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By K. Kim

"All milling operations would like to achieve the best possible recovery in combination with the highest achievable throughput. Unfortunately, many operations have problems with low recovery, low throughput or both. In the majority of these cases investigated by the author, the solutions to improve recovery and throughput were simple. The solutions did not include implementation of new technology or major capital, but rather a return to fundamentals. In most cases, problems occurred because the operation was not following their own operating procedures, because the design of the circuit was changed without adequate change management or understanding of the implications of changes, or because basic metallurgical measurements and control were not taken or ignored. In this paper, examples of these problems and their solutions derived from long and varied experience will be discussed. The objective of this presentation is to provide the milling operator with practical and readily implementable solutions to common milling issues to improve throughput and recovery.INTRODUCTION Mill operations can be evaluated by many operating parameters, but the two best indicators are recovery and throughput. These two parameters summarize the wellbeing of an operation. The grade to the mill is also a good indicator, but this is usually controlled by the mine. The best recovery and throughput are achieved through a team work involving operators, maintenance workers and metallurgical staff. The milling operations include many unit operations, such as crushing, grinding, flotation, leaching, carbon in leach, Merrill Crowe, roaster, autoclave and refinery. The tools available to the operations are plant design, process measurements, assays, metallurgical balance, and operating strategy. Twelve real life examples of improvements of recovery and throughput are presented in this paper. EXAMPLE 1: CRUSHING CIRCUIT WITHOUT FINE ORE BIN At this operation plant throughput could not be maintained at a high rate because feed to the mill became coarse during the day. The cone crusher was feeding the ball mill directly. As the day wore on, the gap on the cone crusher would slowly increase, which would cause the product size to increase. This would increase the re-circulating load on the ball mill. The throughput would decrease accordingly. Furthermore, the throughput would decrease more with high frequency of maintenance on the cone crusher."

Jan 1, 2019

By Alex MacEachern

Air is the gaseous substance that envelopes the earth and forms its atmosphere. It is remarkable in the constancy of its composition; for while this is being continually changed as the result of the respiration of men and animals, and by addition of gases arising from organic changes and the products of combustion, it is ever being brought back to normal and the proper balance restored by the processes of plant and vegetable life. Nature sees to it that the air in which we live and breathe is kept purified. This does not apply to the air in a coal mine, where there are no natural forces to change and make use of the different gases formed or evolved, and where mechanical ventilation is the only effective means of keeping the air pure. The atmosphere consists of oxygen and nitrogen, not in the combined state but merely mixed. By volume, the composition is: oxygen, 21 percent, nitrogen, 79 percent, there being included with the latter small quantities of such substances as water vapour, carbon dioxide, nitric acid, ammonia, ozone, argon, neon, and organic gases. Of the two principal gases which form air, oxygen alone supports life. When air is inhaled into the lungs the oxygen is absorbed by the blood, which carries it through the body to nourish and energize it. Exhaled air consists of water vapour and about 4 per cent carbon dioxide, with from 16 1/2 to 17 per cent oxygen and 79 per cent nitrogen; the oxygen alone having been drawn on to any considerable extent.

Jan 1, 1930

By Craig Faulkner

Discharge cones for large Semi Autogenous Grinding (SAG) and Autogenous Grinding (AG) mills are subjected to high wear as significant volumes of ground ore and slurry exit the mill. With the larger diameter mills of 32ft to 40ft in size becoming the norm, very high, concentrated wear is highlighting the limitations of conventional discharge cones and frequent changes are subsequently required. This paper outlines the advances made in the design of the Bullnose discharge cone. Superior wear materials to increase wear life over conventional rubber or chrome-moly steel discharge cones and the introduction of key design features to reduce reline times and improve fit and safety during installation, offer significant opportunities for the mill operator. Collated from multiple case studies, the wear data and reline history from 2004 to present clearly illustrate the way in which superior component longevity has reduced the frequency of relines over the life of the product to increase mill availability and effectively increase the tonnes milled in a period.

