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By Paul Staples, Paul Messenger, Greg Lane

"Every project is different. While “conventional” SAG and ball mill circuits will suit many projects, for others there are alternatives, which may produce improved outcomes. This paper examines particular examples of recent front end designs which either went against conventional thinking or which employed “out of the box” thinking to realize the desired results.One such example is the design strategy employed for a small capacity gold plant in Victoria, Australia. The selection of HPGR technology for small capacity projects is not generally favoured, given the relatively high cost of small HPGR machines. However, the unusual size distribution of the gold and its liberation characteristics were expected to lead to improved gold recovery offsetting the higher capital cost.Another example is the first large scale application of milling in acid for copper recovery, at a project in south east Asia. The stainless steel, single stage SAG mill using ceramic grinding media was more expensive than a mill constructed of conventional materials. However, the steps of scrubbing, slurrying, grinding and leaching could all be achieved in a single unit operation and the need for thickening and repulping with acid after milling was eliminated.Rod mills were selected for both primary and secondary milling duties for another south east Asian project despite their somewhat outdated reputation. A review of previous industry experience confirmed that rod mills could outperform conventional rod/ball or SAG/ball circuits in cases where the size distribution of the ground product is critical to downstream recovery.These examples are discussed with particular focus on the key drivers in each case."

Jan 1, 2008

By W. E. Segsworth

Introduction By far the largest part of the money raised for mining is raised by honest and legitimate means; but a not inconsiderable amount is raised by fraudulent sales methods. It will be conceded without argument that the greatest menace to the mining business is the fraudulent promoter. The sale of worthless mining stocks to the public by high-pressure. salesmen, house to house canvassers, telephone campaigns, fraudulent use of the mails, fraudulent statements, and reloading, has seriously prejudiced the public against even legitimate mining. A very small percentage of the funds raised by such fraudulent means is ever spent on the property, but instead is absorbed by the promoter in illegitimate' profits, enormous commissions, high office rents, and other expenditures, and is just so much subtracted from the fund which the legitimate developer needs to bring new mines to the point of production. The mining fraternity has been at fault in that, while they recognized this situation, they made no adequate attempt to rectify it. They knew that these fraudulent practises were conducted by parasites who attached themselves to the mining business in boom times and claimed to be part and parcel of it, but who were merely professional salesmen and promoters who, when there was not a mining boom, were selling sky-line real-estate, worthless oil stocks, or fraudulent securities which happened to be popular with the public. While mining people had this distinction well in mind, the public did not differentiate between the crooked promoter temporarily selling fraudulent mining stock and the honest promoter who made mining finance his life work; and we did little to make this distinction clear to the public or to sweep these money grabbers out of our house. The historic boom of 1927-8 and '29 brought with it the usual crop of crooked mining promoters, and the scandals resulting from their operations forced the Governments into the enactment of laws to attempt to protect the gullible public against the operations of these meanest of thieves and to appease public clamour.

Jan 1, 1934

By Wendy L. Naysmith

This paper deals with the various options considered and factors that influenced the final selection of the headframe, shaft layout and hoisting systems required at the Impala No 16 Shaft in order to hoist both the required 3 Mt of ore per annum, and transport men, material and equipment between the surface and the underground workings to a depth of 1640 m. The layout and construction method used for what is at present the world?s tallest concrete headframe is discussed together with the integrated hoist room foundations designed to suit multiple mechanical and electrical hoist supplier?s solutions. The mechanical components of the two tower mounted 6,5m 4 rope Koepe hoists and deflection sheaves and their layout is dealt with in detail. Various features of the bearing type, brake units and brake control system are also discussed. Installation of the mechanical and electrical hoist equipment in the headframe took place during the sinking phase of the project and placed severe restrictions on the use of the heavy lifting facilities. This required a well-managed and systematic approach to delivery of the hoist components and associated equipment, as well as close co-operation between all contractors on site.

