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By B. Pollack, L. G. Stevens

INTRODUCTION In other chapters of this volume many of the important technical aspects in the design of concentration and dewatering circuits have been discussed. This chapter will deal with the steps necessary to bring that information together in order to produce the specifications necessary to purchase the equipment and complete the design. It deals with the plant as a whole rather than just concentration and dewatering, since the steps are essentially the same. Prerequisites to Engineering Design Feasibility studies will have been completed and design parameters established prior to the start of the engineering design stages for a metallurgical plant. The data base for the feasibility studies will have included laboratory and/or pilot plant test work, historical data, proposed plant site data such as climatology, topographic mapping, geological and geotechnical information. These studies will have established the general project design criteria as well as the process design criteria leading to the preparation of preliminary flowsheet ( s) and/or alternative process flowsheets. These will have incorporated metallurgical and material balances, allowing identification of major equipment items, and development of preliminary plant site plot plans. Preliminary technical and economic assessments and recommendations will have been prepared during this phase for Owner's review and evaluation of the technical, physical, and cost effectiveness of the overall project and its component process, process facilities, and supporting facilities elements. After Ownert s approval and decision to proceed, the engineering design can be initiated, using the above information as the basis. Engineering Design Phase The engineering design of metallurgical plants and their elements are generally developed in two sequential stages, namely: (1) Basic ("Front end") Engineering Design (2) Detail Engineering Design Figure 1 relates these engineering stages to the entire program from feasibility through construction.

Jan 1, 1986

By Chris A. Fleming, Daan Seymore

The Golden Jubilee Mine in South Africa is the first mine in the Western World to introduce resin-in­pulp technology for the recovery of gold from a cyanide-leached slurry. Located in the Eastern Transvaal region of the country, the plant processes approximately 375 metric tons• of ore per day, of which over 90 per cent is mined in an open pit adjacent to the metaflurgical plant, while the remaining 5 to 10 per cent is trucl<ed in from two small high-grade deposits, located about 10 kilometers from the plant. The gold grade in the open pit is about 1 git, while the values m the two high-grade deposits range between 5 and 15 git. At the current treatment rate, the proven reserves m the three locations will last about another 10 years. Early testwork indicated that the ore was not well suited to conventional filtration processing or to heap leaching because of its high cfay content, and that carbon-m-pulp (CIP) would probably prove to be the most viable metallurgical route. Tcstwork to establish the feasibility of CIP for this application was carried out at Mintek in 1985. This worl<, which was based on batch-leaching and carbon-loading tests, indicated that CIP was technically feasible, but that both the rate of gold loading and the gold-loading capacity of the carbon were inferior to those obtained with Witwatersrand ores. The poor adsorption characteristics of the carbon were attributed to the abnormally high concentration of natural organic compounds (humates and fulvates) in the ore. Batch tests were therefore also carried out with strong-base resins, since resins are known (1] to be far less susceptible to organic fouling than is activated carbon. The results were very promising, and pointed to fast kinetics and a high loading capacity. (Fig. 1 ). Notwithstanding these findings, it was decided to recover gold with activated carbon at Golden Jubilee Mine because the CIP process was, by then, well established in South Africa and elsewhere in the world, whereas resin-in-pulp (RIP) was unproven technology. The r>lant was commissioned in September 1986 and, for 18 months, operated in a carbon-in-leach (CIL) configuration, i.e. with a total of . six leach tanks, the last four of which contained activated carbon. As could have been predicted from the laboratory results, the performance of the CIL plant was generally poor, low gold loadings on the carbon (less than 1500 git) and high losses of soluble gold (0.2 to 0.3 p.p.m.) bemg characteristic of the operation. Consequently, it

Jan 1, 1990

By M. M. Nash

Since the late 19th Century, scholars have been concerned about finding proper methods of managing business. The search seems to be taking us full-circle to the time and motion studies of Taylor (Horn, 1987). It wasn&apos;t until the late 1970&apos;s, however, that systematic investigations were made in the mining industry. One of the first was a study by Sanders, Patterson, and Peay (1976). That project explored the relationship of attitudes and safety. Peay, Atkin, and Goodman (1977, then reviewed the whole area of Organizational Development, including the so-called Rushton experiment.

