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By K. A. Lewandowski

Agglomeration techniques are widely used by industry to form fine particles into larger masses that are easier to handle and process. One area where agglomeration is potentially useful is in heap leaching operations. With-out agglomeration, fine particles travel through the heap, clogging the spaces between the larger particles and resulting in poor leach solution flow. Poor flow of leach solution will result in long leach rates and/or decreased metal recovery. Agglomeration immobilizes the fine particles and therefore improves heap permeability to fluid flow. Additional additives (binders) are needed to prevent agglomerates from breaking up as leaching solution percolates through the heap. Type II Portland cement and lime are two well-known binders used in gold and silver leaching, but these are limited to alkaline leaching environments. Various other products have been tested as binders, including polymers. This paper summarizes the benefits of agglomeration in heap leaching and the results obtained from the testing of several different agglomeration binders in heap leaching operations.

Jan 1, 2009

By S. K. Kawatra

A high calcium fluid-bed combustor ash has been shown to be an effective binder at dosages of 1 to 2% of the magnetite concentrate weight. Magnetite pellets 1.3 cm (1/2 inch) in diameter were produced with dry crushing strengths greater than 22.3 Newtons/pellet (5.0 pounds force/pellet), which is comparable to the results produced using conventional bentonite binder. The effectiveness of fly-ash-based binders was considerably improved when calcium chloride was added as an accelerator. Addition of calcium chloride at a rate of 0.1 to 0.2% of the total powder weight increased the strength of dried pellets by as much as 22% compared to the strength of pellets made using fly-ash without accelerators.

Jan 1, 1997

By D. D. Banerjee, S. K. Kawatra, T. C. Eisele

A high calcium fluid-bed combustor ash has been shown to be an effective binder at dosages of 1 to 2% of the magnetite concentrate weight. Magnetite pellets 1.3 cm (1/2 inch) in diameter were produced with dry crushing strengths greater than 22.3 Newtons/pellet (5.0 pounds force/pellet), which is comparable to the results produced using conventional bentonite binder. The effectiveness of fly-ash-based binders was considerably improved when calcium chloride was added as an accelerator. Addition of calcium chloride at a rate of 0.1 to 0.2% of the total powder weight increased the strength of dried pellets by as much as 22% compared to the strength of pellets made using fly-ash without accelerators.

Feb 24, 1997

By Vincent Castranova, Jane Y. C. Ma, Joseph K. H. Ma, Chang-geng Mo, Carl J. Malanga

"A group of bisbenzylisoouinoline alkaloids has been shown to exhibit various degrees of effectiveness in preventing silica-induced fibrosis in animal models [1, 2]. The objective the present study was to characterize the binding of several of these alkaloids to phosphatidylcholine vesicles and rat alveolar macrophages using fluorometric and equilibrium dialysis methods, respectively. The lipid binding affinity of these alkaloids was found to depend upon several structural factors including hydrophobic substitutions, chiral configurations, and double oxygen bridge-restricted conformation of the benzylisoquinoline moieties. Tetrandrine, which is a highly effective agent in preventing fibrosis, showed strong binding to both lipid vesicles and alveolar macrophages. In contrast, certain analogues of tetrandrine such as curine and tubocurine, which have little or no effect on silicosis, exhibited only weak binding to lipid vesicles and almost no binding to cells. The moderate binding affinity of fangchinoline to vesicles and cells corresponded to a moderate effectiveness of the compound as an antifibrogenic agent. Methoxyadiantifoline, an alkaloid of unknown antifibrogenic potential, also exhibited high binding affinities for lipid and cells. In conclusion, the results of these studies indicate that alveolar macrophages exhibit large binding capacities for certain members of this class of bisbenzylisoquinoline alkaloids. A positive correlation was observed between binding affinity to alveolar macrophages and the reported antifibrotic potency of these compounds. These data also suggest that the ability of these drugs to interact with alveolar macrophages may be a key step in inhibition of the progression of silica-induced pulmonary disease.INTRODUCTIONInhalation of crystalline silica is associated with the development of silicosis. This fibrotic disease is characterized by the appearance of concentric hyalinized nodular lesions in the lungs with the progressive development of pulmonary dysfunction [3, 4]. Many theories concerning the etiology of silicosis involve silica-induced activation of alveolar macrophages. Evidence indicates that in vitro silica exposures result in the generation of chemiluminescence, and the release of superoxide and hydrogen peroxide from alveolar macrophages [5]. Activation of alveolar macrophages has also been demonstrated after intratracheal instillation or inhalation of silica [5, 6]. Such excess release of reactive products from pulmonary phagocytes has been associated with damage to the lung parenchyma [7, 8]. In addition, silica exposure results in the release of mediators from alveolar macrophages, which enhance proliferation of fibroblasts and collagen synthesis by these pneumocytes [9-12]."

