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By M Bird, B Oats, M Sganzerla

Mining operations are continually aiming to reduce operating costs to improve plant profitability. One way in which the Cannington operation sought to achieve this was by increasing the wear life and reducing the energy consumption of their flotation mechanisms. This was made possible using Outotec’s FloatForce mechanism. The FloatForce mechanism has been developed by Outotec over a six year period involving both CFD modelling and rigorous site testing. FloatForce delivers improved air dispersion and cell agitation efficiency; as such it can be operated at lower rotor tip speeds when compared to Outotec’s previous mechanism.Cannington trialled three FloatForce mechanisms in a train of ten OK38 zinc roughers. The mechanisms’ rotational speed was reduced by 10% compared to the previously installed MultiMix mechanisms. The purpose of the trial was to quantify the energy saving and assess whether there was any reduction in plant metallurgical performance.The trial was successful with FloatForce delivering a 17% reduction in power, an improvement in wear and improved recovery. Analysis of pre and post-installation metallurgical accounting data showed the following:The FloatForce installation resulted in a recovery increase of zinc to zinc final concentrate of 0.4 – 4.0%*The FloatForce installation resulted in a recovery increase of lead to zinc final concentrate of 0.0 – 0.3%*There was no statistically significant change in silver recovery to zinc final concentrate that can be attributed to FloatForce**95% confidence interval (CI) using multiple linear regression models.The Cannington operation is now in the process of further optimizing its power consumption and wear savings by changing the remaining OK38 zinc and lead rougher float cells to FloatForce mechanisms.CITATION:Bird, M, Oats, B and Sganzerla, M, 2015. Improvements in flotation cell maintenance, power consumption and operation at South32 Cannington, in Proceedings MetPlant 2015, pp 230–245 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By Allen W. Hatheway, John A. Albritton, Lloyd B. Underwood

Missouri River Division (FORD), U.S. Army Corps of Engineers (COE), has completed (October 1982) a study for the U.S. Air Force Ballistic Missile Office, in which desireable and needed changes in contracting methods for underground construction were identified. Due to the importance of geotechnical considerations in such construction, a good number of the resulting recommendations relate to geotechnical considerations. Corps contracts have traditionally served as models for contract documentation by public agencies and in private enterprise. Several standard features of present-day contracting methods were Corps innovations. Corps officials are generally in agreement with the recommendations of the Better Contracting reports published by the U.S. National Research Council (NAS/NRC), through its U.S. National Committee on Tunneling Technology (USNCTT). However, the findings of the 1982 MRD study indicate that additional changes are warranted for underground construction contracting methods; changes that deal specifically with site geological conditions, both known and to be reasonably anticipated, as well as with their associated impacts on construction. The 1982 MRD report identifies the need for nine specific improvements in geotechnical aspects of contracting; improvements based on recognition of geological conditions.

Jan 1, 1983

By Linda Duncan, Trevor Yeomans, Chris Potorieko, Michael Fullam

"NVI Mining’s Myra Falls Operation is a 4,000 mtpd copper/zinc flotation circuit with by product gold of ~28,000 ounces per year. Gold recovery has historically averaged 40-55%, however, a portion of this was recovered in the zinc concentrate and received poor payment. Two Knelson CD-30 Concentrators have been operating in the grinding circuit since 1992, with gravity recovery averaging about 2-5% over that time period.The Myra Falls gravity circuit was one of the very first hard rock mining installations operating in the world with automated Knelsons. The mine has employed a unique and unusual upgrading method for the Knelson concentrate that had never been evaluated as to its efficiency. Recent Gravity Recoverable Gold Testing by McGill University, and mathematical modelling of the Gravity Circuit by Knelson Gravity Solutions indicated the gravity circuit was not living up to its potential. Myra Falls Personnel changed the upgrade system-operating regime, and a complete gravity audit of the grinding circuit was carried out, with the results confirming the initial suspicions. Gravity recovery increased from 5% to 15%, with overall gold recovery improving by 5%.INTRODUCTIONNVI Mining operates a 4000 tpd mine and mill complex on Vancouver Island. The milling circuit consists of open circuit rod milling, closed circuit ball milling, gravity recovery, copper flotation, zinc flotation, and tails disposal. There are two milling circuits, “A” circuit, and “B” circuit."

