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By S. R. Amos, N. O. Lotter, A. L. Hannaford, J. F. Oliveira, D. W. Broughton

"Ivanplats Ltd appointed Xstrata Process Support to perform the flowsheeting development work for their hypogene and supergene geomet units of the Kamoa Copper deposit, located in the Democratic Republic of the Congo. Through systematic flowsheet development using modern Process Mineralogy, the optimised milestone flowsheet delivered a saleable concentrate grade of 32.8% Cu at 85.4% recovery with hypogene ore, and a saleable concentrate grade of 45.1% Cu at a recovery of 83.4% for supergene ore. The significant value of this development is that a single flowsheet will treat both hypogene and supergene ores and produce saleable concentrates. Further work to advance the flowsheet performance has been identified for investigation in the near future.INTRODUCTIONLocation and Description of the Kamoa DepositThe Kamoa copper resource is located some 40 km west of the city of Kolwezi, in the south west of the Katanga Province of the Democratic Republic of the Congo, in the region of Central Africa. Drilling at Kamoa in 2008-2009 had discovered laterally continuous, sediment-hosted, high-grade stratiform copper mineralisation in a newly discovered copper district that forms a previously unrecognised western extension of the famous Central African Copperbelt – which hosts such world-class deposits as Kolwezi, Tenke-Fungurume, Konkola and Nchanga. This discovery showed that the western end of the Copperbelt in the Congo does not terminate at Kolwezi (Friedland & Broughton, 2009). The resource contains hypogene and supergene geomet units with a transitional zone located inbetween the (upper) supergene and the (lower) hypogene. In the hypogene unit, the major copper sulphides are bornite, chalcopyrite and chalcocite, whilst in the supergene, the sequence is led by chalcocite, then bornite, and finally chalcopyrite. Covellite is present in both units as a minor copper sulphide. Both geomet units will be mined and treated in one concentrator, either as blends or as campaigns."

Jan 1, 2013

By S. Hunt, S. Jayasekera, J. Kyle, N. Perera, K. Stone

A preliminary investigation has been conducted to determine the conditions for the precipitation of phosphate from the liquor produced after a hydrochloric acid pre-leach and rare-earth recovery from a rare earth containing fluorapatite concentrate from the Nolans rare earth deposit in the Northern Territory of Australia. The results show that at 50oC the phosphate can be precipitated in two stages using limestone to produce a Stage 1 precipitate containing most of the impurities including iron (94%), aluminium (92%), fluoride (98%), uranium (84%) and thorium (94%), followed by a relatively pure Stage 2 dicalcium phosphate precipitate (DCP) containing only 0.05% Fe, 0.05% Al, 0.1% F, 0.01% U, and <0.01% Th. The initial Stage 1 precipitate contained about 25% of the phosphate while the remaining 75% reported to the Stage 2 phosphate precipitate. Depending on the required radioactivity specifications, the amount of phosphate in the Stage 1 precipitate could be reduced. Reagent requirements were 11.4 kg limestone (as pure CaCO3) per cubic metre of solution for the Stage 1 precipitate and 39.7 kg limestone (as pure CaCO3) per cubic metre for Stage 2. The analysis of radionuclide balance indicated that radionuclides deported mainly to the final filtrate (86.4%) compared to Stage 1 precipitate (5.4%) and Stage 2 precipitate (8.2%). Settling and pressure filtration tests indicated the precipitates were both readily settled and filtered. The final moisture contents of the Stage 1 and Stage 2 precipitates were 62.5% and 49.3%, respectively.