Jan 1, 2012

By L. Jacobsson, J. E. Lindqvist

A series of laboratory tests were conducted to study stress-induced spalling on medium to coarse-grained granite specimens. The specimens made from cylinders had two manufactured notches on opposite sides aimed to represent the tangential loading around a circular opening. Specimens of three different sizes were tested with notch radii, 98.5, 225 and 375 mm, representing 197, 450 and 750 mm diameter holes, to study the effect of notch radius on the spalling initiation stress. The cracking was monitored by acoustic emission sampling. The fracture patterns were investigated visually on polished slabs and by microscopy on thin sections. The crack analysis describes how the cracks propagate in relation to the grain structure in the rock and to the macroscopic stress field.

Jan 1, 2015

By H. Zniber El Mouhabbis

Ore dilution or stope overbreak increases the cost of production and ultimately reduces the profitability of a mining operation. The adverse economic impact of ore dilution is due to the added costs associated with the mucking, haulage, crushing, hoisting, milling, and treatment of waste rock or low grade ore in the hangingwall and footwall. One factor that could have a significant influence on stope overbreak is the undercutting of the stope into the walls. Undercutting stope walls is often necessary, in particular in narrow vein mines. Moreover, equipment size has a role in drift sizing where stope undercutting may become a must in order to fit the mobile equipment while respecting legal clearances.

May 1, 2009

By Christie Myburgh, James Mackenzie, Ross Hammond

Modern mining operations are increasingly characterised by their access to large volumes of data and advanced computational tools. Over the past two decades, the industry has made substantial investments in digital technologies supporting geological modelling, mine planning, equipment dispatch, and process control(Newmon et al., 2010; Paraszczak, 2019). These systems have significantly improved the ability to generate and analyse information across the mining value chain. However, despite these advances, the decisions that ultimately determine operational performance remain largely implicit and unmanaged (Kruger et al., 2023; Jia, 2022). Mining decisions rarely occur in isolation. Decisions made in geology influence resource models, which shape mine plans, production schedules, and downstream processing strategies. These, in turn, affect operational execution. As deposits become deeper, ore grades decline, and operational constraints increase, these interdependencies create increasingly complex decision environments (Newman et al, 2010; Topal, 2008; Darling, 2011; Dimitrakopoulos, 2004). In practice, coordination across these domains often relies on informal communication, iterative meetings, and manual interpretation of analytical outputs. Explicit decision support systems provide a mechanism to capture these dependencies, maintain consistent decision context, and coordinate decision-making across geological, planning, and operational domains (Power, 2002; Shim et al., 2002). This paper argues that a fundamental gap remains in current digital mining systems: while data and analytics are well supported, decision-making itself is not. Addressing this gap requires treating decisions as explicit, structured elements within the operational system. By integrating data, computational analysis, and decision processes, explicit decision support systems offer a way to better coordinate complex, interdependent decisions across mining operations.

May 2, 2026

By D. R. Griffiths

"Oxidation of pyrrhotite prcxiuces sulphuric acid which in turn leaches out heavy metals, resulting in acidic contaminated seepages. The establishment of a marsh on top of the pyrrhotite would result in an anaerobic sediment, which should prevent further oxidation of the pyrrhotite. Initial data indicates that concentrations of sulphates and heavy metals in the seepage water are greatly reduced. Further hydrogeological studies are required however, to determine if metal and acidic loadings to the environment have increased.L'oxidation du sulfure de fer produit de l'acide sulfurique qui a son tour attaque les métaux ayant pour resultat une contamination d'acide et de métal des eaux d'infiltration. L'etablissement d'une couverture faite de boue et de vase au-dessus du depot du sulfure de fer réduit les effets de l'oxidation.Les données initiales indiquent que les concentrations de souffre et de métaux dans les eaux d'infiltration sent grandernent réduites.Des études plus poussées sent nécessaires pour déterminer si les quantités de souffre et de métaux dans les eaux d'infiltration ont augmentées.INTRODUCITONPyrrhotite tailings are readily oxidized through a combination of precipitation and atmospheric oxygen causing acidification of the unsaturated zone above the water table. This reaction is usually catalyzed by the bacteria, Thiobacillus ferooxidans. As the pH decreases, heavy metals become more soluble resulting in contaminated seepages to ground and surface waters.By creating a marshland on top of the pyrrhotite, an anaerobic intermediate layer should form between the organic covering and the tailings, preventing the oxidation process from progressing.In September 1986, Falconbridge Limited implemented a tailing reclamation project that involved creating a marshland on top of pyrrhotite tailings. The following paper will discuss and illustrate the preliminary results obtained during the sampling period of May to September 1987."