Jan 1, 2006

By Cosmin Carpinisan, Erich J. Hofmann, Stephen J. Hall

"Since presenting a technical paper regarding their unique capabilities in Forged Steel Mill Gearing at the SAG-2006 Conference, Australian heavy engineering company Hofmann Engineering has pioneered a number of new manufacturing processes and design concepts for components of large comminution equipment. These include: 1. Novel design improvements for HPGR Rolls with forged steel tyres and a unique patented tungsten carbide insert designed to improve wear life, enhance autogenous layer build-up, and to reduce breakage & chipping under load. 2. Development of forged fabricated Mill Heads using rolled & welded high-tensile steel plate as alternatives to cast conical mill heads. 3. Insitu Girth Gear measurements for profile and wear via portable 6-axis CMM. 4. Gear and Pinion designs to AGMA-6114 for SAG mills of 38’-40’ diameter to 24MW and for Ball Mills of 26’ diameter to 18MW. The paper presents case studies from the Australian heavy manufacturing facilities of Hofmann Engineering, combined with news of their new gear manufacturing and gearbox overhaul facility in Canada."

Jan 1, 2012

By Tom Meikle

Long tendon support systems provide several challenges when used in-cycle as part of the secondary or primary support cycle. A two-component pumpable resin, Carbothix, has been in development for use with self-drilling rock bolts, but many of the attributes of this new resin system make it ideal for grouting long tendon support systems. While neat Portland cement grouts or polyester resin capsules have been used with long tendon support systems for many years, two-component pumpable resin systems overcome many of the shortcomings in these systems. The two-component systems dramatically improve the set-time to enable mining face advance with fewer delays, enable longer pumping distances, improve quality control, and enhance load transfer mechanisms. This paper describes the key benefits associated with a new pumpable resin and details the Australian Department of Mines and Petroleum department atmospheric testing results and cable load testing completed by Minova personnel to date. It also details the results of the Australian mine site trials and the introduction of these systems into production use.

Jan 1, 2012

By P Cotton, N Cox

The Brisbane City Council has implemented a program of continual improvement at its Mount Coottha Quarry in the heart of Brisbane, Australia. The program has been underway for the past 6 years, and has resulted in very significant improvements in terms of both the cost effectiveness of its operation, and in terms of its environmental impact on nearby residents. The work has included a focus, amongst other things, on blasting efficiency and has challenged conventional thinking in terms of the size of blasts fired, the frequency of firing, the diameter of blastholes, and the use of bulk emulsion or slurry explosives.

Jan 1, 1996

By Coppock BW

Sintering of lead and zinc concentrates is practised by Sulphide Corporation Pty. Limited to provide both desuiphurised lump sinter feed, for simultaneous reduction to zinc and lead in the Imperial Smelting Process blast furnace, and sulphur dioxide gas for sulphuric acid manufacture. From November, 1969 a 20 percent increase in production rate has been obtained through improvements in operating technique. A gradual increase in bed permeability was achieved by modifications to the feed mix conditioning equipment and by improving moisture control. However advantage could not be taken of the higher permeability to increase sulphur elimination because the hardness of the lump sinter decreased. Higher throughput, better quality sinter and more stable sintering conditions were however made possible by simultaneously: 1. reducing segregation and compaction in the sinter bed, by narrowing the discharge opening of the main layer feed hopper, 2. reducing the sizing of sinter returns to give a closer size spectrum of particles in the feed mix, and 3. increasing the sulphide sulphur content of the feed mix to give higher bed Temperatures.

Jan 1, 1972

By Holly J

The period following World War II has seen many changes in stoping techniques at The Great Boulder Gold Mine. The new methods resulted in improved unit production figures, and have given some relief from the rising worldwide cost spiral in the post war years.Significant production figures are shown graphically in...

Jan 1, 1956

Since the introduction of water cooled test rings the operation of cupelling retort bullion has not alone been sImplified, but has also been the means of concentrating the bullion for the fining test in a much shorter time.The first water cooled test ring which I used was rectangular in shape, inside dimensions 5 ft. 3 in. x 2 ft. IQ in., and made of i in. mild steel plates, with a water space of 9i in. x 3t in. However, it was found that as soon as the filling commenced to wear and the litharge came in contact with the jacket, the plate was gradually affected on the lines of the wash, caused by the blast. After a while the inside steel plate went beyond the factor of safety, and was then substituted on the sides and the front of the test ring by a tin copper plate, which has stood now for the last five years without showing the least signs of wear or leakage.The test remains in use as long as the bottom is regarded as safe, and toward the end of the life of the test the litharge is allowed to work against the copper plate.