Mar 1, 1992

By E. Dzingayi

Keywords: Pyrometallurgy, furnace, Bindura, nickel The smelter at Bindura Nickel Corporation processes concentrates from its own mines and other external sources. Concentrates are dried, smelted, and converted to a desulphurised matte (leach alloy) for further processing at the refinery. The smelter comprises a drying plant, submerged arc electric furnace, electrostatic precipitator, and three Peirce-Smith type converters capable of treating 150 000 tonnes of concentrates per year. Concentrates are dried in a rotary coal-fired kiln, blended with fluxes, and smelted in a six-in-line submerged-arc 15MW electric furnace. Slag is tapped and granulated for disposal, and matte is tapped at regular intervals for blowing in Peirce-Smith converters. The paper details the 37-year history of the smelter, including furnace rebuilds and operating parameters as they have evolved in response to changing feed compositions. Special challenges, particularly relating to the treatment of high talc concentrates, are also described.

Jan 1, 2006

By A. Mboma

Keywords: Furnace, decommissioning, care and maintenance, re-start, funding, nickel Bindura Nickel Corporation (BNC) operates two nickel mines, and treats concentrates from these mines as well as toll concentrates from the region around its Bindura Smelter and Refinery (BSR) complex. At the smelter, concentrates of at least 5% nickel content are blended and dried to 4% moisture in a coal-fired rotary kiln. Matte smelting of concentrate is carried out in a six-in-line electric arc furnace, where the furnace slag is granulated and discarded. Furnace matte is transferred via ladles into Peirce-Smith converters, where, after granulation, a leach alloy containing 68%Ni, 20%Cu, and 6%S is produced. Converter slag is recycled via the matte-smelting furnace. The onset of the global economic recession towards the end of 2008 resulted in a collapse of metal prices, worsening the local situation that was already marred by unfavourable macro-economic conditions in Zimbabwe. As a result, BNC mines were put on care and maintenance in November 2008, followed by Bindura Smelter and Refinery in February and March 2009 respectively. The business environment has since changed, and BNC is getting ready to re-start the plant. This paper describes the decommissioning of the Bindura furnace, asset preservation during the care and maintenance programme in the past two years, and preparation for starting up of the Bindura smelter in the near future.

Jan 1, 2011

By M Robotham

In April 2013, Rio Tinto Kennecott Copper’s (RTKC) Bingham Canyon mine experienced what is arguably the world’s largest ever in-pit slope failure. The failure initiated along a major, continuous, low-strength bedding fault, named the Manefay bed, and comprised approximately 145Mtonnes of rock and waste dump material. Initial East wall slope deformations were detected some months prior to catastrophic slope collapse by RTKC’s slope monitoring systems. However, the failure mechanism was different to that which had historically been experienced in the prior more-than-100 years of open pit mining. Failure occurred as two separate events, the initial one likely consisting of a frictional failure of rock materials along the Manefay bed itself, before a second phase of failure occurred, which included a large mass of old rail dump material. The combination of these events led to a much larger failure run-out than had been anticipated by the RTKC team which led to loss of, and damage to, mining equipment and infrastructure as well as significant interruption to mining activities. Due to the diligent monitoring of the slopes no safety impacts were experienced at the mine, and as such the details and learnings from this failure can readily be shared with the broader mining and geotechnical industries to avoid similar recurrences elsewhere. This is an extended abstract only. CITATION:Robotham, M, 2018. Bingham Canyon Mine – from adversity to excellence, in Proceedings The Fourth Australasian Ground Control in Mining Conference (AusRock), pp 3–4 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Nov 30, 2018

By Robert Cefalo

Drill and Blast Engineer Abstract In 2019, the Bingham Canyon Mine, owned by Rio Tinto Kennecott Utah Copper Company, mined through the active underground that dewaters the pit. The active underground required the limitation of vibrations to avoid catastrophic damage or damage that would require work to the shotcrete and additional roof support. The surface design of the current sector next to and through portions of the active underground. The drill and blast group was required to test site law vibration parameters to ensure that vibration limitations were lower than limits set by the underground management team. Seismographs were used to validate the vibration prediction model and check performance of blast in areas of the underground. The bench conditions and limited pounds-per-delay created large obstacles for the blasting team, making it difficult for them to accurately load the pattern with the number of decks in the blast. Methods were used to improve the loading instructions and ensure that each hole achieved pound requirements based off of the distance to the underground that it was designed to protect. The project evolved from start to finish, and the process to estimate distances and loading improved to make the blast a more repeatable process for the size of the project.

