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By Steve Hansen

Heap leach mining has long been an economical method for mining oxide copper ore, and with the U.S. Bureau of Mines' discovery of a way to economically strip gold and silver from carbon, it has become the standard in the gold and silver indus­try as well. Sulfide leach in copper recovery has always been a byproduct of oxide leach mining, although the methods and recovery rates have increased with technology. SX-EW has kindled a new interest in large deposits and dormant dumps of low grade sul­fide ore. Gold ore bio-oxidation was developed in the 1980's, but not tried on a large scale until US Gold built the Tonkin Springs Mine. This mine was dedicated to the large scale production of low grade sulfide ore that could be recovered through the newly discovered bio-oxidation method. On a small scale the method worked, but as time went on, problems with the process were costly and recovery was poor. US Gold did not have the finan­cial backing to perfect the process, and the mine was closed in 1990. Since that time, Newmont Gold Company has taken the lead and has dedicated a lot of resources to the perfection and implementation of this method. Some small mines have discov­ered that if they can use this technology they may be able to dou­ble and triple current ore reserves, because they will be able to mine deposits previously considered not to be economical.

Jan 1, 1998

By Thomas J. DeMull

Amax Gold's Sleeper Mine was brought to production as an open pit mining, cyanidation milling operation in March 1986. The Sleeper deposit is unique in that it contains zones of very high grade gold ore. Despite blending of ore, mill head grades have varied over a broad range. These grade variations were anticipated during mill design and affected, in particular, the sizing and selection of equipment for the CIP circuit. When grades proved to be even higher than anticipated, design operating parameters were adjusted shortly after start-up to accommodate the higher grades. Operating results have been excellent: during the first 18 months of operations the Sleeper mill has processed 375,600 tons of ore and produced 229,000 ounces of gold.

Jan 1, 1998

By Michael R. Straka

ALPKEM A Brief History, Cyanide Questionnaire Conclusions

Jan 1, 1998

By Hans von Michaelis

Welcome to RANDOL GOLD FORUM 88. It is clear from the list of delegates and speakers that this conference will lead to excellent discussions of the latest developments in this fast-moving industry. Less than a year ago Randol International Ltd. published an eleven-volume report titled "Innovations in Gold and Silver Recovery - Phase 111". In the short space of time since then, many new developments have been noted, many of which will be described in this Forum. I believe that some of the more significant innovations currently under development are those that address the following:

Jan 1, 1998

By L. J. Warren

Recent research at the Parker Centre in Pe1ih, Western Australia, has provided opportunities to reduce gold production costs by: reducing lime costs in the carbon-in-pulp process, understanding the mechanism of selective extraction of gold over copper using ammoniacal cyanide, and increasing throughput and improving overflow clarify in thickeners. This paper reviews the work of these three Parker Centre project teams, and highlights those instances where the results have been applied to plant practice.

Jan 1, 1998

By D. D. Carda, S. Dunn, W. E. Dunn, T. Storbeck

Gold chlorination which will be presented in this paper is limited entirely to the use of gaseous chlorine in a fluidized bed reactor at elevated temperatures in the absence of aqueous water. The only water used in this process is that which is used in scrubbing the effluents. Low temperatures are defined as those below 500°C. All experimentation for this paper was carried out on a laboratory scale, with all calculations extrapolated frpm this. Some of the data is drawn from work with other projects which have been operated at pilot and larger scale.

Jan 1, 1998

By Stuart Ratcliffe, Denis Kidby

The development of Vitrokele™ Technology over the last 10 years is reviewed with reference to mine site piloting and com­mercial applications. The first mine site piloting was conducted in Australia in 1989 followed by a further six continuous site trials in Australia, Canada and the USA. These major pilot plant studies are complemented by over 50 laboratory scale batch and pilot testwork programmes. The first commercial plant using Vitrokele™ Technology was the Connemara project commissioned in Zimbabwe in 1995. Subsequent to this, three commercial scale projects have been designed using Vitrokele™ to recover precious metals, base met­als and cyanide. The various projects are discussed with relation to the differ­ing flowsheets applied to each particular case.

