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By V. Prasad, A. Afacan, K. Popli, S. Dubljevic

Froth flotation is one of the most common and widely used separation processes in the mineral processing industry; however, its complexity means that complete understanding of the process has not yet been achieved. A dynamic fundamental model is needed to enhance the understanding of the process and to improve process control. It is challenging to capture all the phenomena involved; hence, we propose a multiscale modeling approach with a framework ranging from macroscopic (equipment scale) to microscopic (attachment, detachment) models along with distribution models for ore particle sizes. Real-time froth properties are obtained using a vision-based sensing system. These measurements can be used for developing a soft sensor for grade using statistical methods such as PCR (principal component regression) and PLS (partial least squares) regression. The fundamental model is updated in real-time using extended Kalman filtering. Attachment dynamics are studied for different particle size distributions. The modeling and soft sensing is tested on batch flotation cell for the pure mineral galena with different particle size distributions using Xanthate and MIBC as collector and frother, respectively. The model, online measurements and soft sensor are useful in developing monitoring methods for froth flotation.

Jan 1, 2015

By M. Sukhram

In the year 1992, T.A. Utigard published a paper titled "The measurement of the heat-transfer coefficient between high temperature liquids and solid surfaces." In that work, he instrumented an agglomerate of materials with thermocouples to infer the heat transfer coefficient of a high temperature liquid on a solid. The purpose of that research was to help in the design and operation of metallurgical reactors. Since that time there have been many researchers that have worked to characterize heat, mass, and momentum transfer phenomena in high temperature metallurgical processing operations. This paper presents results from the author’s experience with instrumenting thermocouples in copper elements coated with carbon to infer velocity of high temperature liquid metals. It also presents a methodology to determine velocity of a high temperature liquid by inferring the local heat transfer coefficient at a solid-liquid interface

Jan 1, 2015

By J. Sliwinski, H. Kikutani, J. Atwood, D. Larimer, J. Pyecha

"The Pogo mine start-up milling targets of 2005 are vastly different than the targets of today. Improvements have been driven by unintentional design oversight, continual circuit optimization or optimization due to changing mineralogy. The more significant process improvements to date have occurred in the gravity, flotation and leach/CIP unit operations. Details of the significant improvements are presented along with the impacts to the process.INTRODUCTION Deposit Overview Pogo mine is located along the Goodpaster River, southeast of Fairbanks, Alaska. This deposit sits in the center of the Tintina Gold Province (Figure 1), a region of similar Intrusion Related Gold deposits in Interior Alaska, the Yukon and British Columbia Canada (McCoy et al., 1997). The Pogo deposit is hosted in a rock sequence of amphibolite-grade gneisses intruded by mid-Cretaceous granitic plutons and dikes, which in turn, were cut by and host the auriferous quartz veins of the Pogo deposit.The Pogo deposit is comprised of three distinct zones of auriferous quartz veins spatially adjacent to each other. These are the Liese Zone, North Zone, and the East Deep Zone. The Liese Zone consists of three stacked, massive quartz veins, designated the L1, L2, and L3. Vein thickness averages 3.0 m, with variations from 0.3–18 m thick. The North Zone mineralization is comprised of four veins with more consistent thickness, between 1 and 1.5 m. The East Deep deposit lies northeast of the Liese Zone ore body. It is separated by a post mineralization, quartz diorite pluton. The East Deep Zone is comprised of two stacked massive quartz veins with similar orientation as the Liese Zone."

Jan 1, 2017

By Iina Vaajamo, Jani Jansson, Lauri Pesonen

In pyrometallurgical operations, structural integrity of a high temperature furnace plays a crucial role in the overall safety, profitability and ecological footprint of the plant. Furnace integrity is related to how reliable a furnace is and it can be compromised, for example, by having poor operating and maintenance practices, an inefficient cooling system and flaws in the overall furnace design. These flaws and poor practices might lead to unexpected shutdowns, production losses, increased emissions, or worse. This paper presents the main factors to consider when engineering a furnace and developing its operating practices, while ensuring safe and reliable operations without compromising process efficiency and quality of the final products. In this respect, Outotec’s solutions for the cooling system and for automation systems like PROSCON, Process Advisor, Sentinel and our Smelting Information Management System, are also introduced.

