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By Yves Breau, François Robichaud, Jacques McMullen, Pierre Pelletie

"The Expert System implemented at the East-Malartic mill controls a copper flotation circuit while taking into account the profitability of the operation. Treating a copper gold ore, the flow sheet integrates a flotation step followed by cyanide leach circuit. The Expert System calculates the actual net smelter revenue of the flotation circuit, accounts for the operating cost of the cyanidation circuit and defines optimal metallurgical operating targets to optimize the overall economics. To be realistic, probability factors and circuit diagnostic analysis are integrated in the operating target selection. The Expert System has proved to be successful, robust and flexible. It resulted in a copper concentrate grade increase of 1% while maintaining recovery. The use of the expert system also gives plant personnel good training procedures and promotes interaction with mill operator.INTRODUCTIONThe East-Malartic mill is located close to the town of Malartic in North Western Quebec, Canada. The mill was first commissioned in 1938. The flowsheet at that time was a straight cyanidation circuit. The original mill operated in that mode up to the discovery of the Bousquet 2 orebody in 1989 which consisted of a massive copper sulphide ore averaging 0.7% copper and 7 g/mt of gold. Bousquet 2 ore processing required a mill retrofit. Grinding capacity, gravity and copper flotation circuits were inserted prior to the cyanidation circuit in order to achieve 3,200 mtpd capacity at expected recoveries.In 1993, control of the flotation circuit was deemed critical in order to maintain the flotation performance and to reduce cyanide consumption since the copper sulphide contained in the Bousquet 2 ore is a high cyanide consumer (50% bornite). (McMullen, 1999) As a result, the implementation of advanced control strategies in order to increase the metallurgical profitability of the plant and to reduce the operating variability between operators was the most rational alternative. In 1994, Corem was chosen to perform the plant audit and to write the first set of rules. The on-line control strategy was started up in 1995. In 1996 and 1997 the Expert System was shutdown because of an extreme change in the ore coming from the milling of Bousquet #1 ore and the departure of the projects engineer. In 1998, the system was restarted and the results were impressive. Furthermore in May of 2001 a patent was issued for the control strategy. (Breau, 2001)"

Jan 1, 2002

By C. Garcia, H. Arias, J. D. Miller, C. L. Lin

The question of ultimate recovery in heap leaching operations is always of particular concern with respect to economic considerations. Of course the particle size distribution is a critical factor which determines ultimate recovery and which must be established based on a balance between the extent of mineral exposure and transport phenomena. Now it seems that the ultimate recovery for a given particle size distribution can be established from mineral exposure analysis by x-ray microtomography (XMT). Using recently developed software, micro-CT data can be used to determine the fraction of mineral exposed and thus the ultimate recovery. Examples of mineral exposure analysis are given for the copper heap leaching operation at Zaldivar, Chile.

Jan 1, 2002

By R. Parada

In January 1995, Disputada Mining Company Ltd. (Compañia Minera Disputada de Las Condes) started up the Expansion Project for the Chagres Smelter, following an investment of US$M 2 15. The new smelter replaced the 44,000 tomes per year revervatory furnace with an Outokumpu Flash Smelting Furnace (FSF) designed to produce 118,000 tonnes per year of copper. Nowadays, this smelting unit has achieved a 40% over design performance. The landmarks of this modernization project are described. The start up period in 1995-1996 was characterized by the impacts of several restrictions that prevented the smelter from reach design production. The design performance was reached in 1997-1998 through the implementation of solutions designed to eliminate, or at least mitigate, the restrictions found early on. The smelter has been further optimized in the 1999-2000 period, leading to a new record anode copper production rate of 148,000 tonnes in 2000 while obtaining 98% approval for our different anode shapes. The objective of this paper is to discuss the consecutive processes of start-up, achievement of design capacity, and operational improvements to go well beyond the design capacity. These processes took place between early 1995 and late 2000, under the principles of Continuous Improvement that promotes the effective participation of the workers in the technology innovation and Enterprise Management.

