium/steel clad has been selected as the material of construction for six pressure acid leaching autoclaves for nickel production from laterite ores. These six pressure vessels are now in production service in western Australia. Titanium provides reliable corrosion protection in the nickel laterite pressure leaching environment. Clad metal construction offers a significant cost reduction for equipment of this type in comparison to solid titanium. Clad metal construction offers superior durability and reliability in comparison with non-metal or titanium loose-lined equipment. Experiences in titanium clad equipment construction and performance are reviewed. The presentation addresses aspects of design, fabrication, and testing which are necessary to assure reliable equipment. The explosion cladding proces and titanium alloy selection considerations are also discussed.

Jan 1, 2000

By Jerry Kolstad

The Stillwater Mining Company Base Metals Refinery (BMR) leaches a PGM bearing nickel/copper smelter matte to produce a concentrated platinum/palladium filtercake. The BMR employs a two-stage sulfate based leaching process. The first stage (nickel atmospheric leach circuit) leach is performed under atmospheric conditions at elevated temperature to leach the majority of the nickel present in the matte feed. Approximately 85% of the solids mass fed to first stage leach report to the second stage (pressure leach circuit) leach. The pressure leach circuit consists of two batch autoclaves in parallel. Each autoclave has a separate feed tank. This paper will describe the second stage leaching process and report associated operating costs.

Jan 1, 2000

By Jock McGregor, Deepak Malhotra, Leonard Harris

After more than 100 years, alkaline cyanide leaching of gold and silver ores, either directly in the case of oxidized ores, or after pretreatment of refractory ores by roasting, pres­sure leaching or bacterial leaching, remains the dominant r leaching method to extract the precious metals f om ores. Leaching with halides (chlorine, bromine and iodine) and with thiourea and thiosulfates is less common but prac­ticed in some cases to dissolve the precious metals both from ores and jewelry and electronic scrap. Cyanide solutions can contain from 1 ppm Au to 30,000 ppm Au. According to the source, i.e., agitated tank leach­ing, heap leaching, eluates from stripping activated carbon or waste electroplating solutions. Similar variations occur with silver which can have a profound influence on the recovery method. The presence of other elements in the leach solu­tions, particularly mercury and copper, likewise play an important role in the procedures required to recover the gold r and silver values f om solution. The same circumstances are found when lixivants other than cyanide are used to dissolve the precious metals. For decades, the preferred method of recovering gold and silver values from alkaline cyanide leach solutions was by zinc dust precipitation according to the Merrill Crowe process developed in the late 19th century. Finely ground gold and silver ores or concentrates were either leached directly or after roasting, in agitated tanks or Pachucas and subjected to solid/liquid separation by filtering or by treat­ment in counter-current-decantation washing thickeners (CCD). This solid/liquid separation step was often very dif­ficult especially when ores containing high quantities of clay were treated which caused filtration or thickening problems. Following testing and development by the U.S. Bureau of Mines (USBM) in the late 60s, the introduction of carbon­in-leach (CIL) or carbon-in-pulp (CIP) plants to recover gold and silver from leach pulps was one of the greatest opera­tional and cost saving improvements made in the industry in South Dakota and quickly spread around the world to be the most common process to recover gold and silver from cyanide solutions.

Jan 1, 2000