Jan 1, 2014

By Martin Plante, Denis Hamel, Marie-Pier Bédard, Jeff McLaughlin

"The results and methodology for the optimisation of the zinc flotation circuit at the Matagami Mill using the 6-Sigma methodology are shown in detail while only the base line and final results are presented for the copper circuit. As a result of the six sigma project, the zinc concentrate grade was improved by 2% and the zinc recovery by 3%, with reduced dosage of reagents while the copper concentrate was improved by 2.4%. The process variation in the zinc concentrate grade and recovery was also reduced by over 50%. The main factors contributing to the project success were identified to be improvement in the plant measurement systems, an internal benchmarking exercise and statistically designed laboratory and in plant tests to guide the process improvement. The annual value to Noranda resulting from this project has been estimated at approximately $5 million.INTRODUCTIONThe Matagami concentrator started ore processing from the new Bell- Allard deposit in July 1999. Concentrator performance (grade and recovery of zinc and copper concentrates) was highly variable and work was ongoing to fix the sources of variation. In the mean time, Noranda embarked on its 6-Sigma initiative across the company. The 6-Sigma DMAIC (Define, Measure, Analyse, Improve, Control) methodology was used in the two flotation circuits to reduce variation and improve performance. The statistical 6-Sigma methodology moves towards identifying and controlling critical process operating variables (the X' s) to achieve customerspecified performance (the Y's). The goal of the methodology is to describe a process in a numerical equation known as the transfer function, given as Y = f (XI, X2, X3.. .), where Y could be concentrate grade or recovery and examples of X's are reagent dosage, particle size, etc. With the transfer function, optimal operating conditions and control tolerances are established for the key X's to ensure the desired Y performance is obtained.Each phase of the 6-Sigma methodology is explained below with examples from the Matagami project."

Jan 1, 2001

By D. M. Fraser

"Brunswick Mining and Smelting Corporation Limited operates two mines; one open pit (No. 6) and one underground (No. 12), approximately 20 miles south-west of Bathurst, New Brunswick. Both are massive sulphide deposits containing copper, lead, zinc and silver. The No. 12 property began operation in 1963 and is presently being mined at a rate of 3600 tons per day underground and is in the completion stages of an expansion to achieve 11,000 tons per day underground by the end of 1930.Originally at Brunswick Mining, acid mine drainage was added to tailings and neutralized by an excess of lime in the tailings. A conventional recycle system was established with a biostabilization pond for the treatment of thiosalts, a liming station and sludge settling area for neutralization of acidic water and a final reclaim pond with a pumping station for reclaim water.We found that not more than one third of the reclaim water could be used as it upset the flotation circuit every time it was used. It was established that the mine water and surface drainage were the cause due to oils and detergents in the water. It was also found that the biostabilization pond method Cf thiosalt treatment was not efficient for year round operation in our climate.In 1974, we reviewed the problems and began a 3 phase program to control effluents from the property:"

Jan 1, 1980

By A. P. E. Dirige

Extensive field study has been performed to assess the capabilities of thin sprayon liners (TSLs) and conventional spray-on support systems for preventing rock and support material damage that often results due to mining-induced rockbursts. Support performance was studied using field scale explosive detonation trials to simulate dynamic failure effects that are known to develop during typical rockburst events. Multiple seismic and high speed photographic monitoring techniques were used to provide detailed information concerning rock motion, surface fracturing, ejected fragment motion, and support liner survivability characteristics. Results of this study have demonstrated that TSL?s and variant layer combinations may be as effective as or better than conventional support materials for mitigating rockburst or like damage in highly stressed mine environments. In this study, field results have been verified using numerical modeling procedures to better understand the support behaviour of TSLs when subjected to highly stressed mine environments and mining-induced rockbursts, a factor that is essential when designing any rock support system. A series of numerical modeling assessments were conducted using FLAC3D modeling of a half circular TSL-lined tunnel, influenced by anisotropic stresses and simulated mining-induced rockbursts, to investigate the support potential of TSLs under prototype conditions. The effect of a mine rockburst was simulated using the three-dimensional dynamic analysis option of FLAC3D. Results of TSL-lined tunnels in highly stressed and mine rockburst conditions indicated exceptional effectiveness of TSLs for suppressing rock deterioration resulting from stresses and rockbursts. The rock support potential of TSLs on tunnel surfaces was compared with that of thin shotcrete linings, and results indicated that thin spray-on lining products currently available may be equally as effective in support as shotcrete materials.