Oct 1, 2010

By Greg Barnes

Agenda ? The Mining Stock Life Cycle ? Current Environment ? Valuation ? Golds ? Valuation ? Base Metals ? Case Study ? Quebrada Blanca Hypogene Commodity Investment Cycle ? Macro-Economic Indicators ? LME Inventories ? watch the trend; rising inventories ? bad for prices, declining inventories good for prices ? OECD Leading Indicators ? PMIs ? Purchasing Manager Indices ? Industrial Production ? more important for metals consumption than GDP ? Housing Starts ? US, Europe ? Auto Sales ? All things China ? metal imports/exports; SHFE inventories; SRB stockpiling ? Seasonality ? it does play a role ? What is Chris Dutton (TDSI Quantitative Analyst) saying?

May 1, 2010

By R. D. Lindsay

Pamour Porcupine Mines, Limited has been actively engaged in the ''Custom Tolling'' of Gold-Bearing materials throughout the past decade. Experience acquired in this area was utilized to design and commission a custom gold milling facility at its operations in Timmins, capable of:(a) Accepting a bulk ore test sample at the rate of 150 t/d for crushing, sampling, and metals analysis;(b) Processing gold-bearing ores at a rated capacity of 150 t/d, to produce a goldbearing sulphide concentrate;(c) Processing free milling gold ores at a rated capacity of 80 t/d for total cyanidation;(d) Cyaniding custom gold flotation concentrates at a rated capacity of 80 t/d; and(e) Processing of complex gold/copper or carbonaceous ores, requiring an impurity flotation concentrate separation stage prior to cyanidation, at a rated capacity of 100 t/d.Items considered in the process design and development included:- various gold ore types available for processing;- flowsheet flexibility required;- sampling strategy as related to head grade determination and metals accounting; and- contract considerations.This paper highlights how these various considerations were used to design Pamour's ''Custom Gold Milling Facility''.

Jan 1, 1987

By D. C. Peck, H. D. M. Cameron, N. M. Halden, L. S. Jobin-Bevans

Abstract-The late Archean Pipestone Lake anorthosite complex (PLAC) is a 0.9 x 17 km sill-like layered intrusion that is part of a suite of coeval megacrystic anorthosite bodies in the Cross Lake region, northwestern Superior Province. Exploration for Ti-V-Fe oxide mineralization and concurrent geological investigations have contributed to a greater understanding of the lithostratigraphy of the PLAC and its oxide mineralization. Mapping and drill core studies have established a laterally continuous igneous stratigraphy comprising six leucogabbro/anorthosite zones and three melagabbro/gabbro zones. Field evidence, including disrupted blocks of layered units, scour contacts, and size-graded and modally-graded layering, suggests younging towards both the northern and the central parts of the complex. A decrease in the anorthite content of the feldspars from An75 in the south to An30 in the north suggests that the magmas become more evolved to the north. Macrorhythmic layering and gross morphological features suggest that the PLAC crystallized from four major influxes of geochemically similar basaltic magmas. The paucity of magmatic erosional features in the PLAC indicates that layering developed in a relatively static magma chamber, so that in-situ crystallization processes are required to account for the observed petrologic diversity. Drilling has confirmed that a significant Ti- V-Fe resource is contained in two of the four discrete mineralized subzones in the PLAC. Textural evidence and the stratiform nature of the oxide-enriched subzones are consistent with a magmatic origin for the oxide mineralization.