By Robert Jacob Cefalo

In 2019, the Bingham Canyon Mine, owned by Rio Tinto Kennecott Utah Copper Company, mined through the active underground that dewaters the pit. The active underground required the limitation of vibrations to avoid catastrophic damage or damage that would require work to the shotcrete and additional roof support. The surface design of the current sector was mined next to and through portions of the active underground.

Feb 1, 2020

By William I. Busenbark, Elmer C. Newman

At Bingham Canyon, the world's largest open-pit copper mine, annual grease consumption is in the neighborhood of 109 000 kg (240,000 lb), all of which was 544 (120-16) purchased, warehoused, and distributed in 54-kg (120-1b) and 180-kg (400-1b) drums. While perhaps a menial and mundane chore, grease distribution shows on the ledger as a significant expense item. To improve labor and cost performance, Kennecott maintenance engineers undertook a study to find the most direct method for moving multi purpose grease (MPG) from the refinery to the point of final consumption. What they found was a direct vendor system for hulk grease so simple and flexible that long-established drum distribution is being phased out in favor of the newer method throughout 75% of the operation.

Jan 9, 1977

The greatest mining center in the state of Utah is the incorporated town of Bingham about twenty-five miles southwest of Salt Lake City. The principal industry of this vicinity, prior to the early fall of 1863, was lumbering and the first saw-mill in the state was built near the mouth of Bingham Canyon. Early in the fall of that year. George B. Ogilvie discovered gold and shortly afterward the first mining district in the state was organized. Some writers place the discovery of gold in the canyon in the late fifties. If this be so, however, the matter was kept extremely quiet because no mining was engaged in until after Ogilvie's discovery. Bingham was a placer mining camp, producing about one million dollars' worth of dust and nuggets from placers up and down the canyon and in Bear Gulch until early in the seventies, or about ten years after the discovery of gold, when a large body of argentiferous lead ore was discovered and soon after heavy shipments were made from a half dozen or more properties.

Jan 1, 1925

"The greatest mining center in the state of Utah is the incorporated town of Bingham about twenty-five miles southwest of Salt Lake City. The principal industry of this vicinity, prior to the early fall of 1 863, was lumbering and the first saw-mill in the state was built near the mouth of Bingham Canyon. Early in the fall of that year, George B. Ogilvie discovered gold and shortly afterward the first mining district in the state was organized. Some writers place the discovery of gold in the canyon in the late fifties. If this be so, however, the matter was kept extremely quiet because no mining was engaged in until after Ogilvie's discovery.Bingham was a placer mining camp, producing about one million dollars' worth of dust and nuggets from placers up and down the canyon and in Bear Gulch until early in the seventies, or about ten years after the discovery of gold, when a large body of argentiferous lead ore was discovered and soon after heavy shipments were made from a half dozen or more properties.In 1 8 74, A. H. and George L. Bemis erected the first concentrating plant in the state for the treatment of sulphide lead ores.The history of the camp as a producer of copper begins in the summer of 1 88 7, when Enos A. Wall noticed, in observing prospecting drifts and inclines driven some years before, the discoloration caused by the coppery solution. As a large part of the adjacent ground had been abandoned, he located two claims, which he called the ""Dick Mackintosh"" and the ""Charles Reid,"" after two of his friends.Late in 1896, the Highland Boy Mine produced sulphide ore rich in copper, causing a revival of interest in the copper potentialities of the camp, and during the next seven years a number of new claims were located ."

Jan 1, 1925

By R Dwyer

Iron ore currently mined in Australia generally requires very little beneficiation. However, depleting high-grade resources means that in the future low-grade iron ore deposits will need to be mined to meet the increasing demands of the global steel industry. Along with the increased demand, the industry faces additional pressure to reduce the environmental impact of mining and mineral processing. This has stimulated research beyond incremental improvements to conventional processing into alternative low-impact processes, including biotechnological approaches to mineral processing.Bioflotation and bioflocculation have emerged as relatively recent technologies, in which bacteria and/or their extracellular material may be used as flotation reagents (collectors or modifiers), enabling improved selective separation of minerals. The primary advantage is the production of a selective, environmentally-benign alternative to conventional flotation reagents. A biotechnological approach may also be taken in the beneficiation of high-phosphorous iron ores utilising bacteria capable of iron reduction and phosphorous solubilisation.Samples from three iron ore deposits in Western Australia were examined for bacteria suitable for iron ore benefi ciation. A number of common soil microorganisms including Pseudomonas spp, Limnobacter thiooxidans, Paenibacillus spp, and Ralstonia insidiosa were identified using culture-independent molecular techniques. A number of anaerobic species belonging to the genus Clostridium were also identified in the core samples. Selected aerobic species were enriched and isolated on high nutrient media in the presence of haematite. Several of the isolated strains showed an affinity for iron ore, attaching to haematite in enrichment cultures and further demonstrated through adhesion studies. Other isolated species such as Ralstonia isidiosa and Pseudomonas stutzeri are known to solubilise rock phosphates in soils and have potential for the removal of phosphorous from Australian iron ores.