Jan 1, 2015

By S. Beskri, N. Geoffroy

When metallurgical plants are designed, a lot of consideration is almost always given to material selection and possible damage mechanisms. Materials engineers are generally involved and will strive to select optimal alloys or refractories for the design conditions. Once in operation however, things often change. Equipment is overstressed to increase production, corrosive leaks are not always promptly addressed, proper welding procedures are disregarded, etc. This paper describes various cases from the mining and metals industry where serious mishaps, associated consequences, and costs could have been avoided if simple and proactive steps had been taken. It also presents a strategy, based on safety reviews, to help predict and prevent damage to critical pieces of equipment.

Jan 1, 2015

By Eric Barnard, Andreas Nashitati, John Tero, Guy Deschênes, Setta Mbalamba, John Rajala

The Otjikoto Mine, owned at 90% by B2Gold Corporation, is located 300 km north of Namibia’s capital city of Windhoek. The reserves from the open pit mine, estimated at 25.9 million tons with an average grade of 1.28 g/t Au, contain gangue minerals, pyrite and pyrrhotite, and have an estimated 10 year mine life. The feasibility study included an optimisation of gold leaching using CSTR for the original design. The results of the test work were used to establish the design criteria. Gravity tails from three composites (drill cores), representing the major ore types, were used. The XR3 sample (gravity tails) contained 0.32 g/t Au, while the XR2 and XR1 gravity tails samples (used for variability) contained, respectively, 0.30 g/t Au, and 0.47 g/t Au. The optimum leaching conditions were: a pre-treatment of 7 h at pH 10.5 with 100 g/t lead nitrate, DO > 5 ppm followed by cyanidation at 300 ppm NaCN, pH 10.0, DO > 5 ppm for 48 h. The gold extraction was 91.5% (97.2% overall extraction gravity/leach) and the cyanide addition was 0.57 kg/t NaCN. Increasing the DO to 16 ppm did not show any economic benefits. No pre-treatment or a 4-h pre-treatment reduced the gold leaching kinetics. The XR2 and XR1 gravity tails samples had gold extractions of 92.9% and 92.3%, respectively. At the plant scale, an 11 h pre-treatment is used followed by 42 h cyanidation with 250 ppm NaCN and an average DO of 8 ppm and 230 g/t lead nitrate in 2016. The cyanide addition was 0.49 kg/t NaCN. The commercial operation started on February 28th, 2015. The overall gold recovery and production were 98.4% and 145,696 ounces for 2015 and 98.1% and 166,286 ounces for 2016. It was found that retention times, gold content of leach residues and cyanide addition are comparable for the lab and the plant. Details of the Otjikoto process flowsheet are discussed in this paper along with the results of the lab leach optimisation test program and the plant leach circuit performance and improvements.