Jan 1, 1998

By Stephen R. Brown

Current conditions in the gold market demand that mine and plant operators make budgeted production targets at the lowest possible unit costs. For those companies bringing new gold pro­duction capacity on-line, achieving budgeted production levels as quickly as possible after start-up is vitally important to mini­mize unit costs and to begin a positive cash flow. Whether the objective is to simply improve unit costs or successfully start-up a new, complex plant, success will be strongly influenced by the skill levels of the operators and supervisors. The only way to assure return on plant investment, and to survive during depressed metal prices, is to ensure that plant operators have the knowledge to effectively run the plant. Technology available in computer-based, multimedia training systems, including: inter­active animation, videos, voice-overs, schematics, and text can now be used to train operators at their own pace using plant-spe­cific information. Additionally, it has been shown that learning through multimedia provides a higher degree of long term reten­tion than more traditional learning methods.

Jan 1, 1998

By Donald D. Gullickson

The entire system is built around pre-designed and pre-engineered modules which are assembled to meet the metallurgical and production parameters of the project. The carbon vessels are the key to the flexibility of the system. The vessels are made of a coated mild steel, which allows the carbon vessels to be used in the adsorption, desorption and acid wash cycles. In the adsorption mode, the solution is pumped up-flow through four (4) vessels in series at 250 gpm fluidizing the carbon bed. When the carbon in the lead vessel is loaded, it is disconnected from the adsorption circuit via rubber hoses with quick-disconnect fittings. The second vessel is then made the lead vessel and a stripped carbon vessel is added to the end of the adsorption circuit.

Jan 1, 1998

By Donald D. Haas

Contract mining has a definite place in the mining industry, both in the United States and around the world. A mine owner should evaluate the utilization of contract mining in the devel­opment and production of mining properties. This evaluation of contract mining should be performed at various times in the life of a mining prope1iy from the development and initial operation of a new mining project, periodically throughout the mine's life, and at mine closure. Many factors must be considered in ana­lyzing and evaluating the potential of contract mining and those factors are both quantitative and qualitative. Quantitative factors are those factors for which costs or measures can be determined or estimated objectively; and qualitative factors are those factors for which costs or measures must be determined subjectively and do not lend themselves to objective determination or estimation. Some of the qualitative aspects may provide only yes, maybe, or no answers while others will provide a tendency or partiality toward one answer or the other without a quantified cost. The major quantitative aspects include operating and capital costs, monitoring costs, capital preservation, acquisition and disposal of new and used equipment, direct payroll and administrative costs, recruiting and training costs, and employment and termi­nation of staff and hourly personnel. The major qualitative areas include corporate philosophy, risks associated with capital and operating costs, financing the project, operating control, operat­ing flexibility, recruiting and training of personnel, employment and termination, administrative concerns, and owner/contractor relationship.

Jan 1, 1998

By Geoff Whebell, Dianne Coulthard

Sampling studies of high silver (+70%), gold dore led to the development of mine site sampling techniques and superintend­ing for the collection of samples for assay and bullion weights for settlement of shipped material. Data is presented which con­firms the reliability of the procedures against the traditional remelting and sampling at the refinery. The advantages to both mine and refiner are significant and are discussed.

Jan 1, 1998

By Terry I. Mudder, Michael M. Botz

In general, the cyanidation of silver ores requires higher con­centrations of cyanide in comparison to gold ores to affect simi­lar leaching rates and metal recoveries. The requirement for high cyanide concentrations in a silver ore leaching circuit may translate into higher operating costs, however with operation of an acidification-volatilization-reabsorption (AVR) plant to recover and recycle tailings cyanide, cyanide consumptions can be significantly reduced. At each of the currently operating AVR plants in the world, overall cyanide consumptions have been reduced by approximately one-half by recovering and recycling tailings cyanide. In addition, the AVR plants have reduced tail­ings cyanide concentrations to less than 20 to 30 mg/L WAD cyanide and reduced potential adverse impacts to wildlife in the tailings impoundments. This paper presents an analysis of the application of A YR to a silver ore leaching operation which has a CCD/Merrill-Crowe circuit included in the metallurgical plant.