Jan 1, 1997

By John Wilson

"The Rietveld numerical method was used to calculate the relative abundances of phases in both synthetic binary mixtures and synthetic and natural ores, using X-ray diffraction data. The results were compared with those of image analysis and a chemical method. The ranges of the relative errors were estimated. The Rietveld method is found to be acceptable for determining the abundances of major and minor phases and the amorphous component of partially crystalline samples. In complex mixtures, where there are several trace phases (~<2 wt%) present, the technique becomes less accurate. It is most useful as an alternative technique to image analysis when sample preparation is problematic or sample particle sizes are sub-micron. It is a manual method which requires user input during the fitting process, but is both simpler and faster than image analysis due to the reduced set up time and sample preparation required. It is now implemented at CANMET as a technique for quantitative analysis.INTRODUCTIONUntil recently, the Applied Mineralogy group at CANMET used only image analysis and chemical techniques to determine phase quantities. An effort to develop quantitative X-ray diffraction (XRD) has been on-going for several years. Initially, the reference intensity ratio (RIR) method with external standards was tried with some success (Szymanski and Petruk, 1989). The main difficulty with this technique was finding adequate standard material for each phase present in the sample. This shortcoming made the method ultimately impractical, given the wide variety of materials which come to the laboratory for analysis.The Rietveld refinement method of quantitative XRD (Hill et al 1993, Mumme et al 1996), in contrast, requires no standards and requires minimal sample preparation and therefore a more rapid turnaround compared to image analysis. The Rietveld method also has advantages over image analysis in that it can identify and quantify polymorphs, ultra fine materials and many types of hydroxide products. As well, it is useful for analyzing materials such as bauxite or talc, which do not polish well enough for making mounts of the quality required for image analysis. To quantify amorphous material and phases which are present in amounts below the detection limit of XRD, the addition of a standard material is still required. However, in such cases only one standard is needed, which is alumina."

Jan 1, 2003

By Stephen G. Downs

PCF?, or Penetrating Cone Fracture, is a propellant-based technique for rock excavation, which has significant potential for the mechanization of narrow-vein mining. The technique is currently being developed for use in the narrow-vein flat-dipping gold and platinum deposits in South Africa in conjunction with major mining companies. The technique is also applicable to steeply dipping vein deposits, such as those found in North America, Australia and elsewhere. The implementation of PCF? in South Africa to date is reviewed and plans for the introduction of PCF? excavation in other areas are highlighted.

Oct 1, 2001

By D. F. Strong, P. P. O'Neill

"The Isle aux Morts Prospect is the first polymetallic, sulphide mineralization reported from the Port aux Basques Complex of southwest Newfoundland. Zn-Pb-Cu-Ba-Ag mineralization hosted by quartz-muscovite semipelite, occurs at the contact between a quartz of eldspathic unit and pelitic unit with intercalated amphibolite are minerals comprise sphalerite-galenachalcopyrite, in order of decreasing abundance. The principal gangue minerals are quartz, muscovite, feldspar and barite. Three morphologic types of mineralization are present: massive with more than 50% sulphide, flanked on one or both sides by disseminated and/or banded types. The massive type of mineralization exhibits a :durchbewegung"" fabric of rounded silicate fragments in a sulphide matrix, characteristic of intensely deformed and metamorphosed sulphide bodies. Sulphide minerals have been mobilized and recrystallized and share the same metamorphic and deformational history as the host rocks. Quartz muscovite schist which hosts disseminated mineralization, displays a K2O enrichment and Na2O depletion, that is typical of alteration associated with sulphide bodies in volcano sedimentary sequences. Isotopic ratios of sulphur are comparable to those of volcanogenic massive sulphide deposits.Despite penetrative deformation and metamorphic recrystallization, features of the local geology and the mineralization suggest that the Isle aux Morts Prospect is volcanogenic in origin. IntroductionFollowing the release of a government lake sediment survey (Butler and Davenport, 1980), which indicated anomalous concentrations of metals in southwest Newfoundland, geologists with Utah Mines Ltd. discovered the Isle aux Morts Prospect, a Zn-Pb-Cu-Ba-Ag showing, located approximately 15 km northeast of Port aux Basques (Figs. I and 2). The mineralization occurs in quartz-muscovite schist and is the first significant basemetal discovery in the Port aux Basques Complex."