Jan 1, 1988

By Neri Roux, Ross Gilders, Yemi Oyediran, Leo Cheung

Quest Rare Minerals Ltd. is developing their Strange Lake B Zone REE deposit located in Northern Quebec. An extensive batch bench scale testing program was launched to investigate open circuit rougher flotation performance under different conditions. The objective of the flotation study was to demonstrate the effectiveness of rejecting gangue minerals to flotation tailings while concentrating rare earth elements as well as yttrium, zirconium, and niobium into a concentrate suitable for further hydrometallurgical processing. Mineralization of interest at Strange Lake occurs within peralkaline granite-hosted pegmatites and minor aplite. The REE and high field strength element (HFSE)-bearing phases are hosted primarily in pegmatites as relatively fine-grained phases or pseudomorphs. The gangue phases comprise of quartz, feldspar, amphibole, and pyroxene. Potential ore minerals comprise predominantly of kainosite, gerenite, gadolinite, zircon, pyrochlore, and gittinsite. These complex mineralogical characteristics increase the difficulty for processing and provide a challenge for choosing the correct reagent scheme in rougher flotation. Process options including reverse flotation to reject the gangue minerals and de-sliming prior to the direct rougher flotation were investigated. Optimization trials were conducted using various reagent regimes and under different flotation conditions. Encouraging results were found using a combination of collector reagents supplied by Cytec Canada Inc.

Jan 1, 2014

By Norm Clegg

The Plant Engineering and Maintenance Association of Canada PEMAC is a national, not-for-profit industry association for plant and facility maintenance, engineering and physical asset management in all industry sectors in Canada. Our mission is to provide professional development for our members and the profession in Canada

Feb 1, 2008

By Richard W. Hutchinson, Christopher Osterman

The Selebi-Phikwe deposits are hosted by amphibolite to granulite facies gneisses of the Limpopo belt. The sulfide orebodies are generally stratiform and conformable to the foliation of the wallrock gneiss. Sulfide remobilization has occurred during metamorphism and has produced discordant sulfide veins, called piercement structures, which project into the hanging wall and footwall gneisses. These piercement structures are compositionally similar to the stratiform sulfides, consisting mainly of pyrrhotite, pentlandite and chalcopyrite. However, texturally the piercement sulfides are coarse grained and inclusion-free, whereas the stratiform sulfides are fIne grained and packed with tectonically produced wallrock inclusions. The piercement structure sulfides and adjacent stratabound sulfides were sampled and analyzed for major base metals and PGE's for comparative purposes. Most of the piercement structures were enriched in Cu, Ag and Au, whereas they were generally depleted in Ni, Co, Fe and PGE's. Changing elemental associations were observed from the stratabound sulfides and along the length of the piercement structures. This and the degree of depletion or enrichment of various major and minor elements in the sulfide piercement structures may reflect the relative mobilities of metals under metamorphic conditions. The similarities between sulfIde piercement structures and the footwall Cu-PGE veins in some Sudbury deposits are reviewed.