Jan 1, 2002

By R G. Barker, N Mortimer

In New Zealand, platinum group metals (PGM) occur in three main geological environments of economic interest: layered mafic igneous complexes, the Dun Mountain Ophiolite Belt, and in association with placer gold deposits. Most of the layered mafic complexes with PGM potential occur in the Median Batholith. These include the Longwood (Permian), Bluff (Permian), Riwaka (Devonian) and Rotoroa (Jurassic) igneous complexes. Exploration of the Longwood Complex discovered PGM associated with gabbroic rocks. Best assays to date include a 1 m drill intersection of 1 g/t Pt + Pd and float rock with 3.0 ppm Pt and 3.3 ppm Pd. The Greenhills complex at Bluff consists of basal dunite overlain by wehrlite and gabbro. PGM occur with chrome spinel in the basal dunite and Pt geochemical anomalies have been identified associated with the wehrlite-gabbro contact zone. The Greenhills complex has some similarities to Alaskan-Ural type complexes.Reconnaissance exploration in the Dun Mountain Ophiolite Belt has identified PGM geochemical anomalies, but no follow-up work has been carried out. During the late 1800s and early 1900s, PGM were recovered as a byproduct of placer gold mining in Southland. Placer gold prospects with PGM potential include the Waiau River, deposits flanking the Longwood Complex and some Southland beaches.

Jan 1, 2002

By Steve Dillingham

A blast site incident has just occurred. Tensions are high, and, as the blaster, you’re in charge of the crisis at hand. Your mind is reeling, your thoughts frantic. The main areas of concern for you at the scene are to deal with immediate problems...aid the injured, take a head count, assess the damage, call emergency response, contact company headquarters, calm the neighbors, update your customer, and respond to the press on site. You feel as if all the bases have been covered...but, then again, have they? One of the biggest mistakes blasters and their companies can make is not including their Insurance carrier in the critical on-site accident procedures and emergency call list. Unfortunately, many companies believe that they are immune to the perils that can often, within a matter of minutes, create chaos that only happens to someone else.

Jan 1, 2002

By Dan Kump

This paper provides an overview of Barrick Gold's Bullfrog underground mine backfill program. The Bullfrog underground mine was a gold mine that primarily used the underhand cut-and-fill mining method. The first portal was established June 18, 1991, and mining continued until Dec. 29, 1998. This paper begins with a discussion of the events that took place to reach about 1.8 kt/d (2,000 stpd) of backfill. It ends with a commentary of what was learned. The Bullfrog experience suggests that there are two essential factors to a successful backfill program: a well-graded aggregate supply and proper placing procedures.

Jan 1, 2002

By Brian Clifford

Thoresby Colliery is in the process of recovering an old roadway that was flooded following the closure of an adjacent mine. The aim is to re-use the roadway as a gate road for a longwall retreat panel and it is therefore important to establish the condition of the existing rockbolt support during the recovery operation. Two NDT methods, ultrasonics and RMT's newly developed RF (Radio Frequency) system were used in combination to interrogate the rockbolts to determine their condition. This paper describes the condition of the rockbolt supports, the NDT methods used and the problems that had to be overcome to successfully apply the two methods.

Jan 1, 2002

By F P. Hao

Organo-sulphur-based collectors (eg xanthates, dithiocarbamates and dithiophosphates) are widely used in the flotation of sulphide minerals. Xanthates (ROC(=S)Sû), for example, adsorb strongly at sulphide mineral surfaces, in a reaction that is electrochemically coupled with the reduction of dissolved oxygen. One of the oxygen reduction products, hydrogen peroxide, reacts directly with dissolved xanthate, leading to its oxidative decomposition. Experimental work has been conducted, using ethyl xanthate, to understand the molecular mechanism by which hydrogen peroxide reacts with xanthates. A number of degradation products have been identified, some of which have not been reported previously. This oxidative decomposition reaction pathway is discussed in the broader context of xanthate decomposition in flotation systems. One of the identified ethyl xanthate decomposition products, ethyl perxanthate (ROC(=S)SOû), has been observed in the process water of a number of mineral processing operations. The interaction of this molecule with goethite (α-FeOOH) particles, typical of that found in tailings dams, has been studied in more detail using attenuated total reflectance (ATR)-FTIR. The ethyl perxanthate molecule has been found to coordinate to iron (FeIII) at the goethite surface, and undergo a surface-catalysed decomposition process. In the presence of both PbII and goethite, a ternary surface complex is formed, where ethyl perxanthate is coordinated directly to surface adsorbed PbII atoms. The results obtained give some insight into the environmental fate of ethyl xanthate in tailings streams, and a basis on which to consider the environmental importance of such species in tailings dams. Strategies for the destruction of residual xanthate levels in waste water streams are discussed in terms of the likely reaction products.