Jan 1, 1988

The amount of hydrophobic materials constituting the mineral froth strongly influences the froth viscosity. Higher froth viscosity on the other hand can retard the drainage of physically carried over hydrophobic particles. In phosphate flotation tests a direct correlation was observed between froth viscosity and recovery and an inverse correlation between froth viscosity and grade. Phosphate flotation tests in the presence of a silica depressant indicated that higher froth viscosity is an effect rather than a cause of silica particles reporting in the froth.

Jan 1, 1992

By H. Peter Knudsen

Karst hosted lignite deposits are characterized by variable thickness of lignite that was deposited in depressions in the karst topography and by the variable extent and shape of the lignite pods. Since the lignite to be mined will feed a mine mouth generating plant, an extremely important criteria in the mine plan is to assure continuous feed to the plant. The variability in both the extent of the pods and the thickness of the lignite within the pods must be taken into account in any mine design in order to quantify the risk that an area being developed will have enough lignite to feed the plant for the specified period. Indicator kriging was used to create a model of lignite thickness of the deposit. Pod boundaries were determined from the indicator kriging model by two methods. First, contour maps showing the probability that the lignite is above a minimum mining thickness were prepared. Using these maps the mine planning engineer can determine either conservative or optimistic boundaries. The second method recognized that the most costly error that can be made in the mine plan is to run out of lignite. Thus, a loss function was determined from the costs of overestimation and underestimation. Using this function, the probability that minimizes the risks of overestimation versus underestimation was calculated.

Jan 1, 1989

By Paul M. Keyser, Donald G. Foot, Jeffrey D. Mckay

In the past 30 years, there have been tremendous advancements in the uses and applications of column flotation. From their first use as final cleaners that could produce excellent grades at the cost of recoveries, columns are now being used in every stage of the flotation circuit as well as is SX-EW. Columns as roughers, final scavengers and even at the end of CIL circuits, are finding their way into the marketplace. Operational results of these new uses are presented. INTRODUCTION Flotation columns have been in use since the early 1950&apos;s in the U.S. (Hollingsworth, 1952) and the early 1960&apos;s in Canada (Trembley, Boutin, Wheeler, 1963). Application of column flotation has been somewhat diverse. In the early years, columns were used predominately for molybdenum cleaning in Canada and for phosphate flotation in the United States. Unfortunately, results met with skepticism and disdain as the columns were hard to operate, temperamental and although producing high grades, could not achieve acceptable recoveries. Since the inception of column flotation technology, the degree of knowledge for design and operation of columns has vastly improved. Despite improvements in the technology, there is still some reluctance by mineral producers to investigate the use of column flotation cells for processing stages other than cleaner flotation. This characterization is in part due to the proven advantage of flotation columns in reducing gangue entrainment in the froth product which results in higher grade products and/or fewer processing stages. Also, during the development of column technology, different types of spargers have been used with varying degrees of success. Furthermore, the general knowledge base of parameters affecting column flotation design and operation have advanced tremendously. Inefficient, or primitive, sparger design, coupled with the lack of column design and operating knowledge and experience, resulted in poor metallurgical and mechanical performance in many cases. Unfortunately, this lack of knowledge caused many column installations to be characterized as failures. The industry felt that columns could not achieve high recoveries, especially when dealing with coarse particles. Therefore, columns were characterized as cleaners, where low recoveries could be tolerated as recirculating loads rather than direct losses and froth cleaning advantages of the quiescent column flotation regime could be realized. Fortunately for the minerals industry, some producers have stood at the forefront of technology and allowed the column to be utilized for new applications. In the last decade, column flotation applications have expanded to virtually every mineral system and plant location throughout the world. The expanded application of columns has generated a new wave of interest for processing various streams. One of the most notable is in the use of columns as rougher cells. This is of particular interest to "green-field" plants and plants where expansions are taking place. Here, metallurgical superiority can be combined with maximum capital and operating cost advantages for a rapid return on investment. The superior results experienced to date, have generated a cohesive vision of the future in mineral processing where flotation columns function as single stage primary separation devices (roughers) with a single stage cleaner, if necessary. The advantages of column flotation go far beyond their original uses. We now have seen columns used as final tail scavengers, in SX-EW plants and even at the end of CIL circuits. Some of these cases will be reviewed. CASE STUDIES In an attempt to show the diversification of column flotation to many facets of the mineral processing plant, a variety of case studies will be discussed. Some of these were designed by the authors while others have been provided by plant sources. It is important to note that in each successful case, the columns were designed using the author&apos;s design and scale-up approach. This method assures that the columns are designed correctly for their particular application. For successful