Jan 1, 1901

By K Niyomjinda, B Etschmann

Chatree Gold Mine is currently the only modern day gold mine operating in Thailand, and is situated approximately equidistant from Chiang Mai in the north and Bangkok in the south. Environmental guidelines set by the Thai authorities require Chatree Gold Mine to achieve a Total Cyanide level of 20 ppm or less in the process plant discharge slurry stream prior to release into the tailings storage facility. This paper describes both the initial difficulties faced in achieving compliance on this limit utilising the conventional INCO SO2/Air cyanide destruction system and the subsequent process improvements initiated to both the leaching process and the standard INCO process to achieve the current compliance levels of approximately 99/100 shifts. Improvements were focussed on the dual aspects of reducing the formation of WAD cyanide and ferrocyanide species in the leaching circuit coupled with process changes to improve removal of the ferrocyanide species from solution during the cyanide reduction stage.

Jan 1, 2004

By T Hughes

The Gekko InLine Pressure Jig (IPJ) was unleashed on the World gravity separation market in 1996 and has since sold over 150 units in applications including tin, diamonds, silver, coal, garnet and gold. During the past twelve years the knowledgebase of the best applications and capabilities of the IPJ has greatly increased. Improvements to the original IPJ design have included engineered ceramic ragging in specific gravities from 1.6 to 5.0, full automation and improved designs of feed presentation and tailings and concentrate handling systems. The IPJ has been found to be able to handle a wide feed size range and recover mineral at liberation size without significant addition of water to the mass balance. Test work carried out during full-scale operation of the IPJ has shown the IPJ can recover diamonds down to 0.5 mm, sulfides down to 0.3 mm and gold down to 0.1 mm which greatly expands its application in the mineral processing industry. A significant volume of data now supports the symbiotic benefits of an IPJ and flotation circuit combination to pre-concentrate an ore and minimise downstream processing requirements.

Jan 1, 2008

By C Barton, B Randall, T Weldon, M Lefler

FLSmidth-Summit Valley Technologies has been a leader in gold processing equipment for nearly two decades. Over the past several years an extensive research and development effort has led to improvements in Mercury Abatement systems and process efficiency in Adsorption Desorption and Regeneration (ADR) or "Carbon" plant operations. Two technologies will be discussed that are focused on efficiency improvements followed by an explanation of Mercury Abatement systems. Gold and silver can be desorbed from carbon in several ways. FLSmidth has made significant improvements to the Pressure ZADRA process allowing for lower energy consumption and lower capital costs. This patented process is known as the Split-ZADRA Strip method. Split-ZADRA allows a plant to elute loaded carbon in a semi-continuous fashion. This increases the grade of the Pregnant Strip Solution, improves electrowinning efficiency, reduces capital equipment costs, and reduces energy requirements. During desorption and electrowinning for the Pressure ZADRA process, the pressure and temperature of the circulating strip solution is changed multiple times. A self-contained heating and cooling system has been developed which decreases the energy requirements for elution. Mercury Abatement technology has become increasingly important in recent years. Along with FLSmidth Summit Valley Technologies' complete Mercury Retorting Systems, FLS-SVT has developed systems for the capture and removal of mercury from electrowinning cell and strip solution exhaust, Carbon Regeneration exhaust, and the dore furnace exhaust. This paper describes each of the technologies introduced above and their success in operational gold and silver mines. Case studies will be discussed showing the advantages of each specific technology as it applies to operations around the world. CITATION:Lefler, M, Weldon, T, Barton, C and Randall, B, 2013. Improvements in the mercury abatement and process efficiency of adsorption, desorption and regeneration gold processing operations, in Proceedings MetPlant 2013 , pp 468-478 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Yoneji Kanoh, Masahiko Ohtsuka

In Japanese tunneling history, it has commonly been accepted that the long-round driving is difficult due to the complicated geological condition. Therefore, the maximum past record has been less than 3 m per round. A new record of advance was established in the 99 m2 headrace tunnel of Imaichi Water Power Station Project with an advance of 239.5 m in a month by drilling 3.9 m deep blast holes. The geology of the headrace tunnel composed of pyroxine andesite (ie. 960-1770 kg/cm2, VP3.1-4.3 km/s) which had several clay seams and open cracks and was moderately weathered. Automatic shotcrete machine was used for shotcreting. Rock support was specified according to the N.A.T.M. with each different rock type. The contractor achieved a remarkable tunneling advance not earlier experienced in Japan.