Jan 1, 1988

By K. J. Fair, H. W. Smith, D. R. Francis, J. M. Toguri

"Bench-scale batch milling and screening tests were carried out on secondary aluminum dross 10 produce an aluminum concentrate. To complement these tests, an analysis of a commercial plant was also performed by sampling dross at various stages in the plant&apos;s milling and screening circuit. These studies have indicated that benefits of increased capacity, grade and recovery of aluminum metal can be realized by addition of screens before the ball mill, longer grinding period and by grinding the smaller size fractions more efficiently.To test the predictions, a plant test was performed on the milling of100tons of secondary dross. The recycling of the large size fraction (+1/8 in.) of aluminum dross through the impact mill rather than through the rate limiting ball mill resulted in a comparable aluminum grade. The ball milling of the _1/ 8 in. + 10 mesh size gave a dross grade of71% AI. A lower feed rate to the ball mill resulted in a higher final grade. With minor modifications, secondary dross can be processed in 22% of the time it takes with the present circuit without a sacrifice in grade.IntroductionSecondary aluminum dross is a mixture of metallic aluminum, aluminum oxides and salts (alkali halides). Any comminution process deforms or slowly grind s the malleable metal phase and reduces the size of the friable, brittle, oxide-salt phase relatively fasterr(1).The milling of aluminum dross is performed to upgrade the metallic aluminum fraction. Figure I shows a flowsheet for the milling of secondary dross as presently practised at Metals and Alloys Co. Ltd., Toronto, Ontario. At point A, large acceptable grade material is hand picked for refurnacing, the unacceptable off-grade material is sent to the sweat furnace and the remaining, + 2 in. fraction is recycled through the 3.9 ft by 4.1 ft impact mill. For simplification, three ball mills are shown. However, in reality there is only one, a 5 ft by 10 ft ball mill used in a semi-batch mode. The 2 in. + 3/8in. and 3/8 in. + 10 mesh products are remilled in the ball mill. The -10 mesh material is discarded as waste."

Jan 1, 1987

By Paykan Safe

?? Background ?? WorleyParsons Gas Cleaning ?? PT Inco Smelter ?? Process Design Considerations ?? Furnace Control and Combustion ?? Combustion Chamber ?? Spray Chamber ?? Draft Control ?? Baghouse ?? Secondary Ventilation ?? ID Fan ?? Dust Handling Equipment ?? Project Execution ?? Heat Recovery ?? Conclusion ?? WorleyParsons Gas Cleaning ? Irving, TX ?? Formerly Gas Cleaning Technologies ?? Acquired by WorleyParsons in 2005 and now part of a global EPCM company ?? 14 years experience in off-gas system design for ferrous and non-ferrous facilities worldwide

May 1, 2008

By Jim Wickens, Vince Lofftus, Mark Kravetz

"This paper discusses how Bald Mountain Gold Mine (Ely, NV) dramatically reduced mercury production by treating process solutions with a liquid reagent based on organic sulfide chemistry. Cherokee Chemical Co. Inc. (Vernon, CA) markets this reagent as UNR 81 1A.A summary of the bench tests comparing various reagents is given. The ensuing plant trial is discussed and successful mercury removal results are presented. Data is presented to show that early removal of mercury in the process reduces the amount of mercury collected at retort. Data is also presented to show that use of this reagent does not reduce gold recovery. Plant trial treatment costs are discussed. Finally, the potential of this technology to substantially reduce closure costs as compared to traditional mercury removal options is discussed.INTRODUCTIONBald Mountain Mine produces gold. Mercury is a costly by-product of gold production because no revenue is generated from mercury. Traditionally, mercury leaches out with gold and follows the gold throughout the processing circuit until it is eventually condensed and collected at Retort. Minimizing or eliminating mercury production minimizes worker health and safety risks, minimizes environmental liability, and reduces costs. In the long term, minimizing mercury production will make mine closure easier and less costly.Bald Mountain Mine dramatically reduced mercury production by treating process solutions with liquid reagents called UNR 811 and UNR 811A. Several reagents were bench tested before proceeding with a plant trial. The reagent complexes the mercury to form an insoluble organic sulfide precipitate. In independent tests, the precipitate passed acid mobilization tests and is considered stable."