Jan 1, 2017

"The successful commissioning and ramp up of the Albion Process™ at the GPM Gold Project relied on the successful scaling up of the process from batch and continuous pilot plant campaigns (Voigt et al., 2015). Critical information about reaction kinetics and residence time, grind size and pulp density were determined at the laboratory scale and successfully applied to the commercial scale. A limitation of small scale testwork, is that some parameters cannot be measured reliably and scaling up is a function of the physical size of the equipment which isn’t possible to test with laboratory scale equipment. Oxygen mass transfer rate is one such parameter since this is a complex interaction of many factors including slurry temperature, solution and slurry chemistry, slurry viscosity, agitator type, dimensions and power, oxygen bubble residence time, oxygen purity, tank geometry and oxygen injection technique. Oxygen generation represents an important operating cost for the Albion Process™. Pivotal to the Albion Process™ operating economically at atmospheric pressure is the capability to efficiently transfer oxygen while utilising as much oxygen injected to the process as possible. To respond to this Glencore Technology developed the HyperSpargeTM supersonic gas injector. This paper compares the HyperSparge™ against other sparging techniques to quantify the benefits of oxygen injection via a supersonic gas jet on scale up of the oxygen mass transfer system. The paper then examines plant survey data from the GPM Gold Project to demonstrate the very high oxygen utilisation that can be achieved with a correctly designed oxygen mass transfer system.INTRODUCTION One of the main challenges in chemical reactor design is the scale-up of processes from the laboratory to industrial scale. Processes which cannot be faithfully simulated with an experiment at the laboratory scale face challenges due to the physical dimensions and complexity of full scale operation. One example of this is the design of oxygen mass transfer systems in atmospheric oxidative leaching circuits such as the Albion Process™. A number of constraints associated with the use of laboratory scale equipment to design full scale circuits are involved in gas mass transfer processes in agitated slurries such as the Albion Process. Chiefly, typical laboratory and pilot size equipment lacks the required volume to provide useful design data without relying on empirical correlations: the specific agitator power input is artificially high, the bubble residence time in the vessel is artificially low, the oxygen partial pressure at the base of the vessel is artificially low and the oxygen delivery method may differ significantly to the industrial process. Further, the dynamic nature of the process introduces additional impacts on gas mass transfer, including the presence of solids, recycle streams and minor elements, plus the variances within the reality of a process plant such as disruptions or variance of feed quality."

Jan 1, 2017

By Yihan Liu, Jintao Zhang, Chen Xiao, Xiaomeng Zhao, Guanglei Song

To estimate the performance of the inert anode materials based on NiFe2O4 spinel ceramic during it used for aluminum electrolysis, we investigated the wetting process of cryolite molten salt which is in composition of industrial aluminum electrolysis with carbon anode and NiFe2O4 based cermet materials, by means of determination the interface wetting angle between the molten cryolite electrolyte and the solid anodes interface. The results show that the wetting angle between the electrolyte and carbon anode is larger than 90 angulation, this means that they basically can not wetting; however the nickel ferrate spinel ceramics behaves much better. In regard to the NiFe2O4 matrix materials, their initial wetting angles is 76.9. The initial wetting angles for 1.0wt%MnO2, 2.5wt%TiO2 and 0.5wt%V2O5-doped samples are respectively 56.86°, 52.98° and 51.93°. However, after 50s later, all the wetting angles came down below 15°.

Jan 1, 2015

By M. B. McClenaghan

"The Ontario Geological Survey completed a regional till sampling project between 1984 and 1988 in the Black River Matheson (BRiM) area of northeastern Ontario. The project was designed to aid mineral exploration in the area by documenting the Quaternary stratigraphy and by providing a database of till geochemistry. This paper summarizes the results from the sonic overburden drilling component of the BRiM project carried out in areas of thick drift (> 5 m). Results from till sampling in areas of thinner drift (<5 m) have been presented in a separate paper. Approximately 1100 till samples were collected from 225 sonic drill holes. For each sample, the non-magnetic heavy mineral (>3.3 S.G.) and fine (-250 mesh) till fractions were analyzed geochemically and visible gold grains were recovered by panning.Gold and other multielement geochemical data were plotted using proportional symbols to highlight anomalous areas and to demonstrate how to evaluate and interpret a very large geochemical dataset. Thresholds for identifying anomalous concentrations of Au in till samples, defined using the 95th percentile, are 1500 ppb and 12 ppb for the heavy mineral and fine fractions, respectively. The heavy mineral fraction of older ti1ls and to a lesser extent, Matheson Till, display a number of significant gold anomalies in the study area, which in a few cases, are associated with base metal anomalies. The vertical position of gold anomalies in Matheson and older ti1ls varies from directly on bedrock to several meters above the bedrock surface and can provide information of relative ice transport distances."