Jan 1, 1983

By William R. Yernberg

The Fifth International Conference on acid rock drainage (ICARD 2000) was held May 21-24, 2000, in Denver, CO. The three-day conference consisted of about 150 oral presentations and poster sessions that described the state-of-the-art of acid-rock-drainage (ARD) science and technology. The conference also featured a trade show. It included representatives from consulting companies and government agencies with interests in ARD, as well as other environmental issues related to mining. The conference also included field trips to ARD treatment sites and short courses on acid rock drainage issues. ICARD 2000 was planned and promoted by the ICARD 2000 Organizing Committee and the Society for Mining, Metallurgy, and Exploration, Inc. (SME). Financial support was provided by Barrick Gold, BHP Copper, Homestake Mining, Noranda, Phelps Dodge, PlacerDome, the US Bureau of Land Management, the USEnvironmental Protection Agency and the US Geological Survey. Since the original ICARD was held in Roros, Norway, in 1988, knowledge has improved of the behavior of mine wastes as have methods of environmental mitigation. The ICARD 2000 presented the latest advancements in the field of acid drainage.

Jan 1, 2000

By Beevers J

The Ok Tedi Project is now a high production open-pit porphyry copper mine located in the Star Mountains of Papua New Guinea (PNG). At present, total daily production is 190 000t of ore and waste. Large scale drilling and blasting has only been in operation since 1988, prior to which all material was removed by ripping and dozing. This paper reviews the steps taken over the last 12 months in establishing a more efficient drilling and blasting operation and highlights the significant reduction in powder factor. These improvements have been achieved largely through the introduction of air-bags, controlled pattern expansion and an overall focusing on the operation by involving consultants, ICI's technical service and internal departments.

Jan 1, 1991

By Greg M. Hollyer

The search for minerals in the future will be dominated by deeper exploration and the need to accurately target ?blind? deposits as more and more of the ?easy? near surface targets are exhausted. In this context, key technologies are emerging for deep exploration both in grassroots and minesite exploration, including the Titan 24 Deep Penetrating geophysical technology. Introduced in 2001, this technology has grown rapidly into an accepted approach for exploration in a variety of geologic environments, including brownfield environments where discovering additional reserves would most quickly benefit companies. Titan 24 belongs to a new class of sophisticated Distributed Acquisition Systems (DAS) which record high-volume, high-quality data simultaneously at multiple receiver stations. This data is then processed digitally, modeled using specialized inverse modeling software, and interpreted according to geologic and other parameters. The result is a robust, high-quality, high-volume data sets which provide a basis for improved imaging to depth. In this paper, the Titan 24 distributed technology is discussed. Illustrations of the vast improvement to overall exploration are showcased through results in several case studies. These include examples from two gold deposits, a porphyry deposit and a minesite. These examples show the range of applicability of the technology and the ability to effectively image mineralization, lithology, structure and alteration to depth as an aid to understanding prospective mineral deposits and targeting drills more accurately.

May 1, 2008

By A D. Campbell, G R. Power

Many caving mines use numerical flow models to simulate mine production, forecast recovered ore grades and optimise the draw strategy. In sublevel caving (SLC) mines, the effects of blasting and fragmentation at an individual ring scale generally cannot be included in these models. Previous attempts to use results from marker recovery trials to calibrate numerical flow models have been limited due to difficulties in accounting for blasting effects at a ring scale. This paper outlines how an empirical criterion for blasting and fragmentation was used to attribute variable flow properties into a numerical flow model based on the blast design and modelled fragmentation. The flow model was then validated using data from a number of full scale marker recovery experiments. The result of this approach was a significant improvement in forecast accuracy when compared against the same modelled cave marker recovery without the inclusion of these blasting effects. Improvements in the flow model are currently being adopted within the mine scale model to further improve the accuracy of grade forecasting, optimise the draw strategy and increase net present value. The integrated modelling approach is also being used to simulate the effects of different drill and blast designs on cave recovery. It is suggested that, if implemented, the technique would lead to improved blast designs in other SLC mines, increase the value of marker trial data and reduce costs associated with large scale blast design trials.CITATION:Campbell, A D and Power, G R, 2017. Improving calibration of flow models against SLC marker trials by linking blasting effects to particle mobility, in Proceedings 13th AusIMM Underground Operators’ Conference 2017, pp 11–22 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 16, 2017

