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By Kevan Ford, Getulio Junior, Rob Henderson, Wayne Philips, Chris Martin, Rob Thorpe

"Plant 2 at the Kinross Paracatu gold operation in Minas Gerais State, Brazil, was commissioned in late 2008. Designed to be the largest tonnage, lowest grade gold milling operation in the world, Plant 2’s throughput has steadily increased towards its design capacity of 5087 tons per hour.The plant employs a gold-specific flotation scheme to recover the majority of gold, which is present as discrete free gold particles. Additional gold is recovered by jigs in the grinding circuit, and the jig concentrates are reground, upgraded and subjected to intensive cyanide leaching. The flotation cleaner concentrate is reground and leached using a conventional CIL circuit.One year after start-up, with the plant stabilizing operationally, plant circuit surveys were completed by a joint team from Kinross Paracatu and Blue Coast Metallurgy Ltd. The surveys audited the flotation and concentrate treatment circuits to investigate the metallurgical performance.This paper describes the Plant 2 operation and how the surveys were designed and executed. Some of the quality control systems that were employed to provide meaningful data from such a low grade gold ore are described and findings and actions taken to improve metallurgy as a consequence of the surveys are discussed.INTRODUCTIONThe Paracatu mine is located two kilometres north of the city of Paracatu, in the north western portion of the state of Minas Gerais, Brazil, 230 km southeast of the national capital Brasília (shown in Figure 1). The present day Paracatu mining operation, fully owned by Kinross Gold, through its Brazilian subsidiary Rio Paracatu Mineração (RPM) is designed to be the largest tonnage, lowest grade free milling gold operation in the world.The deposit currently hosts some 1.2 billion tonnes of ore at a grade of ~0.41 g/t gold, hence contains a total gold reserve of over 20 million ounces. At a designed plant throughput rate of 61 Mt/year the mine life goes beyond 2030."

Jan 1, 2011

By Victor C. Bryan

One of the most sought after answers in any consideration of blasting activities relative to mines and quarries is how to safely and efficiently use explosives. While that discussion might be relatively straightfonvard in a “site specific” situation. it becomes more complex when viewed from a broad geographic perspective. Such is the case in considering the operations of one United States producer of crushed stone with surface and underground mines spread over a thirteen state area. Differing geologic environments set conditions that dictate to the blaster as now specifically to get optimum results from the blast hole. This treatise is a discussion of the various methods, materials, and principles used in conducting such blasting operations.

Jan 1, 1991

A model was developed to facilitate secondary tailgate support selection based on analysis of over 100 case studies, compiled from two different surveys of operating longwall coal mines in the United States. The ALPS (Analysis of Longwall Pillar Stability) program was used to determine adequacy of pillar design for the successful longwall case histories. A relationship was developed between the secondary support density necessary to maintain a stable tailgate entry during mining and the CMRR (Coal Mine Roof Rating). This relationship defines the lower bound of secondary support density currently used in longwall mines. The model used only successful tailgate case history data, with adequate ALPS SF according to the CMRR for each case. This model facilitates mine design by predicting secondary support density required for a tailgate entry depending on the ALPS SF and CMRR, which can result in significant economic benefits.

Jan 1, 1996

By Bien Ferrer

In most smelting operations, there is a strong incentive to improve safety, reduce downtime and extend the campaigns of furnaces and related equipment. An asset management strategy that is based on information, rather than simple throughput metrics and intuition, can be developed to improve uptime and unlock value currently unrealized at existing smelters. Advances in digital technology, including data analysis, modelling and monitoring for hot pyro-metallurgical vessels, make it possible to assess the current condition of an asset, as well as to make more informed projections about its future condition, using on-line and historical data. This would allow practices around asset management to be more proactive and less reactive, with the end-result of optimized uptime. ‘Digital Asset Management’ describes a concept in which digital technology is used to support an asset management strategy and accelerate decision-making by providing information on what, why and how an asset should be designed, operated or maintained. With the overall goals of effective resource utilization, optimized operations, capital efficiency and social acceptance, Smelter 4.0 is a program of holistic improvement and is underpinned by the effective use of data to drive decisions. This paper focuses on Asset Reliability, which is one of the improvement pillars of Smelter 4.0, and introduces a methodology that is aimed at closing the gap between recorded data and evidence-based decision-making through Digital Asset Management.