Jan 1, 1994

By Ian Ewart, Trevor Bergfeldt, Gourab Satapathy, Ajay Patel

"Conventional electrowinning (EW) of nickel from sulfate electrolytes is complicated by several factors including the requirement for a diaphragm cell to separate the anolyte and catholyte and the need to minimize nickel mist emissions. Developed and commercialized by emewCorporation, this novel process electrowins high purity nickel cathode (99.5%) from copper refinery bleed streams using the proprietary emew vortex EW technology. The emew nickel process incorporates high flow rate in an enclosed cylindrical EW cell operating at high current densities that overcomes the challenges of conventional nickel EW and completely eliminates the risk of nickel mist emissions. The tubular cathodes are easily harvested and mitigate the effect of plating stresses inherent in nickel EW. The present paper describes the emew nickel process and its most recent application to copper refinery bleed streams at full-scale.INTRODUCTION To meet the stringent demand of customers, nickel producers are giving prime importance to production of high purity nickel cathodes. The major challenge for refineries is to improve cathode quality and appearance despite fluctuating electrolyte impurity levels. The basis of achieving good quality cathode includes the control of electrolyte impurities and consistency of specific process conditions. The commercial operation of emew nickel technology has been successfully implemented and has demonstrated the ability to produce high quality nickel cathode from refinery bleeds. This paper emphasizes the importance of upstream impurity removal to achieve the required nickel emew feed composition by evaluating the benefits of using selective precipitation as a purification scheme with the aim of improving the overall nickel recovery while ensuring suitable nickel concentration in the advanced electrolyte is achieved. Nickel electrowinning is similar to other electrowinning processes that employ insoluble metal anodes & cathodes. It requires the passage of direct current between two electrodes that are immersed in a conductive, aqueous solution of nickel salts. For the recovery of nickel from solution, the most common methods are electrowinning and hydrogen reduction. Electrowinning usually occurs from sulfate, chloride or mixed sulfate/chloride electrolytes. In sulfate electrolytes, nickel electrowinning cells are normally designed to achieve specific criteria as outlined below (Robinson & Tuppa, 2002):"

Jan 1, 2017

By P. C. M. Knops, K. Rijnsburger, R. M. Santos

To overcome the challenges of mineral CO2 sequestration, this work utilizes a unique proprietary Gravity Pressure Vessel (GPV) reactor technology, and focuses on reaction products of high economic value. The GPV provides intense process conditions through hydrostatic pressurization and heat exchange integration that harvests exothermic reaction energy. Here, laboratory-scale tests of the envisioned process was performed in tubular and continuously stirred tank reactor (CSTR) autoclave reactors. The mineral used was Olivine (~Mg1.6Fe2+0.4(SiO4) + ppm Ni/Cr), although asbestos, steel slags and oil shale residues are also under investigation. The effect of several process parameters on reaction extent and product properties was tested: CO2 pressure, temperature, residence time, additives (buffers, lixiviants, chelators, oxidizers), solids loading, and mixing rate. The products (carbonates, amorphous silica and Chromite) were physically separated (based on size, density and magnetic properties), characterized (for chemistry, mineralogy and morphology) and tested in intended applications (e.g. as pozzolanic carbon-negative building material). Economically, it is found that product value is the main driver for mineral carbonation, rather than, or in addition to, the sequestered CO2. The approach of using a GPV and focusing on valuable reaction products could thus make CO2 mineralization a feasible and sustainable hydrometallurgical process.