By M. Shapiro, L. A. le Grange, B. Henning

A paper was presented by Bateman Minerals and Metals at INFACONX (2004) describing a simplified Computational Fluid Dynamics (CFD) Model for predicting the temperature and velocity distributions in all the fluid zones of a single electrode DC Furnace simultaneously with the temperature distributions in the refractory lining of the vessel. The boundary conditions imposed on the model consisted of the arc current, external surface film coefficients and ambient temperatures. The temperature and velocity distributions in the free-board, slag and metal were solved simultaneously by coupling across the interfaces between the fluids and transportation phenomena developing in the plasma arc. A simplified model was used to describe the ex-change of energy by radiation between the arc and surfaces enclosing the freeboard region. The strengths of this model were reported as being the ability to: ?Solve the different zones and transportation phenomena simultaneously without the need to transfer partial numerical results between different numerical analysis applications. ?Solve velocity and temperature distributions without assumptions regarding internal film coefficients and additional internal temperature boundary conditions. One of the disadvantages of the model was that the energy absorbed by the process was not modelled, resulting in vessel performance predictions under heat loss conditions only. Whilst this allowed potential problem areas such as localized refractory heating to be identified, the model was only capable of predicting how these could be improved by varying the overall geometry and materials of construction. This paper presents improvements in the application software and user defined subroutines of the model as follows: ?Incorporation of surface to gas, gas to gas and gas to surface radiation models to improve the accuracy of radiative heat transfer mechanisms within the freeboard. ?Incorporation of a process energy absorption model based on a theoretical temperature dependant enthalpy curve which incorporates melting, smelting and superheating in selected areas of the bath. This enables the effect of feed distribution and power to feed ratio changes to be estimated. The effects of a commercial arc at full power on the freeboard and slag can now be simulated with increased accuracy.

Jan 1, 2007

By H. Do, R. Yoon

Mineral flotation is effective over a relatively narrow particle size range of approximately 10 to 100 µm. If the upper particle size limit can be increased, however, a run-of-mine ore may be coarse ground, and only the middlings are ground further to achieve required grades. This will result in significant energy savings and increased throughput. In this communication, methods of increasing the upper particle size limit will be discussed on the basis of a flotation model that can predict flotation from both hydrodynamic and surface chemical parameters. An example of increasing flotation recovery by control of a chemistry parameter is given.

Jan 1, 2007

By Jose R. Hernandez-Aguilar, Jeet Basi

"The study evaluated the impact on overall circuit metallurgy of improving the performance of the two flotation columns that make up the final Mo cleaning stage in the Cu/Mo separation circuit at Highland Valley Copper mine. The results showed that a key factor to improve the overall circuit metallurgy was to control the size of the bubbles generated in the columns. When a large proportion of small (< 1 mm) bubbles were generated, the production rate of solids-in-concentrate increased by a factor of 4-5 compared to typical production figures without compromising concentrate quality. This increase in concentrate production rate reduced the circulating load in the circuit causing a significant increase of Mo recovery. A statistical analysis of historical production data showed a strong relationship between final concentrate production rate and overall Mo recovery. This relationship along with the results from this study indicated an opportunity to increase the recovery of Mo from 90% (typical) to 94% without downgrading concentrate grade. This 4% increase represents about 14,000 lbs or $500,000 worth of Mo each month at current metal prices.To provide a rational interpretation of the results, this study also examined whether the model of Gorain et al. (1997; 1998; 1999) could explain the increase of Mo recovery seemingly resulting from the decrease of bubble size. The data showed that the model predictions did not agree with the experimental data, i.e., for a given change (decrease) of bubble size, the predictions underestimated significantly the observed recovery increase. An interpretation based on the fundamental analysis of Finch and Dobby (1990) and Hernandez-Aguilar et al. (2005) is proposed to explain the discrepancy between measurements and predictions obtained from Gorain et al.’s model.INTRODUCTIONIt is generally accepted that the size of the bubbles generated in a flotation cell – a concept usually referred to as “bubble size” – has a significant effect on metallurgical performance. However, a significant number of mineral processing practitioners often question, with valid reasons, the practical benefits of implementing process improvement strategies based on controlling bubble size. “Small” bubbles are often considered to be “favourable”, but how small they need to be for a particular case, or how to adjust operating conditions to control a target bubble size, or whether the bubbles need to be smaller in the first place are questions that usually remain unanswered. Two reasons explain this situation."

Jan 1, 2009