May 1, 2009

By Steve McAlister, Colin Sprake

"Enhanced gravity concentration machines have been applied successfully in the following areas of precious metal recovery flowsheets:1. Primary Grinding Circuits2. Shaking Table Tailings3. Pre-Concentration of Leach Feed4. Flotation Concentrates -•, Flash•, ConventionalAlthough great progress has been made, the ability to produce directly smeltable concentrates still remains elusive. Even without this ability, centrifugal concentrators are finding wideningapplications in precious metal concentration:1) PRIMARY GRINDING CIRCUITSEnhanced gravity concentration technology has largely replaced jigging as the technology of choice in precious metal grinding circuits worldwide. The benefits of using a centrifugal field to concentrate both coarse and fine gold are well documented but the placement of these machines within grinding circuits is still evolving. Conventional wisdom dictates that the best location for enhanced gravity machines is cyclone underflow on account of the elevated grade found in this stream when compared to cyclone feed or overflow. Plant operating experience at both large and small scale indicates that there are compelling arguments to place ENHANCED GRAVITY MACHINES on cyclone feed instead. At least two new plants, presently in the detailed design stage will incorporate gravity circuits that treat mill discharge or cyclone feed, Teck Cominco’s Pogo and Newcrest’s Telfer Expansion.Current Conventional PracticeThe current stream of choice for enhanced gravity concentration within grinding circuits is cyclone underflow although recent information indicates a swing toward cyclone feed. Here are some of the arguments for treating a portion of cyclone underflow:"

Jan 1, 2003

By Alice H. Zhu

Belt conveyors are widely used in materials handling industries. The bulk materials which can be transported include ores, coal, earth, grain, limestone, wood chips, fertilizer components such as potash and many others. Along with the new technology development and enhanced industrial automation requirements, belt conveyor instrumentation has also been modernized to improve conveyor availability and performance. Traditionally, belt conveyors are equipped with emergency pull cord switches to shut the conveyor down, misalignment switches to signal the belt offline condition, speed sensors to detect the belt slippage, and level switches to prevent material plugging in the discharge chute. Belt rip detectors are also normally provided for long belt conveyors. As a rule, equipment condition monitoring is not automated at most operating facilities, but is performed manually by maintenance staff via time-based surveillance. The new generation of condition monitoring instrumentation and control equipment can be successfully utilized to design a reliable, cost-effective, and centralized monitoring system, capable of monitoring a wide variety of mechanical equipment. The implementation of the condition monitoring automated system can provide continual monitoring of the plant equipment to ensure safe operation of the equipment to its required capacity. Any abnormal behavior of the motors, gear reducers and pulleys can be analyzed, alarmed, and recorded immediately, so problems can be detected and resolved before critical components failure. Therefore, the current trend is to provide the belt conveyors with condition monitoring system in addition to the traditional instrumentation, where temperature probes and vibration sensors can be installed on motors, gear reducers and all pulleys. Another innovative development is a three-in-one type belt rip detector which combines laser, tray and cord type detection together to ensure a prompt belt tear indication. The purpose of this paper is to present the latest development of belt conveyor instrumentation and introduce the application of newly developed instruments.