Jan 1, 2001

By M. Pourkani, M. Karga, Samid Banis, Andre Laplante, G. Langari-Zadeh

"The Sarcheshmeh mine processes 40,000 t/d of ore grading 0.9% Cu and 0.035% Mo. Grinding is effected in single stage ball mills using 80 mm forged steel balls, with an average consumption of 850 g/t. One of its 5 m diameter, 8 m length ball mills was emptied to measure the ball size distribution. The broken balls were first separated from the total charge, and the remaining balls classified into five size intervals of +7O mm, -70 +60 mm, -60+50 mm, -50+40 mm, -40 mm.The charge was composed of 280,534 balls (excluding broken balls) with a total mass of 305,180 kg. It was found that 4.0 % of the balls were broken; the size distribution of the charge was also markedly different from the desired one, in particular for the small-sized balls. For instance, 9% of the balls were expected to measure 2.54 to 3.18 cm in diameter, but none was found. On the other hand, the amount of top size balls was 30% higher than expected. The radial hardness of balls, which was determined by cutting the balls in halves, showed that the hardness sharply drops when the balls become smaller than 65 mm. The unexpected ball size distribution was attributed to the rapid change in the balls radial hardness. Based on the measured ball size distribution, a new ball make-up charge which uses 80% of 80 mm and 20% of 60 mm balls instead of 100% of 80 mm was proposed and implemented. The effect of the new ball make-up procedure in terms of ball consumption and grinding efficiency is being investigated."

Jan 1, 1999

By R. Patrick

As a unique South African organisation, CSIR: Division of Mining Technology (Miningtek) strives to support the mining industry by improving health, safety and productivity through developing, adapting and transferring technology. Considerable effort is currently directed towards the development of potential non-explosive mining methods with the potential to allow continuous mining in narrow reef conditions. Besides improving productivity, continuous mining results in concentrated mining which has a significant impact on reducing infrastructural costs. Impact Ripping and Water Pulse Rock Breaking have been tried on gold mines, whereas Activation, Mini-Disc? cutting and the Plasma Holemaker are currently being tested on platinum mines. The organisation?s many years of experience in novel rockbreaking, together with its world-wide collaborator network, has placed it in a unique position to assist the mining industry and manufacturers in developing and/or adapting existing technologies for application underground. Currently a range of technologies are being investigated, which have reached different stages of maturity. The main technologies under investigation are; - Impact ripper system - Water pulse rock breaking - Activated undercutting rollers - Mini disc cutters - Electric rock breaking

Oct 1, 2001

By Roy McKinstry, Mark Rantapaa, Thomas Bolles

"More efficient drilling and blasting techniques have shown measurable improvements in throughput at the Barrick Goldstrike wet grinding mill.A decrease in throughput at the autoclave, due to increasingly hard ore, was identified in early 2002. A team of individuals from the Open Pit and Process areas participated closely on the Drill-to-Mill (D2M) Continuous Improvement initiative to ensure that it would address the needs of both groups, with the target of improving throughput in future years, despite the projected harder ores. Plant studies were conducted to determine if adjustments to drilling and blasting could positively influence throughput. At the Goldstrike mill the greatest opportunity from the D2M initiative is realized on the hardest ore. Grinding throughput for softer ore, <15 kWh/st, can meet or exceed the downstream pressure oxidation requirements. Grinding throughput for harder ore, >15 kWh/st, is limited by the SAG milling capacity. Better fragmentation in the D2M ore, as demonstrated by image analysis, increased throughput 5% to 10% (25 to 50 stph) compared to the standard mining methods.Better fragmentation and a subsequent increase in mill throughput were achieved through the use of:1) Electronic caps for more precision and flexibility, as well as for allowing extremely fast shots.2) Explosives with a higher velocity of detonation (VOD), to provide for improved shock energy.3) Improved distribution of the explosives by decreasing pattern spacing.INTRODUCTIONThe Barrick Goldstrike Open-Pit group, along with the Process division, began experimenting with novel blasting technology and techniques to improve mill throughput in the spring of 2001. A series of tests were developed to determine if fragmentation and ultimately mill throughput could be influenced by optimizing the drilling and blasting program in known"