Jul 11, 2011

By Terzis D. PhD, Katterbach M.

While awareness around the environmental impact of existing grout materials and chemical binders is increasing rapidly, biotechnologies are growing traction as sustainable alternatives in groundwork operations. Herein we present the principles and application methods of bio-grouting. The term is used to describe a system which is based on soil, groundwater or marine enzymes which are able to catalyze the production of calcite replicating a natural phenomenon. The system’s end result are mineral crystalline bridges which act as binders to improve the geotechnical properties of soils. This paper presents a comprehensive description of bio-grouts, their underlaying mechanisms contributing to mineralization as well as environmental considerations. With their water-like rheology, bio-grouts have a wide application range and are minimally invasive, requiring only very limited injection pressures. The equipment is the same as that used in conventional cement grouting, and the reactant components are worldwide available or easily suppliable, which explains why bio-grouting has nowadays become a valuable and sustainable alternative towards efficient soil treatment. Recent developments in the last years have allowed to further increase the applicability and efficiency of bio-grouts to ultimately bridge the gap between research and practice. A case study is illustrated in this paper showing the successful implementation of bio-grout for the stabilization of weakly cemented sandstone to safeguard an adjacent road segment in Switzerland

May 1, 2022

By C. Joulian, A. G. Guézennec, A. Chmielarz, Y. Ménard, M. Hanke, P. d’Hugues

"The copper concentrate used in this study is produced by flotation of a black shale organic rich ore. This resource is a carbonate-rich, polymineral concentrate. In the last 5-6 years, ore characteristics changed and the concentrate grades degraded. This study evaluated bioleaching of the concentrate in stirred tank reactors as an alternative to the pyrometallurgical technology that is currently applied, and which may no longer be feasible in future given the concentrate chemistry.The first part of the study focused on testing non-traditional operating conditions during continuous bioleaching experiments: high solids concentration (> 20% solids), reduced agitation and aeration rates. For the same residence time, bioleaching performance at high solids loading (25%) was the same as that reached during previous bioleaching experiments at 15% solids. No mixing or microbial issues were encountered. The bacterial consortium used in the experiments demonstrated a high copper tolerance.The second part of the study was devoted to technology development for metal recovery from copper bearing solutions obtained during bioleaching experiments. Due to the high copper concentration of the leachate, solvent extraction prior to electrowinning was not necessary. After iron removal, high quality copper cathodes (morphology and composition) were obtained from the PLS by electrowinning."

Jan 1, 2014

By A. D. Davis, J. L. Sorensen, C. J. Webb

Environmental impacts from acidic mine drainage are growing national concerns that are particularly acute in the headwaters of the Rocky Mountain region. In the Black Hills of South Dakota, approximately one thousand mines are inactive or abandoned, most of them in the headwaters of major drainages. This paper examines the Bear Butte Creek basin, a heavily mineralized watershed with significant historical mining impacts and a surface gold mine permitted in 1997. The watershed loses its surface discharge to swallow holes in the karstic Madison Limestone. The integrity of the aquatic ecosystem was monitored with a suite of sitespecific bio-indicators. Stream surveys covered the entire reach of Bear Butte Creek from near its headwaters to the swallow holes in the Madison aquifer. Data from the stream surveys, water-quality sampling, and bio-indicator surveys clearly showed that water-quality impacts are limited mainly to Strawberry Creek and to the area of Bear Butte Creek near and downstream of the town of Galena.

Jan 1, 1999

By A. D. Davis

Environmental impacts from acidic mine drainage are growing national concerns that are particularly acute in the headwaters of the Rocky Mountain region. In the Black Hills of South Dakota, approximately one thousand mines are inactive or abandoned, most of them in the headwaters of major drainages. This paper examines the Bear Butte Creek basin, a heavily mineralized watershed with significant historical mining impacts and a surface gold mine permitted in 1997. The watershed loses its surface discharge to swallow holes in the karstic Madison Limestone. The integrity of the aquatic ecosystem was monitored with a suite of site-specific bio-indicators. Stream surveys covered the entire reach of Bear Butte Creek from near its headwaters to the swallow holes in the Madison aquifer. Data from the stream surveys, water-quality sampling, and bio-indicator surveys clearly showed that water-quality impacts are limited mainly to Strawberry Creek and to the area of Bear Butte Creek near and downstream of the town of Galena.