Nov 1, 2011

By C. A. Petch

Abstract - The High Lake polymetallic deposit is located in the northern Slave province, 40 km south of Coronation Gulf, Nunavut. The main zone, the AB zone, hosts an estimated resource of 3.56 Mt grading 5.0% copper, 1.1% zinc, 0.06% lead, 1.7 g/t gold, and 18.2 g/t silver. Archean felsic metavolcanic and metavolcaniclastic rocks are the dominant rock type and are associated with lesser mafic metavolcanic and carbonate-rich metasedimentary rocks. The sequence strikes north-northeast, dips steeply to the west, and is truncated to the west by a large granodioritic intrusion. The mineralization at the AB zone is comprised of massive and stringer chalcopyrite-sphalerite-pyrrhotitepyrite± galena. At the core of the mineralized zone, intensely chlorite-altered rocks are locally metamorphosed to form distinctive zones of anthophyllite-magnetite-cordierite-altered rock. Peripheral to the mineralized core, alteration consists of sericitization, silicification, and weaker chloritization. Primary morphology and facing direction of the zone are difficult to interpret in part due to poor primary metal zonation of the deposit. However, the irregular shape of the mineralized zone and the erratic zones of zinc enrichment at the fringes are consistent with the interpretation that the zone was formed by the replacement of a porous volcaniclastic pile.

Jan 1, 2004

By J. Kazakoff

"The success of gold recovery at the Jolu gold mill depends on many variables. The most important ones are the people, the ore body, plant design parameters, equipment selection and cost control. This paper will briefly hiqhlight the above, the main focus, however will be on the gravity gold circuit.The gravity circuit requires judicious operator attention in order to operate properly. In return the circuit gives immediate visual results for mill peopleIntroductionThe development of the Jolu property to the production stage was carried out quickly, efficiently and economically. The property became a gold producer ahead of schedule and under budget.The Jolu property is a joint venture between International Mahogany Corp., a 70% partner, and Corona Corporation, a 30% partner. Corona Corporation operates the Jolu Gold Mine, located 140 kilometers north of LaRonge and 520 kilometers north of Saskatoon."

Jan 1, 1990

By D. W. Hendriks, C. Daoust, K. V. Konigsmann

"The concentrator of Mattagami Lake Mines Limited commenced operation in 1963. It had been designed with instrumentation proven at that time. New control techniques were added in subsequent years.An on-stream X-ray analyser was installed in 1968. It provided circuit analyses for six years without the aid of a computer. In late 1974, control of the flotation circuit by computer was incorporated into the system. Flotation efficiency improved considerably, zinc"" recovery increased by one percentage point and concentrate grade by four-tenths of a percentage point. Reagent costs decreased modestly through reduction of copper sulphate consumption."

Jan 1, 1976

By Laura Mottola

This paper outlines a framework for ensuring the success of the implementation phase that follows research and development of new mining technologies and systems. It is based upon recent and past lessons learned that have demonstrated the critical challenges to effective technology transfer, which frequently receive inadequate attention within the culture of the mining business. The paper focuses on mining automation implementation challenges and then outlines a Roadmap which is proposed as an integrated framework to deal with the key aspects of people, process and technology. This framework is built upon: assembly of a Strategic Team to develop a Roadmap; fully understanding the business requirements of the technology initiative; defining Key Performance Indicators in a Balanced Score Card; performing a Stakeholder Analysis to identify the affected groups; and finally developing a master Project Plan to execute the Roadmap.

Oct 1, 2009

By N. C. Clarke, T. Wu, M. le Page, K. J. Henley

In 1994, Gold Mines of Australia acquired the rights to the historic Mt. Lyell copper mine, and commenced a feasibility study into expanding production. The ore was shown in laboratory tests to be amenable to single-stage, fully autogenous grinding (FAG) of underground primary crushed ore, and this route offered the maximum cost savings. Flotation performance was expected to be enhanced. However, batch flotation tests done on pilot-scale autogenously ground ore showed an unexplainable recovery loss of between 1% and 3% Cu. A second pilot plant trial was set up, with the ground product feeding banks of continuous flotation cells. Single-stage FAG, FAG/pebble and FAG/ball circuits were tested. Results confirmed a loss of about 3% recovery with single-stage FAG milling. The FAG/ball circuit eliminated the loss. Analyses showed that autogenous milling probably produced more chalcopyrite/pyrite composites and that recovery of these composites was lower than with ball milling. In size fractions below about 53 microns, where chalcopyrite is well liberated, copper recovery was less affected by milling method and flotation selectivity. It was concluded that for the Mt. Lyell situation, a FAG/ball circuit was preferable to single-stage FAG.