Jan 1, 2015

By D. Paul Bishop, Kevin P. Plucknett, Hung-wei Liu

"Spark plasma sintering (SPS) process has been evaluated for producing the commercially pure (CP) Ti, TiAl and a TiAl-B4C composite. Comparisons were made between the materials in terms of the sintered density, resultant hardness and microstructures. In the present work, the titanium aluminide powders (Ti-48Al, producing a mixture of y-TiAl/a2-Ti3Al) were synthesised „in-house? using a simple reaction-sintering and mechanical attrition approach. This allowed various size distributions to be generated. The powders were then blended with a fine boron carbide (B4C) powder (up to 6 wt.%), and the resulting mixtures were consolidated using spark plasma sintering (SPS) under vacuum in graphite dies. An applied stress of 50 MPa was used for all SPS runs. The SPS parameters were varied in terms of the ultimate sintering temperature (up to 1300°C) and hold time (up to 10 minutes) for each material. It is demonstrated that high densities can be achieved this approach (exceeding 95% of theoretical, with optimised samples close to full density). Microstructural characterisation was conducted using optical microscopy, scanning electron microscopy, and X-ray diffraction. The B4C additions were seen to partially react with the TiAl to form reinforcements, such as TiCx and TiBx. Preliminary mechanical property assessment will also be briefly discussed.INTRODUCTION Titanium- and titanium aluminide-based alloys possess many unique properties, such as excellent corrosion resistance and high temperature strength, respectively (Cardarelli, 2001; Leyens & Peters, 2003). Compared to many other competing materials (e.g. stainless steel or Ni-based alloys), Ti- and TiAl-based alloys also have relatively low densities (~4.5 and ~3.9-4.1 g/cm3, respectively), which is critical for performance in aviation and automobile applications. However, the manufacturing cost is high, due to the expensive raw Ti material and difficulties in machining. TiAl-based alloys are particularly difficult to produce because of their limited ductility (Lütjering & Williams, 2007). To overcome those problems, powder metallurgy (PM) technologies have shown great potential as near-net shape processes for Ti- and TiAl-based alloys. The general PM process largely avoids laborious post-machining and minimises material use. In industrial production, the PM approach has been successfully utilised to manufacture aluminium- and iron-based alloys (Huo & Heath, 2008)."

Jan 1, 2017

By V. Concha, M. Hashemzadeh

"The objective of this study was to gain a better insight into the kinetics of chalcocite leaching in an acidic ferric sulfate media. Chalcocite leaching in acidic media is known to occur in two sequential stages, with the first stage being much faster than the second. The leaching residue from the first stage is typically assumed to be a covellite type of material. This study hypothesized that the mineralogy after the first-stage leaching varies in response to different leaching conditions. We investigated the dependency of the mineralogy of the first-stage leaching residue on temperature and initial ferric concentration. The experimental results showed that chalcocite leaching behavior altered upon temperature and initial ferric concentration. A proposed combined reaction model was found to be able to describe the experimental data. The first stage was described very well by the shrinking core diffusion model while the second stage was described very well by the shrinking core chemical reaction model. This finding has important implications for mine operations to manipulate leaching conditions to create the desirable leaching kinetics.INTRODUCTION The kinetics of chalcocite leaching in sulfate media has been extensively studied (Cheng & Lawson, 1991; Fisher, 1994; Fisher, Flores, & Henderson, 1992; Niu, Ruan, Tan, Jia, & Sun, 2015). Sullivan (John D. Sullivan, 1930) proposed a two-stage process for chalcocite leaching in an acidified ferric sulphate solution. The two-stage leaching of chalcocite is presented as the following reactions:"

Jan 1, 2017

By David Ulrich Furrer

Materials and manufacturing processing technologies have played an important role in the development and capabilities of nearly all manmade products. Market drivers for fuel efficient, low cost, environmentally friendly, more capable transportation has given rise to significant materials challenges and subsequent developments. The rate of improvement and implementation of new commercial products can be limited by the rate of new materials and process technology development and qualification. As many materials are being designed for unique requirements and even location-specific unique properties, the implementation of tools and methods to enable rapid characterization and validation of material definitions and design systems must also be accelerated. A review of new integrated material, manufacturing process and component designs, engineering processes and emerging tools and methods will be discussed. The linkage of computational materials science and engineering into component design will also be discussed along with the challenges and opportunities for further growth and application of integrated computational materials engineering (ICME).

Jan 1, 2015

By Jirí Faltus

The paper deals with studying the impact of structural properties and anodizing of surface on the corrosion properties of extruded rods from commercial aluminium alloys: AA6082, AA6262, AA6012, AA2007 and new lead-free aluminium alloys AA6023, AA2015 and AA2111B. Samples were exposed to the corrosive atmosphere NSS, AASS in the chamber by EN ISO 9227. Surface of samples were either in the original state or anodizing by selected mode. The depth of corrosion attack and the form of corrosion attack are evaluated depending on the type of alloy, the metallurgical condition and surface treatment of the samples.