By D. Spitty

Mining companies often have many disparate systems and repositories of data in their organization for planning and scheduling outbound mining supply chains. To optimize ore quality, throughput, transport logistics scheduling and delivery to contract, planning teams need to model and manage the value chain accurately and achieve a consolidated, enterprise view of operational performance. Planning teams coordinate a complex series of activities to ensure production forecast accuracy. They also negotiate and execute complex contracts often with disconnected and limited visibility of production forecasts, quality, and variability with little ability to accurately market potential product specifications over longer time horizons. This market is becoming increasingly dynamic, with increasing variability and the time for planning teams to react is decreasing. This is driving the need towards using science to generate the necessary scenarios required to support the decisions made by planners on a frequent basis. Resource-to-Market is a highly flexible, user-configurable supply chain management system for the mining and metal processing industries. This provides an integrated view of the supply chain that supports the dynamic nature of planning in a mining company, embraces variability of elements across the supply chain with the ability to optimize across all the functional areas of the operation to enable optimal decision making for often competing objectives such as throughput, quality, cost, revenue and profit.

Feb 23, 2014

By E. McCullough, D. Preece, M. Ortel

Geophysical explosive charges are used in mineral resource exploration. They are detonated subsurface and radiate sonic waves into ground monitors, which detect the vibration waves and their interaction with underlying geologic strata. Geophysicists perform computer analyses of the waves reflected from the strata to determine their depth and thickness (Strobel, Berger & Schaefer, 2012). The purpose of this research is to determine how the detonating explosive charge interacts with the adjacent ground and how the induced waves propagate through the surrounding medium. Furthermore, it is necessary to optimize the location of the initiation point within the charge. Establishing both the direction and intensity of the waves will allow geoscientists to refine and optimize geophysical studies that employ explosive charges.

Jan 1, 2013

By P. R. Brenchley

Main ore pass systems should last the life of a mine, and too often expensive and hazardous remedial measures are required to repair a damaged ore pass in an attempt to extend its life. In order to maximize the life expectancy of all ore passes at Moab Khotsong, ?wearing blocks? and ?softer support? systems, combined with basic rock engineering principles, have been implemented. Failure of an ore pass can have severe financial implications, both indirectly because the ore pass cannot deliver the broken rock either from level to level or directly in the shaft ore pass system to the required level for tramming to take place, and directly due to the cost of the repair work that is required. Several factors need to betaken into consideration so that production interruptions are eliminated or minimized. Investigations of damaged ore passes at Moab Khotsong and surrounding mines revealed some interesting mechanisms of damage, and some innovative methods of reducing or eliminating the damage have been implemented at Moab Khotsong. The system design was based on 30 years, experience in main shaft rock passes. The design was to counteract scaling, hang-ups and dust problems associated with main rock passes, and the objective was to increase the life of rockpasses. These problems, including the initial design aspects to try and eliminate the repair measures, are discussed in detail.

Jan 1, 2006

By M. Rezaee

Push backs used in the production planning of open pit mines play an integral role in generating annual cash flow. Although several algorithms for push back designs have been proposed, none have studied the optimum number of push backs. In this paper, different algorithms have been implemented for the push back design of a cross section of a copper deposit and the results discussed. Moreover, the optimum number of push backs has been determined using analytical and multiple attribute decision making (MADM) methods based on minimizing the risk associated with grade uncertainty, and minimizing stripping ratio, while maximizing net present value (NPV). According to the findings, the optimum number of push backs has been proposed to be between three and six, as lower quantities of push backs are more likely to achieve the calculated net present value, and have smoother stripping ratios for different pushbacks. This approach was examined in an operating mine and the optimum number of push backs determined to be four.