Jan 1, 2002

By T. G. Joseph, K. Barron

A strain-softening constitutive relationship is introduced that describes the post-failure stress-strain curve for rock regardless of whether the rock is intact or broken. The core of this relationship is an “apparent friction” concept that relates the post-failure apparent cohesive and frictional characteristics of the rock to the strain. The relationship can be determined for a given rock via a series of triaxial strength tests establishing the peak strength and corresponding strain for a range of confining pressures, together with the determination of the base angle of friction via a simple tilt test. The postulates and assumptions used in deriving this relationship are verified from results of tri-axial tests on both intact and broken rock. This strain-softening relationship is then applied to coal. Having determined the post-failure stress-strain curve for coal specimens, this information can then be used in a finite element program, such as Phase 2, to examine the post-failure characteristics of coal pillars. Using example data, the strength of coal pillars of different width/height ratios are estimated and compared with well-known empirical pillar size-strength relationships. In addition, the post-failure stress-strain behaviour of a coal pillar is compared with an empirical relationship reported in the literature.

Jan 1, 2003

By Pierre Beaudoin

"This paper deals with the repairs made on two damaged mills. It investigates briefly the causes of the damage, explain its nature and the design of the repair. It explains the detrimental effect on operation and the solutions implemented to reduce them. Finally, to review the follow-up required for such repairs. LOCATIONThe Holt McDermott Mine is located 75 kilometers Northeast of Kirkland Lake and 30 kilometres west of the Quebec border in Northeastern Ontario. The town of Kirkland Lake is located approximately 500 kilometres north of Toronto. HISTORYThe discovery of gold in Holloway Township dates back to early 1920. In 1984 Barrick Resources, which amalgamated with Camflo Mines, acquired more claims on the property and initiated an extensive drilling program. By 1985, the drills indicated reserve increased to 2,500,000 tonnes grading 6.8 g/mt. In 1986 a production decision was made and in 1988 the mine was officially opened.As of December 31, 1998, 4,691,507 tonnes grading 5,66 g/tonnes have been milled from 4 ore-bodies. The mill started up in June 1988."

Jan 1, 2001

By F. W. Brackebusch, R. O. Sack

"A method for determining the fineness of Au in electrum from the composition of fahlore coexisting with pyrite and chalcopyrite is presented. This method is based on previously published experimental brackets and activitycomposition models for electrum and fahlore, and it is potentially useful for defining temperatures of hydrothermal mineralization and retrograde evolution of precious metals deposits. The authors demonstrate that it successfully predicts compositions of electrum reported for this assemblage in the literature and illustrate its application for three gold-quartz vein deposits from the Coeur d’Alene mining district, Idaho, that are prospects of the New Jersey Mining Company, the Coleman vein, High-Grade prospect, and Silver Strand mine. Temperatures calculated from average electrum compositions estimated from gravity concentrates (molar Au/(Au+Ag) = 0.76-0.39) and from microprobe analyses of the fahlores (molar Ag/(Ag+Cu) = 0.039 ± 0.004, Zn/(Zn+Fe) = 0.57 ± 0.03, As/(As+Sb) = 0.23 ± 0.02) from the Coleman vein indicate that the electrums underwent retrograde re-equilibration to temperatures between about 80°C and 240°C, roughly 80°C below the temperature of hydrothermal mineralization and 10°C to 40°C above the temperature inferred for retrograde equilibration of Fe and Zn between sphalerite and fahlore. Fahlores from the High-Grade prospect [molar Ag/(Ag+Cu) = 0.009 ± 0.004, Zn/(Zn+Fe) = 0.55 ± 0.11, and As/(As+Sb) = 0.04 ± 0.03] and Silver Strand mineralized zone [molar Ag/(Ag+Cu) = 0.10 ± 0.04, Zn/(Zn+Fe) = 0.63 ± 0.02, and As/(As+Sb) = 0.06 ± 0.02] exhibit strong core to rim depletions in Ag due to retrograde operation of the reaction1/10Cu10Fe2Sb4S13 + Ag + FeS2 =Cu-fahlore electrum pyriteCuFeS2 + 1/10Ag10Fe2Sb4S13chalcopyrite Ag-fahlorewhich proceeds to the left with decreasing temperature. Electrum inclusions in arsenopyrite from the High-Grade prospect [molar Au/(Au+Ag) = 0.90 ± 0.02] define a minimum bound on the temperature of hydrothermal mineralization of 273°C, and the temperatureelectrum composition curve constructed for the most Ag-rich fahlore in the Silver Strand mine indicates that the fineness of its electrum is significantly less than in the other deposits."