Jan 1, 2002

By D. Dimitriadis, T. Polglase, M. M. Botz, W. Phillips, R. Jenny

Cyanidation processes for the extraction of gold or silver frequently involve the processing of sulfurcontaining solids that react with cyanide to form thiocyanate. The formation of thiocyanate is an undesired side reaction, and in many cases thiocyanate formation results in a prohibitively high cyanide consumption. With the increasing number of gold and silver mining projects that involve the processing of sulfide ores or concentrates or that utilize a biological sulfur oxidation process, more attention is being focused on minimizing thiocyanate formation and in treating solutions to eliminate toxicity associated with thiocyanate. Though not yet commercially applied, there are several processes available to recover cyanide from thiocyanate to reduce tailings toxicity and to allow the reuse of cyanide otherwise lost to thiocyanate formation. This paper presents an overview of processes available for recovering cyanide from thiocyanate along with estimated operating costs for the processes. Pilot testing data suggests that in some cases cyanide can be recovered from thiocyanate for approximately the same cost as newly purchased cyanide.

Jan 1, 2002

By J. W. Hawkins, K. B. C. Brady, K. Miller, J. Cuddeback

Remining of abandoned coal mines in Pennsylvania requires the implementation of pollution abatement and mining techniques called Best Management Practices (BMPs). Water-quality data from over 100 remining sites with more than 230 abandoned discharges were analyzed with respect to the types of BMPs employed to abate the pollution loadings of acidity, iron, manganese, aluminum and sulfate. Discharges exhibiting a significant decrease in acidity were most highly associated with sites where large volumes of alkaline materials were encountered (66.7%) or added (63.7%). The best results for iron loading were achieved with large-quantity alkaline addition (54.6%) and water handling systems (47.8%). Water handling systems (47.4%), daylighting (40.7%), and revegetation (40.2%) were associated with significantly lower manganese loadings. The decreases in acidity and sulfate loads associated with increasing the amount of alkaline material in the backfill indicates that the production of acid mine drainage can be retarded by adding large quantities of alkaline materials.

Jan 1, 2002

After considerable input from the mining industry, the Canadian Securities Administrators (CSA) finalised National Instrument 43-101: Standards of Disclosure for Mineral Projects. This Instrument, which became law across Canada on 1 February 2001, applies to all technical public disclosure on mineral projects and requires all technical disclosure to be based on the work of a æqualified personÆ (QP). While the QP is quite similar to the Competent Person in Australia there are important differences when it comes to all disclosure. This paper will summarise the main areas in which the Instrument introduces major changes to Canadian disclosure standards on mineral projects including the role and responsibility of the qualified person; the increased requirements to file technical reports; the incorporation by reference of the October 2000 CIM definitions of resources and reserves and additional rules governing written disclosure of scientific and technical information. In October 2001, eight months after the implementation of NI 43-101, the CSA compiled a list of frequently asked questions (FAQs) and CSA responses to assist mining industry participants and their advisors in understanding and applying NI-43-101. This document has been well received by industry. The CSA plans to update the FAQs when further guidance is requested. Two industry committees have been established to provide the CSA with technical advice on the application of NI 43-101. As recommended by the Ontario Securities Commission/Toronto Stock Exchange Mining Standards Task Force, the CSA has established an external industry advisory committee û the Mining Technical Advisory and Monitoring Committee (MTAMC) û to monitor the application of NI 43-101 and advise the CSA on industry and professional developments. The role of the CSA-Canadian Institute of Mining, Metallurgy and Petroleum (CIM) Working Committee on Reserves and Resources is to ensure that the future changes and updates to the CIM Standards can be efficiently and effectively incorporated in NI 43-101. During this first year, the Canadian securities regulators have seen an improvement in the quality of disclosure on mineral projects, which will increase investor confidence in the industry.

Jan 1, 2002

By Michael A. Trevits

Mine fires can be especially perilous because toxic products can quickly spread well beyond the fire zone thereby exposing all underground miners to dangerous and deadly conditions. Since November 1998, there have been six major underground coal mine fires or explosions in the United States (Willow Creek (twice), Sanborn Creek, Loveridge No. 22, West Elk and the Jim Walter Resources No. 5 Mine). In each case, the entire mine or specific areas of the mine had to be sealed due to the build-up of dangerous gases and the fear of uncontrolled spread of the fire. Effective placement of mine seals can deprive a mine fire of oxygen and is often followed by water flooding or injection of inert gas into the affected area. When access to the fire zone is impossible because of safety reasons, airtight mine seals can be constructed, in the area of the fire, remotely from the surface through vertical boreholes. Remotely constructed mine seals are commonly made from cementitious material. Since these mine seals are typically erected blindly, it is difficult to determine if mine roof-to-floor and rib-to-rib closure has been obtained. This paper provides a review of the available materials and technology used to remotely construct mine seals through vertical boreholes.