Jan 1, 1994

By Yan Jie

The oxygen-enriched bottom-blowing continuous converting process for copper matte was recently developed by the China-ENFI Engineering Corporation. The first commercial plant based on this technology was successfully commissioned at the Yuguang smelter in China in March 2014. The present paper describes this new continuous converting process and compares technical characteristics with other continuous converting processes including: Kennecott-Outokumpu flash converting, the Mitsubishi Process, the Noranda Converter and TSL continuous converting. The bottom-blowing oxygenated continuous converter with competitive capex and opex costs is seen as an attractive alternative to the Peirce-Smith converter.

Jan 1, 2014

By G. E. Parsons

"The Bidgood is a small gold mine about 5 miles east of the main Kirkland Lake camp. Since the beginning of production in 1934, gold having a value of $5,000,000 has been produced from the property. Practically all of this production has come from seven veins in a diorite stock that intrudes the Timiskaming sediments and lavas of the area. The veins consist of quartz, pyrite, and molybdenite with minor amounts of chalcopyrite, calcite, and tellurides, and occupy northeast striking and northwest dipping thrust fault fractures. They have no apparent direct structural association with the faults of the main Kirkland Lake camp or the Larder Lake 'break' to the south; however, the veins closely resemble the former in their mineralogical composition and in their close association with syenite intrusives.ROCK TYPES AND THEIR STRUCTURAL CHARACTERISTICSThe dominant and, from an economic standpoint, most important rocks in the ore area consist of two separate families of Algoman intrusivesa diorite and a later syenite group."

Jan 1, 1954

By L. C. Hsu, M. O. Desilets, P. J. Lechler, Jr. Bonham, J. G. Price, L. J. Garside

Geochemical background levels have been established for unmineralized sedimentary rocks that are elsewhere the hosts of Carlin-type gold deposits in the Getchell Trend. The Paleozoic rocks in the Winnemucca Quadrangle consist predominantly of the lower Paleozoicsiliceous and clastic sequences that were carried eastward along the Roberts Mountains thrust during the Late Devonian and Early Mississippian Antler Orogeny and the late Paleozoic Havallah and Pumpernickel sequences brought along the Golconda thrust eastward during early Mesozoic Sonoma Orogeny. Over 260 rock samples were collected from the Paleozoic sequences. Major and trace elements were determined by instrumental methods best suited for the specific elements. The general geochemical features of the Paleozoic sedimentary rocks are discussed in detail with reference to the data of average abundances of elements in sedimentary rocks. The background and threshold values of certain trace elements in sandstone, shale, and carbonate rock of one formation, as well as back-ground levels for the entire sequence were obtained. The characteristic geochemical features of the Paleozoic rocks in this area include: consistently high Ba and low Au contents (1.1 ppb, 1.5 ppb, 1.1ppb Au for average sandstone, shale and carbonate, respectively); generally low contents of those elements which may be of environmental concern such as As, Cd, Hg and Pb. Plots of major and trace elements suggest that the majority of the Paleozoic clastic rocks are related to a passive-margin tectonic setting. Samples with gold values higher than threshold are considered to have been affected by hydrothermal alteration related to gold mineralization. Most of these samples generally also have higher values of Sb, Hg, V and/or As. These observations support the use of such elements as pathfinders for gold, although V has not been identified as such before. Ba is not effective for gold exploration in this area due to the generally high background value of Ba, even though it may be an important pathfinder elsewhere.

Jan 1, 1995

By A. Suzue, T. H. Okabe, Y. Taninouchi

Methods for the physical separation and enrichment of platinum group metals (PGMs) from autocatalyst scrap were studied in order to develop an environmentally friendly and efficient recycling process. In general, an autocatalyst has a honeycomb-structured ceramic substrate that is coated with a catalyst layer containing platinum (Pt), palladium (Pd), and rhodium (Rh). Therefore, physical separation of the PGM-containing catalyst layer directly from the ceramic substrate is favorable for upgrading the autocatalyst scrap. In this paper, the authors present a scrap-upgrade process consisting of electroless iron plating and magnetic separation techniques. Iron was plated on the surface of a catalyst sample used to represent an autocatalyst, which was then crushed and magnetically separated. The Pd in the catalyst sample was successfully extracted and concentrated in the magnetic powder. Under certain conditions, the process increased the Pd concentration by a factor of 4 and recovered 89% of the Pd in the autocatalyst sample.