Jan 1, 2004

By Baoquan An

The energy required to fragment a rock is proportional to the increase in the fracture surface area and hence is proportional to the rock?s surface area. In comminution, the slope of the linear relationship between size reduction ratio and specific energy is usually defined as grindability. Another definition of grindability based on newly created specific surface area and specific energy is introduced. The two definitions for grindability reflect the grindability properties of rocks and can be used to measure of the efficiency of mills or crushers. The feed particle size distribution influences the energy needed to comminute the rock. For a given ratio of average feed size to product size, the smaller feed size requires more energy.

May 1, 2004

By Karl Hoover, Cassandra Spence, Brent Bachewich, Jaakko Levanaho

"Since year 2000 the gold recovery into copper concentrate at Hudson Bay Mining and Smelting has reduced considerably during the summer months. This initiated a testwork program in the fall 2003 to find reasons and solutions for such change. During the testwork mineralogical factors, water quality effects and different reagents were evaluated. The reason for the lower recovery appeared to be the sensitivity of some collectors to pulp temperature. As a result of the work different collectors are being used in the mill in the summer than in the winter. A modification to the water system was also made to provide cooler water to the mill in the summer months.INTRODUCTIONHudson Bay Mining and Smelting (HBMS) is located in Northern Manitoba, just on the border of Manitoba and Saskatchewan. The complex consist of four different mines, Callinan, Trout Lake, Konuto Lake and 777 mine including copper smelter and zinc hydrometallurgical plants producing metallic copper and zinc. Gold is a very important byproduct providing about 30% of the mine revenue. In early 1990s when the company was facing declining ore reserves and was starting to gradually close down the operations, the 777’th exploration drill hole discovered a new orebody, which initiated a $0.5 billion expansion program. The main projects were a new 777 hoist with underground development and a new zinc cell house. About $30 million was used to increase the mill throughput to the present 2.27 million tonnes or 2.5 million short tons per year. The expansion programs were finished by the end of the year 2003.Historically the gold recovery at HBMS has varied between 60 and 70%. The recovery has been somewhat lower during the summer months. Gold recovery improvement projects were conducted throughout the 1990s, but were not focused on the seasonal gold recovery variance. However, since 2000, when the water system modifications to meet the increased water demand were completed, the gold recovery during the summer has been much lower than in the past. In August 2003 gold recovery fell below 30%, which initiated a metallurgical research program to discover the reasons behind the low gold recovery in the summer."