Jan 1, 2015

By H. Pempel, J. Markowski, P. Ay

"Metal-coated thermoplastic parts find more and more functional and aesthetic applications in the interior and exterior of cars. The vapor-deposited or electroplated coatings are usually composed of a plurality of nickel- and chromium-containing layers, which are applied to copper-containing carrier layers on the polymers. Previously, recycling processes are mainly focussed at the recovery or thermal utilization of the plastics. Targeted and selective recycling of the metallic coatings is usually not carried out. Together with several SME, BTU developed a process, in which a complete and separate recovery of all components in high purity is possible with biotechnological methods. The bioleaching is carried out with iron and sulfur-oxidizing bacteria, especially Acidithiobacillus ferrooxidans. The copper-containing layers are dissolved in the solution; chromium- and nickel-containing particles are precipitated as solids. After the bioleaching, a mechanical separation of the individual metal-containing components and their separate workup are carried out. End-products are metallic copper, a nickel- and chromium-containing solid and the cleaned plastics. The bioleaching ensures a high purity of the end products. Through the use of bacteria, which are also found in nature, the process is environmentally friendly. Compared to chemical leaching using inorganic acids, considerably shorter leaching times can be achieved. In addition to the optimization of the leaching process, the R/D-project also includes the development and testing of the apparatus technology.INTRODUCTION The material complexity of many end-user products has increased in recent years, especially in the fields of electrical appliances, vehicle technology and medical technology. However, the demands on functionality, safety, comfort and energy efficiency still play a greater role in product design as factors such as sustainability and usability. For example, if a car still holds more than 70% of steel in the 1980s, a vehicle nowadays includes a larger proportion of a variety of difficultly separable plastics and composite materials, as well as complex metal composites. This relates in particular to composites made from such different materials as metals and plastics. The processing and recovery of the components of those complex material mixtures is difficult for recycling companies."

Jan 1, 2017

By L. Magne, M. Maldonado, R. Varela

Real-time optimization of flotation circuits demands for accurate and reliable measurements to support the decision making process. The collection zone gas holdup is an important variable in this context as integrates the effect of machine and chemical factors on the bubble size and velocity distributions. It has been demonstrated that gas holdup not only correlates with bubble surface area flux, which defines the particle collection rate and recovery in the collection zone, but also with water overflow, a variable which has been related to the froth zone recovery. Therefore, on-line gas holdup measurements provide a reliable alternative to judge efforts leading to the optimization of flotation cells and columns. Estimation of gas holdup in flotation from electrical conductivity measurements has been proposed and extensively used in lab and industrial installations. The approach is based on the application of Maxwell&apos;s model, which relates the concentration of a dispersed phase in a continuous medium to measurements of the conductivity of the liquid medium and of the mineral pulp with and without air bubbles included. These measurements require a conductivity cell which covers a representative volume of the flotation cell, and creates a homogeneous electric field throughout this volume that ideally is not affected by the conductivity of the medium. The development of such a cell in the limiting space and geometry of a laboratory flotation cell has been problematic, but a multi-electrode arrangement offers a promising alternative. Electrodes were installed in the flotation cell of a Denver unit; the results of preliminary testing are discussed with a focus on its performance in the measurement of two- and three-phase dispersion conductivity.