Jan 1, 2014

By Emmanuel John M. Carranza, Martin Hale

Abstract- An application of logistic regression to mapping of gold potential in the Baguio district of the Philippines is described. Categorical map data such as lithologic units and proximity classes of curvi-linear features, based on spatial association analyses, are quantified systematically and used as independent variables in logistic regression to predict the probability for presence or absence of gold mineralization. Regression experiments to compare between using all independent variables that are associated spatially with the response variable and using only statistically significant independent variables are performed. The results of the regression experiments are similar; however, the use of all independent variables produces slightly optimistic results but better prediction rates for the known gold deposits in the test district. At least 68% of the ‘model’ large-scale gold deposits and at least 76% of the ‘validation’ small-scale gold deposits were predicted correctly. The predicted geologically favorable zones are also similar to delineated geochemically anomalous zones. The technique presented using logistic regression as a data integration tool is effective for geologically constrained technique of mapping mineral potential.

Jan 1, 2001

By H. E. (Buzz) Neal

"Abstract - The Labrador Trough contains world-class iron deposits which have been mined since 1954. The direct shipping of Knob Lake ores were mined at Schefferville from 1954 to 1982. Concentrate production began in 1961 in the southwest end of the Trough, with three mines currently producing concentrate and pellets at a rate of 35 Mt per year. West and north of Schefferville, several billion tonnes of taconite have been outlined in fine-grained, cherty magnetite iron formation. Several deposits of highly metamorphosed magnetite-specularite iron formation are located west of Ungava Bay. Numerous studies have shown that this medium- to fine-grained iron formation can be beneficated to 66% to 68% iron. In the area from Wabush Lake to Mont-Wright, a medium- to coarse-grained friable specularite-quartz iron formation is repeated by folding to form several large deposits. In this area, three mining operations are located with reserves and resources in the order of 5 billion tonnes.The iron deposits occur within iron formation in sediments in the extensive Proterozoic geosyncline called the Labrador Trough. Several facies of iron formation within the Sokoman Formation reflect variations in chemical composition and depositional conditions. The correlation between the mineralogy and textures is discussed to illustrate the development of different types of iron ores. This band extends for about 1100 km southeast of Ungava Bay through both Quebec and Labrador. Further south, it turns southwest past the Wabush and Mont-Wright areas to within 300 km of the St. Lawrence River. The iron formation is essentially folded and faulted along most of its length. The degree of metamorphism is variable, ranging from intense in the northern and southern portions to greenschist facies in the central portion.The stratigraphy, structure and mineralogy of the producing mines are described along with the history of discoveries. Geological input is required to achieve the strict specifications of the international iron ore market."

Jan 1, 2000

By K. Johanson, M. Hubert, C. Eckert, D. Ghose

The mining industry routinely processes material with different particle sizes. Coal, nickel ore, copper ore, lignite, shale, and phosphate ore are all examples of materials with wide particle size distributions. It is often assumed that these materials are homogenous and that any particle size distribution has the same chemical activity and composition. It is entirely possible, and quite likely, that chemical composition is a function of particle size distribution. In addition, particle size distributions in ore materials are often responsible for the difference in flow behavior in process equipment. This is evident in coal electrical production facilities. Fine coal may have the same ash content, sulfur content, and BTU value as coarse coal. However, all electrical production facilities know the extreme flow problems that result when attempting to handle wet fine coal. Segregation of these bulk materials is an important issue that must be understood to prevent these cohesive flow problems. Additionally, fertilizers are mixtures of particles with different shape and sizes. These mixtures must remain homogenous to optimize fertilizer performance. Segregation leads to poor product quality. This paper presents a method of measuring the magnitude of sifting segregation occurring in bulk material and the relationship between the strength of the bulk material and the separation tendency. It shows an inverse relationship between the yield strength of the material and the bulk segregation.