Jan 1, 2012

By S. Dixon

The Peñasquito deposit in Mexico is one of the largest grassroots precious metal discoveries developed in recent years. Goldcorp Inc. acquired the gold-silver-lead-zinc property with the acquisition of Glamis in 2006. The Peñasquito property is located in the northeast corner of Zacatecas state, Mexico. The elevation of the property averages 1,900 m (6,200 ft) above sea level. It is situated in a wide east-west valley. Minera Peñasquito, S.A. de C.V., wholly owned subsidiary of Goldcorp Inc. has operated twin SABC-flotation lines since June 2010. Each line is capable of processing 50,000 tonne per day using a SABC grinding circuit followed by flotation to produce lead and zinc concentrates. The addition of a Polysius Polycom HPGR 2417 with dual 3,000 kW drives to reduce the crushed pebbles produced by the SAG mills was planned to increase production to 65,000 tonne per day per line. The production has been limited to 100,000 tpd due to operating issues in the grinding circuit. The operating issue has been the amount of pebbles generated by the SAG mills is significantly less than originally planned. This paper describes the planned installation of a crushed augmented feed to maximize utilization of the HPGR capacity. This coupled with full utilization of the SAG and Ball Mill available energies there is the potential to achieve a 50% total capacity increase from the grinding circuit.

Jan 1, 2012

By A. S. Macfarlane

This paper describes how knowledge of the orebody morphology and ore morphology can be used to optimize the planning, mining, and metallurgical output from an open pit copper mining operation, such as to significantly increase the stability of the whole value chain process, and increase the reliability and value of the process outputs. In the case under consideration, the orebody contains both copper and cobalt. This in itself provides a challenge, in that the two metals do not occur in consistent ratios across the orebody as a whole. Furthermore, mineralogical differences within the orebody have a significant impact on plant performance in terms of throughput rates, acid consumption, and recoveries. In order to stabilize and optimize the plant performance, it is necessary to firstly have a complete understanding of the geometallurgical factors that affect performance, and then to have a sound knowledge of how these are distributed within the orebody. These models then inform the mine planning strategy that optimizes cash flow and NPV, and also allow the development of a stockpiling strategy that not only stabilizes the plant, but also allows variations in the plant feed according to ore type and grade in volatile price scenarios. Integral to the realization of these opportunities is the establishment of an appropriate measuring, control, and reconciliation system, customized to the optimization objectives. The paper describes how all of these factors and strategies can be integrated to produce optimal value from the orebody through to final dispatched product. It also shows the significant value that can be released through such an approach.

Jan 1, 2014

By A. de Meyer

Zincor experienced significant losses of metallic zinc to dross during the melting of zinc cathode plates. In this study five factors affecting the formation of dross are identified from literature. Dross from both the plant and that produced in the laboratory is characterized using XRD. An empirical model, based on laboratory-scale investigations, was developed to quantify the effect these factors on their own or in combination with each other has on the amount of zinc loss to dross. The predictive capability of the model is evaluated based on the laboratory-scale investigations. Predictions are made on the effects that heat treating the cathode plates prior to melting, increasing the cathode plate thickness, washing and drying prior to melting, and loading the furnace in a controlled manner have on the amount of zinc loss to dross. Keywords: Zinc, dross, optimize, smelter, yield, losses, empirical, model, XRD.

Jan 1, 2010

By David A. Campbell

There has been a long history of ironmaking on the North East coast of England centered around the River Tees. The industry developed here because of the availability of good coking coals to the North in Co. Durham, and the discovery in 1851 of ironstone in the nearby Cleveland Hills, South of the .River. Cleveland ironstone is relatively poor in quality, with an iron content not exceeding h% and high proportion of sulphur and phosphorous. The iron exists in chemical association with alumina and silica, and physical beneficiation processes involve a serious loss in iron unless the upgrading is limited, when the economics of the process become doubtful. Over the years, richer foreign ores have replaced the local ironstone, and the last operating mine was closed in 1964.

Jan 1, 1982

For a large scale open pit mining and concentrating operation, on a low-grade disseminated ore body, it is possible to set an approximate lower bound on economically feasible operating scales and an approximate upper bound on economically desirable scales in a relatively straight forward manner. The optimum scale ofplanned operations, with respect to the objective ofmaximisation ofthe net value ofthe orebody, will have to be arrived at by iterative planning runs, but it may be expected to lie close to this upper bound. The effects of infrastructural costs and of the addition of a risk premium to the cost of capital, to form the discount rate for planning purposes, are considered theoretically and by worked example. It is concluded that a perceived special, unsystematic, risk should not be accounted for by the use of such a risk premium as this is inducive to placing a greater amount of investment capital at risk, for no greater return-rate to investment.