Jan 1, 1993

By Jim Avraamides

Historically, much of Western Australia&apos;s gold production has come from the refractory sulphide-telluride ores located in Kalgoorlie&apos;s Golden Mile. Most of the recent gold boom has been associated with low grade, open pit free-milling oxide deposits. Primary sulphides are commonly encountered at depth and in many cases are highly refractory. Different approaches to the problem of recovering go1d from these ores have been adopted subject to local conditions both technical and environmental. The least preferred option is the preparation of a gold- rich flotation concentrate which is shipped to a smelter. Roasting of flotation concentrates can be practised in certain remote locations where sulphur emissions are tolerated. Fine grinding of flotation concentrates followed by direct cyanidation is another popular approach although this often leads to fouling of carbon by flotation reagents in the adsorption section and high soluble gold losses.

Jan 1, 1989

By Andrzej Luszczkiewicz, Kazimierz S. Sztaba

Flotation tailing of Polish copper sulfide ores represents more than 90% of the mass of run-of-mine ore. The tailing contains mainly quartz, dolomite, clay minerals, traces of sulfides, and some accessory minerals. Almost all minerals of the tailing are well liberated and, therefore, any further beneficiation process applied to the tailing is expected to be inexpensive. In this work, results of investigations on utilization of flotation tailing using classification and gravity concentration are presented. It is shown that due to classification of flotation tailing in hydrocyclones, the coarse fraction becomes suitable material for gravity separation providing backfill material for underground mines as well as heavy minerals, a source of valuable rare elements. It was also found that heavy minerals separated by gravity methods contain a significant amount of rare elements such as zirconium, titanium, silver, rare earth metals, and uranium. The light fraction of the gravity separation contains well deslimed quartz particles and meets strict requirements for hydraulic filling material ked for structural support in underground mines. Evaluation of the cost of the proposed technology indicated that investment to implement the method would provide a return within 2-4 years.

Jan 1, 1995

By J. R. Sturgul

Computer simulation models of working mines can be of great benefit to the mining engineer. Such models have been used in mine planning (how many trucks/shovels to have, when to add new equipment, etc.), mine design (should a dispatch system be purchased, where is the optimum location for mine equipment, etc.). A simulation model can be thought of as a dynamic representation of the mine and can easily be changed to reflect a wide variety of different situation. Often a major problem for the engineer is how to present the results of the simulation study. Using PROOF(R) animation it is now possible to interface the results of the simulation and project them onto a computer screen in cartoon fashion.

Jan 1, 1993

By Michael Honerkamp, Clemens Mann

A quarry is not a static, but a dynamic structure that greatly affects the appearance of the surrounding area. Excellent planning is required today to cope with this continual change. In this paper several case studies are presented where computerized three-dimensional visualization has been successfully applied.