Jan 1, 2004

By A. B. Morrow

Consulting engineers are well aware of large variations in plant operating cultures between countries, companies, and even within sites and operating crews. These operating cultures must be considered when designing Advanced Process Control (APC) applications in order to maximize utilization rates and return on investment. Designs must be driven by an understanding of the totality of unit operations. Economic factors, equipment constraints, management philosophy, maintenance department responsiveness, instrumentation reliability, operating crew skills and teamwork, and individual operator concerns are all important and must be considered during application design. A general approach to incorporating operating culture considerations into APC application design is described. A case study for an iron ore concentrator plant is presented.

Jan 1, 2014

By R. M. de Carvalho

Empirical and phenomenological models of SAG and AG mills have dominated the scene for the last few decades, being used nearly every time a mill is scale-up or an attempt is made to improve its performance. However, in spite of their success, these models fail to describe the details of both the grinding environment and the breakage mechanisms. The result is a generally good track record, with a few – but very important – instances when these models fall short in their predictions, which can be very costly. Further, nearly all of these models require detailed calibration to industrial and pilot plant data, being costly in their application, although still with limited predictive capabilities. Recognizing these challenges, a new model framework has been proposed which overcomes the limitations of currently used models by coupling the microscale population balance model, the discrete element model and functions that describe internal classification at the mill grate. This model framework has already been applied to describe breakage in ball mills, with showing very promising results. However, in the case of SAG and AG mills a much greater level of complexity is involved in the model, given the interaction between the mechanical environment that is formed totally or, in part, by the ore itself, and the breakage response in the mill. The paper describes the model framework, demonstrating how it can address appropriately effects such as mill speed, mill filling and size distribution, on the response from the mill. Some of the advantages of the model are related to its intrinsic multi-component and dynamic nature, which allows simulating appropriately mixtures of ores of different competences in a transient manner.

Jan 1, 2012

By L. C. Hsu, H. F. Jr. Bonham, M. O. Desilets, P. J. Lechler, J. G. Price, L. J. Garside

Abstract-Geochemical background levels have been established for unmineralized sedimentary rocks that are elsewhere the hosts of Carlin-type gold deposits in the Getchell Trend. The Paleozoic rocks in the Winnemucca Quadrangle consist predominantly of the lower Paleozoic siliceous and clastic sequences that were carried eastward along the Roberts Mountains thrust during the Late Devonian and Early Mississippian Antler Orogeny and the late Paleozoic Havallah and Pumpernickel sequences brought along the Golconda thrust eastward during early Mesozoic Sonoma Orogeny. Over 260 rock samples were collected from the Paleozoic sequences. Major and trace elements were determined by instrumental methods best suited for the specific elements. The general geochemical features of the Paleozoic sedimentary rocks are discussed in detail with reference to the data of average abundances of elements in sedimentary rocks. The background and threshold values of certain trace elements in sandstone, shale, and carbonate rock of one formation, as well as back- ground levels for the entire sequence were obtained. The characteristic geochemical features of the Paleozoic rocks in this area include: consistently high Ba and low Au contents (1.1 ppb, 1.5 ppb, 1.1 ppb Au for average sandstone, shale and carbonate, respectively); generally low contents of those elements which may be of environmental concern such as As, Cd, Hg and Pb. Plots of major and trace elements suggest that the majority of the Paleozoic clastic rocks are related to a passive- margin tectonic setting. Samples with gold values higher than threshold are considered to have been affected by hydrothermal alteration related to gold mineralization. Most of these samples generally also have higher values of Sb, Hg, V and/or As. These observations support the use of such elements as pathfinders for gold, although V has not been identified as such before. Ba is not effective for gold exploration in this area due to the generally high background value of Ba, even though it may be an important pathfinder elsewhere.

Jan 1, 1995