Jan 1, 1986

By W. A. Hodgson

"In order to be able to map the variation in the concentration of elements in soils, it is necessary to sample at intervals that will give adequate coverage of the area and will allow determination of the rate of fluctuation of concentration with distance in any environment. This rate of fluctuation with distance can be referred to as the continuity of concentration.The continuity of concentration in soils varies according to the chemical characteristics of the element being considered, the underlying rock type or orebody and in response to the dispersion processes that operated during soil formation. Within any environment there is a maximum distance between sampling points within which adjacent sample values are related. This distance, the critical sampling interval, can be determined by means of a correlograrm.Where the sampling grid has been chosen to provide an adequate coverage over unmineralized rock, adjacent samples being related, anomalies may be missed if the element continuity in the anomaly is less than in the background. Results show that a knowledge of the critical sampling interval of the environment being examined may used to select a more efficient sampling pattern for a geochemical survey."

Jan 1, 2014

By Fengyu Ren, Ruslan Puscasu, Kunpeng Yu, Gideon Chitombo, Liangliang Kang

Weak rock mass and poor flow of material can cause excessive ore loss and dilution in sublevel caving. This paper proposes a method to establish design parameters for an inclined deposit within a weak rock mass and evaluates its effectiveness through a case study. In order to solve the problem of low production capacity and poor safety conditions of sublevel caving mining at the Yingfangzi silver mine in China and to ensure a smooth production from the refractory ore body, it is necessary to select appropriate stope structure parameters. Based on random medium theory of gravity flow and the improved equation of ore discharge in random medium, an end wall drawing experiment is carried out to determine the optimum design and flow parameters. It was observed from the experiment that, due to the influence of the randomness of particle movement, there is a mismatch in the flow parameter measurement. The flow characteristics and distribution of the marker particles are different from that of the tested particles resulting in large drawbody shape distortion. The study finds that the flow parameters obtained by the new method are more practical and account for drawpoint width and recommends that the new method for determining the sublevel stope height is used when the drawbody is a non-standard ellipsoid. The outcomes have shown a significant reduction in the dilution and improvement in the recovery rates, and the safety and efficiency of mining have been greatly improved.

"Option pricing is used in finance for valuing options to buy (or sell) shares at some future date because it provides a convenient framework for quantifying values subject to uncertainty. As one of the main sources of uncertainty in mining is the price (sales) of the metal, this approach can also be used for valuing mining projects.The first part of this paper reviews options and option pricing; the second part presents the approach developed by Brennan and Schwartz (1985) for using option pricing to value natural resources. Several applications of this methodology have been published; these are described. From a mining point of view, the assumptions made by Brennan and Schwartz are too simplistic. The weaknesses are discussed with a view to improving an apparently promising new way of assessing the value of projects. IntroductionThe collapse of the British merchant banking group, Barings, has highlighted the risks that can be incurred by speculators and arbitragers in the futures and options markets. But this negative attention on futures and options should not make us forget their positive aspects. They can provide producers and consumers of metals with more predictable sales prices. The introduction of the new traded average price options, TAPOS, by the London Metal Exchange in January 1997 is a response to this need. Equally important, the theory that the finance industry has developed for valuing options provides an interesting framework for valuing mineral projects as well. While this paper was being revised, the South African gold mining house, JCI, announced that it was using a methodology based on option pricing for valuing the mineral rights to deeplevel gold resources (see Box 1)."