Jan 1, 1996

By J. Bartrum, A. Bowler, G. Butcher

The purpose of this paper is to outline the design, specification, and operation of the 8.5-m- diam (28-ft-diam) SAG mill commissioned at Kidston Gold Mines during January 1985. Amenability of Kidston ore to SAG milling, coupled with substantial cost advantages, led to the specification of this mill, equipped with variable speed drive to overcome the large variation in ore hardness. Operation of the mill is effected via a number of automatic control loops. Problems experienced with automatic control plus other electrical and mechanical failures have led to design changes and the formulation of future operating strategies.

Jan 1, 1987

By D. Zaharaki

The present experimental study underlines the advantages of factorial design in environmental, geotechnical and waste management experimentation. A typical case study regarding solidification of metallurgical wastes is presented and the main effects and interactions of three main factors are determined in order to establish the optimum experimental conditions in terms of compressive strength. Finally, a regression equation that predicts accurately the real compressive strength of a specimen under various experimental conditions is derived.

Jan 1, 2005

By J. Sharp, R. Arnold, P. Rusin, T. Young, N. A. Sinclair

Many oxide silver and molybdenum deposits remain undeveloped because chemical extraction yields poor recoveries or is environmentally unacceptable. Bioreductive leaching of such ore samples at MBX resulted in high extractions of silver and molybdenum. When baseline, three-day, cyanide bottle-roll tests were conducted on manganiferous-oxide silver ore, 13.7% of the silver was extracted. In contrast, 86% of the silver was microbially solubilized into the organic growth medium by bioreduction with 99.8% dissolution of manganese. A followup cyanide bottle-roll test yielded an additional 8.5 % silver dissolution, for a total extraction of 94.5%. Baseline, three-day, acid bottle-roll tests of the iron-oxide molybdenum ore Yielded 1.8% molybdenum. However, bioreduction solubilized 93.3% of the molybdenum into the growth medium. An additional 0.3% molybdenum was solubilized during the followup acid bottle-roll test. Microbial treatment of refractory oxide ores with bioreductive bacteria resulted in higher extractions of silver and molybdenum than conventional chemical leaching. The bioleaching process occurred at a near-neutral pH at ambient temperatures. The bacterial solubilization of silver and molybdenum was achieved without the use of cyanide or sulfuric acid.

Jan 1, 1993

By D. Gove

Several coal mines in Southeastern United State face the problem of multiple, very thin coal seams or seams adhering to interburden, and because of the strip ratio economics, these seams must be recovered. Over the past few years several mines have discovered a common method to solving these problems...use of a Caterpillar RR-250 Road Reclaimer.

Jan 1, 1995

By Joel D. Hammond

Lightweight concretes date back to before the Roman Empire. The earlier concretes were made by combining a burnt lime for cementious material with pumice or volcanic rock for aggregate. Although structural value was limited due to its primitive nature, many structures were able to withstand the test of time. The rotary kiln expanded shale industry had a slow start that began around 1908. The industry was founded by Stephen J. Hayde of Kansas city, Missouri. Mr. Hayde noticed that the bloating effects of some aggregates were undesirable by the brick industry. Material of this type was considered waste and avoided in brick production, but he realized it had all the qualities and basic requirements for a concrete aggregate that would reduce weight and still retain structural value. It came into national attention by use in ocean-going vessels through a shipbuilding program undertaken by the united states Fleet Corporation. This research was brought about by the need to find a suitable material to replace high-grade plate steel due to a shortage created by World War I. The need prompted the government to supply the reserves that Stephen Hayde desired to continue and complete research into producing a uniform lightweight aggregate. His results pointed to the rotary kiln method for which he was granted a patent in 1918. One of the most famous and largest concrete ships built through this program was the U.S.S. Selma. Although the Selma

Jan 1, 1977

By T. Janke

When Homestake Mining Company&apos;s Mclaughlin Gold Project was being evaluated for development, it was apparent that recovery of gold from mined ore would be difficult and relatively expensive. The ore was refractory, averaging less than 50% recovery in conventional direct cyanidation milling tests. Extensive testing narrowed the processing choices to either autoclave or roaster oxidation before cyanidation. Roasting was ruled out due to higher capital and operating costs --the Mclaughlin mill would be the first large-scale application of autoclave oxidation of a refractory gold ore.