Jan 1, 1998

By Ibrahim S. Balbaa, J. Terry Strack, James G. Hopkins

A microwave system for continuously reactivating carbon, used in gold processing, has been demonstrated at a gold mine in Ontario, Canada. The pilot unit produced reactivated carbon at a rate of 12 kg/h. Comparisons with the mine's existing reacti­vation kiln indicate that microwave reactivation technology has several clear advantages over conventional regeneration kilns. Upon completion of the original study, the microwave reacti­vation technology was further developed. An advanced rotary type microwave system that can be scaled up to reactivate car­bon at a rate of 120 kg/hr was designed and smaller pilot-scale equipment was commissioned and tested. Under an agreement with OHT, Harper International Corporation will manufacture, supply, and market the new technology. In addition to carbon reactivation, the rotary microwave system can be used in many other heating applications such as ore treatment, ceramic pro­cessing, and cleaning of minerals.

Jan 1, 1998

By G. I. Voiloshnikov, V. E. Dementyev

Wide use of adsorption methods for metal recovery is one of the most important achievements of gold metallurgy of the last decades. Anion exchange resins or activated carbons may be used as adsorbents. This paper presents a brief overview of IRGIREDMET effotts on development, testing and implementation of techno­logical flowsheets using both adsorbent types and attempt to compare their technological properties. IRGIREDMET Institute was founded in 1871 as a laboratory for gold smelting and gold ore testing. In 1930 it obtained the status of the Research Institute. IRGIREDMET functioned as leading research center for gold mining industry in the former Soviet Union. At present it is the Open Joint Stock Company dealing with all s01t of research and design works for gold min­ing (ranging from geology to gold refinery). IRGIREDMET started development of ion exchange technol­ogy in 19641• The first stage of work (1964-1970) including development of principle flowsheet of RIP process was carried out jointly with the Moscow VNIIKHT Institute (All-Russian Scientific Research Institute of Chemical Technology)2• The flowsheet of RIP process is presented in Fig. I and includes the following basic operations: gold adsorption from pulp; washing of loaded resin; acid treatment; thiourea adsorp­tion; gold elution by acid thiourea solution; resin washing to remove thiourea; alkaline treatment of resin; resin washing and gold recovery from eluates by electrowinning. The technology developed and equipment used were tested for treatment of clayey ore of Kuranakh deposit at a pilot plant of the Lebedinsky gold complex ("Aldanzoloto" company, Yakutia, Russia). The pilot plant throughput was 200 t/day. At the same time IRGIREDMET conducted the tests on ion exchange technology for ore and concentration products of oper­ating gold plants and for ores of new deposits. Laboratory and pilot plant tests were done and developed initial data and process design criteria for designing of 15 plans of the former Soviet Union. In the course of this work a great number of newly synthe­sized anion exchangers including strong and weak base resins was studied, the peculiarities of anion exchange resins using two different raw material types ( ores and concentrates includ­ing clayey, carbonaceous, silver bearing, arsenic, antimony and base metals bearing products); some theoretical regularities of adsorption process were investigated; the technology of two stage adsorption of gold and silver from silver gold ore, improved flowsheet for gold elution and resin regeneration, design of adsorption equipment including pulsation columns, design of electrowinning cells were developed; conditioning technology for pulp with complex ion composition prior to gold and silver adsorption was developed, etc.3·8• IRGIREDMET specialists took part in commissioning of practically all the plants in the former Soviet Union using RIP and RIL process including Lebedinsky, Kuranakh, Sovetsky, Karamken, Matrosov's plant and Mnogovershinny plants. Due to this works RIP process became standard technology for Russia and the CIS.

Jan 1, 1998

By J. E. Wennen

Screens serve several important functions in CIL and CIP processes for gold extraction. One important screen application known as interstage screening allows slurry to be continuously transfered through a series of CIL or CIP tanks while retaining activated carbon in the tank. In some cases, this has been accomplished by using airlifts to carry slurry containing activated carbon to an external screen which separates carbon as oversize and returns it to the tank by gravity. The undersize slurry advances to the subsequent tank. More recently this has been accomplished using launder screens and Kambalda type screens. These are essentially static screens that rely on air blasts or mechanical sweepers to clear carbon away from the screen surfaces.