Jan 1, 2005

By H. A. Steane

"This presentation will cover some crushing and grinding considerations in plant design and operation. There is nothing basically new in the subject matter presented here; however, the viewpoint and interpretation may be novel and some of it controversial.The presentation is based on experience gained in the metallurgical design of plants for Placer Development Limited from 1960 to the present. The plants are listed on SLIDE No. 1.These plants have conventional crushing, followed by rod mill and ball mill grinding. I would like to think that autogenous grinding plants are the answer for eliminating secondary crushing plants and reducing the capital and operating costs; however, the autogenous plants seem to have some problems of their own and I have had no experience with them.Fineness of Grinding RequiredFirst let us consider the fineness of grinding required.The fineness of grind will affect the recovery obtained, and the relationship must be determined. If the grinding is too coarse, some of the valuable mineral, either free or locked in middling grains, will not be floated. However, as grinding is probably the greatest single operating cost, we do not want to grind any finer than is justified economically.Finer grinding should not be carried beyond the point where the net smelter return for the increment saved becomes less than the added operating cost. Even this fineness will be beyond the economic limit because of the additional capital cost for the equipment needed to achieve it. These factors will be discussed in more detail later.The Bond work index is the commonest method of expressing a measure of the effort that has to be expended in grinding. It is the kilowatt-hours required to reduce a ton of rock from an infinite size to 80% passing 100 microns. The formula allows a calculation to be made for other size ranges."

Jan 1, 1976

By Timothy R. Eby

"The Wabush Mines project was formed in 1956 to develop a large iron ore property in Western Labrador. The town of Wabush along with the mining and concentrating facilities are located 640 air miles from Montreal, and 734 air miles from St. John's. The operation has been in production since late 1964.While mining and concentrating operations are located in Labrador, the pelletizing facilities are situated 275 miles south at Sept-Iles, Quebec. Dedicated in 1965, Wabush produces six million tons of high quality iron ore pellets annually. The company employs 1, 550 people at Wabush and the Pointe Noire plant at Sept-Iles.Wabush Mines is an unincorporated joint venture of three companies -The Steel Company of Canada, Dominion Foundries and Steel Ltd. and the remaining 58% by the Wabush Iron Co. Ltd. Wabush Iron Co. Ltd. is in turn owned by six companies: The Youngstown Sheet & Tube Company, Inland Steel Company, Interlake Inc., Wheeling Pittsburg Steel Company, Finsider International S.A. and Pickands Mather & Company which is also managing agent.The town of Wabush is set in a remote part of Northern Canada accessible only by rail and air transportation. But this in no way has hindered the growth and development of the area. Modern housing units, shopping facilities, airport and of course, recreational facilities are all patt of every day living amenities, an accepted aprt of southern communities, but quite unique for northern isolated mining localities."

Jan 1, 1978

By Glenn Kosick, Roger Amelunxen, Glenn Dobby

"The variability in flotation response within an orebody is often a significant problem to address during the design phase of a flotation circuit. In addition, for existing operating plants, the reasons for such a variability need to be clearly understood and accounted for if plant performance is to be optimized. MinnovEX Technologies, in collaboration with major mining companies, is developing methodologies and tools to address the issue of variability in ore characteristics (such as ore hardness and flotation response). The tool is used for design and scale-up of flotation circuits from lab flotation data, and for prediction of recovery and final concentrate grades throughout the mine block model for any given circuit design.INTRODUCTIOTNH: EI SSUEB EINGA DDRESSEDThis paper describes the current development of a methodology and software tool for improved flotation plant design and enhanced prediction of froth flotation performance in an operating plant. The need for this tool is attributed to two primary factors: variability of flotation response properties throughout an orebody and related difficulties with scaleup from laboratory tests. Consider these in more detail.It is well recognized that separation performance via froth flotation will vary significantly within a single mineral deposit. This has been enhanced through the wide application of SAG milling. Throughput with SAG mills is more susceptible to ore hardness changes than is the case with crushing-rod-ball circuits; it is not uncommon to see SAG mill throughput to vary by up to 100% on a regular basis, e.g. 1000 tph to 2000 tph.The implication of this on laboratory testing for prediction of metallurgical performance is as follows: it is unlikely that either the plant grind (size distribution) feeding froth flotation or the flotation residence time will be known at the time of laboratory testing for a given block of ore. Hence, the grind used for the laboratory test is not likely to be that which actually occurs once the ore is processed, and the laboratory retention time may not represent the plant conditions."

Jan 1, 2002