Jan 1, 1989

By S. J. Jung, F. Lock

This research came about because of the recognized need for a safe, easy way to line small-diameter bored raises (less than 150 cm). Currently, an operator must go down the raise and apply the concrete lining manually, using the shotcrete method of application. With an automated system, there would be no man positioned in the bore itself. All control functions could be commanded from a central location. Shotcreting in the confined space of a small-diameter bored raise presents problems that can be overcome by the application of shotcrete using a remote system.

Jan 1, 1995

By Z. F. Wang, W. K. Choi, A. E. Torma

The present study has investigated the bioleachability of low-grade and high-grade pyritic gold ores and the extraction of gold from the leach residues of bioleaching with thiourea solutions. Final gold extractions as high as 96% were obtained from the high-grade ore and above 93% from the low-grade ore. The gold extraction was found to follow the extent of pyrite biooxidation. Using a cyclic voltammetric technique and carbon-paste-FeS2 electrode it was found that the semiconductor pyrite oxidation involves many intermediate electrochemical reactions. Furthermore, the oxidation is solid-state diffusion controlled as suggested by chronoamperometric and chronopotentiometric measurements.Using Sand&apos;s approach, the activation energy of solid-state diffusion biooxidation of pyrite was determined to be AEa=22.4 kJ. A generalized model for the mechanisms of pyrite oxidation has been presented.

Jan 1, 1990

By Ping Xia, Yaoxin Lu

With productivty increment. it becomes very important to monitor the underground production environment. This paper presents a multi-level computer monitoring and managing system, which was specially developed for the mine. In this system, TF-200, Industrial Standard Buses (STD) and 32 bytes Super micro-computer were integrated into one body as hardware; Data Base was designed by means of software engineering method in the software development; on maitenance of the system, the parameters are managed concentratedly and data are classified to process; therefore, the ystem gets to the advanced level in China. The system is composed of four sub-stations: Signal Transmission. Data Collection, Data Processing and Image Display Sub-system. Signal Transmission Sub-system(STSS) A frequency-division transmission method is used. Data Collect ion Sub-system (DCSS) Industrial Standard Buses (STD) is used. It can change data from STSS into suitable form for DCSS, Calculate average value every minute, decide alarm and transmit data to DPSS. Data Processing Sub-system (DPSS) The host is a S/120. With UNIX Operation System. the data from DCSS can be classified. stored, displayed. printed, by means of real-time and time-division processing. Additionally the functions of the historic data search and data analysis are provide. Image Display Sub-system (IDSS) The real-time and historic data was displayed for curves and diageams on screens. This system has been in operation.

Jan 1, 1991

By B. C. Cornilsen, X. Shan, D. H. Carlson, J. H. Johnson

Airborne respirable Diesel Particulate (DP) presents an additional health hazard in that it has been shown to be mutagenic. This problem is of increasing concern as more coal mines introduce diesel vehicles. If the DP present in coal mine air is to be controlled it must first be measured. This paper describes development of the laser Raman spectroscopic measurement of the amount of DP in DP/coal mixtures collected on filters in the laboratory and in coal mines. The Raman technique provides a chemical measure of the carbonaceous material in each component, and is not dependent upon particle size. When this work was begun there were no known analytical methods for this measurement. Side-by-side in-mine comparisons of the results obtained from Raman, neutron activation analysis, and size selective analyses (MOUDI and personal samplers) are presented. The neutron activation and size selective analyses were obtained by the USBM Twin Cities Research Center and University of Minnesota. Good agreement has been found among these three methods.

Jan 1, 1991