Jan 1, 1998

By David J. Collins

The emergence of activated charcoal adsorption as the most popular recovery method for precious metals, has led to numerous innovations aimed at increasing the efficiency of the process. This article describes a change in traditional charcoal transfer methods which will aid in reducing charcoal attrition losses. Studies have shown that significant charcoal attrition takes place during transfer, be it when using airlifts or centrifugal pumps. Tests conducted at Pinson Mines indicated a 4 to 8% loss to the minus 20 mesh fraction of charcoal after three (3) hours of pumping charcoal. Tests conducted while the author was at Jerritt Canyon indicated that charcoal transfer was a major contributor to charcoal losses; a decrease in the amount of coarse charcoal (plus 12 mesh) and an increase in the amount of finer charcoal (minus 16 plus 20 mesh) was noted as charcoal was moved to the head of the adsorption circuit.

Jan 1, 1998

By John Litz

The term "refractory gold ores" refers to a wide number of ore types which are not readily amenable to direct cyanidation. A number of processes have been used commercially, and a number of others have been proposed and in many cases pilot tested. The selection of the appropriate process for an ore should not be arbitrary. Ore grade may preclude some processes, but a good understanding of the ore mineralogy can guide the selection. Many present gold operations and many potential gold operations have faced or are facing problems with refractory gold mineralization. We at Hazen Research have had the opportunity to perform bench testwork and in some cases, pilot plant testing on a number of refractory ores. The data included in this paper are excerpted from the testing of fifteen ores which cover a wide range of mineralogical compositions. This paper is not intended to be a treatise on the processing of refractory gold ores. In many of these gold projects, not all of the standard process alternatives were evaluated, nor was adequate mineralogical work performed. Such is the dilemma of contract research. "If I believe that I don't need it, why should I pay to have it done." The intent of this presentation, therefore, is to show how different ores respond to the various processes, and to demonstrate that one must have an open mind when developing a process for a specific refractory gold ore.

Jan 1, 1998

By Kathleen A. Altman

INTRODUCTION The basic premise of the ideas presented in this paper are as follows: Engineers believe that "theoretically" it will work. Operators ask what they must do to make it work. And, people can screw it up. r Today the challenges conf onted during the engineering, startup and operation of mines are becoming more complex. As mining and processing professionals, we are called upon to trav­el all over the world, are subjected to a wide variety of climates and must deal with a numerous cultures and people. Historically, for the majority of the people working in the mining industry, the primary challenges related to projects have focused on the differing perspectives of the disciplines involved. For example, geologists focus on resources and reserves, mining engineers relate to tons or tonnes, metallurgists count ounces or pounds or kilograms of product, mechanics emphasize availabil­ity, human resources personnel deal with absentee rates and turnover and accountants watch the bottom line ($$'s). As the world has become "smaller" and the mining industry has become more globalized, the puzzle is becoming increasingly difficult. Even the most experienced in the crowd of mining profes­sionals are oftentimes surprised by the types of problems that are encountered. Try as we may, we cannot anticipate the complex­ity of dealing with the human side of an operation.

Jan 1, 1998

By Ray Soper

Important progress has been made in developing the K-Process as an alternative to cyanide as a method of recovering gold from ores and other materials.

Jan 1, 1998

By C. Botha, M. J. Walls, C. T. O'Connor

The role of copper sulphate in the flotation of pyrite has been studied. A survey of a number of pyrite flotation plants using copper sulphate showed that in correct dosages, it was able to increase both grades and recoveries. This was confirmed in batch tests. Copper sulphate had no significant effect on the rate of adsorption of PNBX onto pyrite. Copper adsorbed irreversibly onto the pyrite when the latter was slurried in a copper sulphate solution. Copper sulphate had a significant effect on the maximum froth height obtained in static three-phase froth tests. Proposals to explain these observations are made.

Jan 1, 1998