Jan 1, 2004

By Valentin Choquenaha Bombilla, Oscar Alvarez Muiloz

"Tintaya’s basic production line is copper concentrate, which has an important gold content. The process used is flotation; the objective of the metallurgical department is to obtain the best results in the copper recovery without neglecting the gold, using very specific reagents. Copper recoveries are considered high, nevertheless every day emphasis is placed upon increasing those recoveries. Regarding gold, optimum recoveries could not be achieved with flotation; and implementation of a gravity circuit was considered.According to microscopy studies, the coarse and very fine grains of gold in native form are lost to tails. The native gold due to its high specific gravity is concentrated at the underflow of the cyclone, remaining in the circulating load of the circuit. It reaches three times the concentration compared to the head grade entering the ball mills. This re-circulation generates very fine and laminated gold particles inside the ball mill, passing to the classification stage making a short circuit to the overflow of the cyclone.The very coarse gold particles as well as the thick flakes of gold do not react favorably to the conventional flotation process; thus studies that have included gravity separation have been conducted to increase the gold recovery. Part of the research included concentrating tables, jigs, and Knelson Concentrators. The Knelson Concentrator proved to be the best selection in terms of metallurgical performance and recoveries considering the throughput and operation conditions of the Tintaya Plant.The gravity concentration circuit with the Knelson Concentrator was commissioned in BHP Tintaya in October 1998, as per the flowsheet shown later on. Presently the global gold production surpasses any estimated expectations.Present efforts are directed towards showing the evaluation and optimization of the different parameters that govern the performance of the Knelson concentrator, as well as illustrating the difficulties and successes throughout the operating period.In the first year of operation 200 tons of gold concentrate have been produced with an average concentrate grade of 320 gramdton, having paid back in full the cost of the automated KC-XD- 48 Knelson Concentrator, the peripheral equipment, and the cost of the installation."

Jan 1, 2002

By J. Andrew Cornier, Mike Cooper

"Upon successful completion of the AG/SAG Mill project (Cooper et al., 2001) the Brunswick Mine concentrator was configured with single line processing through the AG/SAG mill, followed by two parallel ball mill and flotation circuits. The Stage Grinding project was undertaken to utilize a pre-flotation stage on the AG/SAG mill primary cyclone overflow and simplify the flowsheet by consolidating the two ball mill and flotation circuits, resulting in single line processing fi-om AG/SAG mill to final concentrate. Concurrently, the reclaim water supply capacity was increased to enable flotation cleaning at lower percent solids.Benefits from the Stage Grinding project include revenue enhancement from increased zinc grade and recovery combined with additional lead recovery. Further benefits included a reduction in the number of process pumps, reduction in loss associated with spillage to sumps and process simplification through efficient use of equipment layout.The Stage Grinding project was implemented in six phases over a period of seven months in 2000. Each phase was commissioned during scheduled concentrator shopdays with minimal additional downtime required. One year after project approval the Stage Grinding project was completed at a total cost of $1 1.8 million.INTRODUCTIONThe Noranda Inc. Brunswick Mine, located near Bathurst, New Brunswick, is one of the world’s largest leadzinc mines. Milling of ore began in 1964 from the No. 12 orebody, with an expansion in 1966 to accommodate ore fkom the No. 6 open pit located several kilometers away. In 1980 the pit was exhausted and the concentrator rationalized to accept a design feed rate of 10,500 tomes per day from the No. 12 mine. In excess of 100 million tomes have been milled to date, representing over three-quarters of the known reserve. The concentrator employs differential froth flotation to produce lead, zinc, copper and leauzinc bulk concentrates. The ore is massive sulphide, with approximately 20% valuable minerals, 60% pyrite and 20% silicates."

Jan 1, 2002

By K. Leung, J. E. Udd, L. B. Geller, F. Kitzinger

"Sixteen miners died tragically at the Paymaster gold mine in Timmins, Ontario, in February 1945 when a badly corroded hoist rope broke. The investigation of the Royal Commission that followed arrived at a number of recommendations (The Legislative Assembly of Ontario, 1947) aimed at avoiding future disasters of this kind. One consequence was the development and legislated use in Canada, several decades ago, of powerful electromagnetic (EM) instruments for the non-destructive testing of mine shaft wire ropes. The authors have been involved for many years in the design, production, and testing of EM instruments (Geller and Udd, 1990, 1992; Geller and Kitzinger, 1991; Geller et al., 1992). Since the mid-1990s, particular attention was paid to the design and operational results obtained from the computer controlled portable MagnographTM II wire rope tester (Geller et al., 1995, 1998).In the present paper, the authors summarize further hardware- and software-related developments of this instrument. Further, an account is given of the results obtained from the most recent design known as the Perma- ScanTM testing system. This is also a computerized dual-function system. In it, however, the sensor head is designed primarily, if not solely, for permanent installation and for remotely controlled operation. This represents a basic departure from traditional designs, which were intended for ad hoc temporary installations. The remote-controlled instrument described in this paper has now been in operational use for more than four years."