Jan 1, 2015

By L. Tafaghodi, A. Hosseinpour

"Silicon is considered as the most appropriate semiconductor material for manufacturing solar cells because of its natural abundance and being nontoxic. The transferable knowledge and technology from the electronics industry and the long history of silicon-based semiconductors are also assisting the domination of silicon as the most common semiconductor material. Developing an environmentally and economically viable process for producing solar grade silicon has been one of the main challenges in the silicon industry in the past few years. Metallurgical refining processes have received significant attention because of their high productivity and low cost. Slag refining is one of the purification methods which is based on oxidation of the impurity elements, followed by its dissolution into a slag phase. This article presents a review of various slag refining processes that have been employed for purification of silicon and silicon alloys. SiO2, CaO, CaF2, CaCl2, Al2O3, MgO and Na2O are the major components of the slags used for silicon refining. These slags can be classified into three main categories including binary, ternary and quaternary slags.INTRODUCTION Silicon can be categorized into three different grades based on its application or purity: metallurgical grade silicon (MG-Si) with purity of ~98 %, solar grade silicon (SoG-Si) with purity of ~99.99999 % and semiconductor grade silicon (SeG-Si) which has the purity of 99.9999999 % (Johnston & Barati, 2010; Krystad, Tang, & Tranell, 2012; Tang, Øvrelid, Tranell, & Tangstad, 2009). Producing SeG-Si is carried out through an energy-intensive and complicated process named Siemens. This purification process is relatively slow and involves using toxic and corrosive reagents (e.g. Trichlorosilane). At present the majority of SoG-Si is produced via Siemens or Siemens-like processes and there is very limited production via processes dedicated to SoG-Si. Because of the difference in silicon specifications required in microelectronics and photovoltaic industry, and the cost and energy associated with the Siemens process, an interest has emerged to develop technologies dedicated to producing low cost SoG-Si (Istratov et al., 2003; Johnston, Khajavi, Li, Sokhanvaran, & Barati, 2012; Mitrašinovic, D'Souza, & Utigard, 2012; Wu et al., 2012)."

Jan 1, 2017

By Alessandro Navarra, Kristian Waters

Mineral concentrators are designed from preliminary geological data, and are therefore subject to geological uncertainty. This uncertainty has a demonstrable impact on the mining lifecycle, and has motivated stochastic strategic mine planning algorithms. The current paper describes how these algorithms may be extended to consider mineral processing operations in conjunction with open-pit mining operations. In particular, the paper describes an effective way to incorporate variable concentrator feed grade into these algorithms, which is the first step toward more elaborate representations of mineral concentrators. The resulting framework will be able to connect geological data to alternate configurations of the downstream resources, hence comparing the benefit of each configuration, and the corresponding capital investments. Sample computations are presented, comparing the NPV and utilization for several different mineral processing capacities.

Jan 1, 2015

By I. Caraconcea, M. Cousineau, S. Gariepy

"Several base metal plants operate in low grade/high tonnage conditions which impose strict cost control on all fronts for their operations to remain profitable. This leads to decisions regarding plant design, procurement, operations and maintenance that often favor cost minimization over value optimization. This may hinder the representativeness of the metal accounting systems while this should be a priority in a low margin environment. Such poor representativeness not only creates confusion in plant scheduling but can also hide suboptimal metallurgical performance. Furthermore, this situation can run undetected for a while since one dominant feature of a poor metal accounting system is its poor self-awareness. During their practice, authors have particularly identified measurement bias and reproducibility, as well as their impact on metal recoveries as areas of concern. These issues have not been extensively reviewed in the specific context of precious metals in base metal plants. Pragmatic solutions are proposed either at the design stage for a new project or to retrofit an actual operation. These solutions should be based on a business analysis that set a value of information matching the contribution of precious metals as well as the potential to use such information to act toward increasing plant profitability. Conclusions are that trade-offs are an inherent part of the design/audit/retrofit of any metal accounting system in any plant processing either base or precious metals. However, compromises must be evaluated on economic/technical ground.INTRODUCTION Every mineral processing plant must produce metal accounting reports (Morrison, 2008) where estimated saleable metal flows and inventories are published. These metal accounting reports are delivered to a variety of stakeholders who use them for internal management purposes (day-to-day plant production planning, plant operation optimization, capital spending, etc.) as well as for external management (royalty settlements, tolling agreements, etc.). Hence, there should be no doubt that state of the art metal accounting is instrumental for mining companies to reach and sustain high-quality corporate governance (Gaylard, Randolph, & Wortley, 2014). However, producing a metal accounting report involves much more than just printing it (Lachance, Leroux, & Gariépy, 2015a). The underlying metal accounting system (Figure 1) is responsible not only for the reliable production of the metal accounting reports but also for the quality of the outcome. As such, the crucial tasks of its design/audit/retrofit should neither be seen as ancillary nor be left as an afterthought."

Jan 1, 2017