Jan 1, 2002

By H. Sis, D. Dahlin, S. Chander, C. Summers

Bench-scale selective-flocculation tests were conducted on samples of Florida phosphate and Western phosphate process tailings to recover upgraded phosphate concentrates. After physical and mineralogical characterization, the slurry samples were treated with a broad suite of flocculants with a range of molecular weights and anionic functional groups. Parameters investigated included pH, dispersant and flocculant types, and dose; conditioning parameters and settling times were, for the most part, held constant. Where selectivity was achieved, phosphate minerals remained dispersed, whereas silicate minerals flocculated and settled. Single-stage tests using reagents with low to medium anionic characteristics produced upgraded phosphate concentrates at moderately elevated pH. Two- stage site-blocking tests, in which low-molecular-weight flocculants were used as site-blocking agents, gave improved results.

Jan 1, 2002

SASOL Synthetic Fuels has recently completed the design of sampling systems for raw and blended coal feeding the gasifiers at Secunda, South Africa. The new systems will replace manual, stopped belt sampling and have been designed to achieve specific accuracy targets on a daily basis. The sampling system is unusual in the coal industry in that the fines content (-5.5 mm nominal) of the coal is very critical and is to be determined with high accuracy.The sampling system was designed to meet carefully considered target accuracies using methods of modern sampling theory. The heterogeneity of the coal streams involved with respect to the critical analytes was determined by appropriate sampling and sample analysis. The statistical characterisation of the time variation of analytes in the process streams was based on variograms derived from on-line ash gauges. From this point, the design was completed using fundamental statistical sampling theory and some simulation studies. The paper discusses the development of the sampling system design in detail as well as the plans to use the data stream to provide timely alarms when the coal quality deviates from the target specification.

Jan 1, 2002

By M Wilkes, C-Q Liu

Microbial oxidation of refractory sulphide ores (particularly gold and copper ores) are well-established techniques that are increasingly employed because of their low capital and operating costs and environmental benefits. CSIRO has established a multidivisional project, the æBioMineral Processing InitiativeÆ, with the goal of generating new and improved high temperature micro-organisms for biological oxidation of these refractory ores. The project is currently focused on the discovery/generation of novel hyperthermophiles for the bioleaching of copper from chalcopyrite. As part of this project we are investigating the practicalities of genetic modification of iron/sulphur oxidising micro-organisms. The molecular biology of iron/sulphur oxidising acidophiles is still in its infancy. This work is aimed at improving our knowledge of vectors, promoters, selectable markers, gene transfer and expression in these organisms. The Acidithiobacillus ferrooxidans genome is currently available and genomics is proceeding at a rate where in the next few years we can expect at least one or two relevant microbial genomes to be sequenced each year. New genes that impart useful characteristics to iron/sulphur oxidising acidophiles will be available from published genomes and the study of newly isolated hyperthermophiles. We need to be in a position to clone and express those genes. This paper will describe the isolation, transfer and expression of thiocyanate hydrolase genes in Escherichia coli and At. ferrooxidans. Most common antibiotics are not effective against iron/sulphur oxidising acidophiles. Also, the use of antibiotics or their resistance markers outside of a laboratory setting would not be appropriate. Resistance to thiocyanate should be a useful selectable marker, without implications for human or animal health. Additionally, thiocyanate resistant iron/sulphur oxidising acidophiles might have application in gold bio-oxidation plants in arid areas where reuse of contaminated tailings water is desirable. The cloning of thiocyanate genes in broad host range plasmids under the control of E. coli and At. ferrooxidans promoters and the expression and phenotypic effects in both species will be described.