Jan 1, 2003

By Michael Young, Josh Rubenstein, Michael Cooper, Tom Shouldice, Dan Curry

"Xstrata Nickel Australasia’s Cosmos plant in Western Australia is currently implementing a debottlenecking project to increase nickel output while maintaining metallurgical performance and a low unit cost for production. Mineralogical analyses indicated that the processing bottlenecks could be removed by simply reconfiguring portions of the circuit as well as adding capacity with technical advancements – notably an IsaMill™, Jameson Cell, Wemco® SmartCell™ and Larox Filter.The Wemco® SmartCell™, which is particularly suited for coarse mineral flotation, and Jameson Cell, which is particularly well suited for fast floating and fine minerals, combine as rougher scalpers to complete the main stream portion of the flotation circuit. Addition of the two new cells meet the required flotation capacity to handle the forecast increase in nickel feed grade and tonnage.The addition of an IsaMill™ for regrinding allows the SAG mill to produce a coarser primary product, thus enabling increased throughput. The advantages offered by the IsaMill™ include operation in open circuit (internal classification), an inert grinding environment (ceramic media) for better downstream flotation (“clean” new surfaces), compact footprint (easy to retrofit into existing plant) and energy efficiency. With the new rougher capacity addition, the remaining original plant cells were reconfigured to suit the new regrind mill and cleaning requirements. The existing 24 m2 Larox pressure filter was replaced with a larger 32 m2 unit to dewater the increased concentrate output.The paper describes the upgrade at the Cosmos concentrator with particular emphasis on the mineralogical data and metallurgical benefits associated with the changes.INTRODUCTIONThe Cosmos concentrator is located 680 km northeast of Perth in Western Australia. The deposit’s development and operations were started in 1999 by Jubilee Mines NL, Cosmos’ previous owner, with the first production of nickel concentrate in April 2000. The Cosmos concentrator treats a komatiite hosted high grade nickel sulphide ore, with sulphides being predominantly pentlandite and pyrrhotite with lesser amounts of pyrite and chalcopyrite."

Jan 1, 2010

By Craig M. Sams

"Variable speed mill popularity has grown during the last 10 years with almost every SAG mill fitted with a variable speed drive. In addition, many of today’s larger ball mills are running a variable speed drive for various reasons. In the past, motor suppliers, especially gearless drive suppliers, have considered mills as being an overpriced rotor. This has lead to mills demanding more torque than what a motor can generate. This paper identifies the reasoning of what has happened and how to mitigate the mismatch in the future. Technical and economical issues are discussed, allowing mill operators to make an informed decision of which path to take in deciding what motor to put on a mill.INTRODUCTIONIt has been generally accepted in the past that motor suppliers and specialists in engineering companies understand the workings of a SAG mill or a ball mill and although there is a fair knowledge within the industry, in regards to mill torque requirements, the advent of variable speed drives in ball mills has shown the writer that a complete understanding of the mill torque requirements are not fully understood.This paper will discuss two aspects of mill torque requirements, (operating torque at various charge levels and start up torque), and how it relates to specifying the proper motor torque requirements.MILL OPERATING TORQUEMill operating torque at a given charge level and density in a mill is essentially constant throughout the entire speed range. For the purpose of this paper, we will take a 38’x 22.5’, 20’ EGL, SAG mill and provide the power draw at variable speeds but fixed loading conditions.The power draw and mill torque of this mill at 8% ball charge and 28% total loading (Highlighted) is shown below as Figure 1, at variable speeds."

Jan 1, 2007