Jan 1, 1997

During the construction of storage caverns, and during their lifetime if the use to which they are put so requires, it is necessary to provide adequate ventilation to ensure the safety and comfort of the underground workforce. An analysis of likely contaminants during construction has indicated that where a large facility is situated in a rock mass of even moderate temperature climatic conditions are likely to be the limiting factor during most of the mining operation and atmospheric pollution when blasting is undertaken. Possible options for improvement are increased air flow, cooling of intake air and reduction of the heat source by altering the number and type of haulage units employed in the cavern. Local solutions are an alternative approach where heat problems are confined to a few specific locations

Aug 1, 1994

By M. A. A. de Klaver

Functional Description Figure 1 is a typical flowsheet for a system for solid fuel addition to filter cake. Solid fuel, coal, coal breeze, or charcoal, is fed from a,stockpile to a surge hopper. The solid fuel is metered into a grinding mill. The fuel is dried and ground in a grinding mill. The on-size particles are removed from the mill by air sweeping. The ground solid fuel is separated from the air stream by a cyclone and stored in a surge hopper. The ground solid fuel is then pneumatically conveyed to a small hopper in the balling area. The fuel is proportioned into the filter cake just prior to mixing. An efficient mixer is very important to have a successful operation. The exact flowsheet would depend on a number of factors including what fuel is used, how the fuel is received, and the cnaracteristics of the fuel as received. Availability of floor space in the plant may also affect the flowsheet. For example, drying air may be supplied from the pellet furnace if the grinding mill can be located near the grate, or the pneumatic conveying system and a surge hopper may be eliminated by placing the grinding mill adjacent .to the mixing area. Also, for a multiple line plant, a ball mill rather than a roller mill may be more suitable.

Jan 1, 1980

By John R. Goode

"This paper reviews options for the separation of a mixture of rare earth elements (REE) into its component elements. Earlier separations used selective chemistry such as double salt precipitation and reductive/oxidative processes – methods that still have a place in the industry. Fractional crystallization was developed for more complete separations of adjacent REE. The latter method was replaced by ion exchange (IX), which was in turn replaced by solvent extraction (SX). Two main SX chemistries are in use, solvation and cation exchangers, with several variants (mixed solvents, ionic liquids, etc.) now under investigation. SX plant configurations have evolved including advanced techniques like “hyperlinking”, novel saponification methods, and alternative stripping techniques. The classic mixer-settler is the most commonly employed device although centrifugal contactors have been pilot-tested. Non-dispersive SX options including microfluidic devices and membrane-assisted SX techniques are being developed and could revolutionize the SX option. Other REE separation techniques now being studied include Molecular Recognition Technology (MRT), Free Flow Electrophoresis (FFE), newer IX systems, and electrolytic processes. Additionally, the classical crystallization and selective precipitation methods and newer bacteria-mediated processes, chloride volatilization, high performance liquid chromatography, and magnetic separation systems have been studied. This paper reviews the options and concludes that conventional SX is the technology of choice but viable alternatives could be demonstrated and acceptable within a couple of years.INTRODUCTIONThe chemical properties of the individual REE are very similar which is why REE minerals and ore deposits almost invariably contain a mixture of all fifteen REE, i.e., La to Lu plus Y. That said, the distribution of REE in a given deposit is frequently dominated by the light REE (LREE, i.e., La to Nd). Examples include the Bayan Obo, Mianning, Lynas Mt. Weld, and Molycorp Mountain Pass deposits where heavy REE (HREE – Sm to Lu and Y) typically account for well under 5% of the REE content. The LREE operations produce some HREE but the main sources of these important elements are the ionic clay deposits of Southern China. Importantly, all of the REE recovery operations referenced above, except for cerianite-bearing ionic clay deposits, initially produce a mixed REE precipitate or calcine with a REE distribution similar to that in the ore (Goode, 2016). However, the consumers of the REE, the manufacturers of magnets, phosphors, catalysts, optical glass, etc., require separated products with purities generally ranging from 99% to as high as 99.9999% depending on the element in question and the end use. Hence there is a need to separate the individual REE one from the other. This paper is intended to review the options."

Jan 1, 2016

A detailed study of the capital investment and production cost for copper electrowinning plants shows that significant savings in both can be achieved by increasing the current density. From the economic analysis it is determined that the optimum current density which will result in lowest capital investment and lowest operating cost is between 60 A/sq. ft. and 70 A/sq. ft., or at least three times as high as the Conventionally employed current density. The specific investment, expressed as $/ton-year, is found to be a function of both the current density and plant capacity and has a minimum value at the optimum current density. Empirical equations are developed for the purpose of estimating the capital investment and operating cost for plants of any production capacity operating at any current density.

Jan 1, 1972