Jan 1, 2002

In the Ngakuru area, zeolite deposits occur in late Quaternary lake sediments and ignimbrites. The deposits are associated with sinters, hydrothermal eruption breccias, and quartz-adularia altered fault breccias: all indicators of a shallow epithermal environment. Several of the deposits are adjacent to epithermal gold prospects. Zeolites are most abundant in lacustrine tuffs of the Ngakuru Formation, a 100-300 m thick sequence of siltstone, tuff, diatomite, sandstone and conglomerate. The formation overlies the Ohakuri Ignimbrite dated at c. 270 Ka, and is unconformably overlain by alluvial sands and gravels which are younger than 20 Ka. Individual zeolite deposits contain 30-80 per cent zeolite over a thickness of up to 45 m in thinly stratified tuff beds. The tuff beds are locally overlain by diatomite. The tuffs are composed mainly of glass shards and pumice clasts, with minor volcanic plagioclase, quartz and biotite crystals. Glass shards in the tuffs are replaced by the silica-rich zeolites mordenite and clinoptilolite. Amorphous silica (opal A), opal-CT, K-feldspar and smectite are also present. The distribution of the Ngakuru Formation is controlled by northeast trending normal faults, which separate it into the Ngakuru and Guthrie grabens. A silicified (quartz-adularia altered) hydrothermal breccia along one of the fault zones suggests that the faults acted as feeders for heated water that caused the deposition of the zeolite minerals. Some of the zeolite deposits are adjacent to sinters and hydrothermal eruption breccias. The location of the sinter about 20 m above one deposit indicates that the zeolites were formed at a depth of 20 to 70 m below the paleosurface. The hydrothermal eruption breccias contain clasts of altered ignimbrite, which contain geochemically anomalous gold and silver values. By analogy with their occurrence in active geothermal systems in the Taupo Volcanic Zone, mordenite and clinoptilolite in the Ngakuru deposits probably formed at temperatures of 60-150oC from near-neutral pH waters as a result of interaction with glass-rich tuff beds. The Ngakuru zeolite deposits are therefore interpreted as shallow hydrothermal alteration zones within larger epithermal gold-bearing systems.

Jan 1, 2002

By B. Genc

After the explosion at Middelbult Colliery, South Africa in May1993, which claimed 53 lives, the South African Coal Mining Industry and the Safety In Mines Research Advisory Committee (SIMRAC) united forces to establish a surface facility to develop and test on-board flame suppression systems for continuous miners and roadheaders. The first test that was conducted in this newly constructed test tunnel at the Kloppersbos Research Facility, CSIR was in July 1995.Since then 70 tests have been conducted using the facility and have focused on on-board active ignition suppression systems for continuous miners (CM) and road heading (RH) machines to enhance the safety of South African mine workers in collieries. These suppression systems are mounted on the CM or RH machine and detect the occurrence of an ignition by means of light-sensitive sensors. The electronic signal from the sensor triggers the suppression system, creating a flame-suppression curtain, containing and extinguishing the flame in the immediate vicinity of the ignition. Forty-three tests have been conducted with an active on-board suppression system present inside the test tunnel. Since flame propagation speed is an extremely important parameter, the CSIR-Miningtek made the results of the test programme available for re-analysis. Flame speed depended on whether a machine was present in the heading or not, the geometry of the heading and the volume and composition of the explosive mixture of gas. Flame speeds of up to 190 m/s were recorded. However, the active suppression systems were almost always successful in containing flame propagation.

Jan 1, 2002

By T. H. Eyde

Worldwide production of natural zeolites during 2001 was estimated to be about 3.5 Mt (3.85million st). Construction and agriculture continued to be the major consumers. Estimated production in North America during 2001, including the United States, Canada and Mexico, was about 40 kt (44,000 st). In the United States and Canada, the zeolitic tuffs are ground, extruded or modified for use as adsorbents, desiccants, ion-exchange media and carriers. In Mexico and the rest of the world, the zeolitic tuffs are cut into dimension stone that is used in construction. Zeolitic tuffs are usually composed of the minerals clinoptilolite, mordenite or both. They occur in a variety of colors and are easy to cut and shape. And they have low thermal conductivity. This construction application is classified with dimension stone rather than with chemical and agricultural uses.

Jan 1, 2002

By Y. H. Zhan

In beneficiation of phosphate ores it is common to use screening to produce the coarse "pebble" concentrate, and flotation to process the -1+0.1 mm size fraction. The -0.1 mm desliming product is treated as tailings. A new partially hydrophobic flocculant, P(MAAA) latex was developed to enhance flotation recovery of fine apatite particles through selective flocculation.

Jan 1, 2002

By Tim Wolf, Barry Fink

Mine site managers reported occurrences of locking assembly bolt failures on the Enlow Fork Coal Mine's slope belt conveyor. The observations were made after a number of years of operation and raised questions as to the status of the assemblies in operation. These questions prompted a detailed review of the situation by independent consultants. Using operational history of the conveyor and confirmation of belt loads by static and dynamic methods, a locking assembly fatigue curve was created to suggest expected service life. From this work, suggestions were made to modify the pulley assemblies for extended service life.

Jan 1, 2002