Jan 1, 1999

"Depletion of known ore reserves and increased demand for precious metals have caused a revolution in biohydrometallurgical processing technology for gold recovery. Known ore deposits and future discoveries are most likely to be lower grade sulfide ores that can be difficult to recover with current leaching technology. Future metal recovery operations will increasingly use bio-oxidation techniques.Bacteria are an integral part of mineral cycling and mineral transformation in nature. Although biological processes are recognized as part of the mineralization and oxidation reactions in some ore deposits, they have only recently been applied to enhancing metal recovery in hydrometallurgical procedures. This paper explores the traditional metallurgical application of biological leaching and oxidation reactions and reviews the complete range of bacteria available for metal recovery systems. Pre-treatment of ores with bacteria improves metal recoveries in tank leaching systems and shows promise for heap leaching methods.IntroductionThere is no longer any question that bacteria playa natural role in the on-going transformation of some ore deposits (1,2). As applied to sulfide ores, a few strains have been specifically identified that exhibit a natural leaching potential (3). These bacteria can be isolated from waters and soils in old mining districts where they contribute to continuing leaching and pollution problems in acid drainage and heavy metal solubilization. Sulfur and iron bacteria as well as many heterotrophic strains have also been found in ore deposits and sedimentary rocks at depths up to 2000 meters (4). Their presence in both ore deposits and processed ores shows the microbial association with natural leaching and the potential role that bacteria can play in the development of new leaching technology."

Jan 1, 1988

By Xiu-Xiang Tao

This study investigated bio-liquefaction of lignite and its model compounds of thymol, bezioc acid and quinoline by a fungus, Hypocrea lixii AH. It analyzed, during bio-liquefaction, enzyme activity of oxidase, LiP, Lac, MnP and polyphenol oxidase, and degradation products by UV-Vis, FTIR, 13C NMR and GC-MS. The results showed that the bio-liquefaction percentage (by mass) of lignite was up to 44.86 %. The bio-liquefaction products of lignite were mainly aniline, amide, ether, carboxylic acid ketone and ester. The aromatic ring number was 1-3 with an aromatic carbon ratio of 0.328, which indicated rings opening, bonds breaking and oxidation reaction. By considering with the enzyme activity analysis results, it showed that LiP and Lac catalyzed reactions to open aromatic cycles and to break bonds; esterase to break ester bond; and peroxidase in oxidation reaction.

Aug 1, 2013

Bacteria can play a key role in the processing of 'difficult' ores. Bioleaching opens the way to potentially extract copper from vast amounts of otherwise hard to process refractory low-grade chalcopyrite. In my talk I will outline our research philosophy to develop bioleaching as a Precision Processing unit process step. In our view, Precision Processing is a sophisticated approach to mineral processing where the ultimate goal is to measure and characterise the ore body in-ground and in real time during mining, allowing the down-stream unit processes (bioleaching, in this case) to be continuously tailored and tuned via feedback and feed-forward controls to obtain the highest possible recoveries at the lowest possible cost and environmental impact. I will describe some of the work that we are undertaking to better understand the interfacial phenomena underlying the fundamental bioleaching process with the aim of coming to a Precision Processing approach. We use techniques such as interfacial electrochemistry (scanning electrochemical microscopy, SECM), AFM, zeta potential measurement, and synchrotron science to elucidate the parameters that drive bacterial selectivity and adhesion, bacterial metabolism, and dissolution and precipitation processes for model systems and real chalcopyrite ores. As examples of our research, I will discuss in some detail our method to produce and characterise micro-patterned CuxS - silica thin films as model substrates for electrochemical and bacterial adhesion work and our approach to the interfacial chemical characterisation of extracellular polymeric substances of bio-active bacterial cells. I will also cover some of our recent findings relating to measurement and interpretation of bacterial adhesion on sulfidic substrates and its implications for bacterial adhesion and substrate selectivity. After having identified and discussed crucial leaching parameters, such as pH, Eh, T, [Cu2+], and [O2], the talk will go on addressing some of the early achievements and challenges encountered in our work to design and prepare low-cost, rugged sensing devices that allow the in-situ (in this case, in-dump or in-heap) localised measurement of these parameters. I will conclude my talk by painting the picture of how the work of our group might contribute to realising the dream of transforming bioleaching into genuine high-tech Precision Processing of minerals. This is an ABSTRACT ONLY. A full-length paper was not prepared for this presentation.

Sep 13, 2010